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By Rolf Christiansson, Daniel Johansson, Urban Åkeson, Henrik Ittner, Mats Olsson

"This paper presents two recent studies on the extent of blast damage after excavation in crystalline rock. The Swedish Transport Administration and the Swedish Nuclear Fuel and Waste Management Company (SKB) are both under regulations to limit excavation damage during construction of tunnels. SKB is also required to limit the Excavation Damage Zone (EDZ), as this could be a potential flow path for radionuclides in the planned repository for spent nuclear fuel. Presented in this paper are investigations of blast damage from three tunnel sites, a road tunnel, an experimental tunnel in Äspö Hard Rock Laboratory and an underground subway depot. As expected the fractures resulting from the bottom charge are both longer and more frequent then those mapped in the column charge. The results show that the requirement to limit blast damage according to Swedish regulations was fulfilled for the column charge at the three studied sites.1 INTRODUCTION The Swedish Transport Administration (TRV) and The Swedish Nuclear Fuel and Waste Management Company (SKB) have both recently completed studies related the extent of blast damage from modern explosives after excavation. SKB studies focused on blast damage from pumpable emulsion explosives for underground construction (Ittner and Bouvin 2015) and hydraulic connectivity in the EDZ (Ericsson et al. 2015). TRV had a broader focus with different types of explosives including blasting for both road cuts and tunnelling with pumpable emulsion explosives. Investigations by means of geophysics were also conducted (Olsson et al. 2015). High demands on perimeter control and excavation damage is usually required for underground constructions with a long operation time, such as public tunnels for transport or underground repositories for nuclear waste. This paper presents the findings of recent Swedish studies and aims to discuss the topic in a broader context."

Jan 1, 2016

"1.0 INTRODUCTIONThese Guidelines reflect the state-of-the-practice of the Deep Mixing Method (DMM) in North America. DMM is an in situ mixing process that breaks down the soil structure; injects binders, fillers and reagents into the soil; and blends them with the soil. DMM is also commonly referred to as Soil Mixing. The final properties of the treated soil in situ are a function of the composition of the native soils and groundwater, the binders introduced, the mixing methods and energy, and the conditions and time of curing. Treated soils generally have increased strength and stiffness and/or reduced permeability relative to the native soils.This document addresses DMM performed by rotating single and multiple axis mixing tools, rotating cutter wheels at the end of a rigid kelly bar, or trench mixing using a rotating cutting/mixing chain around the perimeter of a rigid bar. Binder may be injected through low or high energy (velocity) jets.The treated soils created through wet DMM are heterogeneous mixtures of binder, water, soil, and groundwater. Treated soils produced by dry DMM techniques are a mixture of binder, soil, and the water already present in the native soil.DMM applications described in this document include•,Earth retention•,Liquefaction mitigation•,Groundwater seepage control and containment isolation•,Bearing capacity improvement•,Deep foundations•,Mass stabilization and contamination containment•,Embankment, levee and dam strengthening, and stabilization•,Casing replacementThis document was developed to address deep foundations applications. Use of deep mixing for seepage control is not specifically addressed. The reader is referred to documents prepared by the U.S. Army Corps of Engineers for additional information. Shallow soil mixing and the use of DMM for stabilization/solidification of contaminated soils performed at depths less than 10 feet (3 m) are mentioned briefly. Jet grouting is not covered by these guidelines."

Jan 1, 2016

By A. Y. Senchenko, Y. V. Kulikov

"Different methods aiming at specific energy calculation and design of AG/SAG circuits are used in mining. They include JK DWT/SMC test, SAGDesign test and CWi/RWi/BWi tests. The simplest methods with no secret equations and giving energy required for grinding in kWh/t were proposed by F.?. Bond and J.H. Starkey. D.J. Barratt proposed to use results of CWi/RWi/BWi tests for AG/SAG mill sizing. The present paper gives an alternative for forecast of specific AG/SAG energy. The principle is similar to the theory proposed earlier and consists in cumulative AG/SAG energy calculation using indices of rod and ball grinding (RWi+BWi) without impact crushing index (CWi). Then total energy is divided between two grinding stages using special formulas based on extensive statistical information. The forecast indices of AG/SAG and ball grinding are similar to the SAGDesign testing results. Hereinafter the predicted indices are used for mill sizing of the whole grinding circuit. The method considered in the paper enables prediction of AG/SAG energy based on the test results according to Bond method. The proposed method version was not widely published earlier. The aim of the work was to elaborate cost-effective, reliable and accessible way to determine specific AG/SAG energy. At this stage of method development, it is recommended to use it only for works at preliminary Geometallurgy stage (Scoping, Pre-Feasibility). At design stage the obtained data should be confirmed by appropriate testing using alternative JK DWT/SMC and SAGDesign methods.INTRODUCTIONAppropriate crushing and grinding testing is required to design efficient comminution circuits. It is obviously important to obtain accurate information about ore hardness properties since the main energy consumption at the plant is associated with comminution processes. Moreover, it is required to apply the processes that make it possible to minimize operating costs and efficiently use capacity of the installed equipment installed.When studying ore hardness properties, it is required to take into account that breakage of the material is performed using different equipment. That is why accurate selection of the equipment and the circuit calculation without relevant testworks is impossible. Ideally, the testworks should provide answers to the following questions: determination of ore hardness properties, determination of specific energy consumption for comminution as well as obtaining of sufficient amount of statistically significant results from the tests. The results from crushability and grindability testworks in the first place provide assessment of ore hardness properties and in addition correlate with throughput of the respective equipment. The data obtained can be used for modeling of comminution circuits at the stage of the technology development"

Jan 1, 2016

By Faruk Oksuz, Cary Hirner, Ray Brainard

"Key project participants, including owners, engineers, and contractors continually seek for sound and structured decision analysis on how to select the best contracting method for successful project delivery. In addition to being burdened with technical challenges, lack of resources, budget shortcomings, regulatory requirements, and bureaucratic and politically mandated obstacles, the project participants need a reliable decision analysis model on the best project delivery method. The pendulum of choice for contracting continually swings back and forth between traditional design-bid-build and alternative delivery options such as design-build, progressive design-build, construction manager at risk, and public-private-partnership. For large tunnel projects, the decision process is further complicated due to contract packaging options as well as risks in underground construction. Contracting strategies for large tunnels require thorough consideration of performance, risk, quality, operability, cost and schedule. This paper compiles an array of decision making criteria and tools for an unbiased and balanced evaluation and ranking system in the procurement of large tunneling projects. INTRODUCTION Successful project delivery hinges upon meeting the owners’ expectations and key performance indicators. Large tunneling programs benefit from a thorough understanding and successful implementation of project delivery options by key project participants including the owners, engineers and contractors. The key to success is a collaborative advancement of project as the key project participants knowledgably address the applicable management, performance, risk, quality, cost, operability and schedule considerations throughout a project realization cycle. PROJECT REALIZATION CYCLE All projects have customary planning, design, construction, commissioning and operation phases that may seem to be sequential but in reality that are well integrated and dependent on one another. A glitch in any phase of a project realization cycle could hinder a successful outcome and none of the project partners are immune to consequences whenever and wherever they may surface."

Jan 1, 2016

By G. Bulut, Ü. Yenial

"The use of recycled water in flotation has significant effects on flotation and selectivity because the recycled water contains many dissolved compounds and ions that alter the chemistry of the system. In this study, the effects of calcium, magnesium and sulfate, which are abundant components in recycled water, were investigated on galena, sphalerite and pyrite flotation using pure minerals and a complex sulfide ore by conducting bench-scale flotation, microflotation and zeta potential measurements. The bench-scale flotation tests indicated that higher recoveries of galena and sphalerite are obtained when water is recycled, due to higher concentrations of ions in recycled water. However, there was a critical ion concentration for galena recovery. The microflotation tests showed that galena recoveries at different pHs in recycled water are lower than in tap and distilled water. Pure sphalerite recoveries improved in recycled water in the bench-scale test with ore. Pure pyrite was depressed with recycled water as well. Zeta potentials became less negative with increased calcium and magnesium ion concentrations due to their adsorptions, and the presence of sulfate ions was seen to increase the negative charges of sphalerite and pyrite, conversely for galena. IntroductionWater is among the most important elements for mining and mineral processing. The distance to water sources is one of the major factors for mine site selection. The mining and mineral processing sector needs and consumes large quantities of water. In Chile in 2014, the copper mining sector alone consumed 12.7 m3/s fresh water for 1.189 tons of ore processing, and recycled 74 percent of the consumed water (Chilean Copper Commission, 2015). A plant that does not reuse or recycle any water will require 1.9 to 3.0 m3 of water per ton of ore processed (Gunson et al., 2012). Many stages of mineral processing, such as grinding, gravity concentration, dense medium separation, wet magnetic separation, flotation and hydrometallurgical operations, use large volumes of water (Schumann, Levay and Ametov, 2009).In mineral processing plants, the process water is recycled from the tailings dams, thickener overflows, and dewatering and filtration units. Wet concentration processes can require large quantities of water. Flotation, the most common process, typically takes place at 25 to 35 percent solids by mass. Most flotation plants practice at least some water reuse and recycled. Modern mines and mineral processing operations generally aim for zero water release (Levay, Smart and Skinner, 2001). In most cases, water quality has been found to affect flotation performance, and this interaction remains under investigation."

Jan 1, 2016

By Randolph A. Pax, Brian Cornish

The operation of grinding mills in an ore processing circuit is supported by monitoring the input and output variables. These can include the feed ore size distributions, ore feed and water addition rates. The outputs can include the discharge undersize density, oversize tonnage rate and the P80 of the discharge. The grinding mill performance is judged by the power draw, recycle rates and discharge grind size. Conditions inside the mill are inferred from loads cells or bearing pressures and past histories. An overall noise value is sometimes used to evaluate the load as well as the occurrence of excessive impacting of steel balls onto the liners/lifters of the mill. This paper presents results of the internal behaviour of a mill using non-contact stationary microphones located close to the mill outer shell (Pax, 2012). The noise generated by a mill can be attributed to a number of events that occur inside these mills and suitably analysed can provide real-time determinations of in-mill behaviour and can provide powerful insights into the operation of the primary comminution tumbling mills. The acoustically determined signals including a specific 'steel' signal, water hold-up, integrated area together with a classification of impact events. Specific results from case studies will show information of the trajectories inside a mill, steel to rock ratio as well as rheology effects. By incorporating a self-consistent understanding methodology for the in-mill processes from an array of microphones, the information can be used to diagnose the dynamic conditions inside a mill.

Jan 1, 2016

"The Detour Lake Mine is located in northeastern, Ontario, approximately 300 kilometres northest of Timmins and 185 kilometres by road northeast of Cochrane. The mill processes a free milling gold ore using both gravity circuit and leaching with a state-of-the-art carbon-in-pulp circuit. The grinding circuit is a conventional SABC circuit with a tonnage of 55,000 mtpd at 95 microns with the addition of pre-crushing upstream of the SAG mill.The present paper will describe the methodology used to successfully prove that gold of the Detour Lake Mine ore is mostly concentrated into the fine size fraction of the blasted rocks. It will describe the various options possible to create value from this ore property.IntroductionThe purpose of this test work was to determine the grade of the pebbles and consider if there was value into discarding the pebbles and replacing the material by fresh feed.1. Pebble samplingThe pebbles were sampled and assayed for grade every day for 3 months. After 3 months of sampling, the results showed that the pebbles only carried 28% of the fresh feed grade. This phenomenon can possibly be explained by the fact the gold is located into area of fracture in the rocks.January-March 2014 – Pebble assay average• Line #1 = 0.222 g. Au/t• Line#2 = 0.275 g. Au/t• Head grade = 0.88 g. Au/t2. Crushing and grinding circuit surveysWith the above information, a grinding circuit survey was planned. The purpose of the survey was to build a JKSIMMET model of the grinding circuit for mill optimization but also to understand the deportment of gold into various size fractions that may explain why there is so little gold in the pebbles. All streams and size fractions was analysed for particle size analysis and for gold.Since Detour has dual grinding lines, both circuits were sample at the end of May. Two supplemental survey of the secondary crushers were also done and a survey of the gyratory crusher."

Jan 1, 2016

By A. R. Guest, R. Clayton, J. Jakubec

"The potential for mudrushes is a potential hazard that should be evaluated during cave mining studies. Mudrushes are a phenomenon that can have very different origins, but produce the same results: injury, loss of life, damage to property, excess dilution, production delays, or mine closure. Although mudrushes are more common in cave mines than other mines, any mining activity that enables the accumulation of fine particles and water is susceptible to mudflow. This paper describes the process developed by the authors during the past decade to evaluate the risk of mudrushes, specifically in caving and sublevel caving mines.RÉSUMÉ Un danger potentiel qui devrait être évalué durant les études d’exploitation par blocs foudroyés est la possibilité d’afflux de boue. Le phénomène des afflux de boue peut avoir des origines très diverses; les résultats sont cependant les mêmes : des blessures, des pertes de vie, des dommages à la propriété, une dilution excessive, des délais de production ou des fermetures de mines. Bien que les afflux de boue soient plus fréquents dans les mines exploitées par blocs foudroyés, toute activité minière qui permet l’accumulation de particules fines et d’eau est sujette à des coulées de boue. Le présent article décrit le processus développé par les auteurs au cours de la dernière décennie pour évaluer le risque d’afflux de boue, surtout dans les mines exploitées par blocs foudroyés et par sousniveaux foudroyés."

Jan 1, 2016

By K. Turgeon, J. -F. Boulanger, L. Whitty-Léveille, C. Bazin

"Several companies targeting Rare Earth Elements (REE) around the world have completed a Preliminary Economic Assessment showing positive project financial results. Although REE ores may contain high REE value, financing these projects remains difficult in part due to the number of processes required to valorize the elements and the relatively low yield of these processes. Direct ore leaching without the production of a concentrate may reduce the capital and some operating expenditures through process simplification, and increase revenues because of REE recovery improvement.A silicate REE ore is used to test various hypotheses regarding whole ore processing and to develop a simplified flowsheet. An atmospheric leach (200 kg/t H2SO4) of crushed whole-ore containing 0,6% REE, followed by impurity removal and REE precipitation recovers 80% of the REEs in a solution containing REE and Th. The high value contained in most REE deposits makes whole-ore approaches worth considering for most projects, given the losses of valuable species typically associated with the production of a REE mineral concentrate from the ore. INTRODUCTIONRare Earth Elements (REE) find applications in modern and clean technologies, whether civil, industrial or military. With China producing more than 90% of the world’s REE, the embargo imposed by this country in early 2010 increased REE prices for a three year period. With prices having shrunk back many-fold from their peak value, projects put forward during the hike are struggling to secure financing. Owing in part to unconventional processes such as acid-baking and solvent extraction, REE plants are high capital cost and high operating-cost units, and present technological risks (Verbaan et al., 2014)."

Jan 1, 2016

By L. Robles-Stefoni

"Multiple-point simulation (MPS) methods have been developed over the last decade as a means of reproducing complex geological patterns while generating stochastic simulations. Some geological spatial configurations are complex, such as the spatial geometries and patterns of diamondbearing kimberlite pipes and their internal facies controlling diamond quality and distribution.Two MPS methods were tested for modelling the geology of a diamond pipe located at the Ekati mine, NT, Canada. These are the single normal equation simulation algorithm SNESIM, which captures different patterns from a training image (TI), and the filter simulation algorithm FILTERSIM, which classifies the patterns founded on the TI. Both methods were tested in the stochastic simulation of a four-category geology model: crater, diatreme, xenoliths, and host rock. Soft information about the location of host rock was also used. The validation of the simulation results shows a reasonable reproduction of the geometry and data proportions for all geological units considered; the validation of spatial statistics, however, shows that although simulated realizations from both methods reasonably reproduce the fourth-order spatial statistics of the TI, they do not reproduce well the same spatial statistics of the available data (when this differs from the TI). An interesting observation is that SNESIM better imitated the shape of the pipe, while FILTERSIM yielded a better reproduction of the xenolith bodies. IntroductionThe simulation of geological units poses several technical problems that challenge the capabilities of available geostatistical simulation approaches and their ability to deal with spatial complexity of categorical variables. The spatial geometry of diamondbearing pipes and their internal facies controlling diamond distributions are a specific and well-known difficult modelling problem. The geometry of a kimberlite pipe is typically like an inverted cone (Figure 1); the wider part is known as the crater and is located near the surface, and the narrower, deeper part is known as the diatreme. Xenolith bodies can also be found inside the pipe. A very important contribution to the geological modelling of the contours of the pipe is the measure of uncertainty about the location of the contact between the kimberlite pipe and the host rock."

Jan 1, 2016

By C. Vass, A. Noble

"The chemical treatment of mine-influenced waters is a longstanding environmental challenge for many coal operators, particularly in Central Appalachia. Mining conditions in this region present several unique obstacles to meeting NPDES effluent limits. Outlets are often located in remote areas with challenging terrain where conditions do not facilitate the implementation of large-scale commercial treatment systems. Furthermore, maintenance of these systems is often laborious, expensive, and time consuming. Many large mining complexes discharge water from numerous outlets, while using environmental technicians to assess the water quality and treatment regime multiple times per day. As an alternative solution, this paper describes the ongoing research and development of automated chemical treatment systems for mine water discharges. The current work explains the development of a bench-scale prototype that has been used to evaluate various monitoring, notification, and control strategies. Results from this testing are compared to present day practices to show the costs and benefits of implementing an automated treatment and monitoring program. INTRODUCTION Background The National Pollution Discharge Elimination System (NPDES), per Section 402 of the Clean Water Act, requires permitting of all point source discharges from coal mines. This program dictates that all water leaving a permitted boundary, whether it be process water or storm water, must leave through a monitored NPDES outlet. These permitted NPDES discharge points, also denoted outlets, outfalls or monitoring points, must meet a rigorous set of effluent limits to maintain compliance. Common effluent limits monitored by coal companies include but are not limited to iron, manganese, aluminum, total suspended solids (TSS), and pH. Raw mine water is often deficient in meeting these effluent limits, and as a result, various treatment processes are required to bring the water into compliance prior to environmental release. Depending on the mining and geologic conditions, water monitoring and treatment programs can constitute a significant operating cost for the mine operator. In Appalachia, acid mine drainage (AMD) constitutes one of the most significant and widespread water quality challenges that must be treated per NPDES guidelines. AMD is a general lowering of water pH that occurs when water and sulfide minerals interact within oxidizing conditions in coal and metal mining. Acid Rock Drainage (ARD) is a similar term that applies more generally to non-mining causes such as highway construction and other large-scale excavations. Today, mine influenced waters (MIW) is becoming more popular as the general term referring to all types of mining-induced water issues. AMD has been researched substantially over the last 30 years, with investigators studying various causal mechanisms and treatment strategies (e.g. Gazea, 1996; Ziemkiewicz, 1998; Skousen, 2000; Kleinmann, 2001; Johnson, 2003; Akcil, 2006; Kalin, 2006). This research has produced several pragmatic results, which provide numerous methods to predict, prevent, and treat AMD."

Jan 1, 2016

By Amin Saravari, Jamal Jafari, Abbas Sam

"The fourth concentrate production plant includes the comminution systems and the medium-low intensity magnetic separators (LIMS). Based on different conditions, two types of materials are fed into the plant. Type A: 70% of mine ore and 30% of reject materials from magnetite plant and type B: 100% of mine ore. The goal of the present study was to increase the iron grade and the blain number with low sulfur content in final concentrate as the pellet feed. An appropriate pellet feed should have more than 67% of iron, less than 0.1% of sulfur and a Blain number of more than 1800 cm2/g. The Fe, S and Blain no. amounts for the present concentrate are 66.6%, 0.95%, and 500 cm2/g (feed type:A) and 67.8%, 2.3%, and 450 cm2/g (feed type: B), respectively. In this research, the plant improvement efficiency was evaluated by changing the feed particle size distribution and using the flotation system. Laboratory experiments were designed based on the three circuits:1) LIMS (Low Intensity Grinding Rolls) feed grinding-LIMS test-flotation test2) LIMS feed grinding-flotation test-LIMS test3) LIMS concentrate grinding-flotation testThe best results were obtained using the first circuit at the LIMS feed size (d80) of 132 ?m. The processing results using the circuit no. 1 (feed type: A), showed a LIMS concentrate with 69.8% of Fe and 0.36% of sulfur. In this case, the final concentrate (after flotation) with Fe grade of 70.3%, sulfur content of 0.07% and Blain no. of 1571 cm2/g were obtained. In case of the feed type of B, the LIMS concentrate with Fe grade of 68.7%, and sulfur grade of 1.6% was achieved. Also, the Fe and sulfur contents were 69.3%, and 0.4% respectively with a Blain number of 1112 cm2/g. According to the obtained results, it was suggested that a LIMS feed comminution along with a LIMS and flotation systems are necessary to achieve an appropriate iron and sulfur grades with an acceptable blain number. To reach a concentrate Blain number as a pelletizing feed, a High Pressure Grinding Rolls (HPGR) system at the end of the processing line was recommended."

Jan 1, 2016

By R. G. Eggert

"A critical element, as the term has come to be used, provides essential properties to a modern engineered material and is subject to supply risk. The rare-earth elements became perhaps the most prominent of the critical elements in recent years because of their important uses in permanent magnets, advanced lighting, and military materials; the geographic concentration of production in China; and the dramatic run-up in prices in 2010-2011 followed by price collapse between 2011 and 2016. Yet criticality extends beyond the rare earths. What is critical depends on your perspective – who and where you are, and when you ask. This paper reviews the many perspectives on, or faces of, critical elements. It compares and contrasts perspectives of industry (General Electric), national or regional manufacturing sectors (Japan, European Union), emerging energy technologies (as seen by U.S. Department of Energy and, separately, Joint Research Centre of the European Commission) and the world as a whole (as evaluated by academics). This comparison reveals a diversity of not only perspectives but also methodologies and time frames of concern.INTRODUCTIONRare-earth elements appeared prominently in the news in 2010 and 2011 because of the dramatic increase in their prices; their important uses in permanent magnets, advanced lighting, and military materials combined with the geographic concentration of production in China, which reduced export quotas significantly. Rare earths became the most prominent of what have become known as critical elements or materials – that is, those that provide essential properties to modern engineered materials and yet are subject to supply risks.Yet criticality, the state of being both essential and subject to supply risks, extends beyond rare earths. What is critical depends on your perspective. This paper begins by reviewing a little history and presenting a general conceptual framework from which to think about critical materials. It then reviews the many perspectives on, or faces of, critical elements – corporate, national, and global, as well several that focus on emerging energy technologies. The paper concludes with thoughts on what to do to mitigate the potentially negative effects of the supply risks associated with criticality."

Jan 1, 2016

By L. D. Roper

"This paper introduces novel comminution flowsheet concepts involving a novel apparatus, eccentric-high-pressure-centrifugal-comminution (eHPCC), and forthcoming advantages to the international mineral processing community. eHPCC is one-machine synergising high-pressure-rolling surfaces, high-intensity-attrition and centrifugal classification. eHPCC has demonstrated: an absorbed power- intensity of 4 MW/m3; receipt of lump feed whilst producing 80% of product particles less than (p80) 120 µm (choke-fed, dry, open circuit without grinding media; an inert comminution environment); tramp metal tolerance, and a minimum embodied-free-energy saving of 15% as compared against conventional comminution (this comparison withstanding 133-times difference in throughput). Furthermore, this paper introduces: process design and operating characteristics of eHPCC (wet, dry, with and without grinding media); reline considerations (vertical-lift without confined-space). The international mineral processing community is invited to consider eHPCC as an alternative to conventional comminution circuits and/ or complimentary so as to enhance existing process flow sheets.INTRODUCTIONEccentric-high-pressure-centrifugal-comminution (eHPCC) was conceived in 2013 (Patents pending) and has the potential to eliminate the in-efficiencies and complexity of conventional tumbling mill circuits. During the development and testing phase eHPCC demonstrated improved energy efficiency and sustainability offsets.eHPCC will compliment any upstream feed source, be it run-of-mine (ROM), primary crushed rock, or any other conventional comminution stream such as tumbling mill oversize. Another novelemerging technology, Conjugate Anvil-Hammer Mill (CAHM) (Nordell and Potapov, 2011), receiving ROM, will be a complimentary open-circuit feed to eHPCC for very high throughput flow-sheets.eHPCC may compliment downstream process requirements through selective mineral liberation. Selective mineral liberation is entirely feasible as the ore is comminuted upon itself (autogenously) in the high pressure zone caused by the synchronous rotating components."

Jan 1, 2016

By Rob Farnfield, Ben Williams, Ashley Haslett, Diane Cartledge

Major accidents that occur within our industry are often tragic and expensive, damaging reputation and threaten the livelihood of the business. There isn’t anything in them that can be seen as positive for those that experience them. They undertake what are usually very painful, detailed and time consuming investigations to discover how the incident occurred and what needs to be done in the future to prevent similar incidents occurring. Many admirably choose to share the lessons learnt through industry organizations such as SAFEX International so that we can all have the opportunity of preventing similar incidents from occurring within our own organizations.

Jan 1, 2016

By S. Masambi, S. M. Bradshaw, C. Dorfling

The presence of iron in base metal leach solutions complicates nickel and copper recovery processes. Leach solutions are commonly purified by precipitating iron as hematite, jarosite or goethite. Fast oxidation of ferrous to ferric is an important step to remove iron by precipitation at low pH values. This study reviews the ferrous oxidation mechanism and reaction rates in chloride media using molecular oxygen. This work contributes to the development of a better understanding of iron precipitation processing steps, which continues to be an important matter in hydrometallurgy. The specific objectives were to investigate (1) the effect of key process variables (acid concentration, copper concentration, and temperature) on the rate and extent of ferrous oxidation by dissolved oxygen and (2) the oxidation mechanism by varying chloride and hydrogen ion concentrations separately. Batch oxidation tests were performed using synthetic chloride solutions containing 45 g/L Fe and 3 g/L Ni at 50 and 80°C, dissolved Cu concentrations (0.3 to 3 g/L) and HCl concentrations (2 to 4.6 M). Regression analysis indicated that the significance of the effect of different variables on the extent of oxidation achieved after five hours decreased in the following order: HCl concentration > Cu concentration > temperature. Increasing the HCl concentration from 4 M to 4.6 M caused the degree of oxidation achieved after two hours to increase from 58.3% to 98.1%. The catalytic effect of dissolved copper on ferrous oxidation was more significant at low acid concentrations. Experimental data suggest that rapid oxidation of ferrous is possible at high HCl concentrations for two main reasons. First, the formation of ferrous chloride complexes allows ferrous oxidation to proceed without the formation of superoxide as an intermediate product (the rate limiting step in dilute acid solutions). Second, the formation of ferric chloride complexes stabilises the oxidation product.

Jan 1, 2016

By Chris Ashton, Andreas Rädle, Taner Aydogmus

"The Contract C310 is part of the current biggest infrastructure project of Europe “Crossrail” which is a major new cross-London rail link project and comprises the construction of the North Woolwich Portal, Plumstead Portal and the twin tube Thames Tunnels with a length of approximately 2.6km. Two Mix-Shield TBMs (Diameter 7.12m) were driving through differing challenging ground conditions (Thanet Sand, Gravels, Flint and Chalk) below the ground water table. The two tunnels were underpassing several listed buildings, sensitive structures, operational railway tracks with low overburden and close to existing subway tunnels in an urban environment. Several additional measures as compensation grouting, micro piles and an intensive monitoring has been carried out to ensure a safe tunnelling process. PROJECT OVERVIEW CROSSRAIL Project Crossrail Crossrail is currently the biggest infrastructure project in Europe which has been developed to serve London and the southeast of England. The project includes the construction of twin-bore tunnels on a west-east alignment under central London and the upgrading of existing National Rail lines to the east and west of central London. The new rail track, as shown in Figure 1, starting in Shenfield/ Abbey Wood in the east of London and ending in Reading / Heathrow Airport in the west of London, includes the construction of nine central area stations, providing interchange with London Underground, National Rail and London Bus services, and the upgrading or renewal of existing stations outside central London.Altogether there will be 118km of new rail tracks, including 42km of tunnels and 40 train stations. After completion in 2018, Crossrail expects 200 million passengers per year (Tauriainen, Rädle, Ingram 2013)."

Jan 1, 2016

By E. L. Chanturiya

The research and characterisation for compositional, physicochemical, structural, electrical and flotation properties of various pyrite samples for a copper-zinc sulfide ore was carried out. Various methods were used during the research, such as optical microscopy, X-ray diffraction, electron probe micro-analysis (EPMA), phase emission analysis, routine chemical analysis, auger electron spectroscopy (AES), scanning electron microscopy (SEM), back-scattered electron images (BSE), potentiometry, and instrumental neutron-activation analysis, flotation. Analysis of obtained results established the interrelation between impurity structures and concentration of electric charge carriers in minerals, Butyl xanthate sorption and flotation yield of pyrite. The research concluded that pyrite samples differ by morphology, micro defects of structure, concentration of donor and acceptor impurities (Co, As, Sb, etc.) and conductivity parameters (thermo-electrical force, specific resistance and concentration of charge carriers The peculiarity of pentagon-dodecahedral pyrite is the high concentration of electric charge carriers (electrons) and the more negative surface potential (by 25–75 mV) in comparison to cubic pyrite. The surface of cubic varieties is more active, therefore it is oxidized in alkaline lime medium much faster, than the surface of pentagon-dodecahedral varieties. This phenomenon is caused by high reaction ability, irregular jointing and defects of cubic pyrite. This promotes the increase of calcium ion sorption on its surface and the decrease of Butyl xanthate sorption. According to this, an increase in alkalinity (lime medium) from a pH of 10.0–11.5 leads to an increase of gold content reporting to the tail of bulk flotation. Gold content is increased from 0.58 g/t (?? 9.5) to 1.9 g/t (?? 11.6), which represents an increase in gold recovery of 24.68 to 79%, respectively.

Jan 1, 2016

By L. Bam, R. Machaka, S. Chikosha, N. S. Muchavi

"Parts manufactured through power metallurgy (PM) typically contain pores that can be detrimental to the final mechanical properties. This paper explores the merits of 3D X-ray computed tomography over traditional microscopy for the characterization of the evolution of porosity in metal injection moulding (MIM) and direct powder rolling (DPR) products. 17-4 PH stainless steel (as-moulded, as-debound and sintered) dog-bone samples produced via MIM and Ti-HDH strips (as-rolled and sintered) produced via DPR and were analysed for porosity. 3D microfocus X-ray tomography (XCT) analysis on specimens from both processes revealed spatial variations in densities and the existence of characteristic moulding and roll compaction defects in agreement with traditional microscopic microstructural analysis. It was concluded that micro-focus XCT scanning can be used to study MIM and DPR parts for the characterization of the amount, position and distribution of porosity and other defects. However, the majority of the sub-micron sized pores could not be clearly resolved even at the highest possible instrument resolution. Higher-resolution scans such as nano-focus XCT could be utilized in order to fully study the porosity in MIM and DPR parts. IntroductionMetal injection moulding (MIM) is a novel process, which combines the advantages of powder metallurgy (PM) and plastic injection moulding. MIM has found widespread applications in the cost-effective production of high-sintered density small parts with complicated shapes and mechanical properties equivalent to those of wrought materials (German and Bose, 1977; Machaka and Chikwanda, 2015; German, 2013). There are four basic processing steps involved in MIM, namely; feedstock preparation, injection moulding, debinding and sintering. These steps are discussed in greater detail elsewhere (Machaka, Seerane and Chikwanda, 2014; German and Bose, 1977; Machaka and Chikwanda, 2015; German, 2013).Feedstock preparation involves mixing metal powder with a carefully selected composition of polymeric binder materials at a specific temperature. The feedstock is then granulated and injected into a predefined mould die with the desired shape. The part produced during the moulding step is referred to as a ‘green’ component. The green component typically contains no porosity since the spaces between adjacent powder particles are readily filled with the binder materials (German and Bose, 1977; Li, Li and Khalil, 2007). Debinding is the systemic removal of the binder components by chemical, catalytic, or/and thermal means while maintaining the shape of the component. The part produced after the debinding step is referred to as a ‘brown’ component. Debinding is known to be the source of porosity in brown components (Ji et al., 2001; Tsai and Cen, 1995). Finally, the brown debound part is sintered to full or nearfull density (Sotomayor, Varez and Levenfeld, 2010). The sintering step and associated densification closes up the majority of the pores. Sintered MIM parts are typically sintered to high density (95–99%) and retain an irreducible amount of residual porosity (Barriere, Liu and Gelin, 2003; German, 1990)."

Jan 1, 2016

By W. Jomaa, V. Songmene, O. Mechri, Laval Université, P. Bocher, J. Levesque

"A 2D finite element modelling (FEM), based on pure Lagrangian approach, is developed for studying the serrated chip formation during high speed machining (HSM) of 7075-T651 alloy. The solution was achieved using a commercial software package, ABAQUS/Explicit v6.13. The Johnson-Cooke (JC) constitutive equation is used to describe the work material behaviour. Moreover, the JC damage equation is implemented into the FEM to take into account for the shear localization during the serrated chip formation. Modified Coulomb friction model has been used to characterize the sliding/sticking effects on the tool-chip interface with the friction coefficient and shear flow stress determined by force calibration and machining data, respectively. The proposed FEM is validated using experimental data obtained in HSM of 7075-T651. The FEM was able to predict accurately serrated chip morphology. The intensity of chip segmentation was found to increase with cutting speed.INTRODUCTIONHigh speed machining (HSM) is one of the most used processes for manufacturing aircraft parts with aluminum alloys. For aluminum alloys, the use of HSM increases metal removal rate and reduces the formation of built up edges and burrs. However, it was found that serrated (also named segmented or sawtooth chip) and discontinuous chips can be produced during HSM of some high strength aluminum alloys, such as 7075-T6 alloy (Rao & Shin, 2001). Many parameters were found to affect the segmented/discontinuous chip formation during the machining of aluminum alloys.There are two cases in which the serrated chip can forms: the first is when machining hardened materials (Morehead, Huang, & Luo, 2007), and the second, when machining ductile materials with a cutting speed higher than a critical value (Barry & Byrne, 2002). Different theories and models were developed in order to explain the formation mechanism of such kind of chips. According to Astakhov (2006), the segmented chip formation is attributed to variations in stress and plastic deformation states, and resulting temperatures on the cutting zone. Liyao et al. (2013) stated that the segmented chip formation was mainly attributable to adiabatic shear instability/catastrophic strain localization. Others (Vyas & Shaw, 1999) suggest that the fracture/crack propagation mechanism is at the root of chip generation."

Jan 1, 2016