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By A. Giacomini, M. Nazem, E. Fathi Salmi

"Numerical simulation of collapse of tunnels in weak rocks is one of the challenging problems in rock mechanics. Collapse can impose technical and financial difficulties during the construction of underground excavations. This phenomenon, particularly in shallow excavations, may lead to propagation of a caved zone toward the surface and formation of chimney subsidence. Chimney subsidence has numerous catastrophic consequences such as the adverse environmental impacts and damage to surface structures in vicinity of excavations. Due to the importance of subsidence in civil engineering, the main goal of this study is to propose an appropriate method for preventing the formation of subsidence in shallow tunnels in weak rocks. The Dolaei road tunnel is investigated as a case study, where a large chimney subsidence has occurred. The geology of the area and the geostructural characteristics of the rock mass surrounding the tunnel are briefly reviewed in this paper. Two-dimensional as well as threedimensional numerical simulations are conducted to study the tunnel stability. Moreover, the effects of staged excavation and pre-supporting method on controlling the ground movements are studied. Outcomes of this study indicate that employing forepoling and staged excavation can be a practical remedy to control the ground movements and prevent the formation of chimney subsidence.INTRODUCTIONPredicting the formation of subsidence, mainly sinkhole subsidence over civil or mining excavations, is a very challenging task. An accurate prediction of subsidence is required for selecting an appropriate control and mitigation system to reduce the level of ground movements and its impact on the surface life (Bétournay et al. 1994; Leca and New 2007). Excavations, particularly in weak grounds, could result in surface subsidence; they modify the in-situ stress conditions as well as the hydrogeology of the area. Construction of unsupported excavations in soft soils and relatively weak rocks usually leads to the formation of a failure zone behind the face. In a very soft ground, the failure zone can extend towards the ground ahead of the tunnel face. Propagation of this zone toward the ground surface results in generation of sinkholes."

Jan 1, 2015

By Donald Hulse

"Mining has been a source of controversy for at least 500 years. “Since there has always been the greatest disagreement amongst men concerning metals and mining, some praising, others utterly condemning them…” (Agricola, 1556). In 2016, it is widely recognized that mineral resources and reserves must give due regard to the social license in order to operate.“Most commonly, the social license to operate (SLO) is understood to refer to ‘the ongoing acceptance and approval of a [project] by local community members and other stakeholders that can affect its profitability’ (Moffat, 2014).” “Social License to Operate has gained traction, in part, because it is also a concept which – while remaining poorly, technically defined – is generally easily and widely understood by community stakeholders (Bice, 2014).”A generation ago we learned that mining is based on a stable platform supported by three pillars, geology, mining and metallurgy. The three-legged stool is a very stable structure (Fig. 1).In 2016, it seems that we have added some other legs to the stool (Fig 2). The Australasian Code for Reporting of Exploration Results, Mineral Resources and Ore Reserves (JORC Code) addresses “social, and governmental factors…” (JORC 2012), and refers specifically to social license in Section 4 of the Report Template “Estimation and Reporting of Ore Reserves.”The Canadian Institute of Mining, Metallurgy and Petroleum (CIM) Guidelines refer to “environmental, legal and social data…(CIM 2003).”Compared to these, the 2014 SME Guide is positively verbose stating “a discussion of any potential social or community related requirements and plans for the project and the status of any negotiations or agreements with local communities,” (SME 2014) although in all cases the scope of this disclosure is left at the discretion of the competent person.When there are more than three legs on the stool, it is imperative that all legs be constructed exactly to the design. Any one or more legs that are out of alignment will cause the stool to wobble.Engineers are trained to create designs to meet specifications. Loads can be estimated, forces calculated and cost studies completed that will lead to, not only a stable design, but the most efficient design that meets the specifications."

Jan 1, 2015

By (Journal for the Fields of Gunpowder and Explosives) Germany (1914 Issues)

RBH Note: The following items are a deviation from the usual content of these articles, but I thought they were kind of interesting from an historical point of view (other than just explosives-history historical.) The interesting things to me are the military-related products, keeping in mind that World War I didn’t start until August, 1914, and then it was kind of an accident of political alliances gone awry. Obviously companies in Germany saw it coming. Of course, all the ads also included dynamite and safety explosives for mining and tunneling as well as the military items.

Jan 1, 2015

By Matej Petružálek, Václav Vavrycuk, Tomáš Svitek, Tomáš Lokajícek

The most common type of waves used for probing anisotropy of rocks in laboratory is the direct P wave. Information potential of the measured P-wave velocity, however, is limited. In rocks displaying weak triclinic anisotropy, the P-wave velocity depends just on 15 linear combinations of 21 elastic parameters, called the weak-anisotropy parameters. In strong triclinic anisotropy, the P-wave velocity depends on the whole set of 21 elastic parameters, but inversion for 6 of them is ill-conditioned and these parameters are retrieved with a low accuracy. Therefore, in order to retrieve the complete elastic tensor accurately, velocities of S waves must also be measured and inverted. For this purpose, we developed a lab facility which allows the P- and S-wave ultrasonic sounding of spherical rock samples in 132 directions distributes regularly over the sphere. The velocities are measured using a pair of P-wave sensors with the transmitter and receiver polarized along the radial direction and using two pairs of S-wave sensors with the transmitter and receiver polarized tangentially to the spherical sample in mutually perpendicular directions. We present an inversion method for elastic parameters describing general triclinic anisotropy. We demonstrate on synthetic tests that the inversion becomes more robust and stable if the S-wave velocities are included. This applies even to the case when the velocity of the S waves is measured in a limited number of directions and with a significantly lower accuracy than that of the P wave. Finally, we analyze velocities measured on a rock sample from the Outokumpu deep drill hole, Finland, including the error analysis for several levels of confining pressure.

Jan 1, 2015

By S. Dereski, G. Chancellor

"INTRODUCTION Barrick Goldstrike underground mine is located in Northern Nevada on the Carlin trend. The underground mine produces approximately 1.5 to 1.8 million tons a year and approximately 400,000 ounces of gold a year. The mine is comprised of two main mining methods, underhand drift and fill and long hole stopeing. The mass blast project stated in 2012 as Value in Use project between Barrick, Southwest Energy and Orica, the goal of this project is to be able to blast an entire drilled stope in one blasting event instead of taking multiple blasts. This will improve productivity by eliminating intermediate blasts, reducing additional blast time, eliminate drill hole cleaning due to the previous blast. Project implantation started in the fourth quarter of 2013 and mass blasting has been common practice throughout all of 2014. STOPPING PRACTICE AT GOLDSTRIKE BEFORE MASS BLAST PROJECT The production from the Goldstrike mine is approximately 70% from stopes. The timely completion of all stoping blocks is imperative to maintaining the plan, delays in the execution of any particular block can have detrimental ripple down effects as neighbouring stoping blocks become delayed. Before the implementation of this project the standard practice for Goldstrike was to: 1. Drill the entire stope 2. Blast a bottom shot, normally between 10 feet and 20 feet off the bottom of the slot rings. This would be mucked out before the next shot 3. Blast a pull through shot, this included the raise and one or two production rings. Again mucking this out before the next shot 4. Blast production rings, one or two more blasts depending on stope size. In most cases between each of these blasts the holes in the other rings of the stope would have to be cleaned. This meant either cleaning manually using air and water, or mechanically cleaning with a bench drill. In many cases this resulted in delays in completing the stoping block."

Jan 1, 2015

By A. Warczok, T. A. Utigard

"Slags from smelting of copper concentrates contains from 1 to 15% of copper. Copper is present in the form of copper or copper matte inclusions of size from 2 to 1000 micro, and as dissolved cuprous oxide. Removal of the copper requires the slag reduction, primarily reduction of magnetite and co-reduction of cuprous oxide. Thus, the kinetics of the slag reduction play an important role in copper recovery. Instantaneously, at the contact of carbon and a slag the gaseous film is formed. The magnetite and cuprous oxide reduction is going through a gaseous film, separating the slag and carbon of a coke or electrodes. The thickness of a gaseous film grows to a critical value and gas bubbles, containing CO and CO2, are created and rise up in the slag. Results of measurements of kinetic of the slag reduction with graphite showed high value of activation energy, close to the value of activation energy of Boudouard reaction. Strong temperature dependence of the reaction rate points out the thermal instability of the reacting system. It was found that the slowest process in the reduction stages determines the loop of CO and CO2 transfer and magnetite diffusion to the slag/gas film boundary. Strongly endothermic Boudouard reaction seems to cause thermal instability on the reaction surface. So, heat transfer to the reaction surface is very important. Due to low thermal conductivity of a slag the convection dominates in the heat transfer. So, any slag stirring accelerates the rate of reduction and coalescence of metallic copper or copper matte inclusions."

Jan 1, 2015

"This model specification includes sample text shown in normal font with commentary in italics. The commentary is intended to highlight project-specific items the specification writer should consider during development of the specification. In some sections, typical values are presented to indicate common practice, and these values may be changed to reflect project-specific requirements. The commentary should be removed before using the specification for a project. 1. SCOPE The work consists of designing, furnishing, installing, and testing helical piles used to support foundation loads (compression, tension and lateral), and any ancillary materials (e.g., load transfer devices, etc.) according to the project plans provided and these specifications. Unless otherwise noted, the installing contractor shall provide all labor, tools, equipment and materials necessary to install the required piles. The parties referred to in this specification are as follows: • The Owner is the property owner. • The Owner’s representative is the individual or firm hired by the Owner to design and oversee the overall project. • The pile designer is the individual or firm generally hired by the installing contractor to design the helical piles. • Installing contractor installs and tests (if necessary) the helical piles, and possibly tasks associated with the project. It is important to clearly define the roles and responsibilities of every party on each project to promote good communication and reduce potential for contractual misunderstandings. Different types of contractual vehicles (design-build, value engineering, etc.) require different roles and responsibilities for the various parties, which should be considered in specification development. The Owner will provide suitable access to the construction site for the installing contractor’s personnel and equipment. Unless specifically noted otherwise in the contract documents, the Owner will remove and replace any structures, utilities, pavements, landscaping or other surficial improvements in the work area as necessary to facilitate the work. The Owner will be responsible for overall construction oversight to minimize potential for developing unsafe conditions. The work may include post-construction monitoring of pile performance if required by the Owner or the pile designer to confirm performance of the piles subsequent to their installation. The work may also include installation of additional piles if the initial installation does not meet specified capacity or performance requirements. Responsibility for providing subsurface investigation shall be addressed in the bid documents. The Owner is responsible for providing to the installing contractor all available subsurface soils, rock and groundwater information and geotechnical testing data."

Jan 1, 2015

By Christian J. Sorensen, Christopher Armstrong, Andrew Matejunas

A team consisting of junior and senior mechanical engineering students at New Mexico Tech worked on the design of an explosively loaded vessel, with a maximum load of 15 grams (0.53 oz) TNT equivalent explosive. The main challenge presented was to meet the stringent sample positioning specification of 3 microns in two Degrees Of Freedom (DOF) and one degree of rotation in a third DOF. This is to accommodate precise sample placement in a tight x-ray beam, and to bring areas such as explosives/metal interfaces into magnified field-of-view photography. This presentation describes the process and design decisions to arrive at the final product presented to LANL in December 2014. Our engineering analysis techniques will be reviewed, including use of American Society of Mechanical Engineers (ASME) Boiling & Pressure Vessel Code (BPVC) Code Case for Impulse Loaded Pressure Vessels (ASME BPVC Code Case 2564-3). Also discussed will be integration of Hydrocode computer models with Finite Element Method analysis.

Jan 1, 2015

By Lance Rasband, Richard Hanke

"Seattle Tunnel Partners (STP) started mining on Seattle’s SR99 tunnel on July 30, 2013, working slowly through a 15 ft (4.6 m) thick fiber-reinforced concrete headwall. Once through the headwall, the machine would move through roughly 400 lineal ft (122 m) of jet grout-improved soil at a rate slightly over 6 ft (1.8 m) per day. It was anticipated that once through the improved area, Bertha—the world’s largest tunnel boring machine—would move at a rate of 35 ft (10.7 m) per day. By the end of October 2013, Bertha had mined roughly 430 ft (131 m), averaging 4.73 ft (1.4 m) per day, and had begun mining within native soils. By the start of December 2013, tunneling reached the 800 ft (244 m) mark and Bertha averaged 12 ft (3.7 m) per day, achieving as much as 42 ft (12.8 m) of progress on some days. However, on December 6, 2013, Bertha began to stumble and all progress quickly came to a halt. Preliminary InvestigationInitial reports stated that an obstruction had stopped the machine in its tracks. Malcolm Drilling received an early morning call on Sunday, December 8, 2013, from STP to rapidly mobilize a Bauer BG-50 drill rig with crews to investigate what was hindering Bertha’s progress. Malcolm’s equipment and crews flew into action and were completely mobilized and operational by mid-week. The preliminary investigation involved installation of 10 deep dewatering wells to reduce the hydrostatic head within the ground around the machine and allow STP personnel to inspect the cutter head from within the shaft for presence of obstructions. By the close of December 2013, the wells were installed and the dewatering system was fully commissioned. STP crews were then able to inspect the cutter head and found small fragments of a steel pipe wrapped around the outside of the shield. The steel was apparently from an abandoned 10 in (0.25 m) diameter monitoring well casing previously installed by WSDOT (Washington State Department of Transportation) to monitor groundwater conditions for the design and planning of this very project. After the steel was cut out of the head and cleared from Bertha’s path, she attempted to move forward but was only able to manage a slow crawl"

Jan 1, 2015

By Jack Young

U. S. Steel Canada Inc.’s Lake Erie Works is the last green field integrated plant to be built in North America. The plant was designed using the best available environmental technology to develop an environmentally friendly production facility. A summary of the technology and measures used in the construction of the plant are summarized in this paper.

Jan 1, 2015

By Brett P. Spigarelli

"To meet the growing need for CO2 capture and storage technology, Michigan Technological University is studying CO2 capture using alkali-based solvents. The objective of the present study was to find a way to increase the absorption rate of CO2 into an alkali solution without reducing the absorption capacity of the solution. One approach to increasing absorption rate is to use a surfactant to chemically alter the gas bubble size. The surfactant chosen for the study was a neutral-charge polypropylene glycol methyl ether (PPGME) with a molecular weight of 200. Experiments were conducted to study the absorption rate of CO2 at varying surfactant concentrations. Results showed that as the concentration of PPGME increased in solution, the absorption rate also increased. The CO2 absorption rate increased from 3.45 x 10-3 mol/min CO2 at 0g/L PPGME to 3.92 x 10-3 mol/min CO2 at 0.48 g/L PPGME. This amounted to a 14% increase in the CO2 absorption rate with no decrease in the absorption capacity of the solution. IntroductionChemical absorption using an amine solvent is currently the most mature carbon capture and storage technology available. Amines are advantageous in that they have a fast CO2 absorption rate, which leads to a high CO2 removal efficiency. However, amine absorption has some considerable drawbacks, such as high energy requirements, high equipment corrosion rates, amine degradation in the presence of oxygen, high waste generation and a large increase in plant footprint if new equipment is constructed (Herzog and Golomb, 2004; D’Alessandro et al., 2010). Due to these drawbacks, Michigan Technological University (MTU) is studying CO2 absorption using alkali-based solvents, which address the above disadvantages of amine solvents."

Jan 1, 2015

By J. R. Donald

"Project development has been increasingly formalized in the past decade, with most organizations having extensive and descriptive deliverables documents and processes to govern the stage gate progress of capital projects. Although this has improved the general governance of capital project development and execution, it has perhaps not led to improved business success. This paper identifies specific challenges associated with developing complex projects with multiple stakeholder interests over the long timeframe of the project life cycle. The paper outlines these challenges and suggests management approaches and aspects of project development where increased focus is required to achieve improved business outcomes."

Jan 1, 2015

By Joel Bradley, Kot Unrug, Kyle Perry, Mark Klimek

"A West Kentucky mine operation in No. 11 seam, encountered floor heave, due to the localized increase of the thickness in the fireclay mine floor. Floor heave has overridden seals installed in two mined out panels. The third seal’s location was planned for isolating that area from the Mains. A plan of support has been developed to prevent repetition of the floor heave and related problems outby the seals. The applied ground control measures were successful. An attempt of a 3D numerical modeling was made, that it would match the observed behavior of the mine floor and could be used as a design tool in similar conditions. In the paper described are sequence of events, a mitigation ground control system applied, and the first stage of numerical modeling.IntroductionWest Kentucky coal mine operation in the No. 11 seam has approached an area where the fireclay floor thickness increases to about 5 ft. Delayed floor heave has been observed. In the first sealed area (Panel KK), floor heave has overridden the seals and has begun to progress outby. This could not be allowed at the new seal location PP described in this paper because such override would affect the mains. Previously numbers of standing support systems were used, but their effectiveness was not satisfactory as is illustrated in Figure 1, Figure 2, and Figure 3. Therefore, with sealing of the next area approaching, mine management was looking for a better solution that would eliminate the problem. In that stage, our team looked closely at the geology and strength of roof and floor, as well as the characteristics of ground failure around the seal at the first site. The technical literature has been searched as well Haramy et al. 1986 Hsiung and Peng 1987, Peng 2008, Santos & Bieniawski 1987. This led to the identification of factors responsible for the ground failure. It has been determined that increased fireclay thickness from typically less than 2 ft to about 5 ft, when compared to the previously mined parts of reserve, and the strong limestone strata just above the immediate roof composed of 2 ft of black shale, created conditions of failure. It appeared that, when pillars were punching into the mine floor, the strong roof did not break but was bending, exerting high pressure on outby pillars, causing rib failures and closure. This is a similar mechanism to a strong roof affecting longwall shields. The remedial action planned was additional support."

Jan 1, 2015

By Taisuke Sakakibara, Shinya Suzuki, Tatsuya Kato, Chiharu Tokoro, Kenichi Muto

Surface complexation using a diffuse layer model were constructed for arsenic (As(V)), zinc (Zn(II)) and silicate (Si(IV)) for aluminum hydroxide in the co-precipitation process. From experimental investigations using isotherms, zeta potential measurement and XRD analysis, it was confirmed that co-precipitation involved not only surface complexation but also surface precipitation. However, surface complexation was major mechanism for As(V), Zn(II) and Si(IV) removal under the target removal level of the Japanese effluent standard. In surface complexation modeling, exchange capacity of aluminum hydroxide was determined from specific surface area obtained from experimental measurement and site density obtained from reference. Surface complexation coefficients were determined by fitting the removal property and sorption isotherm obtained from co-precipitation experiments. These parameters were in agreement with the numerical parameters found by Karamalidis and Dzombak (2010) who reported a database of adsorption equilibrium constants for gibbsite. The surface complexation models constructed in this study were applied to neutralization process of an actual AMD treatment. Our model could successfully represent the pH edges for As(V), Zn(II) and Si(IV) in the neutralization of AMD.

Jan 1, 2015

By Eric Bain Wasmund, Lance Christodoulou, Julio Jairo Carmona Franco, María Fernanda Castillo, Jose Concha

"A number of technologies are in practice for selectively removing coarse gold from conventional grinding circuits. These circuits are often designed so that the grinding mill output is size classified, with large (or high density) particles being removed before the tails are returned to the mill. Because of the high relative SG of gold, and the fact that some forms of gold such as free gold do not break apart during conventional grinding, coarse gold can accumulate in the circulating load, and eventually be lost.Eriez has developed a flotation cell that uses fluidized water to enhance flotation of coarse particles. More than 40 units have been sold in industrial minerals, and we are now exploring applications for the HydroFloat® in the gold industry.Mineros S.A currently produces approximately 120,000 oz of gold per year by gravity concentrating alluvial gold ore with a mean particle size of 330 microns, followed by further concentration using a Falcon separator. A 400 mm diameter pilot-scale HydroFloat® was added to the tails of the Falcon to test whether additional gold could be captured. Enrichments of 50-600 times and recoveries normally in excess of 95% were achieved. This allowed direct smelting of the gold concentrate. Metallurgical results and operating parameters such as water addition and power will be discussed during the presentation.This result opens the possibility that the HydroFloat® could be used directly in the grinding circuit, for removing coarse gold in the circulating load. This work also shows the possibility that the HydroFloat® can produce a throwaway tail, which will reduce the size of the circulating load stream and the grinding requirements of the circuit."

Jan 1, 2015

By Ørjan Nerland, Torgeir Haugen, Astri Eggen, Kjell Karlsrud

"Ground improvement by the deep dry mixing (DDM) method is used in Norway since the late 1970's. A brief review is given of the Norwegian guideline for ground improvement with DDM issued in 2012, but focus is on practical examples and experiences related to improving the stability of excavations and natural slopes in soft clays. Two examples deal with experiences from 10 to 18 m deep excavations in soft and partly highly sensitive clays, where DDM panels and block stabilization were used to both give sufficient stability against bottom heave and to limit lateral wall displacements. A third case deals with improving the stability of a natural slope in quick clay by installing DDM panels near the crest of the slope. To limit disturbance and excess pore pressures generated during the DDM works, vertical drains were installed in advance in between the DDM panels. This ensured that the excess pore pressures generated by the DDM works (up to 150 kPA) dissipated quickly, which was instrumental to avoid triggering a landslide during the stabilizing works.INTRODUCTIONThe lime column (LC) method developed in Sweden and Japan in the mid 1970's (e.g. Broms and Boman, 1977). Since then, there have been significant developments in Scandinavia and around the world in terms of rigs, mixing machinery and tools, and type of binders used. The method, presently named the ""Dry Deep Mixing"" (DDM) method in contrast to the wet deep mixing methods (WDM) that also have developed significantly over the past decades, e.g. Kitazume and Terashi (2013). The first application of the DDM method in Norway was in the late 1970's to improve the stability of an excavation in quick-clay, then using only lime as binder. Most DDM applications in Norway have also thereafter been to improve the stability of cuts, supported excavations or natural slopes in soft clays. The Norwegian Geotechnical Society (2012) issued in 2012 “Guidelines for design of ground improvement with DDM methods"". The following highlights design issues dealt with. The paper focuses however, on some practical cases where DDM has been used to improve stability of deep excavations and a natural slope in soft and partly highly sensitive clays."

Jan 1, 2015

By Dominic Parmantier, Jason Page

"In the past, the designers of DSM have analyzed various failure modes and then specified a minimum unconfined compressive strength (UCS) for the soil-cement. The specified minimum UCS reflected the compressive stress in the soil-cement under design loads and an appropriate factor of safety. With the increased use of finite element analysis for the design of DSM applications where allowable strain as well as stress are considered, there is a growing trend for designers to specify a modulus and occasionally a tensile strength for the soil-cement in addition to the UCS. This paper compares the relationship of modulus and tensile strength to UCS for soil-cement from a recent DSM project with unique testing requirements. These results are compared to published data. The case is made that designers should utilize published relationships to characterize the required strength and stiffness by a single acceptance criterion: UCS.INTRODUCTIONAs the use of DSM has increased in popularity so has the use of service state deformation analysis in lieu of more traditional failure mode analysis. Most DSM designers are interested in the appropriate modulus values and occasionally tensile strength values of soil-cement as well as simply the unconfined compressive strength (UCS) of soil-cement.Although there are numerous published correlations between the UCS, tensile strength and modulus of soil-cement, some DSM project specifications are produced which have acceptance values for tensile strength, modulus, and UCS. If this specification of multiple strength properties is consistent with the nature of soil-cement, then there is really no harm except for the expenditure of client money on unnecessary testing. If however the multiple strength properties specified are inconsistent with the material properties of soil-cement, then the specifications can create the expectation that the DSM contractor can somehow create a custom soil-cement with tensile strengths and modulus characteristics which are unachievable.This paper presents a brief summary of a project in Burnaby, B.C. which specified minimum values for the tensile strength, modulus, and UCS of the soil-cement. A comparison of those test results to published correlations between the UCS and the tensile strength is presented. Additionally, a comparison of modulus derived from two different methods of testing is presented along with a comparison to published correlations between UCS and modulus for soil-cement."

Jan 1, 2015

By T. H. Etsell, P. Kerr

Over the past 50 years, there have been a number of geological, mineralogical and metallurgical studies carried out on the Clear Hills ironstone deposits in northern Alberta, Canada. Due to the low grade and complex mineralogy, previous metallurgical studies have achieved limited success. After rejecting some of the more ‘conventional’ techniques for iron ore beneficiation, the authors chose to investigate the grain enlargement/iron segregation process for the beneficiation of the Clear Hills ironstone. The segregation reactions for iron have not been explored in as much detail as they have for copper and nickel. Iron segregation roasting involves the addition of a carbonaceous reductant and a chloride transport agent to an iron oxide ore, and heating the mixture to an appropriate temperature. The benefit of this process is that it allows ores in which the value minerals are intimately associated with gangue minerals to be processed in circumstances where conventional iron ore processing techniques are not suitable or capable of upgrading the material. As iron is one of the few elements that can be transported through this process, a clean high purity metallic concentrate can be achieved.Through the use of crucible testing followed by Davis tube magnetic separation, scanning electron microscopy, X-ray diffraction and atomic absorption spectroscopy analysis, characterization of the reaction products has been made with an improved understanding of the reaction mechanism.

Jan 1, 2015

By Hiroyuki Sano, Hiroshi Chida, Katsuya Toda, Takafumi Sasaki

Saganoseki Smelter & Refinery is one of the largest copper producers in Japan to produce 450,000 tons of new copper annually. Saganoseki used to operate six PS converters with "4 Hot-2 Blow" scheme, but managed to change its operation to "3 Hot-2 Blow" scheme with four PS converters, while maintaining the same production capacity. To achieve the operational change, the following improvements have been carried out; 1) Extending service life from 220 to 350 batches, 2) Shortening cycle time by increasing the blowing rate and the matte grade, 3) Reducing environmental impact by applying sophisticated fugitive gas collection system and 4) Saving energy by waste heat boiler’s modifications. The operational change has been successfully executed, and results in drastic productivity increase and cost reduction. Currently, Saganoseki is maintaining the efficient and consistent operation with 4 PS converters. This paper describes the above-mentioned improvements for increasing productivity and the recent operational conditions of the PS converters.

Jan 1, 2015

By J. W. van der Merwe, A. Palazzo

"Owing to the corrosiveness of the untreated brackish cooling water typically used for steel mills (and other environments), it is important to treat the water and monitor corrosion in such systems. Generally, corrosion rates are monitored with corrosion probes inserted into a pipeline or vessel. This has been standard practice for many years, and is widely accepted in industry. Typically, two kinds of probes are used - electrical resistance and linear polarization resistance (LPR) probes.In this study, the effectiveness and accuracy of the LPR technique was evaluated by comparing the electrochemical measurements with the results of mass loss tests using corrosion coupons. The corrosivity of the environment, a synthetic brackish water, was varied by varying the calcium hardness and alkalinity, and to simulate actual plant conditions temperatures of 35°C and 45°C were used. In addition to the corrosion rate measurements, the iron concentration was measured, as well as the imbalance from the probe.The corrosion rates obtained by LPR were from 57% lower to 385%higher than those from the immersion tests. Most probe measurements were higher than the immersion results, and 50% of the probe results were50% or more higher than the immersion results. The best correspondence between the two methods was obtained at low calcium levels, except for one measurement that was 93% higher than the coupon results. There was no clear correlation between parameters such as temperature and total alkalinity and the difference between the results. It would therefore appear that LPR measurements can differ significantly from immersion results, and LPR results should therefore be used with caution in industrial applications."

Jan 1, 2015