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By W. P. C. Duyvesteyn, B. J. Sabacky

Reprinted with revisions from Extractive metallurgy of copper, nickel and cobalt, volume I: Fundamental aspects. ed. Reddy R.G., Weizenbach R.N. Warrendale, Pennsylvania: The Minerals, Metals and Materials Society, 1993. Development work on the Escondida process, concluding with the successful operation of an integrated leach-SX-EW pilot plant and a pilot flotation plant for the upgrading of leach residues, demonstrated that all major process objectives could be achieved. Extraction of 40% of copper in concentrates containing monovalent copper was achieved with essentially no oxidation of sulphide sulphur. The Cu contents of leach residues from four different types of concentrate were successfully upgraded to the original feed grades, giving a product that has potential as a high-quality concentrate for the smelter market. A compact solvent extraction section effectively recovered the ammonia lixiviant for recycling to leaching and selectively transferred Cu into a conventional acid sulphate electrowinning system. High-quality "six-nines" copper cathode was produced on commercial-scale stainless steel blanks, demonstrating that the process will be able to compete effectively in the premium cathode market

Dec 1, 1995

By I. Marklund, W. Hustrulid

Sublevel caving is likely to remain the dominant system at both Malmberget and Kiruna for the foreseeable future. The sub-level interval has increased from 12 m in 1983 to 30 m, requiring more effective drifting and the development of a contour blasting technique to reduce requirements for rock reinforcement. Production drilling is mainly by hydraulic hammers or water-powered in-the-hole machines drilling 115 m diameter holes. Loading operations are undertaken 7 days/week with 15-25 tonne capacity electric shovels. Production has increased by nearly 70% since 1983 and productivity has risen threefold

Dec 1, 1995

By H. K. Taylor, B. Denby, L. D. Smith

Contributions by H.K. Taylor and G.A. Davis discuss the three papers published in Transactions IMM A, vols. 103 and 104, with responses by Smith and Dowd

Dec 1, 1995

By K. Nielsen, J. Kristiansen

A series of laboratory blasting and grinding tests on three types of hard and competent rock (coarse-grained monzonite, fine-grained granite and very fine-grained gabbro) showed that a higher level of applied explosive energy enhanced grindability and produced a larger amount of fine (-0.106 mm) material. This confirmed reported industrial experience and the results of previous investigations. However, the results did not provide any information on the quantitative relationship between the energy applied in primary blasting and that required in subsequent comminution. Only about 1% of energy consumed in conventional grinding is used to create new surfaces, while power efficencies in cone crushers have been estimated at 70-80%. In blasting, up to 20% of explosive energy may be transmitted to the surrounding rock as elastic strain energy, leading to both primary rock breakage and the generation of microcracks

Dec 1, 1995

By S. P. Singh

The purpose of the cut is to provide a free face to which the remainder of a development or breasting round can break. The results of field testing in drifts and at a quarry face were used as a basis for a description of the rock breakage and flushing mechanism in the cut. It was concluded that the important features of a cut design are proper hole spacing, sufficient relief volume, drilling accuracy and relief holes slightly longer than the planned length of the round. The void space provided by the relief holes should be about 15% of the cut volume, with more required in weak, highly fissured rocks. The importance of drilling accuracy increases with round length, an error being magnified by the small blasthole spacing. The first hole pulls only about 20% of the round length, 4-6 holes having to be fired before the cut is pulled close to its design depth. The first four blastholes should be fired with a minimum inter-hole delay of 100 ms to provide progressive relief of burden and avoid the superimposition of ground vibrations. The earliest-firing charge should be closest to the relief area and act laterally, while the first of the vertically-fired charges to be detonated should be the uppermost. Problems during cut-pulling include sympathetic detonation, dynamic pressure desensitisation, charge disruption and freezing of the cut

Dec 1, 1995

By J. A. Finch, D. Lin

The robustness of the large-sections correction procedure, Hill's fast approximation, Barbery's correction and the PARGEN correction was examined by comparing their ability to reconstruct the true liberation distribution using sectioning data from computer-generated spheres. The results indicate that the flexibility of a correction procedure is related to the assumptions it makes about the continuity of the liberation distribution, locked-particle characteristics and ore texture. Overall, the large-sections procedure appeared to be the most generally applicable. The Hill fast approximation performed well, but this was probably because it partially incorporates the sphere model; the performance of the PARGEN and Barbery corrections varied from case to case.

Dec 1, 1995

By N. Krauland, A. Nystrom, M. Board, S. Sandstrom

Several deep Swedish cut-and-fill mines experience severe ground control problems, including roof collapse and wall sloughing, as a result of variable rock quality and high in situ stresses. A project to examine the problem included two main areas. The first was prediction of mining conditions at depth and the adaptation of cut-and-fill mining to such conditions; the second was the assessment and improvement of support methods at present and future depths. Simple, elastic, mine-scale numerical models were used to optimise stope sequencing and more detailed, stope-scale models to simulate the failure processes around a stope and the interaction of rock mass and support. Kristineberg was chosen for testing and calibration of the predictive methods because of its long history of severe ground conditions and the large base of observational and monitoring data available for comparison. Horizontal cut and fill was found technically suitable to depths beyond 1 000 m and economically viable if ore value covers support costs. Stability can be achieved with the present support technology down to 1 000 m but the 7-strand 15.2 mm cables have poor deformation properties (5% failure strain) compared with rebar rock bolts (17%). Reducing the intervals between levels from 100 m to 50 m will cut support costs and improve production reliability and capacity. Simulation of sill-pillar mining indicated that conditions would be most severe when pillar height was reduced to 15-20 m; mining of a sill pillar has been carried out successfully to the last 3 m, whose extraction is planned for the near future

Dec 1, 1995

By B. R. Reddy, Y. V. Swamy, B. V. R. Murthy, H. S. Ray

The Ni oxide was reduced with a CO-CO2-N2 gas mixture and the effects were observed of process variables such as roasting temperature, time and CO partial pressure. Extraction of over 90% of Ni was achieved by ammoniacal leaching of ore that had been reduced for 1 h at 760 degrees C under a gas mixture with a volumetric CO/(CO+CO2) ratio of 0.57. The kinetic data were found to conform to the Ginstling-Brounstein equation. The applicability of this model was confirmed by evaluating the apparent activation energy with the use of independently constructed differential and integral plots, which showed an excellent match

Dec 1, 1995

By C. A. Pickles, J. M. Toguri

The refining of two molten Ag-Cu alloys, containing 7.5 and 11.2 mass% Cu, with a borosilicate slag was investigated using both air and pure O2 to determine the effects of the following variables: flow rate of oxidising gas; injection time; mass of sodium borosilicate flux; and injection of the oxidising gas into either the slag or the metal. The results demonstrate that more than 90% of the Cu can be removed with Ag losses of less than 5% and that refined metal with a Cu content of less than 0.5 mass% can be produced. Ag losses to the slag increased with the amount of Cu removed, and a mechanism is proposed to account for this

Dec 1, 1995

The deposit was discovered during systematic reconstruction of the geological history of glacial overburden, which averages 6 m in thickness over 80% of Sweden, by geochemical sampling and searching for small grains of eroded bedrock. The gold is mainly concentrated in and around high-grade quartz veins within a broad shear zone, though the correlation coefficient between quartz and gold in samples is not significant. Production from two pits, now connected, in the Central and Eastern orebodies has increased steadily from 1 238 kg Au in 1989 to 2 120 kg in 1994, the highest in Europe. The mine has adapted and improved its mining methods to achieve significant productivity increases and cost reductions. Most of the improvements have been achieved through a better understanding of the controls on mineralisation and of the implications of those controls for selective mining. Geostatistics has played an important role in the quantification of grade variability and gold occurrence. Better blasting and loading techniques have improved selectivity, grade control has been enhanced by a grade-control drilling programme, and significant improvements in mineral processing have been made

Dec 1, 1995

By K. Clifton, K. Kar, M. Gautam, J. T. Jurewicz

"This paper describes the history of LDV measurements employed in research involving gas-solid flows. Much of the discussion deals with measurement techniques employed to obtain separate and simultaneous solid and gas phase velocities. Also, LDV based measurement techniques that arc used to obtain particle size and concentration information in conjunction with the velocity measurements arc presented.INTRODUCTIONThere are numerous examples of industrial processes in which the motion of a solid or droplet dispersed phase in a suspending gas phase is critically important. The applications range from spray droplets injected into combustion chambers to the understanding of the time release mechanisms of particles generated by dissolving pharmaceutical tablets. In many of these processes, the heat, mass, and/or momentum transfer between the dispersed phase and the suspending fluid arc the items of interest. In the past, much of the phenomena were characterized by empirical models derived from flow averaged measurements. Gradual developments in laser Doppler velocimetry (LDV), have provided researchers with an unobtrusive measurement technique capable of obtaining the particle size velocity and concentration with good spatial resolution.In the two decades that LDV instrumentation has been available, most of the uses have concentrated on single phase fluid flow measurements. The light scattered from seed particles small enough to follow complex fluid motions, including turbulence, is converted into velocity information. While the utility of this instrument in single phase flows has been demonstrated beyond question, the use of LDV in gas-solid multiphase flows has had a more gradual development. The measurements ·of interest in these flow regimes are usually the velocity of the suspending fluid as well as that of the dispersed particulate phase. Early investigators were quick to see the potential of this instrument for measurements in gas-solid flows. The interest soon expanded to the development of instruments that could also simultaneously measure particle size and concentration within a two-phase flow field.This paper tracks the historical development of LDV technology as applied to gas-solid flows. The techniques to measure particle velocity, size, and concentration arc treated in separate sections although much of the development occurred simultaneously. Finally, some unique applications conducted at West Virginia University and other locations will be discussed in the application section."

Nov 1, 1995

By V. A. Marple, K. L. Rubow, B. A. Olson

"INTRODUCTION Inertial classification, gravitational sedimentation centrifugation, and thermal precipitation arc techniques that can be used to collect particles for subsequent analysis or for particle classification. The inertial classifiers, which include impactors, virtual impactors, and cyclones, are widely used in the sampling or particles. Settling chambers, which include centrifuges as well as gravitational settling devices, are less widely used. Thermal precipitators arc seldom used.Impactors, in particular, have been used extensively, studied both theoretically and experimentally, and arc the instrument or choice for the determination or aerosol mass size distributions. Many versions or impactors arc available commercially and many more have been designed, built, and used in special studies.Virtual impactors are a more recently developed inertial classifier and possess a feature not round in conventional inertial impactors; namely, that the particles remain airborne after classification compared to the conventional impactor, where the particles arc collected on a solid surface. The feature or keeping particles airborne is important for transporting the particles to other particle-analyzing instruments, or to filters, and in concentrating particles larger than the cutsize in a small fraction of the total now."

Nov 1, 1995

By H. Polat, Q. Hu, M. Polat, S. Chander

"The electrostatic charge on spray droplets of ionic surfactant solutions and coal particles was measured and the results were correlated with the dust collection efficiency. When various surfactant were added, the magnitude of the droplet charge increased significantly and it was observed to be a function of surfactant type and concentration. The concentration of maximum droplet charge coincided with surfactant concentration where maximum collection efficiency was observed for these surfactants. Particles of coal also carried substantial amount of charge magnitude of which seemed to be a function of coal rank.Based on the results presented in this paper, it was concluded that ionic surfactant primarily act as a strong electrostatic charge inducer for droplets. Due to interactions between these highly charged droplets and naturally charged particles, the efficiency of droplet-particle collisions play a primary role when compared to the wetting and engulfment phenomenon which could only follow a successful collision. INTRODUCTIONWater spray are widely used to suppress airborne dust in mine atmospheres (Walton and Woolcock, 1960; Kobrick, 1970; Hamilton, 1974; Jayaraman et al., 1986). Several investigators have considered the use of surfactants to enhance the effectiveness of water sprays especially for difficult to wet particles such as those of coal (Glanville and Wightman, 1979). The capture of dust particles by water droplets involves droplet-particle collisions, adhesion of particles to droplets, and engulfment of particles into droplets. Surfactants affect these sub processes through their influence on droplet charge, surface tension, and wetting. The last two mechanism have been thoroughly studied in recent years (Walker et al., 1952; Cohen and Rosen, 1981; Glenville and Haley, 1982; Chander et al., 1988; 1991). However, little attention has been paid to the role of electrical charge on particles and droplets on the collision and adhesion of spray droplets and dust particles."

Nov 1, 1995

By V. Castranova

"A pneumoconiosis is best defined as the accumulation of dust in the lungs and the tissue's reaction to iu presence. Thus, silicosis is the name given to the fibrotic disease of the lungs caused by inhalation of dust containing silicon dioxide, primarily in the free crystalline form. Coal workers' pneumoconiosis (CWP), which was originally thought to be a variant of silicosis, results from inhalation of coal mine dust that usually contains relatively small amounts of free crystalline silica.HISTORYSilicosis is the older and more well known of these mineral pneumoconiosis. In contrast, CWP was not recognized as different from silicosis until the pivotal work of Collis and Gilchrist. 26 They noted that coal trimmers, i.e., special stevedores who leveled coal in the holds of ships at the Cardiff and Swansea docks in Wales, developed identical nodules on the chest radiograph to those of underground miners. The difference was that these men had never worked underground and that the coal was washed before it was loaded into ships; thus, it was unlikely that these men were exposed to silica. Gough54 examined the lungs of coal trimmers who died and found that the histologic appearance of the pulmonary lesions was distinctly different from the whorled nodules seen in silicosis. Gough,"" and subsequently Heppleston,"" then showed that the lung lesions in coal trimmers were similar to those in underground coal miners and different from those of classical silicosis. Nagelschmidt 78 analyzed the mineral content of miners' lungs that became available at autopsy. These studies caused him to propose a scheme in which the relative proportions of silica, other minerals, and/or coal deposited in the lungs determined the type of pulmonary response which develops, i.e., classical silicosis, mixed-dust disease, or CWP."

Nov 1, 1995

By M. K. G. Whateley, W. Hatton

Paper presented at the conference: Risk assessment in the extractive industries, held in Exeter, UK, 23-24 March 1994, and first published London: IMM, 1994, preprint volume, 20pp., 31 refs. Estimates of coal tonnage on UK open cast mining sites often vary from the recoverable tonnage. This is because the estimates depend on the geological variability of the coal measures. Geological parameters, such as thickness, quality and disturbance of the seam, have a direct control upon this variance. Risk analysis techniques have been applied using commercially available software to combine each parameter's variability into a cumulative variance, resulting in a tonnage distribution. Sensitivity modelling has also been used to identify the geological parameters which have the largest influence on the variance of the simulated tonnage distribution. An understanding of the relationship between the tonnage and geological variability has helped to focus exploration more efficiently. A cost to risk relationship can now be monitored, helping management to avoid negative consequences on site

Aug 1, 1995

By S. G. Tsimas, A. K. Moutsatsou, G. K. Parissakis, M. A. Komiotou

For Greek kaolin producers, a considerable proportion of whose output is from deposits containing more than 4 wt% Fe2O3, the colouring resulting from iron oxide impurity represents a serious problem that necessitates upgrading of the ore to meet commercial specifications. Autoclave leaching with oxalic acid for 1 h at 120 degrees C and 5-6 bar was shown to reduce Fe2O3 by up to 90% without affecting the structure of the kaolin, which maintained its physicochemical properties. The iron oxalate product can either be removed from solution or precipitated as iron hydroxide with recycling of the oxalic acid

Aug 1, 1995

By M. Gallego, R. Oyarzun, L. Ortega

Evidence of metallogenic activity in an area dominated by Upper Precambrian and Palaeozoic metasediments was partially explained in the 1980s when drilling and a geophysical survey detected hidden intrusions, but questions remained to be answered about the nature of the fluids. Sb mineralisation at El Juncalon vein-type deposit was selected for geological, geochemical and fluid inclusion studies as a model with a relatively simple quartz-stibnite-pyrite paragenesis. Many of the characteristics were those of Chinese-type vein Sb deposits, which can be regarded as atypical of the epithermal type as they are hosted by clastic rocks

Aug 1, 1995

By T. J. Serenko

The epithermal deposit is hosted by Tertiary volcanic rocks that lie between mid-Miocene normal faults of the Northern Nevada Rift. Petrographic, laser-ablation and metallurgical observations suggested that the gold occurs in two principal forms: native (and electrum) and disseminated in arsenopyrite. It was proposed that gold is distributed between two parageneses with distinct mineralogical associations. Detailed downhole geochemical study supported the observations. Concentrations of Au, Ag, As, Sb and Se were determined from drill core and reverse-circulation cutting composites and contoured on cross-sections. Gold was indeed shown to have a bimodal distribution with the two parts separated spatially and perhaps temporally, implying that two separate genetic processes acted to concentrate gold at Mule Canyon

Aug 1, 1995

By A. Ersoy, M. D. Waller

The principal factors which require consideration in predicting drilling rates are the bit-type, the bit operating parameters and the characteristics of the penetrated rock. A single index is not a sufficient basis for predicting performance. A variety of rock types were drilled in the laboratory with polycrystalline diamond compact (PDC) and impregnated diamond core bits using a fully instrumented drilling rig at different rotational speeds and with a range of weights on the bit. Quantitative determinations of a wide range of textural, mechanical and intact rock properties were also made. Multi-variable linear regression analysis was then used to develop predictive models of rates of penetration from the operating and rock property data. The models have been verified by statistical tests. The analysis indicated that the models for the pin and hybrid PDC bits have potential for practical application. However, although the model for the impregnated diamond bit appears to be reasonable from a purely statistical point of view, it may not be satisfactory for drilling uses as it is based on two measures of rock hardness alone. The application of multiple regression analysis to PDC drilling performance is novel and the technique shows promise for the prediction of rock drillability with PDC bits. The ability of the technique to provide a mathematical characterisation of the performance of new drill bits in specific rocks may prove to be of value to drill manufacturers and users

Aug 1, 1995

By B. S. Terry, C. L. Harris

Reduction kinetics from slags containing CuO(0.5), ZnO, PbO, NiO and SnO into a Cu-based metal phase were subjected to computer simulation using a previously developed model for the kinetics of metal-slag-gas reactions that assumes mass-transfer control in all phases. The effects were examined of changing bulk Fe oxide activity, gas reducing potential, temperature, Fe content of the Cu phase and metal/slag ratio. The results permit practical conclusions to be drawn about industrial slag-cleaning practice, but the model is still limited in terms of thermodynamic inputs and the idealisation of reaction conditions

Aug 1, 1995