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By M. Tangstad, H. Mølnäs, J. D. Steenkamp

"Temperature affects several aspects of pyrometallurgical systems, including thermodynamics and reaction kinetics. Reliability of temperature measurements in laboratory and plant applications is thus important from process, safety and financial perspectives. This case study briefly introduces different techniques utilized for temperature validation, and demonstrates temperature validation on laboratory scale utilizing the wire-bridge method. Pt/Ptl3Rh thermocouple hot junctions were constructed by mechanically connecting thermocouple wires through a pure metal bridge consisting of copper, gold, nickel or palladium wire. When heating the wire-bridge thermocouple alongside a regular Pt/Ptl3Rh thermocouple, temperature offsets were quantified as the wirebridge thermocouple short-circuited at the melting points of the pure metals. At the melting points of gold (1064°C) and palladium (1555°C), average measured temperature offsets were -2.1°C ± 2.3°C and 0.2°C ± 0.4°C, respectively. Results from the copper and nickel wire-bridges were inconclusive. The paper concludes with a discussion on the potential industrial applications of the technique.IntroductionThermocouples are probably the simplest of all temperature sensors, but are widely utilized due to simplicity, versatility and ability to handle a variety of experimental conditions and industrial applications. Additionally, thermocouples are often the only option in research laboratories requiring high temperature measurements, and a high level of reliability is usually required from thermodynamic, kinetic as well as safety points of view.The study presented here originated from a test program where the compatibility between different types of carbon-based refractory materials and industrial slag produced in silicomanganese furnaces were investigated on a laboratory scale utilizing the static crucible test[l]. Due to the nature of the silicomanganese production process, the compatibility tests were to be conducted at 1600CC[2]. Details of the experimental set-up utilized for the compatibility tests are discussed in the Experimental Set-up and Method Statement section later in this paper."

Jan 1, 2012

By Otávio da Fonseca Martins Gomes, Renata Hiraga de Vasconcellos Cruz

Maghemite is a mineral formed from magnetite oxidation at low temperatures, an intermediate term of the magnetite-hematite series. Maghemite could be misidentified as magnetite by X-ray diffraction, and/or as hematite by spot chemical analysis. Nevertheless, non-stoichiometric magnetite was detected and quantified in samples of Brazilian soils and iron ores by the Rietveld method refinement of its structure. The results were confirmed by optical microscopy and Raman spectroscopy, thus validating the method. X-ray diffraction with the refinement of the isomorphic substitution of Fe2+ by Fe3+ along the magnetite-maghemite solid solution could help to suitably characterize maghemite in iron ores.

Oct 3, 2019

Validation and Application of Filtration Theory to Plate and Frame Pressure Filtration - From Laboratory to Full Scale

Sep 13, 2010

By M. McClintock

"High Pressure Grinding Rolls (HPGR) is increasingly being chosen for comminution circuits for its energy-efficiency for hard rock mining operations. Despite HPGR’s growing popularity, geo-metallurgy programs are still prohibitively expensive because of large sample requirements. Traditionally, sizing HPGR application requires a significant amount of sample, in the order of 1 to 10 tonnes, depending on the level of study and complexity of the resource. Therefore, engineering and design of HPGR circuits typically are reliant on few composites that are required to be representative of the resource and mine plan. Three bench scale HPGR test methodologies were developed in 2015 at NBK Institute of Mining Engineering at the University of British Columbia (UBC) capable of defining the energy size breakage relationship of pilot HPGR. These methodologies were developed to allow bench scale testing for different levels of study from PEA (Preliminary Economic Assessment) to detailed design and operations. The Piston Press test defines the energy size reduction relationship by measuring specific energy consumption and corresponding feed and product size distributions. The advantage of Piston Press testing is the small sample requirement of 5 to 10 kg. Small sample requirements allow multiple samples to be tested across a deposit. Piston Press testing allows extensive geo-metallurgy programs that can determine ore variability and inform in optimization and production planning. To date, the Piston Press methodologies have been validated on a pilot-scale HPGR unit located at UBC. Recently, testing was conducted to calibrate and validate the Piston Press test against full-scale HPGR on a gold sulphide ore deposit. The program included the collection of operational data with the respective HPGR feed and recycle sample. Sample collected was used both for Piston Press testing and HPGR piloting. This paper discusses the test-work and results as carried out during this program, using the aforementioned methodologies."

Jan 1, 2018

Validation and Simulation of Optimised Compressive Crushing Ores and aggregates are used in countless applications all around in the society. The frequent and escalating usage of these natural resources requires efforts aimed at not only making do with what is available, but also undertaking actions to improve the production yield and the processes involved. This strive to improve the performance and efficiency of existing crushers and crushing processes has brought about research concerning optimisation of crushing plants as well as theoretical optimisation of crushing. Previous work shows that different applications and different materials require different compressive crushing in order to accomplish a theoretically optimal size distribution. These optimisation results, obtained by genetic evolutionary algorithms and evaluated with so called fitness functions, convey the theoretically optimal number of compressions and their corresponding compression ratios. Presented in this paper are thus some laboratory crushing tests, which are conducted in order to validate a set of previously optimised crushing sequences. More specifically, interparticle crushing sequences are carried out in a Piston-die testing equipment, where samples are sieved between each compression. The subsequent analysis of these results shows good correlation with model predictions, which combined with a comparative study between presented optimisation results and measured data from a real crusher indicate a significant potential for improvement. However, before redesigning crushers according to what is theoretically optimal, the resulting impact as well as the effects on the outcome of a crushing plant must be examined. Crushing plant simulations using the software PlantDesigner« are consequently performed. Models of existing crushers are altered, resulting in changed particle size distributions from some of the crushers in a crushing plant. Thence, it is concluded that significant gains can be made in terms of capacity, process yield and energy consumption.

Sep 13, 2010

By Gaurav Soni, Roe-Hoan Yoon

A first principle flotation model has been derived from the basic mechanisms involved in flotation. The model consists of a series of analytical equations for bubble generation, bubble-particle collision, attachment, detachment, and froth phase recovery. The model can predict flotation from both hydrodynamic and surface chemistry parameters such as bubble size, particle size, energy dissipation rate, ?-potentials, contact angles (?), etc. The model predictions have been compared with the results of a series of laboratory flotation tests conducted using mono-sized glass beads of different particle sizes and contact angles under different operating conditions. Some of the experiments were conducted using a 1:9 mixtures if hydrophobic silica and hydrophilic magnetite, so that the product graded could be readily determined by simple magnetic separation. The model predictions are in good agreement with the experimental results both in recovery and grade. A computer simulator developed on the basis of the model is capable of designing a preliminary flotation circuit on the basis of feed characteristics, e.g., size-by-liberation data, and the hydrodynamic information on the flotation cells to be incorporated in the circuit.

Jan 1, 2014

By G. Soni

A first principle flotation model has been derived from the basic mechanisms involved in flotation. The model consists of a series of analytical equations for bubble generation, bubble-particle collision, attachment, detachment, and froth phase recovery. The model can predict flotation from both hydrodynamic and surface chemistry parameters such as bubble size, particle size, energy dissipation rate, ?-potentials, contact angles (?), etc. The model has been validated in a series of laboratory batch flotation experiments, in which mono-sized glass beads are used as feeds. The experimental results are in good agreement with model predictions both in terms of grade and recovery.

Feb 23, 2014

By E A. Amaral Jr, A C. Chieregati, J C. O Souza

Cross-belt samplers are designed to sample particulate material in processing plants, usually when there is no space to install a conventional linear falling stream sampler. Most of the available cross-belt samplers are mounted on the top of conveyor belts, and remove each increment from a loaded moving conveyor with a 360° rotation of an open faced cutter, in a plane perpendicular to the material flow. Despite the practicality of this equipment and the fact that it occupies very little space in the plant, cross-belt samplers are well known for collecting biased samples, especially due to the increment extraction error. Sampling consultants around the world tend to condemn this sampling equipment, claiming that it is incapable of collecting the fine material from the bottom part of the load, and, since the sampling probability is not uniform for all fragments and depends on its position in the stream, this kind of sampler generates biased samples and its use should be avoided. Furthermore, the greater the segregation effect between particles, the larger the bias. However, some plants, whose initial design did not plan for the installation of a falling stream sampler, must rely on cross-belt samples for process control and reconciliation. For the past years, sampling equipment manufacturers have been putting effort in modifying the cross-belt sampler design in order to comply with the principles of correct sampling. Changes to the cutter material, shape, position, speed and movement in relation to the material flow have been made, and are continually being tested for different types of ore with various chemical and physical characteristics. This paper presents the improvements made to a cross-belt sampler at a gold plant feed in Brazil and describes the tests performed until it was possible to validate the new sampling equipment for reconciliation purposes.CITATION:Chieregati, A C, Amaral Jr, E A and Souza, J C O, 2017. Validation of a modified cross-belt sampler for reconciliation purposes, in Proceedings Eighth World Conference on Sampling and Blending , pp 247–254 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2017

By L. Rintala, P. Latostenmaa, T. Kalliomäki, O. Forsén, I. Lehtiniemi, M. Lundström, J. Aromaa

Conductivity is a typical physico-chemical property that has a substantial effect on electrical energy consumption in the electrorefining process. The objective of this study was to examine the validity of regression models predicting the conductivity of industrial copper electrorefining electrolytes. The models were based on data measured with synthetic solutions on a laboratory scale. The variables included in the models were temperature and the concentrations of copper, nickel, arsenic and sulfuric acid. Both first-order and combined effects of the variables were investigated. The measured data were analyzed using MODDE 8.0 modeling and design software. The validity of the models was investigated by comparing the predicted values with tankhouse conductivity measurements taken at the Boliden Harjavalta Copper Refinery in Pori in Finland. During the tankhouse tests, the conductivity and temperature of the industrial electrolyte were measured, and the composition of the electrolyte was analyzed. The measured conductivity values were compared with the predicted conductivities calculated using the developed models. The conductivity model developed in this paper was shown to be more accurate than previous models and suitable for industrial use.

By John A. Herbst, Xiangjun Qiu

"Prediction of wear on a microscale level in mineral processing equipment turns out to be a challenging undertaking. This is particularly true for cases in which the objective is to use such predictions for wear parts design. The key to obtaining such predictions has turned out to be the use of physics based models along with phenomenological constitutive equations. In this paper, two components of the HFS tool set, one for particles (DEM) and one for slurry (MPF), are used for modeling. These tools are applied to the simulation of wear of SAG/AG shell lifters/plates and wear in slurry pumps. In each case wear predictions are validated with plant measurements.INTRODUCTIONHigh Fidelity Simulation (HFS) has emerged as an important tool set for mineral processing plant equipment design and optimization (Herbst and Potapov, 2003; Herbst and Nordell, 2002; Herbst and Lichter, 2006). This tool set consists of Discrete Element Modeling (DEM) of particle motion, Multi-Phase Flow (MPF) for liquid motion, discrete grain breakage (DGB) for particle fragmentation and discrete grain liberation (DGL) for mineral liberation (Campbell, Potapov and Tsuji, 1997; Ferzinger and Peric, 1997; Potapov and Campbell, 1996; Herbst and Potapov, 2005).Three sample snapshots of basic HFS illustrating the use of each of the various types of mineral processing equipment are shown below.Figure 1 shows a snapshot of a DEM simulation of ball charge motion in a commercial scale Vertimill. DEM simulation involves simultaneous solution of Newton’s Laws of Motion for 400,000 balls."

Jan 1, 2007

We are moving into an era where we experience the consequences of the skills crisis û namely many resource models have been generated by inexperienced people under pressure to deliver high quality resource estimates in unsupported environments, often without technical mentors. These resource models form the basis of our decision to pursue actual mining. This begs the question: how valid are the resource models that form the basis of our mining decisions? This paper presents various model validation tools such as comparison of input and output statistics, swath plots, sectional or bench comparisons between drill holes and models as well as a variety of other approaches. Each model validation tool currently used in industry is examined:how the tool generates results,what assumptions exist,what constitutes a pass/fail in the test, and what interpretations to consider when using the validation tool. Each validation toolÆs suitability and the inherent flaws in the underlying assumptions are also discussed. These are supported with examples of good versus bad validations. Our principles based reporting codes provide flexibility in how models are generated and what approaches and/or parameters are used to generate resource estimates. This flexibility works well when used by experienced practitioners. However, our reporting codes assume a level of experience not always available in the current skills crisis. This paper seeks to provide minimum model validation prerequisites for model acceptance and suitability, regardless of the resource analystÆs experience. As we move forward, our immediate challenge is to ensure our baseline resource models are material, transparent and competent.

Jan 1, 2009

By J. Jordan, D. K. Denton, D. Tesarik, D. F. Scott, T. J. Williams

Personnel from the Spokane Research Laboratory of the National Institute for Occupational Safety and Health integrated the results of studies from a seismic tomographic survey, a finite-difference analysis, laboratory measurements of compression wave (ultrasonic) velocities in rock cores, and site geology to evaluate the use of seismic tomography for identifying induced pressures in an underground pillar at the Edgar Mine, Idaho Springs, CO. The key findings were that (1) the seismic tomograms showed that seismic velocities in rock adjacent to mine openings were low, (2) a difference tomogram in which in situ stresses on the east and west sides of the slot were compared showed that velocities increased west of the slot but decreased east of the slot, (3) geologic features (rock types and a fault) identified through geologic mapping were recognizable in the seismic tomograms, (4) ultrasonic velocity measurements on the rock cores agreed with seismic velocity measurements in the tomograms, and (5) results from a finite-difference analysis compared well to the seismic tomograms west of the slot but not east of the slot. The significance of this research is that seismic tomography is a useful tool for determining relative stress in underground pillars.

Jan 1, 2004

By P. Bissert, M. Klein, L. Yan, D. Yantek, R. Matetic

"U.S. Mine Safety and Health Administration (MSHA) regulations require underground coal mines to use refuge alternatives (RAs) to provide a breathable air environment for 96 hours. One of the main concerns with the use of mobile RAs is heat and humidity buildup inside the RA. The accumulation of heat and humidity can result in miners suffering heat stress or even death. MSHA regulations require that the apparent temperature in an occupied RA not exceed 95 °F. To investigate this, the U.S. National Institute for Occupational Safety and Health (NIOSH) conducted testing on a 23-person tent-type RA in its Experimental Mine in a test area that was isolated from the mine ventilation system. The test results showed that the average measured air temperature within the RA increased by 9.4 °C (17 °F) and the relative humidity approached 94 percent at the end of a 96-hour test. The test results were used to benchmark a thermal simulation model of the tested RA. The validated thermal simulation model predicted the volume-weighted average air temperature inside the RA tent at the end of 96 hours to within 0.06 °C (0.1 °F) of the average measured air temperature. IntroductionIf an accident occurs in an underground coal mine, miners who fail to escape from the mine can enter a refuge alternative (RA) for protection from adverse conditions, such as high carbon monoxide levels. One of the main concerns with the use of mobile RAs is the potentially adverse thermal environment inside an RA from the metabolic heat of the occupants and the heat released by the carbon dioxide (CO2) scrubbing system. Moreover, the humidity within the RA will increase through occupants’ respiration and perspiration, and from the chemical reaction within the CO2 scrubbing system. The accumulation of heat and humidity can result in miners suffering heat stress, heat stroke or even death."

Sep 1, 2016

Validation of the JKMRC Rotary Breakage Tester (JKRBT) Ore Breakage Characterisation Device

Sep 13, 2010

By Paloma Lazaro, Moe Momayez

Heat-related illnesses (HRI) are relatively common in both hot surface and underground mining operations. When workers are exposed to extreme heat or strenuous work in a hot environment, they become prone to heat stress. Heat strain is the result of the body’s response to external and internal heat stress. It is therefore vital for the conditions leading to heat strain be detected and treated in a timely manner. Heat-related illnesses are manifested by exhaustion and heat stroke. The predicted heat strain (PHS) [ISO 7933 (2004)] model has been developed to predict the health condition of the worker in terms of core body temperature and water loss. The PHS model tested in this study is based on eight physical parameters that are measured at different intervals during a work shift. They include air temperature, humidity, radiation, air velocity, metabolic rate, clothing insulation, posture, and acclimatization. The model predictions are then compared with a direct physiological measurement, such as core body temperature. We present the results of an extensive study that monitored and predicted body’s response to heat stress under different environmental and working conditions. The PHS model provided reliable results in most instances in comparison with other prediction methods currently in use in the field.

By P. Jonsén

Understanding mill charge motion is important. In the charge, the centre of gravity is shifted from the rotational centre of the mill system, and its motion is induced by rotation of the mill, while at the same time the charge creates a torque into the mill system. Breakage of ore particles and wear of liners/ball media are closely linked to the motion. To study these phenomena in a physically correct manner, numerical models for different parts of the mill system are needed. Validations of such models are scarce, because of the difficulty to measure in a tumbling mill. Experimental measurements in a lab mill were done for diverse load cases: varying feed materials, mill fillings, mill speeds and pulp liquids. The mill is set up to directly measure the charge-induced torque. The accuracy is good with relative uncertainty smaller than ±2% for relevant load cases. A full three dimensional numerical model of the whole mill is used to predict induced torque. Agreement between predicted and measured torque at steady-state is good. In addition, the model can accurately predict the mill start-up behavior for torque and mill power. This proves that the model is physically correct, and can be used for full-scale mills.

Feb 27, 2013

Entry of personnel under a vertical raise bored hole is not standard practice in Australia. Where access is required below a rise, mining operations must be confident that they understand the capacity of the ground control specified and installed. Physical modelling was conducted on Callie mine to evaluate the performance of 5 mm steel wire weldmesh secured to the base of a vertical raise bored hole of 1.4 m diameter. Joint orientation data was used with Unwedge to calculate a series of potential wedges likely to form within the rise. The mass of the most likely wedges were then replicated by collecting rocks in 5 kg increments (¦10 per cent), which were allowed to freefall onto installed mesh at the base of a 40 m vertical rise. The results indicate that two sheets of mesh can retain a freefalling rock of at least 20 kg mass although rupture of strands can result. This paper outlines the test conditions, expected results based on theoretical calculations and actual outcomes of the testing.

Nov 25, 2010

By Gustavo Henrique Bolognesi Donato

O projeto e a operação de estruturas que podem vir a conter trincas demandam estudos de integridade estrutural suportados por propriedades mecânicas à fadiga e à fratura advindas de ensaios experimentais (p. ex.: curvas J-R ou da/dN vs. ?K), sendo tais experimentos altamente dependentes da medição instantânea do tamanho da trinca. Essa medição em muitos casos é realizada com base na variação da flexibilidade com o crescimento do defeito. O objetivo do presente trabalho é validar experimentalmente soluções numéricas recentes de flexibilidade elástica que descrevem o tamanho instantâneo de uma trinca em corpos de prova de geometria C(T) e SE(B) incorporando efeitos tridimensionais. Ainda, objetiva comparar tais soluções com as disponíveis nas normas ASTM vigentes. Corpos de prova C(T) e SE(B) foram usinados conforme as referidas normas e testados em máquina universal de ensaios MTS 810.25. Na sequência, os dados obtidos foram convertidos em valores de flexibilidade normalizada (µ), determinando-se o tamanho de trinca (a) esperado com base nos referidos equacionamentos. As previsões de tamanho de trinca geradas foram comparadas com medições reais da profundidade de trinca obtidas de fractografias das amostras após separação final. No geral, tanto as soluções da ASTM como de Moreira (2014) foram consideradas acuradas e com erros máximos abaixo de ~ ±1,5%. No entanto, os resultados mostram equivalente aderência experimental das soluções disponíveis nas normas ASTM com as de Moreira (2014) para amostras C(T), mas melhor desempenho das propostas de Moreira para amostras SE(B) de variadas geometrias e profundidades de defeitos.

Aug 17, 2017

By Ruilin Yang

Based on large amounts of field data, this paper evaluates the validity of the above equations. During the evaluation, the different selections of the frequency in the equations were examined with field data. It is found that when they are used to estimate the vector sum values the above equations could result in large deviations from the values obtained directly from the field measurements or the waveform integration. The simple equations may be used to make rough estimations for single components of blast vibration provided that appropriate safety factors are taken into account. For single component vibration, the principal frequency (from ‘zero-crossing’) seems more effective to describe the blast vibration than the dominant frequency (fron FFT) for vibration peak value estimation using the simple equations.

Jan 1, 2012

By J. P. Bellot

During the non-ferrous metal processing, the melting step under vacuum or under rarefied gas leads to volatile metal losses. It is the case of the metallurgical processing of the nickel-based, titanium-based or zirconium-based alloys where the evaporation losses don't allow a sufficient control of the alloy chemical composition. A theoretical approach has been carried out involving both a continuum description in the liquid phase and a molecular approach in the rarefied gas phase. The finite volume method is used in order to solve the coupled transport equationsin the liquid, whereas the Boltzmann equation is modelled by using a Monte Carlo method. At the liquid metal and metallic vapor interface, the volatilization and recondensation fluxes link up the two calculations. Simulation results are given for the melting and refining of reactive metals such as titanium alloys where the control of the chemical composition remains a major difficulty. The validity of the kinetic Langmuir's law is discussed for different operating conditions.

Jan 1, 1996