Search Documents

By E. Siami-Irdemoosa, S. R. Dindarloo

"Pareto analysis was used to investigate the failures database of a Hitachi EX1900 hydraulic shovel over one year of continuous operation. The hydraulic system and hydraulic links, hoses and piping were identified as the most critical system and subsystem, respectively. A three-parameter gamma distribution function was identified as the best fit for a probabilistic modeling of the time between failures (TBFs). This distribution was used in a Monte Carlo reliability analysis of the hydraulic system. Autoregressive integrated moving average (ARIMA), within the context of a time series analysis of the TBFs, was proposed as a viable alternative to the traditional technique of distribution fitting. The mean absolute percentage error (MAPE) metric was used to compare the two models. The MAPE value that resulted from the ARIMA was 66 percent smaller than that from the traditional technique in predicting the TBFs.Resumen ¦ Se usó análisis Pareto para investigar la base de datos de fallas de una pala hidráulica Hitachi EX1900 durante un periodo de un año de operación continua. Se identificó al sistema hidráulico y a los enlaces hidráulicos, mangueras y tuberías como el sistema y subsistema más importantes, respectivamente. Se identificó una función de distribución de tres parámetros gamma como el más apto para un modelado de probabilidades del tiempo transcurrido entre las fallas (Tabes por sus siglas en inglés). Esta distribución fue usada en un análisis de confiabilidad Monte Carlo para un sistema hidráulico. El promedio de movimiento integrado auto-regresivo (ARIMA por sus siglas en inglés), dentro del contexto de análisis de serie temporal de los TBFs, fue propuesto como una alternativa viable a la tradicional técnica de ajuste de distribución. Se usó el porcentaje de la media absoluta de error (MAPE) para comparar los dos modelos. El valor MAPE que resultó de la ARIMA fue 66 por ciento menor que el resultado obtenido con la técnica tradicional de predicción de TBFs."

Jan 1, 2015

By P. Chu, J. A. Finch

The formation of small bubbles in flotation is usually accomplished by the use of frothers, or sometimes is due to the presence of inorganic salts in the process water. The effective mechanism associated with the presence of these solutes is generally considered to be coalescence inhibition. However, recent work has demonstrated that the presence of frothers and salts also reduces the size of bubble at the initial formation stage. In this paper we adapt the same experimental setup to investigate the time that it takes for a bubble to form; for a known system power input, the energy to form a bubble can then be estimated from the time. The hypothesis is that the presence of frother and salt will reduce the time for a bubble to form, which can be interpreted as an added energy component being derived from the solute. Testing different types and concentrations of frothers and salts, the hypothesis is supported: the mechanical energy required to form a bubble decreases by about 10% in the presence of these solutes.

Jan 1, 2015

By M. Mikolás, L. Pomothy, K. Špakovská, M. Vanek

"Enterprises are faced with increasing economic competition and managers are obliged to look for methods that will ensure a competitive edge in their companies’ markets. These methods include managerial concepts that employ common sense and are low cost. One of these approaches is the KAIZEN methodology, of Japanese origin; kaizen means continuous improvement (CI) when translated. A mining company, despite some of its idiosyncrasies, is just an enterprise where the application of KAIZEN can be advantageous. The company investigated, OKD, is the only domestic producer of hard coal in the Czech Republic and operates four mines that produce 11 Mt of coal annually. The OKD management team opted for KAIZEN as their principal method of continuous quality improvement. This paper suggests ideas for development and application of processes that provide for continuing improvement of production and management. The authors have taken the OKD Company to be their benchmark in the field of mining activities. The paper also focuses on possible difficulties accompanying the introduction of CI sustainable methods. Three years of application of CI methods has increased the income of the company by almost US$38.1 million, which provides a strong argument for continued application."

Jan 1, 2015

By Masahiko Yamaki, Takahiro Yamanashi, Hijiri Hashimoto, Hirochika Hayashi

"In this study, the authors used heat conduction analysis with the aim of quantitatively evaluating whether treating improved ground with cover soil is an effective measure for maintaining strength development in the surface layer of improved ground after constructing cement treated soil for the winter season. This report describes a simple procedure to evaluate covering soil thickness, which is necessary for the strength of the surface of cement treated soil, by using the freeze index and both the water content ratio and dry density.INTRODUCTIONIt was reported that when ground improvement using cement is performed in winter in a snowy cold region (Fig. 1 photo, Fig. 2), the uppermost 1 m of the improved ground (i.e., the cement-treated soil) tends to become prone to solidification failure from exposure to the cold air during curing (Hashimoto et al. 2006). In light of this, our research laboratory conducted unconfined compression tests using curing temperature as a parameter of analysis on improved ground toward understanding the influence of curing temperature (ambient air temperature) on the strength improvement afforded by ground improvement.The authors found that if the curing temperature is maintained at 0°C for the first 28 days after improvement and then at 5°C for the next 337 days after improvement, the improved ground is expected to have 90% of the unconfined compressive strength of improved ground whose temperature was maintained at 20°C for the first 365 days after improvement (Hashimoto et al. 2011)."

Jan 1, 2015

By C. G. Anderson

"As demand for copper and precious metals continues to grow, the need to develop new supplies increases. In the imminent future, the new large global ore bodies are more complex, with enargite, tennantite and tetrahedrite as the abundant contained mineralogy. These resources also contain considerable gold and silver. As such, direct treatment by conventional smelting is prohibitive due to the potential environmental impacts and copper quality issues. This paper outlines the effective application and associated economics of industrially proven Alkaline Sulfide Leaching (ASL) hydrometallurgical technology to an enargite concentrate for selective removal and recovery of arsenic, antimony, gold and silver, leaving a clean high-grade copper concentrate. The fundamentals behind the technology are described, along with those of hydrometallurgical arsenic fixation and stabilization. Flowsheets and unit operations are elucidated, along with an in-depth economic analysis. INTRODUCTION Hydrometallurgical methods can be employed for treatment of gold-, arsenic-, antimony-, tin- and mercury-containing materials, concentrates and ores, as well as complex ones containing any number of metals (Conner & Anderson, 2013). The alkaline sulfide leaching (ASL) system is one of these. It is essentially a mixture of sodium sulfide and sodium hydroxide with other meta-stable alkaline species as required. This is a unique hydrometallurgical system beause it is a very selective lixiviant for the distinct leaching of tin, gold, antimony, arsenic, tellurium, silver and mercury (Anderson, 2000, 2001a, 2001b, 2002, 2003, 2012, 2014; Anderson & Twidwell, 2008a, 2008b, 2010; Anderson et al., 2004, 2005; Glazkov & Tseft, 1961; Gnatyshenko & Polyvyanni, 1961; Nadkarni et al., 1975; Nadkarni & Kusik, 1988; Polyvyanni, 1963). Worldwide, ASL technology has been employed industrially in the former CIS, China and the United States for the production of antimony (Anderson et al., 1992, 1994; Anderson & Krys, 1993; Holmes, 1944; Kaloc, 1967; Nordwick & Anderson, 1993; van Stein, 1971)."

Jan 1, 2015

By S. Jeon, T. H. Kim

"Understanding the frictional properties of discontinuities is crucial to ensure the stability of underground structures. In particular, the frictional behavior at depth depends on the complex interaction among mechanical, hydrological, thermal and chemical characteristics and their coupled effects. In this study, a series of triaxial compression tests were carried out to investigate the behavior of rough shear surface of synthetic rocks. The frictional behavior showed little variation at different confining and water pressures. The test results were analyzed using Coulomb’s failure criterion. In addition, numerical analysis was carried out using PFC2D to simulate the test.INTRODUCTIONUnderstanding coupled behavior of rock at depth is of great importance in design, construction and operation of underground structures such as a disposal facility of radioactive waste, hot dry rock geothermal system and oil reservoir. In particular, many uncertainties are involved in characterizing deep rock mass deformation in the designing process and interactions among fluid flow of groundwater, high temperature and stress disturbance should be considered. Many independent studies have been carried out to investigate the thermal, hydro, mechanical and chemical coupled effects in numerical and experimental methods. They include the researches by Lockner, Summers, Moore and Byerlee (1982), Jafari, Amini Hosseini, Pellet, Boulon and Buzzi (2003), Tembe, Lockner and Wong (2010), Lee, Lee and Jeon (2012), Indraratna, Premadasa, Brown, Gens and Heitor (2014)."

Jan 1, 2015

By I. Ward, E. Milosavljevic, M. Botz

"The silver nitrate titration method is a rapid and acceptably accurate means of analyzing for cyanide in leach solutions that contain primarily free cyanide. However, in leach solutions containing elevated levels of copper, the titrimetric method overestimates the concentration of free cyanide and underestimates the concentration of weak and dissociable (WAD) cyanide. The authors have developed a modified potentiometric (MP) titration method for determining WAD cyanide that overcomes issues associated with high copper levels in solution. The new MP-WAD method involves addition of a chemical ligand to the sample prior to silver nitrate titration to release cyanide bound to copper. Once released from copper, cyanide in solution is no longer affected by the presence of copper, and titration results are quantitative rather than empirical. In multiple laboratory trials with synthetic solutions and complex actual leach solutions, analytical results obtained with the new MP-WAD method were found to be within about ±5% of analyses obtained with the USEPA OIA-1677 WAD cyanide analytical method.IntroductionThe silver nitrate titration method is widely used to estimate the concentration of cyanide in leach solution for purposes of cyanidation process control. Cyanide determined by silver nitrate titration is commonly referred to as “free” cyanide, but frequently should be referred to as “titratable” cyanide. By definition, free cyanide is the sum of the concentrations of aqueous hydrogen cyanide HCN(aq) and the cyanide anion CN- (ASTM, 2010). Titration will only yield a reasonably accurate measurement of free cyanide when metal-cyanide complex concentrations (e.g., cadmium, copper, mercury, nickel, silver and zinc) in solution are low. In other words, titration will only yield a reasonably accurate measurement of free cyanide if the solution primarily contains free cyanide."

Jan 1, 2015

By M. Pineda

Sublevel stoping (SLS) is one of the oldest and most used methods for underground mining. It relies heavily on the use of drilling and blasting techniques to remove the rock, and gravity to transport the broken rock to drawpoints located at the base of the stope, with LHDs to transport material from the drawpoints. Current SLS operations are based on the assumption of stable geometry of the stope. Thus, the stope design includes the definition of the geometry according to the orebody shape and geomechanical constraints to avoid instability, which may cause excessive dilution. Under some circumstances, dilution could enter the stope due to geotechnical instability, especially when large stope geometries are used. A review of current design and planning practices for large SLS operations indicates that no consideration is given to the material flow and the mixing that occurs after blasting. Material flow could have a large impacton the mixing of ore when grades are heterogeneous in the stope. In this paper, we discuss the influence of gravity flow on the design and planning of large sublevel stopes with and without vertical dilution, based on laboratory experiments. The outcomes of this investigation are used todevelop guidelines towards the design and planning of large SLS mines, which would complement the currently used geotechnical considerations.

Jan 1, 2015

By Biplop Das, E. Herrera, A. Burrows, P. J. Mackey, G. R. F. Alvear Flores

Since the first commercial plant was built at Mount Isa, another twenty ISASMELT™ furnaces have come into commercial operation, and construction of new plants continues. The primary copper ISASMELT™ top submerged lance (TSL) technology continues to attract interest from potential users who seek to smelt productively. In addition to the known benefits of productivity and flexibility, ISASMELT™ operators have also achieved improvements to energy efficiency when switching from their previous technologies. The recent production statistics for operation at Tuticorin, India show that ISASMELT™ has taken the first steps into territory beyond 400,000 t/y (copper cathode basis) and this will likely be the scale chosen by future new copper smelters operating purely on a toll smelting basis. Highly energy-efficient technologies will be expected at these smelters

Jan 1, 2015

By Joshua Taylor Drake

This report answers specific questions concerning underwater blasting considerations, and blasting safety. The blasting considerations discussed consist of basic blasting principles, and new variables to be accounted for. Blasting safety will include the safety of personnel and structures. The environmental considerations will also be discussed with mitigation methods. To be most effective, this document requires the reader to be familiar with key fundamentals of explosive engineering. In order for a blasting professional to benefit from this report, the following questions will be asked:

Jan 1, 2015

By Fadeela Saloojee, Frank K. Crundwell

"Pressure leaching is an option for copper recovery from chalcopyrite. Leaching takes place at high temperatures and pressures in the presence of an oxidising agent. This work shows how the performance of pressure leaching circuits may be improved by optimising the configuration of autoclaves and the heat-removal method. The objective was achieved by creating an autoclave model by combining mass balances, energy balances and population balances. A base-case circuit consisting of a single autoclave was chosen, and this base case was compared with options for increasing capacity by adding more autoclaves to the circuit. These capacity–increase options include circuits in which the additional autoclave is added in parallel, in series and in series with thickening between the two autoclaves. The copper extraction, productivity and cooling requirements for these options are compared. The series circuit with inter-stage thickening has the highest extraction and productivity, however, the cooling duty in the first autoclave is high. In addition to comparing circuit options, three options for heat removal were investigated: cooling coils, quench water and flash recycling. The flash-recycle option results in the highest copper extraction, and the quench-water option gives the lowest copper extraction. INTRODUCTION Background Copper sulfide ores and concentrates containing chalcopyrite are typically hard to leach under atmospheric conditions. Smelting of these ores may also be a challenge, due to the inability of smelting processes to handle low-grade ores, as well as impurities such as arsenic and antimony. Alternative hydrometallurgical routes to treating chalcopyrite are therefore required. One option is pressure leaching, which is the focus of this work. In the pressure leaching process, sulfide ores and concentrates are leached in autoclaves at temperatures of 200 to 220°C and a pressure of about 3000 kPa (Schlesinger et al., 2011). An oxidising agent, usually oxygen, is required to oxidise sulfide ions to sulfate ions. The oxidation of sulfur to sulfate is exothermic; consequently, a method of heat removal is necessary in order to maintain the temperature in the autoclave."

Jan 1, 2015

By S. Hearn, S. Boskovic, A. Smethurst

"The digestion of minerals in strong acids or at elevated temperatures can result in the release of large amounts of silicic acid which can polymerize in solution to form colloidal silica and gels. Colloidal silica can cause a number of problems including interfering with flocculation, initiating crud formation in solvent extraction (SX), decreasing SX extraction kinetics and increasing SX phase disengagement times. Huntsman’s POLYSIL® polyether coagulants have a “lock and key” relationship with the surface of colloidal silica to help lower the concentration of these particles in solution, improve process efficiency and reduce reagent losses by minimizing crud formation. This paper investigates some of the issues caused by colloidal silica in hydrometallurgy processes and illustrates how the use of POLYSIL® coagulants has helped to improve process outcomes. INTRODUCTION Coagulation differs from flocculation in a number of ways. Coagulants are relatively small molecules that modify the surfaces of fine particles, weakening repulsive forces between them and allowing particles to stick together, while flocculants are generally molecules that are large enough to bridge the boundary layers between the particles. With flocculation, addition rate and mixing all make a difference to the flocs formed. Coagulation, on the other hand, is an equilibrium process. With coagulation it is only necessary to achieve good mixing, and coagulates will form as Brownian motion pushes the particles into each other. In real systems, this process is complete within seconds. Huntsman’s POLYSIL® polyether based coagulants have a strong affinity with the surface of colloidal silica formed by the polymerization of silicic acid. While silica found in minerals has a low aqueous solubility, large amounts of silica as silicic acid can be released as these minerals are digested in strong acids at elevated temperatures. The solubility of free silicic acid is about 150 ppm under pH conditions typical in acid leach environments (1), so the bulk of the silica will polymerize in solution to form colloidal silica. Colloidal silica can pass through a hydrometallurgy process without affecting any of the operations. However, it can cause a number of problems. These include gelling in a leach, interfering with flocculation or crystallization, initiating crud formation (2,3,4), decreasing extraction kinetics and increasing phase disengagement times (5,6) in solvent extraction. In these cases, coagulating the silica with POLYSIL® coagulants can reduce or eliminate the problem by enabling these particles to be flocculated and removed from the solution."

Jan 1, 2015

By J. de Korte, Z. Loubser

"SynopsisThe aim of a blending stockpile is to minimize the natural variation in properties of a material. Two simulation models were written, for coneshell and chevcon stacking, and used to investigate the influence of different stockpile parameters on blending efficiency. The coneshell model is used to show that blending efficiency is highly sensitive to stacked height, with lower output variances observed for higher capacities. Output variance in both models also decreased when the stacker movement increment was decreased. For chevcon stacking, increasing stacker speed significantly increases the blending efficiencies. Increasing the length of the blending tail also reduces output variation, but this parameter would need to be weighed against the accompanying decrease in buffer capacity.IntroductionEven in the most uniform deposit of materials in nature, material properties will vary. The degree of variation can be measured, and usually resembles a normal distribution. The aim of blending and homogenization operations is to minimize the standard deviation of this normal distribution (De Wet, 1994). In general, the reduction in variation will result in a more efficient and cost-effective downstream process. Cement plants need a precise blend of raw materials to ensure desired kiln performance; boilers used in power generation are optimized for fuels of a constant specification; and even though the separation density in a coal washing plant can be adjusted, a constant product quality cannot be produced from highly variable feed (Denny and Harper, 1962). The process efficiency, product quality, and environmental compliance depend on consistency of characteristics in the material fed (Kumral, 2005) Many industries involved in"

Jan 1, 2015

By Zhenyu Han, Dion Weatherley, Ruslan Puscasu

"This study aims to demonstrate the capacity of the Discrete Element Method (DEM) to model and simulate fracture in brittle rock, capture the crack propagation process and determine crack propagation rates for various levels of external loading. In the numerical experiments reported here, a macroscopically homogeneous body of brittle rock, containing a single pre-existing crack, was subjected to tensile stress loading. Simulations concerned with model I crack growth process in 3D were carried out. The process of fracture has been observed under various steady state and dynamic conditions. The numerical results obtained reproduce qualitatively and quantitatively a variety of observed fracture phenomena. Specifically, this study examined the onset of cracks, single dominant cracks that grow across the specimen, crack bifurcations and branching. The density of fractures that can be nucleated and grow to a significant size with and without arresting each other, crack growth speed and stress distribution, all have been consistently and systematically analyzed. Suggestions on potential future developments are made and discussed.INTRODUCTIONFracture and failure mechanics are very important in mining, manufacturing, materials processing, mineral processing, civil and mechanical engineering, and many other disciplines of science and engineering. Yet, due to the complexity of fracture phenomena, no theoretical models of broad applicability are currently available (Bieniawski 1967). The simulation of crack propagation is therefore considered an open question in numerical rock mechanics. Although, a significant body of experimental research on fracture of materials was carried out since the early days of fracture mechanics (circa 1940s) (Poncelet 1946, Mott 1948), often in parallel with the development of fracture mechanics theories as well as with the development of experimental and observational techniques themselves, the experimental results were often done on particular classes of material such as glasses and other very brittle materials. Indeed, a number of specific experimental observations on the behavior of growing cracks in brittle materials were made in the 1940s for which generally accepted explanations based on physical principles are still lacking. Likewise, quantitative numerical modeling, based on both continuum and discrete methods, as a basis for understanding dynamic crack growth is still in a preliminary stage."

Jan 1, 2015

"Foreword by Lisa SchlinkSuperintendent, operations, Freeport-McMoRan Inc.,Green Valley, AZ, USAThe sixth annual Student Poster Contest hosted by the Mineral & Metallurgical Processing Division of the Society for Mining, Metallurgy & Exploration was held during the 2015 SME Annual Conference and Expo in Denver, CO. The contest had another record-breaking attendance of 31 entries: 27 graduate and four undergraduate. The universities represented were: Colorado School of Mines, South Dakota School of Mines and Technology, University of Kentucky, University of Utah, Southern Illinois University Carbondale, University of Wyoming and West Virginia University.The competition began with an extended abstract review by a panel of judges selected from MPD members. At the SME Annual Conference, all students displayed their posters, highlighting their research. The students with the top abstracts from the graduate and undergraduate divisions presented their research at the MPD Student Poster Session Wednesday morning. The panel of judges then provided tallied scores for the abstract, poster and presentation to determine the winners of the 2015 Student Poster Contest. The first- and second-place winners of both the graduate and undergraduate divisions received $1,000 and $500 scholarships, respectively. The third through seventh places received $200 each, and all other entrants received $100 each and were invited to join the MPD Luncheon.In the undergraduate division, Annette Hein of the University of Wyoming received first place for her research on “Solvent Extraction of Europium from a Nitric Acid Solution.” Second place went to Jennifer Galvin of South Dakota School of Mines and Technology for her research titled “Solvent Extraction of Neodymium Using PC88A.”In the graduate division, Caelen Anderson of the Colorado School of Mines received first place for his research titled “Fundamentals of Rare-earth Flotation Surface Chemistry: Hydroxamate Adsorption on Bastnasite”. This is Caelen’s fourth year placing in the top finisher. Second place in the graduate division went to Seyed Hassan Amini of West Virginia University for his research on “Ultra Clean Coal Production for the Solar-cell Industry.”The 2015 Student Poster Contest was chaired by Lisa Schlink (Freeport- McMoRan Inc.) and Emily Sarver (Virginia Polytechnic Institute and State University). The panel of judges included Aaron Noble (West Virginia University), Nick Gow (FLSmidth), Ren Bryce (Freeport-McMoRan Inc.), David Perkins (Derrick Corp.), Jim Metsa (Weir Minerals) and Scott Shuey (Newmont).A special thank you is extended to the sponsors of the MPD Student Poster Contest, to all the students who participated and to the panel of judges. Watch for more information on the 2016 MPD Student Poster Contest to be published later this year on http://www.smenet.org/mpd/ and in the November issue of Minerals & Metallurgical Processing."

Jan 1, 2015

By T. W. Wong, M. A. Whitney, A. Hadadzadeh

Uniaxial compression tests were performed on cylindrical specimens, 10mm in diameter and 15mm in height, machined from an extruded AZ31B magnesium billet. The tests were conducted under isothermal conditions to a true strain of 0.5. The study compares macroscopic flow anisotropy between the extruded (ED) and transverse (TD) directions in the temperature range of 300°C to 500°C, and strain rate range of 0.001s-1 to 1s-1. Compression of ED specimens at low strain rate (0.001s-1) exhibited axisymmetric flow, and no significant differences were observed between geometries of specimens deformed above 350°C under the same strain rate. Deformation of TD specimens at low temperature and/or low strain rate resulted in elliptical cross-sections, with the anisotropy of flow being less significant at higher temperatures. Other studies performed using rolled plates have proposed that pyramidal slip and cross-slip at higher temperature eliminate the effects of initial texture, while the dominance of prismatic slip at lower temperatures will result in anisotropic flow. It is believed that the initial fiber texture common among extruded HCP-structured materials plays a role in the anisotropic deformation behaviour observed in the extruded specimens

Jan 1, 2015

By A. Mortazavi, H. Nasab

"The storage of petroleum products on surface is associated with difficulties and limitations. Accordingly, a viable alternative is to excavate underground space in rock and provide a safe way for oil storage. Soft rocks such as salt domes provide good conditions from environmental and operational points of view. The potential for high-volume storage and low permeability are encouraging aspects for oil storage in salt domes. The complicated shape of oil storage caverns, the complicated behavior of salt rocks, and boundary conditions associated with large underground openings are important challenges in the design of oil storage caverns. The aim of this paper is to delve into the stability and deformation mechanisms of storage caverns created in salt domes. A parametric study of effect of the cavern size, orientation, and depth is carried out as a function of ground stress regime. The stress field and deformation mechanisms are calculated for each case aiming at providing design guideline.INTRODUCTIONOne of the most popular soft rock that is used for underground oil storage is salt rock (halite). Salt rock has particular characteristics which makes it suitable for oil storage. Salt rock has several advantages for oil storage, these are: high production rate, high degree of availability, short filling period, high level of safety and low permeability [1]. The low permeability is due to the fact that halite deforms in a plastic manner over a wide range of pressures, temperatures and rates of deformations. This property prevents joints or gaps opening up in the formation, thus preventing the escape of liquids and gases. The state of stresses around the cavern in salt domes depends on the depth of the cavern (initial stresses and rock mass temperatures are increasing with depth), the in-situ stress state within the rock mass, and the internal oil pressure in the cavern. Furthermore, the salt creep behavior and the cavern geometry are influencing stress redistributions during loading and unloading phases.Rock mass structure, cavern geometry, material behavior and cavern operation patterns require complex physical models to describe the load-bearing behavior of the geomechanical structure. The determination of stress, strain and deformation in the rock mass due to cavern construction and operation are complex problems which can be evaluated employing numerical tools such as the Finite Element Method (FEM) or Finite Difference Method (FDM). In this study, the finite difference method was used to evaluate the behavior of oil storage cavern in salt rock."

Jan 1, 2015

By H. X. Li, A. Correa, M. M. Zhang, W. Xuan, M. Andrade

"With increasing demand for steel and depletion of high-grade iron ore deposits, more research efforts are being directed toward extending the life of existing ore reserves and developing technology to treat low-grade iron ore resources. Among all the reported technologies, biotechnologies in mineral processing – specifically bioleaching and microbially induced flotation – have emerged to be considered as low-cost, environmentally friendly potential alternatives to many of the current mineral processing techniques. This paper provides a comprehensive review of current research on the use of microorganisms for iron ore beneficiation and, further, discusses the applicability of bioleaching, bioflotation and bioflocculation for the beneficiation of low-grade iron ores.IntroductionIncreasing global demand for raw materials has led to diminishing resources of high-grade iron ore. As a result, the mining and utilization of low-grade hematite, limonite, specularite, siderite and goethite ores have attracted more and more attention. However, these types of iron ores are of complex paragenesis and fine disseminated grain size, and often contaminated by phosphorus in the form of solid solution. The distribution of phosphorus throughout the iron mineral crystals prevents the effective use of physical separation techniques, and these complex ores are at present largely untapped due to a lack of cost-effective and efficient processing methods. Chemical leaching and roasting-magnetic separation approaches have been mainly tested only on the laboratory scale and are all either cost prohibitive or ineffective when used on low-grade complex iron ores."

Jan 1, 2015

By A. Mitrašinovic, A. Wolf

"The aim of this investigation was to determine the most suitable additive for recovering metals from converter slags generated during Ni extraction. Fluxes analyzed were silica and lime and reductants included pig iron, ferrosilicon and copper-silicon compound. Slag was settled at 1300°C for one hour to simulate the smelting environment. The newly formed matte and slag were characterized by chemical composition and morphology. Microstructural studies showed that slag formed after adding reductants consisted of primarily fayalite, with traces of magnetite. Entrained matte was present in the slag mostly as prills of Ni3S2-FeS matrix and a Cu2S-FeS secondary phase below 10µm in diameter. Kinetic parameters of matte formation, valuable metal recovery rates and partition coefficients were deduced. Silica additions generated higher partition coefficients for copper and nickel than the addition of lime. Additives used as reducing agents had higher valuable metal recovery rates and partition coefficients. Silica additions favoured the formation a higher grade matte while lime additions will hinder metal recovery. Pig iron, ferrosilicon and Cu30Si were the most effective reductants for valuable metals recovery. Cu10Si and coke additions had little to no effect on valuable metals recovery."

Jan 1, 2015

By S. K. Shaha, W. Kasprzak, D. L. Chen, J. Friedman, F. Czerwinski

The role of solutionizing conditions within the T6 heat treatment of the cast Al-Si-Cu-Mg alloy with micro-additions of Zr-Ti-V was assessed in terms of their influence on microstructure and mechanical properties. As a solution treatment, a single step process at 485 and 510oC and a two-step process at 510 and 525oC for varying time intervals from 0.5 to 9 h, were examined. In all cases, solution treatment was followed by isothermal aging at 150oC for 100 h. The microstructural analysis showed that the solution treatment changed the eutectic silicon morphology from needle-like, present after casting, to spherical shape in the T6 state and that the extent of changes was strongly influenced by temperature and time. The Cu- and Mg-rich phases completely dissolved during solution treatment while the Fe-containing phase, Al8Si6Mg3Fe, remained partially in the microstructure. The Ti, V and Zr containing phases, Al13Si2Ti3Zr and Al3Si26FeTiV10, present in as-cast state, were partially dissolved during solution treatment, reducing their size by 10 - 48%. The studied alloy reached the maximum ultimate tensile strength of 335 MPa and yield stress of 303 MPa for two-step solutionizing with a total time of 4.5 h. It is concluded that the two-step solution treatment resulted in higher tensile properties than the single-step process.

Jan 1, 2015