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By W. Jomaa, V. Songmene, O. Mechri, Laval Université, P. Bocher, J. Levesque

"A 2D finite element modelling (FEM), based on pure Lagrangian approach, is developed for studying the serrated chip formation during high speed machining (HSM) of 7075-T651 alloy. The solution was achieved using a commercial software package, ABAQUS/Explicit v6.13. The Johnson-Cooke (JC) constitutive equation is used to describe the work material behaviour. Moreover, the JC damage equation is implemented into the FEM to take into account for the shear localization during the serrated chip formation. Modified Coulomb friction model has been used to characterize the sliding/sticking effects on the tool-chip interface with the friction coefficient and shear flow stress determined by force calibration and machining data, respectively. The proposed FEM is validated using experimental data obtained in HSM of 7075-T651. The FEM was able to predict accurately serrated chip morphology. The intensity of chip segmentation was found to increase with cutting speed.INTRODUCTIONHigh speed machining (HSM) is one of the most used processes for manufacturing aircraft parts with aluminum alloys. For aluminum alloys, the use of HSM increases metal removal rate and reduces the formation of built up edges and burrs. However, it was found that serrated (also named segmented or sawtooth chip) and discontinuous chips can be produced during HSM of some high strength aluminum alloys, such as 7075-T6 alloy (Rao & Shin, 2001). Many parameters were found to affect the segmented/discontinuous chip formation during the machining of aluminum alloys.There are two cases in which the serrated chip can forms: the first is when machining hardened materials (Morehead, Huang, & Luo, 2007), and the second, when machining ductile materials with a cutting speed higher than a critical value (Barry & Byrne, 2002). Different theories and models were developed in order to explain the formation mechanism of such kind of chips. According to Astakhov (2006), the segmented chip formation is attributed to variations in stress and plastic deformation states, and resulting temperatures on the cutting zone. Liyao et al. (2013) stated that the segmented chip formation was mainly attributable to adiabatic shear instability/catastrophic strain localization. Others (Vyas & Shaw, 1999) suggest that the fracture/crack propagation mechanism is at the root of chip generation."

Jan 1, 2016

By Jamal Rostami, Alireza Salimi, Christian Moormann

"Rock mass classification systems are often applied in many empirical design practices in rock engineering, some contrasting with the original intent and applications of these classification systems, for example, estimation of TBM performance in various ground conditions. While accurate estimation of machine performance is significantly impacted by rock mass properties, parameters used in many of the existing classifications are more related to ground support design and not rock mass boreablity. The results of many investigations on this issue have shown a weak correlation between TBM rate of penetration and rock mass classification. This limitation can be overcome by fine tuning the rock mass classification input parameters to represent influence of rock mass properties on TBM performance as has been the objective of RME or QTBM. This paper will offer an overview of the impact of rock mass on TBM performance and introduces an empirical equation for predicting performance of rock TBMs based on rock mass classification. The results of the preliminary analysis of a new model has revealed that the use of the proposed system can offer a reasonable accuracy for estimation of TBM performance in various rock masses. 1. INTRODUCTION Hard rock tunnel boring has become more or less the standard method of tunneling for tunnels of various sizes with lengths over 1.5–2 km. Estimating the performance of TBM is a vital phase in tunnel design, and for the choice of the most appropriate excavation machine. During the past three decades, numerous TBM performance prediction models for evaluation of TBM rate of penetration and advance been proposed. In brief, all the TBM performance prediction models can be divided into two distinguished approaches, namely theoretical and empirical ones (Rostami et al., 1996). The most common and recent works on this topic are summarized in Table 1. Currently, two models including Colorado School of Mines or CSM (Rostami and Ozdemir, 1993; Rostami, 1997) and Norwegian University of Science and Technology or NTNU (Blindheim, 1979; Bruland, 1998) models are the most recognized TBM performance prediction and prognosis models in use around the world."

Jan 1, 2016

By G. O. Oniyide, H. Yilmaz

The South African platinum mines in the Bushveld Complex (BC) have unique features that distinguish them from the gold mines. They have a higher horizontal stress closer to the surface, lower occurrence of seismic activity (caused mainly by pillar failure), and are sited in an area of high geothermal gradient. One of the future challenges of platinum mining is the increasing temperatures as the mining depth increases. High temperatures invariably bring about higher ventilation costs and require different approaches to human factors and ergonomics. Excavation stability would also be another area of concern due to increasing stresses. In this investigation, the effect of temperature on the physical and chemical properties of selected Bushveld rocks (chromitite, pyroxenite, norite, leuconorite, gabbronorite, mottled anorthosite, varitextured anorthosite, granite, and granofels) was studied by means of optical microscopy and scanning electron microscopy using energy-dispersive Xray spectrometry (SEM-EDX). The rock specimens were heated in a temperature-controlled oven a rate of 2°C /min to 50°C, 100°C, and 140°C and kept at temperature for five consecutive days. Samples were allowed to cool to ambient temperature (approximately 20°C) before image capturing. Micrographs of the specimens were taken before and after heat treatment. All the SEM samples were also subjected to heating and cooling on alternate days for ten days in order to observe the effect of repeated heating and cooling on the rocks. The results of the optical microscopy analyses showed minor physical changes in the rocks. The SEM images revealed that cracks initiating at lower temperatures extend with increasing temperature. The chemical analyses showed that the temperature range considered in this research is not high enough to induce changes in the chemical composition of rock samples.

Jan 1, 2016

By Alain Blouin, Mohamad Sabsabi, Aissa Harhira, Paul Bouchard, Greg Lithgow

"The objective of this study was to demonstrate the application of Laser-Induced Breakdown Spectroscopy (LIBS) to the continuous analysis of online monitoring of Al, Mg, Ni, Mn, Si and Fe in nickel ore limonite and saprolite slurry samples. Analysis was performed on slurry samples in air at atmospheric pressure. Two pure samples of limonite and saprolite were used. Mixtures of the two samples in varying proportions were used to build calibration curves, study the influence of solid/liquid ratio, and evaluate short and long term reproducibility. The LIBS measurement of these elements is independent of the water content (from 70-85%, the range allowed by our setup). Repeatability of the measurement and long term reproducibility (from day-to-day) were below 1.2 % and 2% respectively for all the elements studied in our conditions. The results obtained showed that an industrial LIBS analyzer could provide the chemical composition of the six elements Al, Mg, Ni, Mn, Si and Fe within 1-2 minutes.IntroductionThe metal-producing industry faces the major challenge of increasing productivity, reducing costs, and maximizing benefits from existing equipment. By pyrometallurgy, metal making involves the basic steps of charging the furnace, melting the charge and refining. By hydrometallurgy, the metal refining is carried out through the dissolution of the metal by chemical reaction and electrolysis. During refining either by pyrometallurgy or hydrometallurgy, it is critical that operating parameters be adjusted and controlled so that the chemistry of the melt or the solution is within predetermined limits. Presently, the complete turnaround time for sampling, sample transfer, analysis and communication of the results to the operators is often 30 minutes or more."

Jan 1, 2016

By Anthony J. Konya

"This paper was written during part of the author’s student co-op with Cargill Salt at its Avery Islandunderground salt mine in Louisiana. Blasting salt is a unique type of blasting that is different than blasting other rock types. The plastic nature of salt, along with its large swell factor make salt a challenge to blast. The Cargill salt mines use and have tested a variety of different methods for breaking salt in an efficient manner, however these blasting methods are rarely used in other operations nor talked about today."

Jan 1, 2016

By Lifeng Li, Jhon Silva-Castro

In a previous work, the authors analyzed the overlapping probability of two adjacent charges in a single hole for pyrotechnic and electronic detonators. This document extends such work to a complete mine blast where more than two holes are detonated. In a mine blast, all the blast holes are connected as a network by detonators to follow a given initiation sequence. Such initiation sequence’s performance is based on the adequate timing between charges in the mine blast. The analysis of the reliability of a mine blast based on the timing between charges and the initiation type is presented in this document. For a long-run time and under proposed operating conditions, the reliability of the mine blast can be analyzed based on the network which is treated as a system. The failure of the system is defined as no success between any two delays charges either in a single hole or in between two holes.

Jan 1, 2016

By Alejandro Ferrada Vergara

Most blasting techniques that are designed to improve fragmentation and subsequently improve ore work index to downstream comminution processes, apply powder or energy factor increases, either by stretching the drilling pattern (burden/spacing ratio) implementing faster initiation sequences or using more energetic explosives. The new application will move detonation parameters up, making the blasting process riskier for the surrounding boreholes, explosive column or initiation systems functioning.

Jan 1, 2016

By Peter Richards, Alexander Lewis-Gray, Mark Davies, Nicholas Katsikaros

"Gekko Systems developed the Gekko Resin Exchange Column (G-REX) in order to optimise the recovery of gold in complex leach-to-electrowinning processes, as an intermediate step using a highly gold-selective resin to isolate contaminant metals. The AuRIX®100 resin produced by Purolite is licensed exclusively to Gekko, with the G-REX column designed specifically for this resin (Lewis-Gray et al, 2015). Operational experience has been gained at the CGT Ballarat Gold Plant in near continuous operation since 2008, treating unclarified concentrate leach solution. The extension of the technology to higher throughputs and more complex chemistry is discussed.Aurix®100 ResinAuRIX®100 resin is a cross-linked polystyrene alkaline resin developed by Henkel (Virnig et al, 1996). The resin beads are off-white in colour, spherical, with a nominal size of 100% +600µm. This resin is highly selective for gold and silver over many metals, by way of extracting precious metal cyanide complexes from leach solutions with a pH less than 11.5. The higher end of the pH scale produces best selectivity according to the order of preference: Au > Ag > Hg > Zn > Ni > Cu > Co > Fe. Purolite produces the resin and Gekko Systems maintains licensing of AuRIX®100 resin for use in its G-REX column as part of its unique suite of gravity gold handling equipment.Significant cost savings over carbon-in-solution (CIS) systems are realised with AURIX®100 resin, of around 4% to 12% in capital savings and 27% to 40% in operating costs (Virnig et al, 2004). Allied to this is that AuRIX®100 resin is not susceptible to fouling, that is, the resin does not load with inorganic salts or organic compounds which would affect the loading and extraction of precious metals. To counter any potential for fouling by inorganic salts, in service a dilute acid wash is carried out periodically on the resin to unblock resin pores."

Jan 1, 2016

By J. N. Van der Merwe, M. Mathey

"The South African squat coal pillar strength formula, developed by researchers from the Chamber of Mines Research Organization in the 1980s, predicts an exponential increase in coal pillar strength once a critical width-to-height ratio of 5 is exceeded. The arguments that have been proposed in favour of this formula are discussed critically in this paper.Field experience with squat pillars in the USA and evidence from published physical, analytical, and numerical model pillar studies corroborate the fact that a squat effect is unlikely to occur in coal pillars at width-to-height ratios less than 10. Furthermore, an exponential increase in peak strength of coal pillars does not exist. An alternative design criterion for squat pillars in South Africa is therefore suggested. IntroductionFive decades of coal pillar research in South Africa have produced a wealth of information on the mechanisms contributing to the strength and failure of in-situ coal pillars and accompanying phenomena. The relevant knowledge was sourced from, and for, a South African coal mining environment that remained largely unchanged in the second half of the 20th century. The depth of mining seldom exceeded 250 m, with mined seam thicknesses averaging 3 m and typical pillar width-to-height ratios (w/h) of 3–4.It is therefore not surprising that comparatively little research has been directed at the prediction of coal pillar performance in deeper deposits, where squat pillars of larger width-to-height ratios will be required to support the overlying strata. However, a thorough understanding of squat pillar performance will be necessary should the remaining deep coal deposits of the country be extracted in future, for instance in the Waterberg or Ermelo coalfields.A squat coal pillar strength formula has already been proposed in South Africa. The origin of this formula will be discussed in some detail in the following sections and its appropriateness will be critically reviewed against a great amount of evidence from relevant squat coal pillar research conducted internationally."

Jan 1, 2016

By M. Soleymani Shishvan

"Continuous mining systems containing multiple excavators producing multiple products of raw materials are highly complex, exhibiting strong interdependency between constituents. Furthermore, random variables govern the system, which causes uncertainty in the supply of raw materials: uncertainty in knowledge about the reserve, the quantity demanded by the customers, and the breakdown of equipment. This paper presents a stochastic-based mine process simulator capturing different sources of uncertainties. It aims to quantify the effect of geological uncertainty and its impacts on the ability to deliver contractually defined quantities and qualities of coal, and on the system efficiency in terms of utilization of major equipment. Two different areas of research are combined: geostatistical simulation for capturing geological uncertainty, and stochastic process simulation to predict the performance and reliability of a large continuous mining system.The process of modelling and simulation in this specific production environment is discussed in detail. Problem specification and a new integrated simulation approach are presented. A case study in a large coal mine is used to demonstrate the impacts and evaluate the results in terms of reaching optimal production control decisions to increase average equipment utilization and control coal quality and quantity. The new approach is expected to lead to more robust decisions, improved efficiencies, and better coal quality management.IntroductionContinuous coal mining systems containing multiple excavators producing multiple products of raw materials are highly complex and exhibit strong interdependencies between constituents. A network of conveyor belts is used for transportation of the extracted materials to different waste dumps or the coal stockpile.Optimal decision-making in short-term planning and production control are impacted mainly by geological uncertainty associated with incomplete knowledge of the coal deposit represented in the reserve block model. These uncertainties cause deviations from expected process performance. For more robust decision-making, understanding the impacts of these stochastic elements plays a key role."

Jan 1, 2016

By Jun Yang, Zongshan Zou, Mei Qu, Jianjun Zuo

For technical renovation of the thermal plant, one frame structure workshop of 50,000 m2 (59,800 yd2) construction area and one reinforcement concrete chimney of 150m (492 ft) height shall be demolished by blasting at same time. The engineering environment of which is complicated and the accommodation space is limited. Therefore, the collapse sequence, direction, scope of the dismantled building must be accurately controlled to ensure the safe operation of the adjacent generator unit and transformer station. By taking technical measures of theoretical analysis and numerical simulation etc., as well as research on structures collapse method and detailed delay interval, it puts forward the technology of bidirectional folded collapse of the workshop and it uniquely adopts the initiation system that combined with “half-second delay inside drilling” and “millisecond delay outside drilling”. Additionally, by using of the integrated vibration reduction technology in combination of the blasting ruins, buffer ditch and damping ditch, it has safely accomplished the demolition blasting work in high efficiency. Besides the demolition blasting vibration signal is collected and analyzed. The success of the demolition blasting will become valuable reference to other similar works.

Jan 1, 2016

By Yan Germain, Université Laval, Bernard Dallaire, Jocelyn Bouchard, Peter Radziszewski, Gilles LeBlanc, Michelle Levesque, Nicolas Tremblay

"The comminution process is estimated to be only 1% efficient, resulting in waste energy dissipated as heat, noise, and vibration. Energy recovery from grinding circuits has not been implemented mainly because recovering heat from the surface of the grinding mill or from mill slurry can impede operation, increase maintenance requirements, and prolong plant shutdown time (and production). However, currently very little information is available in the public domain regarding the amount of waste energy and that potentially recoverable in the grinding circuit of a mineral processing plant. Availability of such information could drive innovation and improve decision-making regarding opportunities for waste energy recovery. The Canadian Mining Innovation Council (CMIC) has initiated a study with CanmetMINING and mining industry partners to develop a model to map the energy flows in grinding circuits and to quantify the potential for energy recovery. The paper outlines the underlying fundamentals and data requirements for use in the model and then focuses on quantifying the energy recovery potential of the semi-autogenous grinding and ball mill circuits at the Agnico Eagle Goldex Division. Results show that most of the electrical energy (over 75%) is used to heat the slurry, leaving only a relatively small amount of it to achieve mechanical work (~9%). INTRODUCTIONCanmetMINING commissioned a study in 2013 to better understand the barriers for adoption of new technologies in the mining industry (MNP, 2013). The conclusions highlighted the importance of enhancing industry/regulator engagement and communication to raise awareness and improve the industry’s comfort level with new technologies.In November 2014, the Green Mining Innovation Advisory Committee (GMIAC) held a workshop to explore the possibility of accelerating the uptake of green mining technologies by bringing together key stakeholders among the mining value chain to address industry priorities. Participants included representatives from mining companies and associations, academia, provincial governments and federal departments and organizations. Two key priority areas emerged at the workshop: i) energy saving, and ii) water management."

Jan 1, 2016

By Noelia Valencia, Carlos Agreda, Jean Arenales, Juan Llerena

"In this technical paper is reported the several tests and the preliminary results that has been obtained so far. It must be emphasized that this investigation was started several months ago.On the other hand, it is known that acid water exists in some underground mining operations as well as in open pit mining operations all over the world. Taking into account this problem, our work teamdecided to carry out the present investigation. Therefore, it ensures a decrease in blasting costs avoiding this problem and as well as this, it allows to reducing fatal accidents that could occur caused by poor control of acid waters within mining operations."

Jan 1, 2016

By P. M. Solozhenkin, O. I. Ibragimova, I. P. Solozhenkin

Molecular models of complexes of poorly studied bismuth, gold, and arsenic mineral clusters and reagents were created for use in collector activity forecasting using Chem Bio 3D and ChemOffice2005, with optimization by MM2. The density functional theory approach was used to determine HOMO, LUMO, SOMO, and total energies, atomic charges, and s, p, d- populations for various compounds. The structure-based virtual screening (SBVS) and docking technique was proposed to reduce the vast number of compounds to a more manageable number for selection of potential flotation candidates. The prognosis of collector activity evaluation (PCAE) strategy was proposed as a consistent approach to estimate the interaction between a collector and a mineral cluster as the difference between the total energy and sum of cluster energy and collector energy to search the analogue of butyl xanthate. The negative relationship between PCAE and flotability was shown. The combinations of dialkylamino sulfhydryl collectors can be considered as prospective reagents for gold-bearing sulfide ore flotation. These results were confirmed by experimental data in ore flotation. The increase in recovery of gold and bismuth with the aid of a combination of reagents has been established and additional cyanidation of tailings has been avoided.

Jan 1, 2016

By Chulgi Suk, Hoon Park, Hyonsoo Kim, Hakman Kim, Sangho Cho

Dust emission from blast demolition and other construction activities can be a nuisance; it is widely recognized that fine particles less than 10 µm in equivalent diameter (called PM10) may cause health problems. Mist spray systems, such as rain guns, sprinklers, water/surfactant sprays (or foams) etc., are some of the most effective dust suppression methods. A large amount of research has showed that when water droplets are produced in an equal amount to that of dust particles, the airborne dust is suppressed by the agglomeration of dust and mist particles. A method for generating micro-sized mist from water, achieved by the detonation of explosives in the water tube, was suggested and is called the ‘detonationdriven water bag burst system’. There are many experimentally observed limitations of the explosioninduced water break-up process. The water bag explosion tests were simulated using the AUTODYN software, in order to investigate the aerosolization mechanisms of the detonation-driven water and water break-up process into micron-sized droplets. As a result of the numerical analyses, the diffusion direction of water when detonating in the central interior part of water tube was radioactive and significantly stronger than when detonating in the bottom exterior part; this is due to the compressive flow of the volume change inside of the water tube, which resulted from the blasting wave inside of the tube, as well as the reflected pressure on the ground. Blast tests of full-scaled reinforced concrete columns were conducted to verify the effectiveness of the suggested detonation-driven water bag burst system. The water breakdown and dispersion that occurred while blasting the reinforced concrete columns were observed using a high-speed camera, and dust generation was monitored using four density detectors. The suggested detonation-driven water bag burst system showed that the average dust density decreased by up to 7 mg/m3.

Jan 1, 2016

By Ewan Selers, Gary Cavanough

Drilling automation technology is well advanced and automated drill rigs are in use at a number of operating mines. This is not the case for the other drill and blast processes due to significant technical challenges to overcome. These challenges, with regard to the current “on bench” practices, include placing the initiators, loading the explosive and connecting up the initiation system. Although difficult, these challenges will be solved with engineering advances.

Jan 1, 2016

By L. Cáceres, G. Leinenweber, P. Bustamante

"Given the severe scarcity of fresh water sources in Northern Chile the use of seawater has become the only alternative to allow mining expansion. This option however poses several technological challenges as a result of the high concentration of natural salts that promote various forms of metal corrosion. Therefore the steel piping protection has been a constant challenge for design engineers responsible for solving the problems of corrosion. Known protection alternatives are varied and expensive, a few of them are rubber coatings, protection based centrifuged concrete, extra wall thickness of pipes in combination with corrosion inhibitors, extra wall thickness of pipes without using corrosion inhibitors, and the use of highly corrosion resistant steel materials.In this framework the aim was to study the corrosion kinetics of carbon steel pipe API 5L X70 under electrochemical and weight loss testing. The test conditions include a range of seawater velocities between 0.2 to 3.0 m/s.For electrochemical experiments the API 5L X70 steel specimen was a 4 mm diameter disk embedded in an 8 mm diameter Teflon rod and exposed to seawater. Duplicated coupons were placed in a standard test apparatus that was built according to the standard ASTM D 2688 – 94.The main results were: a) corrosion mechanism explained in terms of the counterparts partial processes which are the hydrogen evolution and oxygen reduction reaction; b) for the test specimen a corrosion band like feature that suggest a lateral dispersion of aggressive solutions from corrosion pits; c) a range of corrosion rates between 1 and 1.96 mm/year for flow rates between 0.2 and 3.0 m/s; and d) a convenient inhibitor dose between 20–25 mg/L for optimum inhibition efficiency to obtain a maximum value of 80% for corrosion efficiency."

Jan 1, 2016

"A fire design innovation of the concrete lining of the Ohio River Bridges East End Crossing Tunnel has been developed. As a result from a fire suppression and tunnel ventilation system, the project design Heat Release Rate (HRR) was able to be constrained from 300 MW to about 50 MW. With this reduced HRR, concrete lining without passive fire protection may be acceptable, if the tunnel concrete lining will not result in explosive spalling during the designed fire event. Concrete explosive spalling test was proposed to verify this assumption. Since no standard concrete fire explosive spalling testing procedure exists, a project specific testing procedure was developed and fire tests conducted. From fire test results, it is concluded that the proposed tunnel concrete lining, in conjunction with the proposed fire suppressing and ventilation system, will not experience explosive spalling and does not require a passive fire protection system. INTRODUCTION The Ohio River Bridge East End Crossing Tunnel is part of a Public Private Partnership project, which connects transportation network between Louisville, Kentucky and southern Indiana. Located in Louisville, Kentucky, the twin-tube highway tunnel provides northbound and southbound lanes of the Kentucky approach to a new bridge across the Ohio River. Tunnel lengths are approximately 1,675-ft and 1,685 for the northbound tube and the southbound tube, respectively. Connected by two cross-passages, both tubes have a roadway width of 40-ft, for 3-lane traffic, and a vertical clearance of 26.5-ft.The Tunnel was constructed by drill and blast method with shotcrete and rock dowels as initial ground supports. The final tunnel lining consists of 16 inches cast-in-place concrete lining and 20 inches invert slab, with a waterproofing system around the tunnel perimeter. Two (2) tunnel side drains and one (1) invert drain were provided for each tube. This paper describes the rational in assessing fire design requirements of the tunnel final concrete lining, to answer the question whether a passive fire protection system is needed or not."

Jan 1, 2016

By Cathy Aimone-Martin, Brent Meins

A comprehensive instrumentation program was implemented at the Howland Hook Marine Terminal on Staten Island, NY during proximate underwater rock blasting in 2014. Forty-two blasts took place over a 4-week period to deepen the 1200-ft (366 m) Berth 3 from -45 ft (-14 m) to -50 ft (-15 m) MLW to accommodate Post-Panamax vessels. Approximately 86,000 yd3 (65,752 m3) were blasted 120 to 9 ft (37 to 2.7 m) from the wharf to a total depth of -57 ft (-17.4 m). Pre-blast planning included developing and implementing a comprehensive monitoring plan and setting vibration and strain limits to protect the wharf. The plan outlined methods to measure vibrations on five corners of four concrete deck sections, on five concrete-filled pipe piles just below the pile cap near deck corners, and in bedrock adjacent to pile sockets. Water overpressures were measured near instrumented piles for 19 blasts closest to the wharf. A total of 19 geophones were secured to the wharf structure and buried 12 ft (3.7 m) in drilled holes.

Jan 1, 2016

To meet the energy requirements, hydroelectric projects are planned and executed in many countries. Though these projects requires a high capital investment, the returns are regular with minimum maintenance after commissioning of the project and are ecofriendly. Bhutan is situated in the eastern Himalayas and covers an area of 38,394km2 (14824.01sq. miles. It is bordered by India in East, South and West and by Tibet in the North. The hydropower potential of the country is estimated at 30,000MW, out of which around 5% has been harnessed.

Jan 1, 2016