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By S. Özgen

In this study, the possibility of beneficiation of chromite tailings in the Uckopru/Fethiye-Turkey region by a combination of hydrocyclone and multigravity separator (MGS) was investigated. The two significant operational parameters of hydrocyclone, which were diameter of the apex and diameter of the vortex, and the three significant operational parameters of the MGS, which were drum speed, tilt angle, and wash water, were varied and the results were evaluated with the central composite rotatable design. In order to produce a chromite concentrate by hydrocyclone and MGS, mathematical model equations were derived by computer simulation programming, applying the least-squares method using Minitab 15. Second-order response functions were produced for the grade and recovery of chromite concentrates.

Jan 1, 2012

By Núbia Suely Silva Santos, Alexandre da Silva Crespo, Frederico Muylaert Margem, Sergio Neves Monteiro, Anderson de Paula Barbosa, Michel Picanço Oliveira

"Environmental considerations in addition to technical, economical and societal benefits are increasingly promoting the substitution of natural fibers for glass fiber in polymer matrix composites. However, natural fibers are heterogeneous in their dimensions, specially the cross section, which plays an important role in their mechanical strength. The fibers extracted from the petiole of the buriti palm tree is a relatively unknown but promising natural fiber for composite reinforcement. In this work, a statistical analysis of the density of buriti petiole fibers using the Weibull methodology was performed. An attempt to correlate the fiber density with the diameter, precisely measured by means of a profile projector, was carried out. The results revealed an inverse dependence between the buriti petiole fiber diameter and corresponding density. Fracture tip observation by SEM suggested a possible mechanism that could justify this inverse correlation.INTRODUTIONIn the past decade polymer composites reinforced with natural fibers obtained from cellulose-based plants, known as lignocellulosic fibers, have been applied in several engineering sectors, specially the automobile industry as both interior and outside component [1-4].Environmental benefits as well as economical, social, and technical advantages are actually promoting the substitution of these lignocellulosic for the traditional glass fiber in polymer matrix composites [5]. Today several lignocellulosic fiber are being extensively investigated [6-11] and considered for reinforcement of polymer composites. Some relatively unknown lignocellulosic fiber with reinforcement potential, however, still need to be characterized aiming at future application in composites. This is the case of the fibers stripped of from the petiole of the buriti palm tree, which is endemic in the central and northern regions of South America [12,13]. Preliminary works on the possibility of using the buriti petiole fibers as composite reinforcement, has shown favorable results [14,15]."

Jan 1, 2012

By R. J. Visintainer, W. L. Whitlock

"Difficulties with the sizing and operation of centrifugal froth pumps are common and the underlying fluid dynamics are complex. Design and selection often relies on previous experience, offering unreliable guidance for novel applications or unexpected problems. The current paper describes a program of extensive laboratory testing on froth handling centrifugal pumps, covering a range of flows, heads, speeds, viscosity, air content and froth stability. Variations in impeller vane design and the effectiveness of an airlock venting apparatus were also examined. The program resulted in a better understanding of centrifugal froth pump dynamics and insight for the troubleshooting of field applications.INTRODUCTION The Challenge of Pumping Froth In pumping mineral processing froth, the handling of large quantities of air within the fluid is often unavoidable. Efforts to reduce the amount of air present at the pump suction, while always recommended for improving pump performance, may have limitations. Some strategies may also carry an economic penalty, such as unwanted process dilution (e.g. due to water spray or injection), or increased capital cost of equipment due to oversized pumps, sumps and/or piping. Froth pumping losses fall into several categories, as described below and represented graphically in Figure 1. • Density effects: Entrained air reduces the pressure created by the centrifugal pump in direct proportion to the reduction in bulk density. This is not a true “loss”, since the head produced by the pump (in meters of froth), may remain unaffected. However, the reduction in pressure often leads to a corresponding increase in pump speed required to drive the system, which itself leads to increased NPSH required by the pump (NPSHR). Furthermore, by adding a gas phase, the overall volumetric flowrate is increased, assuming a fixed quantity of de-aerated liquid being handled. This leads to increased suction velocity which further reduces the NPSH margin by simultaneously increasing pump NPSHR and decreasing system NPSH available at the pump suction (NPSHA). • Viscosity effects: Increased viscosity introduces an additional factor in some froth pumping applications, such as oil sands bitumen froth. Losses result from increased shear stress within the fluid flow, which increase with flowrate. Viscosity also facilitates the formation of airlock by reducing turbulence and allowing individual bubbles to coalesce more easily within the flow stream. Finally, it increases pump NPSHR by increasing local pressure drop in the vicinity of the vane inlet edges. • Airlock effects: Also known as air binding, it occurs when air or gas coalesces within the pump suction or impeller passages and begins to collect there, held by buoyancy forces within the rotating flow field. In essence, the liquid “floats upwards” towards the pump suction against the outward directed centrifugal forces. The airlock acts as a blockage, with corresponding reductions in flow, head and efficiency. NPSHR also increases, due to increased velocity and distorted streamlines in the flow circumventing the blockage."

Jan 1, 2012

By Nickolas Vlahopoulos, Nicholas Stowe

A concept has been proposed for the focusing of underwater energy. An array of spherical TNT charges is used to achieve this aim. The goal of the present research effort is to model such a system and identify optional arrangement and detonation timing schemes. A fast-running model is necessary to perform optimization analysis due to the highly iterative nature of most optimization algorithms. This requirement renders the use of sophisticated numerical solvers impractical. An analytical, physics-based model must be developed to satisfy the demands of the multiple charge optimization problem. This model must capture shock propagation speed, pressure-time histories throughout the fluid domain, and multiple charge interaction phenomena. Such a model is presented herein.

Jan 1, 2012

By Sudarshan Martins

The measurement of acoustic signals produced by a tumbling mill has been previously used to determine the operating state of the mill and correlate the variations of the sound intensity with the operating conditions of the mill. Separately, the discrete element model (DEM), a software simulation of the mill, was developed to provide insight into the operation of the mill. Presently, there has not been much work reconciling the DEM simulation of the mill with the acoustic signal. Working from basic principles of linear, time-invariant systems, agreement between an acoustic DEM simulation and the measured signal is sought. First, the impulse response function of the mill is measured. The DEM provides the forces applied to the mill shell as a function of time. A convolution of these simulated shell forces and the transfer function gives the simulated acoustic signal. This signal is compared to the measured acoustic signal, both in the time domain and the frequency domain. Finally, a discussion of the results is given.

Jan 1, 2012

By D. Nutakor

This paper presents the results of a study conducted on a slope failure that occurred in the Q7 mining cut at Rio Tinto's Bingham Canyon Mine. The slope failure occurred in a weak rock mass with an estimated rock mass rating of 25%. The failure mechanism was of the circular type, involving ten 15-m (50-ft) benches and covered a total width of 152 m (500 ft). The analysis used Adam Technology's photogrammetric method with a two-dimensional rock fall simulation program (RocFall software) to design a 3-m- (1 0-ft-) high berm located 7 m (24 ft) from the toe of the failed mass. Back and predictive analyses were performed on a cross-section through the slide using Slope/W software, resulting in flattening the interramp angle (IRA) from 44° to 38°. This design modification produced a factor of safety (FOS) of 1.14. Sensitivity analysis involving FOS vs. pore water pressure showed that FOS is sensitive to water saturation. A dewatering system using a series of horizontal holes drilled below the slide and dewatering holes drilled from a drainage gallery has since been established to improve the stability of the slope. Throughout the one-year period since this investigation, no significant slope movement has been detected by the slope stability radar, and mining is in progress below the failure.

Jan 1, 2012

By H. S. Price

This report discusses the development of a mathematical model that describes the flow of methane only and methane and water in a coal bed during mining operations. Because of the complex geometry, boundary conditions and fluid properties, the model is based on a numerical solution to the equations describing flow. The goals for the development of this model and requirements to which it complies are for the most part expressly stated in Request for Proposal No. 50110752. In addition to the capabilities specified under the scope of work the model can handle an anisotropic porous medium and a source term has been added which will simulate, somewhat, the effects of desorption. This term will be pressure dependent. The effect of time on such a term is only taken care of in the change of pressure with time. This source term will have the dimensions of Mcf/day/Mcf pore volume. It will be a part of the input data to be supplied by the user and will be entered as a table of rates versus pressure. These models consider the fracture system as the main porosity. All computed results pertain to the fractures. The source term mentioned above represents the flow from the matrix porosity into the fracture. Such flow should be small compared with the flow between fractures since these models handle only one porosity structure system.

Jan 1, 2012

By Ken Eltschlager, J Silva Castro, J. M. Hoffman, Braden Lusk

This case study focuses on analysis of sounds inside a house induced by blasts as result of surface mining coal in West Virginia and how to better communicate technical information to the public. The field study included a house wide vibration and sound monitoring system installed in a home which was subjected to blasts at varied distances and direction. The structure response was separated into ground vibration and airblast induced movement due to the differences in their times of arrival. This signal was then compared to the sounds recorded to determine which component of blast (ground vibration or airblast) induced the maximum sound. Findings shows that blasts at distances less than 762 meters (2,500 feet) had maximum sound responses from both ground vibration and airblast. While for blasts beyond this distance the maximum sound response was caused by ground vibration without exception. The kitchen generally created the most sound. The second phase of the study was to gauge the public’s response or preference to technical information. Three hundred and forty eight (348) telephone surveys were conducted in Logan and Boone counties West Virginia. Based on the survey, the public prefers units of pounds per square inch (psi) for airblast and millimeters of displacement for ground vibration. Ultimately a public relations plan was developed based on the results.

Jan 1, 2012

By J. Jung, W. Keller, A. Zucht

"The agitator design for nickel high pressure acid leach autoclaves (HPAL) is critical with regard to the process result, i.e., the recovery rate. Further considerations during the design phase are the avoidance of acid hot spots which reduce the lifetime, due to corrosion of the wetted parts, including components manufactured from titanium. Besides the process knowledge to design HPAL autoclaves, tools such as, Computational Fluid Dynamics (CFD) supplemented by lab testing allow the design of optimized agitation systems. This paper describes the effect that different feed point locations have on instantaneous blending of the reactants. Furthermore, experiments and CFD show where abrasion issues might occur and how to obtain information about the static and dynamic forces acting on internals. We show how simulations can be validated by lab testing to ensure that the CFD models are applied in an appropriate way.INTRODUCTIONAgitated systems in hydrometallurgical processes have to comply with multiple process tasks and in many cases have to withstand extreme operation conditions such as pressure up to 50 bar, elevated temperatures of up to 250°C and exposure to very acidic or alkaline environments and abrasive ores. The process tasks range from instantaneous mixing of reactants, homogeneous suspensions of up to 65% wt. solids with coarse and heavy particles, enhancing the solid-liquid mass transfer for leaching, dispersing large volumes of reactants (gas-liquid, liquid-liquid mass transfer) and moreover to transport generated heat e.g., from exothermic reactions through the vessel walls or internal heat exchangers if required. For economies of scale, agitator systems have reached sizes of 5000 m³ for large open leach tanks with impeller diameters of approx. 6 m, while autoclaves nowadays have exceeded 5.5 meters in diameter with a power demand for a single compartment drive between 300 - 400 kW. In parallel all process industries require a more efficient use of resources, to generate less by-products and higher yields, while ore-bodies tend to be less qualitative and new process routes (e.g. direct leach) are developed. Besides all these facts the mixing solution must be robust and economic. In this paper we want to address our approach in the development and designing of HPAL agitation equipment."

Jan 1, 2012

By Marco Sonnenschein

As time is costly, engineering companies have developed methods, procedures and mechanical equipment to tunnel faster. But the best excavation method will not be able to cope with the time pressure if there is not a reliable backup system. Therefore, the application of belt conveyors for tunnel boring machine (TBM) drives as well as for drill-and-blast driven tunnels assure a quick and smooth removal of excavated soil in order to enhance the efficiency of the tunneling equipment. During the last 10 years, belt conveyor systems have achieved ?state-of-the-art? levels and have become the first choice for muck removal systems in both TBM and drill-and-blast driven tunnels. Because time has become such a key criterion in tunneling projects, it is essential that all equipment is operated so as to derive optimum efficiency and minimize costs. Efficiency also means to think about new tasks for existing technologies.

Jan 1, 2012

By V. K. Kollipara

Air flow patterns in the face area of a room-and-pillar mining are critical for understanding the dust dispersion characteristics and for developing engineering controls. SIUC has previously performed a CFD study to analyze the airflow patterns in the face area when continuous miner is making a straight cut. Results from this study identified low air velocity and re-circulation zones in the face area and illustrated the significance of line curtain, and scrubber operation on the air flow patterns. This paper discusses similar analyses when continuous miner is making a right turn cut as it is considered to be the dustiest cut among all the cuts made to advance an entry through a crosscut. This paper presents results for box-cut development for a right hand turn x-cut. This paper also addresses line curtain advance and air leakage through the curtain on the airflow patterns in the face area for such a cut. Low air velocity and recirculation zones were identified by analyzing the velocity vectors.

Jan 1, 2012

By Kaixi Jiang, Lei Zhang, Sanping Liu, Yufang Wang, Xiaoping Zou

"Molybdenite concentrates are usually treated by roasting, but low concentration SO2 pollution is a problem. Extraction of molybdenum and rhenium from molybdenite concentrates with a pressure oxidative leaching (POX) and solvent extraction (SX) process was studied. A series of POX-SX laboratory and pilot tests were carried out on the molybdenite concentrate. In the POX stage, more than 95% rhenium and 15-20% molybdenum were leached into solution. Solvent extraction recovered the rhenium and molybdenum from the POX solution. The extraction rates of Re and Mo were above 98%. The loaded organic reagent is stripped with ammonia. The stripping ratio of Mo is more than 98%. Compared to the roasting process, the total recovery of Mo increased from 93% to 97%, and Re from 60% to 90%. In the coming five years, POX-SX technology will be competitive in China.IntroductionMolybdenite is the main resource for the production of molybdenum, and about 99% of the total molybdenum was extracted from molybdenite. Rhenium is one of the important new materials in national defense, space flights, nuclear energy and electronics, because of its high melting point, high strength, plastic properties and significant creep resistance. There are no single rhenium ores in the world; rhenium mainly co-exists with molybdenum. Consequently, molybdenite is also the main resource for the extraction of rhenium."

Jan 1, 2012

By K. Hasselwander, K. Knabel

"A significant area of Outotec’s business involves fluidized bed roasting. With several decades of experience, more than 300 reference plants and strong R&D capabilities, the company provides several industries with optimum processing solutions. Applications include oxidation and sulfation of sulfides found in copper, pyrite and zinc concentrates. Gold production and de-arsenifying roasting are also within this scope. This paper describes the latest furnace developments and includes novel trends. Moreover, hot and wet gas cleaning systems are examined focusing on unit operations related to the removal of components such as dust, SO2 for sulfuric acid production, fumes, halides, Hg, hydrocarbons, nitrous oxides and metals.INTRODUCTIONGenerally, when defining roasting processes, it can be stated that the respective primary pyrometallurgical reaction is exothermic, of gas-solid nature and relates to a value solid product. These processes are a key focus within Outotec’s scope and include: (i) dead roasting (ii) sulfating roasting (iii) partial de-arsenifying roasting and (iv) two-stage, de-arsenifying roasting.Dead roasting involves the oxidation of a given sulfide, thus allowing for a subsequent leaching process, and has been applied to producing ZnO. Dead roasting of pyrite has also been extensively utilized with a primary goal of producing sulfuric acid. In contrast, sulfating roasting involves converting a sulfide to its sulfate, enabling a selective sulfation of components, such as Cu or Co, and their separation from ferrous components during leaching (produced sulfates are soluble). Partial roasting involves partially oxidating the metal sulfide to its oxide with the simultaneous production of gaseous As4O6, which is handled during gas cleaning. The solid product, containing hardly any As, is rich in S and can be fed to a respective smelter (e.g. in the case of Cu). Alternatively, if the production of oxide is required, a dead roasting step is added after the partial roasting step, with the overall process considered as two-stage roasting."

Jan 1, 2012

By Lichao Ding, Chunhua Liu, Yunnen Chen

"In this paper the simulated acid magenta dye discoloring the reaction process was researched. The results showed that it attained highest decolorization efficiency for acidic magenta simulation dye wastewater when pH 9 and reaction time 10 min. With the initial dye wastewater concentration increased, the decolored rate decreased. The decolored rate in general kept a tendency to increase with the temperature increased. Kinetics researches showed that when pH 9, reaction temperature 20 and 35 ?, the decoloring reaction process for the dyes accorded with the First-order dynamic equation. The decoloring reaction rate constant was influenced by initial concentration of dye wastewater and temperature.1. IntroductionIn China, textile printing and dyeing industry is one of industrial departments which using more water and discharging more wastewater. There is about 7 billion tons of waste water discharge each year, of which 80% from the process of printing and dyeing. Being complex ingredients, high chroma, more toxic substances and severe environment pollution, the treatment of printing and dyeing wastewater becomes problem urgent to be resolved. The traditional treatment methods such as adsorption [1], coagulation [2], biochemical method [3,4], which has advantages of simple equipment, simple operation and mature process, but they can cause waste accumulation and secondary pollution [5,6].Magenta is a kind of organic compounds, which classified into acid and alkaline magenta. Considering the advantages of simple operation, low cost, simple experiment equipment and friendly to environment, acid magenta dyes wastewater was chose as object in this paper. Some parameters such as pH, contact time, temperature and the initial concentration on of simulative acid magenta dyes wastewater were studied."

Jan 1, 2012

By David G. Meadows

During the last decade Antofagasta Minerals? Los Pelambres Mine has dramatically increased its ore throughput following the fast initial phase ramp up through a series of planned incremental expansions. The original 85,000 mtpd, two SAG line plant was commissioned in 1999 and rapidly exceeded nameplate tonnage in only a few months. Following this, the inclusion of a pebble crushing circuit resulted in throughputs in excess of 114,000 mtpd and a recent, final third line SAG and ball mill addition have taken the plant to over 175,000 mtpd even with increasing ore hardness and changing ore feed characteristics. The progressive changes are described in this paper together with how the technical challenges have been met.

Jan 1, 2012

By Bonifacio Digay

Stawell Gold Mines (SGM) is an underground mining operation located in Victoria, Australia.The mining method employed is long hole retreat stoping, utilising up and downholes and artificial concrete pillars. Stawell is currently mining the Golden Gift and Magdala orebodies.

Jan 1, 2012

By J Silva Castro, W C. Wedding, B T. Lusk, J Calnan, E G. Morris

The emergence of electronic detonators for use in production mine blasting has enabled mining professionals to rethink the traditional blast design methodologies that pertain to timing. In many ways, electronic detonators can allow great advances in productivity, cost effectiveness, fragmentation, and safety. This paper reports on an independent study quantifying the accuracy of two electronic and two non-electric systems in which 674 detonators were tested. This research aimed to determine the accuracy of commercially available electronic detonators as compared to non-electric shocktube systems. Each system was tested over the viable ranges of delays available. Statistical models were then applied to quantify the scatter present in each system. Suggestions for the use of electronic detonators are made from the findings of this work. This work was made possible through funding from the United States Department of the Interior Office of Surface Mining Reclamation and Enforcement.

Jan 1, 2012

By T. Johnson, D. Kelley, J. Graham

"Hydrometallurgical processes can be exceptionally corrosive. Conditions associated with metal extraction and refining require materials of construction that can withstand process acids and acid chlorides at temperatures up to 90°C (194°F). Process vessels, piping, scrubbers and ducting can be rapidly compromised in these aggressive environments if not designed with care. Design engineers are challenged to find materials that can stand up to hydrometallurgical processes especially for copper, zinc, nickel, cobalt and uranium. This paper will evaluate material solutions to determine which provides attractive economics for initial procurement as well as high durability for reasonable life cycle costs.INTRODUCTIONMining activity in a number of metal ores has been running quite high over the last few years. In particular, those metals that employ acid functional extraction processes such as copper, nickel cobalt and uranium have been particularly active.The world’s largest nickel mine – the massive $4.76 billion Ambatovy nickel mine on the African island nation of Madagascar is nearing completion. When it reaches its full production capacity in 2013, the mine will produce 60,000 MT/yr of nickel and 5600 MT/yr of cobalt. Coming on the heels of the Ambatovy project is the Long Harbour Processing Plant in Newfoundland, Canada which will process the ore from Vale’s Voisey Bay mine in Labrador. Voisey’s Bay is expected to generate more than 50,000 MT/yr of nickel ore when it starts up in 2013. Next up will be the Boleo project in Mexico on the Baja peninsula. When commissioned in 2013, the $858 Million Boleo project is expected to produce 60,000 MT/yr copper, 3100 MT/yr cobalt, 36,000 MT/yr zinc and 100,000 – 250,000 MT/yr manganese carbonate.High nickel alloys and rubber lined steel have been used for decades to design corrosion resistant equipment for mineral processing environments. These materials demonstrate reasonable resistance to corrosion for most environments. Unfortunately, higher nickel alloys are quite expensive. Rubber lined steel is a bit more affordable but requires continuing service over time which ultimately drives up its cost as well. FRP (Fiberglass Reinforced Plastic) has also been used extensively in mineral processing for tanks, piping and ducting employed in aggressive environments. Today, more and more design engineers and material specifiers are calling for FRP composites for both new and replacement equipment used in the refining and processing of a variety of metal ores."

Jan 1, 2012

By Raphaël Mermillod-Blondin, Claude Bazin

"Sampling is an important step for ore body evaluation and daily plant material balances. The Gy’s equation is regularly used to assess the size of the samples to be collected and to estimate the reproducibility of the collected samples. The equation works well for iron and base metal ores but seems to produce pessimistic estimates of the gold content reproducibility for gold ores. A model is proposed to simulate the division of samples using a standard splitter and discrepancies are observed between the Gy’s equation predictions and simulated samples reproducibility for crushed gold ore. Results of the simulation show that sampling a pile of ore crushed to -2 mm should lead to more reproducible gold content than it is observed in practice and predicted by the Gy’s equation.INTRODUCTION With current gold prices above $1400 per troy ounce operators seek for new economical ore bodies. The metallurgical evaluation of an ore body is one of the numerous steps required to justify the investment for the development of a gold mine. Metallurgical testing requires to sample the ore body and to prepare the ore sample for the grinding and separation tests. The preparation implies crushing the ore usually to less than 2mm and its division into batches of a given weight for subsequent processing. For gold ore testing a batch of crushed ore is ground in a laboratory mill and leached using cyanide. Gold recovered in the solution is used as an indicator of the ore processing amenability. One difficulty associated with ore testing is due to the reproducibility of gold content measurements of the feed sample. According to the Gy’s equation (Gy, 1979; Morisson, 2009) the division of a 20 kg batch of -2 mm ore containing 5 g/t of gold into batches of 1 kg may lead to batches containing 5 ± 5 g/t of gold. For this reason the gold content of a feed sample is usually back calculated from the assays of the solution and solids residues of the leaching process. However, these two assays may contain measurement errors that can propagate through the calculation of the gold recovery. The use of the feed assays as a redundant information could add robustness in the evaluation of ore amenability to processing. This paper discusses the problem of sampling reproducibility for a gold ore. The analysis is carried out with reference to the Gy’s equation for the sampling of particular materials."

Jan 1, 2012

By M. M. Makhofane

Anhydrous zirconium tetrafluoride can be used as a precursor for the manufacturing of nuclear-grade zirconium metal. This can be done by fluorinating plasma-dissociated zircon with ammonium bifluoride in a batch reactor. This paper describes the batch process. It was proved that anhydrous zirconium tetrafluoride can be manufactured by this route as confirmed by X-ray diffraction. The process shows potential for scaling up to the kilogram scale and possibly the tonnage scale.

Jan 1, 2012