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By Jun Wang, Bo Zhang, Wenqing Qin, Guanzhou Qiu, Xiaozhen Ma, Key Lab of Biohydrometallurgy of Ministry of Education, Fen Jiao, Central South University, Yansheng Zhang

"Arsenic contained in minerals sulphides such as enargite and tennantite can represent not only a significant penalty element in base metals production, but also a disadvantage to the environment through producing the toxic emissions to the atmosphere. The achieving separation of arsenic bearing minerals either at an early stage in floatation or from the floatation concentration is significantly beneficial to the economic. However, there was no feasible commercial method of separation at the flotation stage because of its similar flotation properties with many other copper sulphides. In this work, the selective floatation of enargite from copper sulphide concentrate containing maily covllite, chalcoctie, bornite and enargite was investigated. A low arsenic concentrate with As 0.2%, Cu 22% and a high arsenic bulk concentrate with As 7.65%,Cu 33.65% were obtained. It was indicated that Ca(ClO)2 is the effective depressor and the optimum floatation condition was obtained. Most enargite could be floated at pH 11 and controlling the pulp potential at 290 mV SHE. Furthermore, the arsenic removal from the high arsenic bulk concentrate by hydrometallurgy methods was study. The results showed that the reaction temperature and the concentrations of NaOH were the most important variables affecting the rate of arsenic removal. A low arsenic concentrate with As 0.24%, Cu 37.80% was obtained in the optimum leaching condition.INTRODUCTIONArsenic is mainly produced as a by-product of base metals smelting, in particular copper concentrate. China has imposed an upper limit of 0.50% arsenic for concentrates entering (Long et al., 2012). Arsenic amount of copper concentrate within 0.40% has also been imposed in China, and above which will be introduced about 50 RMB penalties per ton for each 0.10% increasing by smelters now. Therefore, it is necessary to remove arsenic from the copper concentrate.In copper concentrate, arsenic is mainly in the form of arsenopyrite (FeAsS), enargite (Cu3AsS4) or tennantite (Cu12As4S13). There are two types of arsenic in the separation of copper and arsenic: arsenopyrite and arsenic bearing copper mineral. It is easier to separate arsenopyrite from the copper sulphide by flotation in comparsion with the separation of enargite or tennantite from non-arsenic copper minerals (Pineda et al., 2015). The main difficulty in the separation of arsenic copper mineral from non-arsenic copper sulphides is their extremely similar floatability, which depends on the fact that tennantite and enargite contain high copper content (Pineda et al., 2015)."

Jan 1, 2016

By Northeastern University, B. Y. Cui, B. Y. Wang, D. Z. Wei, W. G. Liu, Z. C. Guan, S. L. Gao

To recover iron values from low grade ores by reverse froth flotation method, further research on cationic collectors used in reverse flotation of iron ores is launched to promote the utilization efficiency of iron ores. In this paper, one new cationic surfactant, bis(2-hydroxylethyl) dodecylamine (BHD), that could be dissolved in water easily was used as collector for quartz flotation. Flotation results indicated that BHD shows stronger collecting performance on quartz than hematite. The maximum recovery of 96.30% to quartz is obtained at a collector concentration of 20.0 mg/L in the pulp pH range from 5 to 7. This collector can be used to float quartz from hematite. And optimal separation results with 86.59% iron recovery and 66.60% iron grade to synthetic sample were achieved at a collector concentration of 20.0 mg/L and pulp pH of 5.02 when hematite and quartz were mixed at a mass ratio of 3:2. The adsorption mechanism of the collector on quartz surface was investigated by XPS analysis, infrared spectroscopic analysis and zeta-potential measurements, which revealed that electrostatic attraction and hydrogen bonding adsorption occur between collector and quartz surface.

Jan 1, 2016

By H. W. Kasaini, E. Bourricaudy, T. Larochelle

Rare Element Resources Inc., a U.S. based company, has developed a three-stage process for producing a +98% mixed REO powder from hard rock feedstock (-48 mesh, 2.9-4.8% REO) consisting of bastnaesite and ancylite minerals. Firstly, the whole ore is digested in chloride media at low temperature in counter-current flow mode. Secondly, the rare earths (REEs) are selectively precipitated as oxalates directly from an impure pregnant leach solution (PLS). Finally, significant amounts of free acid and water are recovered from the REE-depleted filtrate and subsequently recycled within the process. Excess heat from the oxalate calcination process is captured and reused in the plant. Due to the low leach temperature (45 ºC) and moderate acid dosage (240-297 kg/t, HCl), rare earth oxides (REOs) are preferentially leached out of fine solids leaving most of the base metals (Ba, Fe, and Al ) in the residue. Selective recovery of REEs from the PLS is achieved by mixing dilute oxalic acid (33% H2C2O4) and PLS at elevated temperature (85-95 ºC). The REEs plus thorium are precipitated as oxalates (REE2 (C2O4).xH2O) while the base metals are left behind in the barren filtrate. Multiple batch and pilot test results have confirmed that 50-80% of the oxalic acid can be recovered from the REE-depleted PLS through low-temperature crystallization (10-15 ºC). Typical leach efficiencies of critical rare earths at 45 ºC range from 85-99% (average 93%) while oxalate precipitation at high temperature increases the crystal size of RE oxalates (>450 microns, d80) thereby improving filtration. The economic benefits of this process include elimination of flotation and magnetic separation Capex and driving hydrometallurgical Opex down to $6- 7/kg, REO produced. As part of a comprehensive risk mitigation strategy, Rare Element Resources Inc has operated multiple pilot plants at SGS in Lakefield, Ontario, Canada to optimize counter-current leaching (CCL), REE oxalate precipitation (OXP), and thorium removal circuits. This paper presents pilot testing data from CCL and REE OXP circuits.

Jan 1, 2016

By M. Fafard, F. Chevarin, D. Ziegler, H. Alamdari, M Kavand

"Carbon anodes, used in the Hall-Heroult process, are consumed by the electrochemical reaction to produce metallic aluminum. It is also consumed by parasitic reactions with air and CO2. The carbon anode is made of petroleum coke with different particle sizes, butts (recycled anodes) and coal tar pitch. The mixture of fine particles (less than 150 µm) of coke together with the pitch material forms a matrix, binding the large coke particles together. It is generally thought that the binder matrix is more reactive than the other anode constituents. This conjecture was not clearly proved in the literature. The present study is focused on the CO2 reactivity of binder matrix and anode constituents at 960°C, both under chemical regime (100% of CO2) and under a concentration gradient (diffusion). The apparent reaction rates of these materials were measured. The role of the binder matrix in anode consumption and its disintegration (dusting phenomenon) was discussed.INTRODUCTIONThe metallic aluminum production is one of the most important industries in Canada. The Al metal is obtained by the Hall-Héroult process. The principle of this process is the electrochemical reduction of alumina in molten cryolite carried out by an electrical current between carbon anodes and cathode at 960°C (Equation 1). The carbon anode is typically composed of calcined petroleum coke (65 wt.%) and recycled anode (called also butt, 20 wt.%) with coal tar pitch (15 wt.%), playing the role of cement to ensure the cohesion of the anode block."

Jan 1, 2016

By V. S. Melamud, A. G. Bulaev

"Sulfide ore processing is characterized by significant losses of metals, for example, with flotation tailings. Therefore, flotation tailings can present an important source of metals. The treatment of flotation tailings is a technological issue due to low content of valuable metals (e.g. copper and zinc) and high iron content. The goal of the present work was to investigate extraction of base metals and gold from old flotation tailings containing 17% iron, 0.26% copper, 0.22% zinc, and 0.7 g/t gold. Chemical leaching in columns with 0.5 to 10% sulfuric acid solutions and bioleaching in air-lift percolators were used for the extraction of base metals. 1% H2SO4 provided high extraction of base metals and best selectivity. Recovery of copper and zinc reached 35% and 40%. Increasing H2SO4 concentration did not lead to significant increase in base metals extraction, but led to increased iron concentration in the pregnant solutions. The 1% H2SO4 leaching solid residues were used for further experiments. Acid leaching and bioleaching did not result in significant increase in base metals recovery. Leaching of the residue with 10% H2SO4 provided extraction of 4% copper and 20% zinc, and bioleaching for 100 days provided extraction of 16% copper and 12% zinc. The recovery of gold by cyanidation from the flotation tailings, the 1% H2SO4 leaching solid residue and residue of two-step acid leaching were 50, 49, and 65%, respectively. The results suggest that acid leaching can be effective approach for treatment of old flotation tailings.INTRODUCTIONAbout 80% of base metals (copper, nickel, zinc) are produced through pyrometallurgical treatment of sulfide ores. Mining and metallurgical treatments of sulfide ores are presently characterized by significant losses of non-ferrous and precious metals into the various wastes. For example, flotation of sulfidic ores yields formation sulfide flotation tailings. These wastes pose a problem not just because of their sheer volume, but some of them may affect local ecosystems. Nowadays, mining and metallurgical wastes can be considered as technogenical source of base metals."

Jan 1, 2016

By S. K. Sharma, Sanket Bacchuwar, Prabal Kumar Agrwal, G. V. Rao

"Iron ore processing industries play a vital role in the Indian economy. At present Iron ore of around +64% Fe is used for production of Iron through blast furnace. To produce +64% Fe from low/medium grade ores, crushing & beneficiation is compulsory. But during these processes, large amount of slime is generated. It is estimated that 18% -25% of tailing is generated during the processing of iron ore. The iron ore slime is discarded because of its particle size and chemical composition not being suitable as feed to the blast furnace. Although the fines/slimes can be agglomerated to larger particle, the alumina to silica ratio which is normally more than one pose serious problem during sintering process and subsequent smelting in blast furnace. The alumina content in the slime needs to be reduced for it to be used as the feed for blast furnace. The sample assayed 61.40% Fe, 7.68% SiO2, and 1.52% Al2O3, LOI 2.63% and all other elements were found in critical limit. A series of 27 tests were conducted by using a spiral for optimisation of process parameters to produce a pellet grade concentrate from the stacked slimes obtained from Kirandul. This paper deals with the optimisation studies of various parameters of a spiral concentrator and helps to utilize the fines from tailing ponds.INTRODUCTIONReserves of high-grade iron ores are diminishing all over the world at an alarming rate. As a result, alternative ways of augmenting and conserving precious and non - renewable natural resources are being seriously considered. One such attractive option is the recovery of metal values from slimes / tailings. Iron ore tailings containing around 48 - 60% Fe are generated from the iron ore washing plants and are disposed into tailing ponds without any further utility. These tailings in the form of slimes are not suitable in iron and steel making due to the presence of higher amount of gangue constituents. Several beneficiation techniques have been tried from time to time to reduce the gangue so that the beneficiated products could be effectively used."

Jan 1, 2016

By T. Holmes, S. Davison

"The Special Standard Surge bin at Agrium’s Vanscoy Potash Operations (VPO) has been plagued with flow problems and wear, and corrosion issues for it’s entire working life. Investigation showed that the carbon steel construction, bin geometry, and resultant funnel-flow pattern were directly responsible for production losses and disproportionate maintenance and capital costs. Potash enters this bin at between 140°C and 165°C, but the stagnant potash outside the active flow channel was much cooler, allowing moisture to migrate toward the outer regions, which caused corrosion of the walls and reduced live capacity as the potash in this area hardened and built up on the walls over time.A 2013 inspection revealed holes and paper-thin areas in the lower cylinder wall sections and in the conical hopper. The only thing preventing major leaks and even a potentially catastrophic failure was the buildup of stagnant hardened product on the cone walls. It was concluded that the cone had reached the end of its life and required replacement. VPO’s original plan was to replace the cone in kind and repair the cylinder as necessary; however, a failure-mode and bin-performance investigation combined with a lifecycle- cost analysis indicated it would be better to redesign the hopper.For success in retrofit projects, it is essential at the design stage to consider the bulk solid flow properties and the operating environment involved. Because education in this area is not offered at a university level, engineers often do not fully appreciate the effects of the flow properties of bulk solids on bulk material handling equipment.Jenike & Johanson conducted flow properties tests on samples of potash and using the data, redesigned the bin and the feeder. After the modifications, VPO’s surge bin provides safer, more reliable operation with a much longer predicted working life. Using this retrofit as an example, we aim to provide a general understanding of bulk solids flow theory and highlight the importance of customizing the design to the appropriate flow properties in the cost effectiveness, reliability, and safety of a bulk material handling system."

Jan 1, 2016

By A. R. Farkoosh, J-P. Fortin, M. Pekguleryuz, S. Bagherpour

"Titanium aluminides are structural intermetallics which offer an attractive combination of high temperature strength and light weight. For such properties, these intermetallic alloys have become front-runners in replacing nickel-based superalloys used for several high temperature applications. These alloys are produced from metallic titanium, aluminum and master alloys involving an expensive and difficult process. A low cost alternative to current industrial production method is the new modified aluminothermic process which directly reduces titanium oxide (TiO2) to titanium aluminides. Nevertheless, this process has itself significant challenges in achieving alloys free of oxide inclusions; the close densities of the slag and the titanium aluminides makes slag/molten metal separation a challenging task. Usually, the alloy produced requires a second refining step. In this study, thermodynamic calculations based on CALPHAD method were performed to determine the solidification path and an attempt has been made to develop a criterion to increase the density deference between the slag and the alloy by alloying with appropriate elements. Furthermore, scanning electron microscopy (SEM) and x-ray diffraction (XRD) techniques were utilized to examine the microstructure and phase selection of three Ti-Al alloys produced by the aluminothermic reaction, including the as-cast, refined in a controlled atmosphere and inert-gas-refined alloys. The composition range of the alloys studied was restricted to the a2-Ti3Al + ?-TiAl phase field (Ti-30Al) in the binary Ti-Al phase diagram leading to a lamellar structure with different complex intermetallics as shown in Figure 1.INTRODUCTIONTiAl based alloys are promising structural materials for high temperature aerospace and automotive applications. This is due to some attractive properties such as low density, high specific strength, high specific stiffness and high temperature strength retention (Wen-bin, Xue-wen, Hong-fei, & Yong-feng, 2011). These alloys have become leading candidates to replace Ni-based super alloys in gas turbine engines. Replacement of Ni-based super alloy parts with titanium aluminides is expected to reduce the structural weight of high performance gas turbine engines by as much as 20–30% (Kothari, Radhakrishnan, Sudarshan, & Wereley, 2012)."

Jan 1, 2016

By Greg Sanders, Michael Gilbert, James G. Shaughnessy

"A new raw water intake from the South Holston River to the Kingsport water treatment plant is under construction. The exploration for the 335 meter long horseshoe shaped tunnel design took advantage of the site topography along the alignment to better define the complex geology consisting of Knox Limestone and Sevier Shale formations separated by a fault zone. To assess the geological conditions and to determine the extent of the fault zone, a 183 meter long horizontal boring and geophysical investigation was performed along a portion of the tunnel’s horizontal alignment. Explorations defined the fault zone width at approximately 5 meters and packer testing along the alignment provided a means of estimating groundwater inflows. As the tunnel excavation advances, comparisons of exploratory data versus encountered conditions will be made. This paper provides details on the geotechnical investigation, lessons learned, and the influence of the geology on the tunnel design. PROJECT OVERVIEW The Kingsport WTP is supplied with raw water via the South Holston River. The City of Kingsport (City) owns and operates the Kingsport Water Treatment Plant (WTP). The existing raw water intake system, consisting of pumps, power supply, raw water piping and appurtenant facilities has been determined to be vulnerable to failure. The original Raw Water Pump Station (RWPS) was constructed in 1928 as part of the original Kingsport WTP project. The 1928 RWPS operated until 1970 when it was replaced by the existing RWPS. This existing system still utilizes the 1928 piping and piping tunnel. Improvements to the RWPS hydraulics and capacity are required to meet the City’s future water treatment needs. The system extracts water from the South Fork of the Holsten River and coveys it via three pressure pipelines to the WTP. The conveyance piping exits the RWPS, ascends approximately 23 m up a near vertical rock outcropping then enters a 120 m long tunnel. Upon exiting the tunnel the piping continues underground to the WTP. The drill and blast tunnel is horseshoe shaped and nominally 3.3 m high by 3.3 m wide. The easternmost 62.3 m of the tunnel is without any type of support. The remainder is lined with concrete. According to the City of Kingsport, the concrete lining was installed in the 1970’s as part of upgrades to the facility. An evaluation of the current facilities concluded that the conveyance piping was in poor condition and required replacement."

Jan 1, 2016

By Andrzej Luszczkiewicz, Magdalena Duchnowska, KGHM Polska Miedz S. A., Witold Pawlos, Jan Drzymala, Alicja Bakalarz, Przemyslaw B. Kowalczuk

A pre-flotation process of the Kupferschiefer ore with only frothers produces a concentrate enriched in carbonaceous matter and tailings for further upgrading steps. A partial removal of easy-to-float components of the feed before the main enrichments steps by flotation (rougher, scavenger) improves overall efficiency of separation of valuable elements from the ore. Since the types and doses of frother used for pre-flotation effect the process, the aim of this study was to determine the influence of selected frothers on the efficiency and selectivity of the Kupferschiefer ore processed by KGHM Polska Miedz S.A. A series of pre-flotation tests in the presence of different poly(propylene glycols) ethers, poly(ethylene glycols) ethers and aliphatic alcohols were conducted. The obtained results indicated that the types and doses of frother determine the flotation selectivity of copper and total organic carbon. The evaluation of the pre-flotation process was based on the analysis of selectivity parameters calculated from the recoveryrecovery Fuerstenau upgrading curves as well as the values of copper and organic carbon grades in the flotation products. It was shown that pre-flotation performed in the laboratory scale using a suitable frother provides higher overall flotation selectivity of organic carbon with lower overall flotation recovery of copper in comparison to flotation without the pre-flotation step. Thus, the pre-flotation process improves the quality and quantity of the final concentrates produced from the Kupferschiefer ore.

Jan 1, 2016

By Carlton M. Ray, William P. Levy, Thomas Lindberg

"The District of Columbia Water and Sewer Authority (DC Water) is implementing its $2.6 billion DC Clean Rivers Project to reduce combined sewer overflows to the District’s receiving waterbodies and mitigate chronic sewer flooding in District neighborhoods. The First Street Tunnel project is a major component of the DC Clean Rivers Project, designed to mitigate sewer flooding and basement backups in the District’s historic and densely populated Bloomingdale neighborhood. Bloomingdale has been historically affected by sewer flooding and was severely impacted by four storms in the summer of 2012 that caused significant damage to homes, the environment and public property. As a result, DC Water accelerated the design and construction of the First Street Tunnel in order to mitigate the effect storms have on the undersized sewers serving the neighborhood. The infrastructure designed to mitigate flooding, including the tunnel, are located within the highly urbanized neighborhood – with some structures being less than ten feet from residents front door steps. The success of a large public works project of this magnitude and in this unique location depends on a well informed and supportive public. With the local community impacted by flooding but concerned about heavy construction impacts, this paper details the components of a successful public outreach plan and lessons learned throughout the design and construction process. Early identification of community mitigation, working cooperatively with stakeholders and frequent dissemination of accurate information required the project team to establish a culture of problem solving collaboration with the community. BACKGROUND Chronic Flooding in the Northeast Boundary Sewershed The Northeast Boundary sewershed, in which the Bloomingdale neighborhood is located, is served primarily by a combined sewer system and has a long history of chronic flooding problems during moderate to severe storm events. The sewer system that serves the Northeast Boundary drainage area was constructed by the Federal Government in the late 1800's when developed areas of the District terminated at what is now Florida Avenue. Since construction of the system, population within the sewershed area has grown at an exponential rate. In meeting the growing needs of the population, the District experienced development that transformed previously low-density rural areas into new communities. Impervious areas have increased drastically since the sewer system was constructed and consequently, the existing sewer system does not have the capacity to convey storms with return frequencies beyond the 2-year storm without flooding. As a result of the capacity limitations, many of the low-lying areas have become chronic flooding areas due to the surcharging of sewers."

Jan 1, 2016

By J. C. C. C. Menezes, R. A. S. Silva, A. V. Colling, I. A. H. Scheneider

"Coagulants rich in ferric sulfate can be obtained from pyrite-containing coal tailings using a biohydrometallurgical process. The aim of this study is to evaluate the relationship between quantity of pyrite and rate of oxidation, with regard to the consequent production of ferric sulfate for potential use as a coagulant for water and wastewater treatment. Leaching experiments were carried out on the laboratory scale on four coal tailings with different concentrations of pyrite. Characterization of the coal tailings was conducted for the following parameters: total sulfur, pyritic sulfur, sulfate sulfur, organic sulfur, and elemental analysis of CHN (carbon, hydrogen, nitrogen). The samples were also subjected to X-ray diffraction analysis to assess their mineral compositions. The leaching experiments were accomplished using a laboratory column constructed as a packed bed reactor with a sprinkling system in a closed circuit. After four weeks of leaching, the liquor was filtered and evaporated to an iron concentration of about 12 percent w/w, which is typical of the ferric sulfate coagulants commercialized in Brazil. IntroductionCoagulants used for the treatment of water and wastewater are predominantly inorganic salts of ferric iron and aluminum. Aluminum salts, including aluminum sulfate and aluminum chloride, and prehydrolyzed metal-ion reagents, such as polyaluminum sulfate (PAS) and polyaluminum chloride (PAC), are the coagulants most widely used for water treatment (Bratby, 1980; Tchobanoglous et al., 2003; Buzin et al., 2014).However, the presence of residual amounts of aluminum in drinking water has been controversially implicated in neurological diseases (Association of California Water Agencies, 2000; Becaria et al., 2006; Campbell, Hamai and Bondy, 2001; Rondeau et al., 2000; Walton, 2006). A possible alternative is to use iron-based coagulants, such as ferric chloride, ferric sulfate or polyferric sulfate, instead of the aluminum salts (Jiang, Graham and Harward, 1996; Jiang and Graham, 1998). Iron-based coagulants are commonly produced by the acid dissolution of iron scraps or iron ore (Tchobanoglous et al., 2003).Recent studies have shown that it is possible to produce ferric sulfate coagulants from the pyrite present in coal tailings through a biohydrometallurgical process (Colling et al., 2011). The main advantage of this process is that it does not require acid addition, which can be favorable in terms of production costs. Acidophilic bacteria, such as Acidithiobacillus ferrooxidans, can increase the rate of pyrite oxidation and dissolution by several times (Kontopoulos, 1998; Brett and Jillian, 2003; Johnson and Hallberg 2003). They can be highly significant in the bioprocessing of coal tailings for the production of ferric coagulants, as their action favors the acidification of the medium and iron leach (Colling et al., 2011)"

Jan 1, 2016

By Z. Luo, China University of Mining & Technology, C. Duan

"The magnetic separation removal rate of pyrite could be improved effectively by increasing the susceptibility of pyrite. The electromagnetic characteristics and absorption response performance of high-sulfur fine coal were studied in strengthening the susceptibility of pyrite. In the process of treating the sample through the microwave, electromagnetic energy could be converted into heat energy due to dielectric loss and magnetic loss. The RL(dB) was evaluate the performance of absorption response of coal. The microwave improved the susceptibility was in ultra-high frequency region, which is the most natural resonance. The absorption fine coal to microwave was strengthened and microwave energy was improved by adding the magnetite powder with double loss characteristics as the microwave absorber. The dielectric properties and permeability characteristics of the fine coal trend were investigated by maxing magnetite powder. The microwave absorption in different coal thickness was surveyed through the reflection of energy loss.INTRODUCTIONMicrowave desulfurization is one of the most important research directions (Haque, 1999; Makul, Rattanadecho, & Agrawal, 2014; Su, Tang, Zhang, Jing, & Bai, 2014). The working principle of microwave absorption response can be briefly described as the interaction of the sample with microwave energy, which will result in the microwave energy converting into heat energy loss (Keangin & Rattanadecho, 2013). For specific samples, the polarization effect includes multiple polarization mechanisms(Meikap, Purohit, & Mahadevan, 2005). Different polarization mechanisms have different occurrence time and dominant mechanisms. Meantime, energy consumption will be occurred during the process of polarization effect (Chelgani & Jorjani, 2011; Rowson & Rice, 1990) . The absorption of microwave energy in the fine coal is a process of electromagnetic response (Znamenácková, Lovás, Mockovciaková, Jakabský, & Briancin, 2005). Microwave transfers the electromagnetic waves into the heat energy by microwave dielectric loss and magnetic loss for achieving the absorption of microwave energy in the treatment of samples (Lee, Kim, Kim, Chung, & Kim, 2004). The additive magnetic medium is Fe3O4 belonging to microwave energy absorber of double loss medium (Uslu, Atalay, & Arol, 2003)."

Jan 1, 2016

By G. Girard, A. Larouche, J. Colbert, G. Doyer

"The Direct Chill (DC) casting process uses water to extract heat from molten aluminium and helps to control the solidification process. Many factors such as the water flowrate, water distribution around the mould and water impingement angle have significant impacts on the solidification process. It has been noted that the chemistry variation of the cooling water is also an important factor that has a major impact on the presence of defects on the ingot. A significant change in the water quality can produce defects on the ingots such as cracks, bleedouts, or runouts. Understanding the impact of water quality variation on ingots is therefore essential to ensure good ingot production and reduce defects. This paper aims at describing a new approach to follow the variations of process water quality over time. It is an original and innovative method, which is still under progress. A water quality and stability index (WQSI) is under development to evaluate changes in the water composition based on water physico-chemical parameters. The index is calculated by comparing each of the actual parameters with historical values previously modeled by a statistical law. It is a dimensionless number having an adjustable weight factor for each parameter. The positive or negative contribution of each parameter, with respect to the water cooling capacity, is taken into account to calculate the WQSI. The current selection of parameters is based on knowledge from the literature as well as on empirical experience. When the developed tool will be mature, it could be used to track water variations upon time and anticipate problems, enabling proactive actions to ensure good ingot production.INTRODUCTIONFor many years, the impact of water chemistry on heat transfer, during DC casting, has been of great interest in the aluminum industry. Several papers have been published to demonstrate the correlation between water chemistry and heat transfer (Yu, 1985), (Gildemeister, 2014). Although numerous studies do present the effects of water parameters (i. e. hardness, conductivity, oil, and grease…) on cooling capacity under controlled experimental conditions, they do not reflect the strong interactions between the parameters and variations present in a casting center. Wells and Cockcroft also demonstrated that laboratory based studies are not fully representative of real heat transfer in an industrial casthouse, there are too many factors involved (Wells, Li, & Cockcroft, 2001). In this context, it becomes very difficult to obtain a quantifiable relationship between the capacity of water to cool the ingot and ultimately the performance of the cast."

Jan 1, 2016

By F. Ford, J. Dong

"Laboratory and miniplant testwork was carried out to reject uranium from an Iron Oxide Copper Gold (IOCG) deposit that contains an average of 60-70 ppm uranium with high variability. The dominate copper bearing mineral is chalcopyrite with minor bornite and trace covellite. The main gangue minerals are iron-rich chlorite, quartz and magnetite. The main uranium-containing mineral is uraninite (UO2). Downstream processes require the maximum uranium level of no more than 80 ppm in final copper concentrate.Mineralogical examination reveals that uraninite particles are finely disseminated with grain size of less than a few microns in the deposit requiring fine regrind in order to liberate uraninite from chalcopyrite particles. A lab flowsheet was developed to include ultrafine regrind of the rougher concentrate to the particle size of 80% passing 11-13 µm with up to four stages of recleaning in flotation columns. Finer regrind to 80% passing 5-6 µm may continue to improve liberation but does not decrease uranium level in the final concentrate. In each of the successive recleaning stages by flotation column after fine regrind, uraninite is rejected into the column tailings, with the final copper gold concentrate containing less than 70 ppm uranium from a feed containing 83 ppm uranium. The conceptual flowsheet was further tested in an integrated, continuous miniplant showing average 94% copper recovery with average 74 ppm uranium. The uraninite particles that report to the final concentrate are either locked with chalcopyrite or entrained as liberated particles of less than 5 µm in size."

Jan 1, 2016

By T. S. Lundström, B. D. Marjavaara, I. A. S. Larsson

"The flow field in a rotary kiln, used in an iron ore pelletizing process, was investigated using a three-dimensional computational fluid dynamics model. The model is isothermal, downscaled and simplified. The objective was to examine the possibility of capturing the unsteady motion of the flame seen in the real kiln. The results from the simulations were compared with recorded images of the real process. The results demonstrate the possibility of quickly getting an overview of the flow field in the kiln. The main, unsteady behavior of the flame was captured. The model may be used as a tool in the ongoing work of improving and optimizing the pelletizing process.IntroductionThe pelletizing process, in which the crude iron ore from a mine is upgraded into pellets, is a process involving large amounts of hot air flowing in complex geometries. Flow control is a crucial factor in this process to maintain high pellet quality. The rotary kiln is one of the last steps in the pelletizing process, and this is where the pellets are sintered to increase their strength and metallurgical properties. The kiln burner produces a flame that supplies the entire pelletizing process with the necessary heat.Kiln burner flames are large diffusion flames arising from a jet of fuel from the burner issuing into a concentric confining cylinder with a surrounding coflow of air, called secondary air. To enable combustion, the secondary air needs to be entrained into the fuel jet. This mixing of the fuel and air is the slowest step in the combustion process and therefore affects the efficiency of the combustion. The rate of entrainment depends on the momentum ratio between the burner jet and secondary air. The higher the momentum ratio, the faster the entrainment rate and, consequently, the faster is the fuel/air mixing.The kiln of interest in this study differs from kilns used in other industrial processes in both geometry and operating conditions. A distinguishing feature is the large amount of secondary air being induced through the kiln hood and then transported to earlier stages in the process as air or exhaust gas. The secondary air therefore has a substantial momentum, implying that the resulting flow field has a significant impact on the mixing and combustion process in general and the flame shape and stability as well as combustion efficiency in particular. A systematic study of the factors influencing the dynamics of the flow field in the kiln, neglecting the combustion, is therefore justified."

Jan 1, 2016

By K. Turgeon, D. Larivière, L. Whitty-Léveillé, J. -F. Boulanger, C. Bazin

"The processing of ore containing rare earth elements leads to the production of an impure solution of these elements. The separation of the rare earths from the impurities and the production of individual elements is usually carried out by solvent extraction. The effectiveness of the extraction conditions and of the reagents is generally tested in the laboratory. This paper deals with the processing of results from solvent extraction laboratory tests planned to generate data redundancy. A method is proposed to take advantage of the data redundancy by accounting for the pH variation during the extraction. The parallel processing of several tests also allows estimating the equilibrium constants for the extraction. The proposed method produces equilibrium constants that are more reproducible than values estimated using conventional approaches. The method is illustrated with solvent extraction tests conducted on synthetic solutions of rare earth elements.INTRODUCTIONThe processing of ores containing rare earth elements (REE) usually includes the production of a concentrate of the minerals carrying the REE. These minerals, for instance monazite and bastnäsite, contain the 14 elements from La to Lu plus yttrium and scandium. As an example monazite has the general formula of (La,Ce,Pr,Nd,Sm,Eu,Gd,Tb,Dy…Lu)PO4 with a typical lanthanum content of 20-26%, cerium content of 40-50%, praseodymium of 4-6%, neodymium of 16 to 20%, and decreasing concentrations of heavier elements (Gupta & Krishnamurthy, 2005). During the processing of a REE mineral, it is generally not possible to isolate and separate a single REE from all the rest. The mineral molecules need to be broken (usually via a heat treatment followed by leaching with a base and/or an acid) to produce an aqueous solution of the REE of the ore. After purification of the solution, the REE can be precipitated as a bulk concentrate and sold to a refinery that separates the REE into particular groups of REE such as the light versus heavy REE or into individual elements such as lanthanum, neodymium, or europium oxides to yield value-added products."

Jan 1, 2016

By Sitotaw Y. Fantaye

"The first segment of the Second Avenue Subway extension is approaching construction completion. The new extension will operate along Second Avenue from 96th Street to 63rd Street, where it will divert west along the existing 63rd Street line, stopping at the Lexington Avenue/63rd Street Station. The new line will have stateof-the-art stations at 96th, 86th, 72nd and 63rd streets.Most of the two-track, twin-tunnel subway was constructed using bored tunnel methods (Figure 1), with a tunnel boring machine (TBM). The launch and retrieving box of the TBM was strategically located at the south end of the 96th Street Station where bedrock exists approximately 70 ft (21.3 m) below street level. The TBM launch box and the 96th Street Station (Figure 2), including the ancillary facilities adjacent to the station, were constructed by the cut-and-cover method. The cut-and-cover work required the contractor to design and implement a stiff, tightlybraced retaining wall, approximately 100 ft (30.5 m) long, to tie the existing tunnel constructed in the 1970s to the new station, temporary street decking over the entire excavation, and a wide range of excavation support systems at various locations.The cut-and-cover construction posed significant challenges including: installation of street decking on busy Second Avenue, relocation and suspension of the myriad utilities beneath the streets, and configuration of a lateral support system that would minimize movement of adjacent structures but not slow down excavation activities. This article describes the innovative solutions developed to manage and facilitate safe and efficient construction without disrupting Second Avenue, a major southbound one-way thoroughfare.The work was performed in several phases involving: (1) preconstruction condition survey of existing buildings, (2) installation of instrumentation and monitoring, (3) major utility relocation efforts to move vital utilities from within the alignment of the slurry wall on both the east and west sides of the avenue, (4) implementation of maintenance and protection of traffic plans, (5) installation of temporary street decking across the entire avenue and over the excavation to allow an orderly movement of traffic and pedestrians, (6) staged excavation and installation of an intricate temporary bracing system beneath the decking (7) step-by-step construction of the new subway station’s structure and (8) staged removal of the bracing as the structure gained sufficient strength to resist the lateral loads. The main focus in this article is the design and construction of the temporary street decking and lateral bracing systems; the utility suspension system and the north tie-in that allowed the daunting task of excavation and construction of a new subway station in bustling New York City, with minimal disruption to the community, businesses and everyday traffic."

Jan 1, 2016

By J. R. Kadambi, E. Kucukal, J. Furlan

"Hydrocyclone separators are used in various industrial applications, including mining milling and tailings systems, in order to separate or classify solid particles and liquid droplets from multiphase systems. The flow within a hydrocyclone commonly used in the mineral processing industry was investigated numerically and experimentally using Particle Image Velocimetry (PIV) and refractive index matching techniques. The computational simulations were performed using a commercially available CFD package, STAR CCM+. Two turbulence models were used in the numerical calculations: the k-? model and the Reynolds Stress Model (RSM). In both cases, the first order discretization scheme was unable to resolve the flow characteristics accurately due to the high levels of numerical dissipation. PIV measurements were taken at various spatial locations along the cyclone. Both the numerical simulations and PIV data demonstrate that tangential velocities tend to increase when going radially inward from the cyclone wall towards the vortex finder, and reach a maximum value before they begin to decline rapidly and eventually become zero at the wall. The results also demonstrate the utility of non-axisymmetric approaches in cyclone flow simulations for a greater understanding of the fluid mechanics. The computational results were validated globally using pressure and flow rate readings at the boundaries and locally by comparison to the PIV velocity vector maps and profiles. The comparisons demonstrated good agreement between the two models.IntroductionHydrocyclones are devices used to separate and classify solid particles or liquid droplets from liquid-solid or liquid-liquid systems. Versatile in application, they have been widely used in many industrial applications including the food, oil, power generation, chemical and mineral processing industries since 1891, when the first hydrocyclone was introduced by Bretney (Park, 2003). Hydrocyclones have a relatively simple design with no moving parts, which leads to an efficient separation process."

Jan 1, 2016

By Fiona Campbell

"Modern history is full of breakthroughs in technology, all striving to increase productivity and efficiency. What are the elements that should be taken into consideration in the design and implementation of modern automation systems in a control room? Both industry and international standards are now demanding that Human Factors be considered as part of the design of control rooms to maximize efficiency and minimize the potential of human error which can lead to downtime and a loss of profit as a result of interruptions in production. As the current workforce ages and the younger generation matures, this is also becoming a key element when planning a control room. New standards are helping to address some of these challenges that are facing the mining industry today. With an increased focus on the operator, an intelligent and ergonomic workspace can both mitigate risk and optimize production. Optimization is money. We will examine how to analyze and implement innovative control room planning to maximize mineral processing production and minimize risks that can impact overall production and profit.INTRODUCTIONIn this day and age, optimization of production in an industrial environment is becoming more and more of a challenge. With ever changing technology as well as other external factors, this can be especially daunting. There are several key elements that may not be immediately obvious when planning a control room design or renovation, most notably the role of the human in this environment. Fatigue, stress, distraction, reaction times and situational awareness are all critical in a 24/7 environment. With the growing need to include human factors when considering and designing an optimal work and production environment, it is becoming even more important to design a control room that can address as many of today’s challenges as possible.The standard definition of the word “optimization” is “an act, process or methodology of making something (as a design, system, or decision) as fully perfect, functional or effective as possible.” (www.merriam-webster.com). If we apply this to business, what it really means is finding the most cost effective way to achieve the highest level of performance while considering constraints, both external and internal, by maximizing the desired factors and minimizing undesired ones. Sometimes, however, we can get caught up in the day to day processes, without taking a moment to step back and objectively review what it is we need to achieve, and more importantly, the steps that can facilitate our success."

Jan 1, 2016