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By A. G. McGregor

IN THE Southwest a number of large steel chimneys discharge the gases from the copper smelting furnaces. Some of these chimneys show no deterioration after twenty years, others show serious deterioration after tour years service. A steel stack 20 ft. 7 ½ in. (6.3 m.) in diameter by 279 ft. (85 m.) high, Fig. 1, used for roaster gases only at the Calumet & Arizona Mining Co.'s plant at Douglas, Ariz., was lined to the top of the bell, 40 ft. (12 m.) from the base, with common brick placed on end, lime and cement mortar being used. Above the bell, the stack was lined with 4 by 4 by 8 in. (10 by 10 by 20 cm.) building tile, placed on end, making a lining 4 in. thick. The tiles were supported on angle-iron rings, riveted to the inside of the chimney shell about 15 ft. apart. The chimney was put into use in the latter part of 1913. Four years later, considerable of the tile lining had fallen out of place and mixed with the flue dust at the bottom of the chimney. About a year later, several . flattened and distorted sheets were noticed about 70 ft. below the top. An investigation showed that the thickness of these distorted sheets, which was originally ¼ in., had been reduced one half. One year later, or six years after the chimney went into use, several holes, a square foot and smaller in area, appeared near the flat spots mentioned. Soon afterwards, when the chimney was shut down for repairs, it was found that most of the tile lining for 125 ft. from the top had fallen out and that the steel shell was badly corroded; but where the lining remained in place the shell was undamaged. Many of the tile which had fallen out of place had become soft or flaky and crumbling, others were as hard as when placed. An analysis of the hard and soft tile is shown on p. 2. These tile were of a fireclay mixture, and were used instead of common brick on account of lower cost. The steel forming the upper 125 ft. (38 m.) was replaced, and a 4 ¼ -in. (11-cm.) lining of firebrick was laid from the bell to the top of the chimney. The brick were placed on end, wedges and keys being used. After each 8-in. course was set, keyed, and wedged tight, thin mortar -water, sodium silicate, and finely ground silica-was worked into the joints. The brick are supported on angle-iron rings, every 15 ft., in the same way as the tile.

Jan 1, 1921

By R. Dekkers, J. Plessers

The feasibility of using hydrogen to obtain clean steels is investigated. High hydrogen contents are generally considered as detrimental due to the risk of flakes, bubbles and breakouts during casting. Hydrogen can nonetheless be removed by degassing of the steel. The results of industrial campaigns, where total oxygen content and hydrogen content were monitored, are presented. High resolution microscopy of inclusions and laboratory experiments on the rate of inclusion removal by CaO-Al2O3 slags at different partial hydrogen have been carried out. So far, evidence that hydrogen may influence inclusions or the steel cleanliness is not clear. Keywords: hydrogen, cleanliness, inclusions.

Jan 1, 2004

By Remi Tremblay

This paper describes the laboratory study which permitted an exploration of high grinding ball consumption in the secondary open circuit wet grinding mills at the Sidbec-Normines plant, Port Cartier, Québec. Corrosion undoubtedly exists but is of minor importance. Abrasion resulting from the physical nature of the company's iron concentrate is the main reason for the high ball wear. It was found that at least 30% reduction in ball consumption is possible by decreasing attrition grinding through the use of lifters in the mill. At the industrial level this would entail more lifters and/or higher lifters in the mill linings.

Jan 1, 1984

By Lawrence K. Nordell

Historical methods of designing steel cord belt splices are compared with modern finite element modeling (FEM) methods. Dependence of the belt strength rating on the splice dynamic fatigue strengths is reviewed. A number of splice schematics are examined, using simple spring theory and FEM methods. Steel cord wire rope design is discussed. The importance of the insulation gum rubber properties and their splice dimensional factors and tolerances are analyzed. Splice fatigue lie analysis procedure is reviewed. This may be used to predict splice life or time of failure, depending on how the conveyor belt is operated.

Jan 1, 1993

By Galyn Rippentropp, Finn Erik Overlie

INTRODUCTION The wet shotcreting system utilizing steelfiber microsilica shotcrete with remote controlled equipment (The Robocon System) was developed in Norway 7-8 years ago. Norway was the natural origin for this system due to several factors. Almost 30% of all underground hydro-power stations in the world are located here. These projects created a need for high productivity shotcreting rigs for the rock support work in the caverns and in the connecting tunnels. During the period of 1976-1980, more than 1000 miles of tunnels were completed in Norway. Secondly, the utilization of microsilica in concrete was also developed in Norway due to a concentration of the world's ferroalloy p ants there. Robocon has presently placed approximately 110,000 m (150,000 cu. yds.) of this superior shotcrete, and has consequently an extensive experience in the shotcreting method. During a relatively short period of time (1975-1980), Robocon had a change from hand-operated, dry-process shotcrete to remote-controlled, wet-process shotcreting, because of improved productivity, reduced rebound, safer and cleaner working conditions. The introduction of microsilica and water-reducing admixture made it possible to produce wet-process shotcrete of high strength.

Jan 1, 1987

By Peter Shuttleworth, Chris Fesq, Eddie Woods

Precast concrete segmental linings for tunnels have traditionally been designed with conventional steel bar reinforcement. In many cases, this has been satisfactory in service, but in others, major problems have occurred with the durability of the linings. Commonly this has resulted from corrosion of the reinforcement, mainly from chloridesin ground water, causing spalling of the concrete and leading to very expensive and disruptive repair programs. This paper discusses the relative merits of designing tunnel linings with steel fiber reinforcement to provide long-term durability, improved impact resistance and toughness for greater load capacity across joints, enhanced robustness during transportation and erection, plus improved fire resistance with the addition of polypropylene fibers. Guidance is also given in the selection of the correct fiber type, mix design and testing methods to establish the optimum dosage required and production techniques to ensure even distribution and compaction.

Jan 1, 2005

By Mike Dry, Rod Dry

If humanity is truly serious about reducing emissions of carbon dioxide into the atmosphere, today’s power plants burning fossil fuels will have to be replaced by power plants that do not emit CO₂. Unless carbon capture/sequestration becomes practical, the new power plants will be hydroelectric, wind, solar or nuclear installations. Hydroelectricity requires the appropriate geography. Solar installations can only deliver power as and when sunshine is available, and wind installations when the wind blows. Therefore, power from these sources will be intermittent, but the demand for electricity does not follow the patterns of sun and wind. That will require large-scale electricity storage and/or load following by the remaining power suppliers, increasingly so as the use of fossil fuelled power generation declines. Modern nuclear power plants are designed for demand following. However, operating at lower than design output has a negative impact on the economics of nuclear power plants because the overall cost of the electricity they generate is dominated by capital cost. Primary (blast furnace) iron smelting is responsible for a significant part of global CO₂ emissions because the reagent used is carbon. Were it available in sufficient quantity (and at a low enough cost), hydrogen could replace carbon in the manufacture of raw direct reduced iron (DRI), using technology such as modified HYL (Tenova Hyl, 2018) or Midrex (Ravenscroft, 2017). This paper examines a scenario in which, instead of demand following, nuclear power stations are operated at their design capacities and surplus power is used to generate hydrogen in off-peak periods. This hydrogen is then used to replace carbon in the manufacture of raw steel.

Jan 1, 2020

By Jeongbok Seo

The Dulles Corridor Metrorail Project (DCMP) involves the design and construction of a 23.1-mile extension of the Washington Metropolitan Area Transit Authority (WMATA) rail system. The initial 11.7-mile extension, with five transit stations and a new service and inspection yard, is to be constructed. The construction plan for the initial 11.7-mile extension includes installation of a total of an estimated 4,250 or 160,000 linear feet of driven 12x53 steel H-Piles at more than 80 different locations. At the time of this paper, approximately 40 percent of the piles have been installed and the remainder of piles will be installed by the end of 2010. This paper describes: 1) subsurface investigation program, 2) application of existing Codes and impact on the design of H-Pile, 3) design methods to determine geotechnical bearing capacity and pile tip elevation, 4) verification of capacity including PDA and Static Load Tests, 5) project specific pile load tests, and 6) QA/QC during pile driving.

Jan 1, 2010

By James W. Weaver

The 2,120-foot long cable stayed Penobscot Narrows Bridge that carries US Route 1 over the Penobscot River between Verona Island and Prospect, Maine is supported on four foundation units, one below each pylon and one at each abutment. Due to varying subsurface conditions along the bridge alignment, the structure was designed to be supported on foundations consisting of high-capacity steel H-section piles (Verona Pylon), a mat bearing on a prepared bedrock surface (Prospect Pylon) and spread footings bearing on compacted rockfill (abutments). The 70-foot by 80-foot (plan area) Verona Pylon foundation was designed to be supported by 288, 430-kip design capacity steel H-section piles (HP14x117, 50 ksi steel) driven through up to 100 feet of dense glacial till deposits containing cobbles and boulders up to 3 feet in diameter. The piles were installed using a single-acting diesel hammer (Delmag D62-22) with a maximum rated energy of 165 kip-ft. Thirteen representative piles were selected for dynamic testing (ASTM D-4945) to verify pile capacity, hammer efficiency and pile stresses. Dynamic testing determined that four different pile driving criteria were needed across the site due to variation in the bedrock and soil resistance below the footing plan area. Approximately 4 percent of the production piles were damaged/rejected due to misalignment and/or damage as a result of encountering the cobbles and boulders embedded in the glacial till. The rejected piles were located randomly throughout the plan limits of the foundation mat. Subsequent structural analyses indicated that the foundation was capable of safely supporting the design loads without the need for installing replacement piles. Evaluation of dynamic testing results with signal matching and pile driving records provided valuable information on pile side and tip resistance. Evaluations were made regarding predicted versus actual pile lengths, pile bearing material, distribution of skin friction and end bearing capacities.

Jan 1, 2011

By James W. Harrower, Gerald S. Ball

This paper discusses the installation of steel linings in vertical, raisebored openings. Design criteria used to evaluate the applicability of liner type and design are presented as well as a brief description of installation procedures. Specific projects completed by J. S. Redpath Corporation are then outlined noting special considerations and techniques.

Jan 1, 1985

By Tapiwanashe Chenje, David Hewitt, Peter Radziszewski

"Steel media wear is a major cost component in mineral processing. In the case of existing operating mill, steel media wear prediction can be used to help compare the performance of steel media from different suppliers before completing marked ball tests. It can also be used to investigate how ores from different site of a given mine affect steel media wear. In the case of Greenfield cases, steel media wear prediction can be used to estimate the cost of steel media for a given feasibility study.This paper presents a wear testing and prediction methodology that ties together abrasion wear and corrosion wear testing results through the use of a simplified discrete element charge motion model. The experimentation dimension to this methodology takes samples for steel media, mine site ore and water to determine abrasive and corrosive wear parameters of a given media, ore, water set.The test methodology development is illustrated along with a comparison of wear predictions with observed wear rates in some operating mills. A case study is included that illustrates how this methodology was used to estimate steel media wear performance. The paper closes with a discussion on the use of parts of the experimental methodology to investigate other abrasive wear conditions such as liner wear, paste backfill piping and ore breakage as well as avenues for future test development.INTRODUCTIONThe cost of comminution processes represents a significant part of the overall costs of a mining operation. Grinding media/liner wear alone accounts for 15-25% of the total operating cost. The annual steel grinding media consumption is approximately 2.5 mtpa or 0.3% of total world steel production [Smorgon Steel Group, 2005]. Using an estimated grinding media cost of about US$0.75/kg [Halbe and Smolik, 2002], gives a media cost of over US$1.875 billion per annum. Mining continues to shift towards exploitation of lower grade ores as the higher grades get depleted. These low-grade ores require finer grinding for the liberation of the value minerals, and hence it can be assumed that grinding media consumption will also continue to rise.The Bond abrasion test, dating back to 1963, [Weiss, 1985] is still used to estimate the total mill media wear. This is a purely empirical test based on the ore. From Bond abrasion index tests, it is possible to determine a wear rate using the following function:"

Jan 1, 2009

By Alexander J. Verstraeten

The design and construction of foundations for power transmission line towers present some special problems. This paper describes a system of design and construction for these foundations that was developed in Europe and has attained general use there because of its reliability and cost effectiveness. Transmission line foundations distinguish themselves by having to deal not only with compressive and lateral loads, but with uplift loads and, because of the wind (in some regions earthquakes), with dynamic loading. The construction of transmission line foundations distinguishes itself mainly in the great number of inaccesible locations involved, resulting in extensive geotechnical investigation and logistical problems in moving men, materials and equipment.

Jan 1, 1987

By C. Mawdsley

The Tata Steel mill at Skinningrove in the North East of England produces top hat sections for mineshaft guides in sizes 102 and 150 mm. The top hat section is the technically preferred shaft guide choice for modern deep mine shafts. This paper explores the relative service performance of top hat and square hollow section guides in service. Comparative corrosion performance is reviewed and the paper describes work commissioned by Tata Steel (as Corus) undertaken by Aker Kvaerner Engineering to evaluate relative winding speeds, relative loads and fatigue life in service. The experience of supply to UK Potash mining is discussed and the future view of high capacity hoisting and larger section size market need and availability is assessed.

Aug 1, 2013

The man in the street (and no doubt most members of the Institute) thinks of wire, if he gives it any thought at all, as a most commonplace commodity. It is an accepted necessity, and like most necessities is taken for granted, unless a shortage in one or other of its multitudinous forms or products causes inconvenience.For many years Australia has ·been a large consumer of wire, particularly for fencing. With the rapid development of secondary industry the demand has increased in both size and character until at the present time much of the wire produced in this country is used as raw material for subsequent manufacturing processes. The call has been of so varied a nature that the Newcastle Wire Mills now turn out a greater variety of wire types than any other single plant in the world.In this paper, the aim is to provide a picture of the manufacturing, properties, and uses of wire. No attempt is made to cover the subject in any detail, as the field is much too broad for anything other than general treatment. Many phases, particularly in regard to manufacturing processes, are, therefore, dealt with cursorily, but it is hoped that the paper will, without delving too deeply into the technical aspects of Wire production, give a general appreciation of:- (a) How steel wire is made. (b) The remarkable physical characteristics obtained by judicious combination of chemical composition, heat treatment, and subsequent cold work. (c) The uses of steel wire.HISTORY.Best known of the early references to wire is that appearing in Exodus, where mention is made of gold wire being used for the sacerdotal robes of Aaron. However, the period in question, about B.O. 1491, is comparatively modern history as far as wire is concerned, for specimens believed to have been made about B.O. 4600 have been found. It is fairly certain that the Egyptians produced iron wire in B.O. 4000. Of particular interest is the

Jan 1, 1947

By C. D. Hebert, M. R. King

The 56,000' (17 km) long San Vicente Aqueduct Pipeline tunnel is being constructed using precast concrete rings to act as preliminary ground support through two sections of the bored tunnel with lengths of 9,450' (2.9 km) and 33,700' (10.27 km).The six segment bolted trapezoidal ring was manufactured using a combination of steel fiber reinforced concrete and self compacting concrete in vertical moulds. This paper briefly describes the design and function of the segments, and reviews the development stages of the concrete mix, and the advantages and disadvantages of the adopted manufacturing method.

Jan 1, 2007

By Don Rose

INTRODUCTION A number of tunnels supported and permanently lined by steel-fiber-reinforced shotcrete (SFRS) have been built in North America in the 1980s. The material is more economical than, and technically equal or superior to, conventional shotcrete using wire mesh. The design and construction of SFRS-lined tunnels is straightforward, and only a few new design principles, laboratory tests or construction equipment modifications appear necessary in order to use this material. Modern tunnel Contractors may use cyclic drill-and-blast methods on some tunnels, with intermittent shotcreting as part of an orderly cycle. The Dry Mix method is most suitable for cyclic, intermittent, relatively small-scale shotcreting. However, modern Contractors excavating tunnels continuously using large long Tunnel Boring Machines (TBMs) or Roadheaders may prefer Wet Mix shotcreting on a mass production basis. In either case, the use of steel-fiber-rein¬forced shotcrete (SFRS) promotes the rapid and economical excavation of tunnels. The addition of microsilica will improve SFRS properties and reduce rebound, and is expected to become standard practice with SFRS in North America, as it now is in Scandinavia. HISTORICAL REVIEW Steel-fiber-reinforced shotcrete (SFRS) at the present time (1985) is essentially conventional shotcrete with straight or deformed steel fibers added, and in general SFRS for tunnel linings encounters the same problems that conventional shotcrete does. Shotcrete history is well known. The use of sprayed plaster on wire frames for mounting animal skins by Carl Akeley of the Smithsonian

Jan 1, 1985

By Don Rose

Steel-fiber-reinforced-shotcrete (SFRS) methods of testing and the wording of specifications vary from country to country. In the USA ASTM C1018 is widely used. The Canadians have taken a close look at C1018 and point out that exact determination of the first crack is very subjective, and they propose a method of design that eliminates this variable. The Europeans (EFNARC) have taken the principles of testing a step further than ASTM C1018, and have added a new step in measuring the effectiveness of SFRS. EFNARC uses an "energy absorption" of a plate loaded in its center, in addition to the principles of C1018. The principles of SFRS design are also used in Japan, Norway and elsewhere.

Jan 1, 1999

By H. Moosberg-Bustnes

In cement-based products, such as concrete and mortars, a balance between the particle sizes of the components must be kept in order to obtain the required material properties, such as workability and strength. Sometimes the aggregates lack the necessary amount of fines, hence fine particles, i.e., filler materials, have to be added. Large quantities of filler material are needed in the production of modern concrete types; one principle of self-compacting concrete (SCC) is, for instance, the use of large amounts of fillers to reduce the friction between the coarser aggregates. Use of by-products such as slag, dust or sludge from the metallurgical industries as filler materials in concrete may help to conserve natural resources and at the same time be an economically positive option. However, to be able to successfully use the available materials they must be suitable for the planned purpose, i.e., they must be compatible with cement. In this paper three different experimental studies of steel-slags will be discussed. The aim of the studies has been to investigate if it is possible to improve the steel-slags properties, by selective screening, fine wet grinding or remelting, so that the steel-slags can be used as mineral-addition/filler material in concrete. Keywords: concrete, filler, steel-slag, modification

Jan 1, 2004

By B. M. Larsen, W. E. Shenk

This paper describes a method of reversal control of the open-hearth furnace that obtains in practice those effects considered below as essential to a completely automatic control, without appreciable interference with the natural rise and fall in temperature of the regenerative portions of the furnace system. Growing out of some studies of radiation pyrometry in open-hearth regenerators, it was developed during 1934-1938, and has been successfully applied to a number of commercial furnaces. The goal of open-hearth furnace operation is the highest rate of production of steel of proper quality consistent with good refractory life and fuel economy. This requires rapid heat transfer from furnace to charge, which in turn is dependent upon heating the furnace refractories to the highest safe operating temperature. The greater the heat input to the melting chamber, the sooner this limiting temperature will be reached, so that control methods in general that are designed to protect against overheating of refractories should help to maintain maximum fuel input and production rate. For the typical open-hearth system, with fixed regenerator capacity and with rate of fuel input usually restricted in its range of variation, our basic assumption is the idea that the only other important variable —that is, the time interval between successive reversals—should also be held constant or within a small range. The present reversal control was designed therefore so that, under normal operating conditions, no arbitrary limitation is imposed other than to keep the reversal interval within the optimum time range. However, since a near approach to completely automatic operation involves protection of refractories through the balancing of furnace end temperatures as well as emergency protection against temperature peaks above some upper limit, it was also felt essential to employ, as an integral part of the control unit, a temperature-measuring instrument to register the true temperature of the refractory surfaces at some critical region in the hot ends of the regenerative zones. As the basic elements of the control, we thus have one "maximum" and one lLminimum" time relay and a potentiometer recorder-controller, combined with switches and relays to operate as follows: I. Reversal normally occurs within an optimum range limited by the maximum and minimum settings to about 4 to 6 min. variation, but the actual interval usually is less variable and closer to the minimum setting. 2. The margin between minimum and maximum time is utilized, together with a "floating temperature limit" in the potenti-ometric control instrument, to correct any tendency toward temperature unbalance between ends of the furnace. 3. A second "maximum temperature

Jan 1, 1945

During the last 125 years, the steel industry has witnessed revolutionary changes in the process of steelmaking. The Bessemer process was the predominant steel production technology during the last two decades of the 19th century. The open hearth process accounted for the lion's share of world steel production for six decades from 1910 to 1970. With the appearance of the LD process on the industrial stage in 1952, the importance of open hearth process declined and currently the basic oxygen processes are contributing more than 60 per cent of the world steel production. The LD process also led to the development of several other oxygen blown processes such as LDAC, OLP, OBM, QBOP, EOF, Clc.

Jan 1, 1999