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By P. Radziszewski

"The comminution energy curve is a profoundly simple graphical technique that displays detailed operating efficiency information for industrial comminution processes. The database underlying the methodology has recently more than doubled, to now contain a substantial fraction of the international comminution output (1.7 billion tonnes of rock per year) across more than 8 major commodities. This increase has deepened the analytical capabilities and effectiveness for assessing comminution circuit performance in relation to comparable operating mines. This paper will explore how the energy curve methodology can be used to examine the ability of stirred mill technologies to increase efficiency.Specifically, this paper explores how the energy curves methodology can be used to present energy efficiency gains achieved at three mines employing a stirred mill technology under different duties. The first of these cases studies was conducted by Rosa (2014) who compared the performance of two ball mills operating in parallel with a Vertimill in the regrinding circuit at the Samarco Iron project in South East Brazil. The Vertimill was found to achieve the same product specification while consuming 40% less energy. Brissette (2010) investigated the impact of grinding media on the performance of both ball mills and Vertimills. The energy savings achieved varied from 10% to 40% for the ball mills and 30% to 60% for the Vertimills. Lastly, Bergerman (2012) investigated the operating conditions of the Sossego regrind circuit from 2006 to 2011 against design specifications and laboratory testing. The operating work index of this circuit varied from 5.2 kWh/t to 44 kWh/t over this 5 year period. The full suite of energy curves"

Jan 1, 2016

By S. Tuylu, D. Adiguzel, A. Bascetin, O. Ozdemir, U. Cinar

"In recent years, use of mineral processing tailings as a paste backfill has been significantly increased due to the environmental problems occurred during the disposal of the tailings in mine area. The paste material used to fill the stopes excavated is generally consisted of tailings (solid ratio: 70–85%) and cement (3-7%w/w). Meanwhile, the strength of the paste material is completely related to ratios of these materials. Cemented Paste Backfill (CPB) system is used as support depending on the roof pressure and also as an underground disposal method. Therefore, temporary strength value of the paste material gains a great importance. For example, the paste backfill material must compensate the minimum 4 MPa strength value in order to procure the permanent fortification, and the mixture cost must be minimal as well. For this reason, in this study, the Pb-Zn tailings were used to prepare for the paste backfill material using cement in order to perform the uniaxial compressive strength (UCS) tests. Additionally, a statistical experimental design and linear programming techniques was used to find the optimum mixture in terms of strength and cost. The pulp solid ratios (PSR) of the tailings and cement (by the solid) were varied as 75-85% and 3-8%, respectively. The results of this study; the optimum mixture is ~79.5%PSR and 6.8% cement ratio (by the solid) for 4 MPa UCS (28 day) and 16-17 cm slump value determined by this method with statistically reviewed experimental data. INTRODUCTION Fine-grained tailing waste materials resulting from mining activities are an important environmental problem. In terms of environmental protection, the use of tailings with paste backfill is a very attractive approach and a desirable solution to tailings management. Paste backfill, which is used to fill underground openings, is made by primarly mine tailings mixed with hydraulic binders and water. Its main benefits are not only disposal of mine tailings in underground, but also providing a certain strength to ensure a safe working environment. Therefore, it is necessary to use hydraulic binders due to durability of the system (Benzaazoua et al., 2004). Paste backfill, formed from the mix of dewatered plant tailings (75-85 wt. % solids), water and binder (3-8 wt. %) (Brackebusch, 1994; Landriault et al., 2005).Water is used to determine the chemical reactions between tailing and binder materials for strength as well as increasing pumpability. Portland cement and ash can be used as binder materials (Douglas and Malhotra, 1987). The factors which affect strength and stability of paste backfill separate into two groups called interior and exterior factors. Interior and exterior factors determine the strength, stability and deformation features of backfill in short and long terms and also affect the transportation of backfill to underground (Benzaazoua et al., 2004; Erçikdi et al., 2006; Yilmaz et al., 2010; Nasir and Fall, 2010). Material properties of tailings as well as site operations to fill the underground openings are the most important steps for the design purposes. Grain size distribution, chemical, and physical properties of tailings, and mechanical properties of paste fill material are used to understand the suitability of tailings as paste fill material (Ozturk et al., 2014). In addition, Fig. 1. is also proposed to apply a typical design for the operational stages of paste fill applications on the site."

Jan 1, 2016

By Tong Guan, Guangqin Fu, Lihong Deng, Yuanlin Chen, Xiaotong Zhou

"In natural world, some kinds of scheelite minerals are rich in molybdenum. Molybdenum exists in the crystal lattice of scheelite in the form of isomorphism, and the content of MoO3 varies from 2% to 10%. As a result, the flotability of seyrigite (scheelite with molybdenum) turns to be weaker. One seyrigite mine, which has been built for 3 years,still could not produce qualified seyrigite concentrate due to the weak flotability of seyrigite (Mo-bearing scheelite) in raw ore. In our experimental research, through adopting new seyrigite collector TA-3 and advanced mineral processing technology, the seyrigite concentrate with a grade of 65.62% WO3 at a recovery of 87.47% was obtained for the raw ore containing 0.19% WO3 and 0.074% Mo. By applying the new technical achievement, for the raw ore containing 0.272% WO3, the seyrigite concentrate assaying 68.03% WO3 with a recovery of 77.56% was obtained in industrial production.INTRODUCTIONIn natural world, some kinds of scheelite minerals are rich in molybdenum. Molybdenum exists in the crystal lattice of scheelite in the form of isomorphism, and the scheelite is changed to be seyrigite (Ca[(W,Mo)O4]) (Ma, Bian, & Wang, 2013). The content of MoO3 in seyrigite varies from 2% to 10% usually, the content of MoO3 in some of the seyrigite even reaches 34%. The flotability of seyrigite is weak (Zhang, 2007), and the seyrigite is difficult to be recovered by flotation with common collectors and regulators. One scheelite mine in Anhui China, which is a skarn type seyrigite mine, has not produced qualified concentrate yet since 3 years it has been built due to the limit of beneficiation technology. Therefore, it is necessary to conduct research on the collectors with high efficiency and developing advanced processing flow for this kind of ore."

Jan 1, 2016

By S. Tuylu, D. Adiguzel, A. Bascetin

"Optimization techniques are successfully used in many different fields such as engineering, physics, economy, and politics in order to enhance the performance of the systems. In concrete technology, Aggregates are prepared by mixing the water and cement in proportional quantities. In order to obtain desired quality control parameters, the determination of the ingredients ratios is one of the important problems for the optimization. Additionally, in the quarries where the aggregate quality constantly changes, blending optimization must be made to obtain a sustainable aggregate quality. This study showed that linear programming, which is easy and which includes many aggregate properties, cannot be used in terms of some aggregate properties. Therefore techniques such as nonlinear programming or genetic algorithm must be used. INTRODUCTION Concrete is a used construction material and made by mixing the aggregate, cement, and water. The concrete properties are directly related to the properties of these materials in blending. The quantity of aggregates in concrete is approximately 70 percent of the concrete’s volume. Therefore, the most important material is aggregates. The extraction of aggregate materials in quarries is more problematic because of variable bedrock properties. Therefore, the quality of the materials changes and the characteristics of the concrete are also influenced directly. In terms of sustainable use of natural resources, produced aggregate materials which have different qualities should be used optimally (Adiguzel et al., 2014). Nowadays, in the solution of the blending optimization, various optimization techniques are being used such as linear programming, nonlinear programming, and genetic algorithm. In this study, blending optimization techniques especially used for concrete aggregates blending have been summarized, and the advantages and disadvantages of these techniques have been introduced. BLENDING PROBLEMS Blending is a frequently encountered problem in process-type manufacturing such as mining, refinery, food industry, chemical industry and metal industry (Sakalli 2010). Blending is a commonly used method in lots of practical solutions (Sarker and Newton 2008). Several optimization techniques are available for blending problems (Furman and Pardalos 2009). The most important issue is to blend with minimum cost. The blending problem is a special linear model which was developed to solve this problem. In blending optimization research, linear programming is a widely used method (Adiguzel et al. 2011; Bascetin and Adiguzel 2011)."

Jan 1, 2016

By Peter Johnson, David Barber, Lachlan Henderson

"The traditional approach to rail tunnel fire safety design is to follow NFPA 130, which assumes a major tunnel fire could occur and requires bi-directional emergency ventilation. There is no regard to the impact of ventilation on fire growth and smoke production. In Europe and other parts of the world, the need for tunnel ventilation systems to provide smoke management in the event of fire is being questioned. The European Commission’s Safety in Railway Tunnels TSI is based on a philosophy that improved running capability (preventing fires and other events stopping the train in the tunnel) and elevated fire performance of materials means the chances of a major fire in a tunnel is highly unlikely, with only small fires expected, and no tunnel ventilation required. This approach is reinforced by the International Tunneling Association which has recently published an Engineering Methodology for Performance Based Fire Safety Design on Underground Rail Systems, which includes a methodology that does not require assessment of tenability in tunnels, but requires a scenario based risk assessment to be undertaken to determine overall fire safety measures. Recent research by the University of Edinburgh has shown that forced airflow from a mechanical ventilation system may promote fire growth and increase smoke volumes much more than with natural ventilation. Whilst the concept of no mechanical ventilation (i.e. natural ventilation) is a new concept for some, for many rail tunnels it is worthy of serious further consideration. RAIL TUNNEL SMOKE MANAGEMENT AND STANDARDS Smoke management using mechanical bi-directional ventilation systems has been a central part of the fire safety design solution under NFPA 130 for rail tunnels since 1982. The current version of the standard, NFPA 130: 2014, states that mechanical ventilation should be fitted to rail tunnels of length greater than 305 meters and an engineering analysis should be undertaken for tunnels of length 61 to 305 meters to determine whether mechanical ventilation should be fitted. However, this approach is not necessarily reflected elsewhere in the world. In Europe in particular, mechanical ventilation systems for smoke control within rail tunnels have taken a much less central role within the standards framework."

Jan 1, 2016

By Yongsheng Song, Yong Chen, Wenjuan Li

"Detailed characterization and improved recovery of a micro-fine, low-grade refractory gold ore from a beneficiation plant in Yunnan Province, China, was investigated. Different analytical techniques, such as videlicet size analysis, scanning electron microscopy, and mineral analysis by a Mineral Liberation Analyser, were used for mineralogical characterization of the ore. This paper describes an experimental study on the effect of the grinding fineness and the use of various flotation reagent regimes involving collectors, depressors, and activators on the flotation behaviour of micro-fine auriferous pyrite. Two-stage flotation resulted in high gold grade (32.71 g/t) and gold recovery (80.02%) of the bulk gold concentrate. This process opens the possibilities of maximizing Au recoveries in a micro-fine low-grade refractory gold ore where low recoveries are common.INTRODUCTIONWith the rapid development of the gold industry, refractory gold ores are becoming increasingly important resources for gold production (O’Connor & Dunne, 1994; Agorhom, Skinner, & Zanin, 2012). Among these refractory gold ores, sulfur and micro-grained native gold ores represent a significant challenge, since they are not amenable to gold recovery by direct cyanidation. The gold contained in this type of ore is very finely disseminated and encapsulated in sulfides, which makes it inaccessible to the cyanide solution during direct cyanidation (Bulatovic, 1997; Allan & Woodcock, 2001). Autoclave pressure oxidation (AC POX) of the sulfide ore and subsequent cyanidation is a common technology used to recover the gold in such types of ore. Flotation is often used as a pre-treatment method to refractory gold ore (Monte Lins, & Oliveira, 1997).As the gold-carrier minerals are usually finely disseminated (sometimes under 10 µm) and intimately associated with gangue minerals, a fine grind is necessary to get a high degree of liberation. At the same time, the fine grind usually causes the production of significant quantities of slimes, which comprise easy-to-float gangue minerals such as mica, dolomite, and calcite. These mineral phases are naturally hydrophobic and float readily, competing with the value minerals in the froth phase and resulting in lower concentrate grades."

Jan 1, 2016

By R. F. Favreau, Favreau Patrice

"The economy profits from the rock excavated in mines and quarries and the excavations required for the construction of roads and buildings. However such excavations are achieved by blasting withexplosives, and explosions create fly rock and vibrations which in some cases may throw rock far intoinhabited regions and may vibrate buildings excessively in these regions. Society, however, no longeraccepts that their quality of life be disturbed by the risks of fly rock or the perturbation of vibrations.Thus it is important to know how to design blasts that do not cause excessive fly rock or vibrations, and to understand why sometimes a blast does create excessive vibration or fly rock. An article presented at the 2015 ISEE (reference 1) explains how unacceptable vibrations can be avoided, while the present article explains why dangerous fly rock occurs and how it can be avoided. The article shows by rigorous calculations with the blast simulator Blaspa that long range fly rock can be due to short collar or short burden, but mainly it explains how inadequate blasting that allows the floor to rise can cause even further reaching fly rock, a situation not usually recognized by most blasters."

Jan 1, 2016

By N. P. Hristov, L. V. Kuzev

"A simulation study of the fill factor of a drum mill was conducted using two types of grinding media: balls and tetraballpebs. Each medium was composed of equal number of grinding bodies having equal weight but different shape. The difference was in the density of the two grinding media.Standard spherical grinding bodies (balls), which were used in practice, and equivalent (by weight) grinding bodies in the shape of spheroidal tetrahedrons (tetraballpebs) were studied. The simulation was conducted in a module of a 1.2 m diameter drum mill, whose length exceeded twice the diameter of the corresponding grinding body. The grinding balls had a few percent (3 to 6) higher fill factor than the grinding tetraballpebs in the same shell.Vertical sections of the grinding medium were taken across the studied shell module along its axis. They showed the location of each grinding body in the fill volume. Defects in the packing of the grinding bodies and the contacts between them and with the inner surface of the shell were also show. Differences in the contact points of the balls and the tetraballpebs were noted. For the tetraballpebs, we observed contacts both between the spherical surfaces and with the edges and vertices of the grinding bodies.The topography of the grinding media is shown visually.INTRODUCTIONThe grinding balls have been studied extensively. It is the traditional grinding medium in ore processing industry. The parameter characterising the grinding medium is its density. It is the mass of the grinding medium per unit of volume. The parameter may have a range of values. It depends on:• The physical properties of the material they are made of;• The shape of the grinding body;• The dimensions of the body;• Size distribution of the grinding bodies in the grinding media.In comminution, the fill factor of the mill shell is the process parameter that is representative of the grinding medium. Some publications have indicated the disadvantages of ball grinding. For example, Wu, Xiang, Glen, and Duan (2008) note in the analysis of the mechanism of grinding that the balls are not the best grinding media and disadvantages include among others:• Easy over-grinding resulting from the point contact between the balls;• Attrition surface is the smallest in the grinding media;• Poor selective exposure of minerals resulting from the accidental and often significantly more powerful impact on the feed;• The grinding efficiency drops as the fineness of grind is increased;In the Handbook of mineral processing, Polkin (1950) noted that the shape of the grinding bodies determines the volume of the void spaces therein and therefore the shape affects the grinding efficiency per unit of volume of the grinding medium."

Jan 1, 2016

By K. Loutet, A. Guenkel, K. Nikolaisen

"The INCO SO2/air process was patented by INCO in 1985. Well over 80 mining operations worldwide are using this process to oxidize cyanides to cyanates in the tailings from gold, silver and copper mining operations. The sulphur dioxide (SO2) for this process can be supplied either as liquid SO2, SO2 gas or as a sulphite-based salt. The majority of SO2/air operations have used sulphite-based salts as the ‘SO2’ equivalent probably due to low capital cost. Liquid SO2 has also been used frequently, but due to concerns with safety and availability, this option is often not preferred. The solid salt sodium meta-bisulphite (SMBS) is commonly employed, but its cost is an order of magnitude higher than that of sulphur. Due to the high cost of SMBS, the increased capital cost for a sulphur-burning SO2 gas plant (green field or retrofit) usually has a pay-back of less than three years. In addition, a SO2 gas plant offers potential for significant heat recovery from the sulphur burning process. In terms of safety, the SO2 gas plant only requires the storage of relatively benign sulphur and the site inventory of SO2 will be limited to the plant gas volume. Therefore, a SO2 gas plant will not trigger the Canadian Environmental Protection Act (CEPA) E2 Regulations or the US Clean Air Act Section 112(r) accident prevention regulations, as may be the case for liquid SO2.Most existing mining operations using ‘SO2’ are gold operations, but in recent years there has been an increased interest in larger sulphur dioxide gas plants for hydrometallurgical facilities that employ leaching of cobalt/manganese minerals or precipitation of manganese/iron (e.g. Tenke Fungurume and El Boleo).This paper focuses on the production of sulphur dioxide gas generated on site and on demand for the use in hydrometallurgical processes. The capital and operational costs of a SO2 gas plant is compared to conventional process alternatives using sulphite-based salts or liquid SO2."

Jan 1, 2016

"Guideline Augered Cast-In-Place (ACIP) Pile Specification and Commentary11.0 GENERAL1.1 SCOPEThe Pile Contractor shall furnish all labor, materials, tools and equipment necessary for furnishing, installing and testing Augered Cast-in-Place (ACIP) piles as shown on the Contract Drawings and as specified herein.ACIP piles are commonly referred to by several other names. Some of them are trademarks or service marks owned by Foundation Contractors and some are names that try to describe the installation process. The term “cast-inplace” is sometimes replaced with “cast-in-situ,” especially in Europe. Some common names are Auger Cast Piles, Intruded Mortar Piles, Augerpress Piles, Augered Pressure Grouted Piles, AugerPile Foundations, Continuous Flight Auger (CFA) Piles, Grouted Bored Piles, Augered Grout-Injected Piles, Drilled or Augered Uncased Piles, and Uncased Cast-in-Place Concrete Piles. To avoid confusion, ACIP pile will be used exclusively herein.1.2 PILE CONTRACTOR QUALIFICATIONSThe ACIP piles shall be installed by an experienced Pile Contractor who upon request of the Engineer shall submit evidence of successful ACIP pile installation under similar job and subsurface conditions, including a job supervisor who shall have a minimum of five years of method specific experience.The proper installation of the ACIP piles is dependent upon the procedures used by the Pile Contractor’s field representatives and equipment provided. The Pile Contractor’s personnel responsible for the installation should have relevant experience with the auguring and pumping equipment, experience placing piles under similar site conditions (including restricted headroom if appropriate), in similar subsurface conditions, as well as experience handling the special grout mixes, admixtures, etc."

Jan 1, 2016

By Türker Hüdaverdi, Özge Akyildiz

"In this research, image analysis technique, Kuz-Ram and KCO Models were used to examineefficiency of the quarry blasts. Investigations were performed in Cendere region, Istanbul. As a firststep, image analysis software was used to determine particle size distribution of muckpiles.Additionally, the results of KuzRam and KCO fragmentation models were compared to the results ofthe image analysis technique. The efficiency of KuzRam and KCO models was investigated and theimportant points to be considered were explained. Additionally, the effect of the rock factor valueson the size distribution curves was investigated. The blasthole diameter is 89 mm. (3.5 in) in thestudied quarry. Each measured blast has a different burden, spacing and stemming length. Blastholes was drilled in a staggered pattern. It is concluded that, KuzRam and KCO models can be successfully used to determine fragment size distribution in Cendere Region Quarries, Istanbul. Site engineers can predict blast fragmentation using the theoretical fragmentation models and they may change blast design parameters before blasting operation if necessary. It is possible to calibrate the Kuz-Ram and KCO fragmentation models using the measurements obtained by image analysis technique."

Jan 1, 2016

By Z. L. Xue, J. L. Li, X. Y. Wang

"In low-carbon energy-efficient basic oxygen furnace (BOF) steelmaking processes, limestone partly or completely replaces the active lime. The effects of limestone calcination temperature (1200–1500°C) and time (5–15 minutes) on lime reactivity and CaO grain size were investigated. The reactivity was evaluated by titration with hydrochloric acid, and the CaO grain size was analysed using scanning electron microscopy. The results revealed that for calcination temperatures higher than 1300°C, the reactivity reached a maximum and then decreased . The higher the temperature, the earlier the peak of reactivity appears. The CaO grains grow with increasing temperature and time, which leads to the decrease of reactivity. Notably, the effects of temperature on CaO grain size and reactivity are more marked than that of time. To obtain active lime calcined at ultra-high temperature by flash heating, the calcination conditions should be 1300–1400°C for 10–15 minutes, or 1400–1500°C for 8–10 minutes. IntroductionLime is one of the most important slag-making materials for dephosphorization and desulphurization in the basic oxygen furnace (BOF) steelmaking process. The reactivity of lime is a measure of its capability to take part in slag-making. Lime having a reactivity of more than 300.0 mL (4 N HCl), determined by hydrochloric acid titration is generally referred to as active lime (Rusjan et al., 2007; Zeman, 2008). At present, the active lime used for BOF processes comes primarily from a kiln or shaft kiln, where limestone is preheated at 700– 900°C, and then calcined at 1050–1200°C (Drenhaus et al., 2010; Oates, 2007)."

Jan 1, 2016

By R. Venugopal, V. K. Saxena, A. K. Mukherjee

"Coal, iron and manganese ore samples were exposed to different ultrasonic intensities of 250, 300 and 350 W/L for five minutes and to an ultrosonic intensity of 270 W/L for different time durations of 3, 5 and 7 minutes. The ultrasonically treated samples showed reductions in D80 particle diameters of 6 percent for the coal samples, 5.95 percent for the iron ore samples and 35.63 percent for the manganese ore samples during grinding. The ultrasonic treatment was also observed to assist in reducing ash content in the coal product by 8 percent and to reduce manganese losses in rejects by about 5 percent. Ultrasonic treatment was concluded to be capable of assisting in the comminution of friable ores more prominently than the hard and porous materials.IntroductionComminution is an important unit operation in the mineral-processing, cement-making, powergeneration and pharmaceutical industries. But most of the milling technologies are considered to be energy inefficient, with less energy consumed in real size reduction and most of the energy consumed in the machine. This is more critical for the mineralprocessing industry because of the growing need to exploit lower-grade ore bodies and process rejects (Blazy et al., 1994; U.S. Department of Energy, 2005). Low-grade ores require crushing and grinding to liberate the valuable minerals, which are further separated from gangues by various beneficiation methods such as gravity separation, flotation and leaching. Various studies have been carried out to minimize energy consumption during milling by developing pretreatment methods that can initiate new fractures or improve the fracture density in materials before comminution. These studies were mainly focused on chemical additives; thermal, ultrasonic and microwave treatments; and electric disintegration (Klimpel and Austin, 1982; Norgate and Weller, 1994; Bearman, Briggs and Kojovic, 1997; Gaete-Garreton, Vargas-Hermandez and Velasquez-Lambert, 2000; Kumar et al., 2010; Wang, Shi and Manlapig., 2011, Singh et al., 2012).The fragmentation effect of ultrasonic fields in solids has been investigated since the 1950s, and Gärtner was probably the first researcher who attempted it (Gaete-Garreton, Vargas- Hermandez and Velasquez-Lambert, 2000). Sound waves can propagate in solids in the form of longitudinal waves, shear waves and surface waves, and in thin materials as plate waves.In surfaces, fractures and interfaces, various types of elliptical or complex vibrations of the particles make other waves possible. During ultrasonic-vibration treatment, cavitation bubbles nucleate, grow and collapse, generating microjets, whose impacts on the particles initiate microcracks. The ultrasonic waves can enhance the nucleation, growth and coalescence of flaws, caused by tensile or shear stress. The mechanisms operating in the materials and inducing these stresses have been identified as spall and compression-induced tensile microcracks, nucleating at preexisting flaws. These mechanisms are driven by the shock wave and cavitation effects in the surrounding fluid (Chen, Huang and Shih, 2003)"

Jan 1, 2016

By Larry G. Twidwell, Corby G. Anderson, Camille M. Fleuriault

"The selective precipitation of iron as ammonium jarosite is a well-established industrial technology in base metals hydrometallurgy. It is a key technology in minimizing iron tenors which would be disruptive to downstream processing. It also provides a more readily filterable iron solid to better facilitate materials handling. This paper elucidates the fundamentals behind industrial iron precipitation. Then, the details of the successful optimization of an industrial ammonium jarosite circuit are presented.HYDROMETALLURGICAL IRON REMOVAL FUNDAMENTALS Iron is the fourth most abundant element in the Earth’s crust (5% by weight) and is often found in complex ores such as sulphide-bearing formations. Iron represents an issue though during leaching, a technology which is widely used for the treatment of this type of ore: •,Iron has the particularity of forming hydroxides when leached under certain conditions. Iron hydroxides form a viscous gel, which is difficult to filter and traps valuable elements such as silver. •,Iron is solubilized along with other metals and interferes with the subsequent extraction steps. As a result, purification of the pregnant leach solutions is required to achieve economical extraction of base metals. In the 1960s, metallurgists developed iron precipitation processes for solution purification (Habashi, 1999). Nowadays, precipitation of iron bearing species, such as goethite, hematite or jarosite, has become one of the most common methods used in the industry to purify leach liquors. To be suitable, the precipitate has to be readily filterable and thus must not be too fine of particle size. Precipitation can take place in autoclaves at medium to high temperatures, under an oxygen or air overpressure (Tourre, 1984, Fleuriault 2016, Fleuriault Anderson Shuey, 2016))."

Jan 1, 2016

By A. Pranowo, G. R. F. Alvear F., N. Aslin, M. S. Moats

"The toxicity of arsenic is well known and documented; however, the presence of arsenic in copper electrorefining anodes and electrolytes is critically necessary to produce high-quality cathode. Arsenic as well as antimony and bismuth concentrations vary relative to their concentration in the anode copper received from the smelter. The behaviour and benefits of arsenic in copper electrorefining and the detrimental effects of antimony and bismuth on cathode quality and tankhouse performance are discussed. This will include the minimization and mitigation of problems associated with arsenic, antimony, and bismuth—including cathode contamination, floating slimes, scaling, and anode passivation.RÉSUMÉ La toxicité de l’arsenic est bien connue et documentée; toutefois, la présence d’arsenic dans les anodes de l’électroaffinage du cuivre et dans les électrolytes est d’une nécessité critique pour produire une cathode de grande qualité. Les concentrations en arsenic, ainsi qu’en antimoine et en bismuth varient selon leur concentration dans l’anode de cuivre reçue de la fonderie. Le comportement et les avantages de l’arsenic dans l’électroaffinage du cuivre et les effets indésirables de l’antimoine et du bismuth sur la qualité de la cathode et le rendement des cuves d’électrolyse sont discutés. On traite aussi de la minimisation et de l’atténuation des problèmes associés à l’arsenic, l’antimoine et le bismuth – incluant la contamination de la cathode, les schlamms flottants, l’entartage et la passivation de l’anode."

Jan 1, 2016

By K. Mayhew, A. Lossin, H. Salomon-de-Friedberg

"The proportion of arsenic-bearing copper concentrates that supply the copper industry is on the increase. The current strategy of miners and smelters to blend feeds to reduce average arsenic levels is rapidly becoming unsustainable as more concentrates with even higher arsenic levels enter the marketplace. In addition, the capability of smelters to manage increasing arsenic levels to more stringent and restrictive environmental standards is limited by available process technologies.CESL Cu-As Technology is a viable technical and economic alternative to traditional smelting. It offers the advantage of simultaneous leaching and precipitation of the arsenic in a single processing step while achieving high copper extractions. The process has been piloted in six separate, fully-integrated pilot campaigns for feeds ranging from ~1% to 12% arsenic in concentration. This paper will focus on the behaviour of arsenic in CESL’s leaching/precipitation step and operational factors that influence it, and on the chemical and physical characteristics of the subsequent iron-arsenic residue that represents today’s best available technology from a long-term sustainable (capital/operating costs, metal recovery, safety, environmental) perspective.The examples provided will demonstrate copper extractions approaching 99% and arsenic deportment to residue of 99%. Instantaneous settling rates of the residue were measured at 15+ m/hr. Data from subsequent short and long-term stability testing of the residue confidently support the view that the scorodite-bearing residues from the process will be stable and provide an acceptable arsenic management practice. The technology offers increased revenue and environmental certainty for miners, smelters & refiners to support the development of metallurgically challenged copper-arsenic deposits. Furthermore, results will be presented demonstrating the technology’s ability to successfully incorporate hazardous arsenic containing smelter by-products such as dust into the process feed and simultaneously extract copper value while fixing the arsenic in a stable residue."

Jan 1, 2016

By I. Y. Bausov, L. G. Stolarczyk, R. E. Pillmore, A. J. Hillard, J. T. Duncan

"Prevalence of lung disease in younger miners surprised industry regulators, congressional members, researchers and black lung clinic staff members. Mitigation researcher focused on low-coal mining in the Appalachian regions until Miners Colfax Medical Center (MCMC) Black Lung Clinic examinations discovered 25 of 72 Wyoming coal miners with lung disease. To reverse recent upward trend in lung disease, research programatic have been directed at reducing exposure to respirable “float” dust. This paper suggests broadening the scope of research to include boundary detection in efforts to improve outcomes. Beginning with a better understanding of biochemistry of anaerobic bacteria methylation processes precipitating sulfur and heavy metals into thin seam boundary layers. Expanding research and development objective to focused on minimization of bit-pick crushing cone volume and preventing mining thin boundary coal layers and out-of-seam dilution. Black lung clinical evaluations of miner will confirm outcomes directed towards reduced occupational disease and smoke stack emissions. INTRODUCTION Miner exposer to bit-tip crushing cone volume, fragmentation and auger movement generated respirable “float” dust and boiler emissions are related science-technology –engineering-mathematics (STEM) problems. Formidable but not intractable problems are driven by oxidation of upper flood plain elements in the periodic table and biochemical metabolic presses occurring in coal basin. Because of burial compaction, quartz and trace heavy metals (Fe2+, Mg2+) are concentrated in thin seam boundary layers. By not cutting through thin boundary coal layer and out-of-seam into hard quartz containing rock layers, miner lung disease and smoke stack emissions are minimized. Cutting bit-pick elastic wave hydrodynamic principle force vectors in the coal layer must be aligned to minimize respirable dust generation, constrained by fragmentation size. Dust abatement by water spray and machine design are effective; but for, failure to address cutting cone dust volume generation and its distribution along run-of-mine (ROM) transportation systems the boiler. Real-time precision thickness measurements by integrated cutting drum (icDrum) sensor, machine man-interdiction from a dust free control room, is a cost effective way to prevents respirable dust exposure. The recommended STEM research and demonstration initiative addresses issues raised by discoveries of increased rate of lung disease discovered in young miners and concerns over emissions from coal-fired electric generation stations (Global Warming). In-mine demonstrations must be validated by on-site MCMC mobile Black Lung Clinic data acquisition and analysis."

Jan 1, 2016

By James Wonneberg, William Edgerton

"Today’s underground construction megaprojects are tremendous feats of engineering on a massive scale, excavating through ground conditions once thought impossible, using new and innovative contracting practices. But one important truth remains unchanged; projects are built by people. What separates winning projects from the rest? Great people, working in great organizations. In straight-talk fashion this paper sets forth fundamental differences between good project leaders and bad ones, on topics ranging from client relations, design management, and scheduling, to use of the whiteboard, and everything in between. Broadly applicable to all corners of project delivery, this paper will resonate with project leaders from around the world and help identify skills necessary to succeed in the management of underground facilities. A NOTE FROM THE AUTHORS This is a training document, and not really a “paper” per se. We have attempted to tackle some big and potentially complex topics using bite-sized paragraphs, each of which are intended to promote thoughtful introspection and dialog. So please feel free to skip around, or even set this document down while you reflect on your own personal experiences, tactics, and philosophies. We have found that providing examples of “what not to do” is oftentimes more instructive than simply listing “what to do”, hence the Good/Bad format of this document. Please note that “PM” refers loosely to anyone on the project management team not just the “Project Manager”. We also wish to preface this with the following cautionary statements: • The authors do not pretend to be the “Good PM” in all cases. In fact, we’re almost certainly the “Bad PM” for some. We aim to improve on those areas. • It has been said that “The only real training for leadership is leadership.” (Antony Jay) We all started somewhere, and nobody has 20 years of experience on day one. • Converting this text into some sort of prescriptive checklist would be a disservice to the evolution of project management. Our world – and our awareness of it – is constantly changing. We must always be open minded to new ideas and different perspectives on project delivery."

Jan 1, 2016

By A. Mellek, M. Pischtschan, M. Perrucci

ABB has received an order for one of the most challenging mill drive projects in its history. With one SAG mill and one ball mill to be added at an iron ore mine in Sweden, the customer’s plant managers wanted to have the most efficient solution for driving their mills but had the budget limitations typically faced by the majority of mining companies during periods of market downturn. To find the best balance between cost of acquisition and highest performance throughout the lifetime of the plant, ABB was selected to deploy a synchronized bypass solution, in which only one drive system is used for two different mills in series. However, being one of the first grinding mills in the world with such a solution was not the only challenge the ABB team faced: The inclusion of some mill application functions - e.g., frozen charge protection, automatic positioning and creeping mode - brought the demands on the engineers to another level. With only one frequency converter and one mill application controller available, the configuration logic and interlocks had to be meticulously designed and thoroughly tested to ensure a smooth and safe startup. The solution offers a footprint reduction and more operator flexibility at a reduced investment as each mill can be run in both directions, and wear on the mechanical components can be greatly reduced due to ABB’s premium ring-geared mill drive (RMD). This paper will describe the details of the project, the configuration developed and the tests performed to guarantee correct software functionality. Mill startup is scheduled for January 2016.

Jan 1, 2016

By D. K. Sarkar, Jiawei Xiong

"Self-assembled monolayers (SAM) on the aluminum substrates are used as the adhesion promoter between two aluminum substrates when bonded with the adhesive in adhesive bonding technology. Traditional surface analysis tools are not capable of identifying the presence of SAM on a surface; therefore, EIS has been used to determine their presence on the aluminum substrates. In this study SAMs have been deposited on aluminum using the monomer of (3-Glycidyloxypropyl)trimethoxysilane (GPTS) organosilane. AA6061 aluminum alloys substrates were chemically cleaned with NaOH and HNO3 to remove the native oxides, followed by immersion in silane solutions. In a second method, SAMs were prepared by applying a spin coating of silane solution to the samples. The prepared SAM coated aluminum samples were analysed by EIS in the three electrode corrosion cell using a diluted alkaline solution. The impedance of the SAM coated aluminum is found be higher than the as-received aluminum. It has been also observed that the open circuit potential (OCP) of the SAM coated aluminum is higher than the as-received aluminum. Both elevated values of the impedance and OCP confirm the presence of SAM on aluminum.INTRODUCTIONSelf-assembly (Schreiber, 2000) is defined as the spontaneous formation of complex hierarchical structures from pre-designed building blocks, typically involving multiple energy scales and multiple degrees of freedom. Generally speaking, SAMs are created by the chemisorption of ""head groups"" onto a substrate from either the vapor or liquid phase followed by a slow organization of ""tail groups"" of a molecule. Typically, head groups are connected to a molecular chain in which the terminal end can be functionalized with groups such as –OH, –NH2, –COOH, or –SH to vary the wetting and interfacial properties (Chauhan et al., 2007; Ulman, 1996; Vashist, Lam, Hrapovic, Male, & Luong, 2014). Though there exist several methods to prepare SAM (Chauhan et al., 2007; Chen, Yang, & Zhang, 2014; Cho, Park, Jon, & Choi, 2007; Igor Luzinov, 2000; Reis, de Melo, & Costa, 2006; Song, Zhai, Wang, & Jiang, 2006; Sugimura, Hozumi, Kameyama, & Takai, 2002; Vashist et al., 2014), the two methods vapor phase (Song et al., 2006; Sugimura et al., 2002) and solution(Chen et al., 2014; Igor Luzinov, 2000) are commonly used. Recently, many articles have been published on the fabrication of superhydrophobic surfaces with SAM technology (Cho et al., 2007; Pan, Shen, Shang, & Xing, 2012; Siddaramanna, Saleema, & Sarkar, 2014; Song et al., 2006). Brassard, Sarkar, and Perron (2011) successfully obtained a superhydrophobic film by applying fluoroalkylsilane via self-assembly on monodispersive silica. SAMs are also reported as good candidates for anti-corrosion and adhesion promotion (Chen et al., 2014; Saleema, Sarkar, Paynter, Gallant, & Eskandarian, 2012). However, papers on the characterization of SAM properties are rarely seen. The most commonly used substrate for SAM is silicon and the method implemented is scanning probe microscopy (SPM) such as atomic force microscope (AFM) (Igor Luzinov, 2000; Moores, 2011; Zhang, 2003, 2005). Igor Luzinov (2000) analyzed the epoxysilane SAMs’ surface morphology and microstructure properties using scanning probe microscopy (SPM) and ellipsometry on single-crystal silicon wafers. SAMs have been used to improve the adhesion bonding of aluminum or plastics but no characteristic data have been presented yet (Saleema et al., 2012; Telegdi, 2007; Wang, Xu, Luo, Wang, & Wang, 2009). Recently, Reis et al.(Reis et al., 2006) have studied SAM of alkane diphosphonate (Gardobond X4661) on Al 5052 alloy samples by EIS in a naturally aerated sodium sulfate solution."

Jan 1, 2016