Mining And Refining: Mine Dewatering

From space, the most striking feature of our Pale Blue Dot is exactly what makes it blue: all that water. About three-quarters of the globe is covered with liquid water, and our atmosphere is a thick gaseous soup laden with water vapor. Almost everywhere you look there’s water, and even where there’s no obvious surface water, chances are good that more water than you could use in a lifetime lies just below your feet, and accessing it could be as easy as an afternoon’s work with a shovel.

And therein lies the rub for those who delve into the Earth’s depths for the minerals and other resources we need to function as a society — if you dig deep enough, water is going to become a problem. The Earth’s crust holds something like 44 million cubic kilometers of largely hidden water, and it doesn’t take much to release it from the geological structures holding it back and restricting its flow. One simple mineshaft chasing a coal seam or a shaft dug in the wrong place, and suddenly all the hard-won workings are nothing but flooded holes in the ground. Add to that the enormous open-pit mines dotting the surface of the planet that resemble nothing so much as empty lakes waiting to fill back up with water if given a chance, and the scale of the problem water presents to mining operations becomes clear.

Dewatering mines is a complex engineering problem, one that intersects and overlaps multiple fields of expertise. Geotechnical engineers work alongside mining engineers, hydrogeologists, and environmental engineers to devise cost-effective ways to control the flow of water into mines, redirect it when they can, and remove it when there’s no alternative.

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Junk Bin Build Lets You Test Fuel Injectors On The Cheap

Fiddle around with cars long enough and you’ll realize two things: first, anything beyond the simplest repairs will probably require some kind of specialized tool, and second, those tools can be prohibitively expensive. That doesn’t mean you’re out of luck, though, especially if you’ve got scrap galore and a DIY spirit, as this junk bin fuel injector test stand ably demonstrates.

[Desert Rat Racer]’s test rig is designed to support four injectors at once and to test them under conditions as close as possible to what they’ll experience when installed. To that end, [Rat] mounted a junk intake manifold to a stand made from scrap wood and metal found by the side of the road. A pickle jar serves as a reservoir for the test fluid — he wisely used mineral spirits as a safer substitute for gasoline — and a scrap electric fuel pump pressurizes a junk fuel rail, which distributes fuel to the injectors under test.

For testing, the injectors are wired up to an electric injector tester, which is one of the few off-the-shelf components in the build. The fuel pump and injectors are powered by the 12 volt rail of a scrapped PC power supply. Just being able to watch the spray pattern is often enough to find a faulty injector, but in case a more quantitative test is indicated, each injector is positioned over a cheap glass cylinder to catch the test fluid, and scraps of a tape measure are used to measure the depth of the collected fluid. No fancy — and expensive — graduated cylinders required.

While we truly respect the hackiness of [Desert Rat Racer]’s build, the concept of avoiding buying tactical tools is foreign to us. We understand the logic of not dropping a ton on a single-use tool, but where’s the fancy blow-molded plastic case?

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A Compact Electrohydrodynamic Pump Using Copper And TPU

Electrohydrodynamics (EHD) involves the dynamics of electrically charged fluids, which effectively means making fluids move using nothing but electric fields, making it an attractive idea for creating a pump out of. This is the topic of a 2023 paper by [Michael Smith] and colleagues in Science, titled “Fiber pumps for wearable fluidic systems”. The ‘fiber pumps’ as they call the EHD pumps in this study are manufactured by twisting two helical, 80 µm thick copper electrodes around a central mandrel, along with TPU (thermoplastic polyurethane) before applying heat. This creates a tube where the two continuous electrodes are in contact with any fluids inside the tube.

For the fluid a dielectric fluid is required to create the ions, which was 3M Novec 7100, a methoxy-fluorocarbon. Because of the used voltage of 8 kV, a high electrical breakdown of the fluid is required. After ionization the required current is relatively low, with power usage reported as 0.9 W/m, with one meter of this pump generating a pressure of up to 100 kilopascals and a flowrate of 55 mL/minute. One major limitation is still that after 6 days of continuous pumping, the copper electrodes are rendered inert due to deposits, requiring the entire system to be rinsed. Among the applications the researchers see artificial muscles and flexible tubing in clothing to cool, heat and provide sensory feedback in VR applications.

While the lack of moving parts as with traditional pumps is nice, the limitations are still pretty severe. What is however interesting about this manufacturing method is that it is available to just about any hobbyist who happens to have some copper wiring, TPU filament and something that could serve as a mandrel lying around.

Thanks to [Aaron Eiche] for the tip.

Rebuilding A $700k Refrigerator

When cleaning out basements, garages, or storage units we often come across things long forgotten. Old clothes, toys, maybe a piece of exercise equipment, or even an old piece of furniture. [Ben] and [Hugh] were in a similar situation cleaning out an unused lab at the University of California Santa Barbara and happened upon an old refrigerator. This wasn’t just a mini fridge left over from a college dorm, though. This is a dilution refrigerator which is capable of cooling things down to near absolute zero, and these scientists are trying to get it to its former working state.

The pair are hoping to restore the equipment to perform dark matter experiments, but the refrigerator hasn’t been in use since about 2016 (and doesn’t have an instruction manual), which is a long time for a piece of specialty scientific equipment to be collecting dust. The first step is to remove wiring and clean it of all the grime it’s accumulated in the last decade. After that, the pair work to reassemble the layers of insulation around the main cooling plate and then hook up a vacuum pump to the device which also needed some repair work.

The critical step at this point is to evacuate the refrigerant lines so they can be filled with expensive Helium-3 and Helium-4. The problem is that there’s still some of this valuable gas in the lines that needs to be recovered, but the risk is that if any air gets into the cold section of the refrigerator it will freeze and clog the whole system. After chasing some other electrical and vacuum gremlins and discovering a manual from a similar refrigerator, they eventually get it up and running and ready for new scientific experiments. While most of us won’t discover a fridge like this cleaning out our attics, this refrigerator powered by rubber bands is a little more accessible to the rest of us.

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The Wirtz Pump Spins

Over the ages, a lot of human activity has been concerned about getting water from where we find it to where we want it. If you want to move water to a lower elevation, there’s no problem. But if you want to move water up, you need a pump. The ancients used what we call Archimedes’ screw to raise water. But a Wirtz pump as [Steve Mould] shows in the video below, is another kind of spiral pump that is also very old and uses the same basic principle as the screw pump.

In a way, the Wirtz is just an Archimedes’ screw in cross-section. Part of what makes it work, however, is air-locking. [Steve] made a small model but found it didn’t work exactly as he expected. Of course, investigating that led to some interesting observations.

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Powerful Water Pump Is Modular In Nature

If you’ve got one decently powerful DC motor, you could conceivably build a water pump. Gang up ten of them, however, and you could build something considerably more powerful, as [akashv44] demonstrates.

The design is straightforward, relying on simple impeller pumps driven by RS-775 DC motors. The pump housings and impellers are all 3D printed. They’re designed so that the motor integrates neatly with the pump housing, and so that multiple pumps can easily be ganged up into a single larger unit. [akashv44] demonstrates a build using ten individual pump units with a large manifold, allowing the output of all the pumps to be combined into one single outlet.

The concept is straightforward enough, and running on a 48-volt power supply, it’s clear that the pump can move a significant amount of water. Notably, though, it would be possible to improve significantly with some design changes. Currently, the water path from the pumps must make several 90-degree turns, harming efficiency. We’d love to see the pumps angled nicely into more advanced manifolds which would more smoothly combine the streams together. This would likely result in a far greater output from the system.

In any case, 3D printing pumps is an increasingly popular pastime around here.

Is This The World’s Largest Dot Matrix Printer?

[RyderCalmDown] was watching a road painting vehicle lay down fresh stripes on the road one day and started thinking about the mechanism that lets it paint stripes in such a precise way. Effectively the system that paints the interspersed lines acts as a dot matrix printer that can only print at a single frequency. With enough of these systems on the same vehicle, and a little bit more fine control of when the solenoids activate and deactivate, [RyderCalmDown] decided to build this device on the back of his truck which can paint words on a roadway as he drives by. (Video, embedded below.)

Of course, he’s not using actual paint for this one; that might be prohibitively expensive and likely violate a few laws. Instead he’s using a water-based system which only leaves temporary lettering on the pavement. To accomplish this he’s rigged up a series of solenoids attached to a hitch-mounted cargo rack. A pump delivers water to each of the solenoids, and a series of relays wired to a Raspberry Pi controls the precise timing needed to make sure the device can print readable letters in much the same way a dot matrix printer works. There’s an algorithm running that converts the inputted text to the pattern needed for the dot matrix, and after a little bit of troubleshooting it’s ready for print.

Even though the printer works fairly well, [RyderCalmDown] had a problem thinking of things to write out on the roadways using this system, but it’s an impressive build based around a unique idea nonetheless. Dot matrix printers, despite being mostly obsolete, have a somewhat vintage aesthetic that plenty of people still find desirable and recreate them in plenty of other ways as well, like this 3D printer that was modified to produce dot matrix artwork.

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