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By Yijun Caoa, Xiuxiang Taoc, Zhongbo Hub, Yinfei Liaoa

A new preparation scheme for a difficult-to-float coking coal from the Kailuan Mine, Tangshan, China was investigated. The results showed that grinding followed by column flotation was beneficial for obtaining products with low ash content. The positive effect of grinding on the coal floatability is attributed to the liberation of intergrowths and coal surface improvement. Tests indicated that 10 minutes was the optimum grinding time, and over grinding resulted in a deterioration in flotation performance. With a grinding time of 10 minutes, conventional flotation had potential to yield a product with around 12.42% ash content and 69.15% combustible recovery. Column flotation can reduce the product ash content to 11.15%and increase combustible recovery to 74.47%. Consistently better flotation results reveal that column flotation is more efficient than conventional flotation for such fines.

Jan 1, 2015

By J. H. Zietsman, S. Maharajh, J. Muller

In the chlorination process for TiO2 pigment production, blends of titania feedstocks such as ilmenite, synthetic rutile (SR), natural rutile, upgraded slag, and chloride-grade slag are reacted with coke and chlorine at a temperature of around 1000°C to form TiCl4 (the main product) and other waste metal chlorides. The TiCl4 is the main feed material for the TiO2 pigment-making process. Feeding different titania materials to the chlorinator affects the amount of coke and chlorine required for the process, the amount of waste generated, waste disposal costs, the amount of TiCl4 produced, and bed build-up rates. These factors influence the value of the feedstock. Generally, a higher TiO2 feedstock is more valued since less waste is generated and less reagents are consumed. To quantify the impact of different feedstocks on the chlorinator, a techno-economic model was developed to describe the chlorination process and estimate process variables at steady state. This paper describes the development of the model and studies in which the model has been used to quantify effects of using different feedstocks.

Jan 1, 2015

By Yang Jun, Qu Mei, Zheng Yao-wu, Chi Li-yuan

Due to the necessity of the prediction of blasting seismic effect around strip mine bench blasting area, the paper provides a method to predict the blasting seismic effect by employing the superposition of seed waveform at different monitoring points. The method assumes that blasting vibration waveform per hole is similar to seed waveform at monitoring point. Therefore seismic wave consists of the superposition of the waves from all of blast holes. Firstly, via sensors multiple seed waveforms can be achieved at different distances from signature hole. Then, by using the given dose and the distance, the vibration waveform of a certain blast hole can be calculated by the corresponding seed waveforms. Finally, the initiation delay time interval per hole is added to the propagation time to the predicting point. The predictive waveform at the whole blasting area can be obtained by superimposing all of the single waveforms. Considering the vibration waveform of a single blast hole changes greatly with the distance, under different distances condition the seed wave employed to superimpose is achieved from the similar distance. The experiments demonstrate that based on the method the predictive vibration waveform and spectrum are basically consistent with monitoring results around near-field blast. Compared with single seed wave method, the superposition method of multiple seed wave is more reliable to predict the duration of blasting vibration, the peak particle velocity, dominant frequency and frequency distribution.

Jan 1, 2015

By T. Tsutsumi, S. Kukino

"During the diametrical compression test, the tensile stress generated near the loading plate is influenced by the contact area between the loading plates and specimen. However, very few studies have determined the contact area. Theoretical or analytical models have shown that for an orthotropic material (i.e., with material properties that differ along each of three mutually orthogonal twofold axes), the maximum tensile stress is generated at the center of disk when the angle of the principal material direction to the loading direction is close to ?/4. The maximum value is almost constant, regardless of the contact area. Conversely, the maximum tensile stress is generated near the loading plate when the angle between the principal material direction and loading direction is small. The maximum value decreases as the contact area increases. Therefore, in the latter case, the influence of the contact area on tensile strength measurement of is significant.In previous studies, the distribution of stresses applied on the loading plate is assumed to be a uniform load. In reality, the applied stress is highest at the center of loading plate and seems to decrease with distance from center. The applied load disappears at the edge of loading plates. In this study, in order to satisfy this boundary condition on the loading plate, the cosine curve is adopted as the distribution of load applied on the loading plates in a theoretical model of the diametrical compression test. Furthermore, the elastic solution using boundary conditions shown in this study is used to obtain the tensile stress distributions on the loading axis for an orthotropic circular plane. These distributions are compared with empirical results obtained under uniform loading with a loading plate or concentrated loading in previous studies."

Jan 1, 2015

"Mine ventilation is in every underground mine a crucial process to ensure mine safety as well as acceptable working conditions. On the other hand is also a major cost factor depending on air requirement and air resistance. Due to the fact that the special layout of mines develop over time, ventilation systems change as well. This may result in complex systems which are suffering severe problems and low efficiency. With attention to the mine safety and costs, ventilation systems have to be controlled repeatedly and optimized continuously to fit changing conditions. The project “Improvement of ventilation systems in narrow vein mines” has been commenced with measuring and data collection in the Bogala Mine, Sri Lanka. This over 150 year’s old graphite mine consists of about 20 levels. The resulting ventilation system is highly complex and suffers problems like high temperatures and humidity as well as a mixing of fresh and used air on lower levels. To solve these problems and to optimize the system the complete ventilation system had been measured on-site first. The gained data have been used for simulations to develop and select an optimal and cost efficient solution. OBJECTIVE As an important process in mining ventilation is a major cost factor and can determine the economic feasibility of a mine. Due to the production mine layouts develop over time and mines increase in size and depth while the ventilation system becomes more complex and may suffer severe problems and inefficiency. Therefore mine ventilation systems have to be controlled and optimized regarding the general requirement of mine safety and health of the miners as well as the costs. Depending on the deposit type, depth, mining method, climate and as well corresponding laws and regulations the possible solutions are varying strongly. The work carried out paid special attention to the improvement of ventilation in narrow vein mines in tropical climate, in this case the graphite mine “Bogala” in Sri Lanka, South Asia."

Jan 1, 2015

By Jun Ohbayashi, Yoshiyuki Yagiura, Hiroaki Miyatake, Masuo Kondoh, Naotoshi Shinkawa

"Reducing the improvement ratio of ground improvement is an extremely efficient way to reduce the construction cost and construction period of mitigation measures for soft ground. The Arch Action Low Improvement Ratio Cement Column (ALiCC Method) is one method for this, and it is being increasingly applied to sites. This method enables us to rationally evaluate the embankment loads that are acting on cement improved soil columns and unimproved ground, by considering the arch action generated in the embankments and from there thusly allocate improved soil columns in spans of a greater distance than those needed for conventional methods. As a result, it serves to reduce construction costs and the construction period, while also minimizing the settling of the embankment and differential settlement, by placing numerous improved soil columns in the ground immediately beneath the embankment at equidistant intervals. In this report, we give a basic overview of the ALiCC Method, report typical construction results from real life cases that have been carried out, and make comparisons with other construction methods in order to report on the effectiveness of this design method.OVERVIEW OF ARCH ACTION LOW IMPROVEMENT RATIO CEMENT COLUMN (ALiCC) METHODIn the area of mitigation measures for soft ground, a significant role is played by ground improvements using improved materials such as cement. For this reason, a reduction in construction costs and construction period required for ground improvements has become of greater importance. The Public Works Research Institute carried out joint research with Kiso-Jiban Consultants Co. Ltd., Kitac Co. Ltd., and Fudo Tetra Co. Ltd. over a period from 1998 through 2002, and, from that, developed the ""Arch Action Low Improvement Ratio Cement Column Method"" (hereinafter referred to as the ""ALiCC Method"") that enables ground improvement with a lower improvement ratio (the improved area ratio is approx. 10% to 30%) than is required for conventional methods, while also ensuring stabilization and minimizing the settling of embankments.In the area of mitigation methods for soft ground by deep mixing, the dominant method until now has been that (50% or more of improvement ratio) shown in Fig. 1. This method comprehensively improves the area under the face of the slopes of both sides of the embankment. This is based on the calculated stability against rotational slip, which states, ""the most effective way to ensure the stabilization of the embankment environment is to carry out improvements of the area under the face of the slope."" Therefore, for the area under the face of the slope, ground improvement by deep mixing was done, and for the soft ground in the area under the middle part of the embankment, accelerated consolidation methods (hereinafter referred to as ""conventional method"") such as sand draining method and paper draining method were used. Mitigation measures that combine these improvement methods have also been mainstream for a long period of time and are used to prevent side deformation around the embankment. However, there have been some problems that have occurred, such as a situation where consolidation settling occurs in the center area under the embankment where no improvement had been carried out. This phenomenon leads to a situation in which the improved soil columns in the area under the face the of slope are pushed to the outside, which results in side deformation occurring around the area of the embankment, and additionally the occurrence of a step due to a situation of differential settlement between the improved ground and the consolidation advancing part, which results in cracks in the embankment."

Jan 1, 2015

By A. M. S. Hussein, B. E. Rogers

Progressively more stringent emission limits and advances in regulations and enforcement have made air compliance more difficult for metallurgical facilities. This has historically required improved collection and treatment of stack sources. Fugitive emission reductions are now increasingly required to achieve compliance. Typically small in magnitude, fugitive emissions have a disproportionate impact on ground level concentrations, can be visible to the public and can influence workplace health and safety. Moreover, these emissions are complex, as they are spread over multiple sources, distance and time and are affected by various activities and conditions. As such it is difficult to find, define and monitor these emissions and their impacts. This difficulty translates to the design of emission reduction measures and operational requirements. This paper presents an overview or ‘heuristic’ of fugitive emissions management for compliance in existing operations. This includes aspects such as the impact of regulations on project scope, approaches to developing a comprehensive emission inventory, considerations for solution development and the plant’s role in sustaining compliance once achieved. Case studies are presented to demonstrate how portions of this approach have been applied.

Jan 1, 2015

By T. Brozell

"Communities near sand mines and processing facilities in Wisconsin have raised concerns regarding possible exposure to ambient respirable (PM4) crystalline silica. Fenceline PM4 (particulate matter captured with a 50 percent cut size of 4 micrometers aerodynamic diameter) crystalline silica concentration data were compiled at Fairmount Santrol Inc., Mathy Construction Inc. and U.S. Silica facilities. The long-term average PM4 crystalline silica concentrations ranged from 0.05 to 0.45 micrograms/m3 when sample values below the limit of quantification were treated as zeros. All of the long-term average concentrations were less than 20 percent of the Minnesota Department of Health’s and California Office of Environmental Health Hazard Assessment’s PM4 crystalline silica chronic reference exposure level of 3.0 micrograms/m3. The measured concentrations were consistently within the local background concentration range.Air Control Techniques P.C. compiled the sampling data using Thermo Fisher Scientific Inc. Partisol 2000i PM2.5 samplers meeting the requirements of 40 CFR Part 50, Appendix L. These samplers were adapted to capture particulate matter with a 50 percent cut size of 4 micrometers. The use of polyvinyl chloride filters allowed for crystalline silica X-ray diffraction analysis by NIOSH Method 7500. The combined use of adjusted PM2.5 filter-based samplers with Method 7500 crystalline silica analyses provided for a highly sensitive limit of quantification of 0.31 micrograms/m3 of PM4 crystalline silica.BackgroundIn 2005, the California Office of Environmental Health Hazard Assessment (OEHHA, 2005) adopted a 70-year chronic reference exposure level (REL) for PM4 (particulate matter having aerodynamic diameter of 4 micrometers or less) crystalline silica. The REL was extrapolated from occupational hygiene epidemiological studies, essentially all of which were based on in-plant PM4 crystalline silica measurements. No well-established ambient sampling technique for PM4 crystalline silica was available at the time that OEHHA adopted its REL. The personal samplers used for the National Institute for Occupational Safety and Health (NIOSH) Method 0600 in-plant sampling of employee exposure were designed for concentrations higher than ambient levels. The limit of quantification (LOQ) of PM4 crystalline silica on NIOSH 0600 filters was too high for the effective sampling of ambient air."

Jan 1, 2015

By Thomas Hauquin, Olivier Deck, Yann Gunzburger

"In this study, 2D numerical modeling of a room-and-pillar mine is conducted along with the calculation of all terms of the mechanical energy balance. Simulations of different geometrical and geomechanical configurations are performed in order to investigate the conditions that favor a high seismic energy release (instability) during the excavation (removal) of one single pillar. At first, classical stressstrain simulations enable us to estimate the elastic and quasi-static response of the mine. Then, owing to the implementation of new functions in the modeling code, the seismic energy released when the pillar is removed is calculated. The obtained values are found to be in agreement with those calculated analytically using a modified energy balance based on the works by Cook (1967) and Salamon (1984).It is shown that the mine’s proneness to release large amounts of seismic energy, after sudden removal of one single pillar, mainly depends on three parameters: the initial extraction ratio of the mine, the depth of the exploited seam and the Young’s modulus of the surrounding rock mass compared to that of the ore. Moreover, it is pointed out that the magnitude of the seismic energy can be greater than that of the stored elastic energy, meaning that the dynamic (seismic) transient stresses should not be neglected when compared to the quasi-static stresses, particularly when trying to prevent the risk of rockburst and collapse in underground mines."

Jan 1, 2015

By K. Neumann

"INTRODUCTION For many automation and safety tasks in open cut and underground scenarios it is crucial to have highly reliable distance measurements at hand. These measurements can for instance be used to obtain the exact position of a machine in one-, two- or even three dimensions. Research and development has shown interest in the ultra-wide-band technology (UWB) in recent years. While for this technology short range, high speed data transfer is the current main research focus, the technology can also be used for highly accurate ranging applications. Due to the use of a very wide frequency band, it is robust against disturbances of many types (e.g. EMC, rain, dust etc.) and is therefore attractive for the use in mining applications. The wide frequency band also offers benefits for ranging applications. Especially in environments with strong multipath problems such as in underground mines it is possible to focus on the dominant signal propagation path, thus increasing the reliability of the measurements. [1] State-of-the-art UWB ranging equipment claims precision within the range of a couple of centimeters and working ranges of more than hundred meters. At the Institute for Mining and Metallurgical Machinery (IMR) at RWTH Aachen University in Germany a modern UWB system was examined in several laboratory and real life tests to examine the feasibility of UWB bases ranging equipment in mining applications. UWB TECHNOLOGY The term ultra-wide-band denotes radio systems that use an ultra-wide frequency band. A common definition for UWB radio systems is that it needs to work on a frequency bandwidth of more than 500 MHz or a bandwidth equal to 20% or more of the center frequency [1]. Due to the ultra-wide frequency bandwidth UWB systems overlap the frequency spectrum of narrow band radio technologies like Wi-Fi, Bluetooth and other mobile communication systems which use a defined carrier frequency onto which information is modulated on (e.g. by using frequency or phase modulation). In order to not conflict with these other radio applications, it needs to be ascertained that the transmission power of a UWB system on a given frequency is so low that narrow band systems are not affected by it. As opposed to this only a small fraction of the UWB system’s bandwidth is affected by the narrow band system. The unaffected remaining bandwidth is sufficient to reconstruct the original signal, even if additional noise is present. Figure 1 shows the power spectral densities of popular radio standards [6], [7], [8]. A significant driver of research and development of UWB systems has been wireless high bandwidth communication. Using an ultra-wide frequency band is highly desirable here, as the channel capacity is dependent on the bandwidth. So far systems have been realized especially for short distances (e.g. wireless USB or Wireless HDMI) but beyond that, communication systems for long distances (several kilometers) are possible [2]. Advances in semiconductor technology led to a reduction in power dissipation of such systems. This enabled higher integration levels which in turn facilitated smaller solution sizes for space constrained applications [3]. Nowadays, UWB is also used for high-precision ranging applications [4], [5]."

Jan 1, 2015

By Lin-fang Shen, Shao-jun Li, Zhi-liang Wang

"The meso-structure of real soil consists of numerous particles with different sizes, while the traditional reconstruction method of quartet structure generation set (QSGS) produce relatively uniform soil particles resulting in significant discrepancy between the actual structure and reconfiguration model. In order to remedy the deficiency, the QSGS is improved by considering the influence of porosity and autocorrelative function of soil, which make the models closer to the real soil. Based on the reconfiguration model, Lattice Boltzmann method is combined in the algorithm to conduct further simulation of fluid flow in soil pores. The D2Q9 model is applied to construct the two dimensional model for simulating mesoscopic seepage field of saturated soil by setting the non-equilibrium extrapolation scheme at the inlet and outlet boundary, and the bounce-back scheme at the soil particles boundary as well as the left and right boundary. According to the case study, the proposed program is realized to simulate mesoscopic seepage field of reconstructed soil with constant inlet seepage velocity. The results show that the seepage direction of soil is along the passage with good connectivity, therefore the permeability is controlled by these passages. The seepage velocity in such channels is faster than in bad connectivity channels. Even if the channel has larger pores, the seepage velocity is still small. INTRODUCTIONUnderstanding the seepage mechanism in porous materials is significant in both theoretical and engineering problems. As a typical porous media, soil consists of solid particles and voids, which form connected channels allowing water to flow through. Such seepage in soil exists widely among geotechnical project of slope, foundation pit, and tunnel, etc. Meanwhile, a number of engineering accidents are caused by limited knowledge of seepage characters in soil (Huang, 2006; Liu, 2013). The conventional method in describing seepage features mostly based on the parameter of permeability, which is a macro statistic mean evaluating the whole connectivity of soil. Obviously, this parameter cannot exactly reflect the details of how water flows through the inner soil structure, especially the flow velocity in local mesoscopic area, hence is unable to represent the actual seepage properties. Therefore, it is necessary to develop mesoscopic approaches to fully study the seepage mechanisms."

Jan 1, 2015

By A. Noble

"Linear circuit analysis (LCA) is a fundamental tool that may be used to evaluate, design and improve the performance of mineral separation. The traditional LCA methodology provides a comparative evaluation of circuit designs purely from the unit interconnections. The quantitative approach uses the analytical circuit solution to evaluate the slope of the circuit’s partition curve at the midpoint. Since the partition slope is often associated with a separation’s general selectivity, this numeric value is used to compare and rank alternative configurations. Unfortunately, the partition curve slope only reflects the separation potential of middling material. By itself, this value does not account for the relatively high unit dollar value of pure material or the gains and losses in mass yield associated with alternative circuit configurations. Realizing the value in the LCA methodology, but respecting the limitations of the partition slope valuation, the authors have derived two new performance indicators that quantitatively address pure particle misplacement (the Partition Moment of Inertia) and circuit mass yield (the Yield Score). Together, these parameters provide a better indication of separation economics in typical mineral and coal separation systems. Since the two parameters provide independent information on circuit selectivity and circuit yield, a Pareto efficiency, multi-objective function selection approach is proposed for preliminary circuit selection.IntroductionOver the past 30 years, numerous scientific and industrial studies have proposed various mineral processing circuit design methodologies that attempt to optimize the allocation of separation resources within the processing plant. Over this period, the methodologies have undergone various transitions, including the increased inclusion of process models and computationally intensive algorithms, as well as a general shift from a purely technical solution (Lauder and McKee, 1986) to partially economic solutions (Abu-Ali and Sabour, 2003; Cisternas et al., 2014). Today, circuit design is largely driven by flowsheet simulation; however, no consistent design methodology is used across the industry.One intriguing approach for circuit evaluation is linear circuit analysis (Meloy, 1983a). This method evaluates the separation potential of the circuit solely considering the unit configuration and stream interconnections. No preliminary data other than the basic circuit configuration is required to use the approach."

Jan 1, 2015

By E. C. Westman, W. R. Thomas, W. J. Conrad, A. J. R. Russell

"Understanding ground control problems continues to remain a focus of the mining engineering community. To aid mine operators and engineers in identifying and responding to ground control issues, the Ground Observation System (GOS) is being developed. The GOS is an integrated, web-based graphical user interface that displays ground response data collected wirelessly from an underground mine. It presents data in an intuitive manner to assist mine personnel, who are on- or off-site, in quickly identifying hazardous areas. Geotechnical instrumentation will be connected to wireless transmitters that will relay data in real-time to a surface computer that stores the information in a database. The GOS website will then display the geotechnical data in graphical and tabular forms, as well as in conditionally formatted mine maps. Data from each measurement device will be able to be viewed in its entirety or within a time interval, and can be downloaded for further analysis. The ability of the GOS to quickly interpret and communicate mine hazards to personnel of varying technical ability should prove to be a useful tool in understanding ground control and thus improving mine safety.INTRODUCTION Computer-based data information centers that convey operating parameters and conditions are prevalent in modern underground mines. Today’s systems are popular in showing ventilation controls and monitoring equipment performance (Jyothi & Meena 2013). In ground control monitoring, Conover, Ross, and Bigby, 2010 have installed a wired telltale roof monitoring system that sends roof displacement data every ten minutes to a computer on the surface. The computer receives, stores, and displays the data in real time. Data can also be viewed remotely through a password protected internet connection. Additionally, an internet connection allowed for remote updates to the system which streamlined software development and maintenance by eliminating travel (Conover et al., 2010). Currently, no such system beyond Conover et al.’s design has been accomplished. The Ground Observation System (GOS) is being developed to fill the void of real-time geotechnical monitoring in underground mines. A wide array of data will be transmitted wirelessly and broadcasted to on- and off-site mine personnel through the internet. The GOS will incorporate geotechnical data from roof deformation, borehole scratch testing, photogrammetry, and seismic monitoring into one interface, all while achieving permissibility for the use in gaseous mines. As a result, a comprehensive view of rock movement due to mining will be available. The overall purpose of the GOS is to deliver warnings; to ensure reliable data is relayed to personnel for the identification of potential ground failures, provide mine engineers information to design more stable mines, and assist with further geotechnical research."

Jan 1, 2015

By M. Westendorf, T. Banerjee, S. Kaushik, D. Tinney

"The Copper Mountain Mine is located in Princeton British Columbia, Canada and produces 80 – 90 million pounds of copper annually, as well as gold and silver by-products. The ore processing plant has a conventional SAG/ball mill circuit with inline pebble crushing, followed by flotation. At most plants, much time is spent evaluating and optimizing the comminution and flotation circuits. The cyclones are a key contributor to the effective operation of the plant: They define the circulating load in the comminution circuit and provide the classification that ensures liberated material is passed through to flotation. If the cyclones are not performing as they should, the results are often a combination of lost recovery, grade, capacity and reduced throughput in flotation. For such an impactful unit operation, cyclones have historically been under-instrumented. Consider as well that the cyclones are typically located at the highest elevation in a plant, and it becomes clear why they often underperform. Copper Mountain Mine recognized the critical role that cyclones filled in their plant and worked to optimize their operation through the implementation of a Portage Cyclone Detection (PCD) system to identify plugging and roping incidents, Portage Pumpbox Control (PPC) to manage the flow to the cyclones, and AwaRE to control the grinding circuit. As a result, cyclones overflow stability has increased, switching out a roped or plugged cyclone now happens within seconds rather than many minutes, and both the grinding and flotation circuits perform better. INTRODUCTION Cyclones are one of the most extensively used pieces of equipment within the mineral processing industry because of their simplistic operating and maintenance philosophies. The cyclones are commonly used as classifiers within the comminution circuit to control the grinding product particle size for satisfactory performance of downstream operations. The cyclones are a key contributor to the effective operation of the plant and have a significant impact on the mineral processing plant operations. If the cyclones are not performing as they should, the results are often a combination of lost recovery, grade, capacity and reduced throughput. Similarly, an inefficient cyclone operation may also lead to low or high recirculating loads that impact the efficiency of the comminution circuit. This highlights the importance to have proper stability in cyclone operation while implementing any plant-wide optimisation strategy."

Jan 1, 2015

By Hang Zhao, Xinping Li, Pingan Wu, Yi Luo

The deep-buried rock surrounding the Jinping II Hydro-power Station was taken as the engineering background. Using model specimens of classified rock materials to simulate fractured rock mass under high in-situ stress conditions, the test about acoustic propagation law on single fracture model of specimen under different pressures and different angles were carried out. The variation of p-wave velocity in fractured rock mass and axial stress-strain relationship in the whole test procedure was also studied. Based on damage mechanics principle and the acoustic wave propagation in cracked rock mass, comparative study on damage constitutive relation of fractured rock mass under high in-situ stress in consideration of equivalent strain and equivalent energy was performed. As the results showed, with the change of axial stress level under constant confining pressure, the change in wave velocity can be divided into three stages: slow increase (small variation in amplitude), rapid reduce (large variation in amplitude ) and accelerate reduction. When the confining pressure is constant, the maximum p-wave velocity and the peak strength of specimens increases with the decrease of the crack angle. When the crack angle is constant, the maximum p-wave velocity and the peak strength of specimens increases with the increase of confining pressure.It is identified that the theoretical calculation results of constitutive relation about elasto-plastic damage model containing variable wave velocity in the fractured rock mass is consistent with the model test results.Therefore,the constitutive relation can provide reasonable suggestions for engineering practice.

Jan 1, 2015

By Garry M. Johnston, Matthew L. Sutcliffe, Nicholas J. Welham

"The predominant current processes for the treatment of oxidized copper–cobalt ores use a reductive acid leach to bring the desired metals into solution. However, the indiscriminate nature of acid leaching results in a solution, akin to a metal soup, containing not only the Cu and Co but also an extensive suite of other metals. These other metals, notably Fe, Mn, Al, Ca, Mg and Si, all have to be eliminated from solution before the copper and cobalt can be recovered. Generally precipitation processes are used, but these tend to result in significant losses of copper and/or more usually cobalt from solution, leading to reduced recoveries. The AmmLeach® process uses ammonia-based chemistry to selectively leach the target metals, leaving the rest behind in the leach residue. This approach eliminates any need to clean the solution of unwanted metals and the consequent metal losses. After solid–liquid separation, the leach solution is immediately subjected to separation and concentration of the copper and cobalt using solvent extraction and electrowinning. INTRODUCTION The Copper Belt extends through the northern part of Zambia and the southern province of Katanga in the Democratic Republic of Congo (DRC) and contains the richest and highest grade deposits of copper and cobalt remaining in the world. Whilst there are a number of mines that produce sulphide concentrates, using froth flotation, the largest deposits are those where near-surface sulphides have been weathered over time to form oxides. The oxides cannot be concentrated by conventional physical means to give high recoveries. Despite this, a number of dense medium separation plants have been installed and used to produce a higher grade concentrate which is typically exported (while the rejects, typically 2 to 3% Cu are stockpiled for treatment at a later date). These plants generally have low recoveries and can only be used on the dwindling supply of high grade materials. In exporting the concentrate, little value adding is undertaken within the country, thus greatly reducing the economic benefits to the country. Recent changes to the regulations in the DRC will effectively ban the export of low value ores, concentrates and intermediates in favour of high value metals. This will necessitate mines to install new processing circuits in order to comply with these regulations. The head grade of ores currently being treated in the DRC is slowly decreasing as the extremely high grade materials are being selectively mined out. In many cases, the removal of a small volume of high grade materials leaves a much larger volume of economically marginal ore behind. This is due to a desire for short-term profits overtaking long-term prosperity. The remaining ore, which in many cases is still of relatively high value by world class standards, is likely to be only treatable by low cost heap leaching. There are some initial trials of heap leaching within the DRC, but implementation at a large scale has yet to be adopted."

Jan 1, 2015

By B. K. Gorain

"Mining of low grade deposits along with the necessity to design and operate process plants requiring high throughputs presents unique metallurgical environmental and sustainability challenges that need to be addressed to reduce project risks, improve project economics and to sustain the profitability of operations over the life-of-mine.Some of the key challenges include poor recovery of valuables and concentrate quality issues due to complex mineralogy and high ore variability, water scarcity and quality issues, high energy costs, complex environmental issues including tailings management, high capital and operating costs, worldwide constraints on resource availability, complicated regulations in emerging economies, changing demographics of mining operations with ever-changing cultural or community issues and the urgent need for a better assessment of project viability to reflect the dynamics of present mining scenario. Developing breakthrough solutions to these problems is the key to success of any new project and maintaining profitability of a mining operation. An integrated multi-disciplinary approach to problem solving is crucial along with the need for a more lateral thinking, strategic partnerships and collaboration involving the right players. This paper presents some of the key findings based on experiences from a large number of challenging projects and operations focused on solving complex metallurgical problems.IntroductionThere is a plethora of challenges in developing new ore bodies. The metallurgical complexity of these deposits has increased significantly due to the need for mining lower grade ores along with the presence of deleterious elements that have environmental and processing implications. In addition, many of the mining projects are capital intensive due to high throughput requirements to be economical along with the need for building infrastructure due to remote locations, while operating costs steadily increase due to high reagent, energy and labour costs, increased state royalties and community obligations, to name a few of the key factors. There is also scarcity of water in many regions requiring the use of sea water or brackish water, which has both environmental and metallurgical implications. The shortage of qualified technical manpower adds significantly to the woes of many mining companies. Considering these multiplicity of challenges, it has become imperative for many mining companies to be innovative in addressing these issues."

Jan 1, 2015

By J-F. Béland, N. Parson

Aluminum extrusions are widely used for automotive crash management systems due to their superior specific energy absorption capabilities, as compared to steel. The Al-Mg-Si alloy series can be readily extruded into complex multi-hollow profiles, as required in crash systems, and can be used to target a range of desired strength levels. This paper focuses on the development of an axial crush test protocol and evaluation of the crush performance of common 6XXX series alloys for a variety of tempers. The observed crush behaviour is then compared to tensile test results.

Jan 1, 2015

By R. O. Suzuki, S. Natsui, R. Nashimoto, T. Kumagai, T. Kikuchi, H. Takai

A newly developed computational fluid dynamics model based on a multi-phase particle simulation is presented for predicting the entrainment behavior of liquid metal into slag due to rising single bubble. By comparing results calculated using this model against experimental data, it was found that the transient behavior of bubbles and the two immiscible liquids can be accurately estimated by this method. The rupturing of the thin water film surrounding the bubble was less reliably predicted, but this 3-dimensional unsteady numerical model still nevertheless provides valuable new information for directly predicting the change in the liquid-liquid interface over time. This model predicted the Young-Laplace pressure, and the interface shape was simulated with volume conservation using this model as opposed to the conventional particle method. This simulation model can calculate both of dispersed phase and continuous phase seamlessly.

Jan 1, 2015

By Juan Pablo Guevara, Victor Munoz, Rob Bush, Gonzalo Marias

Cerro Negro Mine, property of Goldcorp Inc., is in the process of developing four separate underground access ramps for the exploitation of high grade, narrow vein gold deposits with vertical to sub-vertical dips. The Mariana Central, Mariana Norte, and San Marcos accesses are primarily in the development stages, while the Eureka access began production stope blasting in April of 2013. Mariana Central will also begin production in May or June of 2014.

Jan 1, 2015