Search Documents

By K. M. Tait, M. M. McDonald

"An overview of the status of the development and application of Integrated Gasification Combined Cycle (IOCC) power generation is presented. Current projects in North America, Europe and Japan are described, together with the status of plans to apply the technology in Canada. A brief review of the technology is presented, including promising coproduction cycles and hybrid gasification fluid bed processes. The ability of the process to be modified for CO2 to be extracted for enhanced oil recovery or disposal is addressed. The environmental impact of IGCC technology is compared to those of other power generation technologies IntroductionDefinition and HistoryIntegrated Gasification Combined Cycle (IGCC) technology is a concept which has been around for about 50 years but has been generating increasing interest in the last 10 to 15 years. This paper focusses on coal as the feedstock for gasification. Other feedstocks used in gasification systems have included oil, biomass, tires and petroleum coke. IGCC technology integrates coal gasification with generation of electricity by means of a combined cycle system which fires the produced gas in the gas turbine. Figure 1 shows the basic components of an IGCC system which are the gasifier, the gas cleanup system and sulphur recovery plant, the gas turbine/generator set, the heat recovery steam generator (HRSG) and the steam turbine/generator set. The benefits of an IGCC system over a conventional Rankine Cycle pulverized coal (RCPC) fired system for the generation of electricity from coal are that the IGCC system has potential to have higher efficiency and lower emissions of NO., SO and CO2 per unit of power produced than the corresponding RCPC system."

Jan 1, 1994

By S. S. Rahman, A. Gholami, M. A. Aghighi

"This paper provides a foundation for studying the growth of fractures in presence of other discontinuities and different anisotropies of low permeable hydrocarbon formations and helps to improve the design strategies for multistage fracturing.The multistage fracturing technology has recently been used to exploit low permeable hydrocarbon reservoirs. However, the mechanism of hydraulic fractures interaction and the impact of local heterogeneities on ultimate trajectory of the growing hydraulic fractures are not yet understood in depth. A fully coupled poroelastic Finite Element based model is developed to investigate the mixed mode propagation behaviour of growing hydraulic fractures. This model takes advantage of an explicit representation of the fracture which enables us to take the effects of rock and fluid related parameters into account. Moreover, impact of fracture geometry and leak-off phenomenon is investigated. The refined mesh around the crack provides the added advantage of more detailed stress distribution, pore pressure change and back stress in the vicinity of the fracture and in particular at the fracture tip. The potential deviation propensity of the fractures is evaluated based on the fundamental rule that fractures propagate perpendicular to the direction of the minimum horizontal stress.This study shows that pressurization of transverse hydraulic fractures results in the reorientation of local principal stresses, particularly in vicinity of fracture tips. Variation of flow patterns clearly influences the evolution of shear stress around the fracture tips which will potentially lead to mixed-mode I and II fracturing and consequently, fracture deviation. The presence of local heterogeneities such as preexisting fissures and/or fractures is a main source of such pore pressure induced stress redistribution and reorientation and potential deviation of hydraulic fractures.Most existing models ignore or simplify the effect of pore pressure/stress coupling as well as the fracture geometry and fluid flow within the fracture. Also, the fluid leak-off from the hydraulic fracture into the formation, which is a controlling factor in fracture growth, is often considered using analytical models. Taking advantage of a fully coupled porelastic model along with an explicitly discretized fracture, this study provides a more realistic insight into the complex fracture propagation processes of multistage fracturing operations particularly in presence of reservoir geo-mechanical complexities."

Jan 1, 2015

By P. K. Chatterjee

"The operations of a large-scale open-cut mine are simulated to produce a user-oriented interactive digital model. SIMULA is chosen as the programming language and a sophisticated data base system is designed to consider the complex information network of large mines. The main features of the program are the mine planning and mine evaluation modules. These modules are responsible for the computation of truck-shovel performance and other equipment details in a mine. Stochastic methods are employed to generate event times. The use of a Data Base Management System and the data base provide an efficient method of information storage and retrieval. Truck allocation techniques have been examined in detail and comparisons between random dispatching and conventional methods are made. The model is intended for mine operators and engineers and the program is well structured and very readable. It is hoped that these features will make the model readily acceptable.IntroductionThe Department of Mining and Metallurgical Engineering at the University of Queensland has been conducting research into computer simulation methods in mining since 1972. The research has been mainly applied to actual operations, with both open-cut and underground mining being equally emphasized. The results of the research to date have not only strengthened the methodology of the approach to complex mining problems, but have also increased confidence in the use of modelling and computer simulation technique s in mining.The model described in this paper translates a complex LHD situation into a user-oriented interactive digital model using SIMULA. The present methods of evaluating truck dispatching and trolley assist are tedious and laborious. This model provide s the engineer with readily acceptable means of rapidly assessing the relative merits of these techniques in a large-scale open-pit operation. Poor utilization figures in many current operations (for example, 40% for trucks, 70% for shovels) are of serious concern to mine officials and computer-controlled dynamic truck dispatching systems have been considered by some of these mines to improve equipment utilization ."

Jan 1, 1981

By T. D. Brown

"A review of the current status of gasification technology shows that many engineering systems are immediately available for use in the gasification of coal. Widespread international experience can be brought to bear on the atmospheric pressure gasification of all Canadian coals.Unless a high ash content dictates the use of a fluid-bed gasifier, it appears that bituminous coals can be used in gravitating (fixed] bed systems and that the strongly caking coals are most suited to the high-pressure entrained-bed systems . Existing and developing technologies in fluid-bed gasification are attractive for reactive lignites and subbituminous coals.The Fischer-Tropsch based process is the only commercial embodiment of coal liquefaction; the use of Canadian coals in this process depends only on their gasification characteristics. Current developments in hydroliquefaction are directed toward carboniferous coals of medium or high rank. It is not clear that cretaceous coals of the same rank will give similar process yields and economics.IntroductionThe twin coal conversion processes of gasification and liquefaction have a history which dates back beyond the current energy shortages of the western world. Indeed, liquids and gas from coal were produced before this century.Coal gas produced from a coal carbonization process was originated before 1800, and the development of gasification of non-coking coals was patented by Siemens in 1860.This patent represented the first use of air and steam together in the gasmaking process. The pioneering development of coal gasification Using oxygen and steam was demonstrated by Lurgi in the late 1920s. This historical sequence was all carried out at atmospheric pressure, and it was not until the immediate pre-war (1939/45) years that operation of the coal gasification process at elevated pressure became a reality."

Jan 1, 1981

By D. A. Stokes

"In October of 1980, Fording's 15 000-ton capacity clean coal silo was put into operation. The silo was unique in that it was designed to allow the mass flow of material, coupled with a sophisticated computer-controlled dynamic loadout/weighing system.On May 1, 1982, an explosion, attributed to a methane buildup, devastated the top of the silo. .As a contingent plan to minimize the effect of the production loss the conveyance to the silo top was reconstructed and the silo' was back in operation by mid-June 1982, although the silo top was left open to prevent further methane buildup. As dust emissions occurred during loading ofthe silo, an extensive study was undertaken to establish dust control for the silo, while at the same time providing methane detection and control.The study, conducted for Fording by the Cambrian Engineering Group of Calgary, involved an extensive search and investigation of existing coal silos. The study concluded that there IS no universally accepted method of controlling methane emissions in coal silos.The study also produced a unique conceptual design for handling methane, while at the same time, protecting the environment . Fording's Clean Coal SiloThe silo, located at Fording Coal's Fording River metallurgical coal operation, is utilized for the storage and load out of cleaned thermally-dried metallurgical coal.The silo was constructed in 1979 and 1980 to reduce unit train loadout times and to facilitate the handling of “special shipments"" of coal. The silo went into operation in October 1980, under manual control and utilized computerized, automated loading by February 198I.The silo is 21 m in diameter and 76 m high, with a nominal capacity of IS 000 live tonnes. The coal storage portion of the silo is 21 m in diameter and 48 m high, utilizing 2 steep-angled hopper outlets allowing mass flow of the stored coal during train loading. Each hopper has a control gate and a discharge chute, one chute for bulk loading, the other for trim loading of coal into the rail cars."

Jan 1, 1986

By Francis Breton, Lei Pan, Kun Liu

"Effects of Fe, Cu and Mg minor alloying elements on creep properties of 8xxx aluminum conductor alloys were investigated by conducting compressive creep tests at 100 ºC under a constant load of 69 MPa. The microstructural evolution was studied using an optical microscope and electron backscatter diffraction technique. The creep properties were characterized by the primary creep strain in the first stage and the minimum creep rate in the second stage of creep deformation. Results showed that additions of all three minor alloying elements (Fe, Cu and Mg) demonstrated a beneficial effect on the creep resistance but individual alloying elements exhibited different impacts on creep properties. The additions of Fe and Mg showed a strong impact on both the primary creep strain and minimum creep rate, while the Cu addition displayed a favorable effect on the primary creep strain but no impact on the minimum creep rate. Microstructure observation revealed that with increasing Fe contents, the volume fraction of fine intermetallic dispersoids gradually increased while the subgrain size and misorientation angle became smaller, providing strong barriers to the dislocation and grain boundary movements. The addition of Cu moderately reduced the subgrain size and misorientation angle and in combination of solid solution strengthening it promoted the retardation of the creep deformation during the primary stage.INTRODUCTIONThe 8xxx aluminum conductor alloys offer significant advantages such as low density, high conductivity to weight ratio and low price over copper conductors and become an attractive candidate in electrical engineering and building wiring (McQueen, Chia, & Starke, 1986; Birol, 2009; Engler, Laptyeva, & Wang, 2013). The mass resistivity of aluminum conductors is one-half of copper conductors. Thus, only one-half the weight of aluminum is required for equivalent capacities. Therefore, this unique property coupled with a relatively low price of aluminum offers significant economic advantage to develop aluminum conductor alloys for electrical applications in the electrical wire industry."

Jan 1, 2016

By K. J. Brouwer, J. P. Haile

"Construction of the first stage of the tailings disposal facility for the Montana Tunnels Project was completed in October 1986. The project is located 37 km south of Helena, Montana, and involves mining of42 million tons of weathered diatreme are at a rate or 13 500 tpd to produce a gold/silver dore, as well as lead and zinc concentrates. The tailings disposal facility for the project includes a fully drained tailings impoundment for storage of the tailings solids, and a process waterpond for storage of all decanted water prior to recyling to the mill. The over-all facility is designed to achieve the basic objectives ofminimizing seepage to the environment in the short- and longterm, and achieving a fully drained stable tailings mass suitable for immediate reclamation on completion of mining. Specific features of the design include a soil bentonite seal and drainage system within the tailings basin, a free draining embankment with a design flow-through capacity of 4000 US gpm and an ultimate height of 230 ft (70 m), and a soil bentonite lined make-up water pond with a capacity of 420 acre-feet (530 000 m'). The tailings will be discharged in a rotational sequence through multiple spigot offtakes to achieve a thin-layer low energy laminar flow. This 'sub-aerial' deposition results in higher stored densities and maximizes liquid-solid separation on the tailings beaches. The over-all design played a major role in the successful permitting of the project, and was significantly cheaper than a conventional wet disposal system, with overall unit costs for tailings disposal of less than US$0.36 per ton.This paper outlines the site characteristics and the tailings material properties and their influence on the design. Extensive use was made of naturally occurring free draining materials as well as bentonite modified soil liners within the tailings basin, embankment and retention ponds. General construction procedures for the various components are described, as well as on-going construction requirements utilizing materials from the open pit. Finally, the over-all costs and unit costs for tailings disposal are presented."

Jan 1, 1988

By D. François-Bongareon

"In previous publications by the author, significant advances and generalizations of the theory of sampling of broken ores, prompted and confirmed by experimental results, have been presented. This paper shows how to implement these theoretical results in practice. The models to be used are reviewed, with a description of the various sampling parameters involved. Then the methodology for the experimental assessment of those parameters, including segregation factors, is described in simple and practical terms, along with the use of handy sampling protocol charts. Finally, the particularly important case of processing data from a sample-tree experiment is detailed, and examples of applications covering all situations and types of experiments are provided.IntroductionThe reliability of a sample of crushed material , i.e. the expected (average) deviation between its true grade and the true grade of the lot it comes from, mostly depends upon six factors:• the size (mass) of the sample (and to a minor extent, for small lots, the size of the lot);• the size of the rock particles (degree of comminution)• the nature of the mineralization at microscopic scale (i.e., within even the smallest particles);• the geological nature of the mineralization and mineral of interest;• the grade of the lot in the mineral of interest; and• in some cases, the state of segregation of the lot.In practice, one should first disregard segregation problems, and assess sample variability in the segregation-free case. Once the numerical parameters governing this variability have been assessed, then segregation factors can be assessed in turn. In the case of laboratory standard sample preparation procedures, segregation can usually be disregarded altogether."

Jan 1, 1993

By P. C. Richards

"Future Integrated Gasification Combined Cycle (IGCC) power plants will have superior environmental performance and unmatched efficiency.The Shell Coal Gasification Process (SCGP) is a clean coal technology, which can convert a wide range of coals into clean syngas for high efficiency electricity generation in an IGCC plant. SCGP flexibility has been demonstrated for feeds ranging from bituminous coals to lignites and petroleum coke, and the process is ideally suited for combined cycle power generation, resulting in efficiencies of 42% to 46% (LHV).In the Netherlands, a 250 MWe coal gasification combined cycle plant based on Shell technology is being built by Demkolec, a development partnership of the Dutch Electricity Generating Board (N. V. Sep). The plant is scheduled to start up in 1993. IntroductionBasic ConceptShell's experience with gasification dates back to the 1950s, when the first Shell Gasification Process was commissioned with oil as feedstock. There are now over 140 SGP gasifiers licensed. The experience gained on oil gasification provided a firm theoretical and practical base for the start of coal gasification process development in 1972.At that time, there were serious concerns about the future availability and price of crude oil. Coal gasification (making carbon monoxide and hydrogen by the partial oxidation of coal) was considered to be an important option for refinery applications, because the synthesis gas (syngas) produced can be used as:• a chemical feedstock for making transportation fuels and chemicals;• a source of hydrogen (making use of the water gas shift reaction) for upgrading petroleum products; and• a fuel for heating process streams and/or generating electricity."

Jan 1, 1994

By Peter Moon, Lloyd G. Campbell

"How well supervisors supervise, and are supervised determines whether management's goals will be reached and ...how effective the work force will be... Upper management must recognize the potential returns of viable training programs for both management and mine workers… The key to performance, from the standpoint of safety and productivity, is the ability of the line supervisor to manage(1).In this article, the authors will share their experiences in supervisor selection and development. They also draw on the work of two men in particular, Douglas Bray and William Byham, both of whom have contributed significantly to the understanding of supervisory development and training.IntroductionYears ago, there was not much training for supervisors. They worked under an authoritarian style of management and modelled themselves on it. They were generally selected for their skill as miners, mill operators or mechanics. Things have changed. Today, companies have different needs. The selection of supervisors is far too important to rely on guesswork. Progressive companies want supervisors who think like managers - supervisors who know how to plan and organize, set performance standards and monitor them, analyze problems, develop solutions, show sound judgment and deal effectively with people. The evaluation of these supervisory ""dimensions"" is best accomplished through the use of an assessment centre. The Assessment Centre Method increases the accuracy of predicting the future success of candidates being considered for promotion.Mining and other resource companies use assessment centres to select the most suitable people for supervision. The Assessment Centre Method is based on extensive research. It eliminates hit-and-miss selection methods by using several different exercises that simulate the problems and activities that candidates would face if they were promoted into supervision . In other words, they get a realistic "" sample"" of the supervisor's job and are required to deal with and manage interpersonal and problematic circumstances."

Jan 1, 1990

By R. Mariano

"The ability to optimise a concentrator from mill feed to final products requires a process simulator that integrates comminution, classification and separation stages. A key part of any such integrated process simulator is the inclusion of a model of mineral liberation in comminution to predict the particle composition distribution of the comminution products. This need was recognised by Gaudin (1939) who proposed a model of liberation based on the cubic fracture of a mineral texture composed of cubic grains of two minerals.This paper describes the development of a texture-based model of mineral liberation that builds on the method proposed by Gaudin. The approach described here, termed the JK-Gaudin Random Liberation model (JK-GRLM) uses as its basis the measured, volumetric mineral texture data that can be quantified for a given ore using X-ray micro-tomography. The textural data required as inputs for the JK-GRLM include the mineral grain size distribution. While the Gaudin model (in common with other existing liberation models) is a two-mineral (or two-phase) system, the JK-GRLM extends the approach to multimineral systems of up to 15 individual minerals, making it more widely applicable.An example of the application of the JK-GRLM to a base metal sulphide ore is provided. In the example the JK-GRLM is used to simulate the breakage of the measured ore texture and the particle composition distributions of the simulated progeny particles are compared to the measured particle composition distributions of ore that has been physically broken.The ability to calibrate this mineral liberation model with measured ore texture will allow it to be applied in greenfield situations where geometallurgical programs measure texture and in brownfield applications as a key part of integrated process simulations. The development of this model enhances our ability to simulate mineral processing operations as an integrated system."

Jan 1, 2016

By M. C. Villeneuve, P. A. Siratovich

We present an integrated analysis of laboratory-based thermally induced fracturing and results of numerical models to give insight to the role of thermal shock fracture on geothermal reservoir rocks. Thermal stimulation is a reservoir permeability enhancement technique applied to commercial geothermal reservoir rocks to enhance fluid injection capabilities for spent power plant working fluids. The process is well known to enhance permeability but the thermodynamic and physical constraints of the process are less certain. In an attempt to constrain the interaction and the ideal conditions that lead to permeability enhancement, experimental procedures were carried out to mimic the conditions that a reservoir rock would experience during a thermal stimulation using temperature differentials ranging from 50-300°C. Samples underwent such thermal gradients under controlled laboratory conditions and were characterized for the changes to permeability, porosity, ultrasonic velocities, dynamic elastic moduli and petrological changes. The thermal stimulation was simulated in a FLAC2D thermal numerical model to investigate the nature of the thermally induced changes in the sample. The development of this model also allows us to investigate the relationship between geological characteristics and the ability to thermally stimulate any type of rock. The results indicate that numerical thermal shocking experiments are corroborated by laboratory-based results. The implication of this study is that the refined numerical models present an insight to the conditions and constraints under which thermal stimulation can prove to enhance permeability that could not be gained through purely laboratory-based studies.

Jan 1, 2015

By Douglas A. Karvonen

"Competition in the world potash market has increased significantly since the late 1970s. The failure of consumption to grow at expected levels has led to industry over-capacity, a situation which is likely to persist at least until 1990. Individual Saskatchewan producers and their offshore marketing company, Canpotex, have responded to this challenge by increasing mining efficiency, developing more cost-effective and reliable transportation systems and establishing innovative financing and market development programs tailored to customers' special needs. Investment in warehouse facilities to serve U.S. customers and exploration of opportunities for intermodal distribution through the Great Lakes and the Mississippi River system have maintained individual producers' position in the highly competitive domestic market.Export sales through Canpotex have been bolstered by utilization of CIDA funds, Exp ort Development Corporation financing guarantees and other innovative payment plans which enable heavily indebted developing countries to maintain the import levels which are necessary for their agricultural development.IntroductionPotash is the general term applied to various potassium salts both natural occurring and commercially derived. The most common of the commercial product s are potassium chloride, potassium sulphate and potassium magnesium sulphate. The potassium content of potash is measured in units of K20 equivalent. The common grades of potassium chloride produced for agriculture average at least 60 0/0 K20 compared with approximately 50% Kp for potassium sulphate and 22% for potassium magnesium sulphate."

Jan 1, 1985

By D. E. M. Plaumann

"The wet grinding of asbestos has attracted the attention of engineers for many years as a means of improving fibre liberation from the ore. Today, added impetus for wet grinding has resulted from a need to minimize worker exposure to asbestos dust in conventional dry mills using air, as well as a need to provide a cleaner, technically superior fibre for use by product manufacturers. However, high viscosities of asbestos slurries create transport and grinding difficulties which have been a factor impeding use of a wet grinding process.Laboratory evaluation of reagents to reduce viscosities of asbestos slurries found that one reagent, XFS-4272.00, reduced the viscosity of a 35% (by weight) slurry by 75%. The impact of XFS-4272.00 on actual grinding parameters were evaluated using a pilot plant rod mill. Slurries containing 78% solids and XFS-4272.00 were successfully milled and asbestos fibres from that milling compared favourably in liberation and relative surface area to asbestos fibres obtained from milling a 4% slurry without additives. IntroductionAlthough the use of asbestos has been declining over the last few years, the large deposits of chrysotile in eastern Canada (Quebec in particular) remain very important. Asbestos production in Canada stands ninth in volume for mineral production with over 740 000 tonnes produced in 1985. Of this quantity, 722000 tonnes were exported with a value of $446 million. Canada is second in world production of asbestos behind the U.S.S.R. The milling of asbestos ore has been done primarily by a series of steps involving crushing, dry-grinding and aspiration using large quantities of air to release the fibres. Contrast this process to those practiced in the purification of virtually every other mineral. Ores other than asbestos are crushed and milled using an aqueous slurry in rod, ball or pebble mills. The finely ground mineral, still as a slurry, undergoes beneficiation by froth flotation, heavy media separation, hydrocyclones or any of the other aqueous techniques currently employed in mineral processing.One of the driving forces behind the use of air instead of water as a means of separating asbestos is the nature of the aqueous asbestos slurry. While most slurries of minerals contain as much as 80070 solids and can still be pumped and transported, asbestos slurries become highly viscous with as little as 10070 solids. These high viscosities reduce the pumpability of the slurry and create severe handling problems. Mills become prohibitively large and uneconomical due to having to handle slurries containing only 10% rock and 90% water.Health-related issues have affected the use of asbestos in many countries. In Canada, the asbestos-producing provinces have introduced stricter occupational legislation to improve safety in the workplace. This primarily means strict control minimizing release of air-borne asbestos fibres . Quebec and Ontario have set limitations of airborne asbestos at 2 (2) and 1(3) fibre per cubic centimetre of air. With present milling technology, maintaining these low levels in the workplace requires constant vigilance."

Jan 1, 1988

By D. Doyle, T. Cienski

"This paper presents and discusses the results of a detailed study conducted on the subject of energy consumption in the comminution of industrial minerals. The study was based on pilot circuit testing, plant operating data collection, detailed equipment data and literature research. The areas covered by investigations include: high efficiency classification; air classifiers for cement grinding circuits; grinding aids in dry grinding; and dry grinding circuit control based on particle size measurement. Results obtained indicate a large potential for the reduction of energy consumption, in particular in the cement clinker grinding circuits. Better classification techniques and correct application of grinding additives can significantly reduce power used per tonne of product and also substantially increase grinding circuit output."

Jan 1, 1992

By Marcel Laflamme, N. R. Rillette

"In 1982, a study was initiated to investigate relationships between bonus and accidents in Quebec underground mines. In 1983, the study was expanded to include the impact of age and experience on accidents.The paper will describe the methodology followed in gathering information at ten mines from three mining camps in the Province of Quebec, and its transfer to data banks for subsequent treatment. Multifactorial analysis of nine variable files for the ten mines has shown: that age, experience and seniority are linked; that total working hours are tied with overtime; that bonus is linked to the main activity of the miner, and not to accidents. The most tangible factors affecting accidents seem to be the introductory training and subsequent retraining at regular intervals."

Jan 1, 1989

By P. O. Rag, Daniel E. Walsh

"Gravity concentrators are evaluated either in closed or open circuit. The process developed by MIRL employs the use of neutron activated gold (/98Au) and radiation detection circuits which monitor the concentrator's product pulp streams. Concentrator recovery is determined from the ratio of the number of gold particles detected as passing into the concentrate to the total number of gold particles detected over all monitored pulp streams. This system eliminates the experimental errors introduced by sampling, sample reduction, and assaying and allows recovery to be evaluated for gold particles of specific sizes, shapes, and flatness. In addition to allowing for a more accurate and detailed recovery analysis, this process significantly reduces the time and cost required for unit evaluation when compared to other gold recovery analysis procedures. This system enjoys its greatest utility where a large number of tests are to be run in order to evaluate a concentrator over a variety of operational settings, i.e. factorial designs, and allows accurate testing of concentrators operated in closed circuit systems.IntroductionThe surge in gold prices of the late 1970s and early 1980s was followed closely by a renewed interest in gravity concentration processes, especially in concentrators claiming efficient recovery of fine placer gold. Cones, spirals, spinning bowls, jigs and cyclones are all considered potential fine gold concentrators. Fine gold, in this context, is defined as not only that gold finer than 250 um (60 mesh""), but also coarser gold, whose low shape factor may decrease its recovery by conventional, large-scale sluicing operations.Adoption of fine gold concentrators by the Alaskan placer milling industry was retarded by the lack of reliable, accurate, and reproducible data on concentrator efficiency with respect to fine placer gold recovery. In most cases, concentrator performance was based on a limited number of tests run on placer material, about which only slight knowledge of gold size and shape characteristics existed. In order to be prepared for the resurgence of interest in fine gold concentrators, which will follow the next upturn in gold prices, a detailed study of the fine gold recovery characteristics of gravity concentrators needs to be conducted."

Jan 1, 1986

By Chris V. Sellathamby

Condition-based maintenance is replacing preventive maintenance in many industrial operations as a result of gains in productivity. Preventive maintenance is strictly time-based which means that as long as the prescribed time is sufficiently short, failures are prevented. The trade-offs between shorter cycles and increased downtime is a fine balancing act. Condition-based maintenance is gaining momentum as the more cost-effective and green solution to finding the optimal maintenance cycle and improving overall productivity. In the mining industry, various parameters of heavy equipment are monitored continuously to provide feedback for maintenance events. However, strain, shock, and vibration, key factors which lead to yielding and fatigue of metal parts, are not generally monitored by built-in systems, mainly due to the complexity of sensor installation and computational intensity of data processing. Scanimetrics has developed a stand-alone, add-on wireless system for measuring strain, shock, and vibration in heavy equipment and components, the data from which can be directly used to trigger maintenance events. The present system is being deployed in tar sands mining equipment. The system consists of a portable display and control unit, a software platform consisting of data management, sensor instrumentation and data analysis, and wireless strain sensor units, which can be easily installed on equipment. Data from the sensors can be gathered throughout the mine site, processed instantly, and used to generate condition-based maintenance events, improving overall uptime of the equipment and overall productivity of the mining operation.

Oct 1, 2010

By P. A. Verhey

"This paper describes a series of wear-resistant ceramic materials which have been successfully used in the mineral processing industry in Canada. Applications include use with metallic ores, coal, potash and asbestos, and in other processes where wear degradation is of major concern. The paper will also deal with considerations involving the selection of the different ceramic materials available. It will cover the installation of ceramic materials on support structures under varying process ' conditions, as well as the other physical and chemical factors which have to be taken into account.IntroductionIn the mineral processing industry, large volumes of ores tailings and other materials are handled. The abrasive nature of most of these materials results in extensive wear to both handling and processing equipment.Wear ratios versus cost, production losses due to down time and wear-resistant material suitability for a given application all demand particular attention when viewed against the need for increased efficiencies in existing processes. As a consequence, a very active continuous search for materials with improved wear resistance has been carried out for many years.In this search, starting about 20 years ago, dense ceramic materials were tested and evaluated in certain applications, notably in the iron ore and asbestos operations in Eastern Canada. As a result of substantially better performance both in continuous extended life and ultimate economics realized , wear-resistant ceramic applications developed progressively in many other processing applications, replacing traditionally used materials.In the vast majority of wear-resistant ceramic applications, considerable extended life over previously used materials was established. This invariably was not just a fractional increase but, in most cases , in factors of double, triple and often all the way up to 18 and 20 times the life of alternative materials used previously. In certain applications, extended life could not be measured and appears to be indefinite.Obviously, as a result of such experiences, the progressively wider use of wear-resistant ceramic materials is now an established trend."

Jan 1, 1981

By P. Mayer

"Determining the correct mechanism of a boiler tube failure is important for the prevention of future tube failures. Proper corrective measures can be undertaken to alleviate the root cause or causes for a failure only when the correct mechanism is known. A mechanism of boiler tube failure is defined as the process which degrades the tube and produces a failure.An expert system package was developed for use by electric utility power plant personnel during investigation into the cause of a boiler tube failure. It is intended to assist their efforts to recognize and identify a basic failure mechanism that can produce the type of boiler tube failure under investigation. The program guides the user to the most likely failure mechanism by asking simple questions, answers which can be obtained by determining the failure location, type of fuel, and from visual inspection of the failed tube. Expert systems are a form of artificial intelligence which imitate the decision-making process of experts.IntroductionBoiler tube failures (BTFs) continue to be the single largest source of forced outages in fossil fired electricity generating stations. Because of this a concentrated effort is being made to minimize boiler tube failure occurrences. Eliminating boiler tube failures could be worth $5 billion a year to the electric power industry(1).The aggressive service environment of fossil-fired boilers is largely the reason for these failures because the combined effects of stress, temperature, corrosion, erosion and vibration cause deterioration of boiler tube material properties and reduction in wall thickness.Determination of the boiler tube failure mechanism is important for the prevention of future problems. The root cause for a failure can be established and proper ameliorative measures taken only when the failure mechanism is identified correctly. The correct identification of failure mechanism is a complex process which may include many individuals and institutions. Technical specialists in metallurgy, chemistry, combustion, and boiler design frequently cooperate with the station staff in a failure investigation . These individuals rely on personal experience and numerous reports , theories, studies, private communications and investigations concerning the different failure modes and mechanisms."

Jan 1, 1990