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By Aliakbar Golshani, Behnam Eslami

"Surface settlement adjacent to sensitive structures is a challenging issue in the tunnel engineering. In this study, 3D simulation of TBM excavation has been performed with the FLAC3D code and then the results compared with real monitoring data. Sensitivity analysis was carried out for all parameters affecting the surface settlement, such as the tail void grouting pressure (Pt), the face pressure (Pf), the tunnel diameter (D), overburden (q), shield thickness (t) and the length of the shield (L). The results show that the face pressure, tail void grouting and tunnel diameter have a considerable effect on the maximum ground displacement.In this paper, the monitoring data from Mashhad Metro was used to verify the numerical simulation. Data monitoring for about 47 sections between A2 and D2 stations was selected and a multiple regression analysis was performed. Based on this analysis, an empirical relationship was obtained for the coefficient of regression relationship which confirmed the sensitivity analysis.INTRODUCTIONThe surface settlement due to tunnel excavation is a complex issue, since the surface displacement is a function of several parameters that they are related to the excavation method, soil characteristics and TBM elements. Prediction of deformation is a very important issue, especially in urban areas, since these displacements may be affected the superficial structures. In recent studies, one of the most popular empirical relationships that is used to predict the surface displacement has gussian curve that it was suggested by Peck [1, 2]. An analytical relationship was proposed by Chow that its base assume was isotropic of soil, that surface settlement can be estimated based on the tunnel geometry and the shear modulus(G) [3]. Besides these methods numerical approaches such as the Finite Element Method (FEM) and the Finite Difference Method (FDM) have been used over the last twenty years, since numerical modeling has a high capability to simulation a complex soil conditions and irregular geometry [4]. In this study, all aspects of the EPB-TBM on Mashad Metro Line 2 were modeled and the most important influences on surface displacement in urban areas were determined [1, 3]."

Jan 1, 2016

By A. P. Yovanovic, P. Bonadia, M. N. Moraes, C. F. Matos

"The magnesite flotation operation of Magnesita Refractories, in Brumado – Brazil, has four parallel ball mills working in closed circuit with hydrocyclones to grind the ore for the reverse flotation of silicates in mechanical cells. The modification proposed here opens the circuit for three of the ball mills so that their products are collected together to feed a high frequency screen. The oversize of the screen feeds the fourth ball mill in closed circuit for secondary comminution. The product reports to dewatering and flotation. The undersize undergoes desliming and subsequent flotation operation. According to pilot tests performed, the modification on the magnesite flotation operation will promote a 20% increase in the productivity, 8.5% increase in mass recovery and a 26% reduction in water consumption. The gains are due to the fact that the silicates in the feed are concentrated in the smaller particles (<100µm) with over grinding in the existing closed comminution circuit, making it impossible to take advantage of this natural selectivity. The combination of open circuit, more selective milling, and the high frequency screen, ensures high efficiency particle size classification. This renders the process more effective, both to the screen undersize with its high contents of silicates and fines, and to the screen oversize, which is almost without fines and has a higher magnesite grade. This situation allows for the setting of specific parameters for the flotation of both the primary milling undersize and the secondary milling product.INTRODUCTIONMagnesita Refractories, with its operations site in Brumado, is the largest producer of high purity dead burned magnesia (DBM) in Latin America. The magnesite ore is extracted from an open pit mine, named Pomba, after which it is crushed and handpicked. Due to the presence of disseminated silicate the ore has to be ground and concentrated by means of reverse flotation, before feeding the high temperature kilns for sintering and conversion to DBM.The magnesite flotation unit has an impact crusher to reduce the size of the feeding ore, which is transported to the mills by conveyor belts. The milling operation is composed of four ball mills in closed circuit with hydrocyclones. The closed circuit generates a high circulating load with excess fines, which is detrimental to the selectivity of the desliming and flotation operations, reducing both mass andmetallurgical recovery.In the current scenario, the capacity of the flotation plant is insufficient to meet the demand of the DBM kilns, forcing the operation to work with high purity ores in order to attain the highest possible mass recovery in the concentration process. This is not an ideal situation as it requires the mining site to work with higher stripping ratios.The objective of this work was to improve the magnesite flotation unity to increase its productivity. After a detailed analysis, the milling was identified as the limiting process, which made the authors to focus on this operation."

Jan 1, 2016

By J. Noll, A. Miller, J. Volkwein, C. Pritchard

Hecla Limited, Magee Scientific, and NIOSH have combined efforts to evaluate an in-situ air filtration system for use in an underground mine environment. The purpose of the collaboration was to determine the efficacy of such a technology for reducing the concentration of airborne diesel particulate matter (DPM), with the aim of improving air quality in underground hardrock mines. A secondary goal was to evaluate the use of an Aethalometer as a means of real-time measurement of black carbon as a surrogate for DPM. The evaluation included measuring the DPM-capture efficiency of the filter when it was pre-loaded with dust. Toward this end, rock dust was introduced at the filter inlet to create a dust layer on the filter surface, with the intent of providing improved capture of the much smaller DPM particles. The filtration efficiency for DPM was assessed by comparing measurements of DPM taken at the inlet and outlet of the system, using both real-time and time-weighted-average approaches. The real-time measurements were performed with the model AE33 Aethalometer® made by Magee Scientific. The results of the NIOSH 5040 method analysis were used to assess the effects of the system on time-weighted-average concentrations of total carbon. Results showed a reduction in DPM concentrations in the range of 82%-89%. While the calculated efficiencies based on the two different measurement methods were similar, the DPM levels reported by the Aethalometer were higher, possibly due to differences in the performance of the size-selectors used for the two methods (impactors versus cyclones). More research is required to develop a robust correlation between the two methods, to support the use of the Aethalometer for future mining applications. The advantage of the Aethalometer is that it can measure and record DPM levels for weeks at a time, and can be directly connected to a mine monitoring system, potentially at multiple locations. Ideally such data can be used to initiate the startup of the filtration system should DPM concentrations reach an action level. This work demonstrated that in-situ filtration systems, modified to collect DPM and coupled with real-time monitoring, show promise at reducing DPM concentrations in the mine environment.

Jan 1, 2016

By John R. Goode

"This paper reviews options for the separation of a mixture of rare earth elements (REE) into its component elements. Earlier separations used selective chemistry such as double salt precipitation and reductive/oxidative processes – methods that still have a place in the industry. Fractional crystallization was developed for more complete separations of adjacent REE. The latter method was replaced by ion exchange (IX), which was in turn replaced by solvent extraction (SX). Two main SX chemistries are in use, solvation and cation exchangers, with several variants (mixed solvents, ionic liquids, etc.) now under investigation. SX plant configurations have evolved including advanced techniques like “hyperlinking”, novel saponification methods, and alternative stripping techniques. The classic mixer-settler is the most commonly employed device although centrifugal contactors have been pilot-tested. Non-dispersive SX options including microfluidic devices and membrane-assisted SX techniques are being developed and could revolutionize the SX option. Other REE separation techniques now being studied include Molecular Recognition Technology (MRT), Free Flow Electrophoresis (FFE), newer IX systems, and electrolytic processes. Additionally, the classical crystallization and selective precipitation methods and newer bacteria-mediated processes, chloride volatilization, high performance liquid chromatography, and magnetic separation systems have been studied. This paper reviews the options and concludes that conventional SX is the technology of choice but viable alternatives could be demonstrated and acceptable within a couple of years.INTRODUCTIONThe chemical properties of the individual REE are very similar which is why REE minerals and ore deposits almost invariably contain a mixture of all fifteen REE, i.e., La to Lu plus Y. That said, the distribution of REE in a given deposit is frequently dominated by the light REE (LREE, i.e., La to Nd). Examples include the Bayan Obo, Mianning, Lynas Mt. Weld, and Molycorp Mountain Pass deposits where heavy REE (HREE – Sm to Lu and Y) typically account for well under 5% of the REE content. The LREE operations produce some HREE but the main sources of these important elements are the ionic clay deposits of Southern China. Importantly, all of the REE recovery operations referenced above, except for cerianite-bearing ionic clay deposits, initially produce a mixed REE precipitate or calcine with a REE distribution similar to that in the ore (Goode, 2016). However, the consumers of the REE, the manufacturers of magnets, phosphors, catalysts, optical glass, etc., require separated products with purities generally ranging from 99% to as high as 99.9999% depending on the element in question and the end use. Hence there is a need to separate the individual REE one from the other. This paper is intended to review the options."

Jan 1, 2016

By Chengguo Zhang, Bruce Hebblewhite, Faham Tahmasebinia, lsmet Canbulat

"Coal burst is a dynamic release of energy within the rock (or coal) mass leading to high velocity expulsion of the broken/ failed material into mine openings. This phenomenon has been recognised as one of the most catastrophic failures associated with the coal mining industry, which can often lead to injuries and fatalities of miners as well as significant production losses. This paper aims to examine the mechanisms contributing to coal burst occurrence, with an emphasis on the energy release concept. In this study, a numerical modelling study has been conducted to evaluate the roles and contributions of difference energy components. The energy analysis presented in this paper can help to improve the understanding of energy release mechanisms especially under Australian conditions.INTRODUCTIONCoal burst is one of the most hazardous problems encountered in underground coal mines, which occurs at different locations in a variety of mining systems and operations. This phenomenon always involves a violent and dynamic energy release with large rock mass/coal deformation and ejection that can cause severe damage to openings, equipments and may result in fatalities and injuries.The first coal burst occurrence was reported in Britain in 1738 (Dou 2001). Since then, international experiences are available in Canada, South Africa, USA, former Soviet Union, China, India, France, Germany, Poland and Czechoslovakia. Rice (1935) classified coal bursts as two general types, namely excessive pressure bumps and shock bumps and he further mentioned that pressure bumps are caused when pillar stress exceeds bearing strength. Shock bumps are induced by the breaking of thick, massive strata at a considerable distance above the coal-bed, causing the immediate roof to transmit a shock wave to the coal."

Jan 1, 2016

By S. K. Mitterecker, T. Hofbauer, F. Baerhold

"Acid regeneration is a very important process step in each acid leach circuit. It is required to recover dissolved metals and HCl from spent leaching acid. Andritz Metals presents its recently commissioned spray roast pilot plant. The facility is now available for testing and demonstrating acid recovery or metal oxide production which is a requirement in several flow sheets under development for the mining and specialized oxides industries. Results from pilot test campaigns are reported here. We are currently focusing on a nickel ore leaching process, which requires both a feasible iron control and acid regeneration step. In addition, we disclose the results of a magnesium ore and aluminium recycling test campaign conducted in our pilot plant facility.INTRODUCTION Hydrochloric acid regeneration is widely used in the steel industry to regenerate spent pickle liquors into hydrochloric acid at a typical concentration of 18 wt.%. Andritz Metals (formerly known as Ruthner) has built more than 200 acid regeneration plants worldwide (Andritz Metals brochure). As technology leaders Andritz also has vast experience with specialty metal oxide plants, producing metal oxides such as aluminium oxide (Al2O3), magnesium oxide (MgO), nickel oxide (NiO), cobalt oxide (Co3O4) and mixed oxides from metal chloride solutions (Baerhold F., Lebl A., Starcevic J., 2006), (Jedlicka, H., n.d.), (Ruthner M.J., Krischner H., 1973), (Ruthner Ind. Planungs AG, 1967). Hydrochloric acid leach circuits have been developed and proven in the industry for many years. Examples of industrial applications are: synthetic rutile production (TiO2) (Walpole E.A., Winter J.D., 2002), Quebec Iron and Titanium’s UGS process (Patoine M.-C., De Mori A., Borowiec K., Coscia C., 2002), magnesium and potassium production (Priemer H., 1973) and Goro Nickel (Vahed A., Colton D.F., Duterque J.P., Karner W., Baerhold F., 2004), (Taylor A., 2013). One of the critical process steps in developing a hydrometallurgical process is acid regeneration, as it is an economic requirement to recover both the dissolved metals and acid (commonly HCl) from the spent leaching solution."

Jan 1, 2016

By L. M. Lowe, D. B. Chambers, D. G. Feasby

"The presence of the naturally occurring radioactive elements uranium and thorium in rare earth (RE) resources can present challenges in achieving regulatory and social acceptance. The discovery and awareness of radioactivity in mineral resources radioactivity typically generates strong public intuitive responses that may be project prohibitive; a significant proportion of such resources contain radioactivity.The objectives of this paper are to demystify the presence of uranium and thorium in RE resources and to demonstrate how a RE project can be safely developed, operated and closed from a radiological perspective. Radioactivity in RE resources is principally thorium-based. Thorium is interesting and challenging from a metallurgical perspective – one of those stubborn metals commonly assessed as refractory. Thorium is difficult to mobilise into solution and easily precipitates out. Thorium is a common element in the earth’s crust – about 10 ppm on average, and natural geophysical systems conclusively demonstrate its immobility. Specific mine tailings contain elevated levels of thorium, but the contained thorium is neither a significant ecological nor a personal hazard.Waste management for a hard rock rare earth project includes the management of mineral processtailings, waste rock, and metallurgical residue. Proven strategies are available for tailings and waste rockfor all climate conditions. The management of the metallurgical residues is potentially more challenging.Example robust strategies for addressing these challenges are presented.A potential way to reduce the radioactivity of rare earth metallurgical wastes is to selectively remove uranium and thorium. Uranium oxide is readily marketable, but its concentration as a byproduct typically triggers extensive regulatory processes. Thorium is presently not marketable, but may be so in the not-too-distant future with the development of thorium-based nuclear energy. The pro’s and con’s of uranium and thorium byproduct recovery are summarized."

Jan 1, 2016

By Nawshad Haque, Leanne Smith, Hal Aral, Joseph Cho, Warren Bruckard

"Water availability is one of the principal parameters in determining the feasibility of mining projects in arid and semi-arid regions. The volumetric water footprint (VWF) of a conceptual model of a copper flotation plant was found to be 2.45 kL/t Cu ore, compared with an actual measurement reported in the literature of 2.72 kL/t Cu ore. The flowsheet considered included mineral processing stages such as crushing, screening, grinding, classification, separation, flotation, thickening and filtration. The effect of a number of variables on the VWF was evaluated, including solid/liquid ratio, feed mass flowrate, ore loss, water loss, moisture content of ore, ore grade and water recycling. The use of seawater with recycling provided the most environmental and economic advantage among several scenarios evaluated. The study assumed a price of $1/kL freshwater, $4/kL for transport over a 200 km distance at 2,000 m altitude and $4/kL for water treatment. The water related cost of the desalinated seawater use scenario was A$493/t Cu concentrate, while the water related costs of fresh water and blended water scenarios were A$308/t and A$268/t Cu concentrate, respectively. The water related cost (fresh water scenario) accounted for 44% to 49% of the entire mining and processing costs that included drilling, blasting, loading, hauling, crushing, grinding and concentrating. The total overall cost was A$435/t Cu concentrate for the seawater with recycling, compared to A$451/t Cu concentrate for the fresh water with recycling case.INTRODUCTIONReducing the water footprint (WFP) by utilising alternative water sources has been a focus of mining projects due to increasing concerns about water scarcity and growing energy costs. The global mining industry can expect to experience fresh water shortages in the future, and saline or hyper-saline water may be the only available water source to process minerals in arid regions. Extensive studies on alternative water sources (e.g. seawater, desalinated seawater, blended water) and the reuse of process water have recently been conducted (Moreno, Aral, Cuevas, Monardes, Adaro, Norgate & Bruckard, 2011; Aral, Mead, Cuevas, Davey & Bruckard, 2010). Such studies provide sustainable and economic strategies for mines and concentrators in the arid or semi-arid regions of the world such as in Chile, Peru, Indonesia, and Portugal. More work, however, is needed to confirm water consumption data for different base metal flowsheets and use this data to develop water models that can lead to reduced WFPs and more sustainable water usage in the mining industry."

Jan 1, 2016

By S. Acar

"In recent years the gold mining industry has been challenged by declining metal prices as well as having to treat ores that have low grades and are refractory in nature. Many factors must be considered when metallurgical studies are designed to develop process design criteria for these type of ores. These factors are mostly related to the mineralogical and chemical compositions of the ores, the geological setting of the deposit and how the ore/waste will be mined, such as whether openpit or underground, the mine schedule, and the mine fleet type and capacity. The purpose of this paper is to provide an experience-based practical approach to how to select and characterize test samples as well as devise process development metallurgical studies for both oxide and refractory gold ores, and to provide insight into some of the matters that might go wrong during the course of the studies. This paper is intended as both a guide for someone new to the field and also as a reminder for those familiar with the field. IntroductionThe recent decline in ore grades and metal prices have challenged mining companies to reduce capital and operating costs associated with developing new mineral resources. In some cases, metallurgical studies have been sacrificed to prevent cost overruns resulting in inadequate mineralogical, chemical and metallurgical characterization. Consequences have included longer construction schedules, higher initial and working capital, higher operating costs and less than desirable plant performance (Whincup, 2010; Torres, Chaves and Meech, 1999).Mineralogy, geology, mining type and sequence, and the metallurgy of an orebody will determine the process development metallurgical study requirements and eventual process plant design. Therefore, once the geologist has an early indication of a prospective orebody, geologists, metallurgists, mining engineers, and social and environmental responsibility scientists should convene and devise a plan on how to exploit the orebody economically (Lunt, Ritchie and Fleay, 1997).Geologists may find a prospective orebody solely based on grade. However, if the orebody cannot be mined and processed economically, then it is deemed not to be a deposit. An example of this could be a refractory gold deposit, either sulfidic, carbonaceous or siliceous refractory or any combination of those, that may not be mined and processed economically due to reasons such as the physical location of the deposit, depth of the ore lode, or social and environmental concerns. Therefore, an early collaboration between all disciplines must be established.Each orebody may have its own unique mineralogical, geological and chemical characteristics (Guresin et al., 2012). These unique characteristics should be effectively sampled to reduce risks associated with process design and engineering efforts for the process development metallurgical studies. If the sample or samples are not representative of these unique characteristics, then the studies performed will be pointless. The project metallurgist in charge of conducting metallurgical studies should also possess general geology, mineralogy and mine engineering knowledge. Recommended readings are a book on understanding mineral deposits by Misra (2000) and articles on heap leach development by Scheffel (2014a and 2014b)."

Jan 1, 2016

By L. Hutton, S. W. Colley

"The release of soluble salts of base metals from acid mine pits and in the waste water from metal refiners is an avoidable source local pollution and contamination. Tightening of the regulations controlling natural resource extraction and industrial wastewater discharge is mandating the removal and recovery of metals from waste streams, and the remediation of contaminated sites. There is an economic incentive in recovering the valuable copper and nickel, as the value of the recovered metal can offset remediation costs and for high flow waste streams can be a source of income. Extraction of metals from waste streams by conventional Ion Exchange and chelation resins is widely practised, but has limitations on applicability in complex and dilute feeds due to the structure and properties of polymeric resin beads. Composite Advanced Ion Exchange (AIX) materials have been developed for the recovery and purification of base metals from base metal mining and metal processing industries. A silica-composite based resin has been developed for the selective extraction of copper from high iron containing feeds. This resin can be eluted with sulfuric acid yielding a copper stream suitable for return to solvent extraction or to electrowinning. We describe the development and application of the resin and process to two acid mine drain feeds of varying copper and iron concentrations, and show that the copper concentration can be considerably upgraded even at small scale with a final metal content of >95% copper.INTRODUCTIONWaste water with high sulphate concentrations, low pH and containing complex and variable mixtures of metals is an inevitable product in the mining, extraction and metal refining industries. One problematical water source is Acid Mine Drainage (AMD) which in addition to the metals of interest also contains a wide range of contaminating elements. Purge streams from metal refining are less complex in composition but contain significant quantities of the value metals. The typical treatment of such waste streams is treatment with lime to increase the pH of the water, precipitating the dissolved metals and sulphate as a sludge of mixed metal oxides/hydroxides and sulphates. The process is effective in producing a water stream that can be safely discharged but if there are significant concentrations of value metals such as copper, nickel, zinc then there can be a considerable loss of metal value."

Jan 1, 2016

By A. Quilodran, B. Jakovljevic, T. McCallum, P. Wong

"Rare earth separation by solvent extraction (SX) requires multiple separation plants each consisting of many extract, scrub, and strip stages to separate the individual metals. SX modeling advances have brought benefits to circuit design and process optimization by quickly narrowing test conditions without the need for exhaustive laboratory studies. Modeling can be used to optimize circuit configuration, O/A ratios, and acidities, which allows for CAPEX and OPEX savings. A comparison between pilot plant data and the results expected from modeling is presented for rare earth separations with CYANEX® 572.INTRODUCTIONRare earth separations can be difficult due to limited separation between the elements (Xie, Zhang, Dreisinger, & Doyle, 2014). This requires relatively complex solvent extraction circuits utilizing multiple extract, scrub, and strip stages as well as multiple SX configurations to achieve the desired metal purities. Designing rare earth circuits can be complex, and significant time and testing may be necessary to determine the required staging and optimal conditions.Circuit modeling for rare earth separations has been introduced to the industry using CYANEX® 572 extractant (Soderstrom, McCallum, Jakovljevic, & Quilodran, 2014). CYANEX® 572 is an acidic organophosphorus extractant formulation which has a weaker ligand-metal complex strength than that of the traditionally used phosphonic acid extractants. This allows efficient extraction while requiring a significantly lower acid concentration for stripping (Wang, Li, Zhao, Dong, & Sun, 2015). The reduced acid requirement in strip is expected to provide OPEX savings.The modeling can be utilized to quickly determine the required acidity and organic/aqueous (O/A) ratio for a given separation. It is also expected to reduce CAPEX requirements as optimal staging can be determined, and implemented.CYANEX® 572, combined with modeling, was utilized to produce a purified dysprosium (Dy) stream. To achieve this separation, multiple SX circuits were designed and operational conditions specified to separate Dy from the mixed rare earth chloride feed."

Jan 1, 2016

By A. C. de Araujo, M. G. Barbosa, R. Martino, S. Gaydardzhiev

The Iron Quadrangle district is a world-class iron ore mining district in the region of Belo Horizonte, capital of Minas Gerais state, in Brazil. Many mining companies have been mining high-grade hematite ores for decades throughout the region. The mines reserves often include itabirite ores which are available in high volumes, but have lower iron grades than hematite ores and require elaborated mineral processing to meet the requirements of downstream steelmaking. Itabirite ores have acquired importance, with the depletion of high-grade hematite reserves due to their intensive mining. The objective of this paper is to propose a geometallurgical model for the processing of itabirite ores from an Iron Quadrangle deposit, which will allow predicting the behaviour of ores throughout the deposit, according to their local variations. An initial step consists in characterizing representative samples of the different ores to acquire mineralogical and textural data. Then, itabirite ores of known characteristics are processed with different techniques, in order to extract the trends and key parameters upon which the geometallurgical model is developed. At first, the model takes into account the particle size distribution and its shift during mining and screening, as well as the chemistry and mineralogy of the material. Then, using the previously identified key parameters such as iron recovery, the model predicts the composition of the processing products. Finally, this data is used to model the mineralogy and mass recovery of the products. The geometallurgical model is of great importance, as it is able to model the processing of any sampled ore throughout the deposit. The incorporation of the results in a mining block model will assist mine planning and opens new opportunities for an optimized mining schedule.

Jan 1, 2016

By K. Bachmann, M. Rudolph, U. A. Peuker, H. H. Duong, T. Heinig, T. Leißner, H. Schubert, Helmholtz-Institute Freiberg for Resource Technology, Technische Universität Bergakademie Freiberg

"Minerals can be liberated by random fracture of particles into smaller fragments or by detachment along phase boundaries. These two mechanisms represent borderline cases. When ores get comminuted the liberation of minerals is achieved to some extent by both mechanisms. This article describes a method to determine the extent of transgranular and intergranular fracture on surface exposure of minerals based on 2-dimensional liberation analysis.The approach uses the non-biased surface information like phase specific surface area (PSSA), phase specific free surface (PSFS) and phase specific locked surface (PSLS) of minerals and their change with comminution. The amount of transgranular and intergranular fracture on surface exposure can be calculated using the phase specific surface parameters.A sedimentary rock (apatite ore), an igneous rock (nepheline-syenite) and an artificial material (copper slags) were ground to different fineness. Based on the mineral liberation analysis (MLA) of feed and products, the extent of phase boundary fracture on the surface exposure of the minerals is studied.INTRODUCTIONMinerals can be liberated ether by comminution or by detachment (Gaudin, 1939). Liberation by comminution is a random fracture mechanism, which is not being influenced by ore texture, grain boundaries and mineral features (transgranular fracture). Liberation by detachment represents a fracture along grain boundaries (intergranular fracture). Random fracture often is named as the dominating mechanism for the liberation of ore minerals. This has been the basis to simplify models for liberation modelling (Barbery, 1991; King, 1979; Meloy, 1984) assuming that the probability of cracks moving along grain boundaries is zero. Thus, no interfacial area is lost during comminution."

Jan 1, 2016

By Michael S. Moats, Prashant Bagri

"In recent years with increasing concerns about energy consumption in hydrometallurgical processing, there is an ongoing attempt to use Catalytic Titanium Anodes (CTAs) for copper electrowinning. For this work, anodes with IrO2 - Ta2O5 coatings were prepared in the laboratory with the same total coating loading but varying the number of layers by changing the speed of withdrawal in dip coating. A second set of CTAs were fabricated on niobium, Ti Grade 1, Ti Grade 7 and Ti Grade 36 metal substrates. All the anodes prepared in the laboratory were characterized using standard electrochemical techniques and subjected to accelerated life testing. It was found that the coating would not adhere to the niobium substrate, the grade of titanium had a minimal to no effect on the life of the anode, and it is observed that as the coating speed slows, there is an increase in the electrochemically active surface area of the coating which seems to directly contribute to an increase in the Tafel slope of the anodes. There was inconclusive evidence on the effect of coating speed on anode lifetime.INTRODUCTIONLarge scale hydrometallurgical extraction of copper has become widely practiced over the last 40+ years. The hydrometallurgical route entails leaching, solvent extraction and electrowinning. With the increasing desire to process refractory sulphides like enargite and chalcopyrite through the hydrometallurgical route, use of hydro-processing of copper is expected to remain high.In conventional electrowinning, copper is deposited on the cathode and an inert anode is used for oxygen evolution. Presently, the most common anode material is rolled lead-calcium-tin and the cathode is 316L stainless steel (Robinson et al., 2013). This lead alloy is fairly inexpensive and is robust, providing lifetimes typically of 4+ years. The main drawbacks of lead alloys are their relatively high oxygen evolution overpotential, the need for cobalt in the electrolyte to reduce their corrosion, the contamination of cathode product by lead, and the generation of harzardous by-products (Hiskey, 1999)."

Jan 1, 2016

By Ralph J. Holmes, David McCallum, Alan Roberts, Rolando Orense, University of Auckland, Tobias Krull, Tom Honeyands, Kenneth Williams

"The safe ocean transport of bulk commodities like iron ore, coal, nickel ore, manganese ore and bauxite by large bulk ships is vitally dependent on the stability of the cargo under the influence of wave induced ship motion. Safety standards are set by such bodies as the International Maritime Organisation (IMO) with recommended tests for the assessment of bulk commodities. Since the 1960s, the bulk cargo code (BC Code) commenced defining methods to determine the Transportable Moisture Limit (TML) for transportation of bulk commodities. By the latter part of the 1960s, three TML test methods were defined, namely the Flow Table, Proctor-Fagerberg and Penetration tests. All three tests were predominantly aimed at determining TML values for mineral concentrates.More recently, bulk commodity producers, Maritime Organisations and Port Authorities worldwide have been investigating whether commodity based TML methods better reflect realistic safe ship transportation than the current concentrate based TML test methods. In these investigations, the relationship between the mineralogical and particulate parameters of specific commodities with respect to cargo stability and moisture retention has provided insights into the development of tailored TML test methods. To this end, an AMIRA International project (P1097) undertaken by CSIRO, TUNRA Bulk Solids, the University of Newcastle and the University of Auckland assisted the IMO Technical Working group to investigate the relationship between iron ore fines characteristics and a new TML test specific for iron ore fines bulk cargoes.A review of the three standard concentrate based TML methods and characterisation studies of iron ore fines, as well as cyclic triaxial testing to determine liquefaction resistance, resulted in the development of a modified Proctor-Fagerberg method for determining the TML of iron ore fines. Of particular importance in determining TML is mineral composition, porosity, particle density and allowing time for moisture equilibration."

Jan 1, 2016

"This model specification includes sample text shown in normal font with commentary in italics. The commentary is intended to highlight project-specific items the specification writer should consider during development of the specification. In some sections, typical values are presented to indicate common practice, and these values may be changed to reflect projectspecific requirements. The commentary should be removed before using the specification for a project.1. SCOPEThe work consists of designing, furnishing, installing, post-tensioning and testing helical anchors used to support tension loads, and any ancillary materials (e.g., load transfer devices, etc.) according to the project plans provided and these specifications. Unless otherwise noted, the installing contractor shall provide all labor, tools, equipment, and materials necessary to accomplish the work. The parties referred to in this specification are as follows:• The Owner is the property owner.• The Owner’s representative is the individual or firm hired by the Owner to execute project tasks required for the successful design and construction of the overall project. Tasks could include construction management, design, oversight, etc.• The anchor designer is the individual or firm generally hired by the installing contractor to design the helical anchors.• Installing contractor installs and tests (if necessary) the helical anchors, and possibly other tasks associated with the project.It is important to clearly define the roles and responsibilities of every party on each project to promote good communication and reduce potential for contractual misunderstandings. Different types of contractual vehicles (design-build, value engineering, etc.) require different roles and responsibilities for the various parties, which should be considered in specification development.The Owner will provide suitable access to the construction site for the installing contractor’s personnel and equipment. Unless specifically noted otherwise in the contract documents, the Owner will remove and replace any structures, utilities, pavements, landscaping or other surficial improvements in the work area as necessary to facilitate the work. The Owner will be responsible for overall construction oversight to minimize potential for developing unsafe conditions. The work may include post-construction monitoring of anchor performance if required by the Owner or the anchor designer to confirm performance of the anchors subsequent to their installation. The work may also include installation of additional anchors if the initial installation does not meet specified capacity or performance requirements. Responsibility for providing subsurface investigation shall be addressed in the bid documents. The Owner is responsible for providing to the installing contractor all available subsurface soils, rock and groundwater information and geotechnical testing data."

Jan 1, 2016

By C. A. Biley

"A dedicated iron removal stage was installed at Anglo American Platinum’s Rustenburg Base Metals Refiners (RBMR) during an expansion project which began execution in 2010. The Pressure Iron Removal (PIR) process aims to precipitate iron from a nickel leach solution under medium temperature (145 °C) oxidative conditions using caustic for neutralisation. Since commissioning, the process has been robust in removing iron from the refinery but has shown significant variability in the residues produced. These residues, which are typically comprised of ferrihydrite, hematite or natrojarosite, have varying iron contents and different physical properties which have implications for their filtration and ultimate removal from the refinery. Since over 95% of nickel plated at RBMR passes through the PIR section, volumetric constraints caused by poor filtration performance directly influence nickel production and stabilisation of this process remains central to the continued ramp-up of the refinery to full nameplate capacity. This paper details the development of the PIR process and the journey from concept to implementation. Recent laboratory and plant scale tests have highlighted the importance of the initial phase formed in the autoclave for the ultimate residue requiring filtration and how the feed acid concentration is a critical control parameter. On this basis, a new caustic dosing philosophy was implemented which improved pH control in the autoclave. Further optimisation of the PIR process is on-going.INTRODUCTIONIn 2010, an expansion of Rustenburg Base Metal Refiners (RBMR) to increase nickel production from 21 to 33 ktpa began execution. The management of iron was pivotal in the ultimate configuration in the new circuit and one of the primary differences from the original circuit was the addition of a dedicated iron removal stage: Pressure Iron Removal (PIR). A significant drive for this new unit operation was to facilitate the separation of iron from other leach residues. Not only did this result in a significant decrease in the amount of leach residue but, without the constraints associated with iron precipitation during leaching, has permitted more aggressive leaching conditions and, correspondingly, greater throughput and efficiencies.However, as with many commercial implementations of even mature technologies, the journey from development to implementation has presented challenges for the continued ramp-up of the refinery to full nameplate capacity. Specifically, since all nickel bearing leach solution must pass through the PIR section prior to the nickel purification and recovery circuit, throughput difficulties in the PIR section can directly impact supply of feed to the nickel tank house. Since commissioning, the PIR autoclave has effectively removed iron from the refinery, but has shown significant variation in the solids phases produced in the autoclave. This variation presents difficulties for the filtration of the discharge slurry and represents a key throughput limitation which periodically impacts production. Additionally, the increasing production rates associated with the ramp-up of the refinery have resulted in a significant increase in the required volumetric throughput through the PIR process. This has placed even greater emphasis on improving the stability of the solid phase produced in the autoclave, ultimately targeting an easily filterable residue with high iron content."

Jan 1, 2016

By H. Deveci, E. Y. Yazici, A. D. Bas

The leach solutions of waste of printed circuit boards (WPCB) may contain a wide range of base and precious metals with different concentrations due to heterogeneity of these wastes in composition. Therefore, selection of a suitable metal recovery method is of practical importance for downstream processing of pregnant leach solutions of WPCB. Sulphuric acid leaching of WPCB in the presence of a suitable oxidant is capable of dissolving base metals as well as precious metals such as silver. In this study, cementation of silver from sulphuric acid leach solutions of WPCB using metallic copper, aluminum and zinc was studied. The WPCB sample was assayed to have a silver content of 694 g/t. A synthetic leach solution containing 20 mg/L Ag in sulphuric acid solution (0.51 M H2SO4) was prepared based on the silver concentration in pregnant leach solutions of oxidative sulphuric acid leaching tests. Total sulphate concentration ([SO4 2-]T) was kept constant using sodium sulphate at 1 M. Metallic powders of copper (-850 +600 µm), aluminum (-425 +45 µm) and zinc (-45 µm) were used in the cementation tests. The effects of metal type (Cu, Al or Zn), dosage of metal powders (above the stoichiometric ratio by up to 2000-fold) and temperature (20-80°C) on the rate and extent of silver extraction from the solution was investigated. The effect of presence of copper on the cementation performance was also tested. Under suitable conditions high silver recoveries (>90%) was achieved using metallic copper and zinc while aluminum yielded the lowest silver recovery (i.e. 40% Ag). The kinetics of cementation by zinc was comparatively higher than that of other metals. Increasing the temperature was observed to significantly enhance both the rate and extent of silver cementation. SEM-EDS studies were performed to characterise the metallic powders after cementation.

Jan 1, 2016

By P. V. Amosov, V. A. Masloboev, D. V. Makarov, S. G. Seleznev, A. A. Baklanov

"The development of industry and intensive use of natural resources leads to a significant decrease in the share of reserves of rich ores, deposits of which have nearly all been exploited. Large amounts of displaced rock mass are accumulated, significant emissions of gas and dust from mining, dust from dumps and tailing pits, ingress of chemicals and toxic elements in surface and groundwater all can have negative effects on existing ecosystems and human health. Especially dangerous is the impact in Arctic regions with extreme climate conditions. The maintenance of overburden dumps and tailings dams requires significant capital and material costs. In this paper, some mining enterprises of the Murmansk region, in the Russian Federation, consider the environmental problems of the industry and propose some solutions.INTRODUCTIONThe safety of environment during the extraction and processing of minerals is a very acute problem throughout the whole world. The problem acquires a specific character in the Russian Federation. There, rather poor minerals, often existing in unconventional forms and including several mineral components are processed. The Russian mineral base has a specific geographical location; most of the deposits under operation are located in the Subarctic or Arctic regions, as well as in Siberia and in the Far East. Vast amounts of rock waste and tailings pose serious economic and ecological problems in mining regions. The operation of overburden heaps and tailings requires considerable capital and material costs. The dumps withdraw vast lands from potential commercial use. Large amounts of mined rock disturb the existing geological balance; emissions of gas and dust which accompany the mining operations, dusting of waste heaps and tailings, emissions of reagents and heavy metals into natural surface and ground waters all can produce negative effects on existing ecosystems and human health."

Jan 1, 2016

By S. M. Bradshaw, E. Charikinya

"Microwave induced cracks have the potential to enhance metal recovery from coarse sphalerite particles in heap leaching operations by creating new crack surface areas for lixiviant and enhancing value mineral exposure. The mode of fracture and the extent of mineral exposure due to microwave induced cracks have not yet been investigated. The objective of this study was to determine the extent of particle damage and mineral exposure in microwave treated particles. This was done using X-ray computed tomography (XCT) and image analysis techniques. XCT analysis was conducted on small (–5+4.75 mm), medium (–16+9.5 mm), and large (–25+19 mm) sphalerite ore particles before and after microwave treatment (MT). Geometrical properties, such as volume and surface area of each mineral phase in each particle was determined from the XCT reconstructed images using VGStudioMax image analysis software. These geometrical properties were used to calculate the interfacial areas of sulphide mineral grains in microwave treated particles before and after MT. The ratio of specific interfacial area after MT to specific interfacial area before treatment was used as an indicator of the degree of preferential grain boundary fracture. The results showed significant grain boundary fracture after MT at all sizes. For small sized particles, about 31% of the interfacial area was lost compared to 23 and 16% for medium and large particles, respectively. The results also showed an increase in the degree of mineral grain exposure of 28, 26, and 15% for small, medium, and large particles, respectively, after MT. These results provide experimental evidence supporting improved mineral exposure due to MT. INTRODUCTIONFor some years it has been suggested that microwave treatment (MT) of ores might result in preferential grain boundary fracture that would have benefits such as improved grain exposure and particle weakening. (Kingman, 2006). Most of the experimental work investigating the application of microwaves to mineral processing flow sheets has focused on assessing the benefits of applying microwave technology to flow sheets consisting of size reduction and mechanical flotation cells (Kingman et al., 2004). Experimental studies have shown that coarse crushing during tertiary grinding of microwave treated ore resulted in a better liberated coarser flotation feed (Scott, Bradshaw, & Eksteen, 2008). It has been suggested that improved liberation in milled flotation feed, was due to the presence of grain boundary fracture in microwave treated particles. However, this improvement in coarse particle liberation does not necessarily translate to a significant improvement in downstream flotation recovery (Kobusheshe, 2010). This is as a result of the size limit to the flotation of coarse material, due to detachment forces acting on particle-bubble aggregates, which increase as the particle size increases (Jameson, 2012). Current conventional, mechanically agitated flotation cells are not designed to float coarse material (Jameson, 2012). Hence it has been difficult to show the downstream processing benefits of applying microwaves to ores processed by comminution followed by flotation (Kobusheshe, 2010). It is clear from investigations carried out so far that inappropriate downstream exploitation of microwave treated ore would fail to realise a meaningful process benefit (Kobusheshe, 2010; Ali & Bradshaw, 2011)."

Jan 1, 2016