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By David Rahal, Saul Ortiz, Maria Escobedo

The general trend in the minerals industry is towards the processing of fine grained, disseminated mineral deposits. This has led to an increase in the number of fine/ultra-fine grinding installations using stirred media mills. The challenge is that both the equipment type and the mineralogy of the deposit have an effect on specific energy consumption. Fresnillo PLC recognized this issue and addressed it by providing samples for testing in a laboratory regrind system. The objective of the test program was to determine the specific energy required to achieve a product size of 10 µm (P80). A specific energy plot was generated for both a lead and zinc flotation concentrate. It indicated that 34 kWh/t and 51 kWh/t were required for the two samples (Pb and Zn respectively). This difference highlights the effect of mineralogy on the energy required for fine grinding. The regrind feed and products were submitted to a range of basic mineralogy tests to quantify the mineral differences that could have changed the specific energy requirements. These tests provided general mineralogy, documented optical textures, and provided particle size microscopy. The lead concentrate was found to contain significant amounts of silicates in addition to the dominant sulphide, pyrite. The zinc concentrate was determined to be mostly sphalerite with minor amounts of quartz, chalcopyrite, pyrite and galena. The material testing results illustrate the importance of basic mineralogy studies in conjunction with comminution testing to determine specific energy consumption.

Jan 1, 2016

By Matthew Geary, Stephen J. Marino, Jordan A. Schreiner

"INTRODUCTION Project Overview The Southeast Collector (SeC) is a new 15km long 3.0m internal diameter wastewater tunnel designed by Hatch Mott MacDonald (HMM) that twins the existing 2.6m diameter York-Durham Sewage System (YDSS) tunnel. Both sewage tunnels are located north of the City of Toronto in Ontario, Canada. The SeC provides much needed conveyance capacity for the rapidly growing York Region population, supporting development until 2036 and increasing sewage system security (Hatch Mott MacDonald and AECOM 2011). Construction of the SeC will also permit flows of the twinned section of the YDSS to be bypassed in order to clean, inspect and carry out any essential maintenance within the YDSS tunnel. Although owned and operated by York Region, the SeC spans two regional municipalities beginning upstream from the intersection of Ninth Line and Rouge Bank Drive in the City of Markham in York Region to the downstream Finch Avenue and Valley Farm Road intersection in the City of Pickering in Durham Region. See Figure 1 for the SeC and YDSS alignment. The project includes 19 shafts and chambers with depths ranging from 8 to 48m in addition to seven facilities supporting the operation and maintenance of the sewer. The construction contract was awarded to Strabag Inc. in July 2011 for $291M CAD. Construction Management services were provided by a joint venture team of Hatch Mott MacDonald and AECOM. Existing York-Durham Sewage System The YDSS tunnel was completed in 1979 and was constructed using an open shielded TBM with ribs and lagging temporary support, followed by installation of a 380mm thick unreinforced cast-in-place (CIP) concrete final lining. The YDSS sewer system has numerous connections that accumulate flows from various urban areas within York Region. The section of the YDSS twinned by the SeC flows under gravity conditions and had been putting a strain on the municipality’s potential for population and development growth having reached its maximum capacity of 420 ML/d. According to the York Region’s Water and Wastewater Master Plan, the existing YDSS would not have been able to handle wet weather flows past 2016 (Genivar and XCG Consultants 2009). The dependability of this section of the YDSS is also of concern because it is the main and critical connection between the sewer systems upstream and the downstream Duffin Creek Water Pollution Control Plant (WPCP)."

Jan 1, 2016

By R. Prioul, J. Kear, D. Chuprakov, A. P. Bunger

"Hydraulic fracture (HF) growth through naturally fractured rocks challenges the development of accurate predictive HF models. The authors present laboratory experiments differentiating behaviours associated with orthogonal and oblique intersections between HFs and natural fractures (NFs). HFs were created in sandstone and crystalline (gabbro) rock specimens, impinging orthogonally or obliquely on an unbonded machined frictional interface. Ultrasound monitoring was used to observe the rate of propagation through the interface. A contrast was observed between direct and offset crossing for orthogonal and oblique intersection, respectively. The stresses required to promote crossing depended on the intersection angle between HFs and NFs.RÉSUMÉ La propagation des fractures hydrauliques (FH) dans les roches naturellement fracturées pose un défi pour le développement de modèles prédictifs. Nous présentons des essais en laboratoire qui différencient les comportements associés aux intersections orthogonales et obliques entre les FH et les fractures naturelles. Des FH ont été créées dans des spécimens de grès et de roches cristallines (gabbro), heurtés de manière orthogonale ou oblique sur une interface machinée, non liée, de frottement. Un suivi par ultrasons a servi à observer le taux de propagation à travers l’interface. Un contraste a été observé entre un croisement direct et un croisement indirect des intersections respectivement orthogonales et obliques. Les contraintes requises pour promouvoir le croisement variaient selon l’angle d’intersection entre les FH et les fractures naturelles."

Jan 1, 2016

By Ian Orford, Ken L. Boyd

"Can the ever-increasing tonnages of ore and waste being mined today be accommodated simply by using bigger and better crushers? This paper updates the principal author’s earlier publication, “Crushing Plant Design and Layout Considerations” (SME Mineral Processing Plant Design, Practise, and Control, 2002). It reviews the latest primary crushing and large cone crusher designs. Its goal is to help consultants and operators select the optimal equipment and custom-designed items in the material handling flowsheet from the mine to the mill, maximizing operating hours per year.INTRODUCTIONAre larger crushers the answer to meeting the demands of existing or new mining projects for increased tonnage? The principal author’s previous paper in the year 2002 on ""Crushing Plant Design and Layout Considerations"" provided a detailed design and layout review for the design of primary and fine crushing (Secondary, Tertiary, Quaternary) mineral processing facilities. Some of the conclusions in this previous paper had predicted that larger crushers for primary and fine crushing would be beneficial and contribute to the further development of mineral processing. Larger crushers for primary and fine crushing applications are now available.The rock size reduction process, from the mine to the selected milling process facility has not changed since man first broke a rock to get at the interesting mineralization within. The rock size reduction process circuit from the mine to the mill can be summarized into four (4) stages:• Stage 1: Mining ( Rock Breakage and Fragmentation)• Stage 2: Pre-Screening (Scalping)• Stage 3: Primary Crushing• Stage 4: Fine Crushing (Secondary, Tertiary and Quaternary; the crushers used in this stage are identified by the titles which usage has conferred on them)Plant throughput and ore delivery schedule will form the basis for flowsheet design and equipment selection. Once a project's design criteria and the mine plan has been established, the actual circuit's utilization percentage (percentage of hours when the circuit is being utilized) can be optimized for each of the four stages. The mining and process departments are the key stake holders in the selection of the final comminution circuit and both departments should be familiar with and contribute to the design of the circuit."

Jan 1, 2016

By Hans Adden, Anne Lehan, Markus Thewes

"1. INTRODUCTION AND MOTIVATION Traditionally design processes are focussed at creating new tunnels for lowest building cost. But the trend towards sustainable constructions in tunnelling has greatly increased in recent years. A critical subtask of this approach is to realize the potential for optimizing and reducing the life-cycle costs (LCC) of tunnels and their components. To evaluate underground infrastructure projects from an economic point of view is therefore a highly topical subject of public authorities as well as private companies participating in Public Private Partnerships (PPP) projects. Nowadays, in the case of public works contracts, the contracting authorities shall draw up rules not only for the design but also for life-cycle costing. Within the scope of the decision-making process of building a new tunnel, planning the maintenance activities or the refurbishment of a tunnel in operation, the decision-makers need detailed knowledge about the current and future financial conditions of the planned projects and selected sub-measures. But in practice, the initial costs still represent the primary decision criterion in the planning phase, whereas the subsequent or follow-up costs, respectively, are only estimated roughly. Although tunnels are the key components and the most costly parts of the transport infrastructure, only a small number of scientific papers deal explicitly with the calculation of life-cycle costs for underground infrastructure. And in these cases, most authors use as the starting point only the basic form of the Net Present Value method which is known as the frequently applied life-cycle costing technique in building construction. The present study explains the strategic concept of life-cycle costing and its fundamental instruments for operational implementation. It shows the necessity to take into consideration that there are fundamental methodical problems when the life-cycle concept is transposed without modifications from building construction to civil engineering. The paper will discuss in detail some selected associated problems with the net present value method. On the basis of operational and safety related tunnel equipment it is shown, what impact this may have on principle determining the LCC of tunnels. Selected best-practices of maintenance planning for tunnels undertaken by the German Ministry of Transport fill the theoretical approach of the concept with life and give a practical orientation. In particular government authorities but also construction companies are interested parties in modern cost management considerations. The reason for this development is the replacement of aged excisting structures and the advancement of technical standards. The increase in the total numbers of tunnels (Fig. 1) as well as the need for future re-investments in existing tunnels show the overall economic impact and justify the change towards the life-cycle perspective."

Jan 1, 2016

By Baochun Wang, Hongli Jia, Zhaolian Wang, Fengliang Liu

"Promote and apply a new beneficiation technology and equipment effectively processing the refractory and medium-fine grained weak-magnetic minerals. HUATE® Forced-oil Cooling Vertical Ring WHIMS adopts the transformer oil cooling technology to cool excitation coils, solving the easily generated scaling problem resulting from water cooling, thereby to eliminate the demineralized water system. With <25 temperature ?raise, its magnetic field is stable. Wrapped by outer magnetic armor, it can generate a background intensity 1360kA/m. It effects very well in 1) wet preseparating the weak-magnetic coarse grains, like hematite, manganese ore, ilmenite, and purifying the concentrate; 2) removing the ferrous impurities and purifying the non-metallic minerals, like quartz, feldspar, kaolin; 3) enriching and recovering tailings from non-ferrous metals, like copper, lead, cobalt, molybdenum, thereby to greatly improve the mine resource utilization. It has applied 14 relative patents in China, and the invention patent in 56 countries, like Russia, USA, Australia, via PCT international organization. HUATE® WHIMS has been applied and accepted in more than 100 mines in and out of China. Compared with water cooling vertical ring WHIMS, it’s energy-saving and water-saving, and avoiding generating the scale. While compared with JONES WHIMS under the same separation indexes, it’s featured of more space-effective, lighter, lower costs, higher gradient, higher efficiency, larger processing capacity and wider grain application scope. Greatly promoting development of mineral processing technologies, HUATE® WHIMS is the equipment to reduce costs and improve efficiency urgently needed by the mine enterprises now.INTRODUCTIONAt present, influenced by the price and production factors, the international market demand for the grade of iron ores is increasing continuously. Restricted by the ore occurrence state, the beneficiation technology level and product economic value, every year the stope strips the stockpiling and discards hundreds of millions of tons of waste rocks containing iron, especially the weak magnetic hematite and limonite with <20% Fe%. The utilization technological bottleneck of these waste rocks makes their concentration ratio as high as 5-6, which leads to the huge wastes of energy, materials and beneficiation reagents and the increase of production costs. The effective solution is to improve the selected Fe% of the waste rocks like hematite. With the successful application of HPGR technologies in Chinese large iron mines, the mill feeding size has been reduced to 6-0 mm or 3-0 mm from the original 15-0 mm in the crushing system with 3 stages of crushing and 1 stage of closed circuit. This creates the conditions for the wet separation and recovery. While for the medium-fine grained weak-magnetic minerals, it lacks of the effective separation and recovery equipment in the world, which’s badly in need of R&D of the medium-fine grained high gradient wet strong magnetic preseparation equipment."

Jan 1, 2016

By M. Bunch

"THE SUPER CYCLE IS GONE The utopia of the rising sales volume, for mining companies from 2002-2011, was entirely due to rising production volume and prices. The Australian mining sector experienced an 18 percent annual growth rate in revenues, and 11 percent growth in prices. (1) However, EBIT remained flat during the same time period. In addition, Australian mines saw a 7 percent annual decline in both labor and capital productivity. (2) Mines in the U.S. and Canada produced similar results, whereas the world-wide mining industry has seen a productivity drop of 40% since 2001. (3) The decade “Bull Run” of rising prices was trashed by companies that chased low-quality assets while increasing debt on their balance sheet. It seemed everyone believed the “super cycle” would last forever, while completely ignoring the history of cycle downturns. Worldwide mining operations are as much as 28 percent less productive today than a decade ago, according to new McKinsey research. The results from McKinsey’s new MineLens Productivity Index (MPI), which adjusts for declining ore grades and mine cost inflation, show that the pronounced decline in productivity is evident across different commodities and is seen in most mining players and geographies. (4) McKinsey sees three important areas of focus to address the root causes of productivity decline. 1) Embed effective management operating systems at mines 2) Prioritized operational excellence and capabilities development 3) Focus on innovation Reality has now settled back in and companies are struggling to make ends meet. The basic management staple of controlling costs and improving the production/productivity that was lost in the excitement is now back in play. Traditional cost-cutting approaches, such as across-the-board spending cuts, layoffs, and hiring freezes are only short-term initiatives and will not permanently improve a company’s cost structure or improve long- term competitiveness. This can only be accomplished by engaging front-line employees and empowering them to make necessary improvements in their daily work. It is time for leaders to lead and develop cultures of continuous improvement within their organizations in order to sustain their mining project to the end of mine life. Successful operating managers require two different skill sets of Leadership and Management; knowing how to lead people in their organization and how to manage the work they do."

Jan 1, 2016

By T. Marcher, C. Mathiesen, M. Allende, S. Bauer

"A unique pumped hydro storage facility using the ocean as a lower reservoir, combined with solar PV to create consistent, clean power will be presented: the Espejo de Tarapacá Project is comprised of a 300 MW seawater pumped storage hydroelectric plant using the Pacific Ocean as its lower reservoir and an existing natural concavity at the desert as its upper reservoir. The plant site is located in Chile’s northern coast 90 km south of Iquique. The site is characterized by a rocky shoreline and about 600 m of flat terrain moving inland, with an abundance of rock outcrops, after which there is a steep 700 m cliff. The power house and all waterways will be underground. The main focus is to present the rocks being expected in the underground works. As one of the actual most tectonically active regions of the world the seismic activity is particularly relevant and will be outlined in the presentation. INTRODUCTION Valhalla Energy is an independent Chilean-owned power development company. It focuses on the development, ownership and operation of renewable power projects. Valhalla was founded in 2011 with the goal of developing Chile’s natural renewable energy resources and strategically diversifies the country’s energy matrix away from an overdependence on imported fossil fuels. Valhalla began developing pumped storage hydro projects to provide scalable, clean, competitive, and reliable electricity by combining Chile’s superior solar resources with the country’s unique and extensive coastline suitable for storage.The capacity for renewable energy supply is driven by two distinct and unique natural characteristics found in northern Chile: (1) the abundant and reliable solar irradiation in the Atacama Desert and (2) a coastal site that benefits from a steep cliff and a natural concavity both within a relatively small land mass (see Figure 1). There are several potential sites in the northern part of the country that can be developed. The “Espejo de Tarapacá Project” is the first one to be built and subject of the present paper."

Jan 1, 2016

By Maria Flessas, Justin Ray, Danielle Steinmetz, Brian Zuckerman

"The Ventura County Medical Center Hospital Replacement Wing project consists of the construction of a 2- to 3-story building with a basement encompassing the entire footprint and two corridors connecting the new hospital wing to existing buildings. The site is located in the Ventura Basin where strong ground shaking has been observed during moderate to large earthquakes on nearby faults. The upper 90 feet of the soil consists of loose to medium dense finegrained sands and low plasticity silts that are potentially susceptible to liquefaction, seismic densification, and hydroconsolidation. Ground settlement associated with a large seismic event on a nearby fault is estimated at 20 to 26 inches. To account for the anticipated ground settlement, auger pressure grouted (APG) piles gaining support below the potentially liquefiable soil were selected for the support of the proposed structure. Challenges for pile design included the anticipated earthquake-induced ground settlement, high downdrag loads, low soil lateral capacity during strong ground shaking, and the effect of pile installation on the performance of the existing adjacent buildings and the installed shoring system. The replacement hospital is supported on over 600 APG piles, with lengths varying between 120 and 140 feet. Axial pile capacities were verified with an extensive indicator pile installation program and dynamic pile load testing.INTRODUCTIONThe Hospital Replacement Wing (HRW) project is at the Ventura County Medical Center (VCMC) in Ventura County, Southern California (Figure 1). The VCMC consists of three interconnected hospital buildings (Buildings 303, 304, and Fainer Building), the Medical Laboratory/Cafeteria Building, two mental health buildings, a medical office building, an emergency generator building, and surface parking lots. The HRW is near the center of the campus, adjacent to several existing buildings.The HRW is a 2- to 3-story structure, with a 15- to 20-foot-deep basement beneath the entire 95,000-square-foot building footprint. The HRW project includes a Loading Dock, a four-level corridor to the Fainer Building (Fainer connector), and a two-level corridor to the Medical Laboratory/Cafeteria Building (Café connector). The corridors are structurally separated from the existing buildings. Typical dead plus live load column loads for the HRW range from about 635 kips to 935 kips and total loads range from about 860 kips to 1,295 kips."

Jan 1, 2016

By Aidan Giblett, Michael McGlynn, Peter Radziszewski

"On the basis that 99% of the energy input into a mill is converted into heat, it is possible to estimate the amount of energy captured in the slurry, the amount that is lost to the environment as well as the possible means to reduce such losses. As a result it becomes possible to estimate the potential amount of energy that can be captured by technologies such as thermoelectric generators or even Sterling engines. Furthermore, it has been suggested that the energy recovery potential dry grinding circuit could be as high as twice that of wet grinding circuits.In this paper, the energy recovery potential of dry grinding will be explored by examining the case of the Newmont Carlin mine dry grinding circuit. The paper will open with a review of the energy recovery potential of a few wet grinding applications followed by a description of the dry grinding circuit and a definition of the control volume around that circuit. A thermodynamic model will be used to estimate the circuit discharge temperature and an estimate of any losses as well as provide an estimate of the potential impact of different means to reduce energy losses. The paper will close with a discussion of the assumptions used in model development."

Jan 1, 2016

By Hong Zhong, Shuai Wang, Fangxu Li, Guangyi Liu

"The flotation performances and adsorption mechanisms of a-hydroxyoctyl phosphinic acid (HPA) to malachite, cassiterite and wolframite were investigated by micro-flotation tests and X-ray photoelectron spectroscopy (XPS) analyses. The micro-flotation results indicated that compared with styrene phosphonic acid (SPA), diphosphonic acid (DPA), benzohydroxamic acid (BHA) and salicylhydroxamic acid (SHA), HPA exhibited excellent collecting power to the three oxide ores. In addition, HPA showed superior selectivity against hematite, tourmaline, feldspar and quartz. The results of XPS analysis demonstrated that HPA reacts with active species (M) on metal oxide by formation of P-O-M or P-M bonds.INTRODUCTIONIn mineral processing, flotation has been the main process for separation and recovery of valuable minerals from complex ores (Mei, 2013; Zhou, 2014). One of the key requirements in flotation process is to increase selectively the surface hydrophobicity of the targeted minerals by surfactant (known as collector in flotation) adsorption so that these mineral particles can preferably attach air bubbles in a slurry or pulp (Bai, 2004; Hankins, 2004). To anchor a solid surface selectively, special functional group are designed to adjust the interaction between the surfactant and the active sites of solid surfaces (Wu, 2006; Huang, 2014).Organic phosphorous compounds have strong affinity toward metals or metal oxides because they form more stable metal complexes than metal carboxylates (Pazik, 2001; Zheng, 1998). In mineral engineering, phosphorous compounds have been exploited as metal extractants and flotation collectors (Alguacil, 2002; Sun, 2008). Ni (2012) and Zhang (1998) introduced diphosphonic acid (DPA) as an effective collector for flotation of fersmite and niobite. Liu (1999) found styryl phosphonic acid (SPA) was a superior collector for flotation recovery of finely disseminated rutile ores. Gruner and Bilsing (1992) thought SPA was one of the best collectors for flotation recovery of cassiterite which could obtain a high-grade concentrates of more than 40% with high recovery values. Bulatovic (1999) investigated the flotation performances of phosphoric acid ester (PAE) to perovskite, ilmenite and rutile and found that PAE was an impactful collector for selective flotation of titanium minerals from complex ores in the presence of petroleum sulfate. However, a-hydroxyoctyl phosphinic acid (HPA) as a flotation collector for recovery of titanium ores were hardly reported in the previous literatures."

Jan 1, 2016

By Yuki Tsunazawa, Shuji Owada, Sho Fukui, Chiharu Tokoro

"Since the amount of e-waste has been rapidly increasing all over the world, there is a desire to develop the effective recycling process. E-waste has various kinds of electronic components with valuable and/or hazardous materials. Recycling of them is an important subject from the viewpoint of both the recovery of valuable materials and waste treatment. In common with all mineral processing, the comminution of e-waste is a key process because the liberation states after comminution determine the overall efficiency of metal recovery. Since some of useful critical metals are concentrated in a specific component, a special and selective grinding is expected to be effective. However, the knowledge about the mechanism and the effectiveness of the selective grinding is still limited and unclear.To better comprehend the mechanism, in this study, the investigation of comminution process using the particle-based simulation was conducted. Especially, this study focused on the comminution performance of printed circuit boards (PCBs), which are major components of e-waste. The behavior of PCBs and airflow in a drum typed agitation mill having flexible chains was simulated by the discrete element method (DEM) coupled with computational fluid dynamics (CFD). To model the shape of PCBs, the particle based rigid body model was introduced into the DEM. Since this model could not directly simulate the breakage phenomena, collision energy was calculated to qualitatively evaluate the comminution performance. In addition, the simulation results were compared with the experimental comminution tests using simulant PCBs where some capacitors were solder-mounted. These results indicated that comminution performance was affected by the rotation speed of the agitator. It was also demonstrated that the comminution performance was qualitatively evaluated using the particle-based simulation and this particle-based simulation made it possible to investigate the mechanism of e-waste comminution."

Jan 1, 2016

By Timothy Nelson, Simon Burnworth

"The Berkeley Art Museum and Pacific Film Archive (BAMPFA), which currently resides in a 1970s-era post-modern concrete structure just south of the University of California, Berkeley campus, was in need of a new home after an engineering evaluation revealed that the building possessed seismic deficiencies. Pressed for space, the University looked within its portfolio of properties and identified the site of the former University Printing Press facility as the place to build BAMPFA’s new home.The site was perfect; located one block east of bustling downtown Berkeley and its rapid transit station, and directly across the street from the western entrance to the UC Berkeley campus. Thousands of pedestrians pass by the site on a daily basis, thus granting BAMPFA the opportunity to reshape the corner of Center and Oxford Streets with a building that would not only welcome visitors to campus, but also serve as a creative hub for both the City of Berkeley and the UC Berkeley institution itself 1.The original museum plans, drawn up in the mid-2000s, called for complete demolition of the existing abandoned facility and replacement with a visually stunning structure designed by renowned Japanese architect Toyo Ito. Even at this point, the shoring and means and methods requirements of the project were identified as a challenging component, incorporating a shored excavation bounded on three sides by busy city streets and a fourth side by an operating bank and occupied apartment building. Furthermore, a sequenced demolition would be required for the printing press facility’s three-story Administration Building (also known as the Admin Block), one-story printing press warehouse (also known as the Press Building), and an adjacent parking structure. Degenkolb Engineers was retained at that time as the shoring engineer to design the shoring to facilitate this work."

Jan 1, 2016

By T. Thriveni, Ji Whan Ahn

"The current advanced technologies for the manufacture of light weight metals processing significantly increasing and attributes to the safety, performance, recyclability and economy. Still lack of technologies developed for light weight metals processing waste utilization and application. Environmentally friendly methods need to develop for better understanding the processing waste utilization. Alumina and aluminium processing creates a wide range of waste products, the most significant being is red mud. Bauxite residue is a high volume hazardous waste and nearly 3 billion tons have been dumped worldwide. Approximately, 120 Million tons/yr of red mud being produced without any environmental sustainable solution. Currently the most significant technology is waste utilization. The bauxite residue is suitable for road base construction, golf bunker sand, back fill and, general fill. Sustainable recycling technologies are necessary for the bauxite residue utilization for the recovery of rare earth elements and cement materials. Carbonation or CO2 sequestration of carbon dioxide is a method pioneered for the bauxite residue is modified to reduce alkalinity. The carbonation of alkaline material is an inexpensive and safe process that leads to the formation of thermodynamically stable products. The use of the carbonation can be an advantageous solution for environmental climate change and sustainability problems in the new century.INTRODUCTIONIn 2014, bauxite consumption was estimated to be 9.6 million tons, nearly all of which was imported, worth an estimated 269 million dollars. More than 95% of the bauxite was converted to alumina, and the remaining 5% went to non-metallurgical products, such as abrasives, chemicals, proppants, and refractories. Global aluminum demand is growing steadily spurred by growth in India and China (RBCAluminum Market Outlook, 2013) (Figure 1). Aluminum consumption is expected to rise 5% annually through the end of the decade, reaching 67 million tons per year by 2020. Global bauxite production decreased by 17% from that of 2013, principally owing to lower production in Indonesia. In response to a Government ban on exporting bauxite and other unprocessed mineral ores that took effect on January 12, 2014, bauxite mines throughout Indonesia shut down and production decreased from 55.7 million tons in 2013 to an estimated 500,000 tons in 2014. The ban was part of a mining law that was instituted in 2009 to increase development of downstream processing facilities in Indonesia."

Jan 1, 2016

By Bahri Öteyaka, Ali Uçar, Oktay Sahbaz

"A Jet Diffuser Flotation Column (JDFC) is a newcomer flotation device whose operation principles similar with Jameson cell but it has an essential change in downcomer. By taking into account the hydrodynamic and fluid mechanic principles (Sahbaz et al. 2013) downcomer was changed as a diffuser, therefore turbulence at the end of the downcomer was reduced to provide better aggregate stability and homogenous dissipation of the bubbles in the separation tank. Thus the performance increase has been aimed for the coarse particles.According to theoretical results, obtained by the formula of Oteyaka (1993) showing the relationship between velocity gradient and maximum floatable size for the various contact angles, the d50 of quartz flotation of JFDC is about 240 µm and 310 µm for the contact angle of 50° and 60°, respectively. This result was verified by the experiments. According to the experimental results; d50 which was accepted the maximum floatable particle size of quartz flotation of JFDC was about 256 µm and 300 µm for the contact angle of 50° and 60°, respectively.INTRODUCTIONFlotation is a kinetic process used for separation of hydrophobic particles from hydrophilic particles. There are many different parameters affects the success of the flotation and particle size is one of them. While the flotation is very efficient for intermediate size, the efficiency of the process starts to decrease for both fine and coarse sizes (Trahar, 1981; Muganda et al., 2011). Therefore; researchers have tried to find a solution for the efficiency decrease in fine and coarse sizes by modifying the chemical condition and designing the new devices. For example, Jameson cell is a unique device for the fine particle flotation due to the suitable design and fine bubble producing (Jameson, 1988; Evans et al., 1995; Sahbaz, 2010). Because of this success operation the Jameson cell is applied more than 200 flotation plants in worldwide. On the contrary, the efficiency of the cell decreases for coarse particle flotation due to the turbulence occurred in the separation tank (Sahbaz, 2010; Cowburn et al., 2007). That’s why, new flotation device was designed in loboratory scale by Sahbaz, Oteyaka and Ucar in 2010s and it has been called as Jet Diffuser Flotation Column (JDFC) recently."

Jan 1, 2016

"In today’s world of complex projects, where engineering and execution are supported by a high level of project management and systems, how critical is the human factor in design engineering. Based on his involvement on a variety of projects, Tony Lipiec will relate his experiences as the impact of 4 factors: the ‘team’ involved in the design and execution of the project; the project and information systems supporting the project; the impact of scope, time, and budget; and finally the selection of the proper success criteria to judge the project and the people who have enacted the project.The discussion of the team will relate to the quality of people and the impact of their knowledge, attitude and experience. It will also look at the relationships and interests of the various stakeholders. Decision making and taking responsibility will be discussed.Supporting the team are the management, document and information systems. The value that these systems bring to the project as a whole will be examined. How project size impacts the applicability of the systems will be discussed.Scope, time and budget are recognized as critical. Reference will be made to the interplay between these components which are vital to project success. The issue of iterative design and whether it is necessary will be considered together with the development of supporting technical information.Finally the selection of the proper success criteria and the awards provided to the team can have a big impact on the final, production success of the project. The author will discuss his views on the impacts of these on EPCM projects."

Jan 1, 2016

By V. G. Minenko, A. L. Samusev

For efficient leaching of gold from sulfide ores and the oxidation of sulfides into sulfates, it is necessary to introduce a substantial amount of oxidant - atomic oxygen, hydrogen peroxide, ozone, potassium or sodium hypochlorite. In this paper, hypochlorite electrochemical treatment is proposed as an effective method of intensification of refractory ore leaching. The objective of the study is to increase the gold recovery from refractory ores with the application of chlorinated solutions that are modified by chemical or electrochemical treatment. The advantages of the use of the modified chlorinated solutions instead of cyanide for gold-sulfide leaching are considered to be the following: a high concentration of the oxidizing agent (hypochlorite ions) in solution helps to achieve a high speed of gold dissolution in the form of chloride complexes; the possibility to produce hydrochloric acid solutions that may be used for the recovering gold by electrolysis; the possibility of the processing of carbonaceous, arsenic-bearing and others kinds of refractory gold ores. The mechanism of the interaction of the modified chlorine solutions with gold-bearing sulfides (pyrite and arsenopyrite) was investigated. The efficiency of the application of chemical and electrochemical leaching method was proved. The main factor that limits the rate of gold dissolution is a high concentration of sulfate ions (SO4 2-) formed in the solution by the oxidation of sulfide minerals. The optimal parameters of chemical and electrochemical leaching method and effective ways to remove sulfate ions were determined. The method helps to increase the level of the gold recovery up to 87% from refractory ores. The intensification of leaching by chemical and electrochemical treatment opens up opportunities for the creation of modern efficient and environmentally-friendly technologies that may be applied for gold extraction from refractory gold ores.

Jan 1, 2016

By Jerry Gagnon, Matt Burr, Timothy Ellis, Abbas Mirza, Larry Webb

"The mechanical properties of RSR anode alloys (lead-calcium-tin, 009+ and lead-strontium-tin) were investigated as a function of time with an objective of developing lead anodes for use in high temperature electrolytic processes such as in copper liberator cells and in cobalt and nickel electrowinning. At a temperature of 70 oC, the mechanical properties of rolled RSR lead-calcium-tin (PbCaSn) alloy currently used in copper electrowinning decreased gradually while the mechanical properties of rolled RSR lead-strontium-tin (PbSrSn) decreased relatively quickly and stabilized at low strength levels. Cast PbSrSn started off as the weakest alloy but its properties remained stable with time. Rolled RSR 009+ anode alloy showed improvement in ageing properties over the other alloys tested. However, its mechanical properties did not stabilize in the study timeframe of 284 days. Further investigations are planned to study the effect of alloying elements on mechanical properties of RSR 009+ anode alloy over several years as a function of time at 70 oC. The mechanical properties will be evaluated to determine the time at which they stabilize. Comparative plant trials with rolled RSR PbCaSn and RSR 009+ will also be performed in copper liberator cells and in cobalt and nickel electrowinning tankhouses to determine their mechanical and electrochemical performance at temperatures of 65-75 oC.INTRODUCTIONLead-based alloys are the primary anodes used in the electrowinning of copper, zinc, nickel, cobalt and manganese from sulfate-based aqueous systems. Lead anode technology has evolved over the years migrating from pure lead and lead-antimonial alloys to the present day PbCaSn alloys for copper and PbAg and PbCaAg alloys for zinc electrowinning (Prengaman, Ellis and Mirza, 2010). It has also migrated from cast to rolled microstructures in search of improved mechanical properties and higher corrosion resistance. Although great strides have been made in the development of new lead anode alloys and production processes for lead anodes to be used in copper electrowinning, the industry still has some unresolved issues. These relate to the necessity of having higher mechanical properties especially for the lead anodes in liberator cells in copper electrorefining and for cobalt and nickel electrowinning as these tankhouses operate at temperatures of 65-75 oC compared to 40-45 oC in case of copper electrowinning."

Jan 1, 2016

By K. E. Waters, J. E. Nesset, F. Rosenblum, J. A. Finch, S. Moon

"Some materials when exposed to various conditions can exhibit a rise in temperature without requiring an external heat source. Generally referred to as pyrophoric or self-heating substances, they challenge the safety of materials handling, storage and transportation. Reliably assessing the self-heating potential of materials is thus essential. Over the years a number of test protocols have been developed. A widely accepted method is that recommended by the United Nations to certify the safety of shipping pyrophoric goods. Our test work on sulphide materials has shown that the U.N. test can give false negatives if the sample oxidation history is not considered. Depending on the degree of oxidation (“weathering”), the same sulphide material can exhibit self-heating ranging from safe to hazardous. For concentrates, oxidation can occur during storage and transport making the sample weathering history an important consideration in the test work. To make the U.N. test, and other single-stage self-heating procedures, more reliable in assessing self-heating potential when testing sulphide materials, it is suggested that a weathering step be incorporated in the test protocol. This test work for two sulphide samples, an ore and a concentrate, demonstrates the impact of incorporating a weathering stage in the test protocol. INTRODUCTIONSelf-heating occurs when exothermic reactions produce heat faster than can be dissipated to the surroundings. Numerous substances self-heat, ranging from wood chips and powdered milk to coal and sulphide minerals (Beever & Crowhurst, 1989; Hudak, 2002). Mixtures of sulphide minerals, most notably those containing the iron sulphide pyrrhotite (Fe(1-x)S), commonly encountered in the extraction of base metals (e.g., copper, zinc, lead, and nickel), are particularly prone to self-heating (Rosenblum, Nesset, & Spira, 2001; Payant, Rosenblum, Nesset, & Finch, 2012). In the mining and subsequent processing stages, the minerals are progressively liberated and finely ground, then separated, usually by flotation, with the resulting concentrates stored and transported to smelters for metal extraction. At most of these stages the sulphides are exposed to both moisture and oxygen, conditions that promote partial sulphide oxidation and the formation of elemental sulphur. Studies have shown that pyrrhotite, in particular, readily oxidizes to form elemental sulphur (Bernier & Li, 2003; Belzile, Chen, Cai, & Li, 2004; Somot & Finch, 2010). The elemental sulphur becomes fuel for further self-heating as the temperature of the mineral mixture increases above 100 oC (Rosenblum & Spira, 1995; Somot & Finch, 2010). It is believed the propensity of pyrrhotite to self-heat is a result of its iron-deficient, and hence somewhat unstable structure. It is worth noting that pure metal sulphides (with the exception of pyrrhotite) do not exhibit appreciable self-heating. A mixture of minerals sufficiently different in their electrochemical rest potential is required to initiate self-heating at ambient temperatures (Payant et al., 2012)."

Jan 1, 2016

By Ke Yang

"Engineering practices have shown that the skip-fault longwall mining is frequently used when faults with offsets larger than 1 Om are present. Since the skip-fault longwall mining not only reduces the recovery rate of coal reserves, but also increases the cost due to developing another setup room on the opposite side of the fault and moves the longwall into it. The coal pillar so created induced residual stress in and thus affects the safe mining of adjacent coal seams. In order to investigate the influence on panel layout and retreat by a l 6.5m offset normal fault, the similar material simulation model was constructed based on the geological and engineering conditions of No.13 coal seam in the western district of Liuzhuang coal mine employing the down-dip longwall mining. The characteristics of deformation, movement and failure of the overlying strata and abutment pressure when the face cut through the hangingwall and footwall of a normal fault were obtained. There were significant differences between the hangingwall and footwall as conformed by the equilibrium structure model. The results showed that superposition of the tectonic stress from a normal fault of large offset and that induced by mining is one of key factors that lead the severe pressure difficult to control during panel retreating from the hangingwall to footwall. Accordingly, the technical solutions for a fully mechanized mining face directly cutting through the fault are presented and optimized, and the applications of the technical solution in Panels 171301and171303 of Liuzhuang mine enabled them to complete the mining safely and efficiently. INTRODUCTIONFaults have been one of the important technical factors in underground coal mining l1-2i. Engineering practice has shown that the methods of mining through the faults depend on the seam thickness, seam dip angle, offset of fault throw, equipment height, rock strength, and advancing direction l3-5l. In the fully-mechanized longwall mining, the face normally proceeds to cut through the fault directly if the offset of the fault less than 5m, and to skip Uump) the fault if the offset is larger than 5m. In the former case, the most important problem is to efficiently control or avoid roof fall accidents (i.e., crushing, falling, pushover, and rock burst). In the latter case, the most important problem is very expensive to drive a new setup room and move the face equipment to it. The skipped coal pillar may poses problems for mining in adjacent seams."

Jan 1, 2016