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By X. Cui, H. Ding, J. Wen, Q. Gu

This study is a continuation of previous work designed to further explore the mechanism of the bioleaching of sulfide concentrate at neutral pH by heterotrophic bacteria Bacillus megaterium QM B1551. The concentrate contained 13.2 percent nickel (Ni) and 0.2 percent cobalt (Co), which presented primarily as pentlandite and pyrrhotite. Contact and noncontact bioleaching experiments were conducted with finely ground ore at an initial pH of 6, resulting in 44.7 percent of Ni and 38.2 percent of Co leached in the contact-bioleaching treatment. Oxidation experiments of sulfur, thiosulfate (S2O32−) and ferrous ions (Fe2+) by cell membrane were performed to verify whether sulfur transferase, thiosulfate quinone reductase and enzyme cytochrome B558 on the surface of the bacteria could be expressed to oxidize the sulfide. The results show that thiosulfate quinone reductase and cytochrome B558 could be expressed to oxidize S2O32− and Fe2+ to SO42− and Fe3+, respectively.

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 Congling Shi, Marek Borowski, Yue Wang, Jianwei Cheng, Xixi Zhang, Xuan Xu

As the first barrier to prevent accidents caused by explosions in underground coal mines, the integrity and stability of mine seals have great effects on mine workers’ lives and underground production safety. In this paper, the mechanical responding performance of typical mine seals under the impact load are studied by using numerical simulation method. By such simulation studies, the safety of different seals subjected to the explosion load is evaluated. Seals’stability are also investigated under effects caused by various influence factors including thickness of mine seal, cutting depth into surrounding rocks, rock type, and the roof-tofloor convergence under given the explosion load. The research results can provide theoretical basis and reasonable improvements for mine seal’s construction practices for improving its anti-explosion performance.

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 Sean Dessureault

The ubiquity of big data, internet of things (IoT), and smart devices is radically changing society; our personal lives are being tracked, digitally motivated through gamification, where information has become an addiction at all income levels, genders, and generations. These forces should not be held at bay in mining; rather, we should embrace and take advantage of this phenomenon to improve safety and productivity. It is time to rethink long-held conventions behind Fleet Management Systems, such as permanently mounted hardware, connecting through cables and Bblack boxes^, equipment centric rather than operator-centric, wireless requirements, minimal to no feedback to the operator, and high costs. We should also reconsider how we are collecting much of our safety, training, and preoperational forms on paper that then, must be entered into computer systems for compliance, and rarely if ever used in analytics, rather than entering the data directly into a digital device. Collecting safety and location data directly digitally also unlocks the information contained in safety forms and audits enabling new data mining and analytical approaches. Managing then gaining value from this new, greatly expanded mountain of largely unstructured data, requires the use of modern tools and approaches, such as gamification and big data, as well as skill sets, not traditionally available in mines. Furthermore, tablets can now provide a better user experience as well as new sensors when compared with traditional fleet management systems (Mining Magazine 2019, 2016, 2015), at a fraction of the cost, employing the extremely esthetic and engaging visuals derived from the video game industry. Real case studies of these applications of both technology and approach, such as gamification, show that these tracking technologies can bring high visibility and large amounts of data to even the smallest operations and the challenge of making use of the data can be facilitated through the application of gamification. As with our personal smart devices, these technologies are poised to deliver huge improvements in operator feedback, tracking, and performance management, at a much lower cost per unit.

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 SAMUEL A. LOLON, ADITYA JUGANDA, JURGEN F. BRUNE, JR. GREGORY E. BOGIN

Historically, there have been many events of mine fires and explosions recorded in the United States and other countries that have demonstrated the existence of explosive methane-air mixtures, herein referred to as explosive gas zones (EGZs) [1]. The risk of mine explosions can increase if these EGZs migrate out from the gob into the surrounding mine entries — a phenomenon known as gob breathing. A number of 3D computational fluid dynamics (CFD) simulations using various magnitudes and periods of barometric pressure variation have indicated that the EGZ outgassing potentially occurs due to lags in pressure, which are strongly influenced by mine conditions and ventilation systems. Early-warning systems with real-time pressure monitoring and the application of gob ventilation boreholes are recommended to detect and mitigate explosion hazards from gob outgassing.

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 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 Y. V. Vasylchuk

This paper presents an algorithm for optimizing the classification of surface mine material subject to excavating constraints. High-resolution expected profit models are input and optimized to classification maps subject to site-specific rectangular excavating constraints. This optimization problem defies traditional closed-form analytical solutions; a practical heuristic algorithm has been developed to quickly determine the optimal final destination for the material subject to realistic constraints. The optimization is fast and generates results that achieve up to 98–99% of the total expected profit achieved with free selection. This algorithm provides a fast viable option for practical application in short-term grade control and in managing multiple realizations in long-term resource estimation.

By Yuting Xue, Danqing Gao, Brijes Mishra

Heterogeneity and discontinuity significantly affect rock strength. For accurate stability prediction, intact rock behavior is imperatively included in rock mass behavior. However, past research largely used arbitrary scaling approaches to produce rock strength. This paper considers a stochastic approach in order to determine the strength of a rock. Based on the laboratory data, a MATLAB® with extreme value stochastic model generates a database for each physico-mechanical property. Then FLAC® simulates laboratory-sized rock specimens. The grids developed in the numerical model can in turn develop random material properties in MATLAB®, which researchers then applied to the final FLAC® model. Model runs simulate the approach performed in the laboratory. The results from the model indicate that a stochastic approach produces strengths that are lower than a deterministic approach. Failure modes for each specimen are different, similar to observations in the laboratory. In addition, random density also influences the failure mode, highlighting the importance of stochastic analysis in rocks.

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

By Larissa Koroznikova, Steve Durkin, Bradley Drake, Michael Tuck

This paper presents the results from the investigation of the application of thermal fragmentation in Australian hard rock underground narrow-vein mining. Two geologically similar samples from an underground narrow-vein hard rock gold mine were collected to obtain a measure of the technology’s ability to recover ore by the creation of large thermal openings to assess the applicability of the thermal method. Particle size distribution showed a higher generation of fine product, − 2 mm, by thermal fragmentation compared with selective blasting by 31%. The Bond work index for thermal ore (12.62 kWh/t) is half to that of the blasted ore value (25.32 kWh/t). The average grindability obtained for the thermal ore sample was greater than the blasted sample by a factor of 2.44, a higher value indicating a decrease in the energy required to grind. The thermal fragmentation method generates product with higher dissolution of gold in cyanide, by 14% for the − 9.5 + 2 mm size fraction samples. Additionally, the thermal fragmentation results in higher production of − 9.5 + 2 mm material by 15 % compared with selective blasting.

By Jue Kou, Lei Yu, Bern Klein, Lusheng Zhou, Chunbao Sun, Genzhuang Li, Reem Roufail, Amit Kumar

Magnetic liners can improve the performance of ball mills by increasing grinding efficiency, extending service life, and reducing maintenance costs. Despite their importance, the fundamental understanding and the quantitative investigation on the effects of the magnetic liners has not been addressed in the literature. This paper addresses this gap by studying charge motion, and how the use of a magnetic liner affects the breakage mechanism of the mill, using discrete element method (DEM) modeling and the Hertz-Mindlin contact model with relative velocity dependent (RVD) rolling friction. Charge motion was modeled under different mill speeds. Compared to conventional steel and rubber liners, the charge motion in the magnetic liner mill was predominantly cascading. Quantitative analysis of the energy dissipation within the mill was conducted to investigate mill breakage. Regardless of speed, over 50% of the total energy dissipation in the magnetic liner mill was in the form of abrasion and attrition. The results highlighted the appeal of magnetic liners in secondary and regrinding application, where abrasion and attrition are considered more efficient in the fine material breakage, and where impact is ideally minimized to reduce mill wear. A number of experiments were conducted to assess the effect of different model parameters on the performance of the magnetic liner mill. The highest abrasion/attrition intensity was observed with high values of the model parameters namely the restitution coefficient, static friction coefficient, and rolling friction coefficient.

By A. López-Valdivieso, M. A. Corona-Arroyo, M. Llamas-Bueno

Magnetite (Fe3O4) ore is concentrated by low-magnetic-field drums to recover a magnetite concentrate that is low in silica (SiO2). The presence of SiO2 in the magnetite concentrate for steel production increases the steel processing costs, so a major challenge in magnetic concentration is to lower the SiO2 grade in the Fe concentrate. This work presents studies that were carried out on the removal of SiO2 from the magnetite concentration at the plant scale. Studies were performed with a three 36 × 96″ drum unit processing 46 ton/h of rougher magnetite concentrate. These studies showed that silica appears in the magnetite concentrate by three mechanisms, namely SiO2 entrainment in Fe3O4 chains, heterocoagulation between Fe3O4 and SiO2 particles, and mineral locking of SiO2 to Fe3O4. The SiO2 entrainment mechanism had the highest contribution (75%) to the SiO2 recovered in the Fe concentrate. Electrokinetic studies on Fe3O4 and SiO2 showed that heterocoagulation occurs because of the low negative zeta potential of the minerals at the pH of the plant slurry. This study also showed that a high percentage of ultrafine size SiO2 particles trapped in Fe3O4 agglomerates was not removed by the dilution water for the slurry fed to the drum. To lower the SiO2 recovery in the drum magnetic concentration process, work should be directed towards the removal of trapped SiO2 in Fe3O4 agglomerates.

By Maurício Covcevich Bagatini, Maycon Athayde

Water consumption reduction in pellet feed operation is of paramount importance. Compared with traditional ball mills, high-pressure grinding rolls (HPGR) play an important role in Blaine surface area (BSA) generation to improve agglomeration properties, although stability is still a challenge. Grindability improvement of existing operation has a direct impact on the performance of the filtering and pelletizing operation. The results of this study, as a pregrinding operation, can be applied not only in new operations but also in existing ones, helping the operator control process variation in a more effective way while ore hardness increases.