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By A. Y. Senchenko, Y. V. Kulikov

"Different methods aiming at specific energy calculation and design of AG/SAG circuits are used in mining. They include JK DWT/SMC test, SAGDesign test and CWi/RWi/BWi tests. The simplest methods with no secret equations and giving energy required for grinding in kWh/t were proposed by F.?. Bond and J.H. Starkey. D.J. Barratt proposed to use results of CWi/RWi/BWi tests for AG/SAG mill sizing. The present paper gives an alternative for forecast of specific AG/SAG energy. The principle is similar to the theory proposed earlier and consists in cumulative AG/SAG energy calculation using indices of rod and ball grinding (RWi+BWi) without impact crushing index (CWi). Then total energy is divided between two grinding stages using special formulas based on extensive statistical information. The forecast indices of AG/SAG and ball grinding are similar to the SAGDesign testing results. Hereinafter the predicted indices are used for mill sizing of the whole grinding circuit. The method considered in the paper enables prediction of AG/SAG energy based on the test results according to Bond method. The proposed method version was not widely published earlier. The aim of the work was to elaborate cost-effective, reliable and accessible way to determine specific AG/SAG energy. At this stage of method development, it is recommended to use it only for works at preliminary Geometallurgy stage (Scoping, Pre-Feasibility). At design stage the obtained data should be confirmed by appropriate testing using alternative JK DWT/SMC and SAGDesign methods.INTRODUCTIONAppropriate crushing and grinding testing is required to design efficient comminution circuits. It is obviously important to obtain accurate information about ore hardness properties since the main energy consumption at the plant is associated with comminution processes. Moreover, it is required to apply the processes that make it possible to minimize operating costs and efficiently use capacity of the installed equipment installed.When studying ore hardness properties, it is required to take into account that breakage of the material is performed using different equipment. That is why accurate selection of the equipment and the circuit calculation without relevant testworks is impossible. Ideally, the testworks should provide answers to the following questions: determination of ore hardness properties, determination of specific energy consumption for comminution as well as obtaining of sufficient amount of statistically significant results from the tests. The results from crushability and grindability testworks in the first place provide assessment of ore hardness properties and in addition correlate with throughput of the respective equipment. The data obtained can be used for modeling of comminution circuits at the stage of the technology development"

Jan 1, 2016

By G. Bulut, Ü. Yenial

"The use of recycled water in flotation has significant effects on flotation and selectivity because the recycled water contains many dissolved compounds and ions that alter the chemistry of the system. In this study, the effects of calcium, magnesium and sulfate, which are abundant components in recycled water, were investigated on galena, sphalerite and pyrite flotation using pure minerals and a complex sulfide ore by conducting bench-scale flotation, microflotation and zeta potential measurements. The bench-scale flotation tests indicated that higher recoveries of galena and sphalerite are obtained when water is recycled, due to higher concentrations of ions in recycled water. However, there was a critical ion concentration for galena recovery. The microflotation tests showed that galena recoveries at different pHs in recycled water are lower than in tap and distilled water. Pure sphalerite recoveries improved in recycled water in the bench-scale test with ore. Pure pyrite was depressed with recycled water as well. Zeta potentials became less negative with increased calcium and magnesium ion concentrations due to their adsorptions, and the presence of sulfate ions was seen to increase the negative charges of sphalerite and pyrite, conversely for galena. IntroductionWater is among the most important elements for mining and mineral processing. The distance to water sources is one of the major factors for mine site selection. The mining and mineral processing sector needs and consumes large quantities of water. In Chile in 2014, the copper mining sector alone consumed 12.7 m3/s fresh water for 1.189 tons of ore processing, and recycled 74 percent of the consumed water (Chilean Copper Commission, 2015). A plant that does not reuse or recycle any water will require 1.9 to 3.0 m3 of water per ton of ore processed (Gunson et al., 2012). Many stages of mineral processing, such as grinding, gravity concentration, dense medium separation, wet magnetic separation, flotation and hydrometallurgical operations, use large volumes of water (Schumann, Levay and Ametov, 2009).In mineral processing plants, the process water is recycled from the tailings dams, thickener overflows, and dewatering and filtration units. Wet concentration processes can require large quantities of water. Flotation, the most common process, typically takes place at 25 to 35 percent solids by mass. Most flotation plants practice at least some water reuse and recycled. Modern mines and mineral processing operations generally aim for zero water release (Levay, Smart and Skinner, 2001). In most cases, water quality has been found to affect flotation performance, and this interaction remains under investigation."

Jan 1, 2016

By K. Turgeon, J. -F. Boulanger, L. Whitty-Léveille, C. Bazin

"Several companies targeting Rare Earth Elements (REE) around the world have completed a Preliminary Economic Assessment showing positive project financial results. Although REE ores may contain high REE value, financing these projects remains difficult in part due to the number of processes required to valorize the elements and the relatively low yield of these processes. Direct ore leaching without the production of a concentrate may reduce the capital and some operating expenditures through process simplification, and increase revenues because of REE recovery improvement.A silicate REE ore is used to test various hypotheses regarding whole ore processing and to develop a simplified flowsheet. An atmospheric leach (200 kg/t H2SO4) of crushed whole-ore containing 0,6% REE, followed by impurity removal and REE precipitation recovers 80% of the REEs in a solution containing REE and Th. The high value contained in most REE deposits makes whole-ore approaches worth considering for most projects, given the losses of valuable species typically associated with the production of a REE mineral concentrate from the ore. INTRODUCTIONRare Earth Elements (REE) find applications in modern and clean technologies, whether civil, industrial or military. With China producing more than 90% of the world’s REE, the embargo imposed by this country in early 2010 increased REE prices for a three year period. With prices having shrunk back many-fold from their peak value, projects put forward during the hike are struggling to secure financing. Owing in part to unconventional processes such as acid-baking and solvent extraction, REE plants are high capital cost and high operating-cost units, and present technological risks (Verbaan et al., 2014)."

Jan 1, 2016

By L. Robles-Stefoni

"Multiple-point simulation (MPS) methods have been developed over the last decade as a means of reproducing complex geological patterns while generating stochastic simulations. Some geological spatial configurations are complex, such as the spatial geometries and patterns of diamondbearing kimberlite pipes and their internal facies controlling diamond quality and distribution.Two MPS methods were tested for modelling the geology of a diamond pipe located at the Ekati mine, NT, Canada. These are the single normal equation simulation algorithm SNESIM, which captures different patterns from a training image (TI), and the filter simulation algorithm FILTERSIM, which classifies the patterns founded on the TI. Both methods were tested in the stochastic simulation of a four-category geology model: crater, diatreme, xenoliths, and host rock. Soft information about the location of host rock was also used. The validation of the simulation results shows a reasonable reproduction of the geometry and data proportions for all geological units considered; the validation of spatial statistics, however, shows that although simulated realizations from both methods reasonably reproduce the fourth-order spatial statistics of the TI, they do not reproduce well the same spatial statistics of the available data (when this differs from the TI). An interesting observation is that SNESIM better imitated the shape of the pipe, while FILTERSIM yielded a better reproduction of the xenolith bodies. IntroductionThe simulation of geological units poses several technical problems that challenge the capabilities of available geostatistical simulation approaches and their ability to deal with spatial complexity of categorical variables. The spatial geometry of diamondbearing pipes and their internal facies controlling diamond distributions are a specific and well-known difficult modelling problem. The geometry of a kimberlite pipe is typically like an inverted cone (Figure 1); the wider part is known as the crater and is located near the surface, and the narrower, deeper part is known as the diatreme. Xenolith bodies can also be found inside the pipe. A very important contribution to the geological modelling of the contours of the pipe is the measure of uncertainty about the location of the contact between the kimberlite pipe and the host rock."

Jan 1, 2016

By C. Vass, A. Noble

"The chemical treatment of mine-influenced waters is a longstanding environmental challenge for many coal operators, particularly in Central Appalachia. Mining conditions in this region present several unique obstacles to meeting NPDES effluent limits. Outlets are often located in remote areas with challenging terrain where conditions do not facilitate the implementation of large-scale commercial treatment systems. Furthermore, maintenance of these systems is often laborious, expensive, and time consuming. Many large mining complexes discharge water from numerous outlets, while using environmental technicians to assess the water quality and treatment regime multiple times per day. As an alternative solution, this paper describes the ongoing research and development of automated chemical treatment systems for mine water discharges. The current work explains the development of a bench-scale prototype that has been used to evaluate various monitoring, notification, and control strategies. Results from this testing are compared to present day practices to show the costs and benefits of implementing an automated treatment and monitoring program. INTRODUCTION Background The National Pollution Discharge Elimination System (NPDES), per Section 402 of the Clean Water Act, requires permitting of all point source discharges from coal mines. This program dictates that all water leaving a permitted boundary, whether it be process water or storm water, must leave through a monitored NPDES outlet. These permitted NPDES discharge points, also denoted outlets, outfalls or monitoring points, must meet a rigorous set of effluent limits to maintain compliance. Common effluent limits monitored by coal companies include but are not limited to iron, manganese, aluminum, total suspended solids (TSS), and pH. Raw mine water is often deficient in meeting these effluent limits, and as a result, various treatment processes are required to bring the water into compliance prior to environmental release. Depending on the mining and geologic conditions, water monitoring and treatment programs can constitute a significant operating cost for the mine operator. In Appalachia, acid mine drainage (AMD) constitutes one of the most significant and widespread water quality challenges that must be treated per NPDES guidelines. AMD is a general lowering of water pH that occurs when water and sulfide minerals interact within oxidizing conditions in coal and metal mining. Acid Rock Drainage (ARD) is a similar term that applies more generally to non-mining causes such as highway construction and other large-scale excavations. Today, mine influenced waters (MIW) is becoming more popular as the general term referring to all types of mining-induced water issues. AMD has been researched substantially over the last 30 years, with investigators studying various causal mechanisms and treatment strategies (e.g. Gazea, 1996; Ziemkiewicz, 1998; Skousen, 2000; Kleinmann, 2001; Johnson, 2003; Akcil, 2006; Kalin, 2006). This research has produced several pragmatic results, which provide numerous methods to predict, prevent, and treat AMD."

Jan 1, 2016

By R. G. Eggert

"A critical element, as the term has come to be used, provides essential properties to a modern engineered material and is subject to supply risk. The rare-earth elements became perhaps the most prominent of the critical elements in recent years because of their important uses in permanent magnets, advanced lighting, and military materials; the geographic concentration of production in China; and the dramatic run-up in prices in 2010-2011 followed by price collapse between 2011 and 2016. Yet criticality extends beyond the rare earths. What is critical depends on your perspective – who and where you are, and when you ask. This paper reviews the many perspectives on, or faces of, critical elements. It compares and contrasts perspectives of industry (General Electric), national or regional manufacturing sectors (Japan, European Union), emerging energy technologies (as seen by U.S. Department of Energy and, separately, Joint Research Centre of the European Commission) and the world as a whole (as evaluated by academics). This comparison reveals a diversity of not only perspectives but also methodologies and time frames of concern.INTRODUCTIONRare-earth elements appeared prominently in the news in 2010 and 2011 because of the dramatic increase in their prices; their important uses in permanent magnets, advanced lighting, and military materials combined with the geographic concentration of production in China, which reduced export quotas significantly. Rare earths became the most prominent of what have become known as critical elements or materials – that is, those that provide essential properties to modern engineered materials and yet are subject to supply risks.Yet criticality, the state of being both essential and subject to supply risks, extends beyond rare earths. What is critical depends on your perspective. This paper begins by reviewing a little history and presenting a general conceptual framework from which to think about critical materials. It then reviews the many perspectives on, or faces of, critical elements – corporate, national, and global, as well several that focus on emerging energy technologies. The paper concludes with thoughts on what to do to mitigate the potentially negative effects of the supply risks associated with criticality."

Jan 1, 2016

By L. D. Roper

"This paper introduces novel comminution flowsheet concepts involving a novel apparatus, eccentric-high-pressure-centrifugal-comminution (eHPCC), and forthcoming advantages to the international mineral processing community. eHPCC is one-machine synergising high-pressure-rolling surfaces, high-intensity-attrition and centrifugal classification. eHPCC has demonstrated: an absorbed power- intensity of 4 MW/m3; receipt of lump feed whilst producing 80% of product particles less than (p80) 120 µm (choke-fed, dry, open circuit without grinding media; an inert comminution environment); tramp metal tolerance, and a minimum embodied-free-energy saving of 15% as compared against conventional comminution (this comparison withstanding 133-times difference in throughput). Furthermore, this paper introduces: process design and operating characteristics of eHPCC (wet, dry, with and without grinding media); reline considerations (vertical-lift without confined-space). The international mineral processing community is invited to consider eHPCC as an alternative to conventional comminution circuits and/ or complimentary so as to enhance existing process flow sheets.INTRODUCTIONEccentric-high-pressure-centrifugal-comminution (eHPCC) was conceived in 2013 (Patents pending) and has the potential to eliminate the in-efficiencies and complexity of conventional tumbling mill circuits. During the development and testing phase eHPCC demonstrated improved energy efficiency and sustainability offsets.eHPCC will compliment any upstream feed source, be it run-of-mine (ROM), primary crushed rock, or any other conventional comminution stream such as tumbling mill oversize. Another novelemerging technology, Conjugate Anvil-Hammer Mill (CAHM) (Nordell and Potapov, 2011), receiving ROM, will be a complimentary open-circuit feed to eHPCC for very high throughput flow-sheets.eHPCC may compliment downstream process requirements through selective mineral liberation. Selective mineral liberation is entirely feasible as the ore is comminuted upon itself (autogenously) in the high pressure zone caused by the synchronous rotating components."

Jan 1, 2016

By W. Jomaa, V. Songmene, O. Mechri, Laval Université, P. Bocher, J. Levesque

"A 2D finite element modelling (FEM), based on pure Lagrangian approach, is developed for studying the serrated chip formation during high speed machining (HSM) of 7075-T651 alloy. The solution was achieved using a commercial software package, ABAQUS/Explicit v6.13. The Johnson-Cooke (JC) constitutive equation is used to describe the work material behaviour. Moreover, the JC damage equation is implemented into the FEM to take into account for the shear localization during the serrated chip formation. Modified Coulomb friction model has been used to characterize the sliding/sticking effects on the tool-chip interface with the friction coefficient and shear flow stress determined by force calibration and machining data, respectively. The proposed FEM is validated using experimental data obtained in HSM of 7075-T651. The FEM was able to predict accurately serrated chip morphology. The intensity of chip segmentation was found to increase with cutting speed.INTRODUCTIONHigh speed machining (HSM) is one of the most used processes for manufacturing aircraft parts with aluminum alloys. For aluminum alloys, the use of HSM increases metal removal rate and reduces the formation of built up edges and burrs. However, it was found that serrated (also named segmented or sawtooth chip) and discontinuous chips can be produced during HSM of some high strength aluminum alloys, such as 7075-T6 alloy (Rao & Shin, 2001). Many parameters were found to affect the segmented/discontinuous chip formation during the machining of aluminum alloys.There are two cases in which the serrated chip can forms: the first is when machining hardened materials (Morehead, Huang, & Luo, 2007), and the second, when machining ductile materials with a cutting speed higher than a critical value (Barry & Byrne, 2002). Different theories and models were developed in order to explain the formation mechanism of such kind of chips. According to Astakhov (2006), the segmented chip formation is attributed to variations in stress and plastic deformation states, and resulting temperatures on the cutting zone. Liyao et al. (2013) stated that the segmented chip formation was mainly attributable to adiabatic shear instability/catastrophic strain localization. Others (Vyas & Shaw, 1999) suggest that the fracture/crack propagation mechanism is at the root of chip generation."

Jan 1, 2016

By D. Newman

"The U.S. stone industry is in a transition from surface quarries to single and multiple level underground stone mines. The factors driving this transition include surface quarries; ? reaching their economic stripping ratio, ? encroaching on the mineral reserve boundary where the remaining reserves are below the active pit, ? dust, noise, and blast vibration concerns as suburban neighborhoods and development move into formerly rural areas. Ground control is critical to the success of a safe and productive, mining operation. The primary focus of the ground control engineer in an underground stone mine is the stability of the roof or back, development and benched pillar stability, stability of the sill pillar between vertically adjacent mining levels, and floor stability. Roof stability begins with the selection of a stable back horizon based upon the presence of a thin shale parting, stylolite, or other discontinuities from which the production shot can easily ""peel"" away leaving a stable back stratum. Room width and the decision of whether to bolt the roof, the bolt length, bolt type, bolt diameter, and spacing of the support is controlled by the thickness, fracture spacing, jointing, and material properties of the back strata. Horizontal stress controls the header and crosscut azimuth as to avoid driving perpendicular to the maximum horizontal stress direction. Stable pillar dimensions depend upon the interaction of the; ? vertical stress resulting from overburden thickness and multiple level interaction of overlying level(s), ? mining height during development and the final mining height after floor shots are taken while benching, ? presence of faults, folds, or joints passing through the pillar, and ? stone lithology recognizing that the presence of oolitic bands, shale partings, and bentonite beds create zones of weakness that can destabilize an otherwise competent pillar. Floor stability is typically not a significant issue for underground stone mines because the bearing capacity of the stone exceeds the vertical pressure transferred through the pillar. However, floor heave can be a ground control issue where shale partings, moisture sensitive strata, weak stone bands, or horizontal stress is present. Roof stability and pillar stability problems can be initiated as the floor heave enables the pillar and roof to settle. The ground control issues for underground stone mines are most clearly presented through a series of case histories. The case histories presented in this paper are a mix of ground failures and successful mining. The focus is on the geotechnical data required for underground stone mine ground control for roof, pillar, and floor design and stability analysis."

Jan 1, 2016

By Giorgio Höfer-Öllinger, Peter Pointner, Manfred Stadlober

"SUMMARY Investigations from tunnel face are part of risk mitigation measures during the excavation works. With the tunnel equipment, percussion drillings of up to 30-40m can be achieved. Core drillings are state of art method for investigation exceeding 50m. At Koralm base tunnel, up to 270m deep percussion drillings were performed with drilling rigs and accompanied by an intensive investigation program. These investigations consisted of monitoring during the drilling, field tests (with packer, using the preventer, borehole imaging) and in laboratory. Percussion drillings are cheaper and save time of interruption of the excavation progress. INTRODUCTION As part of a proper risk management, horizontal advance drillings during excavation of underground works can be seen as state of art and meet wide acceptance. Core drillings, deep and shallow percussion drillings can be differed. The selection of the type of drilling, meanwhile, causes intensive discussions. On the one hand, only a core drilling allows a direct investigation of the rock mass expected during later excavation works. On the other hand core drillings are expensive in both cost and time – if there is no excavation progress during the investigation measures – in construction time. Percussion drillings can be performed as rapid investigation measure with the excavation equipment (“Jumbo”) allowing two dimensional image of the ground around the cross section. There is some limitation concerning a reasonable depth of approximately 30m and a borehole diameter of 76mm. The applications of preventer, packer or borehole imaging are hardly applicable. By use of a drilling rig depths of percussion drillings of several hundred meters can be achieved relative easily and there is less limitation of the borehole diameter. Installation of a preventer is possible, as well as packer tests and borehole measurements (imaging, gyroscope, borehole geophysics). The gap of information between core and percussion drilling cannot be closed completely, but it can be reduced substantially and sufficiently by combination of an intensive program of measurements and analysis accompanying the investigation works."

Jan 1, 2016

By Xiqing Wu, Liang Dai, Tao Yue, Longsheng Yi, Ruifang Wang

Magnetic seeding flotation (MSF), i.e. adding magnetic seeds and pre-magnetization-flotation, is a new flotation technology especially for fine particles, which improves the flotation performance by enlarging the apparent size of the particles in a way of magnetic agglomeration. Both the fine coal slimes with a size of 66.68% –38µm and the pyrite slimes with a size of 73.95% –23 µm were investigated by the MSF, respectively. Flotation tests with variable of dosages of magnetic seeds and polyacrylamide were conducted, and some measurements, such as laser diffraction size analysis, magnetic susceptibility by vibrating sample magnetometer (VSM) and infrared spectroscopy (IRS), were also applied in order to probe the mechanism of the MSF. Based on the tests, measurements and calculations it was found that both the recovery of coal and the flotation kinetics of pyrite slimes increased with the additions of the magnetic seeds, and in the presence of polyacrylamide the coal flotation was further strengthened due to a synergetic effect of magnetic seeds and polyacrylamide on the flotation and a relatively larger apparent size of slimes after additions of magnetic seeds and polyacrylamide. The reason for the MSF lies in fact that the presence of the polyacrylamide intensified the adsorption of magnetic seeds on the coal particles and increased the coverage of the magnetic seeds on the coal surface from 0.2 to 1.3 wt%, resulting in increased magnetic susceptibility of coal particles from 9.13×10-9 to 22.17×10-9 m3/kg and thus a low magnetic field strength of pre-magnetization needed for the magnetic agglomeration among the coal particles from 602 to 24 mT prior to proper flotation. IRS shows that polyacrylamide chemisorbed on the surfaces of both coal particles and magnetic seeds, thus acting as the bridging media between particles and seeds.

Jan 1, 2016

By M. N. Pons, F. Ferrari, V. Houzelot, B. Laubie, A. Bani, Université de Lorraine-CNRS LRGP

"More than 400 plants in the world are able to accumulate nickel in their aerial parts at concentrations higher than 10 g per kg of dry biomass. Then, nickel (Ni) can be recovered from the biomass of these hyperaccumulator plants. Agromining is a chain consisting in growing such plants and recovering metal and has been developed thanks to the combined know-how of agronomy and hydrometallurgy. Plants can be grown on serpentine soils, containing rather high concentrations of Ni, on sterile heaps or on contaminated soils. This crop enables us to extract Ni from secondary resources, and to improve soil quality by lowering its metal content. For example, Alyssum murale can be grown at the field scale in the Balkans, at yields corresponding to 110 kg Ni per hectare.Hydrometallurgical processes have been designed from the lab scale to the pilot scale to produce nickel salts: ANSH (ammonium and nickel sulphate hexahydrate), nickel sulphate, acetate, etc. and so on. These salts are used for surface treatment and in the paint and chemical industry. Ni salts are prepared from ashes, after plant calcination. Processes are based on the conventional methods of hydrometallurgy: acid leaching followed by different precipitation steps. These processes will be presented, as well as the pilot scale design. A life cycle assessment has been performed and clearly shows the environmental interest of this approach as a potential part of an anti-erosion strategy. An economic assessment has proved process feasibility and the final step is the launching of a start-up. At the moment, the approach is widened to other metals (cadmium, cobalt) and rare earth elements (REEs)."

Jan 1, 2016

By C. Musingwini, A. S. Nhleko, M. J. Mahase

"In an environment like the mining industry, which is characterized by different stakeholders with multiple objectives, multi-criteria decision analysis (MCDA) is a useful approach for optimal decision-making. The application of MCDA techniques in the mining industry has predominantly been in mine planning and related problems, although no comprehensive survey has previously been undertaken to establish the application trends. A survey of the use of MCDA techniques was therefore conducted using case studies from the literature. It was noted that often two or more methods are applied to the same problem in order to increase confidence in the solution derived. As the number of criteria and alternatives increases, some methods become inefficient. A combination of the analytic hierarchy process (AHP) method with other MCDA techniques was the most frequently used approach, indicating the efficiency of the AHP method, especially when evaluating problems with more criteria and fewer alternatives. A combination of fuzzy theory with AHP or other methods incorporates uncertainty. The findings from the survey will benefit users applying MCDA techniques to solve mine planning and related problems.IntroductionA country’s natural resources serve the needs of different groups of people within the country. These different groups are collectively known as stakeholders (Herath and Prato, 2006). Stakeholders have different needs, preferences, and expectations, which describe and define the criteria to be considered in decision-making. The options available as solutions describe the alternatives in decisionmaking theory. The criteria and alternatives have to be evaluated simultaneously when making decisions, and this is when multicriteria decision analysis (MCDA) techniques become invaluable (Herath and Prato, 2006) because the human mind is considered to be limited when solving complex and intangible problems with several criteria and alternatives (Saaty, 2007). MCDA techniques belong to a broad group of techniques called multi-criteria decision-making (MCDM) techniques. The other group of techniques within MCDM comprises the multi-objective decision-making (MODM) techniques. MODM techniques are generally used to solve problems with an infinite number of alternatives, while MCDA techniques are generally used to solve problems with a finite number of alternatives (Musingwini, 2010)."

Jan 1, 2016

By M. Shriwas, F. Calizaya

"Controlled recirculation may be considered as a beneficial means in mines of cold climate, where heating of air is required, and in deep or extensive mines, where cooling of air is required. Controlled recirculation can be designed by proper sizing of the booster fans with respect to main fan. Intuitively, it seems that the buildup of methane at the face will cease when a steady state condition is attained, and also that, at that same time, the maximum concentration at the face will remain same as in the return air. This supposition is proved by mathematical analysis that considers uniform mixing of methane in air in successive cycles of recirculation. This study includes two scenarios to show the effect of controlled recirculation on methane concentration in a sample network. Firstly, when recirculation crosscut exists near the working face; secondly, when recirculation crosscut exists away from the working face. The later scenario shows lesser buildup of methane concentration than the former one. INTRODUCTION The controlled recirculation is designed purposefully to allow a partial fraction of used air that increases the air velocity due to increased quantity of air and consequently allows effective dilution of contaminants to improve local ventilation condition at the working face. It can be designed by proper sizing of booster fan with respect to main fan in a ventilation network. Controlled recirculation may be categorized as crosscut, in-line or combined system based upon the configuration of the booster fan locations in a district ventilation network. Research on controlled recirculation has shown numerous benefits of controlled recirculation especially in deep or extensive underground mines, where further heating or cooling is required (Calizaya 1990; McPherson 1993 and Jones, 1987). However, fear of buildup of concentration has misled the mining communities to view the controlled recirculation as a hazard and deprived the mining industry to derive benefits from recirculation. Intuitively, it seems that the buildup of methane at the face will cease when a steady state condition is attained, and also that, at that same time, the maximum concentration at the face will remain same as in the return air. This supposition is proved by mathematical analysis that considers uniform mixing of methane in air in successive cycles of recirculation. This study includes two scenarios to show the effect of controlled recirculation on methane concentration in a sample network. Firstly, when recirculation crosscut exists near the working face; secondly, when recirculation crosscut exists away from the working face. The later scenario result shows the less buildup of methane concentration than former scenario result."

Jan 1, 2016

By L. A. Cornish, I. A. Mwamba, R. A. Couperthwaite

"In previous work by the authors, it was established that additions of 0.2 at.% Ru to an Fe-40 at.% Al alloy improved the corrosion and oxidation resistance of the alloy. The alloy was produced by mechanical alloying and spark plasma sintering and the work showed that nonequilibrium processing was able to significantly refine the grain size of the material. The sintered material had a higher hardness than the as-cast material and the change in grain size did not significantly affect the oxidation and corrosion. In the present research, the mechanically alloyed powder was coated onto a mild steel substrate using cold-spray coating at a gas pressure of 10 bar and a temperature of 500°C. The coatings were found to be 5–10 um thick, although thicknesses of up to 30 um were observed. The coated materials were subjected to oxidation and corrosion tests to determine the effectiveness of the coating in increasing the oxidation and corrosion resistance of mild steel. This was done to determine the effectiveness of cold-spray coating as a technique to coat these mechanically alloyed powders. IntroductionPrevious work conducted by Mintek (Couperthwaite et al., 2013, 2015) investigated the effect of precious metal additions on the structure, oxidation and corrosion properties of an Fe-40 at.% Al (Fe- Al) alloy. Initial work determined that additions of more than 0.5 at.% precious metal did not improve the oxidation and corrosion properties of the materials and in some cases even decreased the resistance to corrosion. Further work identified Pt and Ru as beneficial additions to the FeAl alloy. Four alloys were then produced by mechanical alloying and sintering (FeAl–0.2 at.% Pd, FeAl–0.2 at.% Ru, FeAl–0.5 at.% Ag, FeAl–0.5 at.% Pt). These alloys were all successfully produced by melting and casting and mechanical alloying sintering and it was found that the nonequilibrium processing greatly decreased the grain size of the materials compared to the ascast materials. It was found that the additions of Ru and Pt were still the most beneficial to the oxidation and corrosion properties, with Ru being considered the most beneficial."

Jan 1, 2016

By P. W. Conrad, C. Todd, N. West, R. Kramer

"Surface subsidence caused by both underground room-and-pillar mining operations and solution mining operations have each been studied separately, but never combined. In 2008, FMC Minerals began using solution mining at its Westvaco Mine as a secondary extraction method in an area that had been previously mined using the room-and-pillar mining method. Mining regulations require that subsidence associated with underground mining activities be monitored and measured annually. Researchers at Montana Tech were able to develop a relationship between measured surface mine subsidence and solution mining that can be used at the Westvaco Mine to estimate the production of trona from solution mining operations. PROJECT BACKGROUND FMC Minerals (FMC) has increased the production of trona from its Westvaco Mine near Green River, Wyoming, using solution mining as a secondary extraction method in an area previously mined using the room-and-pillar method. The area of interest was mined until 2001 with the use of a borer miner at a depth of approximately 1,600 feet. Currently, FMC determines the amount of trona produced using its solution mining operations by measuring the dissolved solids pumped from the mine. This approach, however, does not account for the location from which the trona was removed. The location from which the trona was removed and the size of the cavern created by the solution mining operations is important to FMC’s mine planning. FMC believed that with proper investigation of the subsidence at the Westvaco test site, a correlation might be found that would allow for the use of surface subsidence measurements to estimate the amount and location of trona production from the solution mining activities. The primary goal of this project, conducted by Montana Tech, was to find a relationship between the measured subsidence and the solution mining activities. The project attempted to model the relationship between the measured subsidence and the solution cavern using Salt_Subsid, an existing subsidence software package from the Solution Mining Research Institute (SMRI), to determine the program’s usefulness for locating and developing the cavern created by solution mining activities. The project also attempted to develop an equation that could be used to predict solution trona production based on measured subsidence. The data used in this study were collected over a seven year period, 2008 through 2014."

Jan 1, 2016

By R. Roufail

"Energy consumption in stirred mills has been studied, in the last couple of decades, on a macro scale. Effective operation and meeting particle size required for downstream operations used to be the main objectives behind energy utilization of stirred mills. In this paper, three energy terms are defined to assist in understanding the breakage mechanism for various types of minerals versus mill operation. The types of minerals studied had diverse physical and mechanical properties that are summarized as specific gravity, hardness and crystal structure. The minerals utilized in this study were quartz and galena. The effect of quartz and galena mix has been addressed as well as Lead-Zinc ore sample from SAG mill discharge. The energy input to the mill is function of the agitator speed, therefore three agitator speeds were evaluated, 1000, 1500 and 2000 RPM, respectively. The energy terms studied are specific energy (kWhr/ton). Effective energy is the ratio between net energy and total energy consumed by the mill. Last type of energy is the specific breakage energy, which is the net energy consumed by the mill per one-micron breakage. Results showed that specific energy and specific breakage rate are functions of mineral type, while effective energy is only function of mill input power (agitator speed).INTRODUCTIONGrinding is the largest energy consuming component of a mineral processing operation and typically consumes about 50% of the total energy used at a mining operation (Botin, 2009). Over the last two decades, stirred mills have been extensively utilized in mineral processing operations due to increased mineralogical complexity of ore bodies. Stirred mills grind particles to less than 10 µm by applying a high power intensity. The technology has been the focus of several research studies to investigate mill energy and grinding mechanisms. Becker, et. al. (2001) studied the relationship between different types of energy including input energy, specific energy, volume/mass specific energies, to stress intensity and final product particle size. Other studies such as by Kwade (1999), Kwade and Schwedes (2002), Blecher et al (1996), Partyka and Yan (2007), Stender et al (2004), focused on mill design and/or stress intensity distribution. Peukert (2004) studied the effect of mechanical properties of the grinding media and ground material on the comminution process."

Jan 1, 2016

By Jan Drzymala, Przemyslaw B. Kowalczuk

Froth flotation is widely used for upgrading of ores and other materials. Efficiency of flotation depends on many parameters, including type, chemical structure and dose of flotation reagents. Selection of a proper frother in flotation depends on the material used, necessary dose of frother and its selectivity. The selectivity of flotation can be characterized by proper separation factors and indices. In this paper separation selectivity and power of frothers were evaluated basing on separation data for a given material and frother, plotted as the recovery of the useful component in the concentrate versus the recovery of the remaining components in the tailing. Such a plot is called the Fuerstenau upgrading curve. The selectivity was defined as the location of the whole upgrading curve in relation to no and ideal separation lines, expressed on the scale from 50 (no separation) to 100% (ideal separation). In turn, the flotation power was defined as the dose of frother to reach a certain upgrading level at which recoveries of the useful and unwanted components are equal. The power and selectivity of frothers were determined for the Kupferschiefer stratiform copper ore floated in the presence of a fixed amount of xanthate and varying doses of frothers using a laboratory flotation machine. Basing on the separation results for different poly(propylene glycol) (CnH2n+1O(C3H6O)mH, CnPm) and poly(ethylene glycol) (CnH2n+1O(C2H4O)mH, CnEm) alkyl ethers, it was found that the concentrate yield and recovery of copper as the useful component in the concentrate were greatly influenced by the type and dose of frother. However, the same results plotted in the form of the Fuerstenau upgrading curve clearly indicated that the selectivity of frothers was similar, while their power was different. It proves that both selectivity and power of frothers are useful parameters for characterizing flotation systems.

Jan 1, 2016

By Shingo Morimoto, Toru Sasaki, Masato Shinji

"1. INTRODUCTIONTunnel face stability is one of the most important consideration in New Austrian Tunneling Method. In general, if all of the material properties of ground can be obtained through the field investigations, the tunnel face behavior can be predicted using numerical simulation prior to tunnel construction. However, estimating the safety of a tunnel face is difficult, especially in cases where the ground is very weak such as in an urban area.In this study, numerical analyses of tunnel excavation in very weak ground conditions, such as a low cohesion and low internal friction angle, were carried out. The relationship between the average shear strain distribution on the tunnel face and the overburden was analyzed. This relationship estimates the shear strain of the tunnel face relative to the critical shear strain obtained by the ground properties. The critical shear strain was defined as an allowable value for the maximum shear strain. We proposed the allowable overburden as tunnel face stability index (TFI) that satisfies the critical shear strain criterion of ground. Finally, a design chart of the allowable overburden for various cohesion values and friction angles of ground was created. This chart is useful in the preliminary tunnel design stage to judge the necessity of additional counter measures against normal tunnel support design.2. WEAK GROUND MODELING AND ANALYSIS PROCEDURE2.1 Setting material propertiesWith reference to a past study1), the material properties were adopted on the basis of material properties in the standard worst rock classification case called “DII”2) for standard support pattern of weak ground in Japan. The typical material properties for “DII” are listed in Table 1. In addition, Fig.1 shows the distribution of the representative weak ground according to cohesion and internal friction angle. When the internal friction angle is relatively high and the cohesion is weak, the ground is categorized as sandy ground. Furthermore, when the internal friction angle is low and the cohesion is strong, the ground is categorized as clayey ground."

Jan 1, 2016

By Shengliyang Yang, Jinghu Yang, Jiachen Wang, Xiaomeng Li

"Safe and efficient mining of extremely inclined thick coal seams less than 20m thick is one of the new challenges in China coal industry. In recent years, the extremely inclined thick coal seams have been encountered in some old mines and western China, and currently the top coal caving longwall mining method has been successfully applied to this kind of coal seams. Accordingly, this paper studies the roof movement and its impact on shield supports of top-coal caving longwall mining in extremely inclined thick coal seams. The structure of main roof before failure was simulated by the fix-ended beam, and provided the solutions for determination of maximum compressive stress of the bottom beam end and maximum tensile stress of the top beam end. The failure mode on the upper end of working face is mainly a combination of compression and shearing, while that for the bottom end is tension and shearing. Roof fracture begins at the upper end of working and propagates downward. The shape of collapsed roof strata can be described as parabolic and divided into three segments from top to bottom, including no filling, uneven filling and densely filling segments. The roof loading conditions of no filling segment is more likely to have dynamic burst impacts.INTRODUCTIONExtremely inclined thick coal seam refers to that the dip angle of coal seam is greater than 45° and the thickness is greater than 3.5m (Wang and Zhang, 2015a; Wang and Zhang, 2015b; Wang, 2005; Xie, Gao, and Shangguan, 2005; Wu, et al., 2014; Deng and Wang, 2014; He, et al., 2015). This type of coal seams can be divided into three categories: 1. The extremely inclined thick coal seam, of which the thickness is less than 5m and the dip angle is less than 60°, is usually mined by fully-mechanized longwall mining method. 2. The extremely inclined thick coal seam, of which the thickness is 5 m-20m, is usually mined by top coal caving longwall method. And 3. When the thickness of extremely inclined thick coal seam is greater than 20m, it is mined by the horizontal section top coal caving longwall method. For example, the average angle ofWudong coal mine in Xinjiang province is 45°, and the thickness is 27m. Wudong coal mine is applying the horizontal section top coal caving longwall mining, producing 3 million tons annually per working face (Figure 1)."

Jan 1, 2016