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By Neillm Alastair S.

"This paper looks at what has happened in the past decade in the rare earth industry, particularly for those companies outside China trying to develop alternative projects to the Chinese dominated supply chain. The rare earth industry has gone through a metamorphosis over the past decade. The industry was basically unknown outside China until overnight it became the next hot topic on the financial streets of Canada and Australia. Suddenly various junior miners shifted from uranium and other out-of-favor commodities to rare earths as funds were easy to access from an investment community that did not understand the complexities of the space. The initial funding was done on traditional junior mining metrics of grade and deposit size. This has morphed over time to:1) Lights versus heavies2) Making a concentrate3) The importance of separation4) Off-take agreementsAt the peak of the market frenzy certain flagship operations were built using the “Not Made in China” moniker. Unfortunately certain errors were made during implementation, which are finally coming to the surface and making the rest of the pack wondering what will happen next. A review and update of some of the mistakes made and lessons learned will be discussed.BACKGROUNDAbout ten years ago awareness started to form around the rare earth industry and various groups recognized that because of the closure of Molycorp, Mountain Pass, and the dominance of China, there was a risk of uncertainty of reliable supply. This was not news for those active in the industry like Rhodia (now Solvay), the Japanese, South Koreans and other key consumers but to others it was like a light went on and rare earths became the new “.com” trend for investment banks, investors and some mining companies looking for the next hot topic.In the late 1990’s Molycorp accounted for around 20-25% of the world’s supply of rare earths, mostly lights (La, Ce, Pr and Nd), with small amounts of heavies from other sources. Then environmental issues forced the closure of the operation at Mountain Pass. Within six months China had increased production to plug the gap in supply. Around that time China was developing a strategy to leverage their position in rare earths and implemented a series of regulations to increase the value added component of rare earths inside China."

Jan 1, 2016

By Ralph E. Burnham, J. Kelly Ratliff

"The words “dynamite,” “TNT,” “explosives,” and “blasting” typically cause the general public, andjurors, apprehension and fear. Although blasting operations conducted by well-trained, skilled, andexperienced blasters rarely cause damage or injury, the public’s perception of blasting is that it isdangerous, disruptive, and results in damage to nearby properties. As a result, blasting operations have always resulted in complaints, claims, and lawsuits. However, in recent years, the public perception combined with an increase in public opposition, social media, more stringent regulations, predatory plaintiffs’ attorneys, and the application of strict liability to blasting claims has resulted in an increased threat of litigation to blasting companies and individual blasters. Consequently, many blasting companies find themselves receiving more complaints, involved in more litigation, and facing an alarming number of frivolous claims, which can result in increased insurance costs and other financial tolls. Accordingly, today’s blasting companies must be prepared for litigation and take steps to eliminate accidents and claims before the first shot is detonated on a job. The best way to accomplish this is standard operating procedures that incorporate best management practices, industry standards, and regulations in daily operations. This paper outlines some of the considerations that a blasting company should incorporate into its standard operating procedures before, during, and after the shot."

Jan 1, 2016

By Orlando Rojas, Javier Pizarro, Romke Kuyvenhoven, Francisco Soto

"The concept of geometallurgy has been extensively mentioned and used in the mining industry in the past years. However, each mining firm has a different understanding of what geometallurgy means, and its actual value varies significantly from site to site. Even in the case of properly constructed geometallurgical models, it is fairly common to observe a sub-utilization of the model in the actual operation, because of its low production forecasting capability on the short term. This disconnect between the geometallurgical model and operations is typically caused by a lack of tuning between the original model and the actual plant operation. Also, the absence of procedures and other standards for reconciliation, affects the confidence and the predictive quality of the model. The geometallurgical model should consist of three different levels: (I) adequate capture of information, (II) data analysis and modelling, and (III) development of the block model. Once the geometallurgical in-situ model is finalized, a process model should be developed of the plant at industrial scale, in order to scale up the in-situ geometallurgical parameters from their base or standard condition, to the actual operating reality of the plant. Finally, the stage of reconciliation will close this process, assuring that any deviation between the geometallurgical model and the actual plant operation is not due to lack of tuning, but due to operational issues such as unattended maintenance requirements or poor process control in the operation. The methodology as described in this paper has been applied at several large mining sites in Chile. The paper presents the characteristics of the proposed methodology, and quantitatively describes its benefits with examples from actual operations.INTRODUCTIONIt probably is fair to say that geometallurgy became widely used in greenfield projects in the Andes region during the mining boom of the 90’s, when massive orebodies were studied and developed, and upfront metallurgical characterisation proved its use for accurate economic evaluation including estimates of plant throughput, energy consumption, final product quality and overall recovery. A few examples of such greenfield studies for concentrator plants in the 90’s are Minera Los Pelambres (Antofagasta Minerals, Chile), Minera Escondida, Laguna Seca (BHP Billiton, Chile), and Rio Blanco (then Montterrico Metals, Peru). Large size hydrometallurgical operations such as Cerro Colorado, Quebrada Blanca and Lomas Bayas (all in Chile), also recognised early on the importance and value of relating ore mineralogy, geological characterisation and metallurgical behaviour."

Jan 1, 2016

By K. Chomyn, R. Veenstra, P. Zangeneh, Hatch Ltd., C. Van der Woude, H. Ghorbani

"The furnace is the heart of smelting operations, and therefore the performance, reliability, and campaign life of the furnace are critical considerations. Furnace refractory is exposed to high temperatures and other harsh operating conditions causing brick erosion, crushing, and cracking, typically limiting the furnace campaign life and requiring costly furnace shut-downs for refractory re-lining. Despite extensive study, the in-service thermal / mechanical stresses in these complex refractory systems are not generally well understood. Hatch has developed a thermal-mechanical finite element analysis (FEA) based furnace refractory modeling approach that allows for the quantification of refractory movements, load distribution, and thermal / mechanical stresses.Due to the complexity of the refractory system, a range of models are used to identify and assess damage mechanisms and design improvements, including: 2D models, to capture expansion and movement of individual bricks, changes to load paths, and thermal stresses; and 3D models, to include the effect of differential expansion between bricks in each course, and assess overall load distributions. The 2D and 3D analyses include the effect of nonlinear temperature-dependent properties, thermal expansion, movement of individual bricks with frictional contacts (i.e., gaps can open, bricks can slide), and brick tensile or compressive failure. Both as-built and damaged conditions can be investigated (e.g., after bath zone brick erosion), for circular and rectangular furnaces. 3D models also include papering and brick joint & interface action.Analyses using these models have shown the importance of thermal stresses, papering, and geometry / arrangement of individual bricks. Results have been used to identify and assess damage mechanisms, showing good alignment with furnace autopsy observations. By using this FEA-based approach to quantify the refractory design, the risk of damage can be significantly reduced, low-cost design changes can be identified, and the furnace campaign life can be extended.INTRODUCTIONThe furnace is the heart of smelting operations and therefore the performance, reliability, and campaign life of the furnace are critical to the success of the smelting operation. Furnaces are inherently exposed to high temperatures, often in excess of 1600°C (Holappa, 2004), and furnace operating power has progressively increased over time (Voermann, Gerritsen, Candy, Stober, & Matyas, 2004). The refractory system must withstand high temperature, high heat flux, and other harsh operating conditions. These conditions are particularly significant for the furnace hearth, and can lead to damage including brick erosion due to molten material flows, crushing due to thermal expansion loads, and cracking due to severe thermal gradients within the bricks. Refractory damage typically limits the furnace campaign life, requiring costly furnace shut-downs for refractory re-lining (repair or replacement). In some cases the refractory may lose integrity causing damage to nearby equipment and harm to personnel."

Jan 1, 2016

By J. Mizera, B. Adamczyk-Cieslak, K. J. Kurzydlowski, A. Dobkowska

"AZ31 is the one of the most popular magnesium alloy using in the modern industry. It is well known, that compared with steel, magnesium alloys posse better properties, such as light mass, high specific strength or thermal conductivity. It should be noted that their application is limited by poor corrosion resistance. In this work the corrosion behavior of AZ31 magnesium alloy as cast and after heat treatment were described with the use of testing in neutral salt spray atmosphere.To characterise corrosion resistance and describe layers built on the surface it was necessary to do the metallographic observations with the use of optical microscopy. After that influence of heat treatment for AZ31 corrosion resistance was examined. Measurements were conducted by electrochemical impedance spectroscopy (EIS) and by neutral salt spray tests in artificial atmosphere. Surface and cross section morphology after removal of corrosion products were observed with the use of scanning electron microscopy (SEM).The weight loss measurements show that there is no significant difference between alloys as cast and with following heat treatment.INTRODUCTIONMagnesium and magnesium alloys are popular in modern industry because of the low density and good formability. Magnesium alloys are described by few properties which have got significant influence for their application in transportation and electronics industries (Feliu & Liorente, 2015). Their wide application is limited by poor corrosion resistance. As it is well known Mg is one of the chemically most active metal. Corrosion resistance of Mg alloys depends on several factors, such as impurities, chemical composition or working conditions (Cheng, Qin, Wang, & Zhang, 2009). That all causes that there are many different ways to find well defined and good solution of magnesium alloys processing to improve their corrosion resistance.There are many different versions about the influence of aluminum on the corrosion resistance of magnesium alloy. It is known that intermetallic compounds such as Mg17Al12 due to ß-phase content plays the minor role for corrosion resistance. It is proved ß-phase acts as cathode and it has good ability to build passive layer in broad pH ranges. However it should be noted that mentioned behavior depend on size and distributions of ß-phase in the microstructure (Singh, Singh, & Das, 2015)."

Jan 1, 2016

By James M. Tantalla, Jr. Ellman

"Construction of the powerhouse for the Willow Island Hydroelectric Project, located at the Willow Island Lock and Dam, required a 120-ft deep temporary excavation inside the limits of a cellular cofferdam on the Ohio River side of the excavation and a soil-bentonite seepage cut-off wall on the landward side of the excavation. Stability analyses were performed for critical sections to evaluate the stability of the soil slopes and rock cuts using limit equilibrium, tension crack, and buckling analysis techniques. The stability analyses indicated adequate factors of safety through the landside embankment sections, and for the weighting berm soil slopes in front of the riverside cellular cofferdam. However, the results of deep-seated stability analyses through the rock supporting the riverside cellular cofferdam indicated marginal factors of safety for the 100-year flood condition. Consequently, the riverside portion of the excavation required enhanced stability measures, namely the installation of long, high-capacity rock anchors. Also, the dewatering system was modified to lower the site piezometric head to near the top of rock to improve the stability of the rock cuts.Thirty high-capacity rock anchors were installed on the upstream, riverside, and downstream sides of the cofferdam rock cut. The rock anchors consisted of multiple, seven-wire strands designed to provide the full-required design load at 60% of the strand capacity. Rock anchor loads varied from 1,968 to 2,074 kips. The maximum number of strands per anchor was 59. Bond lengths assumed an allowable bond stress of 100 psi based on the rock bond from pull-out tests.Project DescriptionAmerican Municipal Power, a nonprofit organization that owns and operates electric generation facilities for its member communities, has been in the process of constructing hydroelectric power plants adjacent to existing navigation locks and dams along the Ohio River. The Willow Island Hydroelectric Plant was recently completed on the West Virginia bank of the river adjacent to the US Army Corp of Engineers (USACE) Willow Island Lock and Dam. The plant is on the opposite river bank to the locks, and includes two turbine generating units with FERC rated capacity of 44MW at a 20-foot head differential. The Ruhlin Company of Sharon Center, Ohio was awarded contracts to construct both the cofferdam and the powerhouse. Construction began in mid-2011, and was completed in early 2016."

Jan 1, 2016

By K. K. Mamyrbayeva, G. Z. Guseinova, V. A. Luganov

This paper presents the results of theoretical and technological studies on leaching ore of Bozshakol deposit. The major oxidized copper mineral of Bozshakol ore is atacamite, and the content of malachite, azurite, cuprite, copper sulfide minerals is insignificant. The chemical composition of the test sample, with mass, %: 0.9 Cu; 55.00 SiO2; 22.40 AI2O3; 9.00 Fe2O3; 2.24 CaO; 3.56 MgO. Technological studies on leaching the ore were carried out with sulfuric acid 5, 15, 25 and 50 g/dm3 in one and multistage (up to 4 stages) countercurrents. Size of ore 1 mm, the ratio S : L 1: 4. It was found that with increasing of acid concentration from 5 to 50 at one-mode leaching the copper extraction reaches 55 %. At multistage leaching the copper recovery reaches 73 %, a productive solution containing g/dm3: Cu - 4; Fe – 1.2; Al – 1.1 at a pH of 2.8. When leaching the cinders obtained by ore roasting in an atmosphere with limited value of oxygen, with increasing of the roasting temperature from 650 up to 750 °? the extraction of copper from the Bozshakol ores reduced from 31.5% down to 24.4%. The rate of filtration is markedly increased compared with the crude ore. When leaching the cinders obtained by roasting in a nitrogen atmosphere a marked increase up to 87.2-88 % of copper extraction from Bozshakol ores is observed. As an extractant for the extraction of copper from the pregnant solution used LIX984N extractant in kerosene. On the basis of the calculations it was built extraction isotherm and modeled processes of copper recovery with the circuit 2E + 1P, allowing up to 93 and 96% extraction. The through extraction of copper from the ore in the electrolyte was 67 %. Technology is recommended for semi test.

Jan 1, 2016

"Energy efficiency in mining and minerals processing has attracted considerable public and industry attention because of the significant quantities of energy consumption involved. In this context the question of what are worthwhile targets for energy efficiency improvements ought to be of the highest priority. It is however worth taking a step back to avoid falling in the trap of taking preconceived ideas that have been reiterated repeatedly before as gospel. The aim of this paper is to highlight areas where new or alternative approaches could potentially be the better way forward. Some may come as a surprise to conventional industry thinking. Ultimately any such solutions are attractive to practitioners not just in an environmental but also in an economic sense, and hence should be targeted through applied research and development efforts. This paper highlights key aspects of each group of opportunities and some of the individual approaches to provide an overview of the current status quo.MINING INDUSTRY POWER UTILISATION – WHERE IS THE BIGGEST BANG FOR THE BUCK?The question of where is the biggest bang for the buck when trying to determine worthwhile targets for energy efficiency improvements has not always been reported on broadly enough, typically because industry practitioners operate in specific areas of expertise and comfort zone. Looking beyond the familiar doesn’t always come easy. Any technology or methodology consideration to address energy efficiency needs to take into account the context of alternative opportunities of superior value or risks not achieving desired uptake. The following sub-chapters have been ordered by magnitude of improvement potential as best as is possible, starting with the biggest first, and the smallest last. Some may be a surprise relative to conventional mining industry thinking."

Jan 1, 2016

By S. Parent, J. -F. Lepage, S. Glover

"Goldcorp – Eleonore’s 7 000 tonnes per day gold mill was started up in October 2014 and achieved commercial production in April 2015. During the first year, operation has faced challenges from grinding, flotation, sulfide cyanidation and tailing filtration to achieve targeted throughput, availability and recovery.The optimization of non-sulfide tails filter cloth lifetime and filter press availability had the most significant impact on ramp-up of both mill throughput and availability. A change in steel ball addition size to the grinding circuit was made to meet the targeted p80 of 65 µm. Various optimization efforts were conducted on the flotation circuit, intended to recover all sulfide-bearing minerals. The goal is to attain the environmental target of 0.12% sulfur in flotation tails (to eliminate acid mine drainage or AMD), while an average of 0.31% sulfur was obtained over the first months of 2015. Collectors, frothers, activators and hydrodynamic parameters were tested to improve the circuit desulfurization efficiency. High sulfide reactivity in pre-oxidation and cyanidation severely impacted dissolved oxygen levels and cyanide consumption. Studies were undertaken to understand the effects of mineralogy, grind size and leach conditions on gold dissolution kinetics and cyanide consumption. Efforts were focused on pre-oxidation to restore dissolved oxygen levels as well as optimizing both lead nitrate addition and pre-oxidation time.INTRODUCTIONGoldcorp Eleonore’s mill commissioning started in September 2014. It was considered to operate the mill at 3 500 tpd during design, as the mine was planning to operate at this throughput for the first year. However, with the stockpile of ore and a higher throughput from the mine, the mill was able to run at higher tonnage than initially anticipated.While increasing tonnage, a few bottlenecks were discovered and overcome in areas such as filtration and cyanide destruction. There were also recovery issues which were addressed in areas such as grind and sulfide leach. This paper focusses on the first complete year of operation ending September 30th 2015. A process description and the flowsheet are presented below and it will then go into detail about operational, metallurgical, mechanical and design issues experienced during the year."

Jan 1, 2016

By Gary English

"Tunnel safety is evolving as science, engineering and technology make advances. Applicable safety codes and standards simply do not cover all the potentials of design, construction and operation. This paper reviews a series of tunnel projects code gaps in Seattle USA that were uncovered during the design and construction of a new highway tunnel, conversion of bus tunnels to combined road and rail tunnels, new rail tunnels using TBM and NATM, conversion of a road tunnel to light rail, and retrofit of an existing road tunnel to add lanes and improve safety systems. The perspectives of the ‘fire code official’ (Authority Having Jurisdiction) on methods to identify and resolve gaps in safety code and standard regulations, while garnering the consensus of the owner, designer, and contractors are presented. Additionally, the emergency responder command perspective on safe tunnel design, tunnel rescue during construction and operational safety is explained TUNNEL SAFETY EVOLUTION The underground has become nearly the only option to provide essential transportation corridors to continue our economic growth in key global areas. Tunnels are not built on a whim. Often significant portion of a regions wealth are invested to meet current, and hopefully future transportation demands. There are more transportation tunnels being built now than at any time in the planets history. The location of these tunnels is often selected for us based upon regional demand. Most commonly under densely populated urban centers and between populations’ centers to bypass geologic conditions like mountains and water bodies. Tunnels are being built in unforgiving soils, between tectonic plates, in extremes environmental conditions and often, under the very heart of the highest density population centers on the planet. All of these locations can bring with it conditions that challenge our common assumptions about safety. These extraordinary locations and soils create risks for both those constructing the tunnel, and in design engineering to meet the ‘minimum’ requirements at the lowest costs. There is lengthy history of above ground safety. Most countries and major local jurisdictions have adopted, or created safety requirements for the construction of above ground buildings. Through decades of use, these safety requirements have evolved, changed and been expanded to cover a wide gamut of actual and potential safety risks. However, the use of the underground for tunnel transportation corridors has grown exponentially with limited attention to safety requirements."

Jan 1, 2016

By S. Banisi, A. Haji-Zadeh, A. R. Hasankhoei, M. Maleki-Moghaddam

At the concentration plant of the Gol-E-Gohar Iron Ore Company (Iran) three 9m × 2.05m AG (Autogenous) mills (fixed speed) are used in parallel in a dry operation. The test works conducted in a scale down mill with a diameter of 1m indicated that conventionally used "deflector" type liners did not provide efficient environment for grinding. In this research, to improve the grinding efficiency, a new design using low profile end liners incorporating radial ribs of proper height was investigated. In order to determine an appropriate liner design at different operating conditions, a 100cm×10.8cm model mill was used for experimentation. The special design of model mill made it possible to increase the radial ribs height in steps of 6mm up to 18.5mm. The transparent end of the mill enabled accurate trajectory determination by image analysis. The results indicated that the new lower height profile deflectors and 15.5mm-height (14.5cm in industrial scale) radial ribs improved the mill performance while avoiding excessive pressure drop across the mill and wear on the liner. The image analysis showed that the use of new liners increased the distribution of coarse particles across the mill cross section from 28% to 35%. A new liner design was proposed by decreasing the number of liners in each slice from 5 to 4 pieces. The thickness of the inner head liners reduced from 45cm to 30cm and the outer deflector liners replaced by radial ribs. The distance between the feed and discharge inner head liners increased from the original 115cm to 145cm which increased the effective length of the mill by 26%. The new design reduced the weight and volume of end liners by 9% and 23%, respectively. It was predicted that the new liners design increases the mill throughput by 10% and reduces the metal consumption by 20%.

Jan 1, 2016

By R. O. Loutfy, J. C. Withers

"Titanium powder is produced from a small fraction of sieved sponge, HDH of sponge or gas blown from a melt produced billet. Ore from foreign sources is chlorinated in a very high temperature fluid bed to make TiCl4, then vacuum distilled purified and then reduced to sponge by Kroll processing. Domestic ores of ilmenite or perovskite can be carbothermically reduced to Ti2OC which can be chlorinated at low temperatures of 250–400°C to produce TiCl4 which can be electrolyzed in a fused salt to Ti powder, or the Ti2OC used as an anode in electrolysis to produce Ti powder. The electrolysis process can be operated continuously to produce Ti powder at a lower cost than Kroll processed sponge including produce control size powder. Electrolysis processing was scaled up and operated at the commercial demonstration stage on a continued basis that verifies the potential of a low cost process to produce Ti powder.INTRODUCTIONTitanium and alloys of titanium powder have been elevated to strategic status resulting from a focus of producing meltless titanium components as well as a feed for additive manufacturing processing. However, the high cost of titanium powder has limited wide scale implementation of using titanium powder as a feed to any process to produce titanium components. Titanium powder free of alloying is available as sponge fines from the Kroll process as illustrated in Figure 1. Titanium alloy powder is much more expensive, also illustrated in Figure 1 produced from an alloy ingot or mil product as the feed and then transformed into powder by one of several melt form processes which accounts for the high cost of titanium alloy powder at approximately $60–150/lb. Ton lots of titanium alloy powder (i.e. Ti-6Al-4V) from one source is quoted at $120/lb. in the U.S. It appears that alloy powder production cost by current processing is not sensitive to volume."

Jan 1, 2016

By Technische Universität Braunschweig, K. Saksl, J. Furste, P. Eschenbacher, F. Brunke, D. Wolter, M. Kohnke, C. Siemers, J. Kiese, M. Schlemminger

"In general, titanium alloys combine outstanding mechanical properties with corrosion resistance and biocompatibility and are, therefore, used in many challenging applications. Nevertheless, for special products, well-tailored properties are required which might not be achievable by a specific design so that new or modified alloys are needed. In this overview paper, alloy development strategies performed at the Institute for Materials of the Technische Universitat Braunschweig are discussed at different examples, namely, (1) oxidation-resistant, microstructural-stabilized and cold-workable alloys for exhaust applications, (2) aluminum- and vanadium-free, medium-strength and cold-workable alloys for implants and osteosynthesis applications and (3) free-machining alloys by the addition of particles with low melting points for non-safety critical light-weight constructions to replace heavier steels, e.g. in automotive applications. A special focus is set on the alloy development techniques and the analyses carried out to achieve well-balanced properties by the optimization of the alloy compositions. INTRODUCTIONTitanium belongs to the allotropic metals and can therefore exist in two different equilibrium lattice modifications. Pure titanium crystallizes at 1668°C in a body centered cubic (bcc) structure called ?- titanium which at 882°C transforms to a hexagonal close packed structure (hcp), the a-titanium. A martensitic ?-to-a-transformation is possible at large cooling rates. This thermally induced hexagonal martensite is called the a'-phase. The transformation temperature named ?-transus-temperature (T ?) can be influenced by alloying elements (Peters & Leyens, 2002).For titanium alloy production typical alloying elements are aluminum (Al) and oxygen (O), both a-stabilizers shifting the ?-transus temperature to higher temperatures, whereas tin (Sn) and zirconium (Zr) only show a limited influence on the ?-transus temperature. The ?-stabilizing elements are subdivided into two groups: Niobium (Nb), molybdenum (Mo) and vanadium (V) stabilize the ?-phase between the melting point and room temperature and are therefore called isomorphous -stabilizers. Elements like copper (Cu), iron (Fe) or silicon (Si) also stabilize the ?-phase to lower temperatures but undergo a eutectoid reaction during cooling. ?-titanium then dissociates to a-titanium and an intermetallic compound. Consequently, these elements are called eutectoid ?-stabilizers (Boyer, Welsh & Collings, 1994)."

Jan 1, 2016

By C. Bateman, F. Calizaya

"This study presents the results of three laboratory experiments on pressure balancing carried out at the University of Utah’s coal mine ventilation model. The model includes simulations of two working areas, one longwall mine gob, and a set of stoppings and seals. It also includes a pressure chamber between the longwall face and the gob. The model is ventilated by one main fan and one bleeder fan. A carbon dioxide injection system, equipped with flow control valves operated by a microprocessor, is used to pressurize the chamber and to maintain the pressure in the chamber slightly higher than that of the gob. During each experiment, fan pressures and stopping resistances were changed, the carbon dioxide injection rate was regulated, and the differential pressures across the stoppings were monitored so that the chamber pressure is always kept slightly higher than that the gob pressure. Result of these experiments are reported in this paper. INTRODUCTION Spontaneous combustion (Sponcom) is a safety hazard in underground coal mines. The history of coal mining in the US is replete with mine fires and explosions. Sponcpm accounts for approximately 17% of the total number of fires recorded in the U.S. since 1990. In the U.S., by law, worked out areas in coal mines must be either ventilated by a bleeder system or isolated by explosion proof seals. Experience has shown that seals are not airtight structures and that they allow some leakage of air into or out of the gob. In fact, seals “breathe in and breathe out” with changes in barometric pressure (Francart 1997, and Chalmers 2010). These changes in pressure affect not only the methane emission rate but also the ingress of oxygen to the gob, the lower the pressure behind seals is, the higher the ingress of oxygen. In mines ventilated by a U-tube exhaust system, the gob is often kept under negative pressure. Under these circumstances, an increase in barometric pressure may cause an influx of fresh air into the gob. This quantity may be sufficient to start self-heating of the coal, which can lead to spontaneous combustion. Depending on the coal characteristics and the ventilation conditions, self-heating of coal can start at temperatures as low as 35 ºC. If the heat is not removed it will increase the coal temperature leading to ignition and fire. The risk of Sponcom fires can be reduced by isolating the mine gob using rated seals, and implementing a suitable ventilation system. However, isolation seals are not airtight structures, thus some leakage of air is expected unless the pressure in the gob is neutralized. The alternative is to use a pressure balancing system. This requires a thorough knowledge of the ventilation system, the seal/stopping construction techniques, the airflow behavior in the gob area, and the gas build-up behind the seal line."

Jan 1, 2016

By Megan Becker, Aubrey Mainza, Indigo Research Laboratories, Jenny Wiese, Gaynor Yorath, Lucy Little

Particle shape characterisation has an important role to play in mineral processing, to clarify effects of shape on rheology, equipment wear rates, comminution, classification, sizing and flotation. However in industry, shape characterisation is not routine, and the most commonly used shape descriptor in the field (circularity/ angularity/ sphericity) is not invariant. This study aims to investigate shape measurements for a fine particulate ore sample measured with different analytical devices. Two Automated Scanning Electron Microscopy devices with Energy Dispersive X-ray Spectrometry (FEI QEMSCAN® and Zeiss Mineralogic®), and a camera based image-sizer using dynamic image analysis (Retsch CAMSIZER® XT) were compared. Each device was used to analyse the shape characteristics of specific particles in both a coarse sample (–212/+150 µm) and a fine sample (-53 µm) of UG2 platinum ore. Circularity and Roundness frequency distributions obtained from the three devices were then compared. For selected individual particles, circularity showed higher variability than roundness, and the sample circularity distributions obtained by the three devices were completely different. It is clear that circularity data from different studies relying on different devices should not be compared on an absolute scale. The shape parameter roundness was found to be a more robust descriptor than circularity, and it can give a stronger indication of a particulate sample’s shape characteristics on an absolute scale. However, there were still significant differences in the roundness measurements obtained by the CAMSIZER XT and the two Auto-SEM devices, which was attributed to the dissimilar mechanisms of image capture.

Jan 1, 2016

By G. M. Ross, I. M. Ross, J. A. Scott

"The otherwise waste heat in many water streams in the mining industry can be used to provide space heating of adjacent infrastructure including laboratories, workshops, and offices. This can be achieved by using heat pump systems, which can work as a replacement or in conjunction with existing space heating. In the example investigated—process cooling streams at an ore smelter—the analysis provided illustrates that annual heating costs can be 19% lower and a simultaneous 62% reduction in CO2 emissions can be achieved.RÉSUMÉ Dans l’industrie minière, la chaleur qui serait normalement perdue des circuits d’eau pourrait servir à chauffer des structures adjacentes incluant les laboratoires, les ateliers et les bureaux. Cela pourrait se faire en utilisant des systèmes de thermopompes, qui pourraient remplacer ou s’ajouter au chauffage existant. Dans l’exemple étudié, des circuits de refroidissement de procédé à une fonderie, l’analyse fournie illustre qu’il est possible de réduire les coûts annuels de chauffage de 19 % et d’obtenir une réduction simultanée de 62 % des émissions de CO2."

Jan 1, 2016

By A. Zangooi, J. A. Finch

"A frother analysis technique based on the formation of a colored solution with UV-VIS absorbance proportional to frother concentration over a certain range has been developed. The calculation of concentration requires the comparison of the sample absorbance at a selected wavelength with a linear calibration (frother concentration vs. absorbance) constructed with values collected from solutions of known concentration (standards) at the same wavelength. It has been found that concentration ranges for preparation of standards can vary widely. An integration of our experiences into a databank can offer some guidance on the selection of standard concentrations. The databank includes results from the analysis of 37 chemical reagents, commercial frothers, and natural oils used in research work or at industrial sites. Grouping frothers by similar chemical structure or origin provides a good basis for selecting the standards to approach the maximum absorbance range for the spectrophotometer in use.INTRODUCTIONA technique to determine frother concentration on samples of industrial milling streams based on formation of a colored solution with UV-VIS absorbance proportional to frother concentration has been developed. The concentration is determined by comparison of its absorbance, at some selected wavelength, with those obtained by processing a series of solutions of known concentration (standards), at the same wavelength. It is desirable to have linear calibration (frother concentration vs. absorbance) over the widest concentration range. The upper concentration can be restricted by the instrument, as there is a maximum detectable absorbance (minimum transmittance), which can be reliably sensed by the UV-VIS detector (in most cases maximum absorbance is 3)."

Jan 1, 2016

By X. Cao, H. Huang, Z. Dai

"Crystal phase of copper-containing slag regulation by the slag viscosity, cooling speed and cooling method, where the slag viscosity is related to the temperature and alkalinity. According to the mineralogy properties of a copper-containing slag, experiments of crystal phase regulation and flotation were conducted. When the copper-containing slag that adding a small amount of calcium oxide was cooled slowly at a rate of 3°C/min and about 1050°C n a cinder inclusion system, the viscosity of slag can be remained under 0.25 Pa·S and more than ??% of copper particles that the grain size is larger than 20 ?m in slag. The whole flow of flotation experiment was carried out to recover copper from the copper-containing slag with crystal phase regulating and the copper concentrate grade was ?????%, the recovery efficiency of copper was 94.18%.INTRODUCTIONChina's annual output of copper slag is more than 6 million tons, the current total has reached 80 million tons. It is equivalent to 640 thousand tons of copper metal with the copper grade of 0.82%. Most of the smelting slag were storage. It is not only occupy the land and pollute the environment, but also make a huge waste of resource (Alp, Deveci, & Süngün, 2008; Carranza, Iglesias, Mazuelos, Romero, & Forcat, 2009; Gorai, & Jana, 2003), therefore, it is good way to achieve copper slag resources by the effective recovery of valuable component from copper smelting slag, which is an important measure of the current process of copper smelting slag and implement the central authorities to vigorously develop the circular economy, improve the recycling of resources, increase copper production of intensive development (Zhou, et al., 1994; Zhang, Zhang, & Wang, 2005). Currently, researches on comprehensive utilization of the coppercontaining slag made a much progress (Wei, 2004; Liu, Gai, Yang, Sui, Li, & Fu, 2008; Liu & Zhu, 2008; Zhang, 2010; Sun, Chen, & Tang, 2012; Qin, Wang, Ren, Wei, Peng, & Gu, 2012). Flotation is one of the most effective method to recover the copper from smelting slag, which has the features of low cost and high efficiency (Song & Liu, 2001; Zhang, Wang, & Li, 2012). But the copper particles in the copper smelting slag distribution is very uneven, and the thickness of the material is very serious. The copper content in the micro level is higher, the size of copper sulfide ore is less than 0.043 mm, which leads to the difficulty of the monomer dissociation (Tossavainen, Engstrom, Yang, Menad, Lidstrom, Larsson, & Bjorkman, 2007; Moustakas, Mavropoulos, Katsou, Haralambous, & Loizidou, 2012). In this study, according the process mineralogy of a smelting copper slag, the crystal of smelting copper slag was optimized by controlling the temperature, alkalinity, cooling rate and cooling method, which makes the fine copper mineral particles in the copper slag crystal further, and can be used to meet the particle size requirements of flotation, thereby enhancing the flotation of copper."

Jan 1, 2016

By E. McCullough, S. Gaillard

"Diesel particulate matter (DPM) remains a health concern in many underground metal/nonmetal mines, and has been regulated by the Mine Safety and Health Administration since 2002. While the NIOSH 5040 standard method for DPM monitoring is required to demonstrate regulatory compliance, the FLIR Airtec DPM Monitor can serve as complementary engineering tool. It is a handheld instrument that offers near real-time measurements. As part of an ongoing field study, the Airtec has been used to survey elemental carbon concentrations (a proxy for DPM) in an underground stone mine. Via “spot-checking” and more prolonged area monitoring, this effort was aimed at determining spatial and temporal DPM variation in several key locations. INTRODUCTION Diesel particulate matter (DPM) is the solid fraction of the exhaust emissions from a diesel engine. It is largely made up of elemental and organic carbon (EC and OC, respectively), which can be measured as proxies for estimating mass concentrations of DPM. The National Institute for Occupational Safety and Health (NIOSH) considers DPM to be a health hazard and potential carcinogen [1]. It is believed to cause and/or exacerbate respiratory illness upon inhalation, deposition, and retention in lung tissue [2]. Since DPM exists in both the micro- and nano-particulate ranges, it can surpass typical auto-immuno defense mechanisms that keep larger particles out of the respiratory system [2]. Relative to other occupations, the DPM exposure potential for underground miners is high because these individuals work in enclosed environments where diesel powered equipment is frequently used [3,4]. A variety of engineering and administrative controls have been devised to reduce DPM exposures in underground mines, and increased airflow is often a key component of control strategies. In large-opening mines, which are most common in the metal/nonmetal sector, DPM abatement via increased ventilation can be especially complex due to moving and controlling the large air quantities [5]. The Mine Safety and Health Administration (MSHA) has regulated DPM exposure in metal/nonmetal mines since 2002. The final rule limits personal exposure to total carbon (TC, which is the sum of EC and OC) to an eight-hour time weighted average (TWA) of 160 µg/m3. To demonstrate compliance, operators must use the NIOSH 5040 Method [6]. However, the Airtec DPM Monitor (FLIR Systems, Inc., Nashua, NH) was developed as an engineering tool to provide near real-time measurements of both EC and TC for tracking personal exposures [7]. The portable Airtec works by capturing DPM on a filter and successively measuring laser extinction on the filter as DPM accumulates; the EC fraction of the DPM is dark, and so as it accumulates the filter becomes darker and absorbs more laser light [8]. The laser extinction value is directly correlated to EC, but since EC and TC are generally observed in consistent proportions (i.e., TC = EC*1.3), the Airtec is also programmed to display TC as a TWA [9]. There have been multiple studies conducted to validate the Airtec and the instrument has been adopted by some mine operators as a tool for their health and safety programs [3,8]."

Jan 1, 2016

"The Mine Haul Road Optimization Alliance is an Australian industry-academia collaboration which has been developed to support mine haul road operators by fully integrating mine road design research solutions with industry end-user service providers to design, assess, implement and monitor the various equipment, materials and road management strategies required to optimize the safety, environmental and economic performance of a haul road. Initially, a broad overview of the university-industry collaborative landscape is presented, following which the current situation in the Australian mining sector is reviewed both nationally, and on a country-wide basis, internationally. This insight places realization of a collaboration between Curtin University Western Australian School of Mines Mining Engineering and Metallurgical Engineering (WASM ME2) and the Haul Road Optimization Alliance (HROA) industry members into context of opportunity. Following an overview of the HROA collaborative structure, aims and objectives, it is shown how academia and industry can collaborate to deliver a more robust solution to mine haul road design, performance or management needs, especially where integrated solutions are needed. Critically in this approach, implementation and monitoring data provided by industry and service-providers alike forms the foundation on which to develop research knowledge and innovation that is more responsive to the end-user requirements, typically represented by ‘early goals’ and implementable solutions. The paper concludes with examples of how the alliance collaborations work in practice to deliver improved mine haul road designs and optimized operational performance, together with the mechanisms used to ensure industry needs are met through focused, end-user driven research and integrated solutions implementation."

Jan 1, 2016