Search Documents

By William Skinner, Jim Pae Lem, Massimiano Zanin

It is well known that the specific density of minerals has adverse influence on the classification performance of a hydrocyclone, particularly when liberated high density minerals such as gold or uranium are present in sulphide ores. These liberated heavy minerals often misreport to the underflow and recirculate to the system. Such phenomena does result in serious issues in a closed-grinding circuit, such as overgrinding, leading to production of flaky particles (as in gold) or ultrafines, in addition to increased energy inefficiency. In plants which present gold liberated at coarser size, loss of gold due to cyclone inefficiency is sometimes prevented by incorporating gravity concentrators into the grinding circuit to recover the gold. The work reported in this paper looks at whether the effect of density will prevent successful rejection of liberated U-bearing minerals in the –10µm size range of a plant re-cleaner feed, which is necessary to minimize penalty U accumulation in a copper concentrator. The study was carried out using a cyclone rig with spigot diameter of 0.25 inches in combination with batch flotation. It was found that the density effect is almost negligible at particle sizes below 10µm. Consequently, the liberated U-bearing particles finer than 10 µm were successfully removed in the overflow stream as rejects and hence U grade in the copper concentrate remarkably reduced, by 16 ppm. Based on the results, de-sliming of the re-cleaner feed was recommended for plant trial and implementation.

Jan 1, 2016

"A cationic surfactant, tetradecyl tributyl phosphonium chloride (TTPC), was first used as a collector. Flotation characteristics of muscovite using TTPC have been investigated through flotation tests. And dodecyl trimethyl ammonium chloride (DTAC) was tested for comparison. Their adsorption mechanisms on muscovite surface were clarified using zeta potential measurement, DFT calculation and molecular dynamics (MD). The flotation results indicate that the recovery of muscovite decreases when the pH increases in the presence of surfactants. When a maximum of recovery was reached, the dosage of TTPC was 2×10-5mol/L which was half of that of DTAC. Zeta potential measurements confirm that the TTPC displays a stronger collecting power than DTAC and is a superior collector for the muscovite flotation. DFT calculation and MD simulations show that TTPC interacts with the muscovite mainly through electrostatic attraction and hydrogen-bonding. The conclusions drawn from purely theoretical computations matched remarkably well with the experimental results. Keywords: Quaternary phosphonium salts; Flotation collectors; Flotation INTRODUCTION Muscovite mica is widespread in igneous, sedimentary and metamorphic rocks. It has the general composition KAl2(AlSi3O10)(OH)2. Muscovite mica exhibits perfect cleavage along the (001) plane, which exposes interlayer potassium ions[1-3]. In aqueous suspensions, the potassium ions readily enter into solution, leading to the development of a net negative charge on the (001) plane[4-6]. The surface of the muscovite mica is negatively charged at all pH > 1[7]. Due to the negative charge surface over the whole pH range of 2–12, the muscovite mica would not be expected to respond to anionic collectors in the absence of an activator. Conversely, the mineral is readily recovered using cationic collectors. However, until now, various amines and their derivatives (with N atoms as the center) are still the only available cationic collectors which still had their shortcomings such as weak selectivity, low flotation speed. Since few types of cationic collectors could be used, in some sense, the limitations of collectors are increasing significantly and the cationic flotation is facing more and more challenges. Quaternary phosphonium salts, as novel cationic surfactants, are widely used in antimicrobial, catalysis and surface modification field due to their biological activities, hydrogen bonding capability, stability and superior group electrical property[8-10]. There are a number of processes where quaternary phosphonium salt surfactants have shown better properties than quaternary ammonium salts and amines. Although the adsorption of quaternary phosphonium salt surfactants at the bacterium–liquid interface has been studied thoroughly, the case of adsorption in mineral surface has not been investigated thus far."

Jan 1, 2016

By Dale S. Preece, Ruilin Yang

Shock wave physics is an important part of air-deck behavior since the bulk explosives in the column impart a shock into the air-deck where the air shock then passes through the air-deck at a rapidly attenuating velocity. Through both high-fidelity modeling and shock physics theory it is shown that the resulting pressure in the air-deck is two orders of magnitude less than the detonation pressure of the explosive. The induced air blast reflects from the bottom of the borehole and this reflected pressure, even though doubled, is still approximately two orders of magnitude less than the detonation pressure. Air-shocks will ring back and forth in the air-deck for a few tens of milliseconds while the adjacent explosive column(s) are detonating. Transmission of the initial shock through the air along with reflections is an intensive energy consuming process. Energy balance results in shock heating of the air and a temperature increase. However, the increased temperature of the air is also orders of magnitude less than that of the explosive detonation products immediately behind the detonation front. Replacing high energy explosives with zero energy air-decks in a blasthole will always have a negative impact on the adjacent rock fragmentation and movement.

Jan 1, 2016

By L. Zeka, I. Ndala, J. Frenay, S. Gaydardzhiev

"Reductive leaching of cobalt (III) from a heterogenite bearing ore has been performed. Pyrite was added to the system and simultaneously bioleached in order to provide ferrous iron as reducing agent. Within such arrangement the iron ions are continuously re-circulated inside a Fe 3+ / Fe 2+ loop. As a result Co(III) is solubilized in the presence of Fe 2+ ions in concentrations well below the stoichiometric requirement. The ore has been initially subjected to acid pre-leaching in order to guarantee that the available Co (II) has been entirely removed. Two technological parameters have been studied to show influence on the degree of cobalt leaching: concentration of ferric iron in the inoculum and the presence of bacteria. The bacterial role could be mainly viewed in supplying ferric ions in the system which chemically react with the pyrite to generate ferrous ions used as Co(III) reducing agent. Co(III) dissolution has been less efficient when the concentration of total iron in the system was low, but also when microorganisms were absent. SEM observations on leached heterogenite have evidenced bacterial attack on the mineral; however the precise role of bacterial presence on cobalt (III) leaching is still to be elucidated.INTRODUCTIONCobalt accompanies quite often copper in secondary oxidized ore deposits (Rumbu, 2013). In such associations cobalt is found both as CoII+ as well as CoIII+ (Deliens, 1974). In contrast to cobalt (III), cobalt (II) is leached relatively easy in sulphuric acid solutions. Cobalt (III) when present in mineral form belongs to the heterogenite mineral group with a simplified chemical formulae Co2O3.H2O or CoOOH. In order to be brought in solution, heterogenite should capture two electrons, likewise shown in reaction 1 below:"

Jan 1, 2016

By Peter Johnson, David Barber, Lachlan Henderson

"Within underground portions of metro rail networks the traditional approach to a design fire has been to assume a worst credible railcar fire and develop ventilation and egress measures for life safety. This approach is being challenged as a rail network approach to design fires becomes a more practical and realistic approach. The network approach is based on utilizing an in-depth hazard analysis, to understand ignition and fire load sources in tunnels, above and below the floor of the railcar and within stations, and then utilizing a quantitative risk assessment to determine sets of fire scenarios. The process allows small, medium and large fires to be considered, with the consequences also being quantified. The selection of design fires has a significant influence on fire protection measures within a metro network and hence, is a major cost input. The rail network approach provides more robust decisions on fires, based on the hazards present. INTRODUCTION A fire within a rail car or one that occurs as part of a rail system can threaten the lives of users, maintenance staff and emergency services personnel. Fires in metro systems are rare events but can have severe consequences. As a result, any analysis of a potential fire must be thorough and rigorous and address not only regular accidents and small fires, but also very low probability, high consequence scenarios. The fire safety design process for a tunnel and station must start with the design engineers, contractor and operators making a number of key decisions related to fire protection measures, which may have significant cost considerations. One of the key aspects that influences the required fire protection is the design fire and the design fire scenarios, which is a key input for analysis. This paper provides an overview of the author’s experience in designing fire protection measures for rail networks in Europe, Australia and NZ, where a risk based framework is used to develop design fires and scenarios for the whole rail system – trains, stations and tunnels. This system wide approach is innovative, challenges the norms, but provides significantly more informed outcomes. The range of design fires will include small fires that may halt the network, larger fires for smoke hazard system design and significant post-flashover fires to assess the structural response."

Jan 1, 2016

By Mike Johnson, Greg Andrews, Niels Verbaan, David Dreisinger

"The Search Minerals Foxtrot project in Labrador represents a significant Canadian resource of rare earth elements rich in the sought after heavy rare earth elements (19.8% HREE/TREE). A preliminary economic assessment of the project indicated that the project is technically feasible and economically attractive. A variety of metallurgical test programs have been undertaken which have led to significant streamlining and simplification of the process flowsheet. The improved flowsheet should allow Search to reach production earlier and will use conventional processing equipment. The results of these test programs are presented and discussed in this paper INTRODUCTIONSearch Minerals Inc. (Search) is exploring and developing a number of deposits for rare earth element (REE) recovery in Labrador, Canada. The Port Hope Simpson District is in the southeast of Labrador and is highly prospective for heavy and light rare earth elements. The Foxtrot deposit sits within the Port Hope Simpson REE District (Figure 1), which is 70 km long by up to 10 km wide. The infrastructure available at Foxtrot is excellent; a deep-water port, air strip, and road and power infrastructure are pre-existing at St. Lewis. The three communities of Port Hope Simpson, St. Lewis and Mary’s Harbour are in close proximity to the site."

Jan 1, 2016

By Raymond Sandiford, Taehyun Moon

"In 2012, Superstorm Sandy (Sandy) caused extensive flooding in many of the tunnels in New York City. The inundation resulted in two distinct stress changes to the tunnel structures. The first stress change was water pressure on the inside face of the tunnel lining. The second condition related to the change in buoyancy of the tunnels. In areas where the tunnels were supported on rock and an adjoining area supported on soft soil, overstress issues arose. Numerical analyses were performed to assess the structural impacts of the tunnel water inundation; especially stress changes due to internal pressure as well as changes resulting from the buoyancy effects. The paper will discuss the assessment process and its results; it will demonstrate that the change in internal pressure were of little consequence, however the change in buoyancy resulted in significant increases in bolt stresses. INTRODUCTION Superstorm Sandy caused tens of billions of dollars in damage in the NYC metropolitan area. It also caused significant disruption to the transportation system by flooding most of the under river tunnels servicing Manhattan from the outer boroughs and New Jersey. The rehabilitation of the tunnels was of paramount importance to the restoration of the NY and NJ economies. With this rapid restoration, it was essential to determine whether the flooding of these tunnels caused damage to tunnel structures. A series of analyses were undertaken to ascertain whether the change in the stress conditions and buoyancy of the tunnels, due to the flooding, was significant enough to cause damage or over-stressing of the tunnel components. The effects of this unforeseen loading condition was a concern to the agencies operating these tunnels and were thus analyzed to ascertain if there were any adverse impacts. This was a concern because the majority of under river tunnels in NYC was built earlier in the century and constructed using bolted cast-iron lining segments. The cast iron, although quite strong in compression, is much less so in tension. Also, after nearly a century of use, the bolts connecting these segments together have under gone varying degrees of corrosion. The stress changes in both the liner segments and the supporting bolts were estimated for conservative ground support conditions to provide confidence that the flooding had not caused permanent damage."

Jan 1, 2016

By Ralf Winterberg, Axel G. Nitschke

"Macro synthetic fiber reinforced concrete or shotcrete is seen by many design engineers as offering a viable alternative to steel reinforcement in tunnel linings. The technology is now commonplace for primary and permanent ground support in both mining and civil tunnel applications. It has for instance become the standard form of reinforcement in the Australian mining industry, and has been used for a majority of permanent tunnel linings in recent tunnel construction in Norway. Similarly, macro synthetic fibers are becoming a standard solution for the initial lining in the USA.The use of macro synthetic fiber offers innovative solutions, yielding robust and sustainable tunnel lining designs. Citing recent research and actual projects, this paper presents state-of-the-art design considerations for fiber reinforced tunnel linings relating to structural and long-term performance. Topics include seismic resistance, crack width control, corrosion and durability, as well as sustainment of performance with age.INTRODUCTIONMacro synthetic fiber reinforced concrete (MSFRC) and shotcrete (MSFRS) has reached maturity as an engineered material and is widely used in all forms of tunnel linings, for temporary as well as permanent ground support in both, mining and civil tunnel applications. In the Australian underground mining industry, it became the standard form of reinforcement, where 2014 literally marked the end of steel fiber use in shotcrete [1], and has been used for over 80 percent of permanent tunnel linings in recent tunnel construction in Norway. Similarly, macro synthetic fibers are becoming a standard solution for tunnel initial linings in the USA. Recent examples in civil tunneling are the Devil’s Slide Tunnel and Caldecott Fourth Bore Tunnel in California or the Anacostia River Tunnel Intershaft Connector Tunnel in Washington D.C. In addition, an increasing number of tunnels are adopting shotcrete permanent linings using macro synthetic fibers. Examples include the A3 Hindhead tunnel near Guildford in the UK and the North Strathfield Rail Underpass in Sydney, Australia [2, 3]."

Jan 1, 2016

By J. F. Childs

"INTRODUCTION Comprehensive overviews of the world-class talc deposits and related prospects in Montana were published by Olson (1976) and by Berg (1979). Both of these compilations include detailed descriptions and maps of the talc deposits and occurrences and were followed by a regional map and summary descriptions of the talc deposits published by Van Gosen et al. (1998). More recent publications, descriptions and field guides for some of the deposits include Underwood et al. (2014), Cerino et al. (2007), and Cerino (2002). The present paper focuses on some of the more recent ideas regarding talc formation that have developed since the publication of the earlier overviews. Olson (1976) reported that talc production from the deposits in southwestern Montana was over 200,000 tons in 1974 and that talc production had doubled between 1969 and 1974. The last year for which the U.S. Geological Survey published production records for talc by state was 1993. Production in Montana in 1993 was 350,000 tonnes (Virta, 1994). Remaining reserves are substantial at all three of the producing mines in the district. Minerals Technologies Inc., the parent company of Barretts Minerals Inc., stated in its 2014 annual report that it has reserves of 2,791,000 tons of talc. Imerys stated in its financial report for 2014 that it had 19,638,000 tons of proven and probable talc reserves at its North American mines. Although the Imerys reserves were not reported by individual mines or states, a large proportion of the total reserves would likely consist of the reserves at the Yellowstone mine, located south of Ennis, Montana. Talc mined in southwestern Montana is of high purity and is the quality used in a wide variety of applications including paints, ceramics, plastics, rubber, coatings, agriculture, cosmetics, and pharmaceuticals. GEOLOGIC SYNOPSES FOR MAJOR MINES AND COMMENTS ON REGIONAL DISTRIBUTION OF TALC OCCURRENCES The general geology of southwestern Montana is shown in Figure 1along with the locations of the three producing talc deposits in the area and the extent of pre-Belt marbles that host all of the talc mines and prospects. The term “pre-Belt” is used in the present paper because zircon and other radiometric data developed in recent years indicates that the metamorphic rocks that form the crystalline basement for the middle Proterozoic Belt basin in the Dillon Tectonic Block of southwestern Montana includes both Archean and Paleoproterozoic rocks (O’Neill et al., 1996; Foster et al., 2006; McDonald et al., 2012). An envelope or “corridor” has been superimposed on the geology in Figure 1 which encompasses all of the talc deposits that have a significant resource. This “talc corridor” will be discussed in later sections of this report. The more important talc deposits are discussed in this report section."

Jan 1, 2016

By S. F. Burks

"This paper develops themes explained at two SAIMM platinum conferences. Optimization techniques can be used to significantly increase the value of mining businesses by enabling better long-term planning decisions. Open pit and underground mine design, mine scheduling, cut-off grade and blending, stockpiling, and the linking of these to flexible elements of the metallurgical recovery processes are all evaluated together. Transport or sale of intermediate products and the requirements of the product metal markets can also be considered. Experience shows that net present value (NPV) can be increased significantly, usually even before the expenditure of significant amounts of project capital. Recent studies of NPV have aimed to simultaneously evaluate the impact of the optimized financial solution on the non-financial features of a project or operation.The case study presented comprised a commercially orientated review of the prefeasibility study designs and cost estimates of a platinum group metal (PGM) project in South Africa, followed by value chain optimization and sustainability studies of the project carried out simultaneously to identify potential value uplifts to be gained and guide the owners’ team going forward into the feasibility study phase. Some of the major aspects of the project that were found to have significant potential to add value included enhancement of the business model by the application of activitybased costing and theory of constraints, focus on the highest net value portions of the orebody in the early years of production, enhanced and optimized scheduling of the underground mining operation, application of dynamic grind and percentage mass recovery from ore to flotation concentrate (also known as percentage mass pull) to optimize revenue, application of elevated cut-off grades early in the life of mine, matching of the mining and processing capacity, expansion of the operation subject to capital availability, and installation of downstream processing facilities subject to regional third-party capacities.The investigation of non-financial project features focused on demonstrating that a financially optimized solution could also have a number of other benefits. These are mentioned briefly in the paper, which aims to present the status of the project at an early stage of its development."

Jan 1, 2016

By D. Kruse, M. Sanaei

"3D finite element models of the Segmentally Lined Shaft (SLS) structure are simulated as means of numerical analyses of the system’s structural behavior. Top-down constructed rings, comprised of precast concrete segments, create a large diameter, relatively shallow underground space that can be utilized for various applications. To further investigate the effects of soil conditions and different loadings on the shaft structure, the FE model was run under various boundary conditions. Simulations include a) effects of various soil layers on the SLS, including a circumferential boundary of modified ground, b) effects of various soil layers on the SLS without any ground modification, c) Seismic analysis of the SLS with ground modification and d) Seismic analysis of the SLS without any ground modification. Comparing the analyses outcomes emphasizes the significance of the inclusion of the ground modification boundary in the structural performance of the SLS. INTRODUCTION TO SLS Underground structures are classically built rectangular in shape, which normally requires a two-step construction process beginning with installation of temporary shoring to support earth loads during the excavation, followed by the construction of the permanent structure. Attractive and practical alternatives are circular shafts referred to as segmentally lined shafts (SLS). The structure consists of a stacked series of rings formed from an assemblage of precast concrete segments. Top-down constructed systems of large diameter, relatively shallow SLS structures provide both temporary earth support during excavation and permanent structural support for many civil and building applications. The circular shafts sustain the lateral earth pressure mainly through hoop-stress mechanism, resulting in improved stability and structural efficiency. Cylindrical shell structures with large diameter to wall thickness ratios are prone to buckling under external pressure. In typical designs of small diameter shafts and tunnel linings with small diameter to wall thickness ratios, nonlinear buckling analysis (i.e., nonlinear geometric analysis) is usually not considered, since the buckling capacities for those structures are much higher than typical pressures encountered at their design depths. With an economically viable wall thickness, buckling becomes a critical issue, which should be addressed, for circular shafts with very large diameters. In the design and construction of the SLS, the stability of the structure can be improved by modifying the soil surrounding the circumference of the shaft to a limited thickness and to about 10 ft below the finished shaft structure. This thick wall of soil mixed with cement creates a composite integrated structure while serving additional purposes such as ground control and ground water seepage cutoff."

Jan 1, 2016

By Andy Thompson, Frank Perrone

"As part of the Metropolitan Transportation Authority’s $10.5bn East Side Access Project in New York, 3,200 m of tunnel had to be constructed in rock, mix face and soft ground conditions beneath one of the largest passenger railroad junctions in North America, handling over 780 trains per day. The use of risk based decision making tools was essential in developing the bespoke contract framework that was adopted as well as making informed decisions once excavation commenced. This paper will outline the risk management process adopted, discuss the risks and mitigation strategies adopted and comment on the impacts of this approach on the as built Project cost and schedule. In particular, the paper will outline the unique approach used to establish the baseline against which the Contractors performance would be measured as the selection of a Slurry TBM to excavate the tunnels was considered to compromise the effective use of a Geotechnical Baseline Report. BACKGROUND AND CHALLENGES Contract CQ031, Queens bored Tunnels and Structures was awarded in September 2009 to a joint venture of Granite Northeast/Traylor Brothers/Frontier Kemper (GTF JV) for $717.6m following a negotiated procurement process. A robust approach was taken with regard to the management and payment for risks associated with the construction of these tunnels. Risk assessments were carried out during the design phase and a risk register was developed prior to procurement. During the procurement phase close attention was paid to ensuring that the allocation and pricing of known risks, together with mechanisms for managing future risks were clearly defined between the MTA and GTF JV.In comparison to the excavation work in Manhattan, which was performed in competent hard Manhattan schist, the tunnels in Queens were excavated predominantly through soft ground with a high water table and complex environmental conditions. Not only did this require the use of pressurized face TBM technology, a first in New York, but also a re-evaluation of the contractual mechanisms used to manage the hard rock excavation contracts for their appropriateness to the soft ground tunnel work."

Jan 1, 2016

By Vinícius Resende Domingues, André Pacheco de Assis, Bernardo Cascão Pires e Albuquerque

"The increasing demand for underground works in urban centers, and in particular the need to build undercrossing tunnels, requires constant evolution in building techniques in order to achieve success and safety. In the case of Brasilia, capital of Brazil, in order to preserve an important avenue (Eixo Monumental), where are located many historical monuments, the construction of a tunnel was envisioned as an option to interconnect the National Stadium (on one side of the avenue) to the Convention Center Ulysses Guimarães (on the other side). The excavation design is comprised of a coverage smaller than one diameter, height of 7.5 m, width of 9.0 m and length of 25 m. In order to enable a negligible influence on the avenue’s usage, the structure is designed as a portico system composed of pipe canopy. In this context, this study presents the portico analytical solution computed with the aid of the software Mathematica and a numerical solution using the software ABAQUS. INTRODUCTION Undercrossing tunnels are increasingly common in urban centers as alternative roads or as access to underground works of large dimensions (stations and parking lots). The geomechanical conditions of the soil mass, not always favorable, and the low distance between tunnel’s ceiling and the surface require intense treatment of the soil massif and execution of a rigid support system. The importance of the road just above the undercrossing tunnel emphasizes the need for a highly competent monitoring system because existing structures require minimum allowable displacement and do not allow the interruption of traffic. The soils that are excavated for the construction of undercrossing tunnels are composed, in most cases, of layers of fill and / or soft soil or weak rock, showing stability problems when subjected to tunneling operations. The combination of low coverage and week ground is solved by soil improvement techniques and strengthening of the excavated cross-section with further advance with the so-called New Austrian Tunneling Method (NATM). Another option is to build structural frames that support the surface. In this research, and based on the context of a case study, we propose the study of the construction technique comprising a portico structure composed of pipe canopy. For this paper, the technical standards used are the Brazilian ones as the case study refers to this country."

Jan 1, 2016

By Valerio Violo, Antonio Raschillà, Livia Cicinelli

"The Cityringen project foresees the construction of a new circular metro line in and around the city center of Copenhagen. Both drives, the north and the south one, required the TBMs to be equipped in order to cope with contaminated water table and soil. The north drive mined in water contaminated with chlorinated compounds, including chloroform and vinyl chloride, while the south TBMs excavated in a highly benzene contaminated area, becoming the first TBMs to complete such a challenge. Despite the pollution and the stricter operative procedures, the production has been extremely successful with record up to 520 m in one month and 32 m in one day. 1 INTRODUCTION The Cityringen is an extension of the existing metro line. The 15 km long twin tunnels will form a new circular line with 21 new stations (17 + 4 crossovers). When finished it will interchange with the existing metro, rail and bus infrastructure at key locations around town, taking 90% of Copenhagen citizen at less the 600m from a metro station (Figure 1). The Contract has been awarded in April 2011 to the Copenhagen Metro Team (CMT), a joint venture between the Italian companies Salini Impregilo, Tecnimont and Seli SpA. Tunnels are being excavated with 4 Seli-Kawasaki EPB TBMs, two of which manufactured in Denmark by Seli Tunneling Denmark ApS, which is also operating them. At the moment this article is written 50% of the tunnels have been completed and over 40% handed over for the electromechanical works. Seli Tunnelling Denmark is a Danish company constituted in 2012 as a subsidiary of Seli SpA for this project and subsequently acquired by the Salini Impregilo Group in 2015."

Jan 1, 2016

By J. Lu, D. B. Dreisinger, G. Houlachi

"Zinc metal is primarily produced by electrowinning from sulfate solution. Zinc electrowinning is very sensitive to impurities such as Co and Ni. These impurities have to be removed to produce high-quality zinc and maintain a high zinc current efficiency. Zinc dusts are used to remove these impurities by cementation. However cobalt cementation is extremely slow and it is typically activated by the addition of Cu and Sb. Even with the use of Cu-Sb activation, cobalt is still difficult to remove. The zinc dust used for cobalt cementation is negligible compared to that consumed for hydrogen evolution. In some plants up to 6-7% of electrolytic zinc is used for cementation. This is a great waste of energy. Cu-Sb activation is not well understood. The objective of this study was to further understand the Cu-Sb activation and then find a way to reduce hydrogen evolution and promote cobalt cementation. The investigation reveals how hydrogen evolution (or zinc dissolution) and cobalt cementation and re-dissolution change with temperature, zinc dust dosage, the concentrations of copper and antimony and time. In the Cu-Sb activation, copper is deposited on a zinc particle to produce a porous shell. The zinc particle as an anode dissolves while the shell as a cathode provides a place where cobalt cementation and hydrogen evolution occur and they are catalyzed by antimony. A certain level of antimony (around 0.1 mg/L) is a key to maintain the catalytic effect of the shell. At a higher antimony concentration, cobalt cementation is accelerated slightly while hydrogen evolution is increased greatly. When a zinc particle dissolves to a certain degree, cobalt loses its cathodic protection and starts to re-dissolve. The change in cobalt concentration is determined by the rates of cobalt cementation and re-dissolution. The operation conditions can be optimized to maximize the cobalt removal and minimize the zinc dust dosage.INTRODUCTIONMost of the world’s zinc metal is produced by electrowinning from sulfate media. Many impurities such as iron, copper, cobalt and nickel are co-extracted into solution with zinc. Iron, mercury, indium, lead and tin are removed by co-precipitation as hydroxides. Copper, nickel, cobalt, aluminum, arsenic and germanium are partially co-precipitated with iron while cadmium, magnesium and chloride remain in solution. Cobalt, copper, cadmium, nickel and etc. are subsequently removed by cementation with zinc dust to achieve an acceptable current efficiency and high purity metal product for the economical production of zinc. Zinc provides a strong thermodynamic driving force for the cobalt cementation:"

Jan 1, 2016

By Sandin E. Phillipson

"On April 5, 2010 a massive dust-fueled explosion at a longwall mine in southern West Virginia claimed the lives of 29 miners. The mine had experienced large gas inrushes from the floor on two known previous occasions, and natural gas was found emanating from floor fractures behind the longwall shields after the explosion, indicating a likely fuel source for the initial ignition. In succeeding months, another longwall mine operating in the same seam 15 miles away encountered smaller inflows of natural gas that halted production from two different longwall faces. Production was halted at a third longwall mine, 30 miles south of the first, in May 2011, when explosive levels of methane were detected inby the longwall face on the headgate. The same mine was evacuated on March 20, 2014 when a series of floor gas feeders were encountered on the longwall face. A literature review indicated that there has been little documentation or description of these events, and that their size and frequency are unknown. The most significant floor gas inrushes in the United States are believed to have been associated with longwall mining in the Pocahontas No. 3 Seam of western Virginia, in which an estimated 5.8 x 107 ft3 of natural gas was expended from a floor feeder on the longwall face over a two-week period (Aul, pers. comm.).A variety of mechanisms and circumstances are associated with methane emanations from underground mines. Hyman (1987) defined an outburst as a violent, simultaneous release of gas and comminuted rock material into a working face or the interior of a borehole, and indicated that certain soft or fractured coals have a propensity for outburst based on gas desorption rates. In this mechanism, reservoirs of autogenic gas hosted in pockets of soft, crushed coal surrounded by harder coal are released suddenly as confining stress is removed by mining. Hyman (1987) also suggested that highly stressed, relatively gassy coal that is penetrated by mining-induced fractures could be outburst-prone. Clayton et al. (1993) and Ulery (2008) recognized the importance of faults as potential conduits for gas from adjacent strata into coal mines, and suggested that biogenic gas trapped in adjacent strata could migrate into mined coal seams due to a pressure differential. Ulery (2008) distinguished between an outburst and a blower, the latter defined as an event expending a large amount of gas over an extended time period, most often emanating from underlying strata, but without expulsion of coal or rock. Methane feeders are further defined as a subset of blowers that continually expend gas over a long period of time but at a lower rate. Many of the mechanisms discussed by Ulery (2008) relate to geologic features that can impound gas within the seam, releasing a voluminous amount when mining breaches the elastic dike, fault gouge, or other geologic structure that had restricted and compartmentalized coalbed methane migration. Thus, the events discussed in this paper can be described as blowers and feeders. However, detailed geological observations of the three longwall mines discussed in this paper appear to indicate a mechanism that is different from those described by Hyman (1987) or Ulery (2008), in that they did not involve coalbed-sourced gas, and the reservoirs were not hosted by coal seams."

Jan 1, 2016

By Timothy Batchler

"Pumpable roof supports are currently being used to provide a safe working environment for longwall mining. Because different pumpable supports are visually similar and installed fundamentally in the same manner as other supports, there is a tendency to believe they all perform the same way. However, there are several design parameters that can affect their performance, including the cementitious material properties and the bag construction practices that influence the degree of confinement provided. A full understanding of the impact of these design parameters is necessary to optimize the support application and to provide a foundation for making further improvements in the support performance.This paper evaluates the impact of various support design parameters by examining full-scale performance tests conducted using the National Institute for Occupational Safety and Health (NIOSH) Mine Roof Simulator (MRS) as part of manufactures' developmental and quality control testing. These tests were analyzed to identify correlations between the support design parameters and the resulting performance. Based on more than 160 tests over 7 years, quantifiable patterns were examined to assess the correlation between the support dimensions, cementitious material type, wire pitch, and single-wall vs dual-walled bag designs to the support capacity, stiffuess, load shedding events, and yield characteristics.INTRODUCTIONDeveloped in the 1990s, the first major use of pumpable supports systems in U.S. longwall operations was in the support of bleeder entries (Barczak, Tadolini, 2008). Since then, they have been utilized as yieldable concrete supports to provide a safe working environment for longwall mining gateroads, bleeders, and emergency escapeways while also maintaining adequate ventilation pathways. The basic structure of pumpable roof supports has remained unchanged over the years. Formed in place with a twopart fast-setting grout, the support material can be pumped into a containment bag from several thousand feet away often through surface boreholes. The containment bag then acts as a form to fill the support and provides confinement to the grout during loading and after failure. Pumpable roof supports provide full contact with the mine roof and floor, which eliminates the need for secondary material to establish proper roof contact (see Figure 1). They provide a high peak load capacity and a sustained, confinement controlled yield behavior while maintaining stable ground conditions, which is essential to underground mining operations."

Jan 1, 2016

By C. Horstmann, D. Andreo, G. Barthold

"The concept of large single line grinding circuits provides a valid answer in project feasibility studies by reducing capital investment requirements compared to parallel lines for the same plant throughput rates. The benefits of this concept are reflected as well on the operational aspects, in terms of higher and greater process stability, and reduced operational costs mainly due to the associated lower maintenance expenditures. However, concerns exist in the minerals industry on whether large single line grinding could reduce the overall concentrator plant availability. The mechanical design and integrity, the mill and gearless mill drive integration, as well as assets management aspects of this type of equipment are the key to guarantee successful availability records. Together with an overview of the added value provided by large single line grinding circuits, this paper focuses on risk mitigation strategies during mill and gearless mill drive integration, as well as on the design of the equipment itself, for the key aspects which could put at risk the operations availability.INTRODUCTIONDespite a large long term demand for commodities, the mining industry has never faced complex challenges as it is doing today. Decreasing high-quality and accessible deposits, declining ore grades in existing mines, shortages of electrical energy (e.g. in Chile) and an aging workforce are the most significant among the megatrends affecting our industry. In addition to this, flat underlying commodity prices and high price volatility are currently posing strong requirements to miners when entering into the process of approving investments.Nowadays to get projects financially approved (optimizations, expansions, new plants), capital expenditure has to be reduced, as observed up to 30% compared to the last decade, and at the same time the plant design has to be such to demonstrate that operating costs will also be significantly lower than in the past.When it comes to the concentrator plant, the concept of large single line grinding circuits provides a valid answer in project feasibility studies by significantly reducing the capital investment requirements compared to parallel lines for the same plant throughput rates. The benefits of this concept are reflected as well on the operational costs, in terms of higher and greater process stability and reduced maintenance expenditures."

Jan 1, 2016

By Dale Berner, Michael O’Sullivan

"This article focuses on lessons learned from innovative designs including in-the-wet construction methodology and modified foundation conditions, for two United States Army Corps of Engineers (USACE) megaprojects. Olmsted Dam FoundationThe over $2 billion Olmsted Dam on the Ohio River is currently under construction 16 mi (29.6 km) upstream from the confluence with the Mississippi River. The project is under the jurisdiction of the Louisville District of the USACE. It will consist of an 800 ft (244 m) long tainter gate section, a 1,400 ft (427 m) navigable pass, two boat abutment sections, a fixed weir section, and upstream and downstream scour protection. The Olmsted Dam and its two 1,200 ft (366 m) locks, which were built in 2002, will eventually replace both Locks and Dam #52 and #53, both built in 1929, and thereby bring significant benefits to the Ohio River navigation system.In 2002, the Jacobs/COWI JV completed the design of the dam; which was an engineering challenge for several reasons. A significant consideration was its proximity to the New Madrid Fault, which could impose an 8.4 Richter scale seismic event on the structure, which is located in an area of potentially liquefiable alluvium. The extensive seismic analysis performed by the designer included a response spectra analyses, lateral pushover analyses of pile foundations, hydrodynamic added masses, pile group effects, and the development of kinematic motions as a result of the soil-pilestructure interaction."

Jan 1, 2016

By D. Vogt, T. Hattingh

"This paper argues that the technology change to mechanization is also going to require a change in people. It presents a model for technological progress and adapts it to the mining industry. It then goes on to motivate the need for mines to become learning organizations in order to achieve maximum value from their people as they become less labour-intensive. In an important sense, mechanization is as much about knowledge as it is about technology.The change when a mine introduces mechanization or a level of automation is not simply one of technology but also a stage in the development of mining from ‘art’ to ‘science’. ‘Art’ describes a state of technology characterized by tacit knowledge, an understanding that comes only from experience, and has no formal procedures and little structure. In contrast, ‘science’ represents a state of technology where all the component processes are understood in detail, all knowledge is explicit, and processes and structures are formal.Studies of other industries, including metal part manufacture and aviation, show that each stage in the progression from art to science changes the nature of the organization and requires a different mix of skills from the workforce. Perhaps the most important change is the increase in knowledge and decision-making required as the technology gets closer to science.There is anecdotal evidence that South African underground hard-rock mines are not learning organizations. Mines by their nature are capitalintensive with long lead times from investment to returns, so there is reluctance to change from the original plans or to encourage staff to think independently. Particularly as mines move from art to science, this reluctance must be overcome.The important lesson for engineers involved in introducing mechanization is to understand that success or failure will be determined by the people involved, and not solely by the technology. The process will almost certainly require a culture change on the mine. We recommend that the mechanization team includes an expert in human and organizational behaviour to ensure that a receptive workforce and management are in place to accept the new technology when it arrives."

Jan 1, 2016