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By Lori Kormos, Jhonny Carrión De la Cruz, Dominic Fragomeni, Elizabeth Whiteman, Jorge Oliveira

"Process diagnosis, flowsheet design and optimisation are most effectively and efficiently achieved through the use of metallurgical testwork combined with more modern quantitative mineralogical techniques. Integration of the mineralogical data in testwork programs provides a resolution that cannot be obtained from assays alone and can direct the flow of work to result in optimized conditions more quickly than would otherwise be possible. At Xstrata Process Support (XPS), QEMSCAN (Quantitative Evaluation of Materials by Scanning Electron Microscope) and EPMA (Electron Probe Micro Analyser) information can be employed to diagnose specific issues in a plant or lab scale test and are routinely combined with other metallurgical data sets to benchmark performance, design and optimise flowsheets. Representative sampling protocols for ore bodies or test products, the use of geometallurgical unit classification and high confidence metallurgical test programs are key components of the strategy. Two case studies from Xstrata Zinc’s Antamina Mine and Concentrator in Perú, and Xstrata Nickel’s Nickel Rim South Mine in Sudbury are described to show how the use of quantitative mineralogy were used to diagnose a plant issue and how the data can be integrated into metallurgical programs to assist mineral processing engineers to design and optimise flowsheets.INTRODUCTIONOver the past decade, there has been a shift away from metallurgical testing that employs only chemical assays to quantify performance; the use of empirical observation in order to optimise a flowsheet; and the extraction of bulk samples for testing or piloting. The integration of geological information into the planning and execution of testwork programs including the use of quantitative mineralogy has improved the overall quality and predictability of metallurgical programs. At the same time, improvements to metallurgical testwork protocols such as rigorous statistical assessment of results, the use of factorially designed experimental strategies (DOE), and replicate flotation with appropriate quality controls, has improved the confidence level in these results.Process diagnosis, which utilizes quantitative mineralogy, can clearly define the root cause of the metallurgical issue. Whether used on its own to diagnose an issue or in combination with other metallurgical testwork, the use of mineralogical data has become the standard in the mining industry."

Jan 1, 2010

By Chris Breeds, Larry Leone, Jerry Wallace

Project Owners typically require General and Detailed Blast Plans when blasting close to important structures and specify the maximum allowable peak particle velocity for each potentially affected structure. Low, residential level PPV limits may be specified which significantly restricts the potential for blasting to be effectively used. Contractor’s responding to these contract conditions typically cite historic case studies which may, or may not, apply to the specific situation and/or types of structures for which limits have been set. A long submittal cycle typically follows.

Jan 1, 2010

By M. Westerstrand

It is known that the water chemistry of the process water during ore refinement can affect product quality, such as iron pellet strength. The main objective of this study was to quantify the amounts of major elements, such as Ca, Mg, Na, S and Cl carried by process water and by magnetite grain surfaces to the end product, iron ore pellets made from magnetite ore from the Kiirunavaara Mine in northern Sweden. In addition, the amount of colloids (0.22µm ? 1kD) in the process water was examined by ultrafiltration. The amounts of various elements sorbed to the magnetite surfaces were estimated by leaching with Milli-Q water, MgCl2, NH4-acetate and Na-acetate. Total dissolved solids were between 1,446 and 1,775 mg/l, dominated by Ca, S, Na and Cl (89%). The colloidal fraction was less than 3% for major ions. For Ca and Mg, sorption to magnetite surfaces was a much more important transport mechanism for the pelletizing process than evaporated process water, but for Na, Cl and S process water was an important carrier.

Jan 1, 2010

By John C. Gagliardi

The U.S. Bureau of Mines, in cooperation with Carter Mining Co., conducted vibration tests of four off-road vehicle seats. The purpose of the tests was to determine which seat provided the best vibration attenuation under laboratory conditions. Laboratory tests were constructed to simulate the mining vibration environment within the limitations of the test equipment. The acceleration test levels and corresponding response of the seats were low compared to ISO 2631's fatigue-decreased-proficiency time limits. Two of the seats employed mechanical suspensions and two seats employed air suspensions. The seats were tested using a 22,241-N (5,000-lbf) electrodynamic shaker. Mechanical suspension seats were tested with various preload-to-mass ratios (PMR's) and cushion densities. Air suspension seats were tested with various air pressure levels and seat cushion densities. Air suspension seats provided good vibration attenuation if pressurized greater than 552 kPa (80 psi). Mechanical suspension seats' attenuation performance decreased if the PMR exceeded 9.8. Seat cushions of lower density provided less vibration damping.

Jan 1, 2010

An extensive laboratory grinding study was carried out on a magnetite ore in order to assess the grinding behaviour of magnetic concentrate and tail from low intensity magnetic separation (LIMS).The test work involved Bond ball mill testing, rod milling, low intensity magnetic separation (LIMS), and batch ball milling down to product sizes of around P80~25 microns. A total of 18 Bond tests and over 150 batch grinding tests and sieve sizing were carried out. Throughout the grinding tests, power draw was continuously monitored. The relationship between the grinding energy and product size was analysed using the conventional energy-size concepts. It was found that the Rittinger equation fits the experimental data well. However, Bond?s equation does not fit the experimental data well, and therefore a modified Bond equation was developed. Differences in grinding properties between the magnetic and non-magnetic component were analysed and compared to the bulk ore. It was found that grinding properties differ significantly and therefore separate grinding test work may be required for each grinding step in the magnetite ore beneficiation flowsheet. Keywords: grinding, iron ores, particle size, modelling.

Jan 1, 2010

By Carl W. Lam

The increased obsolescence rate of electronic products has made it evermore pertinent to understand the potential environmental impact of materials choices to help guide electronic waste (e-waste) management and promote awareness of high burden materials. Methods for screening for the performance of materials and their potential burden on human health and the environment can be used to comparatively select constituents of present and prospective electronic products. These methods should be able to yield more robust information when linked to other decision-making strategies where integrated data on consumer preferences, production quantities, and regulatory initiatives are sparse or unavailable. A framework is presented here for generating metrics of ecological toxicity, human health toxicity (cancer and non-cancer categories) and global resource consumption for evaluating environmental impact of materials (specifically metals) in electronic products. The time-dependent impact trends of United States? printed wiring board (PWB) metals usage, principally derive

Jan 1, 2010

By J. P. Burland

The paper describes a number of recent case histories in the United Kingdom where field instrumentation and measurements have played a major role in the design and construction of excavations, piles and foundations. It is shown that the design and construction procedures for deep excavations in London Clay are based almost entirely on the results of field measurements. Examples are given of successful application of such measurements. The present understanding of the behaviour of bored piles in stiff clays and their design is based on a number of instrumented pile loading tests. The results of these tests have led to a radically new concept of pile design in which the piles operate at their full shaft capacity under working loads thereby resulting in considerable savings in design and construction. Some examples of the successful application of this concept are given. Finally it is shown that the present knowledge of the stiffness properties of chalk is based entirely on field observations. An example is given of how direct field measurements were used to solve a foundation problem at the base of a coffer-dam in chalk.

Jan 1, 2010

By K. A. Lewandowski

Heap leaching efficiency is reduced by poor solution flow characteristics (channeling and ponding), which result from compaction and fines migration. Agglomeration of the ore can prevent compaction and immobilize fines, but copper leaching requires an acid-resistant binder to stabilize the agglomerates. Until now, there has not been a satisfactory way to evaluate whether a binder was effective, other than squeezing a handful to see if it ?feels right.? Procedures have been developed to quantitatively determine whether a binder produces agglomerates that can withstand compaction in an acidic solution, and have identified several binders that will provide sufficiently compaction-resistant agglomerates for copper heap leaching. Keywords: Copper heap leaching, Binder performance, Compaction

Jan 1, 2010

By D Olivier

De Beers' Finsch Mine is situated in the Northern Cape province, 170 km northwest of Kimberley. The concentrator facility, designed and constructed by Bateman Engineering, was commissioned in 1967 and upgraded in 1979 using diamond liberation and extraction technology available at the time of design. Since then significant advances in diamond processing and technology have been made and these -have been incorporated into the new main treatment plant and recovery plant flowsheets, making diamond liberation and recovery from the Pre-1979 dumps a viable economic option at Finsch."

Jan 1, 2010

By J. J. Carlson

An important factor in filtration is the zeta potential of the particles. Since zeta potential is a function of pH, it was hypothesized that adding CO would lower the pH and zeta potential. A reduction in zeta potential should enhance the flocculation and increase the filtration rate. This paper describes the effects CO on the zeta potential of both pure hematite and samples of hematite concentrate from an iron ore processing plant. A significant shift in the zeta potential, as a function of pH, curve was observed. These results point to an alteration of the particles mineralogy, not just a shift in pH.

Jan 1, 2010

By Maria I. De Rosa

The U.S. Bureau of Mines performed experiments to determine the embedded hydrogen chloride (HCI) and smoke particle characteristics during combustion of polyvinyl chloride (PVC) and chlorinated mine materials for development of a test parameter. The experiments were conducted in an approximately 20-L furnace at set furnace temperatures of 250° and 1,000° C, for a 14-min duration, with an airflow through the furnace of 10 L/min. The variables studied, as a function of time, were hydrogen chloride embedded on smoke particles, hydrogen chloride concentrations in the gas phase, smoke particle average diameter (dg) and particle concentration (no), and product of smoke particle diameter and concentration (dgno). Other variables included carbon monoxide (CO), carbon dioxide (CO2), and oxygen (O2) concentrations; sample mass weight loss; and furnace temperatures. Results show that there is a correlation between embedded hydrogen chloride, hydrogen chloride gas concentrations, and inverse of the smoke particle diameter-concentration product (1/dgno); the higher the hydrogen chloride gas concentrations, the higher the embedded hydrogen chloride, the higher the 1/(dgno) values. These correlations will enable development of a simple test parameter to assess the toxic hazard that these materials pose during fire.

Jan 1, 2010

By R. L. Levens

Researchers at the U. S. Bureau of Mines conducted investigations to evaluate the potential for ground water contamination by mine waste used as backfill. Samples of cemented waste backfill and water discharging from drillholes and seeps were collected to use in chemical analyses and laboratory tests to determine the physical and chemical factors that control release of heavy metals to ground water. Greater water retention by cemented backfill (as compared to uncemented sandfill) reduces the surface area exposed to oxidation, which in turn reduces the amount of acid produced. The acid is neutralized by the cement and minerals contained in the backfill. The grain-size distribution of tailings used for backfill affects the structural integrity of cemented backfill under attack by acidic water; breakdown of the backfill structure releases neutralizing materials faster. Backfilled stopes in rock with low hydraulic conductivities will constitute preferential flow paths after mine flooding; however, the rate of flow through backfill will be much slower than when the stope is partially saturated during mine operation. Considering all factors, acid generation and release of metal ions from cemented backfill should be less than in uncemented sandfill.

Jan 1, 2010

By Z. Q. Zhou

It is the first worke in design of pile foundation to determine the carring capacity of single pile, and a static loading on site is considered to be the lost derect and reliable way. All values P and settlements S induced can be plotted as a broken-line. Since soil is a kind of elasto-plastic and cohesive material, the increasing of settlements is generally greater than that of loads. Different value Pu nay be given by different tester on his P-S diagram, because of erroys in the test and complicated, characteristics of soil. The analytical method of exponential equation shown in this paper derives a specified solution. After using an exponential curve to regress values of loads P and corresponding settlements S from on-site test, coeficients A and B of exponential equation can be obtained. With this curve an ultimate carrying capacity of single pile can be determined. The resistant forces of pile shaft and pile tip can also be defined by the tangent of the calculated knee point, as it is called (tangent method). At last, an example is given to show how the ultimate carrying capacity of f 500mm bored pile is obtained with this method for a project in Kunming.

Jan 1, 2010

By C. L. Liao

The chief experiences for constructing deep tubular columns foundation under deep water are as follows: 1. P.C. tubular columns were sunk inside the caisson. 2. P.O. tubular columns of 3.6 M. diameter were sunk thru thick soil layer to a depth of 47 M. by vibrators. 3. The double wall steel cofferdam was sunk thru soil layer to a depth 31.3 M.. 4. Bore the bedrock with rotary drill succesfully. According to the successful experiences mentioned above, the deep tubular columns foundation may be constructed beyond 100 meters.

Jan 1, 2010

By Jian Li

Developing the Generation IV nuclear reactor is an international collaborative effort. One of the most promising Gen IV nuclear reactor designs is the supercritical water (SCW) concept, in which the water coolant runs at about 625 oC at the outlet. Under this temperature and high pressure condition, the cooling water is at supercritical state, which poses significant demand for both in-core and out of core materials. High-temperature mechanical properties, corrosion resistance and radiation damage are some of the key challenges. At present, no single commercial material can meet all the requirements of the severe SCWR conditions. Corrosion experiments per-formed under SCW condition yield various kind of corrosion modes, some are very challenging to characterize using conventional techniques. A combination of various advanced characterization techniques proofed to be essential to understand the root cause of materials? degradation.

Jan 1, 2010

By P. L. Sibrell

Previous research by the U.S. Bureau of Mines has shown that autoclave cyanide leaching of used automobile exhaust catalysts for recovery of platinum-group metals (PGM) is technically feasible. The purpose of this work was to investigate the chemistry of the dissolution of PGM in cyanide solutions in more detail. Where possible, samples of pure, elemental PGM powders or foils were used instead of automobile exhaust catalysts, because of their greater purity. Ultraviolet spectra revealed that Pt and Pd were solubilized as the square planar tetracyanometallate (II) complexes, while Rh was solubilized as the octahedral hexacyanorhodate (III) complex. This explained the poor recovery of Rh from solution by carbon adsorption, solvent extraction, and ion exchange observed in earlier research, because of the higher anionic charge and size of the octahedral complex. Leaching rate studies showed that the rate of solubilization was greatest for Pd, followed by Pt and Rh. Although the rate of chemical reaction was the controlling step for the dissolution of elemental Pt and Rh samples, the rate of pore diffusion was rate limiting for PGM in catalyst samples.

Jan 1, 2010

By M. Tominaga

An industrial port complex was constructed on the west coast of Leyte Island The work was started in December 1981 and completed in May 1984. This port complex includes a 665 m long wharf and can accommodate vessels ranging from a 60,000 DWT ore carrier to a 4 000 DWT general cargo ship. It now handles materials for and products from a copper smelter with an annual capacity of 130,000 t and a fertilizer plant with an annual capacity of 900,000 t. The Wharf structures consist mainly of interlocked steel pipe piles, steel sheet piles and steel pipe Piles. Material handling equipment such as unloaders, shiploaders, etc. were installed on the wharf. Site survey, planning, engineering design and construction aspects of the port development are discussed in this paper with particular emphasis on the wharf structure.

Jan 1, 2010

By Thomas Trochalides

Newtown Creek Water Pollution Control Plant in Brooklyn, NY is the largest of 14 Water Pollution Control Plants in New York City. It services over 1 million people with a current processing capacity of 310 million gallons daily. Upgrades to the plant have been underway since 1998. This paper details the foundation elements installed in three separate contracts during 2009: NC-41F, NC-36G, and NC-47G. The elements are Concrete-Filled Pipe Piles, H-Piles, Steel Sheet Piling, Secant Walls, Drilled Caissons, and High Capacity Micropiles. Soils on the site consist of fill over organic silty clay and silty sand. Beneath the organic layers lie lake sand and varved silt and clay, sitting atop glacial till and rock. Due to Federal Mandates, certain plant capacity and secondary treatment requirements had to be met by specific dates. Failure to meet the requirements would have an adverse affect on the NYC areas being serviced. Further complicating the project, the existing plant operations had to be maintained throughout the entire construction phase. To accommodate the constraints of the project, new specialty equipment and several key redesigns were used to maintain construction schedules

Jan 1, 2010

By Thomas Lardner

Excavation for The Bow, EnCana, in downtown Calgary, occurred between May 2007 and September 2008. A monitoring programme was used to determine the behaviour of the shoring wall, soil and bedrock during the excavation for the 21 metre (69 ft) deep excavation with a footprint of approximately 17,000 m2 (183,000 sq ft). Results from the inclinometer readings indicated that significant horizontal movement due to a weak rock layer and shear band effect. These modes of movement account for up to 100 mm (4.0 in) and 45 mm (1.8 in) of lateral deflection, respectively. Based upon the results of the monitoring programme, rock samples were collected from the weak mudstone bedrock, with great difficulty, to determine the strength and deformation parameters. Results from the uniaxial compression tests indicate a UCS around 830 kPa (120 psi) and elastic modulus between 80 and 180 MPa (11 and 26 ksi). Mohr-Columb parameters were determined to be c' = 340 kPa (49 psi) and f' = 24°. Residual strengths were determined to be c'r = 0 and f'r = 15°. Using the results of the laboratory tests and field investigation records, an initial finite element analysis was conducted. Results of the analysis show good correlation when compared with the observed monitoring deformation, indicating accurate portrayal of rock parameters. Additional analysis and investigation is required to determine the principal horizontal stresses in magnitude and direction.

Jan 1, 2010

By F. H. Nehl

The U.S. Bureau of Mines investigated the selective electrowinning of Ag and Au from cyanide solutions contaminated with Cu with the goal of decreasing the amount of Cu codeposited. Decreasing Cu codeposited will reduce refinery costs. Direct current was applied to the cell in pulsed and square wave voltages at 0.070 A?h per 150 mL of solution. Times tested for each cycle ranged from 1 to 10,000 ms. Graphite, lead, and stainless steel were evaluated as electrode materials. Square wave electrowinning at 70° C gave the best separation of Ag and Au from Cu. Applying 2.5 V during the duty cycle, 0.0 V the rest of the period, a duty cycle of 10 to 30 pct, and a period of 100 to 1,000 ms gave the following results: Ag concentrations decreased from 34 to 0.1µg/mL, Au concentrations decreased from 54 to 0.2 µg/mL, and Cu concentrations remained almost constant at 560 µg/mL.

Jan 1, 2010