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By R M. Yanamandra, M Kumar, S K. Tripathy, N Mangadoddy, P Sudikondala

Spiral concentrators are one of the flowing film gravity concentration devices used to beneficiate coal and mineral ores. The aim of the current study is to understand the particulate flow and separation performance of an LD9 spiral concentrator using a multi-phase Computational Fluid Dynamics (CFD) model. The CFD model utilises the Algebraic slip mixture model to simulate particulate flows. The model employs the Renormalisation group (RNG) k-ɛ turbulence models to resolve the fluid turbulence. Initially, the volume of fluid method was adopted to track the water-air interface. Simulations were then carried out at low (0.3 and 3 wt.%) and moderate (15 wt.%) solids concentrations. Multiple particle-phase representing particles of poly sizes (75–1400 µm) and multi-densities (1450–2650 kg/m3 ) were simulated to study the particle segregation on the spiral trough surface. The numerical predictions are compared with the literature performance data at a diluted pulp flow rate of 6 m3 /hr. The results were found in close agreement. Further, the same CFD model is used to study the change in pulp velocity, streamflow rates, and separation performance at increasing solids concentration. For the same density particles, Fine particles mostly show higher volume concentration in the middle and outer trough regions, whereas coarse particles show higher volume concentration in the interior and central trough regions. It implies that the fine particles mostly segregate towards the outer region, and dense particles segregate towards the axial column.

Aug 24, 2022

By Adam Powell, Soobhankar Pati

"Solid Oxide Membrane (SOM) Electrolysis is a new energy-efficient zero-emissions process for producing high-purity magnesium and high-purity oxygen directly from industrial-grade MgO. SOM Recycling combines SOM electrolysis with electrorefining, continuously and efficiently producing high-purity magnesium from low-purity partially oxidized scrap. In both processes, electrolysis and/or electrorefining take place in the crucible, where raw material is continuously fed into the molten salt electrolyte, producing magnesium vapor at the cathode and oxygen at the inert anode inside the SOM. This paper describes a three-dimensional multi-physics finite-element model of ionic current, fluid flow driven by argon bubbling and thermal buoyancy, and heat and mass transport in the crucible. The model predicts the effects of stirring on the anode boundary layer and its time scale of formation, and the effect of natural convection at the outer wall. MOxST has developed this model as a tool for scale-up design of these closely-related processes.IntroductionSolid Oxide Membrane (SOM) Electrolysis is a variation on the Hall-Héroult process for molten salt electrolysis of oxides which promises to solve many of the problems of its predecessors. Magnesium in particular is both soluble in molten salts and highly reactive, such that it migrates to the anode and reacts with the oxygen or C02 anode product, reducing current efficiency to as low as 10-20%. But a zirconia solid electrolyte between the molten salt and anode blocks this reaction, boosting current efficiency to at least 90%. Separating the anode from the molten salt also opens up anode material selection to liquid metals and SOFC cathode materials such as Lai.xSrxMn03 (LSM) and YCr03. And zirconia's selectivity makes the oxygen by-product very pure."

Jan 1, 2012

By Mark Samonds

"Manufacturing processes which involve liquid to solid and solid state transformations in metals encompass a wide variety of physical phenomena. The past twenty years have seen a steady evolution in the complexity and scope of numerical models of these processes, beginning with thermal analyses without phase change. Recently, a few software packages have become available which have true multi-physics capabilities. This permits the treatment of thermal, fluids, stress, electromagnetic, chemical reaction and microstructure development aspects altogether in a fully coupled simulation. This paper will consider various aspects of these types of models.Coupled thermal and fluid flow analyses of continuous castings have been around for fifteen years. Coupled thermal and free surface fluid flow simulations of shape castings have been available for ten years, including view factor radiation models for investment castings. Only recently, however, have fully coupled thermal, fluid, and stress analyses become practical. This implies the reverse coupling of the mechanical deformations to the solution of the energy and momentum equations through modification to the interface heat transfer coefficients and the fluid domain geometry. This has been implemented with a combined eulerian-lagrangian finite element method. Appropriate mechanical constitutive models will also be discussed.Many types of defects need to be predicted in casting processes. Those related to stress include hot tearing, hot cracking, part distortion, and thermal fatigue in dies. Macroporosity, microporosity, and microsegregation are determined by the solidification behavior and microstructure development in a casting. In particular, microporosity is influenced by dissolved gases, the morphology of the mushy zone, the liquid to solid density change, and the local pressure conditions. Macrosegregation is caused by the partitioning of solutes during. solidification and subsequent thermo-solutal convection. An additional transport equation is required for each solute that is being tracked. Computational thermodynamics is being incorporated into these types of analyses to determine transformation temperatures, partition coefficients, densities, and enthalpies. In combination, the microstructure and microporosity models can frequently predict a variety of mechanical models, such as yield strength, tensile strength, and elongation."

Jan 1, 2001

By S. Mao

Total station has been predominantly applied in stationary survey scenarios in construction. With the moving target tracking and point survey automation functions, a robotic total station (RTS) lends itself well to more dynamic applications. Nevertheless, a RTS unit is still unable to track multiple targets simultaneously or to survey a target point when the line-of-sight is temporarily unavailable. In this paper, we propose a methodology to synchronize and automate multiple RTS units intended to address dynamic tracking and surveying applications in the construction field. By using the application programming interface (API) from the manufacturer, we implement the proposed methodology and the prototype system integrates two RTS units in regard to space and time and communicates survey command instructions among RTS units through wireless networks. The two RTS units can be operated to survey the two ends of one swinging sling concurrently in order to retrieve the actual length of the sling within several millimeters accuracy. Besides, in applications where line-of-sight between a target object and one RTS unit cannot be guaranteed all the time, continuous surveying can be materialized by automatically delegating the task to another synchronized RTS unit with clear view of the target object. A field test was conducted to demonstrate the application of the proposed automation approach in which sling length was measured of a rigging framework used for lifting industrial modules. The testing results are presented and achievable accuracy and reliability are discussed. The proposed solution overcomes the limitations of global positioning system (GPS) and laser scanning and holds high potential to provide cost effective solutions to many dynamic field applications.

Aug 1, 2013

By Jerry M. Eyster

The Bush Administration is committed to reducing emissions from existing power plants Candidate George W. Bush said: The key to reducing emissions from older power plants on the federal level is to cap emissions on a level that makes sense?. And harness the power of the market place and provide economic incentives to produce better environmental results. I would want to make sure that any program we pursue does not result in excessive and unnecessary increases in electric bills.

Jan 1, 2002

By G. Scamans, J. Lazaro-Nebreda, Z. Fan, J. B. Patel

"Melt quality is crucial for both continuous and shape casting of light alloys and in order to improve it, removal of excessive inclusions, accumulated impurities and unwanted gases becomes necessary. To address this problem, a new multi-purpose high shear liquid metal treatment technology, based on intensive melt shearing by a rotor/stator unit, has been developed. The device ensures achieving uniform temperature and chemical composition and an efficient dispersion of gas and solid phases in the melt with minimal disturbance of melt surface, and can be used, among other things, for de-gassing and de-ironing of Al-alloy melts. Efficient degassing is achieved by dispersing each argon bubble into many small ones, which significantly increases the overall surface area of the bubbles and the time they remain in the melt capturing hydrogen before reaching the surface. This allows using much lower inert gas flow and mixing times than conventional rotary degassing. When applied to Al-alloy scrap, with accumulated iron, the high shear melt treatment speeds up the nucleation and growth of primary Fe-rich intermetallic particles, allowing a faster removal rate. Therefore it reduces processing times, increasing recycling productivity, and facilitates full metal circulation of secondary Al-alloys.INTRODUCTION Aluminium and magnesium alloys are widely considered in various industrial sectors for the purpose of weight saving (Polmear, 1995). In particular, they are used in the automotive sector, where components are mostly manufactured by high pressure die casting (HPDC) because of its simplicity and relatively low cost, but efficiency and mechanical properties are quite low compared with other processes. To date, the main focus to overcome this problem has been for improving the HPDC machinery (Dahle, 2001) but little attention has been paid to the opportunities of controlling the nature and quality of the molten metal supplied to the die. In this way, liquid metal treatment, which involves a variety of physical and/or chemical processing methods to improve melt quality prior casting, is crucial for both continuous and shape casting products."

Jan 1, 2018

By Leonard Sugin

As we approach the end-of the 20th century we are made more aware of the tremendous role that energy plays both directly and indirectly in our varied way of life. The industralized nations of the world have already established industries and economies which are greatly dependent upon the availability of energy. The underdeveloped and developing nations of the world are slowly and surely moving to the same utlimate requirements. The world wide need for distribution of energy sources is continuing to grow. At the present time there is a great imbalance between the sources of energy and the consuming economies In order to bring about greater equality between supply and demand major efforts and large capital expenditures are constantly being made. Industralized areas are seeking their own independent sources of energy whereas those areas of the world which contain great reserves of energy are limiting its export as well as developing its own industralized capacity. Nevertheless, energy bearing materials are still transported great distances in order to satiate the appetites of power hungry economies.

Jan 1, 1975

By D J. Murray

This paper outlines the principles of friction hoisting and the components involved, and gives a description of a specific mine hoist. Friction hoisting is compared with conventional drum hoisting, and the depth of shaft at which friction hoists become more economical than drum hoists, with respect to power consumption, is determined. Introduction T HE purpose of this paper is to outline the principles of friction hoisting, to describe the components and to show the advantages of multi-rope friction hoisting. Some calculations are made to show that the power requirements and the initial costs of friction hoists are less than those of conventional drum hoists, once a certain depth of shaft has been reached. The use of multi-rope friction hoists is gradually superseding the employment of the conventional drum hoist in many parts of the world. It results in heavier payloads from deeper levels, an increase in shaft safe-ty and a more compact installation for protection against adverse weather conditions. It was observed that where drums and friction sheaves exceeded 30 feet in diameter, a number of mechanical disadvantages were being experienced;

Jan 1, 1965

By Gerald L. Tiley

When payloads and hoisting distances are beyond the capacity of a single headrope, a multi-rope hoist will cost less than, and require less maintenance than, several hoists with one headrope per conveyance. This paper describes the basic type of multi-rope drum and friction hoists in use today, the types of ropes available, and the essentials of a satisfactory installation.

Jan 1, 1981

By M. Tsesarsky, M. Hazan, E. Gal

"Rock masses comprised of stiff inclusions in softer matrix are common in various geological environments. The heterogeneity and multi-scale nature of these materials make the evaluation of their mechanical properties a challenging task, which cannot be accomplished using conventional laboratory tests and composite mixture rules. We employ the homogenization method to estimate the mechanical properties of geological materials with inclusions. The homogenization method solves the equations of elasticity on the material (microscopic) scale for a unit cell subjected to unit strains under periodic boundary condition. The micro-scale elasticity equations are solved using the Finite Elements Method, and are in turn used to obtain the structure scale (macroscopic) material matrix.In this research, Finite Element models for unit cells with spherical and ellipsoidal inclusions were developed. Using the unit cells, a parametric study of the geometrical and statistical microscopic properties of the material composites was performed. The following parameters were studied: volumetric ratio, Young’s modulus ratio, size-distribution of inclusion and inclination angle of inclusions. The main purpose of the parametric study was to study the deviation from isotropy as a function of the aforementioned parameters.It was found that for volumetric ratio of 5%-40%, the deviation from isotropy increases, as the volumetric ratio of inclusions increases. For spherical inclusions, most of the cases studied exhibit quasiisotropic behaviour; whereas ellipsoidal inclusions exhibit considerable deviation from isotropy. The inclination of the ellipsoidal inclusions enlarges the deviation from isotropy (9% at random orientation and 26% at 0°)."

Jan 1, 2015

By Mingju Liu

In this research, we measured fractal characteristics of over ten typical outburst areas on different scales and related them to their outburst proneness, in attempts to provide new methods for outburst prediction. It was shown that both faults and folds follow the power law on coal basin scale, mine scale or mining district scale, whichever it is. Fractal dimensions are appropriate indices to describe geological structures quantitatively. Preliminary relationships have been established between outburst proneness and fractal dimension. Comparisons have been made among fractal characteristics and degrees of outburst proneness on all three scales. The results indicate that multi-scale assessment of outburst proneness can be made based on fractal measurements independently or supplemented by other assessment methods.

Jan 1, 2000

By P. K. Jimack, C. E. Goodyer, A. M. Mullis, P. C. Bollada

"We review the application of advanced numerical techniques such as adaptive mesh refmement, implicit time-stepping, multigrid solvers and massively parallel implementations as a route to obtaining solutions to the 3-dimensional phase-field problem with a domain size and interface resolution previously possible only in 2-dimensions. Using such techniques it is shown that such models are tractable even as the interface width approaches the solute capillary length.IntroductionMulti-scale modelling impinges upon many areas of science, engineering and technology where the interplay between processes occurring on disparate length and/or timescales can affect the properties of systems in a complex, and sometimes unforeseen, manner. One such is the processing of materials where interactions at the atomic scale, through the nano- and microstructural scale can have a profound affect on the macro-scale response of engineering components. Here we focus on one such problem, the crystallisation of alloy melts, to illustrate how a range of advanced numerical techniques make the modelling of such systems tractable.The modelling of solidification structures, in particular the growth of dendritic crystals, is a subject of intense and enduring interest within the scientific community, both because dendrites are a prime example of spontaneous pattern formation and they have a pervasive influence on the engineering properties of metals. For alloy systems, which form the vast majority of engineering materials, solidification involves the rejection of both solute and latent heat from the growing solid, forming a coupled diffusion problem in which both the chemical and thermal diffusion equations should be solved. The multi-scale nature of this problem arises from the disparity between the thermal and solutal diffusivities for most liquid metals, which are typically 10-5 m2 s-1 and 10-9 m2 s-1 respectively. The ratio of these two, referred to as the Lewis number (Le =Dia), is therefore typically of the order 10,000 and gives a measure of the multi-scale nature of the problem. In fact, in many cases the thermal diffusivity is so much larger than its solutal counterpart that thermal diffusion is considered instantaneous, wherein the system can be approximated as isothermal such that the multi-scale calculation does not need to be performed. This is certainly a reasonable approach in most conventional castings. However, there is a class of solidification problem in which this approach is far from satisfactory, namely Rapid Solidification (RS). The application of isothermal phase-field models in such situations are highly likely to produce spurious results or to fail totally, particularly for temperatures below To (the temperature at which the free energies of the solid and liquid phases are equal at the concentration of the bulk alloy), wherein partitionless solidification may occur."

Jan 1, 2013

By Hebi Yin

A two-dimensional multi-scale solidification model was developed to study the heat transfer, fluid flow, and grain growth occurring in the molten pool during the laser engineered net shaping (LENS) process. This model coupled the finite element method to calculate mass, energy and momentum transport in the macroscale with the cellular automaton technique to calculate liquid/solid phase change at the microscale. The validation of the model was performed by comparing the simulation results with experimental data from previously published works, showing good agreement in temperature distribution and the dendrite morphology (size and shape). The simulation results showed that Marangoni convection, caused by the temperature gradient along the pool surface, played a critical role in determining the flow pattern in the molten pool and exerted influence on the pool size and shape. It was also found that columnar dendrites can be formed, with dendrite arm spacings as fine as a few microns due to the high cooling rate during the LENS process. In addition, the influence of fluid flow on the dendrite growth in the pool was discussed.

Jan 1, 2010

"The link between ore texture and mineral liberation has previously been established at a microscopic scale. To construct ore texture models that can be used in mining applications requires this relationship to be retained at a significantly larger scale. This is initially dealt with by finding a basic set of microtextures that form the elements of the ore textures at the next larger mesoscopic scale, simulating these mesotextures at a fine scale, then changing the support of the mesotexture simulations to generate the expected mining block/stope mesotexture distributions. Thus, a mutually exclusive and exhaustive set of spatially locatable mesotextures can be used to fully characterize the metallurgical properties of in situ material.A method that generates expected distributions of mesotextures for any mining block size or shape is proposed, and includes: (1) characterizing the spatial correlation of the set of mesotextures with a single covariance function; (2) generating multiple simulations of mesotextures at a fine scale; and (3) using the simulations at a fine scale to generate the expected mining block/stope mesotexture distributions. A case study, using the George Fisher sediment-hosted base metal deposit in Queensland Queensland, Australia, is developed to demonstrate the proposed methodology as well as show the inadequacy of off-the-shelf approaches.Mining-scale texture models can be used to improve the in situ discrimination of ore from waste by exploiting the joint spatial variability of grades and textures to quantify the expected metal recovery of in situ material, then calculate local marginal cut-off grades. An artificial case study is presented to demonstrate the changes in ore/waste selection when considering ore texture models compared to constant metal recoveries."

Jan 1, 2005

By B. B. Tati

The project report is based on vacation work done by the writer at the Khutala Colliery during December/January 2009?2010. The purpose of this report is to explain and describe the design process in a multi-seam mine design for coal extraction at the Khutala Colliery. The multi-seam design will focus on the No. 2 and No. 4 seams as these are the seams that are currently being mined by underground methods at Khutala Colliery. The seam thicknesses and the parting thickness between the seams provide suitable conditions for designing a multi-seam mine design. An investigation into the pillar design aspects is carried out followed by a numerical modelling analysis of various scenarios. This analysis validates the first principles approach provided by multi-seam design guidelines. The design results from the analysis of the selected pillar design indicate sufficient parting for primitive conditions between seams, thus illuminating the need for superimposing in-panel pillars. This multi-seam mine design confirms the potential for the extraction of coal in a new panel. The design indicates that significant amounts of power station coal are present and suitable for extraction by room and pillar mining methods. The panel block indicates 401 625 tonnes of ROM coal. This block has a life of panel that will be mined just over a 4-month period. This 4-month period is assumed to mined at a production rate of 48 000 tonnes per month. The total capital cost required for the new panel is R48 281 127.05. Keywords Multi-seam mining, panel design, ventilation flow, superimposition.

Jan 1, 2011

By C. K. Chabedi

"This paper discusses the difficulties associated with the potential exploitation of the deep multi-seam resources east of the Daarby fault in the Waterberg coalfield. The resources occur at a depth greater than 250 m and the thickness of the coal is roughly 110 m, but the top 50 m comprises coal intercalated with shale and the bottom 60 m contains five seams with sandstone and shale partings. Various factors affecting multiple seam mining at these great depths are discussed with reference to lessons learned from local and international experience on multi-seam mining. Field geological and geotechnical data was utilized to assess the stability of the roof of the seams. There is no specific rock mass rating for the Waterberg area, therefore approximate coal mine roof rating (CMRR) values were used to propose appropriate support strategies. Analysis of Multiple Seam Stability (AMSS) was used to analyse the strength of the parting or interburden between the various seams, the mining sequence, and the interaction between the various seams.The research indicated that it is possible to mine seams with a low CMRR at high mining rates using longwall mining, although support for gateroads is expected to be expensive, time-consuming and onerous to install, and will impact gateroad development rates. It will not be possible to simultaneously mine zones in close proximity and failure of the interburden is predicted, thus dangerous mining conditions are anticipated. However, it will be possible to mine just two of the eleven zones using longwall mining. IntroductionThis paper discusses the difficulties associated with the potential exploitation of the deep multi-seam resources east of the Daarby fault in the Waterberg coalfield using bord and pillar and longwall mining. Figure 1 illustrates the location of the Waterberg coalfield relative to other coalfields in South Africa, while Figure 2 shows the areas containing deep and shallow resources. The Waterberg resources are expected to contribute to South Africa’s future energy requirements, and are currently exploited at the Grootegeluk open pit mine. Grootegeluk produces coal mainly for a power station, with the higher quality product supplied as metallurgical coal. The deposit is technically unique and challenging, being a multi-seam coal deposit with a total of 12 seams over a thickness of 110 m as shown in Figure 3, including Zone 5. There is currently limited knowledge on the multi-seam mining of the deep Waterberg resources. Multi-seam mining utilizing the bord and pillar method has been practised in South Africa before, but at a depth of less than 100 m in the Witbank coalfields. Multi-seam mining in thin seams has also been performed in the Natal coalfields at a depth of less than 160 m, but mostly using bord and pillar mining and secondary mining (partial pillar extraction)."

Jan 1, 2016

By Sanat Talmaki

Construction and mining worksites pose unique challenges to workers and equipment operators due to their dynamic and unstructured nature. Narrow haul roads, crowded work spaces and presence of workers and equipment in close proximity, combined with large blind spots and overall poor visibility afforded to operators lead to collisions and run-over-type accidents between equipment, workers, and other entities that may be present on the jobsite. Operations that involve machine-infrastructure interaction, particularly in the case of concealed infrastructure such as excavation and drilling lead to unintended strikes between the equipment?s end-effect or and the infrastructure. Such accident-prone scenarios can be avoided by providing operators with real-time feedback and warnings using 3D visualization and proximity monitoring of the entities present in the equipment?s vicinity. Thus the jobsite in the real world is abstracted and represented in a 3D virtual world. However, this requires the ability to create a seamless link between real-world sensors present on the equipment and/or the jobsite and the virtual environment. This paper describes a non-restrictive acquisition allocation framework that allows position and orientation sensor streams from construction and mining job sites to be used for updating 3D virtual scenes in real-time for providing vital collision avoidance warnings to equipment operators.

Aug 1, 2013

By K L. Silversides, A Chlingaryan, A Melkumyan

Multiple data sources can be fused to improve boundary modelling in stratified deposits such as the banded iron formation (BIF) hosted deposits in the Pilbara Region of Western Australia. Accurate boundaries are essential to produce high quality geological models. Initial models are based on the widely spaced exploration hole data. This creates a high level of uncertainty in areas between the holes, with different interpretations of the boundary equally probable. Including directional information collected in these holes in the models can reduce the number of possibilities. Including data collected during mining, such as blastholes and bench measurements, can further guide the model. This research demonstrates a Gaussian Processes based method of fusing these disparate data sources to better inform the boundaries. Our results demonstrate that when only exploration points are used the model creates a smooth boundary with minimal variation between the holes. Each additional data source refined the model and added additional detail to the boundary. For the blast data, the new detail projects down to the bench below the current bench to allow for a better prediction before mining commences on that bench.

Mar 22, 2022

By S. A. Bortz

IIT Research Institute has initiated several multi-sponsored research programs. In this paper the methods for developing four of these programs are discussed. In general, a broad area of investigation must be proposed to interest a spectrum of different industries. The work must not touch upon proprietary data and will probably involve a number of scientific disciplines. Thus, the problem to be solved will attract sponsors who need to know more about the area under study but do not wish, as a single company, to commit the resources required to obtain the necessary know-how for their needs. The paper draws on the background of four IITRI multi-sponsored projects: Size Reduction, a study of grinding of material to reduce their particle size; Melt-Formed Ceramics Research, a method of producing dense, polycrystalline ceramics using glass forming methods; Binders in Ceramic Processing, which addresses the problems associated with the use of organic aids for ceramic processing; and a Study in Air Pollution Technology, a program to review and assess pollution control equipment for current and future applications.

Jan 1, 1984

By Yizhong Yuan, Dao Li, Nannan Xue, Tao Liu, Yimin Zhang

A new multi-stage counter-current circulation leaching process for extracting vanadium from stone coal was proposed, and the main factors on multi-stage counter-current circulation acid leaching process were investigated. The results show that the vanadium recovery could reach 86% under the conditions of sulfuric acid concentration of 4 M, liquid to solid ratio of 2 mL/g, temperature of 95 °C, reaction time of 60 min, mean particle size of 125 µm and circulation acid leaching stage of three. The losses of vanadium in acid leaching solution appeared during the four-stage acid leaching process. The strong adsorption performance of new formed KAl(SO4)2(H2O)12 crystal was main reason.

Jan 1, 2014