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By W. J. Fene, G. W. Grove

An important activity of the Safety Division of the Bureau of Mines , in its efforts to reduce accidents , is the safety inspection of mines . Inspections are made at the request of the operators and are not connected with the inspections by the various State departments of mines . The operating management is furnished with a confidential report of the results of the Bureau's inspections , with recommendations for elimination of the hazards found . These mine - safety inspections include a study of mining practices , conditions , and equipment and in some cases the sampling and analysis of mine air and coal dust . The Bureau of Mines has no regulatory powers , therefore the recommendations made in these reports are merely suggestions , and operators are not required to adopt them . Mine inspections are a check on safety standards , methods , and practices and are essential to any accident -prevention program . A foreman or superintendent may be sincere in his efforts to operate a mine safely and believe that he has done everything possible to attain this end . However , experience has shown that because of his familiarity with the mine and the consequent " nearness " of its various features many unsafe conditions may be , and in most cases are , overlooked ; an inspector , particularly an outsider who is trained to look for hazards , can point out the unsafe conditions overlooked by the foreman or superintendent . Some companies employ safety engineers who make regular inspections of their mines , report substandard conditions and hazards found , and make recommendations for correcting them . Unless these recommendations are carried out the inspections have little value . In making recommendations , due consideration should be given to the feasibility of carrying them out ; the management may and very often does consider a recommendation impracticable because of the

Mar 1, 1935

By R. Cammack

"A fundamental component of the Hoek–Brown empirical rock failure criterion is assessing an appropriate mi constant. In developing their empirical criterion Hoek and Brown normalised triaxial test results by dividing the principal stresses at failure by the uniaxial compressive strength to provide mi values for typical rock types. Experience shows that Hoek triaxial tests for individual lithology types commonly have a large inherent scatter. In addition, tests are often conducted on core from random locations, which although being of one parent rock type, display variations in density as well as minor variations in grain size and alteration.This paper presents experience from projects the authors have been involved in which large sample populations of triaxial and UCS tests on similar rock types were available. Geophysical logging data was also available for some projects. The methods used to estimate the compressive strength for each sample and the effects on normalising the data sets are described. The variability of the data and uncertainties and assumptions involved in the process of assigning a mi value from the normalised data are also discussed."

Jan 1, 2015

By Taekhee Lee, Steven Mischler, Shawn Vanderslice

Diesel-powered equipment is widely used in the underground mining industry and their popularity results from properties including efficiency, versatility, reliability, and durability. In the U.S. approximately 7,700 diesel engines were used in 177 underground metal and nonmetal mines as of 2005 [MSHA 2005], and these numbers have likely increased since that time. Diesel engines have been shown to be a major contributor to submicron carbonaceous, respirable, and total particulate mass in the air of underground metal mines [Zielinska et al. 2002, McDonald et al. 2003], and their extensive use results in approximately 13,000 underground metal/nonmetal (M/NM) miners (MSHA 2005) in the U.S. being potentially exposed to aerosols and gases emitted by diesel engines (MSHA 2001, MSHA 2006). Exposure to diesel exhaust has been linked to adverse health outcomes including cancer, cardiovascular, and respiratory diseases (Attfield et al. 2012, Silverman et al. 2012), and in 2012 diesel exhaust was categorized by the International Agency for Research on Cancer (IARC) as a Group 1 human carcinogen (IARC 2012). Exposure to diesel particulate matter (DPM) is especially concerning for underground miners since underground mine environments have been shown to have some of the highest levels of diesel exhaust in the U.S. (EPA 2002, MSHA 2001, MSHA 2006, Pronk et al. 2009). Due to the potential for elevated DPM concentrations in mines, the Mine Safety and Health Administration (MSHA) promulgated a rule to limit exposures of metal/ nonmetal underground miners to DPM to an eight-hour time-weighted average (TWA) of 160 μg/m3 total carbon (TC) (MSHA 2001, MSHA 2006, MSHA 2008). Since this rule went into effect, DPM exposures have been reduced, but are still elevated when compared to other occupations (Pronk et al. 2009, Noll et al. 2015). MSHA compliance data between 2005 to the present show that underground blasters represent 21% of all DPM overexposures in M/NM mines and are one of the highest exposed professions in mining often resulting from low ventilation in the area where blasters are working. Because mines have difficulty controlling DPM in these low ventilation areas, additional control technologies may be needed to reduce exposures. Administrative controls, where miners work on off schedules or upstream of diesel vehicles to avoid the exposures to DPM (Noll et al. 2015) is one possibility, but these types of solutions are not always feasible or practical. A canopy air curtain is another potential control technology to help reduce exposures of blasters to DPM. Listak and Beck (2012) showed that this control technology reduced respirable dust concentration under a roof bolter’s canopy by 67%–75% and recommended air velocities greater than 0.5 m/s for dust reductions of greater than 50%. Additional work showed that a canopy air curtain could be designed for a shuttle car, and some initial testing by the National Institute for Occupational Safety and Health (NIOSH) showed reductions of respirable mine dust between 66% to 70%. As seen in Figure 1, the canopy air curtain delivers clean air over the operator’s breathing zone. A fan draws in air through a filter to capture the dust and then supplies clean air beneath the canopy where a miner is working. The use of the canopy air curtain to reduce exposures to diesel particulate matter was first discussed by Noll et al. (2020). In this study the diesel canopy air curtain (DCAC) reduced the DPM concentrations under the canopy by up to 90%. For this research the DCAC was designed to attach to the basket cover of an ammonium nitrate fuel oil ( ANFO) loader (Figure 2) and provide clean air blowing over the miners as they work in the basket. The initial tests used clean air drawn from the mine’s intake and did not try to filter the DPM from the air. Filtering DPM has extra challenges when compared to filtering mine dust particles. The particles of DPM are smaller (submicron and nanometer) than dust particles (greater than 1 micron); therefore, the filtration system must be adjusted to capture submicron particles. A MERV 13 filter was used in previous canopy air curtain research on mine dust control, but this filter is only designed to capture 50%–75% of submicron particles, and this capture efficiency is too low for removing DPM, so a higher efficiency filter is needed. Higher efficiency filters increase the pressure across the filter media which results in decreased airflow or leaks around the filter and reduces the effectiveness of the control for protecting miners from DPM. The optimal filter needs to capture DPM particles at a high efficiency while still allowing the needed airflows to prevent contaminated air from entering the miner’s breathing zone. Listak and Beck (2012) recommended velocities greater than 0.5 m/s for dust reductions of greater than 50%. However, airflows too high have been shown to reduce miners’ thermal comfort; Roghanchi et al. (2016) suggest the optimal velocity for thermal comfort is between 1–2 m/s. Thus, airflow over the miner should be limited to the range of 0.5 to 2.0 m/s. This current study presents the results from research evaluating the reduction of DPM concentrations, under the DCAC, when using a higher efficiency filter (MERV 16) to remove DPM from the DCAC airstream.

Feb 1, 2024

By C. D. Litton, I. E. Perera

Experiments were conducted to evaluate the response characteristics of commercially available gas, smoke and flame sensors to fires of common combustible mine materials. The experiments were conducted in the large-scale fire gallery located at the National Institute for Occupational Safety and Health (NIOSH) Lake Lynn Laboratory in Fairchance, PA, using ponderosa pine, red oak, Douglas fir, high and low volatile coals, polyvinyl chloride (PVC) and styrene butadiene rubber (SBR) conveyor belts, No. 2 diesel fuel and diesel exhaust. All the experiments (except those using No. 2 diesel fuel and the diesel exhaust tests) were conducted in a similar manner, with combustible materials heated rapidly by electrical strip heaters, producing smoldering fires that quickly transitioned into flaming fires. The sensors included a diffusion-type carbon monoxide (CO) sensor, photoelectric- and ionization-type smoke sensors, a video smoke/flame detector and an optical flame detector. Simultaneous measurements were obtained for average gas concentrations, smoke mass concentrations and smoke optical densities in order to quantify the levels of combustion products at the alert and alarm times of the sensors. Because the required sensor alarm levels are 10 ppm and 0.044 m-1 optical density for CO and smoke sensors, respectively, the different sensor alarms are compared to the time at which the CO and smoke reached these alarm levels (Litton et al., 1991). In addition, the potential impact of using smoke sensors that have met the performance standards from accredited testing laboratories is also evaluated using the response of an Underwriters’ Laboratory (UL)-approved combination photoelectric/ionization smoke detector. The results are discussed relative to fire sensor needs that can have a positive impact on mine fire safety.

Jan 1, 2014

By Brent A. Slaker, Khaled M. Mohamed

"Understanding coal mine rib behavior is important for inferring pillar loading conditions as well as ensuring the safety of miners who are regularly exposed to ribs. Due to the variability in the geometry of underground openings and ground behavior, point measurements often fail to capture the true movement of mine workings. Photogrammetry is a potentially fast, cheap, and precise supplemental measurement tool in comparison to extensometers, tape measures, or laser range meters, but its application in underground coal has been limited. The practical use of photogrammetry was tested at the Safety Research Coal Mine, National Institute for Occupational Safety and Health (NIOSH). A commercially available, Digital Single-Lens Reflex (DSLR) camera was used to perform the photogrammetric surveys for the experiment. Several experiments were performed using different lighting conditions, distances to subject, camera settings, and photograph overlaps, with results summarized as follows: The lighting method was found to be insignificant if the scene was appropriately illuminated. It was found that the distance to the subject has a minimal impact on result accuracy, and that camera settings have a significant impact on the photogrammetric quality of images. An increasing photograph resolution was preferable when measuring plane orientations; otherwise a high point cloud density would likely be excessive. Focal Ratio (F-stop) changes affect the depth of field and image quality in situations where multiple angles are necessary to survey cleat orientations. Photograph overlap is very important to proper three-dimensional reconstruction, and at least 60% overlap between photograph pairs is ideal to avoid unnecessary post-processing. The suggestions and guidelines proposed are designed to increase the quality of photogrammetry inputs and outputs as well as minimize processing time, and serve as a starting point for an underground coal photogrammetry study.INTRODUCTIONThe stability of underground mine ribs has been a safety concern for underground coal mines for decades. Unfortunately, the average rib fatality rate has been about 1.3 per year between 1996 and 2013 (Jones et al., 2014). In an effort to better understand coal rib behavior, photogrammetry is being investigated in this study as a measurement tool for surveying ribs in an underground coal mine environment."

Jan 1, 2016

By Claude Hubert, Robert Sansfaçon

"The Malartic gold camp includes the Malartic Gold Fields, Barnat, East-Malartic, Canadian Malartic and Sladen mines. From 1935 to 1984, these mines have yielded 212 403 kg of gold. They occur within a 900 m wide belt of highly sheared, dislocated and faulted volcanic and sedimentary rocks (Piché and part of the Pontiac groups) herein named the Malartic Tectonic Znne (MTZ). The zone trends WNW-ESE and separates two lithotectonic sedimentary domains, the Cadillac to the north and the Pontiac to the south. The sedimentary domains are characterized by their coherent fold generations consisting of open to tight reclined and recumbent F1 folds that have been refolded into series of asymmetric upright F2 folds. A flat-lying schistosity (S1 ) and a vertical pressure-solution cleavage (S2) are ubiquitous throughout. Discrete sets of brittle and brittleductile faults are synchronous and parallel to each of these two fabrics.The MTZ trends N320° in the northwestern sector of the town of Malartie, changing to N2800 at its easternmost extremity. The Malartie and Sladen faults constitute its northern and southern boundaries respectively. These two faults also bound another set of faults oriented N305°. Throughout the MTZ, the faults at N280° and N320° and those at N305° outline a series of anastomosed motifs that constitute the principal structural feature of the Malartic district. Locally, a fourth set of minor faults at N065° combines with the other three prominent sets. All these faults have disrupted the gold-bearing volcanic, sedimentary and intrusive rocks encountered throughout the MTZ.The MTZ comprises numerous lozenge-shaped blocks of komatiites and basalts or greywackes and black shales which are cut by disjointed dikes, sills and small intrusions of felsic and mafic rocks. The latter includes gabbro, diorite, lamprophyre, monzonite and pegmatite. They frequently fill conjugate sets of fractures. In some areas, they are clustered into coalescent intrusions. The present morphology of these intrusive bodies( cube, chocolate-tablet boudin, parallel epiped and cigar) is not representative of their primary forms but the result of late shearing and faulting indicative of a major tectonic event subsequent to their emplacement. The intrusions were injected during a brittle stage of deformation related to the F1 folding but prior to the development of the F2 folds and subsequent tearing and shearing by late brittle and brittle-ductile faults . The ultramafic and mafic rocks are intensely altered to serpentine, tremolite, actinolite, carbonate, biotite, hematite and pyrite according to the nature of their proto/it h. In the vicinity of the MTZ, all lithologies exhibit mineral assemblages indicative of the upper greenschist or lower amphibolite facies of metamorphism.The structural evolution of the MTZ involved superimposed folding, shearing, transposition, mylonitization, brittle and brittle-ductile faulting. Each lenticular motif results from the combined effect of conjugate sets of shear zones that outline lozenge-shaped blocks where strain markers indicate different strain states from cores to margins. Bedding in ultramafic flows and/or sedimentary rocks is either NW-SE or NE-SW within the blocks but, in the vicinity of the Malartie and S laden faults, it has been rotated to become subparallel to the faults.Ore shoots are most commonly associated with altered and deformed bodies of diorite and monzonite, or some mafic and ultramafic schists and, at the Canadian Malartic, Sladen and East Malartic mines, with metasedimentary rocks. The shoots occur in close proximity to the various faults of the MTZ but the gold itself is intimately associated with pyrite, biotite and carbonate in halos bordering fractures crisscrossing the different host rocks. The density of fractures and the width of their altered zones have been significant parameters in the production of economic ore shoots. Grains of gold are visible in some veins of quartz a"

Jan 1, 1990

By E. Yigit

Hydrometallurgical production of zinc from concentrates is generally carried out by H2SO4 leaching. For the smooth operation of this process, some harmful components must be removed from the leach solution before the electrolysis stage; MgO is one of these compounds. Zinc concentrate samples from the Mount Isa mines were used in leaching tests. Leaching tests with an aqueous solution of H2SO4 and SO2 gas were carried out at various temperatures, pH levels and leaching durations. While duration and the pH value of the solution were effective parameters in H2SO4 leaching, temperature and pH were more effective in SO2 leaching for the removal of MgCO3 and CaCO3. Removal of MgCO3 and CaCO3 was generally achieved at low pH values. The results show that SO2 gas can be a good alternative to sulfuric acid in the leaching of MgCO3 and CaCO3

Jan 1, 2010

By K Rees

In the ideal world of an underground mining engineer, all narrow vein orebodies would be perfectly straight and continuous, thus would be a dream to mine. However, this is usually not the case. Narrow vein orebodies generally occur in association with shear zones and while shear zones do form linear trends, they most commonly preserve undulating expressions that need to be closely monitored, particularly when overprinted by post-formed structures. The surge in mines using fibrecrete as a primary form of ground support effectively reduces the time available for geological interpretation down to a 30 minute window between bogging and shotcreting. Thus, if the quality of the data collected is not up to scratch, then there is only a limited ability to reassess using 2D face photographs. To negate this, Xstrata Nickel AustralasiaÆs Cosmos mine has upgraded its data collection procedure. Geological information is now collected using photogrammetry survey, producing 3D images of the drive. Once created, the digital image of the drive is loaded into Vulcan, thus enabling geological interpretation to be carried out along entire drives, between levels and in association with all other data (eg drill holes, seismic data, etc). In addition to this, the 3D image can be used to accurately model the location of the ore, enabling stoping panels to be confidently positioned to maximise grade and minimise dilution. However, with the focus at Cosmos changing from narrow vein mining, to bulk mining methods in a more geotechnically complex terrain, the use of the 3D images has become paramount in understanding the structural geometry. Continual interpretation of the data has enabled drive profiles to be maintained through the increased use of ground support in poor ground and the redesign of development to enable optimal intersection of structures. Nevertheless, while the collection of quality data is important, it is only the effective use of the data, which enables significant gains in understanding.CITATION:Rees, K, 2012. The benefits of using photogrammetry in the geological interpretation of the Cosmos nickel mine, in Proceedings Narrow Vein Mining 2012 , pp 145-148 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Mar 26, 2012

By A Suwandhi, H Utama

PT. Indo Muro Kencana (PT.IMK) is a gold mine that is located in Central Kalimantan, Indonesia. Drilling and blasting activity is applied in order to support mining production. Drilling and Blasting (D&B) planning is conducted by its engineers. A drilling and blasting contractor conducts drilling and blasting activity. The objective of this paper is to evaluate the implementation of the scaled depth of burial (Chiappetta and Treleven, 1997) in explosive charging sheet application to increase blast efficiency. The function of the scaled depth of burial is to maintain stemming height above explosive charge in order to prevent the ‘over energy’ condition, to reduce the excessive fly rock possibility, to maintain rock fragmentation (digger’s productivity) and to increase blast efficiency. The focus of this paper is to implement the scaled depth of burial as a reference in D&B planning and practice, especially in designing stemming height. The purpose of this paper is to validate that the scaled depth of burial can be used as an engineering tool in D&B practice in PT.IMK. However, scaled depth of burial cannot applied as an engineering tool to determine stemming height above explosive charge for trim blastholes and secondary blasting area. In general, the implementation of the scaled depth of burial in PT.IMK is applicable for production blastholes (ore and waste blasting). In conclusion, it is clear that scaled depth of burial can be used as an engineering tool to create explosive charging sheet and also to increase blast efficiency (ore and waste blasting) in PT.IMK.

Jun 22, 2022

By A. A. Tytko, T. S. Golosinski

"The paper discusses the accuracy of magnetic inspections of corroded hoist ropes. It quantifies the error of measured LMA (loss of metallic area) caused by presence in the rope of ferromagnetic products of corrosion. The paper concludes that in mining practice this error is not significant. Hoist Rope Corrosion and its AssessmentCorrosion is one of the most common forms of wire rope wear. For ropes working in wet mine shafts, ropes used by the fishing industry and, in general, ropes working in humid and chemically active environments, corrosion wear is usually the prime reason for rope discard. In most mining applications, rope corrosion is accompanied by fatigue cracking of wires, abrasion of external wires, internal nicking and other forms of wear.Quantification of corrosion damage in ropes using standard inspection procedures and examination methods is very difficult. Qualitative comparisons are sometimes used to describe the degree of rope corrosion to compensate for the lack of quantitative measures (SABS 0293, 1996). If available, the results of magnetic examinations of ropes may be of help in assessing their corrosion weakening.Magnetic rope examination requires that the rope first be magnetized. After that, the rope magnetic flux and the leakage flux along the rope are measured. The first is assumed to be directly proportional to rope metallic area (LMA) and its changes are indicative of the rope’s loss of breaking strength (LBS). Existence of the second indicates existence of local faults (LF) in the inspected rope. As the corrosion of rope results in development of corrosion cracks and in loss of rope metallic area, both the LF and the LMA should be used to quantify the level of rope corrosion. More specifically, the changes to the amplitude of the LF signal are considered to provide qualitative information on rope corrosion (Hansel et al., 1990), while those of the LMA signal are believed to provide quantitative information (Geller and Rousseau, 1990; Golosinski, 1996)."

Jan 1, 1999

By Rajasekar Subbian, Jessica Oudhof

In the Netherlands pile foundation design is done using CPTs in accordance with EC7 national annexure. The capacity per tip level is calculated for every CPT followed by zonation to find the tip level per zone. The correlation factors are used to take into account the variability in ground across the zone and they depend upon the number CPTs within the zone. The CPTs and pile tip levels selection for zoning is an iterative process that can demand significant manual effort to produce an economical pile plan. This often leads to the use of conservative correlation factors in order to accelerate the design process. Thus, it has been automated in a tool with CPTs, pile location and loads, and capacities as input. The tool has also been employed in two case studies and the results are compared to the current design practise.

May 1, 2022

By R. I. Iacobescu, Y. W. Chiang, A. Van Audenaerde, R. M. Santos, T. Van Gerven, P. Knops

In this work, we explore a novel mineral processing approach using carbon dioxide to promote mineral alterations that lead to improved extractability of nickel from olivine ((Mg,Fe)2SiO4). The precept is that by altering the morphology and the mineralogy of the ore via mineral carbonation, the comminution requirements and the acid consumption during hydrometallurgical processing can be reduced. Furthermore, carbonation pre-treatment can lead to mineral liberation and concentration of metals in physically separable phases. In a first processing step, olivine is fully carbonated at high CO2 partial pressures (35 bar) and optimal temperature (200 °C) with the addition of pH buffering agents. This leads to a powdery product containing high carbonate content. The main products of the carbonation reaction include amorphous colloidal silica, chromium-rich metallic particles, and iron-substituted magnesite ((Mg1- x,Fex)CO3). Carbonated olivine was subsequently leached using an array of inorganic and organic acids to test their leaching efficiency. Compared to leaching from untreated olivine, the percentage of nickel extracted from carbonated olivine by acid leaching was significantly increased. It is anticipated that the mineral carbonation pre-treatment approach may also be applicable to other ultrabasic and lateritic ores.

Jan 1, 2014

By J. R. Rau

While refuge chambers are common place in most underground mining projects, there are different philosophies as to what life support systems are to be considered and how these systems are to be applied. Case studies in the underground mining industry have examples of emergencies where the external compressed air and power supply to the refuge chamber were compromised due to proximity of services to the fire location. In 2005, The Department of Industry and Resources, Western Australia, drafted guidelines that listed specific requirements for refuge chambers which included a secondary life support system that would operate independently of external sources. The objective of this document is to examine what critical life support systems are essential for safe entrapment in the event of an emergency and to examine considerations for their application.

Aug 1, 2013

By Ajit K. Sinha

"Abstract - Electromagnetic surveys were conducted over the Yava sandstone-hosted lead deposit in Nova Scotia to evaluate the usefulness of such surveys for detecting and mapping sedimentary­ hosted metallic ore deposits. Both transient and multifrequency systems were used for that purpose. The deposit consists of three zones of disseminated galena which also contain minor amounts of pyrite and sphalerite filling the interstices of the sandstone grains. Each zone overlies a basement depression and is separated from the adjacent zone by an intervening basement high. A conductive shale layer underlies the galena-rich sandstone formation at all three zones.Because the concentration of galena (3% to 4% ) and other sulfides is too low to affect the resistivity of the sandstone formations for detection by ground electromagnetic (EM) methods, the strategy for our survey was to look for areas of basement depressions and the presence of conductive shale in those depressions by EM depth soundings. The presence of the galena-rich sandstone formations could be inferred because of the close association of these two features with the deposits in the Yava area. Both transient and multifrequency EM systems were successful in mapping the basement depressions and detecting conductive shale at the three known mineralized zones. The technique, therefore, seems to offer good prospects for mapping similar stratabound sedimentary-hosted sulfide deposits."

Jan 1, 1993

By GEORGE ROBERT DE BEQUE

WHAT is wrong with oil shale? The answer is of interest to the public, to the oil refiner, and to the engineer. Many people have invested in shale land or shale securities, and others would invest if early development of the industry were certain. In the face of increasing demands for oil products, oil refiners are threatened with inability to maintain present output unless the supply of domestic petroleum is supplemented. Development of the oil shale industry would open a new field for engineering services. The object of this paper is to suggest reasons why there is but one shale plant in operation in the United States, and to discuss the probable time when the business will be firmly established in Colorado. As the Colorado deposits are the richest and largest in the world, ample supply of material is assured, consequently, this discussion will be confined principally to technical problems and economic problems affecting shale development.

Jan 1, 1924

By Letícia Pegoraro Leal

O mercado mundial está se desenvolvendo continuamente em todos os segmentos com a finalidade de melhorar a qualidade e diminuir os custos. O aperfeiçoamento e a criação de novas técnicas de soldagem são responsáveis por conservar as propriedades mecânicas e realizar as soldas com um menor número de defeitos. Este trabalho apresenta o processo de soldagem por fricção com pino consumível, conhecido como FHPP (Friction Hydro Pillar Process) em pino AISI 4340 e chapa AISI 4140. Como toda nova técnica é importante conhecer os parâmetros que serão utilizados no processo. Compreender o efeito da velocidade de rotação, força axial e de forjamento, consumo do pino e taxa de carregamento são necessários para avaliar sua influência na microestrutura da solda. Desta forma, no presente estudo, após a soldagem foram realizadas metalografias, a fim de analisar defeitos macro e microestruturais. Por fim, verificou-se significativa influência dos parâmetros de processo no comportamento metalúrgico da região soldada.

Aug 8, 2018

By V. van der Merwe, C. W. Siyasiya

"A petrochemical company experiences premature thermal fatigue failure of the casting moulds used in catalyst production. The aim of the project was to find an alternative alloy that would outperform the current low-alloy cast steel used for the moulds. Based on their thermo-fatigue properties, 3CR12 ferritic stainless steel and H11 tool steel were chosen for testing and comparison with the currently used BS3100 B7 cast steel. Samples of each material were subjected to temperature cycling in a Gleeble 1500TM thermo-mechanical processing simulator, followed by surface analyses. The main parameters derived from the test work were the total true strain, the hot strength of the materials, and the number of cycles to failure. Additionally, the coefficient of thermal expansion for each material was measured using a Bähr dilatometer. H11 tool steel yielded the best performance by way of having the fewest surface cracks, the lowest total true strain per cycle, the most cycles to failure, the highest hot strength, and the lowest coefficient of thermal expansion.IntroductionThe Catalyst Manufacturing Plant (CMP) is a dusty environment with temperatures higher than ambient. Molten mill scale (magnetite, Fe3O4) is tapped from the electric arc furnace into the casting moulds at temperatures close to 1600°C. After 10 seconds the magnetite is quenched with a water spray for 50 seconds to a minimum temperature of 400°C. Sometimes there is residual water in the pans from the cooling fog process (water sprays) in the empty mould. In a typical plant, the factory produces 40–44 batches a day containing between 150–300 moulds, depending on the time required for the specific batch (Buchholz, 2014). The typical batch in the CMP usually weighs about 6 t. The thickness of the tap, speed of the casting belt, and tilting angle all affect the number of moulds per batch.One of the main problems faced during the molten mill scale casting is the premature failure of the casting moulds. Cracks initiate on the surface of the mould, which is in contact with the hot catalyst, and propagate into the interior of the mould. Cracks are generally concentrated in the middle area of the mould where the catalyst makes first contact with the mould, and which experiences the highest temperature fluctuations. This suggests that the cracks are caused by thermal fatigue during the casting process."

Jan 1, 2016

By S. Sekhar, S. Bhargava, A. K. Godugu, J. L. Porathur

Cemented backfilling has enabled underground hard rock mines to extract orebodies more safely with improved ore recovery. It is important to estimate the minimum required strength parameters for a backfill mix by optimizing the binder percentage to enable cost-effective and safe stoping operations. We conducted three-dimensional numerical modelling to study the effect of various stoping parameters on the stability of a free-standing backfill wall. A Mohr-Coulomb material model was used for the backfill material and the rock-fill interface. A strength reduction technique, excluding friction angle, was employed to arrive at a minimum stable strength value for the backfill. For a given combination of strength values, the stability state of the backfill wall could be demarcated using a displacement and yield zone tracking method. The numerical modelling results are compared to some earlier theoretical models. From the simulations, a predictive equation is developed to predict the required strength parameters for a backfill mix to ensure a stable free-standing wall. Examples are given of the successful use of the predictive equation at some underground hard rock mine sites in India.

May 2, 2022

Vertical retreat open stoping (VROS) is a variation of sublevel open stoping (SLOS) that has been introduced at Cannington to minimise the influence of subvertical geological structures during stope extraction. The first application of VROS is described, where structures within the stope resulted in a change in firing sequence and the extraction of two complete sublevels in a single blast. The use of electronic detonators is critical to the success of VROS and their application is described. Numerous benefits of using VROS have been identified and are described. To date, eight stopes have been successfully mined using VROS. In addition to the first application of VROS, two further case studies are described.

Jan 1, 2005

By Z. Tshentu, M. Ngayek, P. Moleko-Boyce

This paper is focused on the development of iridium(IV)-specific quaternary diammonium cations containing electron-donating substituents in the benzyl group of methyl and electron-withdrawing substituents such as triflouromethyl and nitro groups. Quaternary diammonium cations used were tetra- 4-methylbenzyl-1,10-diammonium decane chloride (QuatDMDAMeBnz), tetrabenzyl-1,10- diammoniumdecane chloride (QuatDMDABnz), tetra-3-trifluoromethylbenzyl-1,10- diammoniumdecane chloride (QuatDMDACF3Bnz) and tetra-4-nitrobenzyl-1,10-diammoniumdecane chloride (QuatDMDANO2Bnz). Polyvinylbenzylchloride (PVBC) nanofibres were used as support material, and the functionalised nanofibres were used for separation of Ir(IV) from Rh(III). The sorbent materials were characterised by FTIR and elemental analysis. The efficiency of the quaternary diammonium cations was investigated in a column study under dynamic flow adsorption conditions. Column sorption of [IrCl6]2- and [RhCl5(H2O)]2- on nanofibres functionalised with diammonium cations showed [RhCl5(H2O)]2- was not adsorbed by the sorbent materials while [IrCl6]2- was loaded onto the column. The loading capacities of [IrCl6]2- on the quaternary diammonium sorbent materials increased in the order of F-QuatDMDAMeBnz (3.08 mg/g) < F-QuatDMDABnz (3.39 mg/g) < FQuatDMDACF3Bnz (5.46 mg/g) < F-QuatDMDANO2Bnz (7.10 mg/g). The loading capacity for Ir(IV) with quaternary diammonium cationic nanofibres increased with an increase in the electron-withdrawing nature of the substituent on the quaternising group. The charge delocalising ability of the 4-nitrobenzyl group resulted in the best interaction of the decamethylene diammonium cation with [IrCl6]2-. Keywords: Iridium(IV), rhodium(III), quaternary diammonium, polymer nanofibres, separation

Jan 1, 2020