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By P Hulteberg

In this article, an integrated catalytic reactor design approach to produce PEMFC-quality hydrogen is evaluated. The design is based on a high level of heat exchanging perfonned internally, highly active noble metal catalysts and a woven wire mesh catalyst support system. It consists of an integrated steam refonner and a catalytic burner section, a water gas shift section and a preferential carbon monoxide oxidation section. The reactor design is described and experiments perfonned to evaluate the two reactors built are reported. The two reactors have a maximum output of 3 Nm and 10 Nm3 hydrogen/h respectively. In the larger unit, a total of six fuels, three gaseous (methane, natural gas and liquid propane gas) and three liquid (naphtha, ethanol and methanol), were evaluated. The larger unit was also used to investigate how variations of parameters such as steam-to-carbon ratio in the steam reforming part of the system and the relation between oxygen and carbon monoxide in the preferential carbon monoxide oxidation affect the reactor perfonnance. The smaller unit was used, after implementing automatic control, to run a system life time test for 480 h. The refonner system perfonned according to specifications on almost every aspect.

Jan 1, 2005

By Keith E. Meyers

Condition monitoring is a viable troubleshooting practice among many industries to extend equipment performance, minimize unplanned downtime, reduce maintenance and repair time and costs, and increase related aspects of plant safety. But obstacles abound for mining, mineral-processing and cement operations striving to implement the technologies. Harsh machine environments can muddy efforts. High vibration in machinery can interfere with wide-spread rollout. Staff expertise or skills may be lacking. And costs may be prohibitive. Fault detection has emerged as a practical and cost-effective solution to identify process and machinery faults before failure interrupts productivity or jeopardizes worker safety. Fault detection can be a stand-alone system or connected to plant automation.

Jan 1, 2005

By P. Rice, A. Photolo, A. C. Barnard

Introduction -Sampling Tool Project (STP) -History -Results to date -Costs -Questions

Jan 1, 2005

By Ryan Walton

The Flash Converting Furnace at Kennecott Utah Copper converted over 465kmt of high-grade matte in 2002 but was restricted due to low matte production to 395kmt in 2003. This paper presents updated operational performance data and describes improvements implemented since the mid 2001 rebuild. Matte burner feed distribution, silica and arsenic impacts on settler lime-based slag operability, blister laundering, uptake/boiler accretion control, and dust sulfation will be discussed, as well as current development requirements dictated by operational imperatives and furnace modification plans.

Jan 1, 2005

By R West

The Olympic Dam smelter facility processes copper concentrate feed using direct-to-blister smelting technology to support the current site production rate of 225 000 t/a copper. The metallurgical control of the Olympic Dam smelter is largely managed from a single central control room. Control room operation and management is therefore a key function in ensuring safe and reliable operation of the smelter, including identifying and initiating control of abnormal events. As part of a consolidated smelter reliability improvement program, a team consisting of process and control system engineers was formed. The teamÆs charter was to address and resolve the alarm flooding issues being faced by the control room technicians and the lack of an up-to-date base of supporting functional documentation. The project was successfully resourced with WorleyParsons metallurgists, Citect PLC technicians and the on-site technical team. Implementation was conducted over a 12 month period with the goal of achieving best practice alarm levels. The goal was achieved through a systematic process of alarm design review that analysed every configured alarm versus best practice design standards. Innovative concepts such as group-based alarms, first-up interlock displays, graphic only alarming, alarm help and alarm shelving were developed and implemented in conjunction with improved alarm masking. Total configured alarms were reduced from 20 000 to 5000 while the alarm rates were reduced from in excess of 200 alarms per hour per controlling technician to best practice levels of less than 12 alarms per hour per controlling technician. Completion of this program has provided a firm foundation for implementing further control optimisation and was a key activity in supporting sustained smelter reliability levels.

Jan 1, 2005

Solid Energy New Zealand Limited owns and operates the Ohai coal field (Wairaki Coal Mining Licence, CML) in western Southland. The Morley Stream passes directly through the middle of the CML and has required diversion in the past to enable open cast mining to proceed. Solid Energy is evaluating two new open cast pits at Ohai. Commissioning these new pits would necessitate further diversion of the Morley Stream. One of these potential new mines is adjacent to an abandoned State Coal Mines (State Coal) pit and there is an opportunity to substantially rehabilitate this old pit as a corollary to the new mine and the stream diversion project.   Past Morley Stream diversions were undertaken by State Coal and so they predated the Resource Management Act 1991 and the degree of community environmental awareness and involvement that has become the norm these days. Not surprisingly the design and construction of the historic stream diversions was based purely upon mining (operational) and engineering considerations. This led to the stream being diverted in a manner that achieved the clinical conveyance of design volumes of water from points A and B.   Solid Energy realised that the proposed new diversions need to adopt more holistic and environmentally sustainable design principles while also including appropriate mining and engineering constraints. This project involved the design of a 1.7 km diversion of the Morley Stream (median flow of about 1000 litres/second) that would enable progressive prestripping and development of the new mines and would also address final rehabilitation (of the stream), geotechnical risks, hydrological and ecological issues. To address all of these factors the project required a multidisciplinary approach. Moreover, it required a clear understanding of how the mining operational constraints could be integrated with the environmental considerations. A significant aspect of the project was how to take account of fishery instream habitat needs, the resource consent requirements and most of all, the involvement of key stakeholders such as the Fish & Game Council, Department of Conservation, the Iwi and local community in the design process. This was achieved through coordinated consultation and stakeholder involvement in a technical design workshop.

Jan 1, 2005

By Hong Yong Sohn

Keywords: Barium sulfate, Barium sulfide, Environment, Kinetics, Pollutants, Sulfur dioxide conversion, Thermodynamics Nonferrous smelters and coal gasification processes generate sulfur dioxide streams, most of which are treated to produce sulfuric acid with the accompanying problems of market shortage and transportation difficulties. While the conversion of sulfur dioxide to elemental sulfur has many environmental advantages, no processes exist that are environmentally acceptable and economically viable. A method for converting sulfur dioxide to elemental sulfur by a cyclic process involving calcium or barium sulfide and calcium or barium sulfate without generating solid wastes has been developed. In this process, the sulfate, as the starting raw material, is reduced by a suitable reducing agent such as hydrogen to produce the sulfide, which is used to reduce sulfur dioxide producing elemental sulfur vapor and regenerating the sulfate. The latter is then reduced to reproduce the sulfide. This paper describes work on the BaS/BaSO4 system. Thermodynamic analysis and experimental results indicated that the BaS-SO2 reaction produces mainly sulfur vapor and solid barium sulfate and that the gaseous product from the BaSO4-H2 reaction is mainly water vapor. The rates of the two reactions are reasonably rapid in the temperature range 700-1050°C.

Jan 1, 2005

By Yu Chuang, Zai Jinmin, Liu Songyu

"The piled raft foundation is a geotechnical composite construction method, consisting of three elements, piles, raft and soils, which is applied for the foundation in an increasing number. Differential settlements have numerous negative effects on a superstructure in piled raft foundations. Through the analysis of the production mechanism of differential settlements and differential settlements control measures, a method of adjusting pile configurations is presented to control differential settlements. By comparing the measured data and finite element method analysis of one oil storage piled raft foundation, the new method is verified that the differential settlements can be reduced effectively and the inner forces of foundations are more reasonable with varying length pile configurations. The differential settlements can be minimized or even reduced to zero with right pile length.INTRODUCTIONPiled raft foundations are widely adopted for the prominent advantage of limited settlements and adequate bearing capacities. However, there always exits differential settlements in conventional piled raft foundations. The differential settlement is the main cause that produces additional stresses in the structure. Differential settlements have numerous negative effects on a superstructure as well as on a foundation, and should be restricted to allowable limits. How to control the differential settlement is the key interest.An increasing number of structures are founded on piled rafts. For this reason, design strategies that enable an optimized design have a major importance for safety and economy. An optimized design may be defined as a design achieving maximum economy of the solution, that is minimum cost for the installation of the foundation."

Jan 1, 2005

By Charles Pretorius

Electronic Delay Detonators (EDDs) with remote wireless programming and initiation capabilities have been successfully used for almost two years now. This system has been used in blasts mainly in South Africa, but also in South America and other countries in Africa. Initially the industry was slow to accept the idea of remote programming and blasting. The advantages were not fully understood and there were some safety concerns. With close to 200 successful blasts as a reference, a much better understanding exists. The advantage of such a system becomes even more significant when the programming of the detonators is digitally integrated with the blast design software as used by the Blast Engineer. It is now possible to import a survey file into the blast design software, to do the blast design using actual hole positions and to then export the designed firing times directly to the detonators down the hole via remote wireless communication. Mines that have been exposed to this technology favour it to the extent that wireless centralised programming is becoming the norm against which other electronic delay detonator technologies are measured.

Jan 1, 2005

By D Bruggemann, F Sereshki

There has been an ongoing research on coal and gas outburst for the past two decades at the School of Civil, Mining and Environmental Engineering, University of Wollongong. Research study began with a humble beginning, initially conducting basic laboratory studies on the coal and gas properties, progressing into the determination of gas content of coal by sorption technique and the effect of gas pressures on coal strength. The present laboratory facilities and research interests are extended to include the study of coal permeability and shrinkage properties and their effect of gas drainage characteristics with respect to gas type, and pressures. All the changes are examined with respect to changing in-site geological conditions of the coal deposit investigated. The aim is to provide a long-term support to industry in establishing a data bank for Australian coal deposit characteristics and properties.

Jan 1, 2005

By D. Stone, N. J. Aslin, W. Webb

In today's modem copper electro-refineries, increasingly higher average current densities are being employed. With these increases many refineries are approaching their limiting current density. The nearness of the average operating current density to the limiting current density has placed increasing emphasis on the need to maintain an even current distribution. This paper explores the importance of maintaining even current density and discusses the factors, processes and practices that are necessary to achieve and maintain high quality production at high operational intensity.

Jan 1, 2005

By Adriana Gómez

White dross is a result of the aluminum oxidation during its primary production and is mainly composed of metallic aluminum, Al2O3, with minor amounts of AlN and some other oxides. Because of the great variety of phases, the quantitative characterization is complicated. This work shows a quantitative method to determine the main phases of white aluminum drosses by means of X-ray diffraction (the Rietveld method). Nowadays the Rietveld method is maybe the most useful method for obtaining quantitative phases information in multicomponent mixtures, this method permits relatively quick quantitative phase analysis by fitting the calculated X-ray diffraction profile with the observed one. The analysis were done using powder with a grain size less than 45 µm; to obtain the suitable material size the aluminum dross was grounded by ten minutes, several times. The grounded material was screened, and the material smaller than 45 µm was taken to quantitative XRD analysis. Keywords: Rietveld Method, Characterization, Aluminum dross.

Jan 1, 2005

By Ronnie X. Gu, Xing Zheng, Gem-Yeu Ma

Due to implementation of the rotator construction method from which a smooth shaft was anticipated, a full-scale pile load test (Osterberg Method) was performed at Pier 14 Pile 9 of the main span of the New Benicia-Martinez Bridge to confirm the design parameters of the rock sockets. Two levels of load cells were fabricated in the reinforced cage of the rock socket. Each level consisted of three 670-mm Osterberg load cells with a total testing capacity of more than 50 MN in both directions. In an attempt to separate side friction and end beari ng, a 75 mm thick compressible Styrofoam material was placed at the bottom of the cage. The pile load test was carried out in four stages. The multi-level multi stage pile load test data was interpreted for casing friction, side friction for two rock strata, end bearing, and residual side shear values under repeated loading in opposite directions. The side friction from the casing in soils at Stage 2 is approximately 9 MN. The end bearing at the tip of the rock socket at Stage 3 was calculated to be approximately 17 MN at a displacement of about 75 mm. The residual side shear resistance for the 10 m 50% RQD rock strata was calculated to be 9 MN or approximately 50% of initial values, after being pushed 0.3 mm upward in Stage 1, 71 mm downward in Stage 2, then 55.5 mm upward again in Stage 3, and finally 105.3 mm downward in Stage 4. The test results surprising ly indicate that the side shear resistances from both low RQD intensely weathered rock and higher RQD slightly weathered competent rock are about the same at approximately 19 MN. This pile load test provides very critical information for confirming deep shaft design and analyses.

Jan 1, 2005

By R. J. Smyth

A Steel Compression Reinforcement Repair Technique (PetroSleevel) system has been developed that has the ability to repair pipeline defects such as stress corrosion cracking (SCC) without requiring welding to the operating pipeline. The Technology has been used to repair active cracking in ERW seam and cracking in the pipe body. All repairs were performed while the pipeline was in operation. This paper will discuss the engineering theory, testing performed to verify the engineering theory, and examples of actual sleeve installations.

Jan 1, 2005

By C. P. Kelley, T. J. McKeon

Several recent developments in fine screening technology have been implemented at the DuPont Starke, Florida plant allowing enhanced zircon recoveries while minimizing operator requirements and total operational costs. The total design concept came about through the efforts of engineers at Derrick Corporation (Buffalo, New York), DuPont Titanium Technologies (Starke, Florida) and Roche Mining (Carrara, Australia). The use of the Kelsey Jigs for zircon recoveries from the tailings stream requires two wet sizing functions in order to operate properly. The first wet sizing is required on the initial mineral slurry feed to the Kelsey Jig. This sizing is intended to protect the Kelsey Jigs internal screen basket from plugging with nearsize particles, thereby keeping production rates maximized. The second sizing function is intended to recover properly sized garnet ragging material, which inadvertently ends up in the tailings stream leaving the Kelsey Jig. The unique machine design developed by the three partners in this project incorporated both wet sizing functions (protection and garnet recovery) into a single patented high capacity wet screening machine fitted with patented screen surface technology. This screen surface technology allowed for high capacity slurry handling capabilities at separations as fine as 230 microns while experiencing no nearsize blinding and extremely long screen panel life. The high open area urethane screen surfaces utilized in the application typically last 20 to 30 times longer than stainless steel wire surfaces. The stacked machine design minimized total equipment requirements and screen footprint requirements, and reduced power consumption and overall installation costs.

Jan 1, 2005

By E. Snyders

Two alternative processes for the manufacturing of zircon products were investigated by the South African Nuclear Energy Corporation (Necsa). These were the synthesis of doped-zircon pigments from plasma dissociated zircon, and an upgrading process to convert an inferior grade of zircon into a superior opacifier for ceramic applications. A solid-state reaction process was used to produce doped-zircon pigments. The influence on the colour intensity of the pigments on a ceramic tile were compared for milled and un-milled plasma dissociated zircon (PDZ) material, prior to calcination. Pr-yellow and V-blue zircon pigments produced from PDZ with different degrees of dissociation, were also evaluated. The second zircon beneficiation process entails the upgrading of an inferior grade of zircon to a superior opacifier for ceramic applications. A calcining process in the presence of mineralizers was used to produce the product in a conventional muffle furnace. A pre-milled inferior grade zircon concentrate, with a relatively high iron and alumina content generally not suitable for high quality ceramic applications, was used in this study. The influence of the upgrading process on the opacifying properties of the zircon material was compared to that of commercially available prime grade zircon opacifier products currently being produced in South Africa. The influence of a calcining step in the presence of mineralizers with regard to the milling characteristics of the treated zircon material was also evaluated.

Jan 1, 2005

By John Ralston, Jinming Duan, David R. E. Snoswell, Daniel Fornasiero, Jingwu Yang

The colloidal stability of synthetic silica spheres with clean, methylated and dehydroxylated sur¬faces was studied at different concentrations of dissolved gas and KCl electrolyte at a fixed pH of 4.2. A classic stability ratio/electrolyte concentration analysis shows that hydrophobic, methy¬lated particles undergo faster rates of aggregation with increasing concentrations of dissolved carbon dioxide. Similar data for hydrophilic particles and dehydroxylated particles show no change as a function of dissolved carbon dioxide concentration. Zeta potential data behave simi¬larly, showing a strong influence of dissolved gas only for methylated particles. The results are interpreted in terms of DLVO theory, with the surface-to-surface interaction dominated by the presence of very small protruding bubbles. Direct evidence for the existence of these very small gas bubbles (or "nanobubbles") was obtained using tapping mode atomic force microscopy. Small bubbles do not form on smooth, hydrophilic, or dehydroxylated silicon oxide water sur¬faces immersed in aqueous solutions under known levels of gas supersaturation. Randomly dis¬tributed small bubbles were observed over the whole surface of observation on methylated surfaces of controlled roughness. Bubbles formed on rough, methylated surfaces were larger and less-densely distributed than those on a smooth surface of similar hydrophobicity. The process of bubble coalescence was observed as a function of time. The macroscopic contact angle, measured with respect to the aqueous or gas phase, is very different from the microscopic contact angle detected by TMAFM and appears to be due to the influence of line tension at the pinned three¬phase contact line. The latter has a value of -3 x 10-10 N and acts to stabilize the small bubbles, flattening them and thereby reducing the Laplace pressure.

Jan 1, 2005

By X Meng, W. A. Hustrulid, M. K. McCarter

Rock excavation in both surface and underground mining is largely accomplished using the drill and blast technique. At the perimeter of such excavations, cautious blasting procedures are often employed to minimize unwanted damage to the remaining rock. Of the several different techniques available, the use of explosive charges with a diameter smaller than the holes in which they are introduced (so-called decoupled charges) is the most common. In spite of the long and widespread use of the technique, a technically sound basis for relating the borehole wall pressure to the explosion pressure is still lacking. Such a relationship is required for optimal design

Jan 1, 2005

By David Hake, David Salisbury

The Drainage Services Department (DSD) of the Hong Kong SAR Government commissioned the design and construction of the West Kowloon Drainage Improvement, Stage 2, Phase 2, Kai Tak Transfer Scheme (KTTS) project in 2000 to relieve potential flooding in Mong Kok caused by the insufficient capacity of the existing storm water drainage system. The KTTS involves construction of a 1.5km,4.4m drainage tunnel and a 450m long box culvert, running from Waterloo Road near Hereford Road to the existing Kai Tak Nullah in San Po Kong. This paper describes the design and construction of; the bored tunnel through both hard rock and soft ground using a slurry Tunnel Boring Machine (TBM), six associated access shafts, a connection structure at Waterloo Road and the box culvert connecting the bored tunnel to the outfall at Kai Tak nullah. Details will be provided on the contractor’s alternative designs adopted during the contract including the use of fibre reinforced shotcrete as one-pass temporary and permanent support for three of the shafts and modifications to the Engineer’s design for the box culvert structure.

Jan 1, 2005

By S. V. Rungan

Since 1994, South Africa has been the subject of international attention, especially in regard to its transformation initiatives, which aim to redress the post-apartheid imbalances. Mining, as a major employer and one of the major industries in South Africa, has been the focus of the government?s Black Economic Empowerment initiative with the introduction of the Minerals and Petroleum Resources Development Act and the Broad?Based Socio?Economic Empowerment Charter for the South African Mining Industry. The historical background to South Africa?s transformation and the role of the mining industry are pivotal to an appreciation of certain aspects of the Minerals and Petroleum Resources Development Act and the Broad?Based Socio?Economic Empowerment Charter for the South African Mining Industry. The issues around Black Economic Empowerment and the enabling of a smooth transition to the South African mining industry of the future are explored in this paper.

Jan 1, 2005