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Agglomeration for Copper Heap Leaching Agglomeration of ore is a method which can be used to eliminate the migration of fine grained particles throughout a leach heap. Without agglomeration, fine ore particles are able to migration within the heap, clogging flow channels and producing large areas where access of the solution is poor. In order to gain the benefits of agglomeration and improve agglomerate strength even further in copper heap leaching, an economical, acid-resistant binder is needed. However, most binders have been used without any systematic reasoning. A set of novel testing methods were developed, including a soak test, percolation flooded columns, and larger long-term leach columns. The soak test compares the degree of breakdown when agglomerates are subjected to an acidic environment. While the percolation flooded columns and larger long-term leach columns evaluate the flow of leach solution throughout the ore bed. Systematic studies have been completed on a wide range of binders using these novel testing procedures. It was found that for a low grade chalcocite ore, which was rich in silica, from a southwest US mine, polyacrylamides reduced the fines migration the best in the novel soak test. The non-ionic binder, in particular, was found to reduce fines migration as much as 93 per cent. Several of the binders tested were shown to increase the hydraulic conductivities of the agglomerated ore up to 2.5 mm/sec, compared to a hydraulic conductivity of only 0.25 mm/sec when no binder was used. These binders also prevented 'slumping' of the ore, which indicates a decrease in breakdown of the agglomerates. The use of a binder also showed no interference with leaching reactions in long-term leaching experiments.

Sep 13, 2010

Recently, work was carried out by the Shotcrete Working Group to study anisotropy in steel fibre reinforced shotcrete using strain-controlled, compressive strength testing methods. The shotcrete materials used and specimen preparation procedures as well as testing methods are described. The test results are discussed and it is concluded that, because of the anisotropic nature of fibre reinforced shotcrete, it may be worthwhile investigating the degree of such anisotropy in practice using strain-controlled, strength testing techniques.

Jan 1, 2001

By Mark E. Smith

Oxide ores can consume enormous amounts of expensive sulfuric acid. The problem is amplified with increasing heap heights. One solution is to provide a thin liner and drainage system between each lift of ore, thereby intercepting the pregnant leach leach solution (PLS) after it exits the active lift. However, these liner systems require special attention to hydraulics, slope stability and geomembrane design criteria. Inadequate attention to the first two can result in reduced recoveries, increased acid consumption andsystem failures. The geomembrane selection criteria are different from the base liner, and optimizing its selection can have significant effects on the operation’s bottom line.

Jan 1, 1996

By D Rubery, C Croker

The Boddington Gold Mine (BGM) is located 120 km south east of Perth, Western Australia. The operation is managed by Worsley Alumina Pty Ltd and mined by contractor Henry Walker Eltin (HWE). The mine has been operating since 1987 with ore extracted from a series of pits along strike. Ore is contained within the basement rock, which is overlain by a cap rock layer and transition zone. Cap rock and basement zones require blasting.As the mine neared completion, a high-grade deposit was discovered within 50 m of an existing Western Power substation and 100 m from the processing mill. The substation provides power to the Boddington area and is a back-up power supply to the city of Perth. Due to the delicate nature of the transformers located at the power station, overhead power lines and the mill, blasting in the area was considered very high risk. As such blasting needed to be controlled for flyrock, airblast and most importantly peak vibration and frequency limits which had the potential to damage the transformers.The mine was due for closure in March 2001. The decision to mine the pit was based on its high grade, ability to be blended with lowering grades from other pits and changing of the processing technique with the expansion. This decision extended the life for a further six months.Due to the high potential risks a detailed risk assessment was conducted by Orica, Worsley and Henry Walker Eltin. The completed assessment and the major design parameters were presented to Western Power for approval. The ability to reduce the blasting risk was focused on limiting of vibration through controlling maximum charge initiated per delay, blast timing and firing direction, and other innovative control measures. OricaÆs SHOTPlan« and Sabrex« computer modelling packages were used to predict the outcome of blasts.The success of this project has opened the doors for other high risk blasting projects, which otherwise may be left unmined.

Jan 1, 2002

By D. I. Smith

Constructing tunnels in congested urban areas requires tunnels to be placed closer together and with less cover than was previously necessary. Contract CQ031 of New York?s East Side Access project will construct four six-meter diameter bored tunnels in a three-up one-down ?T? configuration, with less than three meters of soil between the tunnels. Mixed-face rock and glacial till conditions with a high ground water table will be encountered under active railroad yards. The tunnels will also pass beneath the busiest railroad interlocking in North America with cover as shallow as three meters. This paper discusses the challenges of designing segmentally lined tunnels for these conditions.

Jan 1, 2008

By Edmond Chin

The land mass of the Asia and Pacific region comprises 11 million square miles or about 15% of the total Earth's land area. The bulk of the region is contained on the Asian continental land mass. Australia, the world's largest island or the world's smallest continent, alone is almost as large as the continental United States. The islands of New Zealand, New Guinea, Borneo, Sumatra, and Honshu are among the largest in the world. Collectively, they constitute a land area of 1.1 million square miles or an area about one-fourth the size of the United States. The countries in the Asia and Pacific region represent some of the most vibrant economies in the world. Japan is undisputed as one of the world's leaders in manufacturing and commerce. Hong Kong and Singapore are significant both as entrepôt and banking centers. The economies of Australia, the Republic of Korea, and Taiwan compare favorably to the level of the industrialized countries in western Europe. Indonesia, Malaysia, the Philippines, and Thailand have maintained strong economic growth during the past two decades. All these countries in the Asia and Pacific region collectively constitute a significant bloc as to raw materials production and consumption, as to manufacturing, and as to world trade.

Jan 1, 1992

By I. A. Mwamba

Titanium aluminide of composition Ti-47.5 at.% Al was prepared by melting titanium and aluminium of commercial purity with additions of precious metals of 0, 0.2, 1, 1.5 and 2 at.% content. The microstructure, hardness and oxidation properties were assessed. It was found that at 47.5 at.% Al, the microstructure of plain TiAl alloys was duplex, consisting of duplex lamellar grains and ? grains. The lamellar grains consisted of alternating lamellae of ? (TiAl) and a2(Ti3Al), with overall aluminium content in the range of 43?47 at.%. The ? grains had a aluminium content above 50 at.%. The addition of precious metals to the TiAl alloy resulted in the formation of a new phase, with a high precious metal content, occurring mostly in the ?phase, without any major change to the microstructure. Increasing the amount of precious metals resulted in an increase of the new phase amount, at the expense of the ? phase. The hardness of the different alloys was around 300HV10. Overall, the research has shown that addition of precious metals to TiAl resulted in a slight increase in hardness and a significant improvement of the oxidation resistance. This shows that alloying TiAl with precious metals, at the addition levels investigated, does not alter the mechanical properties very much, but improves oxidation resistance.

Jan 1, 2012

By Jeffery L. Dean

Founded in 1974, the ISEE has grown to more than 3600 members representing 72 countries. The Society and its 35 chapters in the US, Canada and Australia promote research and education, provide forums for the exchange of explosives technology, serve as a repository of explosives information, provide expert help to governments, conduct certificate/training programs, and promote the teaching of the safe and controlled use of explosives.

Jan 1, 1997

By R. K. Jade

Although several studies in combining and bifurcating flows in two-way junctions and splits are reported, deviations persist in the estimated shock loss coefficients (SLCs). Due to their complex nature, more work has to be done to be able to correctly predict flow losses at these locations. In two-way splits, the flow at bifurcation is known to be characterized mainly by two recirculating zones in the downstream branches, whereas, in a junction one recirculating zone is observed immediately downstream of the main branch. The relative flow rate in the branches (quantity ratios) is treated as the only parameter defining the losses at these locations. However, the effect of wall roughness, if any, on SLCs becomes important for mine ventilation. This paper presents the critical determinants of shock losses at splits and junctions at varying quantity ratios. The flow at 90º split and junction was examined both experimentally and numerically for Reynolds number in the range of 1.0×104 to 1.6×105. With a well designed laboratory setup, using precision instruments, velocity and pressure measurements were carried out, by using two scales of wall roughness. 3D numerical simulations for these experiments were conducted by using ANSYS CFX modeling tool. CFD simulations yielded results that are reasonably close to experiments, providing high degree of satisfaction in numerically predicting losses across the splits and junctions. However, comparisons of these numerical simulation results with existing literature standards showed significant under-estimation of shock losses by the standard literature by as much as 50%. A clear rise in the magnitude of shock losses was noted in both the approaches, with increased wall roughness. Based on the current studies, predictor equations incorporating quantity ratios are developed for accurate estimation of shock losses. Further investigations on roughness are needed, before one is able to incorporate wall roughness into the prediction of SLC.

Jan 1, 2009

By Mikhail I. Khersonskaya, Mark I. Mantsevich, Andrey V. Tarasov

"Due to depletion of the existing ore deposits the content of non-ferrous metals in produced ores has an inevitable tendency to decrease. Processing of low-grade ores is associated with production of low-grade selective concentrates and poses serious problems for the non-ferrous industry relating to increasing losses and expenses for waste treatment and disposal.The main component contaminating selective concentrates is iron sulphides.Copper-nickel, copper-zinc and polymetallic ores have been discussed as most important types of ores requiring removal of iron sulphides.One of the promising directions for development of selective flotation technology is the use of lowmolecular organic depressors. An advantage of organic compounds is in the possibility of multi-variant structure of organic molecules, which permits selection of a most efficient reagent for the given conditions. Another way for improving the grades of concentrates is concentration of valuable constituents associated with iron sulphides in an intermediate product and upgrading of the latter by chemical and metallurgical techniques.In order to remove iron from nickel concentrates, specific process conditions have been developed for selective flotation of pentlandite with the use of an organic depressor for pyrrhotite. The use of a depressor for flotation of high-grade copper-nickel ores ensures an increase in the nickel content up to 14% in the nickel concentrate produced as compared with 7% when using conventional process conditions, along with a nickel recovery improved by 2-3%."

Jan 1, 2003

In order to deliver a quality shotcrete and concrete product underground for the extensions to the Cullinan Diamond Mine operations it was decided to develop a new, simpler concrete product to meet underground support requirements. The aim was to develop a concrete product that not only reduced costs but also met the performance criteria of the current range of concrete products used on Cullinan Diamond Mine, a 25, 45 and 60 MPa concrete and a fibre reinforced wet shotcrete. The concrete product batching and delivery system was to be from surface as opposed to the current underground batching systems. The operational principle was to include an automated surface batching plant with delivery of the concrete product to a borehole containing suspended pipelines delivering to an underground storage facility from where the product is delivered to the working area by further pumping or agicars. Keywords: concrete, shotcrete, full flow, frictional loss, pipeline transport, positive displacment pump

Jan 1, 2006

By Susanna G. de Jager, Francis W. Petersen

"To enable the prediction of reagents suitable for fine coal flotation, it is necessary to develop a methodology applicable to different South African coal types. Statistical confirmation of the applicability of this methodology is important to avoid recommendation of reagents on a trial and error basis.The study included 5 coal samples from different collieries and included Highveld seam 3 and 4 coal (as one sample), Waterberg coal (zone 10 -11), Highveld seam 5 upper coal and Witbank seam 2 and seam 4 coal. Seam 3 and 4 (mixture) coal, Waterberg and the seam 5 upper coal were all found to be vitrinite rich coals. The coal characterisation study included petrographic analysis, proximate analysis, float-sink analysis, oxygen-containing functional groups, surface extraction, flotation release analysis and contact angle measurements. Flotation tests were used to validate expectations from the characterisation of the coal samples.RESULTSThe flotation data indicated that all of the coal samples were amendable to froth flotation. The best results were obtained with the Witbank seam 2 coal and the poorest flotation with Syferfontein seam 5 coal. The flotation tests showed that the best reagents to float all of the coal samples studied were iso-decanol and dodecene. These reagents produced flotation products that were near to the release curve, which are the optimum flotation results (obtained when using iso-paraffin as collector). Dodecene resulted in low ash products and iso-decanol in high yield products."

Jan 1, 2003

By Wang Hong Qu

This paper observes the shape of throw explosion crater its ejecta locus of internal medium and the process of distance along with slope's angle developing. It was discovered that initial velocity is inversely proportional to slope's angle. The velocity of surface distribution at the lower half crater of explosion is larger than at upper one. It carries the relevant calculated formula and physical process of explosion crater forming under the inclined boundary conditions, and some important law. It proved that the gravity influence is very distinct for the blast action in the little resistance line.

Jan 1, 1991

By W. A. Scheuch

ORDINARILY secondary copper, unless electrolytically refined, is reclaimed directly as foundry ingots used in the manufacture of copper-rich alloy castings. This use does not require the elimination of the impurities to the degree required if the recovered metal is to be used for electrical purposes where a high electrical conductivity is of prime importance. However, as a part of the general policy of reusing its own scrap and by-products wherever possible, the Western Electric Co. at its Hawthorne Works is recovering its secondary copper as wire bars which are delivered to its own rod and wire mill and there processed into wire of high electrical conductivity. This departure from the usual recovery scheme has been accomplished through the careful classification and sorting of the material entering the furnace charges and the careful control of the subsequent melting and refining in a reverberatory furnace. Tests conducted over a period of approximately four years have shown that the quality of wire bars produced from selected secondary copper is equal to that of wire bars produced by the electrolytic refineries. The interest which has been exhibited in the process by those who have seen it has prompted the following general description. It is the authors' opinion that the recovery of secondary copper will become more and more an important factor in the copper production industry. The description is largely of the refining furnace and its operation, but it must be remembered that careful classification and sorting of the scrap materials to eliminate impurities are just as important as the furnace operation toward obtaining a satisfactory final product. Classification and sorting do not lend themselves easily to description; they must just be done. It should also be recognized at the outset that constant intelligent supervision is requisite to the success of the process because there are so many ways in which impurities can find their way into the final product.

Jan 1, 1929

By Emma Arakelova

?2?2 (98 %) vapour passed through a reactor at 25Pa where a Zn? target was placed at 273K- 373?. Experiments were carried out on a flow- type vacuum device. ?2?2 decomposition on Zn? surface accompanied by formation of a Zn-containing volatile complex which transferred to the gas phase, and Zn? deposited on a substrate at condensation. As the substrate, five sequentially located quartz cylinders were used at 293K- 423 K (?n). Decomposition of the Zn-containing complex on quartz substrates carried out as a first- order reaction. ?The complex decomposition constant (??) increased with the substrate temperature (?n=293 K, ??=7.05 sec-1;?n = 373 K, ?? = 87 sec-1;?n = 423 K, ?? =158 sec-1). ?The complex decomposition constant did not practically vary when the target temperature increased; the complex formation rate increased slightly.

Jan 1, 2006

By W. I. Nissen

This Bureau of Mines report presents the design for a commercial-sized flue gas desulfurization (FGD) demonstration plant that uses the citrate process. The goal of the Bureau's citrate process is to minimize the undesirable environmental impacts of industrial plants emitting SO2-bearing gas. The FGD plant is located at the George F. Weaton powerplant, Monaca, Pa. Construction was completed in April 1979 and will be followed by preliminary testing and a 1-year testing and evaluation program. Design capacity of the FGD plant is 156,000 scfm of 0.2-volume-percent-SO2 flue gas yielding about 16 tons of sulfur per day. The plant is intended to (1) clean fly ash, SO2, and Cl- from the gas while cooling the gas in a venturi scrubber, (2) absorb SO2 from the gas using 1,200 gpm of a countercurrent-flowing citric acid-sodium citrate-sodium thiosulfate solution, (3) react the absorbed SO2 in two 13,000-gal stirred closed vessels with added H2S, thus precipitating elemental sulfur and regenerating the citrate solution for recycle, and (4) recover the sulfur from the slurry by air flotation, followed by melting in a heat exchanger and separation from the occluded citrate solution in a sulfur decanter at 35 psi and 135° C.

Jan 1, 1979

By J. R. Piper

“Old Borate,” located in the Calico Mountains east of Barstow, California, lead domestic colemanite production from 1884 through 1907. Mineral exploration at “Old Borate” in the early 1980's, examined borate mineralization in Tertiary lacustrine strata. Surface sample and drill hole locations, geology and structure, were hand-drafted on paper maps. To re-evaluate this data, the information was digitized using Geographic Information Systems software. Digital Elevation Model based terrain modeling integrated surficial samples with drill hole data to locate favorable drilling targets. Structural relationships were used to identify hypothetical resources formed by the leaching of boron from surface exposures, redeposited at depth.

Jan 1, 2001

Research by the National Institute for Occupational Safety and Health (NIOSH) on multiple-seam mining has resulted in two new ground control products. Information Circular (IC) 9495 In some U.S. coalfields, particularly in central Appalachia and the West, most mines are operating above and/or beneath previously mined seams. The effects of multiple-seam interactions can include roof falls, rib spalling, and floor heave. These can seriously threaten the safety of miners and disrupt mining operations. Information Circular (IC) 9495 is a proceedings document containing a variety of papers that summarize recent knowledge about multiple-seam mining. A NIOSH study that analyzed case histories collected from 44 U.S. coal mines is described in detail. The study confirmed that overmining is much more difficult than undermining, and isolated remnant pillars cause more problems than gob-solid boundaries. The study's results were the basis for the Analysis of Multiple-Seam Stability (AMSS) software package. The proceedings also contain two papers describing the LaModel family of software. The original three-dimensional version of LaModel is essential for detailed analyses of complex multiple-seam scenarios. LaM2D implements a simplified, two-dimensional model suitable for quick approximations of the multiple-seam stresses and strains. Three papers in the proceedings focus on case histories. One describes the extensive multiple-seam experience at the Harris No. 1 Mine in West Virginia, a second contains examples of "extreme" multiple-seam mining from the central Appalachian coalfields, and a third describes interactions with regard to longwall mine experiences in Pennsylvania, West Virginia, and Utah. The final paper reports on a numerical modeling study that provided some insight into the mechanics of multiple-seam mining. [ ] AMSS Software Package NIOSH has developed a simple, user-friendly computer program called Analysis of Multiple-Seam Stability (AMSS). AMSS can help mine planners to evaluate each potential multiple-seam interaction and take steps to reduce the risk of ground control failure. AMSS begins by evaluating the pillar design. It first calculates the single-seam pillar stability factor (SF)

Jan 11, 2007

By J. M. Ortiz

Grade control and short-term planning are usually based on the samples obtained from blastholes. These samples may carry a large sampling and sample preparation error. At El Tesoro copper mine in northern Chile, an advance drilling grid is used for short-term planning and grade control. These drill holes are sampled well in advance, and a short-term model that incorporates several variables and sophisticated estimation methods can be prepared for decisionmaking. An additional advantage of the advance drilling samples is that reverse circulation can be used instead of conventional down-the-hole equipment, and a very careful sampling and sample preparation process can be implemented, reducing the total sampling error. Advance drilling can be performed on a wider grid than blasthole drilling, hence the decision about the grid requires assessing the economic benefit of different sampling grids. Furthermore, this process allows the cost of poor sampling and the effect of different estimation procedures to be quantified. We demonstrate the optimization of the drilling grid for short-term planning and grade control at El Tesoro mine by means of the economic evaluation of the performance of different drilling grids, with different drilling techniques (which differ in the sampling error). The methodology is based on creating dense (exhaustive) geostatistical simulations of the grade distribution over a volume defined for a production period in respect of the geological model, and assuming each simulation as the true grade distribution. Then, samples are obtained from the exhaustive simulations at a spacing similar to the advance grid to be evaluated, and a sampling error is added. The short-term estimation procedures used on the mine are applied to determine the destination of each block and the profit obtained. This profit can be compared with the maximum profit (unachievable) and with the profit under different sampling errors and grids. The results show that the current 8 x 8 m drilling grid is appropriate and by reducing the sampling error, misclassification is also reduced, leading to an increase in profit of about US$ 5 million in 4 years.

Jan 1, 2012

By B. K. Gorain

"Mining of low grade deposits along with the necessity to design and operate flotation plants with high throughput presents unique metallurgical and environmental challenges that need to be addressed to reduce project risks, improve project economics and to sustain the profitability of operations over the life of a mine.Some of the key challenges include poor recovery of valuables and concentrate quality issues due to complex mineralogy, the need to use poor quality water such as brackish or sea water, reduce environmental impact from the process, integrate flotation with hydrometallurgy to maximize precious metals recovery, escalation of capital and operating costs, use of unproven technology and constant use of larger equipment, high ore variability, worldwide constraints on resource availability and an ever increasing need for reliable metallurgical input to financial models to evaluate economic viability of projects.The need to develop effective solutions to these problems in a short time frame is becoming a key to the success of any new project and for sustaining the profitability of a mining operation. An integrated multi-disciplinary approach to problem solving is crucial with the need for a more lateral thinking along with strategic partnerships and collaboration involving the right players. This paper presents some of the key findings based on experiences from a large number of challenging projects and operations focused on solving complex flotation problems.INTRODUCTIONThere are various challenges to successful development of mineral resources. Most of the ore bodies being developed worldwide are of lower grades requiring high throughput to be economical. Many of these lower grade ore bodies have significant occurrences of deleterious and penalty elements that could render a deposit unworthy of development unless there are technological solutions to process them economically in a sustainable manner with minimal environment impact. Even in a high metal price scenario, the economics for some of these low grade ore deposits is marginal. From a metallurgical perspective, these ore bodies have complex mineralogy and use of any off-the-shelf technology is not always effective. Development of innovative processes are often required, which is expensive, time consuming and sometimes risky.This paper will provide a broader perspective on the steps involved in solving flotation problems for operating plants and for greenfield development projects. In addition, some of the key challenges in flotation of complex low grade ore bodies along with the economic benefits in developing solutions to these problems will be presented."

Jan 1, 2013