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By B. Whisner, A. Smith, J. Carr

"Electromagnetic based proximity detection systems (PDSs) are utilized on mining machinery to protect workers from being pinned or struck. These systems generate magnetic fields covering the space around a machine, and a miner-wearable component (MWC) detects the field. The PDS determines the distance of miners relative to the machine based on the detected magnetic flux density in the magnetic field. This information is used to establish warning and shutdown zones around the machine. Maintaining a stable magnetic field is essential for system accuracy. However, components used to generate magnetic fields can be influenced by temperature changes. Depending on ventilation conditions and seasonal alternation, a PDS can be subject to significant temperature fluctuation. To better understand and quantify this phenomenon, researchers from the National Institute for Occupational Safety and Health (NIOSH) developed an experimental apparatus to study the influence of temperature on magnetic field generator circuits used in PDSs. Results from the study show that the electric current through a generator can be influenced by both ambient and internal temperatures, modifying the magnetic field that is produced. These findings show that temperature can significantly influence the ability of PDSs, used in underground coal mines, to accurately determine a worker’s position in relation to mining machine. INTRODUCTION Electromagnetic based proximity detection systems have been developed to reduce machine-related accidents in underground coal mines. The first proximity detection systems installed in underground coal mines were developed for continuous mining machines (CMMs). There are five of such proximity detection systems that are approved for use in U.S. mines by the Mine Safety and Health Administration (MSHA) (Mine Safety and Health Administration, 2013; Mine Safety and Health Administration, 2015). There are several basic components that interact within an electromagnetic proximity detection system (PDS). A PDS includes two main elements: a set of generators to create magnetic fields around a CMM and a set of magnetic probes to detect the fields. These systems can determine if a miner is located at a safe distance from the machine based on the detected magnetic flux density. Stability of the magnetic fields is essential for system accuracy."

Jan 1, 2018

By G. Wang, L. R. Moore, Y. Xiong, J. Gu

"Quartz is the second most abundant mineral in the earth’s crust. Not only does quartz have many valuable industrial applications, it is also one of the most concentrated gangue minerals encountered in the processing of other minerals. Minerals such as hematite, apatite, calcite, feldspar, barite, and many more. Numerous applications of industrial minerals are sensitive to the hardness and abrasiveness encountered with quartz minerals, while other applications may lead to processing challenges for the end user. Therefore, process and chemistry optimization must be applied to ensure optimal grade is obtained for these valued industrial minerals. Extensive studies have been conducted in processing various industrial minerals, thus achieving a range of quality specifications, which entailed the application of ArrMaz’s CustoFloat and CustAmine collectors towards the separation of quartz from other minerals. INTRODUCTION Industrial minerals often have the misfortune of the gangue mineral being very similar in surface charge, and coordination properties, to that of the mineral of interest. An example is seen in phosphate beneficiation, when dolomite can be a gangue minerals (Table 1). Therefore, the development of processing reagents are quite complicated. Some minerals, like clays, may be washed away. However, most require the manipulation of the pH, in efforts to fine tune the system to the narrow difference in isoelectric points of the different minerals, as well as the knowledge, and resources that are necessary to exploit the differences to yield and an optimal grade/recovery. In some cases, the application of a depressant may be required, such as the phosphoric acid commonly applied to achieve the optimal balance of grade/recovery for phosphate from a mineral with elevated concentrations of dolomite (Wang, 2016), or the application of hydrofluoric acid to assist in producing feldspar product from a mineral rich in quartz (Heyes, 2012).ArrMaz's CustoFloat and CustAmine product lines have successfully been applied to the processing of industrial minerals for more than 50 years. Applications include, but not limited to phosphate, sand (glass, foundry & high purity quartz), clays (feldspar, kaolin, etc.), and many carbonaceous and sulfate minerals. The successes of these 50 years are largely due to ArrMaz's ability to tailor make the processing chemistries to fit the ever changing and declining mineral feed grade and variations in water quality (Moore, 2015; Moore, 2016). This technical knowledge of mineral processing is strongly complimented by the intimate service programs in place at many of the beneficiation plants."

Jan 1, 2018

By E. G. Ozhogina, O. B. Kotova

"The ores of black, non-ferrous, rare, noble metals are mostly distinguished by a variety of mineral types and complexity of their material composition.The article is devoted to the promotion of the concept of mineral processing in modern realitiesof the deficit of high-quality ores and increase their demand.Normative and methodical documentationsfor specific types of analysis with the definition of the field of application are shown. For example,the pyrochlore-monazite-goethite ores from one of the deposits from Eastern Siberia - Chuktukonskoe ore fieldare tested. The development of mineralogical methods, and testing of specific raw materials are shown.The method of small-angle X-ray (and also synchrotron) scattering, which was developed for solving problems associated with structural high-resolution diagnostics, was tested for bauxites of Vezhay-Vorykvinskoye field. KEYWORDS Technological mineralogy, rebellious ores, ore quality assessment, ?mineralogical-analytical methods INTRODUCTION A highly intense production of many types of mineral raw results in gradual depletion and deterioration of mining-geological and mining-technical conditions of development. Relatively easily accessible and rich deposits are getting exhausted in the first place, and it is necessary to involve poor and rebellious ores into production and processing. Traditional technologies can hardly be applied (Chanturia, 2017; Bazin et al., 2014; Ponaryadov, 2017). The urgency of development of the concept of technological mineralogy focuses on the confirmation of new methods and approaches to the development of mineral raw, creation of scientific and methodological prerequisites for solving the problem of rational development of mineral raw, maximal extraction and integrated application of all minerals (both principal and associated), expansion and strengthening of mineral and raw base. The article is aimed at updating tasks that should be addressed within the applied mineralogical researches: – the forecast of quality of ore at early stages of exploration and technological indicators for the redistribution of raw, – interactive monitoring of these indicators by mineralogical and analytical methods; – assessment of environmental consequences of mining and processing of minerals and measures that eliminate these consequences."

Jan 1, 2018

By L. A. Vaisberg

"Mining processing plants are the most high-performing industrial enterprises in the world economy system. Even at an average-scale mining enterprise, the grain-size separation equipment continuously processes 105 to 106 dissimilar mineral particles per hour. In separation by physical properties, their number increases by at least 10 to 50 times. Mathematical modeling of such a high flow of discrete particles is carried out using two different approaches: the discrete-particle and the phenomenological methods. The calculations demonstrate the possibility of handling big data when describing the processes of separation of granular material. INTRODUCTION The interest to the screening process and the process of formation of new screen designs in Mekhanobr is traditional since the moment of its foundation. It is symbolical that the first publication of the Mekhanobr proceedings in 1924 was the monograph dedicated to screens and screening products as such, which was the first one in the world at that moment. It was a book of Prof. L. B. Levenson, one of the founders of Mekhanobr, who headed the Technical Bureau of the Institute. Vibratory screening is the most mass process in the technologies of solid minerals processing, which determines significantly the energy demands of crushing and grinding cycles, and at some enterprises determines the quality of the final product, for example in case of crushed stone, coal or abrasive materials production. The general understanding and simulation of the process of poly-dispersed granular materials vibratory screening was developed at several conceptual levels taking into account the features of classification of materials with different size and density.Considering the real industrial processes of vibration screening, it shall be noted that at the sieve surface of the screen in the initial part of the deck the classification in a thick material layer (in natural conditions) occurs, which further transfers to a thin layer (free movement). In the process of screening of light minerals, for example coal or metallurgic feedstock, screening is mainly performed in the thick layer."

Jan 1, 2018

By Z. Zhang, X. -G. Chen, F. Breton, A. Arici

"The microstructure of Al-10Si-0.3Mg-0.5Mn alloy with 0.27% Zr and 0.19% V addition was quantitatively analysed and compared to the base material. The addition of Zr and V in the AlSi10Mg alloy exhibit a beneficial effect on the Si modification, resulting in the reduction of the size of eutectic Si particles on both as-cast and T6 conditions. The quantitative image analysis results show that the Zr and V addition and T6 treatment can reduce the size of the intermetallic phases. In addition, the presence of Zr and V is favour to the partial dissolution of the intermetallic phases during the T6 treatment. Different heat treatment procedures were tested to optimize treatment parameters. The mechanical properties of the alloys were evaluated using hardness measurements and tensile tests. The results show that the addition of Zr and V can remarkably improve the mechanical properties on as-cast and T6-treated conditions. The correlation between the microstructure and mechanical properties of the alloys is discussed.INTRODUCTION Al-Si-Mg foundry alloys have been widely used in automotive and aerospace industries due to their high strength-to-weight ratio, heat-treatable capability and excellent castability. The alloying elements such as Cu, Mn, Fe are traditionally added into Al-Si-Mg alloys to improve their mechanical properties (Mohamed, Samuel, Samuel & Doty, 2009). In recent years, the attention has been paid to the effect of the transition elements such as Zr, V, Ti, etc, as minor alloying additives, on the properties of aluminum alloys (Elhadari, Patel, Chen, & Kasprzak, 2011; Kasprzak, Amirkhiz & Niewczas, 2014; Shaha, Czerwinski, Kasprzak, Friedman & Chen, 2015; Shaha, Czerwinski, Kasprzak & Chen, 2014; Mahmudi, Sepehrband, Ghasemi & 2006; Meng, Cui, Zhao & Zuo, 2013). Kasprzak et al., (2014) and Shaha et al., (2015) reported that additions of Zr, V, and Ti in Al-Si-Cu-Mg cast alloys can improve the alloy mechanical properties at high temperature by forming stable intermetallics and precipitates on as-cast and heat treatment conditions. On the other hand, the mechanical properties of near-eutectic and eutectic Al–Si cast alloys depend not only on the chemical composition but also, even more importantly, on microstructural features such as the morphology and size of eutectic silicon and intermetallic particles, which are present on both as-cast and heat treatment conditions (Mohamed et al., 2009). However, there is rather limited information on the effect of Zr and V on the microstructure features and mechanical properties of near-eutectic Al-Si-Mg cast alloys."

Jan 1, 2018

By M. Yekich, W. R. Reed, G. Ross, A. Salem

"Canopy air curtain (CAC) technology has been developed by the National Institute for Occupational Safety and Health (NIOSH) for use on continuous miners and subsequently roof bolting machines in underground coal mines to protect operators of these machines from overexposure to respirator coal mine dust. The next logical progression is to develop a CAC for shuttle cars to protect operators from the same overexposures. NIOSH awarded a contract to Marshall University and J.H. Fletcher to develop the shuttle car CAC. NIOSH conducted laboratory testing to determine the dust control efficiency of the shuttle car CAC. Testing was conducted on two different cab configurations: a center drive similar to that on a Joy 10SC32AA cab model and an end drive similar to that on a Joy 10SC32AB cab model. Three different ventilation velocities were tested—0.61, 2.0, 4.3 m/s (120, 400, and 850 fpm). The lowest, 0.61 m/s (120 fpm), represented the ventilation velocity encountered during loading by the continuous miner, while the 4.3 m/s (850 fpm) velocity represented ventilation velocity airflow over the shuttle car while tramming against ventilation airflow. Test results showed an average of the dust control efficiencies ranging from 74–83% for 0.61 m/s (120 fpm), 39–43% for 2.0 m/s (400 fpm), and 6–16% for 4.3 m/s (850 fpm). Minor modifications to the shuttle car CAC design and placement improved the dust control efficiency to 51–55% for 4.3 m/s (850 fpm) with minimal impact on dust control efficiencies for lower ventilation velocities. These laboratory tests demonstrate that the newly developed shuttle car CAC has the potential to successfully protect shuttle car operators from coal mine respirable dust overexposures. INTRODUCTION The development of the canopy air curtain (CAC) dates back to the 1970s starting with the initial development of the CAC by the Donaldson Company, Inc. under contract from the U.S. Bureau of Mines [Krisko 1975]. This CAC was originally developed for continuous miner operators when continuous mining machines had cabs. The need for a CAC on the continuous miner was eliminated when the cab was removed from the machine design. However, CAC development progressed to include CAC designs for a roof bolting machine to protect roof bolters from respirable coal mine dust [Goodman and Organiscak 2002, Listak and Beck 2012, Reed et al. 2017]. This roof bolting machine CAC research continues to the present day."

Jan 1, 2018

By T. Krichler

"Current mine control stations are either single-position systems with high engineering effort or all-in-a-box solutions with low integration possibilities of third-party devices. Above all, both approaches are cost-intensive and not feasible for small companies. This paper shall be an inspiration of how to enhance the productivity and monitoring of an existing mining system in a modular way by introducing a proven technique of the ongoing digital revolution: A Wi-Fi network based on the communication protocol OPC UA. The starter kit consists of a single-board computer, a WLAN access point and any electronic sensor. INTRODUCTION The majority of the European mining industry is run by small and medium deposits (Europe Geology, 2017). This is due to the fact that most ore mines in Europe are widely distributed within the continent, are generally small and additionally they are often steeply inclined. Such ore bodies are normally mined with underground mining methods and must be excavated with high selectivity because of their small thickness. That is why the economy of scales, higher efficiency through bigger machines, cannot be used in most deposits in Europe except for lignite mines. It is important to find an alternative possibility to improve the efficiency of European mines for making them competitive internationally. For cost optimization and profit maximization it is necessary to use the trends of industry 4.0 and to broadcast these into the mining industry to reach a technological advantage. The goals of the EU within the Horizon 2020 funded project are to shorten the actualisation of the mine and block model to hours, improve the communication with Through the Earth (TTE) via very- or ultra-low frequency for long-time monitoring of the abandoned workings, and develop a cost-effective mine control station for optimization of mining processes in Small and Medium Enterprises (SMEs) as well. This paper deals specifically with the new approach for data acquisition, transmission and visualisation of a mine. SCADA AND ERP IN MINING There are already many Supervisory Control and Data Acquisition (SCADA) and Enterprise Resource Planning (ERP) programs on the market, but these are normally not developed for the mining industry. At the moment this leads to three options. • To hire a system integrator, who shall build a complete control station for one mine that requires a high amount of knowledge in programming and cannot be maintained by the mining company itself. • To buy different types of out-of-the-box systems, whereby every system can include some of the used technology. In this case a huge amount of project engineers and operators – at least one per system and shift- is required. • To buy every machine and program from one company including the service contracts."

Jan 1, 2018

By Klaus M. Hahn, Hermann Wotruba, Bernd G. Friedrich

"Due to an increasing demand for nickel and cobalt and the depletion of nickel sulphide deposits worldwide, the production of ferronickel from lateritic nickel ores becomes more significant. About 60 percent of nickel reserves are present in laterite deposits. Common production methods like acid leaching or smelting operations implicate high material and energy consumption. Physical processing methods are also not efficient, because of the fine microstructural intergrowth of the minerals carrying valuable elements such as nickel and cobalt. Due to the high energy consumption of metallurgical treatment of lateritic nickel ore (nickel grade: 0.8 - 3.0%, Co: 0.05 - 0.15%), the separation of waste material (about 75 - 85%) before the metallurgical treatment is desirable. Therefore, an alternative process has been developed, combining a pyro-metallurgical pre-treatment with selected mechanical processing methods. The developed process consisted of a selective pre-reduction and non-selective segregation of the contained metal phases in the first stage. By this, the properties of the metal carrying minerals were changed and could become subject to concentration by means of fine beneficiation processes afterwards. The parameters of the pre-reduction and segregation were varied and the pre-treated samples were examined concerning their efficiency of metalization grade and metal grain size. This paper describes the investigation of pre-treatment methods of a lateritic nickel ore. The pre-treatment and possible subsequent separation methods were examined with regard to the recovery of the valuable elements. Metalization grade was around 80% for both Ni and Co with metal phase grain sizes below 20 µm. Scanning electron microscopy revealed distribution of new metal phases not only on the reducing agent, but also on the “slag” material.INTRODUCTION Nickel laterites are characterized as strongly weathered regoliths with several zones containing reserves of nickel (Ni) and cobalt (Co). These laterites are formed on serpentinites and ultramafic rocks under climatic and/or tectonic conditions that have changed over time (Butt & Cluzel, 2013). The formation of Ni laterites is influenced by numerous geological and environmental factors. In general, there are three ore types named according to the dominant Ni hosting minerals: oxides, hydrous magnesia (Mg) silicates and clay silicates (Butt & Cluzel, 2013). The most Ni laterite deposits contain two of these ore types, usually an oxide zone and an either clay or Mg silicate zone. Distribution of these principal deposit types, their average Ni-bearing phases and mean Ni grade are shown in Table 1. A schematic profile of the different deposits based on the development on serpentized ultramafic rocks is given in Figure 1 (Butt & Cluzel, 2013)."

Jan 1, 2018

By Junwei Han, Kai Xue, Wenqing Qin, Tan Xu, Fen Jiao, Lianbing Cai, Wei Liu

"The research aimed at solving the problem of the stacked spent magnesia-chrome refractories using in non-ferrous metal smelters, which contain various heavy metals and are considered as a hazardous waste. The purpose of the research is to recycle the spent refractories environmentally and economically using gravity separation and flotation to obtain metal concentrates for smelting and using chloridizing volatilization to remove the trace metals from tailings, providing raw material to reprocess magnesia-chrome refractories. In the course of the study, laboratory techniques for the preparation of experimental samples of spent magnesia-chrome refractories were developed including the sequence of operations of material grinding, gravity separation, tails regrinding, flotation, filtration and subsequent unification of concentrates, filtration and chloridizing volatilization of tails, and collection of volatiles. Laboratory tests carried out on several types of samples of spent magnesia-chrome refractories from different smelters showed that gravity separation provided increase in quality of concentrates including about 80% metals (including Ag, Pb, Bi) and flotation separation provided increase in recovery of concentrates under the condition of 200g/t of emulsified kerosene, and 500g/t of combined collector. Based on combined technology of gravity and flotation separation, about 90% metals were recovered from the refractories by a closed-circuit test and the total concentrates contained 40% metals, which can be returned to smelting process as a feeding. Because a small amount of metal in raw materials will seriously affect the performance of refractories, chloridizing volatilization is necessary for removing the remaining 10% metals from tails mixed 8% coke and 13% magnesium chloride at a temperature of 1200°C. Thus, the tailings can be reused as a raw material for new refractories.INTRODUCTION Magnesia-chrome refractory has been used extensively in various industries such as secondary metallurgy, non-ferrous furnaces and cement making due to their high temperature stability, low thermal expansion and outstanding erosion-corrosion performance at high temperatures (Gotod et al., 2005; Vezza et al., 1997; Gregurek et al., 2015). Generally, the magnesia-chrome refractories are produced from a mixture of magnesia and massive variety of chrome ores. However, massive chrome ores are being depleted throughout the world. Even more serious is that the heavy metal chromium (Cr) can transfer into soil and water, which will have an influence on the survival and development of human beings (Zhao et al., 2006; Jiang et al., 2004; Qintie et al., 2013). As a result, regulations treating spent magnesia-chrome refractories as potentially hazardous waste are being enforced, making their disposal difficult and expensive."

Jan 1, 2018

By N. O. Lotter

The connection between mineralogy and metallurgical performance in a plant was recognised long ago (Gaudin, 1939; Petruk, 1976; Petruk and Hughson, 1977; Cabri, 1981; Petruk and Schnaar, 1981; Kinloch, 1982; Peyerl, 1983, Baum et al 1989 for example). The modern toolbox that we now routinely use for flowsheet development took decades to develop (Lotter et al., 2002; Baum and Lotter, 2004; Lotter, 2011 for example). Many workers contributed considerable time and effort to this overall mission of connecting sampling, mineralogy and mineral processing to integrate the flowsheet development activities. Certain key milestones marked this journey, such as Gy’s treatise on the sampling of particulate materials in 1979, which was later added to by François-Bongarçon, Pitard, Minnitt, and Holmes for example. The development of QEM*SEM by Gottlieb et al. of the MLA by Gu et al. constituted a huge leap forward in accuracy and mineral measurement capacity, as well as a reduction in standard errors of mineral characterisation. The advancement of the microprobe to an automated platform made a significant difference to detailed compositional mineralogy. This led to a strong position from which to draw meaningful processing implications from the mineralogical data. Reproducible flotation testing and reliable plant survey material for characterisation was dealt with by, amongst others, High Confidence Flotation Testing ( Lotter, 1995: Runge, 2010, and Bradshaw, 1997); and Statistical Benchmark Surveying (Lotter, 2005), with earlier prototypes which were steadily improved (Lotter, 1994; Restarick, 1976). The sterling work of Napier-Munn in engaging sound statistical methods with mineral processing led to the successful design and use of methods that could identify and quantify small recovery gains in plant scale trials. This history and present capability are reviewed, including leverage into asset management.

Jan 1, 2018

By F. Bélanger, P. A. Fournier

"Modelling and optimization techniques used in the operation of the Detour Lake Mine leach circuit are contrasted to a 1973 review of contemporary techniques used by a major gold producer. The leach circuit at the Detour Lake Mine was modelled using a full factorial Design of Experiment of stirred tank reactor leach tests using circuit feed. Contour plots of extraction were applied in the plant to optimize addition rates of cyanide and the newly-commissioned lead nitrate system. Contour plot sections were used to understand the impact of sulphur in circuit feed at different operating dissolved oxygen concentrations. The 1973 review paper offers insight into industrially-applied modelling and optimization techniques. In particular, a mathematical model of plant data was developed using multilinear stepwise regression analysis. The model was presented using graphical representations available at the time and applied to optimize the rates of cyanide addition. Off-the-shelf software solutions of today allow mineral processors to quickly and easily visualize data, allowing them to re-allocate time and resources spent processing data to generating raw data and extracting actionable information.IntroductionModelling and optimization in mineral processing is the art of reducing reality through judicious use of assumptions to understand a process and leverage this knowledge to engineer practical solutions to metallurgical problems. Data analysis is at the core of this enterprise.While this paper showcases the modelling work done at the Detour Lake Mine (DLM), the primary objective is to pause and reflect on how far the field has progressed since the 1970’s. A snapshot of state-of-the-art gold cyanidation modelling at that time is a review paper of the Anglo American Group’s capabilities (Brittan & van Vuuren, 1973). The objective of this paper is not a play-by-play of the evolution of modelling and optimization since that time. Rather, it is a comparison of the field at two points in time.In 2016, DLM undertook an extensive bench-scale leach circuit modelling program to better understand the impact of cyanide, dissolved oxygen, lead nitrate, grind size, density, and pH on gold cyanidation (Fournier, 2016). Two major capital expenditure projects were anticipated for 2017: improvements to oxygen control and a lead nitrate distribution system. While the lead nitrate system was planned for construction, the design parameters had not yet been selected. Following the development of the model, plant trials were executed to validate aspects of the model and the methodology was expanded to address other plant issues, in particular the effect of talc chlorite and pyrrhotite in leach feed.The variables of the bench-scale study are summarized in Table 1. Dependent variables were varied using a full factorial design of experiment with two repetitions for each test condition, yielding a total of 300 tests. Test order was randomized to eliminate bias from independent variables."

Jan 1, 2018

By N. Sarmady, Mei Li, N. C. Parson, W. J. Poole

"The mechanical behaviour of AA6082 is a function of the extrusion conditions and in particular, the quench rate after extrusion. It is well known that precipitation of Mg-Si phases on grain boundaries during quenching can negatively affect the ductility of the alloy. In this study, AA6082 alloys containing 0.5 wt. % Mn and 0.15 wt. % Cr were direct chill (DC) cast, homogenized and then extruded to produce 3 mm x 42 mm strips. The microstructure in the as-extruded strips was unrecrystallized due to the Zener-Smith drag from the Mn/Cr dispersoids. It was shown that a solution treatment of 5 minutes at 560°C did not significantly affecting the as-extruded microstructure but if the as-extruded strip was cold rolled prior to heating, recrystallization occurred concurrently with the solution treatment. As such, 3 initial microstructures were produced, i.e. unrecrystallized and recrystallized with a grain size of 9 and 40 µm. After the solution treatment, controlled cooling experiments were conducted using the Gleeble 3500 thermomechanical simulator with cooling rates of 10, 25, 80°C/s as well as water quenched. The mechanical properties (e.g. yield stress, fracture stress and fracture strain) were determined from tensile tests for the different combinations of initial microstructure and cooling rate. The relationship between the quench rate and precipitation of Mg-Si phases on grain boundaries was examined by FEG-SEM. It was found that the yield stress decreased as the cooling rate decreased and that there was complex relationship between the fracture properties and the microstructure.INTRODUCTION As the automotive industry strives to reduce fuel consumption and CO2 emissions with the goal of reducing the environmental impact, there is a need for lighter vehicles. As a result, aluminum alloys are gaining popularity to replace steel parts as structural components. An exemplar of this is the Ford F-150 pickup truck which has an aluminum body and is ˜750 pounds lighter than the previous steel version of the vehicle. The structure includes a mix of aluminum sheet, extrusions and cast alloys. The current research is concerned with the performance of aluminum extrusions in applications such as side rails, crash tubes and other structural parts. These components experience a combination of bending, stretching and folding both during the forming of the part and in service, e.g. crash of a vehicle. There is a need to have detailed information on the influence of processing on final material performance, in particular the cooling rate after extrusion."

Jan 1, 2018

By A. Yaghini, Y. Pourrahimian

"Human factors (HFs) play an important role in the mining and mineral industry, affecting operational and maintenance efficiency and safety. Despite the introduction of new technologies and automation in this sector, it is well known that a significantly large proportion of total human errors occur during the operation and maintenance phase. A comprehensive literature review of HFs across several industries is provided. From this review, the impact of HFs on operation and maintenance is summarized, with a focus on what the mining industry is currently doing and what opportunities exist for additional improvements. Future research directions and themes are also identified.RÉSUMÉ Les facteurs humains (FH) jouent un rôle important dans l’industrie des mines et des minéraux, en ce qu’ils affectent l’efficacité et la sécurité de l’exploitation et de l’entretien. Malgré l’apparition de nouvelles technologies et de l’automatisation dans ce secteur, il est bien connu qu’une grande partie des erreurs humaines (EH) se produisent durant une phase d’exploitation et d’entretien. Cet article propose une analyse documentaire approfondie des FH dans plusieurs secteurs. L’impact des FH sur l’exploitation et l’entretien est résumé à partir de cette analyse, une attention particulière étant accordée à l’évolution de l’industrie minière et aux possibilités d’améliorer davantage ses activités. Sont également identifiés les futurs thèmes et voies de recherche.INTRODUCTIONDuring the past several decades, the mining industry has focused on improving equipment, machinery, and methods that have led to more advanced hardware and software, equipment with higher reliability and productivity, and other technological advancements. These actions have improved safety and productivity and have reduced casualties and maintenance workload. Although today’s mining equipment and machinery are technologically advanced and highly reliable, the risk of accidents is still relatively high and key performance indicators have not improved significantly compared to other industries (Sorensen, 2012). A prominent reason could be due to insignificant integration of human factors (HFs) as part of planning, operation, and maintenance activities. The current mining system is a people system, and inevitably HFs and human error (HE) figure prominently in all aspects of this industry. Even the most advanced technologies and innovations require operators and maintainers with significant knowledge and skill, which could increase the potential for HE."

Jan 1, 2018

By K. E. Harley, M. J. Whiting, T. J. Sabin, E. M. Ryan, J. F. Watts

"Wire and Arc Additive Manufacturing (WAAM) has the potential to enable a very significant reduction in buy-to-fly ratio compared to conventional manufacturing through the ability to build near-net shape components. Components manufactured from AA 2319 by WAAM can exhibit significant levels of porosity. There is also a variation in the physical appearance of the surface deposit sometimes found on such components. This deposit is similar to those observed on aluminium joined by MIG and TIG welding processes. It has been suggested that both the bulk porosity and the surface deposit are caused by hydrocarbon-based lubricant on the feedstock wire. An established correlation between surface deposit and porosity would offer valuable insight into WAAM products and enable early interventions in quality control or process monitoring based on visual examination. The relationship between the nature of the surface deposit and porosity has been studied for AA 2319 WAAM components manufactured using different wire batches. Evidence is presented to support the assertion that (i) there does not appear to be a relationship between surface deposit coverage and porosity, (ii) batch-to-batch variability in feedstock wire affects porosity. This study has led to a better understanding of the cause of porosity in WAAM components.INTRODUCTION There is a high cost associated with conventional, subtractive manufacturing because of the high ‘buy-to-fly’ ratio, a measure of the initial material bought compared to the material found in the finished part (Allen, 2006; Yilmaz & Ulga, 2016). A typical aerospace product may have up to 90% of the purchased billet of forging machined away which is cost inefficient and high in material waste. Wire and Arc Additive Manufacturing (WAAM) has the potential to reduce costs and lead time. Robotically controlled weld torches rapidly deposit feedstock wire in layers to build large near-net shapes with mechanical properties similar to those of conventional manufactured parts (Sequeira Almedia & Williams, 2010; Martina et al., 2012; Ding et al., 2015; Williams et al., 2015). A high level of porosity variation has been observed in aluminium WAAM parts (Cong, Ding & Williams, 2014; Gu et al, 2016) which can result in a range of material properties (Rudy & Rupert, 1970). This leads to difficulties in regards to standardisation and qualification of process and parts. In order for WAAM to be used commercially, porosity will need to be understood, monitored and reduced to a reproducible acceptable level or eliminated."

Jan 1, 2018

By Vishal Shukla, Ashok Kumar, C. Raghu Kumar, D. P. Chakraborty

"Traditional iron ore beneficiation plants using washing, screening, and jigging processes require large volumes of process water. Generated slime during processing, its disposal and impact on water usage, is an important concern for any mining company. The challenge today, during extracting iron ore, is how to dispose of slime such that it is contained and stable, while maximizing water reuse and minimizing surface footprint. The slime disposal methods are sensitive to the environment. Two major technologies presently being practiced for disposing the slime across the world are pressure filtration and paste thickening. In this perspective an attempt has been made to do comparative study between paste thickening and pressure filtration for selection of suitable slime disposable technology for Noamundi processing plant, Tata Steel. From the studies, it is evident that by adopting pressure filtration technique it was possible to produce filtered slime, whereas filtration, rate reduces significantly with the presence of finer fraction. Further , the greatest advantage of paste thickening is volume reduction of slime. By considering the technology limitation and comparative lab test work result, it is opined that combination of filtration and paste thickening technology is favorable in terms of capital and operating cost and slime >45 µ should be filtered and < 45 µ slime should go for paste thickening. The study and the results are presented in details.INTRODUCTION The beneficiation processes always end up with an enriched portion of desired mineral - “Concentrate” and an enriched portion of undesired minerals - “Tailing”. The proportion and nature of tailings generated in every beneficiation process differ from ore to ore and reflects the characteristics of the feed processed. The traditional method of tailing disposal in many mineral processing industries has been to dispose them as thickener underflow at around 35% solids. Though, it had certain advantages of transportation with ease but contribute to a greater volume occupied in the tailing dam. This sustained practice and failure to utilize the space available in the tailing dam judiciously endangered the mining industry. The tailing management has become the toughest task to the mining industry and most of the mines are running out of space for disposing the fresh tailings as many of these are at the verge of getting filled."

Jan 1, 2018

By Indrajit Paul, Atanu Pal, Kapil Modi, Sanjay Chandra, Chandra Sekhar, Srinivas Dwarapudi

"High alumina content in the Indian iron ore fines (2.5% Al2O3) resulted in poor quality pellets at the recently commissioned 6 MTPA pelletizing plant and a study was under taken to establish suitable pellet chemistry through proper fluxing agents. Limestone fluxed pellets were prepared at varying basicity (0 to 0.8) and pyroxenite fluxed pellets at varying MgO contents (0 to 3%) to study their effect on the metallurgical properties. Fired pellets were tested for their strength, RDI, reducibility and swelling. Microstructural studies, optical and SEM-EDS, were carried out to quantify different phases and their chemistry. Acid pellets exhibited poor quality whereas limestone pellets at 0.8 basicity and pyroxenite pellets at 1.5% MgO exhibited optimum metallurgical quality. Formation of widely distributed silicate melt in limestone pellets and high melting point slag & magnesioferrite in pyroxenite pellets found to improve their quality. However during commercial production of MgO bearing pyroxenite pellets, their room temperature and low temperature properties found to be inferior, but exhibited better high temperature properties, viz. softening-melting behavior. Contrary to this, commercially produced limestone pellets, comprising CaO, exhibited better strength and RDI but showed poor high temperature properties. To yield the benefits of both CaO (for good strength and RDI) and MgO (for low swelling and high softening), a dual flux combination was established by using both limestone and pyroxenite/olivine together that resulted in optimum metallurgical properties. Coke rate at the blast furnaces found to be reduced by 1kg for every1% increase of dual flux pellets in the burden.INTRODUCTION Iron ore agglomerate quality plays a vital role in decreasing the reducing agent consumption and increasing the productivity of blast furnace. In most of the integrated steel works, the burden mix for blast furnace is decided as per the availability of the iron ore agglomerates like sinter and pellets. More attention has been given in recent years to the use of fluxed pellets in blast furnace due to their good strength and improved reducibility, swelling and softening melting characteristics. Generally, quality of pellets is influenced by the nature of ore or concentrate, associated gangue, type and amount of fluxes added and their subsequent treatment to produce pellets. These factors in turn result in the variation of physicochemical properties of the coexisting phases and their distribution during pellet induration. Hence properties of the pellets are largely governed by the form and degree of bonding achieved between ore particles and the stability of these bonding phases during reduction of iron oxides (Panigraphy et al., 1990). It is important to note that conditions and parameters of pelletizing are specific to given ore or concentrate; the present study is undertaken for typical Indian hematite ore fines high in alumina. Except authors earlier work on quality of pellets from Indian iron ore (Dwarapudi et al., 2008, 2010), there is no considerable literature reported on the effect of pellet basicity and MgO content in the basicity range of 0 to 0.8 for Indian hematite ore."

Jan 1, 2018

By C. Dorfling, P. Albertyn

"Hydrometallurgical recovery of metals from printed circuit board waste typically involves multiple leaching stages; conventionally, base metals dissolution by mineral acids is followed by leaching of gold using cyanide or halide based lixiviants. Alternative lixiviants for gold leaching can reduce the potential hazardous nature of operation. The aim of this study was to investigate the feasibility of using thiosulfate as lixiviant for gold leaching from waste printed circuit boards. Batch leaching tests were performed to investigate the effects of thiosulfate concentration (0.1 – 0.2 M), ammonium concentration (0.2 – 0.4 M), pH (9 – 10.5), solids content (25 – 50 g/L), and copper content of the feed material on the gold leaching behavior. The concentrations of metals in liquid samples were determined by means of inductively coupled plasma atomic emission spectroscopy, and high pressure liquid chromatography was used to evaluate thiosulfate degradation/consumption. The ratio of thiosulfate to ammonia was found to have the most significant effect on the extent of gold leaching, with the best gold extraction observed at a ratio of 0.5 mole thiosulfate per mole ammonia. The lower pH range of 9 – 9.5 generally produced better Au leaching, while low copper extraction during the first stage base metal leaching stages has proven to be detrimental to gold leaching from the residue. Thiosulfate degradation/consumption increased and gold extraction decreased with higher residual copper in the feed. An optimum gold extraction of 78.5 % from base metal leach residue was achieved with 0.2 M thiosulfate, 0.4 M ammonia, and 0.02 M cupric ions at 25°C in the pH range 9 – 9.5.INTRODUCTION Background and Aim The recycling of e-waste is becoming increasingly important as it provides certain economic benefits apart from the obvious environmental benefits. Printed circuit boards (PCBs) are found in most forms of e-waste and contain especially high concentrations of base and precious metals. Hydrometallurgical processes are often considered for the recovery of valuable metals from PCBs; these processes normally implement several leaching stages to selectively recover certain metals."

Jan 1, 2018

By I. N. Gridasov, T. V. Ignatova, E. V. Shelepov

"Mikhailovskoye Deposit is comprised of oxidized ferruginous quartzites among other minerals with the former widely spread across the ore field and mined along with unoxidized ferruginous quartzites. PJSC Mikhailovsky GOK strategic development is aimed at iron ore product output expansion. The most critical item of the strategic development road map is process design for separation and concentration of hematite contained in oxidized ferruginous quartzites mined as the by-product in the open pit. Laboratory and semi-industrial tests run to design cost-effective, reliable and environmentally friendly process for Mikhailovskoye deposit oxide quartzites processing included the following processes: - pilot tests of reverse anionic flotation which produced concentrate with Fe60.1-62.9% total iron content and 66-69%Fe recovery rate; - combined magnetic separation and flotation (Marubeni Company, 1982) including slime removal, reverse anionic and cationic flotation and high gradient magnetic separation resulting in 48.9% yield, Fe55-57.5%, up to Fe60.5% hematite concentration ( Fe64.1% being the best result achieved),76.2% recovery. - magnetic separation and flotation, including separation in low gradient (1400 Oe) and high gradient (up to 17000-18000 Oe) magnetic field. The results of these pilots tests were the following: 57-59%Fe concentrate, 70%Fe recovery (Mekhanobrchermet, MGOK, 1982-1988): - magnetic roasting in pilot plant of TSGOK (Krivoy Rog) which produced 61.1%Fe concentrate with 81.5% recovery. Major disadvantage of the method is high generation of dust equal to 20% of the initial feed. Based on third-party studies flotation of oxidized ferruginous quartzites process embracing best processing methods was designed by Metalloinvest Management Company LLC and PJSC Mikhailovsky GOK engineers. This paper discusses analysis of studies aimed at intensification of separation processes with application of mechanical slurry agitation (MSA), addition of alkali (NaOH) and elutriation of initial feed. The paper also provides a design solution to implement a lab-scale MSA plant. It includes feasibility evaluation of MSA inclusion in flotation of oxidized ferruginous quartzites process to enable higher yield and hematite recovery in resultant concentrate. Outcomes of the discussed work have significant value for prospective engineering of OFQ concentration process."

Jan 1, 2018

By Carlos Almeida, Bruno Matias, Stef Kapuskiak, Eduardo Silva, José Miguel Almeida, Alfredo Martins

Underwater intervention operations have been supported by robotic systems such as remotely operated vehicles (ROV) for a long time. In particular challenging scenarios such as the deep sea, the use of ROV systems for environment awareness is in fact the main tool of choice. With the technical advances in autonomous robotics, there is an increased effort in substitute ROVs whenever possible for autonomous underwater vehicles (AUV). These systems don't have tether and thus provide large advantages from the operations and logistic point of view. However the limited options for underwater communications render them impracticable for many tasks were real time environment awareness and direct human control is needed. Emerging applications in underwater mining, both at sea [1] and in inland flooded mines [2] pose additional requirements in terms of operation support needs and environment restrictions. Two main tasks are to be addressed by assisting robots in these underwater mining operations: providing adequate environment awareness for human operators and obtain precise realtime 3D environment modelling (particularly relevant for the mining planning). The use of ROVs with umbilical cable, has in this case large limitations due to the nature of the mining cutting (performed by dedicated systems) that limit manoeuvrability and pose high risk of cutting the cable or damaging the vehicle. In this paper we present EVA (Exploration VAMOS AUV) an innovative hybrid ROV/AUV system developed for operations support in inland underwater mining operations. This robot is always operated without tether, and the can be used in a wireless ROV tele-operation mode using very short range high bandwidth underwater communication systems and in autonomous AUV mode.

Jan 1, 2018

By P. Gao, J. W. Yu

"Magnetizing roasting-magnetic separation is an important route for the beneficiation of refractory iron ores. In this investigation, a pilot-scale fluidized magnetizing roasting reactor was introduced and used to study the effects of roasting temperature and the flow rates of reducing gas CO and fluidizing gas N2, on the magnetizing roasting performance of an Anshan-type carbonate-bearing fine iron ore. The results showed that the hematite was almost reduced to magnetite by a gas mixture of 4 m3/h CO and 1 m3/h N2 at a roasting temperature of 540 °C. Under the optimized conditions, a high-grade magnetic concentrate assaying 66.1 wt.% Fe with a recovery rate of 91.2% was achieved from an Anshan-type carbonate-bearing fine iron ore assaying 42.0 wt.% Fe. The XRD, VSM, and optical microscopy analyses revealed that the siderite was successfully converted to magnetite by roasting. Some coarse hematite particles were difficult to reduce to magnetite completely; however, these generated magnetite particles with a fine hematite core could also be effectively recovered by magnetic separation after liberation from gangue minerals due to their strong magnetism. INTRODUCTION Magnetizing roasting followed by low-intensity magnetic separation has been considered as an effective solution, both technologically and economically, when upgrading refractory iron ores (Zhang et al., 2012; Peng et al., 2012; Li and Zhu, 2012). According to the type of roasting reactor, the magnetization roasting can be divided into shaft furnace roasting, rotary kiln roasting, and fluidized bed roasting (Zhu and Li, 2014).Shaft furnace magnetization roasting system is mainly composed of heating and reduction processes. The hematite ore is first heated to 700~800 °C in the heating zone, then falls into reduction zone where the weakly magnetic hematite is reduced to magnetite by coke oven gas at 550~600 °C (Yan et al., 2012). However, several years of engineering practices indicate that the shaft furnace can only process the hematite ores with a granularity of 15 ~75 mm, and the shaft furnace roasting is also characterized by heterogeneity of roasted product. Hence, the shaft furnace magnetization roasting technology is gradually replaced by high-gradient magnetic separation with the development of high-gradient magnetic separator. The rotary kiln generally handles the hematite ores with a grain size of less than 30 mm (Zhu and Li, 2014), however the formation of clinker ring in the rotary kiln will affect the yield of iron resource. In the fluidized bed furnace, the hematite ore is shaken up by an upward current of gas which maintains the individual particles in suspension (Yu et al., 2018). The precise adjustment of the gas velocity to the particle size and the specific weight of the hematite ore, make it possible to generate a floating mixture of gas and solids which behaves almost like a liquid (Yu et al., 2017a). The process is reported to have the following advantages over the other roasting techniques: ease of control due to absence of moving parts within the reactor, homogeneity of roasted products, ability to handle fine particles, and high efficiency of heat transfer and mass transfer (Li et al., 2015; Yu et al., 2017b). However, the simultaneous heating and reductive magnetization of hematite ore occur at the same place in the conventional fluidized bed reactor. Therefore, the reductive atmosphere, as well as the safety and stability of anti-explosion are hard to be controlled. Besides, the roasting temperature for conventional fluidized bed furnace is usually up to 950~1150 °C (Liu et al., 2017). Thus, the formation of clinker ring caused by high temperature will affect the operating efficiency."

Jan 1, 2018