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By J. Day, Matthew X. Yao, Lijue Xue

Hardfacing overlays are commonly applied on the shroud Z-section of turbine blades for enhanced wear resistance. Among various processes that are used to apply the hardfacing overlays, the plasma transferred arc (PTA) welding process offers several advantages including lower heat input, less base material dilution, rapid process time, and reduced operating cost associated with the capability to apply materials in the powder form. The development of a robust PTA process is crucial for overlay performance and repeatability, particularly in the aerospace industry where a quality intensive manufacturing environment prevails. For this reason, the Taguchi method of experimental design was selected to develop a test plan. A 4-factor 3-level (L9) orthogonal array (OA) was used in the experiment. The L9 OA allows for a more detailed (3 level) investigation of critical process parameters, namely plasma gas flow rate, traverse speed, powder feed rate, and arc current. Two hardfacing materials, Stellite 694 and Tribaloy T-800, both Co-based wear resistant alloys, were investigated by deposition onto a cast IN738 Ni-based superalloy substrate. Performance measurements of the hardfacing deposits included deposit hardness, substrate hardness, deposit density (porosity), degree of cracking/inclusions, and a quantified visual inspection. The procedure resulted in optimized PTA hardfacing parameters for both Stellite 694 and Tribaloy T-800 on IN738 turbine blade material.

Jan 1, 2004

By Prodipto Ghosh

This paper is prepared as a review of existing and traditional methods related to electrical maintenance strategy. Its primary focus is to explore newer ideas and how they point the way to a more efficient and effective manner of electrical maintenance. This discussion is primarily related to large electrical distribution assets typical of heavy industry such as mining.

Aug 1, 2013

By J. R. Shore, F. G. M. Gillett, E. J. Zickar

"The addition of fines to rod mill feed has been employed at Inco Metals' Frood-Stobie Mill since 1973. The fines, which act as a ""lubricant"", causes an increase in the pulp fluidity and assists the flow of feed through the rod mill. Fines addition was one of the main factors which led to improved rod mill performance and the elimination of rod mill tangles.This paper outlines the testwork performed in evaluating the addition of fines, and summarizes the beneficial effects on rod mill grinding efficiency, throughput rates, power consumption and noise level. INTRODUCTIONFrood-Stobie Mill is situated within the Frood-Stobie mining complex, on the southern rim of the Sudbury Basin. The Mill commenced operations in November, 1967, and has since processed in excess of sixty-five million tons of ore. Minus 8-inch ore is delivered to the Mill's coarse ore bin by two surface conveyor belts from the Frood and Stobie Mines, while Little Stobie ore is transferred by underground conveyor and hoisted directly into the coarse ore bin a long with additional Stobie Mine ore."

Jan 1, 1981

By R. F. Favreau

"After a blast, the volume of the blasted rock normally occupies more space that it did before the explosion. The degree of such swell significantly affects the efficiency of digging the muck with a shovel or dragline. This paper explains why swell occurs, and describes the new subroutine SWELL of the blast simulator BLASP A which can simulate blast-induced swell. Results are also presented which display the effect of various blasting parameters on the degree and distribution of the swell within the muck pile of a bench blast. IntroductionIt is a common opinion that fragmentation is the most important of the various aspects which affect the efficiency of excavating rock with explosives. This paper proposes that, in fact, displacement and swell of the blasted rock are as important as fragmentation if the excavation process is to be rapid and efficient. It must ""a priori"" be recognized that a minimum degree of fragmentation is indeed necessary. For a given shovel or dragline, this minimum degree of fragmentation may be defined as follows: even the largest fragment of rock must be easily contained within the bucket. Once this criterion is met, however, there are good reasons to believe that displacement and swell take over as the key criteria which influence the rate of mucking, in cubic metres/hour. If the muck pile is not well displaced and swelled, the teeth of the bucket have difficulty penetrating between the rock fragments even if fragmentation is good and, as a result, the mucking is slow and inefficient. The purpose of this paper is to use computer simulations on the model BLASP A to demonstrate the effect of the blast design parameters on the displacement and swell of the blasted rock."

Jan 1, 1993

Experimental determination of the response of an AG/SAG mill treating two components of significantly different impact resistance is challenging for two main reasons: firstly, small scale laboratory tests have yet to be confirmed as valid representations of the full scale milling environment, and secondly pilot plant testing requires 10-20 tonnes of ore per scenario which precludes the use of drill core, rendering the process very expensive. In order to mitigate these difficulties, modelling was considered as a potential way forward. However, as the JKSimMet AG/SAG model currently has no capacity to simulate the interaction of two ore types with differing impact resistance, density and/or feed size distributions, an alternative modelling approach was developed. This approach aims to essentially calibrate the AG/SAG process under a set of given conditions, for which survey data and the ore properties of the main components in the feed blend already exist. This paper describes a new conceptual model, which provides a simplified approach for investigating the multi-component behaviour of two ores of differing hardness/SG in a given AG/SAG milling environment, and which can potentially be used for scale-up from laboratory/pilot testwork and geometallurgical estimation of throughput.

Jan 1, 2012

By C. F. Gleeson

"I HAVE BEEN ASSIGNED the pleasant task of adding a last word in way of summary to this session. I think that the trend set in having a geochemical session at the CIM Annual General Meeting is a good one and I hope it will continue so that members of the mining fraternity can get together on a regular basis and discuss geochemical problems peculiar to our Canadian scene. A series of interesting papers have been presented on what has been considered by many in the past as not only a problem area for geochemistry but even an impossible one. The papers should help dispel some of these fears. Lack of development of geochemical techniques in the Shield has been due to a variety of factors, many of which have been mentioned. However, I feel that one of the main reasons for this lack of development has been timidness on behalf of many people to get out and do the necessary work which helps produce answers to many of the questions asked. New developments and applications of geochemical methods in the Shield will not be done by the faint of heart but by those who have the curiosity, interest, imagination, drive, resources and, most of all, the intestinal fortitude to stick to it and not give up because results or conditions do not meet with preconceived notions. Another element that will be needed by those who will successfully apply the techniques and who will be responsible for new breakthroughs is the systematic approach to sampling and analysis and the integration of geochemical, geological and geophysical results. Erratic sampling patterns - a sample here and a sample there - generally lead to more problems than solutions."

Jan 1, 1971

By W. Marnette

The copper demand is booming. New epicentres with strong dynamic economic growth have arisen in China and other emerging markets. Furthermore, Europe contributes to higher copper demand due to positive economic growth. China and India are therefore expanding their smelter industries, with the backing of a coordinated policy of global raw material sourcing, which includes investments in raw material deposits and state-run measures to support their international trade and competition. Likewise, Europe faces scarcity of copper raw materials. The copper industry in Europe is historically grown and shows excellence in environmental protection and technical leadership. Recycling has always been an important sector. This reiterates the recycling-know-how which exists in the European sector. However, Europe still relies on importing a considerable amount of raw materials from foreign countries. As a result, the global competition for copper and copper raw materials has increased. Tough competition as regards industrial location and costs, the emergence of corporate concentrations and the use of protectionist trading practices by countries like China and India, which distort the markets, now determine the picture. Hence, a copper smelter in Europe is forced to develop tailor-made concepts to safeguard and improve its international competitive position. It is imperative that this is also flanked by improved conditions on the local level and a European raw material policy which takes account of the changed situation on the world market.

Jan 1, 2007

RISKGATE is an interactive online risk management system developed by the Minerals Industry Safety and Health Centre (MISHC; University of Queensland) to assist the mining industry in implementing continual improvement in management of major unwanted events, and so maximising health and safety performance. A comprehensive body of knowledge has been compiled from diverse mining industry experts for risk management of tyres, collisions, fires, isolation, strata underground, ground control open cut, explosions, explosives, manual tasks and slips/trips/falls. This paper presents an overview of the body of knowledge captured from diverse mining industry experts for the management of unwanted strata incidents, and explosions in the underground environment. This knowledge is divided into a series of initiating events within both topics (as listed) with further degrees of classification based on design, operation, and management concerns. Strata Underground Initiating Events: Explosions Initiating Events Loss of strata control at longwall face Fire or ignition in a sealed area Loss of strata control in outbye roadways Fire or ignition in an unsealed goaf area Loss of strata control in roadways under development Fire or ignition in an extraction face Loss of control of overburden and caving behavior Fire or ignition in outbye Loss of pillar system stability Loss of control of goaf edge in pillar extraction Fire or ignition in a development panel or first working Loss of strata control in shafts The system guides the user in generating substantive and leading edge controls to assist industry stakeholders in the design, management and reporting of organisational and regulatory compliance requirements. From a broader industry perspective, RISKGATE provides an environment for knowledge capture and knowledge exchange to drive innovation and best practice in the identification, assessment and management of risk. By capturing operational knowledge from industry experts, RISKGATE provides a cumulative corporate memory at a time of high personnel turnover in the coal industry.

Aug 1, 2013

By Michael Samis

NOFLEX valuation results ? CF deviations and net CF risk discount factors ??Cash flow deviations indicate average cash flow variability. ??Net cash flow riskdiscount factors (NCFRDFs) indicate the size of the risk adjustment applied to a cash flow. NCFRDFs profile should change with variations in cash flow uncertainty since the risk adjustments applied to the project cash flow reflect investor sensitivity to uncertainty.?DCF and RO will often produce different NCFRDFs for the same project since they use different methods of risk-adjustment.

May 1, 2006

By K. Oishi

We have developed a 76Cu-3Si-21Zn alloy "ECOBRASS®" containing no lead. When 3% Si is added to a 78Cu-22Zn alloy, kappa and gamma phases participate uniformly in the alpha matrix. When being machined, stress concentrates on these hard phases, namely kappa and gamma, and thereby lowering the required cutting force and yielding segmentalized chips without lubricant. Kappa and gamma phases transform into beta phase under high temperature, which makes it easier to extrude and/or forge the alloy. When 0.08% P and 50 ppm Zr are co-added, the grains of ECOBRASS® castings are refined significantly to become as small as several dozens of micrometers. The grain refinement by the co-addition of P and Zr improves castability, tensile strength and elongation of ECOBRASS® castings. Meanwhile, the lead leachate from an ECOBRASS® water meter, field-tested in pH 6.8 drinking water for one year, was less than 5 ppb without correction. No indication of dezincification corrosion was observed, either. ECOBRASS® is equally suitable for rods, forgings and castings, and makes it possible to produce a complete set of plumbing parts (valves, faucets, etc.) by its own. This way, not only improving recyclability, ECOBRASS® also realizes size and weight reduction due to its good corrosion resistance and high strength.

Jan 1, 2007

By I. Takahashi

Recently, electronic devices have become smaller for some kinds of electronic devices, thermal dissipation and electrical conductivity of conventional Fe based alloy becomes insufficient. We selected the Cu-Fe based alloy CDA19400 and optimized the wire manufacturing process. Precipitates during aging treatment were observed by TEM. The size and distribution of the precipitates varied according to solution treatment temperature. With solution treatment at 950°C, the precipitates of y-Fe as fine as 10 nm were distributed dense in the copper matrix with coherency. For the solution treatment at 750°C, y-Fe of approximately 200 nm was observed. Comparing heat resistance of drawn wires, the material at 950°C treatment was superior. Electrical conductivity decreased from 63% IACS upon aging to 29% IACS by drawing. It is considered as particular phenomena for wires where materials are drawn with high reduction ratio. By the optimized manufacturing process, we successfully developed a new wire that has superior in strength, thermal conductivity, electrical conductivity, heat resistance and repeated bendability.

Jan 1, 2007

By U. Martin

Advanced copper materials for conducting applications require an optimal combination of high mechanical strength at ambient and moderately elevated temperatures together with superior electrical and thermal conductivity. Mechanical alloying under repeated cooling of the milling vials in liquid nitrogen has been applied to produce ultra-fine grained (UFG) oxide dispersion strengthened (ODS) copper with a high yield strength at ambient temperature. In the present study ODS copper was manufactured by mechanical alloying of copper powder and 3% by volume of incoherent oxide dispersoids. During the high-energy milling a homogeneous distribution of fine dispersoid particles (diameter nearly 100 nm) can be achieved in the powder. Samples with a density of more then 97% of theoretical value were produced by uniaxial hot pressing under 650 MPa at 600°C for 20 minutes. The high yield strength at ambient temperature can be described by a linear superposition of the Orowan stress for particle hardening and of ultra-fine grain strengthening according to the Hall-Petch mechanism. Simultaneously, a best value of 75% IACS could be obtained for the electrical conductivity. The creep behaviour of ODS copper in the temperature range from 500°C to 700°C is described within the frame of diffusional creep deformation.

Jan 1, 2007

Over the years, efficient on-line monitoring of performance and status of an electrolytic copper refining process has been challenging due to the need for complex electrical measurement systems and the management of the enormous volume of data. Recent innovative developments by Kennecott Utah Copper Corporation and Outokumpu Technology in wireless cell voltage and individual cell temperature sensing opens new possibilities to improve and modernize tank house management. This paper describes the powerful Outokumpu CellSenseTM refinery monitoring system for efficient interpretation of data produced by wireless CellSensorTM system with traditional refinery measurements. Examples from commercial tank house installations demonstrate the benefits of the system to improved process control and operation. The Outokumpu CellSenseTM monitoring system is simple to operate and accessible to all the plant operation teams.

Jan 1, 2007

By D. Royston

In SAG mills fed with a variety of ore types, hard packing between the shell lifters can come and go depending on rock type and rock size distribution and the presence of a binder. Packing can appear in all sizes of SAG mills, and can be tenacious. High ball impact forces (depending on ball size) in larger mills may compact and encourage packing. Packing can have a negative impact on milling performance and a change in shell liner design may be required to remove it. However shell liner design changes need to be managed with care to ensure liner reliability. In smaller mills control of packing can extend shell plate wear-life and may help to maintain milling performance in fixed-speed mills through the liner wear-cycle.

Jan 1, 2012

By C. G. Kemsley

THE ore as hoisted is very wet, and difficulty was experienced i~ screening it to remove the fines before going to the secondary crusher. In fact, the fines had a tendency to form balls and roll down the screen, and only a small percentage was removed. Their inclusion with the other ore going to the Symons secondary crusher caused excessive spring action and pounding between the adjustment ring and main frame, resulting in abnormal wear between the two. To overcome this, it was decided to wash the fines through the primary screen, and use an Akins classifier to de-water the screenings, pumping the overflow from the classifier up to the mill and discharging the oversize onto the mill-feed belt.

Jan 1, 1945

By Masafumi Maeda

Metal recycling and waste treatment have become common issues in various metal industries, notably, the iron and steelmaking industry and the nonferrous industry. The former tends to treat mass wastes such as municipal wastes or plastics. However, volatile compounds are condensed in dusts of their incineration processes and they should also be treated, likely by the nonferrous industry. Those "end-of-life" products contain heavy metals that might be harmful to mankind and should be handled by the non-ferrous industry. Not only revenue derived from regeneration of metals from the secondary materials but also the revenue generated from the treatment charges is a strong attraction for nonferrous industry to process secondary materials. The present study presents some statistical data of the Japanese corporations in the iron and steelmaking industry as well as the nonferrous industry on their revenues generated from processing of secondary materials. Some of the companies are now concentrating their business resources on new areas of the market. Although the quantity of waste or recyclable material is still small at present, the quantity will increase in the near future, and it is anticipated that international collaboration is required to handle the greater variety and the larger quantity of secondary materials.

Jan 1, 2004

By João Felipe Costa, Jair Carlos Koppe, André C. Zingano

Abstract - Traditional mine planning based on block models built with interpolation techniques such as kriging does not take into account the uncertainty associated with the estimates. These models are inadequate for short-range mine planning. In contrast, conditionally simulated models reproduce the actual variability (histogram) and spatial continuity (variogram) of the attributes of interest. Conditional simulation can be used to address the problem of measuring the uncertainty associated with an estimate. This paper outlines how the sequential Gaussian conditional simulation algorithm can be used to assess uncertainty of grade estimates and also illustrates how simulated models can be incorporated into mine planning and scheduling. A case study demonstrates the efficiency of the method in assessing risk associated with geological and engineering variables.

Jan 1, 2000

By S. K. Sadrnezhaad, B. Hashemi, Z. A. Nemati, Z. Moghimi

Based on the kinetics relationships of a solid - gas model, a software was developed for the prediction of oxidation. Preliminary prediction of oxidation by the software and experimental results of MgO-C refractories were studied and compared. By using the obtained data from this approach, the effective diffusion coefficient, intermolecular diffusion coefficient and diffusion activation energy in the MgO-C refractories, containing various amount of graphite were obtained at different temperatures. First of all, the prediction by the software was very compatible with experimental results, for different oxidation mechanisms in the MgO-C refractories. The results showed that pore diffusion is the predominant oxidation mechanism in this system. The results indicated that when graphite content was above 10wt%, the intermolecular diffusion coefficient was independent from graphite content, and it was closed to a constant value at each temperature.

Jan 1, 2004

By M. Reza Bateni, M. Zandrahimi, J. A. Szpunar

Titanium aluminides and nickel aluminides offer the potentials, as coating materials, for high temperature and aerospace applications. In this research, attempt has been made to develop Al-Ti and Ni-Al intermetallic compound coatings on the surface of Inconel 738. The coatings applied through pack cementation and simultaneous diffusion annealing processes. Scanning-electron microscopy (SEM), energy-dispersive X-ray spectrometry (EDAX) and grazing angle X-ray diffraction were used for evaluating of coating structure. It was demonstrated that the pack cementation technique could be used to develop TiAl3 and AlNi intermetallic compounds coating on Inconel 738 substrate. When pack cementation technique is based on a halide-activated pack with aluminum and titanium powders, the coating consists of TiAl3 intermetallic compound phase. Whereas, by pack aluminization of Inconel 738, the coating consists of AlNi intermetallic compound phase.

Jan 1, 2004

By M. Bertrand

Oxalic precipitation is usually applied to process radioactive wastes or to recover actinides from a multicomponent solution. Precipitation reactions being highly sensitive to many operation parameters, the computer simulation appears to be a very effective tool to forecast the evolutions of the system subjected to various operating conditions. This study focuses on the tetravalent uranium oxalate precipitation modelling which combines population balance and hydrodynamics. Both experimental and numerical studies are carried out in order to analyse the reactor design influence on the precipitate characteristics. The simulations taking into account primary nucleation and crystal growth are in agreement with experiments.

Aug 1, 2010