Metodologia para análise da confiabilidade estrutural de escavações em rocha.

A methodology for rock-excavation structural-reliability analysis that uses Distinct Element Method numerical models is presented. The methodology solves the problem of the conventional numerical models that supply only punctual results and use fixed input parameters, without considering its statistical errors. The analysis of rock-excavation stability must consider uncertainties from geological variability, from uncertainty in the choice of mechanical behaviour hypothesis, and from uncertainties in parameters adopted in numerical model construction. These uncertainties can be analyzed in simple deterministic models, but a new methodology was developed for numerical models with results of several natures. The methodology is based on Monte Carlo simulations and uses principles of Paraconsistent Logic. It will be presented in the analysis of a final slope of a large-dimensioned surface mine.

Estudo de variabilidade e otimização do circuito de moagem SAG da Usina do Sossego

Sossego was the first Vale SAG mill operation to process copper-gold ore. It is located in the State of Para, southeastern Amazon region of Brazil. In the first three years of continuous operation, Vale investigated different alternatives for improving the circuit`s performance by investigating operating conditions, mainly focusing on the SAG mill. It was decided to further assess the performance of the comminution circuit as a function of ore characteristics. A comprehensive ore characterization program was then conducted, together with the calibration of mathematical models on the basis of surveys carried out at the industrial circuit. The simulator was then used to predict the throughput associated to each ore type, as well as to establish the optimized circuit configuration and tailored operating conditions. This paper describes in detail the main aspects of optimizing the industrial circuit performance, as well as the successful method for predicting the production as a function of ore characteristics and circuit configuration.

Reconciliação pró-ativa em empreendimentos mineiros

The common practice of reconciliation is based on definition of the mine call factor (MCF) and its application to resource or grade control estimates. The MCF expresses the difference, a ratio or percentage, between the predicted grade and the grade reported by the plant. Therefore, its application allows to correct future estimates. This practice is named reactive reconciliation. However the use of generic factors that are applied across differing time scales and material types often disguises the causes of the error responsible for the discrepancy. The root causes of any given variance can only be identified by analyzing the information behind any variance and, then, making changes to methodologies and processes. This practice is named prognostication, or proactive reconciliation, an iterative process resulting in constant recalibration of the inputs and the calculations. The prognostication allows personnel to adjust processes so that results align within acceptable tolerance ranges, and not only to correct model estimates. This study analyses the reconciliation practices performed at a gold mine in Brazil and suggests a new sampling protocol, based on prognostication concepts.

Planejamento para o fechamento prematuro de minas

Several mining companies operating in Brazil have been preparing mine closure plans describing end of life actions to ensure long term physical stability, land rehabilitation and, to a certain extent, socioeconomic measures. Most Brazilian and international guidelines, however, skip early closure and only feature guidance to closure planning after reserve depletion. In this paper, two cases of early closure in Australia are reviewed, causes for early closure are explored, criteria to evaluate preparedness to early mine closure are proposed and tested in two mines. It concludes that, despite recent advances, planning for mine closure seldom take account of early closure risks.

Importância da hidrodinâmica na cinética de flotação de partículas grossas

The processes that govern the rate of particle recovery in a flotation cell include the following sub-processes: collision, attachment, and stability of the aggregate formed by particles and bubbles. Collision is controlled by bulk hydrodynamics inside the flotation cell, while attachment is largely dominated by variables that belong to the domain of surface chemistry (contact angle, induction time). As for the stability of the particle/bubble aggregate, its efficiency depends on both hydrodynamics plus surface chemistry variables of the system. The flotation recovery of coarse particles of apatite and glass spheres was measured by micro-flotation and batch flotation tests in which hydrodynamic parameters were evaluated, such as impeller rotational speed, diameter, and geometry, as well as particle size and density. Results revealed that a proper impeller rotational speed yielded turbulence levels, which enabled to keep particles fully suspended, this way optimizing the collision efficiency between particles and bubbles, without jeopardizing the stability of the particle-bubble aggregates.

Efeitos da alteração do limite de exposição ocupacional à sílica cristalina no processo de seleção de respiradores.

The purpose of this study was to investigate the respiratory protective device selection process and to identify changes in this process when an exposure limit value is updated. Two previous studies conducted in mining industries in the metropolitan area of Sao Paulo were put through the respiratory protective device selection process. The protection factors of the equipment provided by the companies were compared with the required protection factors and with the FUNDACENTRO`s respiratory protection program. The results showed that until 2005, some companies were providing inadequate protection, and after the change in crystalline silica exposure limit value in 2006, all the analyzed companies were providing inadequate respirators. This study suggests that there is an opportunity to create a web portal, where the selection process can be done by the companies with updated information.

Logística para agregados (brita e areia) em grandes centros urbanos

One of the human being`s basic needs is housing. In Brazil, the basic element for this is concrete, artificial stone, which demands a great amount of aggregates, such as sand and gravel. The sand and rocks are abundant in nature and gravel can be produced at low cost. However, transportation to the area of product utilization can be an incremental factor in the final cost logistics. Both sand and gravel have expressive price variations, which are not necessarily related to mining activities, but to logistic activities, mainly their distribution. Restrictive measures adopted in large urban centers, such as prohibition of hauling trucks in certain areas or during certain hours, alternate license plate end number system (even number plate ending can circulate on even-numbered days and visa versa), and axle-control, generate a need for a larger and more diversified fleet, not to mention more employees.

Influência da função distribuição de quebra na modelagem e simulação do circuito de moagem de Carajás - parte 2 - simulação

Using the previously described method for appearance function determination, described in Part I of this article, the breakage characterization of the main Carajas ore types was carried out. Based on such characteristics, the ball mill circuit performance was evaluated through simulations. The model described in the first part was used. The results were assessed by comparing ball mill products and cyclone overflow size distribution, as well as simulated recirculating loads. The simulations indicated the potential for processing such ore types at the Carajas grinding circuit, which until now was unknown.

Modelagem de dados de entrada para simulação estocástica de lavra

Mine simulation depends on data that is both coherent and representative of the mining operation. This paper describes a methodology for modeling operational data which has been developed for mine simulation. The methodology has been applied to a case study of an open-pit mine, where the cycle times of the truck fleet have been modeled for mine simulation purposes. The results obtained have shown that once the operational data has been treated using the proposed methodology, the system variables have proven to be adherent to theoretical distributions. The research indicated the need jar tracking the origin of data inconsistencies through the development of a process to manage inconsistent data from the mining operation.

MEASUREMENT OF ELASTIC PROPERTIES OF MATERIALS BY THE ULTRASONIC THROUGH-TRANSMISSION TECHNIQUE

The elastic mechanical behavior of elastic materials is modeled by a pair of independent constants (Young`s modulus and Poisson`s coefficient). A precise measurement for both constants is necessary in some applications, such as the quality control of mechanical elements and standard materials used for the calibration of some equipment. Ultrasonic techniques have been used because wave velocity depends on the elastic properties of the propagation medium. The ultrasonic test shows better repeatability and accuracy than the tensile and indentation test. In this work, the theoretical and experimental aspects related to the ultrasonic through-transmission technique for the characterization of elastic solids is presented. Furthermore, an amorphous material and some polycrystalline materials were tested. Results have shown an excellent repeatability and numerical errors that are less than 3% in high-purity samples.

Towards modular and coordinated manufacturing systems oriented to services

Nowadays, there is a trend for industry reorganization in geographically dispersed systems, carried out of their activities with autonomy. These systems must maintain coordinated relationship among themselves in order to assure an expected performance of the overall system. Thus, a manufacturing system is proposed, based on ""web services"" to assure an effective orchestration of services in order to produce final products. In addition, it considers special functions, such as teleoperation and remote monitoring, users` online request, among others. Considering the proposed system as discrete event system (DES), techniques derived from Petri nets (PN), including the Production Flow Schema (PFS), can be used in a PFS/PN approach for modeling. The system is approached in different levels of abstraction: a conceptual model which is obtained by applying the PFS technique and a functional model which is obtained by applying PN. Finally, a particular example of the proposed system is presented.

INDUSCON 2010

The following papers constitute a selection among the best papers presented at the Ninth IEEE/IAS International Conference on Industry Applications (INDUSCON) held in Sao Paulo from 8(th) to 10(th) of November, 2010. This event gathered a significant number of people from academia and industry interested in applications of Electrical and Electronic engineering to industry.

Development of Control Systems for Safety Instrumented Systems

Safety Instrumented Systems (SIS) are designed to prevent and / or mitigate accidents, avoiding undesirable high potential risk scenarios, assuring protection of people`s health, protecting the environment and saving costs of industrial equipment. The design of these systems require formal methods for ensuring the safety requirements, but according material published in this area, has not identified a consolidated procedure to match the task. This sense, this article introduces a formal method for diagnosis and treatment of critical faults based on Bayesian network (BN) and Petri net (PN). This approach considers diagnosis and treatment for each safety instrumented function (SIF) including hazard and operability (HAZOP) study in the equipment or system under control. It also uses BN and Behavioral Petri net (BPN) for diagnoses and decision-making and the PN for the synthesis, modeling and control to be implemented by Safety Programmable Logic Controller (PLC). An application example considering the diagnosis and treatment of critical faults is presented and illustrates the methodology proposed.

MODELLING AND CONTROL OF ERSW PROCESSES BY NEURONAL NETWORK

A study on the use of artificial intelligence (AI) techniques for the modelling and subsequent control of an electric resistance spot welding process (ERSW) is presented. The ERSW process is characterized by the coupling of thermal, electrical, mechanical, and metallurgical phenomena. For this reason, early attempts to model it using computational methods established as the methods of finite differences, finite element, and finite volumes, ask for simplifications that lead the model obtained far from reality or very costly in terms of computational costs, to be used in a real-time control system. In this sense, the authors have developed an ERSW controller that uses fuzzy logic to adjust the energy transferred to the weld nugget. The proposed control strategies differ in the speed with which it reaches convergence. Moreover, their application for a quality control of spot weld through artificial neural networks (ANN) is discussed.

Comparison between DC(+) and Square Wave AC SAW Current Outputs to Weld AISI 304 for Low-Temperature Applications

Welded equipment for cryogenic applications is utilized in chemical, petrochemical, and metallurgical industries. One material suitable for cryogenic application is austenitic stainless steel, which usually doesn`t present ductile/brittle transition temperature, except in the weld metal, where the presence of ferrite and micro inclusions can promote a brittle failure, either by ferrite cleavage or dimple nucleation and growth, respectively. A 25-mm- (1-in.-) thick AISI 304 stainless steel base metal was welded with the SAW process using a 308L solid wire and two kinds of fluxes and constant voltage power sources with two types of electrical outputs: direct current electrode positive and balanced square wave alternating current. The welded joints were analyzed by chemical composition, microstructure characterization, room temperature mechanical properties, and CVN impact test at -100 degrees C (-73 degrees F). Results showed that an increase of chromium and nickel content was observed in all weld beads compared to base metal. The chromium and nickel equivalents ratio for the weld beads were always higher for welding with square wave AC for the two types of fluxes than for direct current. The modification in the Cr(eq)/Ni(eq) ratio changes the delta ferrite morphology and, consequently, modifies the weld bead toughness at lower temperatures. The oxygen content can also affect the toughness in the weld bead. The highest absorbed energy in a CVN impact test was obtained for the welding condition with square wave AC electrical output and neutral flux, followed by DC(+) electrical output and neutral flux, and square wave AC electrical output and alloyed flux.