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By Robert S. Holmes

The U. S. Army Corps of Engineers Explosive Excavation Research Office (EERO) of Livermore, California, has been engaged in research and development of excavation techniques using both nuclear and conventional explosives since 1962. Prior to July 1971, this organization was designated the U. S. Army Corps of Engineers Nuclear Cratering Group. The EERO mission is performed as part of the joint Atomic Energy Commission -Corps of Engineers nuclear excavation research pro-gram. During the period 1962-1969, the Corps executed many cratering explosions using spherical charges of up to 85 tons of nitromethane to model nuclear excavation concepts and to develop design criteria for the nuclear cratering explosions. The experience gained in these modeling tests suggested that explosive excavation using large chemical explosive charges could be applied to excavation projects as an economical substitute for traditional excavation techniques. Consequently, the Corps' research program was broadened in 1969 to include development of chemical explosive excavation as a construction tool. The term "explosive excavation" denotes the use of large buried explosive charges to produce an excavation by fracturing the material and casting it into a desired configuration. In its simplest form, this technology involves detonation of a single explosive charge buried at the proper depth to produce a crater which is roughly hyperbolic in cross section. The types of craters produced by various depths of burial are illustrated by Figure 1. Single or Multiple rows of charges are used to excavate linear cuts required for water conveyance or navigation channels. .More complex explosive excavations include small craft harbors, railroad and highway cuts, and removal of W1denvater rock barriers to navigation. While the literature indicates widespread use of large explosions in the (1) ERRO is a field activity of the Waterway Experiment Station, Vicksburg, Mississippi

Jan 1, 1971

By Paul C. Turner

In 1998, approximately 57,000 tons of titanium metal was consumed in the form of mill products (1). Only about 5% of the 4 million tons of titanium minerals consumed each year is used to produce titanium metal, with the remainder primarily used to produce titanium dioxide pigment. Titanium metal production is primarily based on the direct chlorination of rutile to produce titanium tetrachloride, which is then reduced to metal using the Kroll magnesium reduction process. The use of titanium is tied to its high strength-to-weight ratio and corrosion resistance. Aerospace is the largest application for titanium, and titanium cost has prevented its use in non-aerospace applications including the automotive and heavy vehicle industries.

Jan 1, 2001

By G. Sachs, E. J. Ripling, S. I. Liu, J. J. Lynch

INTRODUCTION IT is a generally recognized fact that by repeated straining the fracture stress of any metal is reduced to a fraction of its value for static loading. The value of this fatigue strength depends upon numerous factors, such as the states of strain and stress, the limits of straining, and the number of repeated loadings or cycles.1.2,3 The large volume of previous investigations on fatigue is concerned entirely with large numbers of cycles, say exceeding 10,000 and up to 500,000,000. However, the changes in fracture stress and fracture strain occurring after a small number of repeated loadings have attracted little attention. Apparently the only investigations of this type are those byLudwik4,5 who subjected steel, copper, and aluminum wire to repeated torsion. In each test the torque was varied between identical values in the two directions of twisting. Depending upon the magnitude of the moment, fracturing occurred after a number of cycles, up to 10,000. The results of Ludwik's tests will be discussed later. Such torsion does not readily yield actual stress and strain values. Therefore a preliminary study was made of the effects of repeated direct stresses, i.e., tension and compression stresses. Because such tests are considerably more tedious than torsion tests, only high stresses were used in the preliminary work, yielding definite changes in metal properties after a few cycles. It was found in these tests that strains could be controlled more readily than stresses in the investigated range of high stresses. This paper, consequently, deals with the effects of strains of equal magnitude but different signs. The metal was first prestrained in static tension by a certain amount then subjected to compression to yield the same amount of strain after unloading. This loading cycle was repeated up to a maximum of seven times. After various cycles, the stress-strain curves in tension were determined, up to fracturing. As material for these tests, the aluminum alloy 24ST was selected because it exhibits a comparatively small amount of necking in the tension test. This alloy permitted, therefore, rather accurate control at the high strains necessary to produce fatigue failures at less than seven cycles. The results of this investigation appear sufficiently interesting to extend the method of attack in various directions. It is intended to study (I) the effects of cycles up to a few thousands and (2) the effects of strains of different magnitude in tension and compression, respectively. The latter variable also includes as a special case the effects of compressive strains.

Jan 1, 1948

By Anne Caroline Costacurta Polli, Jose Rojas Cáceres, Roberto Mahler de Morais, Thais Costa Silva

The technology and the knowledge about the behavior of explosives and detonation accessories allowed to create new products for different situations by the restrictions imposed by the market. In a Brazilian underground copper mine the restriction occurred in the use of high grammage Det Cord in the development heading blasts perimeter holes. Enaex Brazil has developed Densiex UG™ (Low-Density Bulk Emulsion), a water-resistant bulk gassing emulsion with a density ranging from 0.60 to 0.90 g/cm³ to replace the high grammage Det Cord in blasts. That product is pumped in the same Mobile Manufacturing Unit (MMU) as Enaex Brazil's standard underground (UG) bulk emulsion. This product has a Lower Velocity of Detonation (VOD), vibration, and detonation pressure, which contributes to a better finishing of the drift, lower impact in the support structures, and lower generation on unstable rocks in the perimeter of the drift. This case aims to summarize the results of the work on the application of the Low-Density Bulk Emulsion in perimeter holes in an underground development gallery at an underground copper mine in Brazil. During this work, 10 horizontal drift blasts were performed using the Low-Density Bulk Emulsion, which presented an average density of 0.64 g/cm³, increasing safety, a 25% reduction in overbreak, a 23% reduction in scaling time, elimination of rework, and a saving of $135,000 per year for this business partner that immediately implemented this new product in all blasts at this mine.

Jan 21, 2025

The basic make-up of the majority of currently produced bulk explosives has changed little in the last 20 years. These explosives would be described as mature in a life cycle analysis. Therefore these explosive products and the practical rules for their use are well understood and well established. In recent years there has been interest in low density explosives, predominantly due to ammonium nitrate shortages and the associated increase in the cost of explosives. In the use of low density explosives some of the practical rules for the more commonly used bulk explosives do not apply. Therefore a shift in the thinking among users is required. At a number of mines low density explosives have been trialled or are being used, utilising the practical rules that apply to bulk explosive products. This has led to poor blast results in many situations. These poor blast results have often then led to a reduction in the use of low density explosives at the mine. This reduction does not acknowledge the advantages that can be gained from this product in the area of reduced cost of mining. This paper looks at low density explosives and discusses how and why these products work. Included in the paper are some practical ideas and examples of how low density explosives can be effectively used at the mine site.

Jan 1, 2007

By H. Aaltonen, T. G. Robinson, M. Morimitsu

"The energy required to plate pure zinc can be the most significant operating cost for an operator in the production of electrolytic zinc. This paper reports on developments on low energy Outotec coated titanium anode process technology with fully amorphous coatings, MSA®, and its application to brownfield zinc electrowinning operations around the world. This technology aims to reduce the operating cost and increase productivity for zinc producers.INTRODUCTIONZinc electrowinning is an energy-intensive process using more than 3,000 kWh/t of electric energy [1-4], and the reduction of the energy consumption is one of the key issues. The high energy consumption is due to a high cell voltage during electrolysis, which is mainly caused by a high overpotential of oxygen evolution reaction on lead alloy anodes which have been widely used in commercial zinc electrowinning processes. The overpotential of oxygen evolution is 0.6 V or more and which is approximately 4 times higher on average than that of the cathodic reaction (zinc deposition) [3,4]. Therefore, the reduction of oxygen overpotential is significant to reduce the electric energy consumption, and this will become more significant with increasing demand in metal production and rising energy costs.Oxide coated titanium anodes have been widely investigated for the oxygen evolution anodes in order to replace the lead alloy anodes [5-9], because it is known that the oxygen overpotential strongly depends on the material and structure of the anode. The most typical example of such anodes is an IrO2-Ta2O5 coated titanium anode, which is usually prepared at thermal decomposition of a precursor solution containing metal salts at 450 oC or more and obtained mixed oxide coating consists of crystalline IrO2 and amorphous Ta2O5. On the other hand, one of the authors of this paper, Professor Morimitsu, Doshisha University in Japan, has developed a novel oxide coated titanium anode, MSA® [10-25]. The most specialized point of MSA® is that the catalytic coatings are prepared at low thermal decomposition temperature and amorphous IrO2 or RuO2 is contained as the components in the coatings. Such amorphous coatings have high catalytic activity for oxygen evolution compared to lead alloy or crystalline coatings. Outotec acquired the international specialized MSA® patent licensing rights from Doshisha University and has produced and commercialized the amorphous oxide coated titanium anodes. These anodes have already been utilized mainly in copper electrowinning plants worldwide and have demonstrated a significant voltage reduction, a cost-efficiency, and a long lifetime. This novel technology is also effective to zinc electrowinning process, thus this paper presents the characterization and performance of amorphous IrO2-Ta2O5 coated titanium anodes and amorphous RuO2-Ta2O5 coated titanium anodes for oxygen evolution in zinc electrowinning."

Jan 1, 2016

By K. H. Boss

In modern iron pelletizing plants fuel consumption has been optimized to such an extent that only minor savings can be expected in the future. Inspite of this fact, different process parameters were studied with a mathematical model and firing tests. The influence on fuel consumption and productivity was established. Furthermore, the adoption of simplified firing patterns was investigated, in particular for coal firing. In view of high costs of oil and natural gas, only substitution of these fuels by coal can substantially reduce production costs. In existing plants partial replacement of oil and gas can be achieved by addition of coal to the iron ore feed and by firing the pellets with pulverized coal. Two systems have been developed for the Lurgi- Dravo travelling grate process which enables coal to completely replace oil or gas. This paper describes in the first part the potentials for fuel savings available in the Lurgi-Dravo process. In the second part, different techniques for the use of coal as fuel in iron or pelletizing plants and in particular the recently developed Lurgi Multistage Coal Injection and Combustion Process (LMC) are discussed. Combined with the LMC process, a wide variety of iron ores and coals - also with high ash contents - can be used in the Lurgi-Dravo travelling grate process.

Jan 1, 1983

Whilst the fossil fuel-based power industry moves towards carbon capture and storage (CCS) or so-called 'geosequestration', the minerals industry should adapt to reap the benefits of the new technology. If CCS becomes viable, the door is open to potential key developments in mineral processing. For example, truly continuous steelmaking could at last be realised using natural or manufactured gas combined with generic melt circulation. Iron ore fines would form a thin molten layer moving countercurrent to the gaseous reductant on one side of a melt circulation loop with efficient post-combustion without deleterious effects of slag accumulation on the other. This eliminates oxygen steelmaking because carbon has no access to the circulating molten iron. Steelmaking merely requires addition of the appropriate low level of carbon and in-line impurities removal to meet product specification. Concerning non-ferrous smelting, nothing short of virtually zero gas emission will be acceptable in the future. For dolomite-hosted Zn/Pb sulfide ores, typified by those in the Carpentaria region of Northern Australia, the way forward proposed is sulfur fixation at the mine site employing the highly exothermic reaction of SO2 with dolomite, followed by encapsulation of sulfated dolomite in fused ore slag. This releases enough energy for direct ore smelting to individual metal products. However, without CCS the strategy would be unacceptable because of greenhouse gas emissions. The scheme is advocated for direct ore smelting at McArthur River. As a result, the environmental problems of disposal of flotation tailings are avoided. Also, highly energy intensive ultra-fine grinding is eliminated, as indeed froth flotation itself, with overall very significant energy savings and exceptionally high increases in metals recovery. Zinc and lead recoveries approaching 99 per cent are predicted to be entirely feasible.

Sep 13, 2010

By A. K. Sirveiya

A major concern with blasting at surface mines is generation of ground vibration, air blast, flyrock, dust & fume and their impact on nearby structures and environment. A study was conducted at a coal mine in India which produces 10 million tonne of coal and 27 million cubic meter of overburden per annum. Draglines and shovels with dumpers carry out the removal of overburden. Detonation of 100 tonnes of explosives in a blasting round is a common practice of the mine. These large sized blasts often led to complaints from the nearby inhabitants regarding ground vibrations and their affects on their houses.

Jan 1, 2005

By B Mohanty, M P. Roy, P K. Singh

"The measured response of residential structures is a critical indicator of troublesomeor potentially damaging ground vibrations. A study was conducted to evaluate theresponse of structures situated in the periphery of four open-pit coal mines in India. Although, most of the structures were at far-off distances from the present blasting sites, an attempt was made to document the response of structures to blast vibration for future applications to optimize the blast designs for the safety of the structures. The study involved a total 215 blasts, employing one-, two- and three-hole calibration study, and production blasts. The bench height varied from 7.5 m to 42 m, and boreholes loaded with emulsion and slurry explosives were 250, 260, 270 and 310 mm in diameter. The explosive detonated in a blast were between 300-198400 kg whereas in a delay it was 33-24800 kg. Up to 12 tri-axial vibration sensors were located in overburden along a linear array from 25 m to 6.5 km distance from the blasts. Altogether, 1512 blast vibration signatures were recorded. Production and specially fi red single-charge blasts allowed the determination of natural ground frequency. The fundamental frequency of the structures ranged between 3.13 to 10.6 Hz, the same as those of the ground vibrations. The amplifi cation of vibration in the structures was in the range of 1.6 to 5.6. The study details the interaction between ground vibrations and selected structures, and the means to reduce amplifi cation of vibrations in the structures and persistence of vibrations through improved blast design."

Jan 1, 2008

By Gordon A. Gross

Banded siliceous manganese-iron bearing sediments recognized as distinctive facies of Algoma type iron-formation constitute low grade resources of manganese in many countries. Manganiferous facies associated with oxide and carbonate facies of iron-formation have iron to manganese ratios ranging from 0.2 to 2 and commonly about one. Manganiferous facies up to 30 meters thick occurring separately or with other iron-formation facies are associated with cherts, carbonates, shales, turbidites, tuffs and lavas. Primary cherty manganiferous facies and their gondite metamorphic equivalents represent significant manganese resources and are protores for higher grade deposits derived by secondary enrichment processes.

Jan 1, 1982

By Gordon A. Gross

Banded siliceous manganese-iron bearing sediments recognized as distinctive facies of Algoma-type iron formation constitute low-grade resources of manganese in many countries. Manganiferous facies associated with oxide and carbonate facies of iron formation have iron to manganese ratios ranging from 0.2 to 2 and commonly about one. Manganiferous facies up to 30 m thick occurring separately or with other iron formation facies are associated with cherts, carbonates, shales, turbidites, tuffs, and lavas. Primary cherty manganiferous facies and their gondite metamorphic equivalents represent significant manganese resources and are protores for higher-grade deposits derived by secondary enrichment processes.

Jan 1, 1983

By Donald P. Ziegler, James F. Klausner, Srinivas S. Garimella

"By 2015, nearly half the world's population will live in ""water stressed"" areas. Production of fresh water utilizing waste heat from industrial processes has been identified globally as a research priority.About 15% of the electricity required to produce aluminum is lost as waste heat in the off-gas. However, the low temperature (low grade) of the heat limits reuse. The off-gases contain 50-150 ppm SO2 ; tightening regulations coupled with increasing coke sulfur levels are motivating SO2 control, for which seawater scrubbing is attractive for smelters with suitable access.We describe a process that produces fresh water, utilizing the waste heat while scrubbing SO2 . It uses direct contact between seawater and off-gas to humidify the off-gas. The vapor is subsequently condensed. In smelter trials, a unit treating a slip stream produced high quality water in the anticipated quantity, attaining over 95% SO2 scrubbing. Future work involves scaling the process to be economically attractive.BackgroundPopulation growth, coupled with industrialization and urbanization, are increasing demand for water. Water scarcity already affects every continent. Around 1.2 billion people, or almost one-fifth of the world's population, live in areas of water scarcity, and 500 million people are approaching this situation. By 2025, 1.8 billion people will be living in countries or regions with absolute water scarcity, and two-thirds of the world's population could be living under water stressed conditions (< 1,700 m3 per person annually) [1]. An assessment by the U.S. General Accounting Office revealed that under normal conditions, by 2013, water managers in 36 states in the USA anticipate water shortages, and that the number might grow to 46 states under drought conditions [2].The obvious choice to alleviate water scarcity is the 97% of available water in the oceans, which is saline and requires desalination for use in biological, agricultural and industrial applications. Technologies developed for desalination include Thermal Distillation, Reverse Osmosis (RO), Electro-Dialysis, and Vacuum Freezing. Distillation and RO are the most commercially prominent. Thermal distillation technologies include Multiple Effect Distillation (MED) and Multi-Stage Flashing (MSF). The report commissioned by the World Bank [3] is one of the many excellent references on desalination technologies. According to the International Desalination Association working paper [4], there were more than 17,348 industrial scale desalination plants installed or contracted by 2004. The total production from these plants is on the order of 8.3 billion imperial gallons per day. RO provides 47.2% of the total capacity. The leading thermal process, MSF, provides 36.5% of the total capacity. Although MSF and RO technologies currently provide the most cost effective means for desalination, their drawback is that they are very energy intensive, and whether or not they remain cost effective strongly depends on energy prices and energy supply."

Jan 1, 2012

Magnetic separation using particle rotation in a continuously rotating magnetic field offers very low to insignificant non-magnetic particle entrapment, and precise magnetic fractions. The precision of rotating magnetic field separations makes the method ideal for dry laboratory magnetic analysis work, where conventional laboratory magnetic separators can give misleading or uncertain data. The very low entrapment characteristics make the method ideal for entrapment-critical separations within the diamond exploration industry or in gold recovery. A single wet rotating magnetic field (RMF) unit is able to achieve a cleaner separation (at similar or better recovery rates) than a three-stage separation using conventional wet drum separators. The RMF separator is able to work effectively at particle sizes below 50 ¦m, and RMF separation could, at least in theory, be used down to single domain particle sizes. Rotating magnetic field (RMF) separation is carried out by magnetically spinning the particles at frequencies up to 300 Hz. The particle rotation itself may be used to roll the particles out of the separator. At angular velocities of 100 Hz, magnetic flocs are unable to form, and any entrapped particles are energetically expelled. In an RMF separator, the outer drum can be stationary while the inner magnet rotor rotates, allowing, for example, the injection of cleaning water underneath the separating magnetics to help remove small suspended non-magnetic particles.

Jan 1, 2000

By Edward J. Jr Walter, Edward J. Walter

The vibration problem is approximately fifty years old. The original investigation of the U.S. Bureau of Mines was begun in 1930. Significant investigation into the problem was done by Crandell, Langefors, et al, Edwards and Northwood, and again by the Bureau of Mines. This resulted in an effective Safe Limit standard expressed in particle velocity as 2.0 inches per second.

Jan 1, 1979

By Jamie Deuel

The a ad on Connection" For the purpose of this paper, we will concentrate on the ubquitous radon gas as the principle, low-level radiation effect from uranium tailings piles. Standards are also proposed for gamma radiations but, by most accounts, this is much less of a low level problem than is radon. I am also aware of some just completed research at Oak Ridge National Laboratories that suggest polonium may be a major concern in tailings, but those data are preliminary at this time. What is radon gas? In the first place it is not a gas in the accepted sense in that it has no driving pressure head. It might prove a more convenient description to call it radon vapor. Radon vapor, then, is 7-1/2 times heavier than air. Radiologically, it is an alpha emitter which means it spontaneously gives off high ionizing potential but low penetrating power particles. In fact, the alpha particle has such low penetrating power that this sheet of paper will completely shield a person. The problem, though, is breathing the radon decay products, called radon daughters. If radon daughter products are ingested into the lungs, their alpha emissions may cause cancer. The principle carcinoma associated with breathing radon, or more basically, associated with radiological effects is oat cell car- cinoma of the undifferentiated mall cell type. Radon has a 3.8 day half life which means in less than four days half of its initial radioactivity has decayed away. In less than a month it essentially becomes inert or non-radioactive. The Tailings Situation The NRC, in its April 1979 Generic Environmental Impact Statement

Jan 1, 1983

Physical and chemical properties of the salt flux phase play a significant role in the recycling of UBC in Aluminum melting processes. Particularly knowledge of several properties such as salt vapor pressure, melting temperature, loss of aluminum, corrosion of refractories are useful for the process control decisions in order to attain a good quality of aluminum produced. A literature review and analysis of several salt flux systems for the selection of a flux for the Aluminum melter (low temperature natural gas bath melting) process were made. Based on these analysis two salt flux systems are recommended for further studies. These are NaCl?KCl?LiF system and NaF?LiF?KCl system with small amounts of other salt additives. Application of these fluxes to Al industrial processes are discussed.

Jan 1, 1996

By Takefumi Takuma, Hiroyuki Nishimura, Shigeru Kambe

"In order to achieve tubular pile driving with low noise and low vibration, the Press-in Piling Method has been adopted on many projects. The method utilizes reaction force derived primarily from previously driven piles to push in the next pile into ground. With attachments, the Press-in piling equipment can deal with hard soil as well as difficult site conditions. At West Toronto Diamond Rail Grade Separation Project in Toronto, Canada, the Press-in piling equipment drove more than 500 of 914 mm (36 inches) diameter tube piles in length of 12 to 25 meters (39 to 82 feet) to construct earth-retaining walls for railway grade separation. Myoshoji River Restoration Project in Tokyo, Japan drove some 600 of 1,000mm (39.4 inches) diameter tube pipe sections in length of 11 to 22 meters (36 to 72 feet) by the rotary Press-in piling equipment to increase the flood drainage capacity of an existing river in highly populated area of the city. Both projects exemplify the advantages of the method in urban settings.1. BACKGROUNDThe Press-in Piling Method was invented some forty years ago in Japan, where a very large number of construction projects were causing widespread construction pollution, especially by pile driving work in densely populated areas. The method has been providing solutions for piling projects which could not have been built otherwise due to the noise and vibration impact to the surrounding communities. The method can be used with various types of piles including sheet piles, tubular piles, concrete sheet piles and so on. With high pressure water jet and continuous flight auger attachments, the Press-in piling equipment can deal with dense sand, stiff clay, gravels, boulders and even soft rock without employing a different set of equipment."

Jan 1, 2015

By Andreas Munko

A Outotec está desenvolvendo em escala piloto o queimador de baixa emissão de NOx desde 2012, resultados expressivos foram atingidos (o pedido de Patente já foi depositado). Em 2014 utilizando simulações CFD, os resultados atingidos em escala piloto foram reproduzidos com boa aderência e os resultados em escala industrial se mostram com os mesmos comportamentos em tendências dos resultados da escala piloto, se mostrando promissores também. O presente trabalho apresenta os passos de desenvolvimento, os promissores resultados e o próximo passo deste desenvolvimento é realizar um teste em escala industrial com o queimador desenvolvido.

Aug 17, 2017

By Allen B. Stanton, Parthiv Brahmbhatt, Michael Grimm, Stanley L. Worst

Constructing a circular shaft consisting of secant piles has its own complications which make it more difficult than typical drilled shaft construction. Add to that performing under low overhead powerlines and sitting inside of a 40-foot deep, 50-foot diameter shaft and it becomes more about logistics than the actual drilling. The complexities associated with the Romeo Arm Interceptor Segment 5 Lining project are the focus of this paper, delving into the details that made it work successfully.

Oct 1, 2022