Search Documents

By Raj Thamburaj

"Over the last few decades, the emphasis on affordability and reduced cost of ownership has necessitated the development of innovative processes to carry out repairs in aero engine components. Conventional weld and braze repairs have evolved into advanced, sophisticated processes using state of the art knowledge in lasers, robotics and materials technology. This paper illustrates past and present scenarios in an attempt to illustrate progress that has been made in this area. The problems encountered in the past have been detailed along with the solutions that have been developed and commercially implemented to address these issues. Apart from technical progress, this presentation also addresses the progress made in business approaches and in Certification/Regulatory issues surrounding aero engine repair. Progress in Technology Repair technologies have also been the embryo from which new and revolutionary manufacturing technologies have evolved as well. Electron Beam Free Forming and LENS are examples of how a completely new manufacturing concept can evolve what was originally only a process to join metals. The current and future potential of these spin offs is discussed providing examples of application. While several problems have been solved over time with the implementation of advanced repair technologies, the demands of the industry have created new challenges. The paper describes these issues, outlines potential solutions and discusses the future of repair technologies in terms of the far reaching influence it is sure to have in design, manufacturing, maintenance management and life extension. Progress in Business Trends.Business approaches to repair and maintenance have also gone through considerable change with the introduction of ""Power by the Hour"" and other similar arrangements between the companies responsible for engine overhaul and the end-users. Program Based Logistics (PBL) is yet another innovation to provide a win-win situation for the repair service provider and the end user. This paper traces the development of these business initiatives and highlights successful applications. Progress in Repair Certification, Regulatory Issues.Understanding of the issues surrounding certification of repairs has also evolved with time and regulatory issues have been clarified considerably. Procedures for analysis and testing are much clearer and ""Check Lists"" are being drafted for certifying repairs on various engine components. The PMA phenomenon has added yet another dimension to the issues regarding certification and these are discussed as well."

Jan 1, 2010

By Roger Francis

There is increasing use of acid leach extraction methods at elevated temperatures and pressures by the mining industry. In many locations there are limited supplies of fresh water, and waters with higher chloride contents must be used, making conditions more corrosive. The fluids downstream of the main autoclave are hot, acidic, oxidizing and contain chlorides and present a challenge to the mining community to ensure reliable operation. Zeron 100 is a high strength superduplex stainless stee, that offers high corrosion resistance at a cost effective price. The paper presents a combination of laboratory data and service experience, particularly in the aggressive fluids found in downstream processing.

Jan 1, 2010

By Tad Crowie, Victor Delgado, Nick Katsikaros, Tim Hughes

"A number of silver producers have identified a need for a system to recover silver and gold from base metal flotation concentrates on site rather than sending the concentrate to third party smelters to improve mine economics. Historically intensive cyanidation has only been used for coarse gold gravity concentrates in batch machines but Gekko have applied the InLine Leach Reactor (ILR) to these difficult to leach concentrates.The ILR’s unique ability to operate at various solid to solution ratios, high mass capacity, the ability to handle fines, the use of peroxide to aid silver leach kinetics and simple operation has resulted in significant economic benefits to Hochschild PLC’s Selene and Arcata operations. This paper describes the commissioning phase of the ILR5000BA intensive cyanidation reactors on concentrates from the Selene mine at the Ares Concentrator.INTRODUCTIONIntensive leaching of high grade concentrates in gold ore treatment is now commonplace and is considered an essential feature of most gold circuits (Lane, Fountain and LeBrooy, 2008). The devices commonly used for intensive leaching (InLine Leach Reactor, Acacia Reactor, etc) are specifically designed for the typical coarse nature of the concentrate.In some of these intensive leach applications, significant amounts of silver are co-recovered with the gold. In fact, the intensive leaching conditions of 1 to 2% NaCN in solution and high dissolved oxygen levels, overcome the issue with silver’s slow dissolution rate in traditional CIL/CIP circuits and avoids the formation of insoluble silver sulphide minerals on the surface of the gold (Marsden, 2006).There are a significant number of mine operators producing silver in the form of mixed base metal sulphides flotation concentrates. Typically the mine operators are paid for the silver after processing of the concentrate by the base metal smelter whom recovers the silver during the refining process."

Jan 1, 2010

By Tatiana Ravani von Ow, Leandro Bomvisinho

"The size of mills driven by ring-gear or by a gearless solution has significantly increased in the last years. This has created additional challenges for the driven equipment. The requirements for the mechanical devices and the power grid have become more demanding. Controlled soft starting and operation, especially in dual pinion mills, as well as the protection of the equipment has gained importance. The selection of the drive solution for the mill therefore becomes more critical. Besides the classical criteria such as performance, efficiency and capital costs other factors come in the evaluation of the system such as flexibility and optimization of operation, reliability and the ageing of the grinding equipment.Variable speed solutions offer significant advantages over conventional fixed speed drives due to their application specific features and process optimization capabilities, even for ball mills where these are not seen yet as a must.The initial capital costs are higher than some of the direct on-line solutions however the benefits for the operation during the lifetime of the mill generated by the use of converter solutions justify the additional higher investment.INTRODUCTIONThe method of powering mills such as AG, SAG and Ball has a long and technically interesting history. It can be said; almost every decade in the last half century had its own trend. The trend was dominated by the market demand, by the process development and requirement of the mechanical and the electrical technology but mostly by the price of the applied technology.All has started about 50 years ago with mill diameters less than 20 feet driven by fix speed synchronous or wound rotor motors with the power of about 2 MW. Around 10 years later, the mill sizes increased, but the necessary torque could not be transmitted by one pinion therefore dual pinion solutions were developed to power the mills. However, realization of the dual pinion solution was only possible when load could be evenly shared between the two pinions."

Jan 1, 2010

Thermal barrier coating (TBC) systems provide thermal insulation to high temperature for aero¬propulsion. A fracture mechanical model developed earlier for multilayer systems is applied on TBC to realize superior performance by enhancement of fracture resistance. Functionally gradient materials (FGM) solution concept is the basis of approach followed here. A few realistic FGM TBCs are considered in the analysis in addition to a conventional TBC as the base case and a hypothetical worst case with YSZ-YSZ interface. Parameters like number, composition and thickness of graded layers and elastic modulus are considered for the analysis and quantitative improvement of fracture resistance of TBCs. The analysis is confined to deep crack with crack size to width ratio as 0.5.

Jan 1, 2010

By Steve Wilson, Bern Klein, Jeff Drozdiak, Stefan Nadolski, Andrew Bamber

"In the adaptation of high pressure grinding rolls (HPGRs) to hard-rock mining applications, circuit development has mainly focused on placing HPGRs in the role of tertiary crusher in the preparation of ball mill feed. In order to take advantage of the potential energy benefits associated with HPGR and stirred mill grinding technologies, work was done to investigate the potential of and resultant energy benefits of placing the HPGR in series with a high speed stirred mill in replacement of the conventional cone crusher / ball mill arrangement. The proposed circuit was designed to operate with two stages of HPGR grinding followed by high speed stirred milling.Using a pilot-scale HPGR unit inline with a 20 liter stirred mill, the design criteria, circuit arrangement and consequent comminution energy requirements for a circuit processing copper sulphide ore from Teck Resources’s Mesaba Copper project were determined. These results were then compared to two other circuits, an HPGR / ball mill circuit and a conventional crusher / ball mill circuit processing the same ore.The testwork indicated at a proof-of-concept level that the HPGR / stirred mill circuit could potentially be appropriate for this duty and further work on the concept is merited. While the results indicate that the HPGR component of the circuit was more energy efficient than conventional cone crushing, the energy efficiency of the stirred mill was found to be lower than that of a comparable ball mill undertaking the same duty. However, increased energy efficiency of the stirred mill portion of the circuit is possible with further optimization and further work on the concept is indicated."

Jan 1, 2010

By S. Oppenheimer, P. Au, R. M. Kearsey, J. Tsang, E. McDevitt

A new superalloy, ATI 718Plus® Alloy (718Plus), has been developed to have a 55oC higher temperature capability over the traditionally used Alloy 718, while maintaining favourable processing characteristics and intrinsic raw material costs. The fatigue and dwell-fatigue behaviour of four microstructural variations of 718Plus are evaluated and compared to Waspaloy: 1) standard heat treated condition (HT1), 2) standard heat treated condition with thermal exposure at 732ºC (1350ºF) for 1000 hours (HT2), 3) fine grain condition with a modified d phase (HT3), and 4) fine grain overaged through modified heat treatment (HT4). The results show that the steady-state fatigue crack growth rates of each microstructural variation and both alloys are identical, with all of the 718Plus variations showing a clear advantage over Waspaloy in the fatigue crack threshold regime. Dwell-fatigue results show that Waspaloy has better resistance to crack propagation under dwell conditions; however, optimization of the precipitate phase shows vast improvement in the dwell-fatigue resistance of 718Plus.

Jan 1, 2010

RÉSUMÉ Cet article traite d’une analyse technique et économique du concept du triage optique en vue d’améliorer la rentabilité des opérations minières. Le principe du tri optique et les principaux systèmes et modules servant au fonctionnement de l’appareil de triage sont décrits. un modèle a été développé pour analyser l’intérêt économique d’une opération de triage optique. L’étude est basée sur des données provenant d’une halde de minerai à faible teneur en or, déposé à la surface, et de minerai extrait des opérations souterraines courantes de la mine Beaufor au Québec. Les résultats de cette analyse indiquent que l’opération de triage optique permet d’améliorer grandement la performance économique; l’opération devient alors rentable pour des teneurs en or relativement petites.

Jan 1, 2010

By X. Cao, A. Birur, R. R. Chromik, J. Cuddy, P. Wanjara, J. Gholipour Baradari, T. Shariff

In this study, 3.1 mm thick Ti-5553 (Ti-5Al-5V-5Mo-3Cr) butt joints were autogenously welded using a 4 kW continuous wave Nd:YAG laser. The effect of welding speed and defocusing distance on the weld quality was investigated in terms of the surface morphology, welding defects, microstructure and hardness. Welds with full penetration were achieved at a defocusing distance ranging from -1 mm to 0 mm and welding speeds from 2.25 to 6.0 m/min. Underfill and porosity were the two main defects most frequently observed but within the optimum process window these defects could be maintained to meet aerospace specification tolerances. The fusion zone (FZ) consisted entirely of retained beta with a refined dendritic morphology. Compared to the bimodal alpha (a) + beta (ß) microstructure of the base metal (BM), the dissolution of the a phase was observed in the heat affected zone (HAZ), which led to an 11 % decrease in hardness from the BM to the FZ. To determine the tensile properties of the welded samples, an automated 3D deformation measurement system was used to measure the local strain in the weld region. The yield strength (YS) and ultimate tensile strength (UTS) increased with increasing welding speed with a highest joint efficiency of 75 % being achieved, albeit with a concomitant reduction in the ductility.

Jan 1, 2010

By Dina Aloi

The need to be seen as responsible neighbours and good corporate citizens is a critical success criteria for mining companies. To be seen as responsible requires both achieving responsible performance, and making that good performance visible to the community, legislators, investors, and other stakeholders. This has broadened the skills required for the successful operation of a mining company to include social sciences, public affairs, communications, and environmental sciences. Mining companies still look to technical specialists to achieve the core of that good performance - broadly characterized as a sustainable operation. However, the degree of understanding that those specialists have of the requirements for sustainability and overall Corporate Social Responsibility has a tremendous impact on the overall performance of the project and company. In her keynote address to the Sustainability for Profit session, Dina will outline some of the key areas in which technical employees and consultants can contribute to achieving successful sustainable mining operations.

Jan 1, 2010

By M. Veiga

"Mining is an energy and water intensive activity. Increasing energy efficiency and reducing water consumption are two of the key requirements in moving toward a more sustainable mining industry. Water reduction, reuse and recycle options are reviewed, identifying cases where these options have been implemented. Then a novel mine water network design method is described, which analyzes a mine/mill water system in order to identify areas where water requirements and water system energy requirements can be reduced. First, a site water balance is determined and major water consumers and sources are specified. Next, multiple possible combinations of supplying water to mine and mill consumers are compared. Finally, low energy and water combinations are identified.INTRODUCTIONMining consumes vast quantities of energy: The whole mining and metals sector consumes over 12% of the world’s energy (DOE, 2009). Mining also requires large quantities of water, although mining water consumption is a relatively small portion of the overall world water use. Even in relatively dry, mining-intensive countries like Australia and South Africa, mine water consumption is only 2-3% of national water demand (Brown, 2003). However, at the local level, when mining takes place in areas where water is scarce, mine water consumption can severely impact local supplies. In addition, acid rock drainage, leaks from waste impoundments, or direct disposal of tailing into waterways can contaminate surface and groundwater (MMSD, 2002). Mine water systems can be large energy consumers, but better mine water systems can reduce both water and energy consumption. Improving water system design and practice are key strategic requirements in moving toward a more sustainable mining industry.This paper addresses conventional base-metal or precious-metal mine sites, which consist of an underground or open pit mine and a mineral processing plant, or mill. Ore is extracted and processed through the plant to produce a saleable product. Tailing, or waste material, is then deposited in a tailing storage facility (TSF). Any rock removed from the mine with no economic value, or waste rock, is stored without being processed."

Jan 1, 2010

By W. R. Tyson

Imperfections such as lack-of-fusion and undercut are inevitable in field welding of pipelines. Above a certain size, such defects must be removed or repaired. In the present state of the art, determination of allowable defect size is done by Engineering Critical Assessment (ECA). This requires measurement of toughness, and comparison of toughness with crack driving force. ECA methods used in current international pipeline standards will be reviewed and compared.

Jan 1, 2010

By P. G. Dunn, J. Fitzgerald

ABSTRACT The scheduling of underground mining activities is a complex task that must simultaneously satisfy a large number of constraints. A schedule optimization tool (SOT) for underground mine planning is described, and its use for investigating strategic decisions is illustrated through a case study. The maincomponents of the SOT include (a) a genetic algorithm that searches for optimal schedules, (b) guidance for the application of heuristic rules, and (c) sliding, which implements just-in-time development. Findings indicated that preliminary scheduling performed before invoking the SOT, intended to provide a good starting point for the search, did not ultimately lead to higher value schedules.

Jan 1, 2010

By I. P. Swainson, A. Ilbagi, H. Henein

Powders of Al-50wt%Ni, Al-40wt%Ni and Al-36wt%Ni were produced using the Impulse Atomization technique, a rapid solidification technique. The molten droplets were cooled in-flight by the stagnant helium or nitrogen in the atomizing chamber. The resulting powders were sieved into different size ranges. X-Ray diffraction and neutron diffraction were used in order to quantify the phase fractions in the samples. The computer software GSAS was used to calculate the weight fraction of the existing phases, namely Al3Ni2, Al3Ni and Al, by profile refinement method. The effect of processing parameters, alloy composition and particle size will be discussed in this paper. In brief, no AlNi was found in any of the samples analyzed. Higher cooling rates resulted in the reduction of the ratio of Al3Ni/Al3Ni2. Also, at high cooling rates, Scheil closely predicted the ratio of Al3Ni/Al3Ni2. Some metastable phases were found in Al- 36wt%Ni.

Jan 1, 2010

By J. Paraszczak

ABSTRACT: Application of teleoperated and automated (or “autonomous”) mobile equipment in under-ground metal mines represents a promising avenue for overcoming some of the challenges facing the industry. This paper addresses the overall effectiveness of autonomous loading and haulage equipment compared with conventional human-operated machines. Factors affecting availability, utilization, and production rate are explored, and an emphasis is placed on some problems and risks not present in conventional human-operated systems, as well as on the character and criticality of autonomous equipment. The need for a more in-depth analysis of factors affecting overall autonomous equipment effectiveness is stressed; these factors should be taken into consideration at the stage of feasibility studies. The paper concludes with recommendations and directions for future research.

Jan 1, 2010

By Li Chongyang, Liu Baolan, Jia Xiaolin, Li Suping

An Al/Al2O3 gradient coating applied on a heat-resistant stainless steel was prepared through a slurry process by using aluminum and ?-Al2O3 powders as the transition filler material, alpha alumina as the surface coating material, aluminum dihydrogen phosphate as the binder, and sodium molybdate as the corrosion inhibitor. The effects of heat treatment temperature, adhesive/filler ratio and ?-Al2O3 content on the bonding strength, microhardness and thermal shock resistance were investigated. The crystal phase and microstructure were characterized by XRD and SEM. The results indicated that the composition of the coating changed continuously from surface to coating-substrate interface. The coating could offer high bonding strength and good thermal shock resistance when heat treated at 700°C.

Jan 1, 2010

By R. C. Reed, L. T. Wu, H. C. Harada, K. Kawagish, R. T. Wu

Oxidation of pure metals is a chemical reaction in which the metal loses one or more electrons, such that the atom of the metal changes from the neutral state to a positively charge ion and reacts with oxygen to form an oxide of the metal. The oxide can form as a protective and adherent scale that slows down further oxidation, or may spall off repeatedly, exposing fresh metal surface to react with oxygen. In multi-component alloy systems such as typical high temperature NiCrAlY bond coats, more than one oxidation mechanism may take place at once and thus, complicates the study of oxidation. To better understand the competition between formations of oxides of different compositions, a thermodynamic assessment is carried out to study the oxidation mechanism of a Ni-27Cr-9Al (at %) ternary alloy. Based on the assessment, it is demonstrated that the layering of different oxides can be determined, with the most stable oxide (alumina) existing directly above the metal-oxide interface and the least stable oxide (nickel oxide) locating on the outer most layer. A comparison between the calculated results and previously published experimental observations shows excellent agreement.

Jan 1, 2010

By X. Wu, W. R. Chen, J-G. Legoux, B. R. Marple, E. Irissou

Cold gas dynamic spray (CGDS) has been considered a potential technique to produce the metallic bond coat for TBC applications, because of its fast deposition rate and low deposition temperature. This paper presents the influence of spray processes for bond coat, including air plasma spray, high velocity oxy-fuel, and in particular CGDS, on the oxidation performance of TBCs with a Co-32Ni-21Cr- 8Al-0.5Y (wt.%) bond coat. Oxidation behaviour of the TBCs was evaluated by examining the coating microstructural evolution, TGO growth behaviour, and crack propagation during thermal exposure at 1050°C. The relationship between the TGO growth and crack propagation will be discussed.

Jan 1, 2010

By S. Boisvert

Risk-based Inspection (RBI) addresses the challenges associated with ageing plants by focusing the inspection effort on the process equipments with the highest risk, thereby improving plant safety and reducing inspection costs. The RBI methodology is commonly used in the oil industry through the API 581 standard. Since no such standard exists in the mining and metals industry, BPR-Bechtel has developed one using inspection data from process equipments in CEZinc. Models were developed for various damage mechanisms, such as uniform corrosion and stress corrosion cracking. The equations were organized into a user friendly software that facilitates the implementation process.

Jan 1, 2010

By Eugene Sun, Qiang Xu

This presentation will review current applications of composite materials in aircraft design and discuss the challenges involved in maximizing the potential of the composites in aircraft applications.

Jan 1, 2010