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By Magnus Evertsson, Johannes Quist

HPGRs have since introduced in the 1980s (Kellerwessel, 1993; Schönert, 1988), now become integral comminution units at several minerals processing plants around the world. Even though a lot of the initial issues concerning performance, availability and wear have been addressed and solved there are still phenomena and aspects which can be improved and understood further. Schönert and Sander (2002) presented experimental results and a mechanistic model including the internal force dynamics between the rollers and the compacted bed. They derived expressions for the pressure distribution involving most of the influencing terms and effects. However, in order to solve the differential equations several of the terms vanish by assumptions. The Schönert and Sander model reflects the experimental data in many aspects but the predicted shear force distinctly deviates from the experimental results at the angular position of the peak pressure level. This finding suggests that the particle to particle interaction and breakage process in the different zones seen in Figure 1 are complex and difficult to model using analytical models. A numerical modelling approach using DEM does not require the same amount of assumptions and simplifications of boundary conditions. Hence such modelling may provide further knowledge and vital understanding. In this paper the breakage process is simulated in order to investigate the shear slip behaviour and how it relates to different operating variables. A laboratory scale HPGR corresponding to the experimental setup used by Schönert (2002) have been modelled in EDEM (DEM-Solutions). The bonded particle model (BPM) is used for modelling quartz particles (Potyondy, 2004). The breakage model strength parameters are calibrated against interparticle breakage experiments in an Instron 400RD compression device. The contact model parameters are calibrated using calibration methods developed by Quist (2015). The floating roller dynamics are modelled using a spring-damper system. Results present insights regarding the interparticle slip behaviour as well as the frictional tangential force distribution on the rollers. The simulated roller pressure distribution shows good correspondence with previously reported findings in the literature.

Jan 1, 2016

By Scott Lewis, Andrew Kositsky

"INTRODUCTIONThe South Napa Earthquake of 2014 caused ground motion at numerous reinforced concrete-lined (shotcrete-lined) winery tunnels in Napa County and Sonoma County, California. The occurrence of seismic ground motion at these tunnel complexes, known as wine caves, presented an opportunity to reevaluate seismic performance of reinforced concrete and reinforced shotcrete lined tunnels. The authors of this paper updated the most recent comprehensive compilation and evaluation of case studies by Power and others (1998), which correlates peak ground acceleration (PGA) at tunnel sites to damage. For this update, the authors evaluated the seismic performance of 31 wine caves near the South Napa Earthquake epicenter; including some of the 90 wine caves they designed since 1991, some caves designed by others, and additional caves constructed by contractors that they frequently work with. Tunnel designers can use the new data presented in this paper to help evaluate the usefulness of detailed seismic design analyses. THE SOUTH NAPA EARTHQUAKE The South Napa Earthquake occurred at 3:20 AM Pacific Daylight Time on August 24, 2014. Figure 1 shows the approximate location of the epicenter, the measured/estimated PGA contours, and the location of wineries with wine caves added to the database where the PGA was at least 0.2 g. The epicenter was along the West Napa fault, about 5 miles south-southwest of downtown Napa, California. The earthquake moment magnitude was 6.0, and measured/estimated PGAs were up to about 0.7 g. The duration of strong shaking was about 10 seconds. This earthquake was characterized by right lateral strike-slip fault movement, ground surface rupture, and after slip at the ruptures. Increased surface water flows were observed at seven creeks after the earthquake. Groundwater level rises of up to 5 feet were observed in Sonoma County wells after the earthquake. The earthquake was the largest seismic event in the San Francisco Bay Area, which includes Napa and Sonoma Counties, since the 1989 Loma Prieta Earthquake. The Napa event caused an estimated $400 million in damage. This damage included moderate to extensive structural damage to older commercial buildings and to some newer buildings in downtown Napa. This damage resulted from ground motions, subsequent fires, and failed underground utility systems."

Jan 1, 2016

By Junhyun Choi, Allan Gomez-Flores, Chonbuk National University, Siyoung Q. Choi, Gahee Kim, Seungkon Kim

In this study, to confirm the effect of depletion attraction on the flotation, we theoretically and experimentally investigate the effect of the depletion attraction force on flotation. While varying the concentration of the depletion agent (polyethylene glycol), three different systems are studied: pure malachite, pure silica, and a 1:1 mass ratio of malachite and silica binary system. We find that recovery increases significantly as the concentration of the depletion agents increases for all three systems, as the depletion agent facilitates the adsorption of the particle on the bubble surface. However, the recovery suddenly decreases in a certain concentration range, which corresponds to the onset of the decreased surface tension when high concentrations of the depletion agent are used. This non-monotonic overall recovery trend implies the surface adsorption of the depletant on a surface. The decreased surface tension of the air/water interface suggests that the recovery rate is lowered due to the adsorption of the depletion agent to the bubble surface, acting as a polymer brush. Based on our observations, we conclude that the depletion force can greatly improve particle adsorption, as predicted in the accompanying theory paper, while simultaneously the adsorption of the depletion agent on the bubble surface plays an important role because it hinders particle adsorption. We also perform experiments in the presence of a small amount of a collector, sodium oleate. An extremely small amount of the collector leads to the increase in the overall recovery, which eventually reaches nearly 100 percent. Nevertheless, the grade worsens as the depletant provides the force to silica particles as well as target malachite particles.

Jan 1, 2016

By Michael Murphy, Khaled M. Mohamed, Berk Tulu

"Failures of coal ribs are major hazards in underground coal mines. For the period of 2010 to 2014, rib falls were the leading cause of groundfall fatalities and accounted for 35% of all groundfall-related fatalities. Currently, the National Institute for Occupational Safety and Health (NIOSH) is conducting a research project to develop an engineering-based design methodology for rib control in underground coal mines to reduce rib fall accidents and fatalities. Numerical models can be used as part of the design methodology provided the models are appropriately calibrated and verified.This paper presents a coal rib model to simulate the mechanism of coal deformation and fracturing that can lead to stress-driven rib falls. The proposed coal rib model was calibrated against published data from an instrumented rib site at the West Cliff Mine in Australia. Fracturing of the coal rib was defined by critical VALUES (of plastic shear strain of the coal material and rib displacement. A critical plastic shear strain of 2.8% and a sudden increase of rib displacement of 30 to 45 mm were sufficient to develop a fracture plane in the rib model. Accordingly, a discontinuous rib deformation was achieved and it compared favorably against field monitoring data.INTRODUCTIONCoal ribs are the vertical walls of coal formed when entries are developed in a coal bed. Failures of coal ribs are a major hazard in underground coal mines. Furthermore, failing ribs can contribute indirectly to roof and floor instability by increasing opening widths across intersections and entryways. Over the last 18 years, there has been a continual occurrence of injuries and fatalities in underground coal mines due to rib falls. For the period of 2010 to 2014, rib falls (excluding longwall face failure and bursts) were the leading cause of ground fall fatalities and accounted for 35% of all groundfall-related fatalities (MSHA, 2015)."

Jan 1, 2016

By L. Yuan, A. Smith

"NIOSH’s mine fire simulation program, MFIRE, is widely accepted as a standard for assessing and predicting the impact of a fire on the mine ventilation system and the spread of fire contaminants in coal and metal/nonmetal mines, which has been used by U.S. and international companies to simulate fires for planning and response purposes. MFIRE is a dynamic, transient-state, mine ventilation network simulation program that performs normal planning calculations. It can also be used to analyze ventilation networks under thermal and mechanical influence such as changes in ventilation parameters, external influences such as changes in temperature, and internal influences such as a fire. The program output can be used to analyze the effects of these influences on the ventilation system. Since its original development by Michigan Technological University for the Bureau of Mines in the 1970s, several updates have been released over the years. In 2012, NIOSH completed a major redesign and restructuring of the program with the release of MFIRE 3.0. MFIRE’s outdated FORTRAN programming language was replaced with an object-oriented C++ language and packaged into a dynamic link library (DLL). However, the MFIRE 3.0 release made no attempt to change or improve the fire modeling algorithms inherited from its previous version, MFIRE 2.20. This paper reports on improvements that have been made to the fire modeling capabilities of MFIRE 3.0 since its release. These improvements include the addition of fire source models of the t-squared fire and heat release rate curve data file, the addition of a moving fire source for conveyor belt fire simulations, improvement of the fire location algorithm, and the identification and prediction of smoke rollback phenomena. All the improvements discussed in this paper will be termed as MFIRE 3.1 and released by NIOSH in the near future INTRODUCTION The MFIRE program, originally developed in the 1970s by the U.S. Bureau of Mines (now the Office of Mine Safety and Health Research (OMSHR) at the National Institute for Occupational Safety and Health (NIOSH)) and Michigan Technological University, has been a mainstay in modeling of the mutual influences between a fire and the mine ventilation system during an underground mine fire. Several update versions have been released over the years, including MFIRE 1.27, 1.29, 1.30, 2.0/2.01, 2.10, and 2.20. The MFIRE program logically comprises four parts: (1) a conventional network calculation, where it performs the basic network balancing without considering heat or mass transfer; (2) a temperature calculation to establish the reference temperature distribution before a non-steady state (transient-state) simulation; (3) a transient-state simulation that follows changes in ventilation step-by-step to produce a continuous description of the temperature distribution, smoke, and contaminant spread through the ventilation system during a fire event; and (4) a quasi-equilibrium simulation to predict the state of the ventilation system after a relatively long period of time (defaulted as 5 hours in MFIRE) as the fire reaches a quasi-steady state. In summary, MFIRE is a computer simulation program that performs normal ventilation network planning calculations and dynamic transient-state simulation of ventilation networks under a variety of conditions including the influence of natural ventilation, fans, fires, or any combination of these (Chang et al., 1990)."

Jan 1, 2016

By C. J. Hartley

"Scandium oxide can be recovered as a by-product from process streams in a number of chemical and metallurgical plants including TiO2 sulphate pigment, Ni/Co laterite, zirconium oxychloride and uranium operations. The feed materials available for processing can be either mid or end of process streams containing many species in solution. This paper describes the strategies available to limit coextraction of elements into scandium containing streams from TiO2 pigment production and the removal of these elements to deliver high purity scandium oxide.A critical part of process development is to work within the constraints of the main process in terms of introducing new unit processes and producing minimal additional process intermediates and residues. This requires flexibility in designing flowsheets and plants to find novel process routes that avoid production of intermediates and/or the introduction of reagents that can compromise the main process operations.Bloom Energy has developed novel solvent extraction processes for the extraction and refining of scandium oxide that minimise impacts on core process streams within TiO2 pigment plants. The additional unit processes are designed to have minimal contact with pigment plant process streams to produce a concentrate that is refined to nominal 3N purity scandium oxide in a simple, small scale commercial plant."

Jan 1, 2016

By V. van der Merwe, C. W. Siyasiya

"A petrochemical company experiences premature thermal fatigue failure of the casting moulds used in catalyst production. The aim of the project was to find an alternative alloy that would outperform the current low-alloy cast steel used for the moulds. Based on their thermo-fatigue properties, 3CR12 ferritic stainless steel and H11 tool steel were chosen for testing and comparison with the currently used BS3100 B7 cast steel. Samples of each material were subjected to temperature cycling in a Gleeble 1500TM thermo-mechanical processing simulator, followed by surface analyses. The main parameters derived from the test work were the total true strain, the hot strength of the materials, and the number of cycles to failure. Additionally, the coefficient of thermal expansion for each material was measured using a Bähr dilatometer. H11 tool steel yielded the best performance by way of having the fewest surface cracks, the lowest total true strain per cycle, the most cycles to failure, the highest hot strength, and the lowest coefficient of thermal expansion.IntroductionThe Catalyst Manufacturing Plant (CMP) is a dusty environment with temperatures higher than ambient. Molten mill scale (magnetite, Fe3O4) is tapped from the electric arc furnace into the casting moulds at temperatures close to 1600°C. After 10 seconds the magnetite is quenched with a water spray for 50 seconds to a minimum temperature of 400°C. Sometimes there is residual water in the pans from the cooling fog process (water sprays) in the empty mould. In a typical plant, the factory produces 40–44 batches a day containing between 150–300 moulds, depending on the time required for the specific batch (Buchholz, 2014). The typical batch in the CMP usually weighs about 6 t. The thickness of the tap, speed of the casting belt, and tilting angle all affect the number of moulds per batch.One of the main problems faced during the molten mill scale casting is the premature failure of the casting moulds. Cracks initiate on the surface of the mould, which is in contact with the hot catalyst, and propagate into the interior of the mould. Cracks are generally concentrated in the middle area of the mould where the catalyst makes first contact with the mould, and which experiences the highest temperature fluctuations. This suggests that the cracks are caused by thermal fatigue during the casting process."

Jan 1, 2016

By K. Forsberg, A. Rasmuson, R. Rodriguez Varela, J. Martinez De La Cruz

"This study analyzes the separation of rare earth elements by means of a supported liquid membrane (SLM) with the final objective of recovering REE from an apatite concentrate (Alemrajabi, Forsberg, & Rasmuson, 2015; Mohammadi, Forsberg, Martinez de la Cruz, & Rasmuson, 2015). In this study, the feed phase consists of an aqueous phase containing REE, the membrane phase contains the organic solvent and carrier (D2EHPA and EHEHPA), and the stripping phase is a hydrochloric acid solution. An evaluation of mass fluxes, separation efficiency, and membrane performance is conducted. In order to analyze the suitability of liquid membranes in the extraction of REE, a deeper insight into the mechanisms causing instability is needed. In this study, surface tension is considered as the key factor of Marangoni instabilities and spontaneous emulsification.INTRODUCTIONThe demand of REE and their compounds has increased considerably due to their special physicochemical features that make them crucial elements for numerous high-tech applications, including wind turbines, hybrid cars, mobile phones, and defense technologies. They are also extensively utilized in traditional industries such as nuclear energy, petroleum, metallurgy, agriculture, and textiles (Xie, Zhang, Dreisinger, & Dyole, 2014; Zhang, Wu, Bian, & Zeng, 2014).Solvent extraction is widely used for the separation of REE (Xie et al., 2014; Zhao, Huo, Pan, Li, & Liu, 2014). Di-(2-ethylhexyl)-phosphoric acid (D2EHPA) and 2-ethylhexylphosphonic acid mono-2-ethylhexyl ester (EHEHPA) are two of the most effective extractants for the separation of rare earth elements among organophosphorus extractants (Gupta & Krishnamurthy, 2005). However, the difficulty in stripping loaded D2EHPA extractant, especially for heavy REE, has limited its utilization. Yttrium can be stripped at lower acidities in EHEHPA systems compared to D2EHPA systems (Gupta et al., 2005), but the extraction efficiency is lower. Conventional solvent extraction by mixer-settlers is restricted by its large solvent inventory and loading limits, and suffers from phase disengagement, emulsification, loss of solvent, and flooding problems (Swain, Jeong, Lee, & Lee, 2007). In this context, supported liquid membranes (SLMs) present a potential alternative due to their advantages, being low solvent inventory, process simplicity, low energy and operational costs, great enrichment ratio, and combination of extraction and stripping into one single step. A SLM is a system in which two aqueous phases are separated by an organic liquid membrane suspended in the pores of a porous support by capillary forces. One of the aqueous phases is the feed solution with the solute and the other is the stripping or receiving solution. The solute diffuses through the liquid membrane and then is extracted into the stripping solution (Kislik, 2010)."

Jan 1, 2016

"A carefully planned laboratory test program is the foundation for the successful development of a sulfide flotation process. In this paper, the development of a copper-molybdenum flotation process is described. However, the concepts discussed can be applied to most sulfide flotation systems and to many industrial minerals projects as well. Each step is examined, beginning with sample procurement and covering sample preparation, flotation test preparation grinding, scoping flotation tests for reagent scheme selection, rougher flotation parameter evaluation and cleaner circuit evaluation, through to locked-cycle testing and pilot plant design and operation. Ore variability and modeling to determine the response of various ore types to the optimum conditions established is also examined.IntroductionA carefully planned laboratory test program is essential for the successful development of any sulfide flotation process. These programs usually begin with a series of batch tests on several ore type composites to evaluate appropriate reagent schemes and delineate optimum rougher flotation conditions, such as primary grind size, flotation pulp density, flotation pulp pH and retention time. Cleaner parameters such as regrind size requirements, cleaner pH, pulp density and number of stages are then defined. Semicontinuous locked-cycle tests are performed using the parameters established in the batch tests to determine the effect of middling streams recirculation on flotation performance. The data generated and the experience gained in the locked-cycle tests may be used to design and operate a continuous pilot plant if relatively large amounts of concentrate are required for further process development, such as optimization of byproduct molybdenum production from bulk copper-molybdenum concentrate.A comprehensive ore variability program is undertaken to determine the response of various ore types to the optimum conditions established. These ore variability programs often test hundreds of samples in standardized batch rougher and cleaner tests to ensure that the orebody is well understood.This article describes the development of a copper-molybdenum flotation process, but the concepts discussed can be applied to most sulfide flotation systems and many industrial minerals projects. The block flow diagram in Fig. 1 provides an overview of the development process."

Jan 1, 2016

By S. Steinlechner, S. Wegscheider

"In the past, the metallurgical industry was most of the time dedicated on their main commodity, recovering base metals like zinc, copper or lead but leaving other valuable side elements in the generated residues. As a result, these accompanying minor elements, like gold, silver, indium or also PGMs can be found in the dumps of the corresponding industry. Because of political unrest, strikes, economic reasons or decreasing primary resources leading to a high supply risk, also those mentioned minor elements moved into the focus of the recycling industry. Therefore, beside the base metals, first of all the recovery of those minor metals would be of high interest contributing to the economic viability of recycling processes, although they occur in much smaller quantities in materials. In this context, residues from zinc industry, like leaching residues or precipitation residues show high potential to carry silver as well as indium next to lead and zinc. Therefore, the paper summarizes carried out thermochemical calculations investigating a possible recovery of silver as well as indium by volatilization and the influence of zinc and lead on this process. Based on these theoretical investigations with HSC, trials in lab scale were done verifying the obtained results.INTRODUCTIONHuge amounts of iron precipitate, mainly jarosite get landfilled every year although there is a high content of valuable metals in this residue beside iron. Nevertheless, jarosite has to be dumped due to the presence of contaminating heavy metals. The accumulation of these residues takes up massive land on the one hand but also causes a series of environmental problems in ecosystems on the other. Moreover, some toxic ingredients such as arsenic and cadmium can be dissolved in rain water and are therefore harmful to the health of the aquatic systems. (Erdem & Özverdi, 2011; ÖzverdI & Erdem, 2010) Approximately 0.5 t of dry jarosite accumulate in the production of 1 t of zinc by the hydrometallurgical zinc-winning route (Svens, 2010). Jarosite is a precipitation residue formed during the iron removal. In general, the iron already exists in the zinc ore which is why zinc ferrite builds up during the roasting step of the zinc ore. Zinc ferrite is only soluble in strongly acidic solutions and during the hot acid leaching step it gets dissolved while zinc and iron enter the solution. It is necessary to get rid of the iron because otherwise it would deposit on the cathode first due to its precious character which would be harmful in the zinc-winning electrolysis. Nevertheless successful investigations were done by adding chlorine to the jarosite to recover silver. These findings leads to another residue which occurs in huge amounts – electric arc furnace dust (abbreviated with EAFD) from the iron and steel industry. In 2013 the annual electric steel production reached about 451 million tons. Around 15-20 kg of EAFD is produced per ton of steel in an electric arc furnace (EAF), creating approximately up to 9 million tons of dust per year. (Grabda, Oleszek, Shibata, & Nakamura, 2014; World Steel Association) Next to elements like zinc, lead and iron, chlorine and fluorine are present in this dust. While galvanized steel plates in the scrap act as a source for zinc, casting powders, flame retardants and synthetic coatings are responsible for the chlorine and fluorine contents in the dust."

Jan 1, 2016

By L. Alagha, M. Khodakarami

"This work focuses on the extraction of rare earth metals (REE) from aqueous solutions using stimuli-responsive polymers. Various parameters affecting the adsorption capacity of the polymer, including pH, polymer concentration and REE concentration were studied. The interfacial behavior of REE in aqueous phase before and after polymer addition and the mechanism of the formation of metal-polymer complexes and their properties were investigated using UV/VIS spectroscopy. Results obtained would help to test the feasibility of employing stimuli responsive polymers in pre-concentration of rare earth elements associated with other elements in mineral aqueous streams prior to solvent extraction. The pre-concentration step would reduce the amount of organic solvents used for extraction and striping compared to conventional extraction processes. INTRODUCTION Rare earth elements (REEs) have become the foundation for several technologies and have been used extensively in many industries such as modern electronics, green energy, health care and transportation and defense [1-4]. As these industry sectors are growing, the global consumption of REEs is going to increase dramatically. The current global REEs demand is estimated to be 105,000 tons of rare earth oxides per annum with an expected annual growth of 5.6% [5-6]. Rare earth elements are produced from different sources (primary and secondary). China is considered as the largest producer of REE in the world, providing about 90% of the world’s mine production while the United States is second with 4% of the mine production [7]. High global demand for rare earth materials results in shortage of such materials in the near future. It should be considered that the term ‘‘rare’’ earth is not an accurate term, since they are abundant in some extent in the Earth’s crust, but are typically finely dispersed. Thus, nowadays looking for more efficient and cheaper methods for extraction, separation and purification of low concentrated REE ores and exploring secondary sources are essential. Rare earth materials are found in raw condition and require treatment that involves several processes, which can consume money and time. Recent improvements in extraction and recycling technology have made the extraction of rare earth elements from rare earth sources more feasible in terms of cost and time [8-10]. Physical and pyrometallurgical methods require high-energy and thus high costs. Moreover, due to environmental problems, environmental protection systems are required, and they are not as adaptable as chemical processes [11, 12]."

Jan 1, 2016

By H. Jung, J. Kim, Y. Lee, Y. Seo

"Shale gas has become an increasingly important source of natural gas supply in North America and around the world. Horizontal drilling and multi-stage hydraulic fracturing are the two key enabling technologies for the economic development of these shale gas reservoirs. It is believed that gas in shale reservoirs is mainly composed of free gas within fractures and pores and adsorbed gas in organic matter (kerogen). It is generally assumed in the literature that the monolayer Langmuir isotherm describes gas adsorption behavior in shale gas reservoirs. In this work, we have analyzed several experimental measurements of methane adsorption from the Horn River Shale core samples that obey the Langmuir isotherm. INTRODUCTION In nature, gas shales are characterized by extremely small grain size, extremely low permeability on the order of nano-Darcy (10-6 md), small porosity, and high total organic carbon (TOC). Shale can serve as both source and reservoir rock. The amount of gas in place in shale is strongly affected by the TOC, clays, and the adsorption ability of methane on the internal surface of solid (Martin et al., 2010). Since a considerable amount of gas in shale reservoirs is adsorbed, investigation of gas adsorption can provide critical insights into evaluation of well performance and reservoir characterization. Generally, natural gas in shale reservoirs is stored as free gas in both larger mineral pores and natural fractures, as well as adsorbed gas within organic matter (Leahy-Dios et al., 2011). EXPERIMENT METHOD & THEORY Adsorption Experiment Several experiments were carried out on 9 shale core samples obtained in a vertical well drilled within Horn River basin (Figure 1). The CH4 adsorption isotherms were measured for the different depth. In order to measure the amount of adsorbed gas, the high pressure Belsorp-HP equipment applying volumetric method was used. The temperature was kept at 298 K and pressure was increased up to 18 MPa. Approximately 5 g of crushed sample was used for each measurement."

Jan 1, 2016

By E. Ghali, C. Su, G. Houlachi

"The influence of lead ions on zinc electrowinning process was investigated by means of electrochemical noise measurements (ENMs) and cyclic voltammetry in conjunction with scanning electron microscopy and X-ray diffraction. All electrochemical experiments were performed in sulphuric acid electrolyte containing different lead ion concentrations as impurity. Lead was added in six trace levels between 0.05–0.8 mg/L in the bath. The lead content of the zinc deposits was dependent on the introduced lead concentrations. The overpotential associated with zinc electrodeposition shifted to higher values with the increase of lead concentration in the solution. An appropriate correlation was found between the different concentrations of lead in the electrolyte and the morphology of zinc deposit by ENM. The results showed that the increase of lead ion concentrations is generally accompanied with the decrease of skew and increase of kurtosis values that could be related to the morphology of zinc deposit. Effectively, the morphology changes from well-defined hexagonal platelets to large hexagonal, layered platelets and finally to non-symmetric refined crystalline structure, respectively.INTRODUCTION In commercial zinc electrowinning, zinc oxide is leached from the roasted calcine with an aqueous acid sulfate electrolyte. Then the zinc-rich solution is purified and transferred into an electrolytic cell. During electrolysis, zinc is deposited on aluminum cathode where lead-silver or pure lead is served as anode. Electrodeposition of zinc could be influenced by several parameters such as bath acidity, temperature, current density, the nature and concentration of impurities as well as additives in electrolyte. Metallic impurities play a complex role during zinc electrowinning and they can adversely"

Jan 1, 2016

By M. Ye. Shulgina, M. L. Bolotin, S. A. Prokopev, Ye. S. Prokopev

Iron ores concentration at Russia’s operations is carried out using conventional flow sheets. They comprise the two-four stage grinding followed by one-two stage magnetic separation. This results in the maximum recovery of magnetite to concentrate and the tailings generation. The final concentrate is generated only during the last stage of magnetic separation. Technologically, this flow sheet layout is not effective at recovering the liberated magnetite grains during grinding to the resulting concentrate. Advanced models of magnetic separators do not allow for the selective separation of the tailings and the portion of the resulting iron ore concentrate. Magnetic product which is the ore mixture of the liberated magnetite grains, high grade and low grade intergrowths is directed to the next grinding stage. In this case, regrinding of the liberated magnetite occurs. In addition, the performance of hydrocyclones during classification in closed grinding circuits is poor. Their classification efficiency does not provide the material separation in accordance with the size. In this case, simultaneous separation in accordance with the density occurs. The quartz particles with the size of 300 mm have similar velocity and trajectory like the particles of magnetite with the size of 60 mm. As a result, light and coarser intergrowths report to the overflow and free heavy magnetite grains report to underflow and return to regrinding (“the density effect”). This resulted in a significant increase of a mill circulating load, the decrease in the feed throughput and higher power consumption. In this connection, the development of iron ore concentrate stage recovery with the focus on gradual liberation of the intergrowths is getting much attention. Gravity concentration technique, particularly, spiral separation is effective at solving the problem of stage recovery not only the dump waste product but also high grade magnetite concentrates at the early concentration stages. This can be attributed to a significant difference in magnetite (4.9-5.2 g/cm3) and host minerals (quartz 2.7 g/cm3) densities, which is the principal during gravity concentration. The test work on concentration of various products samples from current operations (the mills discharges, concentrates from various stages of wet magnetic separation and cyclones underflows) was carried out. Spiral separators SV- 500 and ShV-500 manufactured by Spirit LLC were used for the test work. High grade iron ore concentrate (69.05% Fe) was generated during primary wet magnetic separation concentrate concentration using a spiral separator. During the concentration of mills discharges the content of iron in the resulting concentrates and middlings of wet magnetic separation II stage was 64.5% and 64.6%, respectively. The recovery of iron to the concentrates of spiral separation was 33.6-42.0%. The studies presented demonstrate that by using spiral separation for iron-bearing ores concentration, you can separate magnetite liberated grains at the early concentration stages, decrease their regrinding and circulating loads in grinding circuits. This process is able to improve the overall recovery and economics of iron ores concentration process.

Jan 1, 2016

By K. Wu, X. Yuan, R. Du, C. Chao

"Lump coals are currently employed to replace part of coke in the COREX melter-gasifier for ironmaking. In order to optimize the process, the pyrolysis kinetics of Datong coal used in the COREX process was studied. A sectioning method is proposed to overcome certain shortcomings of traditional methods for studying the pyrolysis of coal. Based on the sectioning method and the characteristics of the coal pyrolysis process, the temperature range was divided into three intervals. In the first, the adsorbed gas and water of crystallization were removed; in the second, the coal was transformed into semi-coke; and finally, the semi-coke was further coked. Three models of reaction were then established to study the different stages of the pyrolysis process: an interfacial chemical reaction model, a random pore model, and internal diffusion with shrinking volume. The results showed that the experimental data fitted the models well, with all correlation coefficients (r2) exceeding 0.97. Finally, the mechanisms of reaction and kinetic parameters for each temperature range were derived, which laid a necessary foundation for optimizing the usage of non-coking coal in the COREX process. IntroductionIn view of environmental concerns and the shortage of good-quality coking coal, the COREX process was designed as a new ironmaking technology, attracting wide attention (Fang et al., 2005). In this process, lump coal and a small quantity of coke are directly charged into the melter-gasifier, where a high-quality reducing gas is generated for the reduction of the iron ore (Kumar et al., 2009). In contrast to the conventional blast furnace (BF) process, non-coking lump coal is used as the reducing agent and as the energy source, and the iron charge consists of lump ore and/or pellets, which results in the elimination of the coke oven and sintering plant as well as a decrease in investment (Kumar et al., 2009; Liu et al., 2012).Although the COREX process has made great progress, in current production practice the energy consumption greatly exceeds that of the BF, and it requires a certain amount of coke to maintain permeability of the semi-coke bed (Wang et al., 2008). In addition, the process consumes a lot of good-quality lump ore and lump coal. The pyrolysis of coal is the first step in most coal conversion processes, such as carbonization, gasification, and combustion (Aboyade et al., 2013). The reaction behaviour of lump coals in the COREX melter-gasifier is crucial, as it determines energy utilization and gas composition, as well as the metallurgical properties and particle size of the semi-coke produced (Prachethan et al., 2011; Zhang et al., 2014). In order to optimize the process and improve its competitiveness, the pyrolysis kinetics of Datong coal used in Baosteel’s COREX C-3000 facility was studied."

Jan 1, 2016

By David M. Langlais, Krystle Pelham

"Explosives used in blasting operations, natural and anthropogenic sources such as septic systems,fertilizers, and decomposing vegetation can potentially contaminate groundwater with nitrate in thevicinity of construction sites and make identification of blasting impacts difficult. Blasting operationsfor a private construction project in Windham, New Hampshire were indicated as the source of water quality impacts to private drinking water wells prompting the New Hampshire Department ofTransportation (NHDOT) to implement a proactive approach to limit the potential for impacts fromblasting for ongoing NHDOT projects. NHDOT has developed a baseline drinking water monitoringprogram designed to detect potential impacts and to ensure alternative drinking water is providedthroughout the construction phase of projects. In 2013, the U.S. Geological Survey (USGS) andNHDOT began a study to determine the source and fate of nitrogen compounds near blasting sites using a combination of isotopic, time series, geochemical, hydrologic, and geologic data. Approximately 1.75 million cubic yards (1.33 cubic meters) of rock were removed by blasting in several locations for roadway construction at a major highway construction site in southern New Hampshire."

Jan 1, 2016

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