Search Documents

By M. Z. Mubarok, Z. T. Ichlas, A. T. Sugiarto, K. Sukamto

The use of ozone as an oxidant for the direct leaching of zinc sulfide (sphalerite) concentrate in sulfuric acid medium under atmospheric pressure was explored. The influence of acid concentration, feed gas injection rate, particle size distribution, stirring speed, temperature and slurry density on zinc extraction efficiency was examined. The experimental results showed that the leaching efficiency depends on all of these operating parameters except for stirring speed. It was found that essentially complete dissolution of zinc from the concentrate with the present method can be achieved in only about seven hours under the conditions of sulfuric acid concentration of 2 mol/L, particle size smaller than 74 µm, slurry density of 50 g/L, stirring speed of 420 rpm and feed gas injection rate of 1 L/min at ambient temperature. The experimental results suggest that the dissolution reactions produce independent elemental sulfur that is readily floated and can be easily separated rather than forming a layer on the surface of the reacted particle, as usually observed in a system with ferric-sulfate as oxidizing agent. It was therefore determined that the dissolved ozone play a key role in improving the rate of zinc dissolution from the concentrate. Analysis of the leaching kinetics indicate that the leaching rate follows the shrinking particle model, and the overall dissolution rate of zinc is controlled by a surface reaction.

By N. Moelans, I. Bellemans, K. Verbeken

Metallic droplets can remain attached to solid particles within liquid slags, resulting in production losses in several movement of solid particles in the liquid slag in a system, considering the attachment of liquid metal droplets to solid slag and on the resulting microstructures is investigated as a function of the velocity of the particles. For all wetting For the amount of metal attached to the particle, a clear trade-off was found between the speed of motion of the solid particle and the wetting regime.

By H. R. Manouchehri

In flotation practices, as particles become finer, such as smaller than 20 μm, process efficiency declines markedly. Selective agglomeration of fine particles is a technique to enhance the recovery of fine valuable minerals in flotation circuits. Different agglomerating methods have been introduced and tested. One method that has recently received much attention is to make use of magnetic force to aggregate fine particles. A selective aggregation of fine paramagnetic particles, such as sulfide minerals, can be achieved in the high-intensity magnetic field prior to or during flotation. The method is simple, selective and effective for fine particles and has low operational cost, though a minimum magnetic susceptibility for fine grains is required to promote the process. In this paper, the implementation of the ProFlote magnetic conditioning device in Boliden’s Garpenberg old concentrator in Sweden, where a complex massive sulfide ore is treated, is presented and discussed based on Boliden’s Garpenberg plant. The results showed an increase in the flotation recovery of fine valuable minerals. Zinc (Zn) production was increased by between 1,100 and 1,500 t/a, while salable yearly silver (Ag) production was increased by 1,500 kg. The copper (Cu) grade in the final concentrate was increased by 1 percent, while reductions in its Zn and lead (Pb) grades were obtained. Moreover, considerable reduction in Zn deportment to the final tail was observed

By J. O. Marsden, C. Green

In 2003, a high-temperature pressure leaching circuit to treat copper sulfide concentrates was commissioned at the copper/molybdenum operation at Bagdad, AZ. In late 2007, a medium-temperature pressure leaching circuit was commissioned at the Morenci mine in Arizona. The Morenci circuit was shut down in mid-2008, following a fire in the autoclave circuit. The onset of the global financial crisis in late 2008 resulted in significant changes to the operating profile in the Southwestern United States with respect to concentrates production, concentrates treatment, acid production and acid consumption. As a result of these changes, the Morenci concentrator was shut down, and the pressure leaching circuit remained offline. In late 2014, the increasing acid requirements in the Southwestern United States prompted a reevaluation of the Morenci concentrate leaching facilities. As a result, the pressure leaching circuit was restarted in high-temperature (200 °C) mode in May 2015 and has operated successfully for three years since recommissioning. This paper describes the current pressure leaching circuit configuration and the factors leading to the successful application of copper sulfide concentrate leaching at this location.

By S. J. Schatzel, J. D. Addis, V. Gangrade, L. L. Chasko, C. A. Hollerich

A ventilation study using tracer gas was conducted at a western US coal mine. The objective of the study was to evaluate the movement of longwall face air exchanges between the face and worked-out area and to document the presence or absence of face airflow pathways between these locations. The mine operator uses a bleederless longwall ventilation system with a back return and a blowing mine ventilation system. The study was conducted on an active panel and included both underground and surface monitoring sites. The study used sulfur hexafluoride (SF6) released as a slug on the longwall face and in the front of the gob inby the face. The velocity of the tracer gas movement in the gob was 0.019 m/s (3.7 fpm). The rate of movement for the overall tracer gas slug averaged about 0.0091 m/s (1.8 fpm). A separate tracer gas test initiated with the release of SF6 into the legs of the first shield showed the existence of more than one pathway of face air in the general direction from the headgate towards the tailgate corner. Maintaining adequate ventilation air on longwall faces is important for worker safety and for the dilution of methane emitted from the face and caved gob. A more detailed characterization of longwall system air and gas movement allows a mine to better assess its ventilation design for controlling gas on the face and in the gob.

By G. H. Sedahmed, S. A. Nosier, M. H. Abdel-Aziz, A. A. Mubarak, M. A. El-Naggar, E. G. Abdel-Aziz

The performance of a rotating fixed bed reactor in recovering copper from industrial waste solutions by cementation is studied under various conditions. The rotating fixed bed is made of stacked woven steel screens to take advantage of two features of screens: the ability to present large area per unit volume and their ability to promote high turbulence. Variables studied are initial CuSO4 concentration, bed rotation speed, mesh number of the screens and bed thickness. The presence of baffles was found to increase the rate of cementation. The data were correlated by a dimensionless mass transfer correlation suitable for the design and operation of large scale cementation reactors.

By Donald P. Tuchman, Justin R. Patts, Emanuele G. Cauda, Andrew B. Cecala, Elaine N. Rubinstein

Video techniques for monitoring exposure, such as NIOSH’s “Helmet-CAM,” employ both real-time dust monitors and mobile video cameras to assess workers’ respirable dust exposures. Many real-time personally worn dust monitors utilize light scattering sensing elements, which are subject to measurement biases as a function of dust type (size, composition, shape factor) and environmental conditions such as relative humidity. These biased and inaccurate dust measurements impair the monitor’s ability to properly represent actual respirable dust concentrations. In the testing described, instrument mass concentration data was collected using three different types of commonly used commercial off-the-shelf personal dust monitors and compared to a reference standard. This testing was performed in a calm air (Marple) dust chamber in which three units of each make and model (for a total of nine monitors) were used for each test. Equivalency factors (EF, a multiplier to match the Thermo TEOM 1400a reference instrument) ranged between 0.746 and 1.879 across all dusts and environmental conditions tested, and between 0.821 and 1.519 on the ISO test dust.

By Éder Domingos Oliveira, Leandro Viana Teixeira, Carlos Antonio Morais, Ruberlan Gomes Silva

The purity of rare earth products depends on the ability of the reagents used to selectively promote the precipitation of the rare earth elements (REE) from impurities present in sulfuric liquors. The present study aims at investigating the conditions required to precipitate REE, either as rare earth oxalates or carbonates, from purified rare earth sulfuric liquor with a low Al3+ and UO2 2+ and a very high Ca2+, Mg2+, Mn2+, and SO4 2− impurity content. The rare earth sulfuric liquor was obtained in a previous study by the reaction of a rare earth ore with sulfuric acid, pyrolysis at 700 °C/2 h, cooling at 20 °C, and water leaching. The impurities such as Fe3+, Th4+, and PO4 3− were completely removed from the liquor in two consecutive neutralization steps. In order to recover the REE, the purified rare earth liquor was then treated with oxalic acid and sodium carbonate. Rare earth oxides (REO) precipitated with oxalic acid displayed a very high purity (99.2% w/w) and low impurity content. In contrast, the rare earth carbonates precipitated with sodium carbonate presented a comparatively lower REO content (68.5% w/w) and 94.2% of purity, but with a higher content of impurities. Better precipitating conditions were achieved at 60 °C, compared with 20 °C, and under stoichiometric reagent consumption, with REE precipitation efficiencies higher than 96%. The dosage above the stoichiometric condition caused the precipitation of calcium oxalates and co-precipitation of rare earth sulfates when oxalic acid is used, and precipitation of calcium, manganese, and uranium carbonates and also a co-precipitation of rare earth sulfate when sodium carbonate were used. An integrated flowsheet to produce a high-quality rare earth product from rare earth sulfuric liquor containing some impurities is proposed.

By Soner Top

In this study, a process to separate manganese and iron from manganiferous iron ores by reductive acid leaching followed by magnetic separation was conceived and experimentally tested. In the leaching process, sulfuric acid was used as lixiviant and oxalic acid was used as reductant. The experimental results showed that the manganese and iron separation was optimum when the concentration of the sulfuric acid and oxalic acid were 0.75 M and 30 g/L, respectively, at a temperature of 80 °C, a solid/ liquid ratio of 67 g/L, stirring speed of 400 rpm, and leaching duration of 60 min. Under this condition, 90.49% and 6.78% of Mn and Fe were dissolved, respectively, from the ore sample with a size fraction of − 106 μm. It was determined that the leaching of manganese from the ores was a second-order reaction with an activation energy (Ea) of 53.38 kJ/mol. The leaching residues obtained under the optimum condition were subjected to high-intensity wet magnetic separation tests to recover the remaining iron content. This separation process produced a concentrate containing 56.20% Fe and 1.79% Mn with iron and manganese recoveries of 56.83% and 66.73%, respectively. A magnetic separation test from an unleached ore sample was also carried out as a benchmark. To the best of our knowledge, this is the first time that a magnetic separation process was used to a residue obtained from reductive acid leaching of manganiferous iron ores to recover iron.

By Z. Xu, Z. Li

Colloidal interactions play a critical role in mineral processing, including grinding, physical separation (particularly flotation), dewatering, and tailings management. Despite great energy input in comminution to liberate valuables from gangues, heterocoagulation between valuables and gangues would prevent the separation of valuables from gangues. On the other hand, selective coagulation/flocculation to increase the size of desired fine particles could enhance physical separation and dewatering, while dispersion is needed for fine grinding. To control the state of colloidal dispersions by creating favorable conditions, it is of paramount importance to study colloidal interactions in a relevant system and understand underlying mechanisms. This review summarizes recent advances in developing the-state-of-the-art techniques and novel methods of measuring colloidal forces, including atomic force microscope, surface force apparatus, zeta potential distribution measurement, quartz crystal microbalance with dissipation, and our recently developed integrated dynamic force apparatus. The basic principle of each technique was introduced first, followed by a summary of critical information derived for the relevant mineral processing systems. Finally, the pros and cons of each technique were discussed to emphasize the use of complementary techniques that assist in solving fundamental problems in mineral processing.

By Ashis Bhattacherjee, Rahul Upadhyay, Nearkasen Chau, Aditya Kumar Patra, Dhanjee Kumar Chaudhary

Heavy earth-moving machineries used in open-pit mines intensively expose the drill operators to whole-body vibration and shocks and thus to musculoskeletal disorders. The roles of an individual, machine, and rock-related factors in their exposure remain poorly understood. This cross-sectional study investigated their role among 39 drill operators from Indian iron ore mines. It shows that 70% of the operators were exposed to high levels of vibration, above the limit values recommended by ISO 2631-1. Multiple linear regression models showed that the whole-body vibration and shock exposures were strongly associated with operator’s age, drill machine model, rock’s hardness, uniaxial compressive strength, and density. The role of body mass index was close to significance (p = 0.08). Univariate analyses found that drill’s age, seat pad thickness, and seat backrest height were also strong predictors. These results help in identifying risky operators, materials and occupational situations, and in implementing appropriate prevention and intervention to reduce and monitor the exposures and health risk.

By Evangelos Petrakis, Kostas Komnitsas

This study investigates the evolution of dimensional properties of grinding products, namely, the mass, the surface area, the length, and the number of particle distributions with the energy input in a ball mill. The size analysis of the mill products enables the calculation of the mass distribution of each material at predetermined size classes and then the determination of the other dimensional properties by taking into consideration the geometry of the particles. Based on the distribution of dimensional properties, an effort was made to determine whether the grinding products are fractal in nature. The effect of material type and grinding conditions on the relationship between the dimensional properties and the specific energy input was also investigated. Special importance was assigned to the study of the specific surface area and the surface area production rate, both during the initial grinding stages and at higher energy levels. The determination of the surface area production rate allows the identification of the grinding limit and the maximum specific surface area which could theoretically be achieved. This approach has as ultimate objective the maximization of energy efficiency and subsequently the minimization of the high grinding cost.

By M. Sadegh Safarzadeh, Stanley M. Howard

The two-dimensional predominance area (Kellogg) diagram (PAD) surfaces bounding the three-dimensional Cu-As-S-O system were constructed at 900 K. The computations employed gases As4O6(g), O2(g), and SO2(g) as the independent coordinate species to generate diagrams of As4O6(g) − O2(g),O2(g) − SO2(g), and As4O6(g) − SO2(g), while the third gas (As4O6, O2, or SO2) was fixed. The results indicate that there is no shared boundary between enargite (Cu3AsS4) and copper sulfate (CuSO4); however, at PO2 < 10−6 atm, PAs4O6 < 10−10 atm, and PSO2 > 10−4 atm, CuSO4 is the stable phase at 900 K. The chemical driving force for oxidation of intermediate phases between enargite and copper sulfate is substantial except for basic sulfate (CuO · CuSO4).

By Yi Luo, Jian Yang, Hua Jiang

Surface subsidence induced by underground coal mining activities, especially longwall mining operations, can cause various problems to interstate highways ranging from structural integrity, drivability to safety. Accurate subsidence prediction, correct influence assessments, and effective mitigation measures are the keys to ensure the safety of highway traffic. The surface subsidence prediction program, called comprehensive and integrated subsidence prediction model (CISPM), was developed based on the principle of influence function method and has been validated with a large number of subsidence measurements. In this paper, the techniques to use the predicted final surface movements and deformations for assessing their influence on the integrity and functionality of highway structures (e.g., road surface pavements, concrete slabs, transverse joints, etc.), vehicle dynamics, comfort level, and drivability are presented. A number of mitigation measures to protect the highway structures and to ensure traffic safety are proposed along with an application case.

By Manuel Pérez-Tello, María M. Salazar-Campoy, Óscar Rodríguez-Hoyos

A common problem during the operation of the Kaldo furnace is the formation of accretions and blockage of the injection lance due to splashing. This typically occurs during the processing of anodic slimes for the production of doré. In this work, a 1:7 scale model of the Kaldo furnace currently in operation at Metalúrgica de Cobre, Mexico, was built in transparent acrylic plastic. Water and colored oil were used to represent the doré and slag, respectively. The model was used to determine the maximum penetration distance of the injection lance under a variety of experimental conditions at room temperature. Input variables included two types of oil, rotation speed, inclination angle, and the fraction of the vessel volume occupied by the liquids (φ). A mathematical correlation for the dimensionless maximum penetration distance of the injection lance d ∗ as a function of φ, the Froude number of the liquids in the vessel (Fr), the Reynolds number of the gas jet (Re), and the oil-to-water kinematic viscosity ratio (η)was developed. Reasonable agreement between the calculated and experimental values was obtained. Digital images showed that splashing was caused by the turbulent gas jet impinging upon the free surface of the liquids, whereas the cascade effect was negligible. The results of this work have been useful to improve the operation of an industrial Kaldo reactor.

By Justyna Swolkień, Nikodem Szlązak, Dariusz Obracaj

Polish coal mines are characterized by severe geological conditions and the co-occurrence of natural hazards. These hazards are associated with methane and dust emissions during mining processes which can provide methane, dust or methane-dust explosions. Besides, there are such natural hazards as gas and rock outbursts, rock bursts, spontaneous combustion of coal and environmental heat load. The mutual influences of various geological conditions, as well as the natural hazards, intensify the increase of the methane explosion hazard. The occurrence of methane explosions in the Polish mining industry between 2013 and 2108 are analyzed. Fatal accidents are compared with similar events in the global mining industry. The methods of preventing the explosion hazard as well as methane emission control in the Polish coal mining sector are presented. Methane hazard prevention should be adapted to levels and other natural hazards, especially those related to ventilation of underground mine. The methods of preventing methane emissions into mine excavations are often contrary to the means of preventing other ventilation-related hazards in the underground mine, e.g. the prevention of spontaneous combustion of coal in the goaf of longwall panel. Therefore, the design of longwall panels should be preceded by a detailed analysis of the results of both methane emission prediction and forecast of other ventilation-related hazards.

By D. Bahrami, W. K. Asante, G. L. Danko

It is prudent to interpret atmospheric monitoring signals in real time for checking the safe limits of the air conditions in underground mines. In gassy mines, real-time evaluation increases the safety of operations. In all mines, continuous monitoring and evaluation contributes to maintaining air conditions within healthy and safe limits. Signal interpretation for safety conditions in mines is difficult for many reasons. An increase in hazardous contaminant concentrations can be predicted by signal pattern recognition, root cause analysis of rapid changes toward deterioration, and forward prediction in time using algorithms and numerical models. The paper describes an early warning system for analyzing monitored signal patterns continuously in real time as well as forward predicting the various environmental and working conditions to recognize dangerous trends that may affect safety and health in underground mines. A dynamic, numerical ventilation model with heat and gas contaminant simulation components is used for the analysis of atmospheric data. Methods and test results are discussed with numerical examples for signal propagation prediction. Several mine examples are studied using controlled, synthetic data for malfunction simulations to evaluate time delays between the detection time of suspicious signal trends and the time of dangerous threshold crossing marking an accident scenario. Delay time is found in the order of 20 min in the examples, signifying the useful time period for preventive intervention between EWS warning and the likely breakout of a following accident.

By Paul F. Ziemkiewicz, Aaron Noble, Christopher R. Vass

Many modern industries rely on rare earth elements (REEs) to produce products that are essential to both civil and defense applications. In a prior study (Vass et al., 2019), the authors showed that REE grades in acid mine drainage (AMD) and associated byproduct precipitates from AMD treatment (AMDp) warrant evaluation as a feedstock for REE production. The current work extends that effort through a broad survey of 141 AMD treatment sites in Northern and Central Appalachia. In this study, 185 raw AMD and 623 AMDp field samples were obtained and analyzed to assess the REE and major metal concentrations. Results show that an average of 282 μg/L and 724 g/tonne of REEs occur in AMD and AMDp respectively. Additionally, both basins contained similar distributions of REEs, and these distributions tended to favor heavy and critical REEs when compared with traditional REE ore deposits. Geospatial analysis identified a total resource of 340 tonnes stored at the 141 sites sampled in this study. While this analysis did not quantify the basin-wide REE inventory, it does indicate the impact that processing cut-off grades will have on the overall AMDp resource base.

By Yang Ge, Yuzhu Pan, Mansheng Chu, Jue Tang, Cong Feng, Lihua Gao, Zhenggen Liu

The low-grade nickel laterite ore used in this study was successfully upgraded through selective reduction by industrialized rotary kilns followed by magnetic separation. The results indicated that both iron metallization extent and nickel metallization extent showed obvious linear correlation. In addition, rational roasting temperature and prolonged grinding time could enhance the overall fineness level of reduced laterite nickel ore. The moderate roasting temperature at a range of 1100–1150 °C should be suitable enough to a conversion of total nickel to metallic nickel and partly inhibited the conversion of total iron. Ultimately, the obtained ferronickel alloy with a nickel content of 7.32% and an iron content of 84.15% was prepared successfully from the lowgrade nickel laterite ore containing a nickel content of 1.92%. Nickel and iron recoveries were 96.72 and 89.08% respectively, which achieved the highly efficient recovery and utilization of iron and nickel from low-grade laterite nickel ore

By LaTasha R. Swanson, Jennica L. Bellanca

Proximity detection systems (PDSs) for mobile machines have the potential to decrease injuries and fatalities. Early adopters of the technology have identified some challenges, which present an opportunity to explore and improve the integration of mobile PDSs in underground coal mines. The current research study applied the task-technology fit framework to investigate the fit between mobile PDS technology and mining relative to health and safety, from the perspective of leaders at two coal mines. Quantitative results from the study show that mine leaders evaluated mobile PDS favorably for training and ease of use, system feedback, user authorization and experience, and less favorably for safety, compatibility, task completion, and reliability. Qualitative results reveal specific task, mine, and system characteristics that may have influenced leaders’ evaluations. The study includes considerations and suggestions for safe technology integration