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By É. Poulin, J. Bouchard, E. M. Pérez-García

Process control and optimization have always been crucial aspects in the mineral processing industry, and expectations constantly increase to cope with more stringent security, quality, efficiency, and environmental performances. The main challenges to reduce variability of key process variables, and steer profits to higher values while maintaining sustainability indexes within acceptable ranges come from nonlinear responses and circulating loads. The most commonly implemented control strategies rely on simple PID controllers for practical implementation and maintenance considerations. If arguably good performances are accomplished when these are adequately set up, there is also room for further gains by using more advanced methods such as model-based techniques. There is thus a need for more realistic process and equipment models. Based on advances of the past few decades, this paper introduces an autogenous/semi-autogenous mill (AG/SAG) model to be included in a modular comminution circuit simulation toolbox comprising ball/rod mills, material handling, and classification devices. The proposed mill model incorporates a modified version of the classic comminution equation that makes grinding rates proportional to the energy input. It requires the determination of a selection function (fragmentation rates) and a breaking function (fragments distribution). The former is modelled with an S-shaped curve characteristic of AG/SAG processes and the latter is a size-relative distribution of the produced fragments. The power draw is predicted employing the empirical equation of Austin. The paper also develops a case study to illustrate how the proposed simulation framework can capture the behaviour of an actual plant. Model calibration consists in an optimization problem that search the global minimum of the difference between predicted and measured/estimated size distributions, power draw, solid fractions, etc. Results demonstrate that the mill simulator can mimic an actual process in its operation conditions. INTRODUCTION Comminution is a key stage in the mineral processing industry, obviously because the phases of interest must be liberated to be able to recover them. In general terms, the global performance of a plant depends largely on the efficiency of the grinding circuit and on the material properties such as its grindability, density, and mineral grades. The subject has vastly been studied since as early as the 19th century, when Rittinger (1867) and Kick (1883) developed some of the first empirical models to relate grinding and energy input. The great interest in the subject comes from the fact that this operation is costly and, probably most concerning, highly inefficient. Buckingham et al. (2011) estimated that ore comminution can represent up to 60% of the overall plant power draw. Moreover, only a modest fraction of the power draw effectively translates into rock fragmentation. For grinding, estimates range between 1% and 25%, depending on the reference used, while the rest is mainly lost as heath (Fuerstenau & Abouzeid, 2002; Tromans & Meech, 2002; Bouchard et al., 2017).

Jan 1, 2019

By Sushil Bhandari, Amit Bhandari

Blast optimization in open-pit operations is a task that often remains at a theoretical stage. Indeed, when it comes to operational blast design and onsite implementation, time restrictions and field conditions make it difficult to execute a planned pattern accurately and optimization according to local conditions is even more difficult. For example, adjusting a drill pattern to a complex face geometry is not something that can be easily undertaken on site. Blasters and engineers will do their best trying to distribute boreholes over the bench and even then, it can take them hours to achieve an acceptable layout. Similar situations occur with delay sequences, when trying to adjust them to address selectivity or vibration issues. For these reasons, operational blast design will often remain at a very basic level and the required adjustments are laid aside due to the difficulty of implementing them on site.

Jan 1, 2019

By Andrew Artzer, Michael Moats, Jack Bender

Antimony and bismuth in copper electrorefining electrolytes can cause cathode contamination, leading to the careful control of their concentrations. This study examined the laboratory scale removal of bismuth and antimony from an electrorefining electrolyte using a solvent extraction mini-pilot plant. The ability of a proprietary phosphonic acid ester extractant (REX-2) in a commercial diluent was studied in a simulated commercial setting. Antimony and bismuth were both extracted effectively from the electrolyte (72% Bi and 70% Sb removed) and Bi was effectively stripped (92% Bi recovered) with 400 g/L sulfuric acid. A final strip solution was obtained from the SX circuit containing 0.36 g/L Bi, 0.043 g/L Sb, 1.3 g/L Cu, and 0.18 g/L As. Unfortunately, most of the extracted Sb remained in the organic phase. Following the pilot study, experiments were performed to examine the precipitation of bismuth from the aqueous strip phase and the removal of antimony loaded on to REX-2. INTRODUCTION For many years, antimony and bismuth have been some of the most problematic impurities in copper electrorefining (ER) (Bardwell & Lapee, 1933). Along with surface roughening, high concentrations of Sb and Bi can contaminate the copper cathode and precipitate at the copper grain boundaries. This drastically reduces the drawing ability of the metal (Bender & Emmerich, 2016). For these reasons, it is necessary to control Sb and Bi concentration in the cathode, which is done by controlling their concentration in the electrolyte. Conventionally, Sb and Bi concentrations are controlled by maintaining a proper As/(Sb+Bi) molar ratio in the anode and arsenic concentration in the electrolyte. Antimony and bismuth are removed during electrolyte purification using liberators (electrowinning cells) and/or ion exchange. Liberators treat an electrolyte bleed stream from the ER circuit and electrodeposit increasingly impure copper as the copper concentration of the solution decreases. Traditionally, first stage liberators reduce the copper concentration from ~45 g/L to ~15 g/L and produce saleable copper. Second stage liberators decrease the copper concentration to ~8 g/L (Biswas & Davenport, 1980) which results in contaminated cathode that is returned to anode production (Biswas & Davenport, 1980; Wang, 2004). Further electrolyte purification is not always required but third stage liberators can be used to reduce copper concentration below 2 g/L which results in significant removal of As, Sb and Bi and very impure deposits which are recycled to a smelter or used for As production. However, liberators do not have very high energy efficiency (Acharya, 2014; Ando & Tsuchida, 1997) and below 0.5 g/L copper, highly toxic arsine gas may form (Biswas & Davenport, 1980).

Jan 1, 2019

By W. Díaz, R. A. Parra, L. E. Arias, C. A. Toro, M. Marin, E. Balladares, V. Parra, G. Reyes, S. N. Torres, D. Sbarbaro

This work presents visible-near infrared (VIS-NIR) spectroscopy measurements, and signal analytical techniques to characterize minerals and relevant pyrometallurgical process variables for the copper extractive industry. Data signal processing techniques such as baseline correction and numerical analysis are used to estimate the continuous and discontinuous spectral components. Such spectral components are used to estimate the process temperature, and patterns such as the integrated radiation. Also, metal combustion emissivity calculation are depicted. Our findings suggest that VIS-NIR spectroscopy may be a suitable technique to assess the process condition state, appearing as an interesting sensing alternative. INTRODUCTION Although the flash smelting process is one key stage in the copper extractive industry, representing about 40% of copper matte production worldwide (Cantallopts, 2017), few attention is dedicated to develop sensing solutions to assess process variables, such as mineralogical composition and temperature, in the feeding and bleeding stages, compared to the steel industry (Strakowski, et al., 2014). In this process and other industries, e.g. the thermoelectric power generation one, combustion and particularly the generated flame are the production chain’s heart. Since the flame is a highly radiative emitting process where chemical and physical transformations take place, many works had been dedicated to characterize the combustion state by sensing its radiation using optical and photonic technologies (Ballester & García-Armingol, 2010). In this context, this work aims to contribute with visible-near infrared (VIS-NIR) spectroscopy and pyrometry techniques to retrieve relevant information from a laboratory scale flash smelting process. On the other hand, since photonic instrumentation allow us to perform contactless measurements of emitted, absorbed, transmitted or scattered radiation, it appears as a suitable technique for sensing process properties in harsh environments, e.g. high temperature processes. One of these techniques is the Visible- Near Infrared (VIS-NIR) spectroscopy, which provides information about the spectral radiation intensity distribution, in this work, the emitted flame’s radiation. It is well known in combustion research that the spectral emission from a flame is composed by a black body continuous radiation background, molecular emissions, elemental emissions and additive noise features (Arias et al., 2011). To make sense of such information signal processing techniques are needed, here we propose to analyse the continuous and discontinuous spectral components separately.

Jan 1, 2019

By J. Navoyski, B. Macdonald, W. J. Helfrich, J. L. Bellanca, B. Demich

DISCLAIMER The findings and conclusions in this paper are those of the authors and do not necessarily represent the official position of the National Institute for Occupational Safety and Health, Centers for Disease Control and Prevention. Mention of company names or products does not constitute endorsement by NIOSH. ABSTRACT Recent advances in computing, rendering, and display technologies have generated increased accessibility for virtual reality (VR). VR allows the creation of dynamic, high-fidelity environments to simulate dangerous situations, test conditions, and visualize concepts. Consequently, numerous products have been developed, but many of these are limited in scope. Therefore, National Institute for Occupational Safety and Health researchers developed a VR framework, called VR Mine, to rapidly create an underground mine for human data collection, simulation, visualization, and training. This paper describes the features of VR Mine using self-escape and proximity detection as case studies. Features include mine generation, simulated networks, proximity detection systems, and the integration and visualization of real-time ventilation models. INTRODUCTION There are many definitions of virtual reality (VR) that include various levels of immersion and features [1]. Some definitions refer to specific technologies [2], while others are limited to visualization [3]. For this paper, a more general definition of VR will be adopted. VR is defined as the collection of hardware and software that interactively engages users and stimulates their senses within a synthetic or virtual environment. From a hardware standpoint, this can include anything from a phone to a head-mounted display (HMD) to a large-scale theater as well as speakers, microphones, haptic sensors, and interaction devices. The software used to create virtual environments (VEs) generally includes a game engine, custom software components and libraries, and two-dimensional and three-dimensional graphical assets. Recent hardware and software advances have increased the fidelity and availability of VR. New and improved technologies including HMDs and high-resolution monitors and projectors can display sharper, more detailed visualizations. For example, in the past five years between the release of the Oculus Rift DK1 (2013) and the HTC Vive Pro (2018), there was a three-fold increase in resolution along with a 50% increase in the refresh rate. Furthermore, despite early claims that low-cost VR technology was readily available [4], computational power has not been sufficient to handle the large amount of data generated by these systems [5]. In the past five years, however, rendering speeds have more than doubled and memory has more than tripled [6], allowing these visualizations to be incorporated into higher-complexity and -fidelity VEs that more closely mirror the real world. Similarly, software capabilities have also significantly improved through game engine advancements and feature development. In the past several years, game engines have added and improved features such as physics, lighting, platform support (e.g. Android), and asset development integration. Some of the current leading commercial game engines are Amazon Lumberyard, CryEngine, Unreal, and Unity, but this can quickly change as is evident in the literature [7, 8].

Jan 1, 2019

By Greg Canivan, Bernie Hertlein, Les Chernauskas, Joram Amir, Garland Likins, E. Anna Sellountou, Tim Kovacs, Peter Kandaris

Nondestructive testing of drilled shaft foundations via Crosshole Sonic Logging (CSL) is often performed as part of the quality assurance process to assess the soundness of concrete. The intent of CSL testing is to identify irregularities such as soil intrusion, necking, soft bottom, segregation, voids and other defects that could result in poor structural performance of the foundation. Over time, CSL rating criteria based on first arrival time and relative energy have incorrectly evolved to often be the sole means of determining the acceptability of a shaft. Some of these criteria have found their way into regulatory agency specifications, with acceptance values often differing from agency to agency.The purpose of this document is to review the state of the practice (including experience gained over the past 20 years), propose improved CSL rating criteria and make recommendations for additional assessment, as well as educate the industry on the proper interpretation of CSL test. CSL test results alone should not be the sole means of rejecting or accepting a shaft. A task force of industry exerts was formed to review the existing CSL rating criteria and propose improvements where appropriate. The recommendations presented herein are the consensus of the task force, which believes that they should be incorporated into future criteria, codes and specifications. This paper was produced as a joint effort between the Codes and Standards Committee, the Drilled Shafts Committee and Testing and Evaluation Committee. A task force was authorized under Testing and Evaluation Committee. The task force contributed their expertise in web-based discussions often every two weeks over a period of three years. Interested participants were invited to participate at any time. The document had two rounds of broad industry review, two rounds of DFI Technical Advisory Committee reviews, and a Public Comments process. All comments were considered in producing the final document.

Jan 1, 2019

By M. S. Moats, C. M. Campbell

Samples of a high impurity (90.05 wt. % Cu, 4076 ppm Pb, 1939 ppm As and 635 ppm Bi) commercial copper anode were characterized and then electrorefined in a laboratory scale cell. Anode inclusions were examined using backscatter mode scanning electron microscopy and energy dispersive spectroscopy. Hundreds of inclusions were measured for size, morphology and composition. Commonly found inclusions were copper oxide (Cu2O), complex oxides (Cu-Pb-Bi-As-O) and copper selenides/tellurides. The weight percent of lead and arsenic increased with increasing inclusion size up to 4- 5 microns. During electrorefining, starter sheet ductility was negatively impacted by thiourea addition. The importance of arsenic (V) concentration on the electrolyte concentration of bismuth was observed. INTRODUCTION Copper electrorefining is a commercial process used to produce the majority of the world’s refined copper. During this process, impure copper anodes are dissolved electrolytically, and high purity copper is deposited on cathodes. As the anodes dissolve, the impurities either accumulate in the electrolyte or report to solids that form on anodes surfaces or at the bottom of the refining cell. These solids are called slimes. Slimes contain precious metals and are collected for further processing. Slimes are also an important outlet for problem impurities such as lead, antimony and bismuth. The electrorefining process is operated in such a way to encourage the deportment of these elements to the slimes. Impurities in copper anodes have been studied extensively by Chen and Dutrizac (1990, 1993 and 2005). The most common impurities found in modern copper anodes include: Ag, As, Au, Bi, Fe, Ni, O, Pb, Sb, Se, Sn and Te. Impure copper anodes are produced by pyrometallurgical methods and have purities ranging from 97.7–99.7% Cu (Moats et al., 2019). The composition ranges of commercial copper anodes from the 2019 worldwide tankhouse survey are given in Table 1. The concentrations of anode impurities vary widely dependent on the source material and prior processing steps. Based on the work of Chen and Dutrizac, both gold and silver are predominantly found in solid solution within the copper grains while a minor amount of Ag can be found in Cu2(Se/Te) inclusions. Nickel is entirely soluble within the copper grains up to anode compositions of 2500–3000 ppm Ni; above which NiO and kupferglimmer phases are formed (Chen & Dutrizac, 1990). As, Bi, Pb and Sb are found in solid solution within copper and within oxide inclusions typically found along grain boundaries. Oxides are formed due to the presence of 0.13-0.18 wt. % O (Chen & Dutrizac, 1990). This is because during solidification of the cast anodes, impurities are enriched in the liquid phase as the copper grains nucleate and grow. The inclusions form from the last liquid to freeze, which is typically along grain boundaries (Wenzl & Filzwieser, 2007; Wenzl, Filzwieser, Mori & Pesl, 2008).

Jan 1, 2019

By Y. X. Li, L. R. Xiao, S. Gong, S. S. He

Porous copper and porous copper based alloys with controllable pore structure have been manufactured successfully by sintering evaporation process. This process consisted of mixing copper or copper based alloys with NaCl powders, hot pressing and final high-temperature sintering to evaporate the filler material of NaCl powders. NaCl was eliminated completely during vacuum sintering, and strong metallurgical bonding in the walls was achieved. The pores’ structural parameter (pore size, shape, and direction) and porosity can be controlled effectively. These porous copper and porous copper based alloys with controllable pore structure have great potential in many fields. Including heat dissipating materials, heat absorbing materials, chemical catalyst carriers, electromagnetic shielding materials, filtering materials, damping materials, silencing materials, battery electrode materials. INTRODUCTION The development of porous materials began in the 1960s. The research of activated carbon with high specific surface area made porous materials enter the stage of material research (Belyakov et al., 2008; Ferey et al., 2008). With the rapid development of science and technology, porous materials play an important role in material research, and gradually become an indispensable part of the material research field (Wu et al., 2012). The research of porous materials has gradually extended to metal, ceramics, plastics and glass and other fields. It has been successfully applied in many fields, such as functional materials, industrial production, aviation, medical materials, biochemistry and electronics, which fully shows that porous materials have considerable development prospects. Porous silicon, plastic porous materials and glass porous materials are the most widely used in the field of non-metallic porous materials (Capelle et al., 2012). Compared with non-metallic porous materials, metal porous materials have developed rapidly in the late 1980s and become new materials with good mechanical properties and excellent physical properties. Porous metal materials have many advantages, such as large specific surface, small specific gravity, good silencing effect, high stiffness, high electromagnetic shielding performance, good shock absorption performance, etc (Li et al., 1999; Ferey et al., 2008). Among its many applications, metal porous materials can be used as both functional materials and structural materials. In some cases, metal porous materials have dual functions and structures. It is a multi-purpose engineering material with excellent performance. At present, porous copper, porous aluminium and porous nickel are the most concerned materials (Chen et al., 2002; Yang et al., 2017; Liu et al., 2018). The preparation methods of porous copper and copper-based alloys mainly include self-propagating high temperature synthesis (SHS), capsule-free hot isostatic pressing (CF-HIP), spark plasma sintering (SPS) (Kvanin et al., 2008; Takahashi et al., 2008; Zhang et al., 2014). However, these methods can not accurately control pore structure parameters (including pore size, shape, orientation, distribution, etc.). In porous materials, pore structure plays an important role in the overall performance of materials. In order to control pore structure parameters accurately and optimize material performance, it is necessary to explore and develop new preparation technology. In this paper, the sintering evaporation process (SEP) was introduced for the preparation of porous copper and copper-based alloys. The core process of the preparation method is hot pressing and evaporative desalination. Hot pressing can make the pore orientation consistent. Evaporative desalination can ensure the complete removal of NaCl in the form of vapor in a short time, thus eliminating the corrosion of residual NaCl on the matrix metal (Gong et al., 2011).

Jan 1, 2019

By S. K. Kawatra, S. Valluri

With increased CO2 emissions from steel and coal industry, there is great opportunity to capture CO2 and utilize the captured CO2 for economic advantage. The primary goal is to develop energy-efficient processes that reductively couple CO2, an abundant and renewable carbon source, for the production of value-added chemicals such as methanol, ethanol, and oxalic acid. These chemicals can be used elsewhere in the refining process or sold as valuable by-products. Geological sequestration, in comparison, has no economic return. Current CO2 utilization research at Michigan Technological University focuses on electrochemical reduction of CO2. Electrochemical reduction of CO2 to hydrocarbons and other chemicals is a complex multistep reaction with adsorbed intermediates. The exact reaction mechanisms leading to various products are not clear from the literature to date and will likely change over the range of conditions like pH, electrode potential, electrolyte medium, catalyst, etc. This paper will present different ideas and their viability to utilize CO2 as a feedstock to produce several value-added compounds. INTRODUCTION Carbon dioxide (CO2) emissions into the atmosphere will need to be drastically reduced to curb the various undesirable effects of climate change. The large contribution in total CO2 emission originates from coal or natural gas power plants, and a considerable amount from steel plants. Average CO2 emissions in the US from steel industry is 2.9t CO2/t steel (Global CCS Institute 2013). Capturing the available CO2 from the steel and coal industries for economic advantage is a win-win situation for the industry. This technology is not only important scientifically but is also vital for a sustainable future. The various ongoing investigations can be categorized as biochemical, thermochemical, photochemical, and electrochemical approaches. Among these, the electrochemical method shows the most promise as an efficient form of CO2 conversion technology, because of its many advantages like high reactivity under ambient conditions and good extensibility from small- to large-scale processes1 BACKGROUND Extensive research has been done on the chemistry of transforming carbon dioxide into more useful products. Methods are known to convert carbon dioxide into a wide variety of substances, including methanol, isobutanol, carbohydrates, methane, carbonates, urea, formic acid, oxalic acid, carbon monoxide, epoxides, formaldehyde, and so on. Several of these (carbohydrates, formaldehyde, isobutanol etc.) are primarily results from biological processes. The rest are results of strong reduction reactions or electrolytic reduction. In short, electrolytic reduction can be used to form methane, methanol, formic acid, oxalic acid, carbon monoxide from carbon dioxide2. CO2 reduces at the cathode in an electrolysis cell. These processes have the general form of generating the carbon dioxide anion radical (2⋅−) and allowing it to react with itself or the electrolyte3. Catalysts can be added to influence the formation of the anion radical or to suppress side reactions3. The electrolyte, catalyst, voltage, electrode material and CO2 content are all known to effect the reaction pathway. Table 1 shows the overall reactions and energy requirements for electrochemical conversion of CO2 to chemicals

Jan 1, 2019

By Kalyani Devabhaktuni, Mike Minton, Mark T. Howe, Yan Zhang

During the procurement phase of a Design-Build (DB) project, design-build contractors must often commit to a fixed price based on limited or incomplete geotechnical information. This lack of information can result in an inaccurate assessment and allocation of project risk to either the contracting authority or the DB contractor. This paper presents a case study of an elevated water tank supported by mixed ground improvement techniques, including Vibro-Compaction (VC), Aggregate Piers (AP) and Compaction Grouting (CG) in East St. Louis, Illinois. An adaptive design and contracting approach provided the best value solution for a complicated set of geotechnical problems, including static bearing capacity and settlement concerns as well as liquefaction induced settlement. Close cooperation between the owner, the tank contractor, the geotechnical engineer and the ground improvement contractor was essential to produce an effective solution. Ground Improvement techniques resolved the geotechnical challenges at the site through adaptive design methods, utilizing progressive rounds of verification and real time data acquisition to achieve performance objectives. This paper details the evaluation of geotechnical criteria, the selection of ground improvement techniques, the adaptive design and implementation of ground improvements, as well as contracting methodologies used to ensure that the best value was provided. PROJECT INFORMATION In November, 2016, CB&I Storage Tank Solutions (McDermott) submitted a design/build proposal for an elevated water tank for Illinois American Water Company (IAW) in East St. Louis, Illinois. The purpose of this tank was to have backup water capacity for power generation. In the RFP, IAW requested two alternate styles of tank: Option 1, a 1250 Million Gallon (MG) Composite Elevated Tank or Option 2, a 1250 MG Waterspheroid tank. Option 1 consisted of a steel tank supported on a concrete tower. Option 2 consisted of a steel tank supported on a steel shaft. The height (determined by IAW) was 140 feet to the top capacity line measured from top of floor slab.

Jan 1, 2019

By Brian Koch

Michels installed 242 drilled shafts to support the piers for a new basket-handle, true-arch twin bridge across the Mississippi River from Moline, IL to Bettendorf, IA. The installation of the drilled shafts was completed with the simultaneous use of two Liebherr LB36 and one IMT 300 drill rigs. Utilizing barges, 233 drilled shafts were installed in the river. Michels crews also installed 7-ft to 10-ft permanent steel casing into the bedrock, and drilled to depths of 60 feet for each shaft. Despite working in strong currents, freezing temperatures and on rocking barges, Michels crews placed the shafts within 3 inches of plan position. Since the drilled shafts are the key piece in supporting the bridge structure, Michels provided cross-hole sonic logging to verify the integrity and strength of the concrete within the shafts and to add another level of quality control for the owner/customer. Extensive planning took place each day to ensure that tugboats, the linchpin of the project, were being efficiently utilized to shift the barges and materials daily. On any given day, Michels transported five concrete trucks by barge from shore to shaft sites to pour between 40 and 240 cubic yards of concrete. The Michels environmental team was diligent with preparing, discussing and implementing a water treatment plan that was accepted by all state and federal agencies and adhered to strict environmental regulations. Grain hopper barges were rented to control and treat the water that was used in the drilling operations. Another challenge crews ran into was the discovery of caverns when drilling into some parts of the bedrock. Michels worked with the engineer to develop a plan to construct the drilled shafts that encountered the caverns.

Jan 1, 2019

By Piotr Kozlowski, Stanley L. Worst, Matthew J. Niermann

Circular secant pile shafts were installed along the tunnel alignments for both the Ohio Canal Interceptor Tunnel project in Akron, Ohio and the Ohio River Tunnel project in Louisville, Kentucky. The diameters ranged from 34 to 51 feet and the depths ranged from 49 to 107 feet. Verticality and concrete volumes were measured on all piles to verify compliance with the design, which for some shafts consisted of a finite element model with multiple openings using unreinforced concrete secant piles. All secant piles were drilled into rock to seal off the groundwater. This paper will discuss the design, construction and quality control of the secant piles for these projects. INTRODUCTION Many Midwest and Northeast cities have Combined Sewer Overflow (CSO) systems which discharge pollutants into waterways during wet weather events. One way to remedy this issue is to provide a temporary overflow tunnel. A temporary overflow tunnel connects to the combined sewer system and collects the overflow during wet weather events, storing the wastewater until the event has subsided. After the storm event, the stored wastewater can be pumped to the treatment facilities and processed as normal. Project Background – Akron, OH The Ohio Canal Interceptor Tunnel (OCIT) project was performed as a result of the Environmental Protection Agency’s (EPA) Consent Decree with the City of Akron, Ohio. This Consent Decree required modification of the existing Combined Sewer Overflow system. The resulting project consisted of a 27- foot diameter tunnel with multiple points of entry to capture the sewer overflow and prevent it from entering waterways. The tunnel is over 6,000 feet long and is as deep as 150 feet below the ground surface; see Figure 1 below.

Jan 1, 2019

By Karl A. Higgins, Michael D. Venezia

The South Capitol Street Corridor Project is one of the District Department of Transportation’s (DDOT) largest projects, and is currently under construction. This case study will focus on the design of the foundation piles for the main spans of the iconic Frederick Douglass Memorial (FDM) Bridge, and will include a discussion of the foundation design evolution from an originally designed alternative foundation system (i.e. coffer dams and drilled shafts), to the current use of driven Large Diameter Open End Pipe (LDOEP) Piles. The paper will provide a discussion of the design methodology used during preliminary engineering and final design, and will highlight insight gained from the extensive load testing program completed to date. The load testing program consists of a combination of high strain dynamic testing (PDA), as well as Statnamic Load Testing on select sacrificial, pre-production test piles. Specifically, data gathered during the nearly-completed load testing program suggests the development of significant internal shaft frictional resistance within the tested LDOEP Piles. This paper will also discuss limitations of currently accepted industry design methods for predicting the capacity of LDOEP piles, a subject that is also currently being researched by FHWA. The data from this test pile program will help design assumptions for future projects. INTRODUCTION The Frederick Douglass Memorial (FDM) Bridge carries South Capitol Street across the Anacostia River in Southeast/Southwest, Washington, DC, and is owned and maintained by the District Department of Transportation (DDOT). The existing FDM Bridge is nearly 70 years old, serves as a major artery into the city, and has been classified as functionally obsolete. As a result of the condition, age and limitations of the existing bridge structure, DDOT deemed it necessary for complete replacement of the bridge. The replacement project consists of the construction of a new bridge traversing the Anacostia River, as well as the reconfiguration of the Suitland Parkway and I-295 interchanges located at the eastern terminus of the FDM Bridge. Final design and construction services for the replacement project were procured by DDOT through a Design-Build contract. This paper will focus on the driven Large Diameter Open End Pipe (LDOEP) Piles used for support of the main span of the new FDM Bridge which is currently under construction. Discussion regarding the LDOEP Pile design methodology has been included, along with commentary regarding currently available industry guidance related to design and construction of LDOEP Piles. Much insight has been gained during the mostly-completed and extensive load testing program which consists of a combination of high strain dynamic testing (PDA), as well as Statnamic Load Testing on select sacrificial, pre- production test piles. Specifically, data gathered during the mostly-completed load testing program suggests the development of significant internal shaft frictional resistance within the tested LDOEP Piles.

Jan 1, 2019

By Brandon Smith, William Bohlen

Riverbank erosion along the Brazos River has modified the structural support conditions for an existing bridge structure in Southeast Texas. The 8-span, 1,200-foot long bridge was completed in 1992 along Highway 99, a key corridor for the Houston area. Foundation support conditions have been altered due to natural, ongoing river morphology for three bents on the affected riverbank. Recent events include three storms within a three-year period that each exceeded the 500-year return probability. This resulted in accelerated erosion along the northern riverbank. Over forty vertical feet of soil has been removed in some locations. Drilled shaft foundations are now functioning as columns. This review considers the behavior of columns and deep foundation elements due to the modified support conditions. The review ultimately presents a rational methodology for the review of the present and anticipated future bridge configuration with respect to current strength, service, and extreme event limits, with corresponding safety factors for the design. Introduction and Background The Fort Bend Grand Parkway Toll Road Authority (Owner) oversees the State Highway 99 Judge Jodie Stavinoha Bridge over the Brazos River. The 8-span, 1,200-foot long bridge was originally designed with four southern approach spans of 115 feet; a three-span continuous river crossing with span lengths of 195 feet-235 feet-195 feet; and a single northern approach span of 115 feet. Figure 1 provides an overview of the northern portion of the bridge. Table 1 provides a summary of the original bridge substructure configuration. When the bridge was completed, the centerline of the Brazos River was located at midpsan of the main span and the northern high bank was originally located at Bent 7. Erosion process has forced the northern high bank to Abutment 9 (also called Bent 9), and the river centerline during normal flow conditions is located south of Bent 8. The overall estimated river excursion at present day is approximately 270 feet to the north from its original location. An erosion wall that was installed in 2017 limits further erosion of the north river bank within the 300-foot width of the roadway corridor right-of-way. This study was developed to better understand the existing conditions, and to forecast the need, nature, and criteria for potential future improvements.

Jan 1, 2019

By Babak Mamaqani, Pirooz Barar

Regional Connector Transit Corridor (RCC) is part of the Los Angeles metro expansion project under construction which adds three new stations into the system. PB&A was responsible for the design of the support of excavation (SOE) systems for two stations, 2nd/Broadway and 2nd/Hope, in RCC. In this paper, challenges and lesson learned from SOE design of 2nd/Broadway station with a main focus on underpinning design are discussed. 2nd/Broadway station required to cut and cover excavation of 500 ft long by almost 100 ft deep, underneath 2nd Street. SOE systems consisting of drilled soldier beams with tiebacks and/or struts. The main challenge in 2nd/Broadway station was to underpin the LA Times building which was partially protruded into the station. A chellenging underpinning system consisted of concrete panels and ground anchors was designed to support the building surcharge and prevent settlement. The underpinning system was designed based on METRO design criteria and the deflection was evaluated by Finite Element Analysis (FEA) program, PLAXIS 2D. A maximum deflection of 0.4 inches was calculated to occur at the top of the underpinning system. Data from settlement and tilt sensors showed minimal movements which aligned with PLAXIS outputs. PROJECT DESCRIPTION The Regional Connector Transit Corridor (RCC) is Los Angeles Metro’s ambitious Light Rail Project. It runs under the City’s main thoroughfares, Flower and 2nd Streets, and when complete will alleviate traffic and parking congestion in downtown Los Angeles. The Regional Connector will connect thousands of residents living in the bedroom communities of the Inland Empire and Long Beach to their jobs Downtown. The rail line will serve 1.9 miles, using the $1.756 Billion budget to construct the underground rail line, including 3 new stations, at 2nd & Hope Street, 2nd & Broadway, and 1st St. & Central Ave (Fig. 1).

Jan 1, 2019

By Chu E. Ho, Paul Napoli

A new waterfront park was developed on Long Island in close proximity to the East River and Newtown Creek. The existing ground consisted of fill over soft organic clay, medium dense silty sand, glacial till and schist bedrock. The ground was initially raised to preload the underlying soft soils to stabilize the ground in preparation for site development. The ground was subsequently cut down to temporary grades for installation of foundation piles for the overlook structures and construction of reinforced concrete cantilever retaining walls forming pathways located adjacent to the water bodies. The retaining walls were located in two rows at different elevations along the sides of a steep embankment. Where the pathways converge, some of the walls were too close to each other, and were redesigned as a combined U-wall with a common base slab. The individual retaining walls were designed for adequate bearing, sliding and overturning resistance. Ground anchors were installed to enhance global stability of the retaining walls. This paper presents the design considerations for the retaining walls for various loading conditions, and evaluation of the trial and proof tests for the anchors. INTRODUCTION The New York City Master Plan included the transformation of an approximately 30-acre parcel of land in Long Island City, Queens, New York from a former manufacturing zone into a residential, commercial and recreational zone for middle-income community. The site was located at Hunters Point South along the eastern shoreline of the East River and Newtown Creek (Figure 1). The development included low to high- rise residential buildings, a public school, and retail structures. Open spaces were provided along the East River and Newtown Creek waterfronts in the form of a continuous park providing for recreational and community-related activities. Waterfront structures included small park buildings, walkways and viewing platforms. The shoreline was surrounded by revetments as part of the flood mitigation strategy. The project involved extensive site re-grading and several retaining walls were constructed. The earthwork volume amounted to approximately 47,000 cubic yard of imported fill and 93,000 cubic yard of cut. The exposed height of the retaining walls ranged from 3 to 15 feet. This paper focuses on the design and construction of the retaining walls for the project.

Jan 1, 2019

By James P. Hambleton, Anastasia Nally

This work focuses on the numerical simulation of multi-plate anchor systems (e.g., helical anchors) in sand subjected to vertical loading. In assessing the stiffness and capacity of these multi-plate anchor systems, full awareness of the abilities and limitations of the various analysis methods must be understood. This work first summarizes studies completed by others and then goes on to assess the failure mechanisms of multi-plate anchors in sand and the influence of (1) plate width-to-depth ratio, (2) number of plates, and (3) relative positioning of plates. The analysis makes use of (1) conventional limit analysis, (2) so-called modified limit analysis that employs reduced strength parameters to account for the influence of soil dilatancy, and (3) the displacement-based finite element method, which considers elastic as well as plastic deformation leading to failure. The work critically reflects on limitations in the current analysis methods for helical ground anchors. INTRODUCTION Helical anchors are a relatively low cost foundation type, typically consisting of a steel rod and single or multiple plate attachments. In recent decades, they have seen rapid growth, and as outlined by Merifield and Sloan (2006) and Hambleton et al. (2014). Design techniques for helical anchors have previously been predominately empirical, as much of the past research in this field is experimentally based. It is common practice for helical anchors to be modeled as horizontally oriented plate anchors in both numerical and experimental analysis. This work focuses on analysis based on the finite element method, including so-called finite element limit analysis and the conventional displacement-based finite element method, with some comparisons made to experimental studies. Numerical simulation of anchor pull-out capacity in cohesionless soils is stunted by the many difficulties faced when using numerical analysis with cohesionless soils. Additional variations can be seen when comparing the serviceability based load capacities to the ultimate load. In this work, both the force-displacement response (stiffness) and the ultimate anchor capacity are assessed, with more focus on the latter. This work focuses only on analysis techniques for multi-plate anchors with vertical loading in cohesionless soils. Many studies have been completed in this area, some of which assume a rectangular plate in a plain strain model (Rowe & Davis, 1982; Merifield & Sloan, 2006; Cerfontaine et al., 2019). Whereas others use axisymmetric conditions (Baker and Kondner, 1966; Saeedy, 1987; Murray & Geddes, 1987; Ghaly & Hanna, 1994; Sakai & Tanaka, 1998; Merifield et al., 2006;) and minimal studies considered both axisymmetric and plane strain in the one study (Vesic, 1971; Tagaya et al., 1988; Murray & Geddes, 1987; Sarac, 1989).

Jan 1, 2019

By Andres M. Baquerizo, Jeremiah J. Filjones, Nicholas Feldt

The Estates at Acqualina located in Sunny Isles Beach, FL, is comprised of two, ocean-front, 50-story, luxury towers with podiums and villas. With city regulations now requesting that above-grade floors be limited to commercial or residential units, parking facilities for the tower structures were situated within two levels of underground basement parking. However, ensuring dry excavation through south Florida’s highly pervious limestone, immediately adjacent to the beach where the groundwater table is very shallow, can be extremely challenging and costly for developers. In recent years, significant advances have been made to overcome this challenge with the innovative use of deep soil mixing to create a “dry hole”, assisting in the construction of foundations and underground usable space for parking, storage, etc. The “dry hole” system includes a soil mix bottom seal, with soil mix secant pile walls in combination with auger cast deep foundation elements to support the future structure. This approach enables groundwater control to greater depths than can be achieved by conventional sheetpiling and dewatering. For the Estates at Acqualina, a successful turnkey, design-build joint venture between two foundation and geotechnical contractors resulted in a dry excavation to 34 ft (10.4 m) below grade and to a record- breaking auger cast pile depth of 182.3ft (55.6 m), all within an aggressive 26-week schedule to deliver the “dry hole” excavation for the first tower. This presentation will discuss the logistics, quality control, design, and safety for the different techniques involved. INTRODUCTION AND BACKGROUND The Estates of Acqualina is a pair of 50-story luxury towers located on Sunny Isles Beach in Florida with a two-level underground basement for parking. The project’s location just steps away from the Atlantic Ocean, geology, and high-water table created a challenging project. The owner, Trump Group, contracted the joint venture of HJ Foundation and Hayward Baker (HJ/HB) to design-assist-build a system to control the groundwater, allowing the 2-story underground parking structure to be constructed. In order to accomplish this task, the JV utilized an installation technique known as deep soil mixing. This technique mixes the in situ material with a cement slurry to create a very impermeable material called “soilcrete”.

Jan 1, 2019

By Diane Reid, Antonio Marinucci, Robin Mao

Super Cells are an innovative, open-shaped bi-directional static load testing device used to promote concrete flow during placement while utilizing greater cross-sectional area of the pile to achieve large applied axial loads at relatively low hydraulic pressures (≤ 250 bar). This paper describes the results of multi-level load testing performed on a sacrificial drilled shaft that was 3.8 m (12.7 ft) in diameter and 110.6 m (363 ft) in length for the Jiaxing-Shaoxing River Crossing Bridge that spans Hangzhou Bay in Shaoxing, China. The test shaft was instrumented with embedded strain gauges and telltale rods along with displacement transducers at the top of the pile to measure the load-induced displacements along the length of the shaft. Load testing was performed twice using a Super Cell placed near the tip of the shaft, prior and subsequent to tip post-grouting, and then again using a Super Cell placed higher in the shaft. The axial resistance for the tested conventional drilled shaft was more than 5 times greater than the estimated axial resistance. In addition, the axial resistance after tip post-grouting (347,100 kN (39,033 ton)) was about 5.3% greater than the ungrouted axial resistance (329,600 kN (37,050 ton)). INTRODUCTION During the past few decades, the magnitude of axial, lateral, and flexural loading has considerably increased due to updated design codes, larger superstructures, and the manner in which extreme event loading (e.g. seismic and scour) is incorporated into design. The diameter and depths to which bored piles or drilled shafts are constructed have increased considerably during the last three decades due to the advancements in equipment technology and capabilities. In addition, monoshaft foundations have become increasingly used, as one large drilled shaft is able to replace a group of smaller diameter piles connected by a cap. Correspondingly, adequate strata, for both side and end resistance, must be discovered/determined as well as achievable to be able to construct the required foundations to support the greater design demands. As design demands have increased, the need to ensure integrity, quality, and performance of a constructed drilled shaft has become ever more crucial. Load tests are essential to validate design assumptions of side and end resistances, to assess the behavior and load transfer characteristics of the constructed drilled shafts, and to evaluate construction methods. Load tests utilizing a bi-directional static load testing (BDSLT) device can achieve considerably large applied axial loads and can be performed more economically, in less time, and in a much safer manner than conventional top-down static load testing methods.

Jan 1, 2019

By M. Drozd, M. Somppi, Z. F. Yamak

"Activated carbon is used to recover gold in solution from various gold circuit designs including carbon-in-pulp (CIP), carbon-in-column (CIC), and carbon-in-leach (CIL) processes; however, the characteristics and durability of the activated carbon can vary. Handling this medium poses challenges when fine carbon losses occur in the CIP, CIC, and CIL circuit discharge. Additionally, adsorbed gold on carbon fines can be lost to the discharge. The studies in this paper aim to standardize laboratory methods for testing activated carbon qualities specific to the gold industry. The investigation focused on size distribution, platelet content, wet attrition resistance, gold kinetics, and gold loading. The results demonstrate that a 96 h attrition test and a gold loading test form a basis for ranking carbon samples based on expected economic performance of the plant. ¦ KEYWORDS Activated carbon, Carbon attrition, Carbon ball-pan hardness, Carbon evaluation, Carbon fines loss, Carbon turnover RÉSUMÉ Le charbon actif sert à récupérer l’or en solution dans diverses conceptions de circuits de broyage d’or, notamment les procédés de charbon en pulpe (CIP, de l’anglais carbon-in-pulp), de charbon en colonnes (CIC, de l’anglais carbon-in-column) et de lixiviation au carbone, ou charbon au lixiviat (CIL, de l’anglais carbon-in-leach). Toutefois, les caractéristiques et la durabilité du charbon actif varient. La manipulation de ce milieu pose des problèmes dès lors que se produisent des pertes de carbone à grain fin dans la décharge des circuits CIP, CIC et CIL. Par ailleurs, l’or adsorbé sur les fines de charbon peut se perdre durant la décharge. Les études réalisées dans le cadre de cet article visent à normaliser les méthodes de laboratoire pour tester les qualités du charbon actif spécifiques au secteur de l’exploitation aurifère. L’étude portait sur la composition granulométrique, la teneur des plaquettes, la résistance au frottement humide, la cinétique de l’or et l’adsorption de l’or, à savoir la capacité du charbon actif à adsorber l’or sur une période spécifique. Les résultats ont montré qu’un test de frottement de 96 heures et un test d’adsorption de l’or constituaient le fondement d’un classement des échantillons de carbone du point de vue économique en vue de trouver l’échantillon générant le meilleur rendement des usines. ¦ MOTS CLÉS charbon actif, dureté de la batée des billes de carbone, évaluation du carbone, perte de fines de charbon, renouvellement du carbone, résistance au carbone INTRODUCTION The use of activated carbon for gold extraction is among the most common processes in modern gold-milling plants. Although gold losses are inevitable in the milling process, operators often focus on reducing gold loss to tailings. One focus area that is important in gold recovery is optimizing the use of activated carbon and examining potential changes to realize improved economics for carbon-in-pulp (CIP), carbon-in-column (CIC), and carbon-in-leach (CIL) processes. Granular activated carbon (Figure 1) is widely used for gold extraction from slurries containing gold-cyanide complexes. This activated carbon—produced from charred coconut shells—is well suited because of its adsorption kinetics, gold-loading capacity, attrition resistance, and ability to be reactivated. The extraction process using activated carbon technology involves adsorbing gold from an aqueous leachate; the gold is dissolved using a cyanide salt and consequently a dicyanoaurate(I) ion (Au(CN)2–) is formed, as noted in equation 1."

Jan 1, 2019