Search Documents

By R. Cooper, K. De Wet, A. Janwong

"Horsehead Metal Products is a zinc refinery in Mooresboro, NC, treating crude Waelz oxide (WOX) to produce special high-grade zinc by a hydrometallurgical process comprising leaching, zinc solvent extraction/electrowinning, melting and casting and bleed treatment. Cadmium removal by zinc-dust cementation plays an essential role in the bleed treatment circuit to prevent cadmium buildup in the circuit. Silica, though present at a low level of approximately 0.3 percent in the WOX feed material, had a significant impact on the efficiency of cadmium cementation with zinc dust, most likely due to the passivation of zinc dust particles with silica gel. Solid/liquid separation efficiency by filter press was also affected. To identify the source of the silica issues, silica levels were mapped throughout the circuit, and adjustments, including using pregnant leach solution as the feed to cementation, and pH control in the WOX leaching and neutralization were introduced to mitigate the issues created by silica gel in the circuit. IntroductionLocated in Mooresboro, NC, Horsehead Metal Products Inc. is a hydrometallurgical zinc refinery processing Waelz oxide (WOX) to produce special high-grade (SHG) zinc. The flowsheet, known as the Modified Zincex process, consists of leaching, solvent extraction (SX), electrowinning (EW), melting and casting and bleed treatment (Fig. 1). Cadmium cementation, part of the bleed treatment process, provides an essential bleed of cadmium from the circuit, as metallic cement. The cadmium cementation circuit consists of agitated cementation reactors, a zinc dust addition system, filter presses, agitated purification (releach) reactors and a cadmium concentrate filter press.At the refinery, WOX pulp is leached at a controlled pH to achieve the maximum zinc extraction, according to the main reaction:"

Jan 1, 2016

By M. Walawalkar, C. K. Nichol, G. Azimi

Rare earth elements (REEs) are essential to the production of technologically advanced products, including wind turbines, electric and hybrid cars, automotive catalytic convertors, hand held electronic devices, and military defense systems. Their application in environmentally beneficial technologies puts them at a high priority for ameliorating environmental concerns. Because of their increasingly high demand and limiting resources, it is highly beneficial to find new sources for them. The present study is focused on leaching REEs from a phosphate based fertilizer by-product, known as phosphogypsum (PG). Global estimated world production of PG is about 240 million tonnes that is stored in the form of wet stacks adjacent to fertilizer production facilities, occupying vast amounts of land. PG also contains trace metals, which are detrimental to the environment, and hence it is crucial to monitor these stacks. We obtained our PG sample from Agrium Inc. (a fertilizer manufacturing company in Canada). We performed a comprehensive characterization of the PG sample and found that it predominantly contains Y, La, Ce, Nd, and Sm. For leaching purposes, we used hydrometallurgical acid leaching techniques. We investigated three acids over a range of operating conditions such as acid concentration, temperature, solid-to-liquid ratio, and residence time. We achieved an average leaching of 81% with hydrochloric acid as leachant using operating conditions that can be easily replicated in industrial settings. If our process is implemented, not only will it reduce the size of the existing PG stacks (mitigating their environmental risks), but also enable the development of new innovative routes for extracting REEs, making countries like Canada less vulnerable to supply disruptions.

Jan 1, 2016

"The main purpose of geometallurgy is to develop a model to predict the variability in the mineral processing performance within the ore body. Geometallurgical tests used for developing such a model need to be fast, practical and inexpensive and include as an input data relevant and measureable geological parameters like elemental grades, mineral grades and grain size. Important in each geometallurgical program is to define the number of samples needed to be sent for geometallurgical testing to enable reliable metallurgical forecast. This is, however, a complicated question that does not have a generic answer.To study the question on sampling a simulation environment was built including a synthetic ore body and sampling & assaying module. A synthetic Kiruna type iron oxide - apatite deposit was established based on case studies of Malmberget ore. The synthetic ore body includes alike variability in rock types, modal mineralogy, chemical composition, density and mineral textures as its real life counterpart. The synthetic ore body was virtually sampled with different sampling densities for a Davis tube testing, a geometallurgical test characterising response in magnetic separation. Based on the test results a forecast for the processing of the whole ore body was created. The forecasted parameters included concentrate tonnages, iron recovery and concentrate quality in terms of iron, phosphorous and silica contents.The study shows that the number of samples required for forecasting different geometallurgical parameters varies. Reliable estimates on iron recovery and concentrate mass pull can be made with about 5-10 representative samples by geometallurgical ore type. However, when the concentrate quality in terms of impurities needs to be forecasted, the sample number is more than 20 times higher. This is due to variation in mineral liberation and shows the importance of developing techniques to collect qualitative information on mineral and ore textures in geometallurgy."

Jan 1, 2016

By Minghao Hu, Hongbo Zhao, Jun Wang, Wenqing Qin, Rui Liao, Central South University

"In the present work, X-ray diffraction (XRD) analysis, X-ray photoelectron spectroscopy (XPS) analysis and electrochemical analysis were carried out to investigate the intermediate species and electrochemical dissolution process of chalcopyrite in the presence of sulfur and iron oxidizing microorganisms. For bioleaching of chalcopyrite by the sulfur oxidizing microorganism Acidithiobacillus caldus, the redox potential was always lower than the appropriate value and chalcopyrite was mainly directly oxidized to polysulfide (Sn 2-), thus resulting in low copper extraction. As for bioleaching of chalcopyrite by the iron oxidizing microorganism Leptospirillum ferriphilum, chalcopyrite was mainly directly oxidized to polysulfide at the initial stage where redox potential was lower than the appropriate value and resulted in low dissolution rate. At the middle stage where redox potential was appropriate (about 350–480 mV vs. Ag/AgCl), chalcopyrite was mainly transformed to intermediate species of Cu2S rather than polysulfide, thus resulting in high dissolution rate. At the later stage where redox potential was higher than the appropriate value, chalcopyrite was mainly directly oxidized to polysulfide which caused the later passivation of chalcopyrite. Finally, a model of electrochemical dissolution process of chalcopyrite in the presence of sulfur and iron oxidizing microorganisms was provided.INTRODUCTIONBiohydrometallurgy is considered as one promising mineral processing technique in processing low grade ores due to the advantages of simplicity, low cost and eco-friendly. Chalcopyrite (CuFeS2) is the most abundant copper-bearing resource, accounting for appropriately 70% of the known reserves in the world, while is recalcitrant to bio-hydrometallurgy mainly due to the coated passivation layer (Klauber, 2008; Li, Kawashima, Li, Chandra, & Gerson, 2013). However, the detailed dissolution and passivation mechanisms of chalcopyrite bioleaching are still uncertain. The microorganisms assisting chalcopyrite dissolution can be mainly classified into three types, including mesophilic microorganisms (e.g., Acidithiobacillus ferrooxidans, Acidithiobacillus thiooxidans and Leptospirillum ferrooxidans), moderately thermophilic microorganisms (e.g., Acidithiobacillus caldus, Sulfobacillus thermosulfidooxidans and Leptospirillum ferriphilum), and extremely thermophilic microorganisms (e.g., Metallosphaera sedula, Sulfolobus sp., Acidianus sp., and Sulfurcoccus mirabilis). Moderately thermophilic microorganisms have a better prospect in the future industrial application of chalcopyrite bio-hydrometallurgy (Olson, Brierley, & Brierley, 2003; Rohwerder, Gehrke, Kinzler, & Sand, 2003). Hence, investigating the detailed dissolution and passivation mechanisms of chalcopyrite bioleaching by moderately thermophilic microorganisms is of important significance, which will provide essential information for promoting chalcopyrite bioleaching by moderately thermophilic microorganisms in laboratory or industrial plant."

Jan 1, 2016

By C. Han, S. J. Zhou, Y. B. Shen, D. Z. Wei, P. Fang

"Collecting property of two hydroxamic acid collectors have different type of nonpolar structure to hemimorphite has been comparatively studied via monomineral flotation test, and the reason causes different collecting performance has been discussed from the view of relationship between molecular structure and collecting property. The flotation tests results show that C5-9 hydroxamic acid has an unbranched linear alkyl nonpolar group shows better collecting property to hemimorphite than cyclohexyl hydroxamic acid which has a naphthenic nonpolar group. FTIR detecting results show that the adsorption type of collector adsorbed on hemimorphite surface is chemical adsorption. Calculation results of polar group’s geometric structure parameters, polar group’s electron density distribution, octanol-water partition coefficient (logP) and molecular frontier orbital energy show that the key factor caused different collecting property of two collectors to hemimorphite is the logP; unbranched linear alkyl nonpolar group is more conducive than naphthenic nonpolar group to make hemimorphite particle more hydrophobic.INTRODUCTIONZinc-bearing mineral recovered from lead-zinc ores is the main source that people can obtain zinc resource from nature. However, natural sulfide ores are currently getting depleted steadily for the primary zinc source. In order to satisfy the future demand of zinc resource, there is an obvious recognition that the recovery of zinc oxidized minerals from the ores is a crucial alternative (Hosseini & Forssberg, 2007; Navidi Kashani & Rashchi, 2008).But the fact that can’t be ignored is the flotation of zinc oxidized minerals is much more difficult than that of zinc sulfide minerals, which is mainly due to the flotation characteristics of these zinc oxidized minerals such as lower selectivity and higher reagent consumption, as well as complex and variety of lead-zinc ores. Presently, there have been many various beneficiation technologies used for recovering zinc oxidized minerals and dealing with ores for recovering metallic zinc such as flotation and hydrometallurgy (Abkhoshk, Jorjani, Al-Harahsheh, Rashchi, & Naazeri, 2014; Önal et al., 2005). But from an overall perspective, flotation is the most common method used for the beneficiation of zinc oxidized minerals, and there have been extensive investigations conducted on the flotation of zinc oxide ores (Ejtemaei, Gharabaghi, & Irannajad, 2014). Until now, the most well-known method used commercially for the flotation of zinc oxidized minerals is sulfidization with sodium sulfide and flotation with a cationic collector of amines containing from 8 to 18 carbon atoms. However, a major problem for this method is the large amount of fines and slime results in the increase of reagent consumption and promotes the phenomenon of slime-coating. For preclude this negative effect, the de-sliming and processing optimization is indispensible (Peres, Borges, & Galery, 1994; Salum, de Araujo, & Peres, 1992)."

Jan 1, 2016

"Liberation is a key requirement for efficient separation in mineral processing. As a consequence of this an understanding of the inherent textural features of an ore is no longer possible since during the process of liberation, texture is destroyed. Knowledge of key textural features, such as mineral grain size and distribution, prior to breakage processes provides the opportunity to understand the textural drivers for ore hardness. Modern characterisation methods, including automated SEM-based techniques, provide the possibility of measuring mineral characteristics at a range of scales. This paper discusses how textural features of two different ore types in a porphyry copper deposit can be measured and interpreted at a number of scales. Standard breakage tests conducted on the ores indicate that one of the ores can be characterised as hard and the other as soft. The impact of mineral grain size and the presence and scale of vein type structures in the two ores have been used to determine the extent to which these features influence ore hardness.INTRODUCTIONIn order to effectively convert ore into metal, knowledge of both the processing stages and the characteristics of the ore are essential. Prior to the advent of technologies that enabled the fundamental understanding of the sub-process at each stage of processing and the measurement of appropriate ore properties the most effective way to understand how an ore would respond to a process was to put it through that process, for example the way to determine how an ore would break was to first break it. Existing comminution models seek to predict the size distribution of rock fragments as the result of applied energy based on knowledge of the rock strength. It is common for these models to consider the rock as homogeneous and despite providing important data for the design and optimisation of industrial comminution circuits these models are only applicable within a narrow range of operation. In order for reliable predictive models to be developed that account for the inherent ore characteristics, a step change is required in the type of measurements that are carried out to characterise an ore and the type of data that is extracted and used as model inputs."

Jan 1, 2016

By Alessandro Boscaro, Daniele Martinelli, Cristina Gabriela Oñate Salazar, Daniele Peila, Carmine Todaro

"The wear phenomenon in TBM machines is not a simple issue, as many parameters are playing an important role on the consumption of the tools during a tunnel excavation. The action of the wear due to the contact with the soil can occur on the excavation tools, on the cutterhead, in the excavating chamber and on the screw conveyor. The test developed at the Laboratory “Tunnelling and Underground Space Center” of the Politecnico di Torino is aimed to reproduce the interaction between the tools and the excavated material, simulating the excavation conditions in terms of soil conditioning and water content. The test, which is not standardized, is studied to evaluate the wear in a global point of view. The present work starts by testing the influence of the use of chemical agents during the conditioning phase on the drop of the wear phenomenon, in terms of metal weight loss. 1. INTRODUCTION The wear phenomenon of the excavation tools used in TBM tunneling machines is playing recently a major role in the design stage of full-section tunnels in both soils and rocks. Concerning EPB excavation technology, the main issue regarding productivity is the wear of its components (Peila et al.,2012), which increases the so called dead time in the whole process. The friction generated between the components and the ground causes the consumption of the tools and other metallic components in contact with the ground, described as primary and secondary wear by Nielsen et al. (2006a). This leads to downtime, with risky and complicated maintenance operations (Peila and Schulkins, 2009), as occurred in recent tunneling works in Liguria (Italy). The study of this argument in granular soils is very delicate, as it encloses not only the properties of the excavation tools, but also the characteristics of the ground to be excavated (hardness, mineralogy composition, shape and dimension of the particles and moisture content). The penetration mechanism is based on the scraping of the ground, by mean of cutting tools, with its consequent consumption. Concerning the rocks, the excavation principle is characterized by crushing the rock mass matrix by applying high compressive stresses through cutting disks. In such a way, to avoid frequent downtimes and their consequent economic losses, it is very important to study this subject and therefore understand and forecast the durability of the components, in order to try to maximize the productivity of the machine by reducing the frequency of maintenance stoppings."

Jan 1, 2016

By Keith A. Heasley, Jian Yang

"LaModel uses a laminated overburden boundary-element model and can calculate not only seam-level stresses and displacements but also surface subsidence for thin tabular deposit such as coal seams (Heasley, 1998). Up to this point in time, the material property wizards in LaModel have primarily been designed for calculating accurate stress distributions in single- and multipleseam situations, and for investigating and optimizing pillar sizes and layouts in relation to overburden, abutment, and multipleseam stresses. However, the critical input parameters that will give the most accurate seam-level stress distribution do not necessarily produce the best surface subsidence prediction. The objective of this paper is to develop a methodology for calibrating the critical input parameters in LaModel to optimize surface subsidence prediction.For optimum surface subsidence prediction, it was found that the gob convergence (as defined by the final gob modulus) and the overburden stiffness (as defined by the lamination thickness) were the two most critical parameters that needed to be calibrated (Heasley, 2016). By calibrating numerous panels with various widths and depths, a formula that provides the optimum final gob modulus to use for subsidence prediction was developed. Also, three different empirical formulas for optimizing the lamination thickness as a function of overburden depth and/or the panel width to- depth ratio were determined for the three cases: supercritical panels, and subcritical panels with and without offsets. Further, if the user has measured data for subsidence factor and angle-of draw, the optimum final gob modulus and lamination thickness can be determined from the measured data. These new subsidence prediction formulas are being implemented into new material wizards in LaModel.INTRODUCTIONIn the past few decades, with the increased need for highly productive mining techniques, full extraction mining methods have been increasingly employed in the U.S. coal mining industry. These total extraction mining methods, which include both longwall mining and room-and-pillar retreat mining, normally cause immediate roof caving and the associated surface subsidence. These methods can be highly productive and cost-effective, but the associated surface subsidence can cause damage to surface structures and negatively impact the surface environment (Peng, 2008). Therefore, a reliable program for predicting the surface subsidence associated with full extraction mining is required for appropriately engineering and managing the surface subsidence impacts of full extraction mining."

Jan 1, 2016

By Jose R. Hernandez-Aguilar

"This paper revisits data from previous studies (Hernandez-Aguilar, 2010, 2011) to better understand the link between metallurgical performance and bubble size (Db) in the collection (pulp) zone of full-scale flotation systems. To obtain conclusive evidence exclusively related to the collection zone, the experiments were designed in those studies to control both the bubble generation method and the influence of the froth zone on the overall metallurgical performance in industrial and pilot-scale flotation columns. The results showed that generating small (1 mm) bubbles had a significantly higher beneficial effect on the recovery of coarse (> 75 µm) particles compared to the effect on fine (< 16 µm) particles. It was observed that, under certain practical conditions, the recovery of liberated coarse particles was close to zero, but could be recovered almost completely by reducing bubble size. The evidence revealed an apparent inconsistency of the so-called “k–PSb” model: at constant froth recovery, increasing Sb did not always result in higher recovery, as the model predicts. Overall, the evidence showed that it was not the Sb but the bubble size that proved to be a more reliable link to metallurgical performance. Only under highly suboptimal bubble size conditions (Db = 3 mm) did the froth zone seem to play a role, possibly reflecting an effect of pulp-zone bubble size on froth stability. However, for the most part, both the bubble generation method and the froth zone played inconsequential roles. An empirical model that better describes the kinetics of particle collection is proposed.INTRODUCTIONStudies showing the link between metallurgical performance and the interactions of bubbles and particles in the collection (pulp) zone of industrial flotation systems are scarce. A common belief among a number of mineral processing practitioners considers that “small” bubbles are favourable to recover “small” particles and that, conversely, “larger” bubbles are more efficient at floating “coarse” particles. However, perceptions like this are often substantiated by anecdotal evidence rather than by rigorous data analysis. What is the optimum bubble size for a particular case, how operating conditions can be adjusted to control a target bubble size, and whether the bubble size needs to be changed in the first place to optimize the operation of a flotation plant are questions that usually remain without solid answers.The studies reported by Hernandez-Aguilar (2010, 2011) were, in part, performed to test the effect of bubble size on flotation response and, thus, help address some of the above questions. The focus of the studies was to optimize the metallurgical grade-recovery performance of the Cu-Mo separation plant at Teck’s Highland Valley Copper mine (HVC). The outcome was compelling and significantly valuable: consolidated production data showed that in 2008 – the year when the recommendations from the studies started to be implemented – the Mo plant recovery was 89%, and gradually increased to 92% and 94% in 2009 and 2010, respectively, along with an increase in Mo concentrate grade. (Note: these production figures were not included in the publications quoted above; however, they were shown during an oral presentation at the 43rd Annual Meeting of the Canadian Mineral Processors in 2011.)"

Jan 1, 2016

By W. Newcomen, G. Dick

"Effective management and mitigation of pit slope instability in open pit mines begins with a comprehensive slope monitoring programme. The ability to differentiate between non-critical pit wall movements due to rebound or relaxation of the excavated slopes and movements that may be indicative of slope failure is important for maintaining a safe working environment and maximizing production. Slope failure prediction methods using velocity, acceleration, and strain criteria have been introduced and put into practice over the past few decades. Forty-eight slope failures with surface monitoring data are presented and assessed using the strain-based failure prediction approach, with consideration of the quality of the rock mass and the potential failure mechanism. The results indicate that the strain-based approach can be used to provide general guidance regarding strain thresholds for pit walls for a variety of failure modes in diverse geological environments. The advantages and potential drawbacks of the strain-based and other slope failure prediction methods are discussed. The importance of implementing a pit slope monitoring and performance evaluation system early in mine development is also emphasized. IntroductionThe successful prediction of the Manefay Slide pit slope failure at Bingham Canyon at 9:30 am on 10 April 2013 (Engineering and Mining Journal, 2014) highlighted the importance of having a comprehensive slope monitoring system that provides an accurate prediction of the time of failure of an open pit slope. Using most of the geotechnical monitoring tools available, the time of the failure was predicted within hours and equipment and personnel were evacuated from the pit well in advance of the failure. From a time to slope failure perspective, the monitoring system in place was a success.There are two general groups interested in monitoring pit walls, with slightly different objectives in mind when the monitoring system is being set up. There are those at the mine site that have to implement the pit slope design, monitoring protocols, and the action response plans, and there are those designing the slopes (often consultants) who regularly visit the mine but may not be responsible for the day-to-day activities. was a success.There are two general groups interested in monitoring pit walls, with slightly different objectives in mind when the monitoring system is being set up. There are those at the mine site that have to implement the pit slope design, monitoring protocols, and the action response plans, and there are those designing the slopes (often consultants) who regularly visit the mine but may not be responsible for the day-to-day activities."

Jan 1, 2016

By Z. Leng

"After detonation of the explosive, the final blast-induced damage area around the blast-hole falls into three categories, namely crushed zone, fractured zone, and elastic deformation zone. This paper presents a modified model to calculate the size of crushed zone around a blast-hole in drill-and-blast, with the hoop compressive stress and cavity expansion effect taken into account. The material in the crushed zone was assumed to be a granular medium without cohesion, but with internal friction. On this basis, the formula for crushing zone radius was derived. The proposed approach was verified with tests reported in the literature and the simulated results from SPH-FEM coupled models. A full statistical analysis was also carried out, and the predicted values were found to be in better agreement with the test results compared with other models. A sensitivity analysis of the modified model showed that the size of the blast-induced damage area is mainly affected by the following factors: rock mass properties, in situ stress, and borehole pressure. In particular, the roles of borehole pressure and in situ stress are discussed. Finally, suggestions are made on how the size of the crushing zones can be decreased. IntroductionOver the past decades, drill-and-blast has become the most commonly used technology in rock excavation. It is well known that in rock mass fragmentation with explosives, the annular rocks around the blast-hole are converted into fines. The formation of these fines consumes a significant part of the energy of the detonation, which in general is ignored in the determination of the efficiency of detonation (Glatolenkov and Ivanov, 1992; Furtney et al., 2012). Many studies show that only 20–30% of the total explosive energy is effectively used in fragmenting the rock, and up to 50% of the energy generated by conventional charges is wasted in overcrushing of the crushed zone and the inner part of the fractured zone (Ouchterlony et al., 2004; Sanchidrian et al., 2007). How to control the crushed zone to enhance the effective utilization of explosive energy, reducing the unit explosive consumption and the engineering cost, is therefore of great significance."

Jan 1, 2016

By C. Clark, J. Seymour, D. Benton

"National Institute for Occupational Safety and Health NIOSH is conducting research on jackleg use and related accidents in underground metal mines. This paper provides an analysis and overview of jackleg drill usage, accidents, operational characteristics, and alternatives, based on information from injury reports, legacy research, stakeholder input, and published literature. Jackleg drills are involved in more ground fall accidents in underground metal mines than any other drill. Jackleg-related injuries are most prevalent at the face in the course of installing initial ground support. Alternatives to jacklegs for drilling and bolting under incomplete support in narrow underground openings are not yet available. Small mechanized bolting equipment needs to be developed to address jackleg-related accidents and improve safety at mines where jacklegs are being used. JACKLEG DRILL Description The term “jackleg drill” is a generic name for a class of handheld, rotary, percussion rock drills that are equipped with an attached reaction leg to provide stability and thrust for the drill (Figure 1). All of the drill and leg controls are located near the operator’s handle at the rear of the head portion of the drill. Jacklegs are classified according to the bore size of their pneumatic pistons which normally range from 6.03 to 8.26 cm (2.375 to 3.25 in) [Kurt, 1982; Clark, 2012]. Jacklegs typically weigh 460 N (103 lbs), but their weight can approach 535 N (120 lbs) after they are fitted for operation with drill steel and air and water hoses [McKibbin and Clark, 2001]. In underground mines, jackleg drills are commonly used to drill 3.8-cm (1.5-in) diameter holes 1.83 m (6 ft) deep in rock. Application The jackleg drill is primarily used in underground mines when the size of the ore body, the ground conditions, or the mining method do not permit large openings to be mined using mechanized equipment (e.g., narrow vein mining). Jacklegs are used to drill blast-holes for explosives and also holes for installing ground support. These versatile drills are used in nearly all phases of mining including exploration, development, production, and maintenance [Kurt, 1982; Williams et al., 2007; Chen and McKinnon, 2012]. The jackleg is used to drill holes in rock using drill bits attached to hollow steel bars called drill steels (rotary percussion drilling). After the hole is drilled, the jackleg can be used to install different types of ground support components, depending on the ground conditions and the specific ground support measures that are needed. For example, the jackleg can be used to install expansion-anchor rockbolts or resin-grouted rockbolts using the drill’s rotary-motion feature. On the other hand, the jackleg can also be used to install friction-type Split-Set™ rockbolts using the drill’s percussion (hammer-motion) feature. As shown in Figure 1, various washer-like bearing plates can be installed along with these bolts to provide additional ground support and to help secure surface control products, such as wire mesh and shotcrete that are in turn used to retain small, loose material between the bolts [Clark, 2012]."

Jan 1, 2016

By T. A. Chepushtanova, I. U. Motovilov, V. A. Luganov, G. D. Guseynova

"Kazakhstan has significant reserves of oxidized nickel ore with low nickel content. Processing of such ores is effective via pyrometallurgical technologies such as smelting to ferronickel or matte with consecutive extraction of metals from melting products. There are also many options for direct hydrometallurgical processing. However, they do not provide high nickel recovery.We studied extraction of nickel and cobalt by using combined technology of low-grade ore processing from the Shevchenko Kazakhstan deposit, which includes smelting to poor matte followed by hydrometallurgical processing of the matte. The nickel content in the initial ore was 0.75–0.9%. Pyrite concentrate of Sokolov-Sarybai Kazakhstan deposit containing 0.17% cobalt and 0.06% nickel had been used as a sulphidizer at smelting.As a result of the study, we were able to extract up to 98% of the nickel and up to 80% of the available cobalt. Obtained matte contained 3.1% nickel, 0.29% cobalt, 71.6% iron and 24.3% sulfur. Matte leaching was carried out by hydrochloric acid. The iron content in the pregnant solution was 170–185 g/dm3. Nickel and cobalt precipitation from the pregnant solution was carried out by hydrogen sulfide. Initial matte or cast iron was used as neutralizers during the process. Practically complete precipitation of nickel was achieved at 3–5% excess of neutralizer at 333–343°K in 4 hours; up to 95% of cobalt precipitation was achieved in 50% excess of neutralizer at 363°K in 8 hours. The purified solution contained 200–600 mg/dm3 of nickel, 80-100 mg/dm3of cobalt and 175–185 g/dm3 of iron. The purified solution allows to obtain iron oxides by high-temperature hydrolysis, and to regenerate hydrochloric acid.As a result of non-ferrous metals precipitation we obtained sulfide concentrate with concentration of Ni up to 25% and concentration of Co up to 5.5%. The technology is recommended for semi-industrial testing."

Jan 1, 2016

By H. Huang, R. N. Gow

"EH-pH diagrams are useful tools in understanding how mineral surfaces react in solution and particularly how aqueous conditions can be changed to enhance mineral leaching processes. Successful application of these diagrams, however, requires that several considerations be kept in mind to prevent what had been termed as “gross errors” in their calculation and use. In this paper, the aqueous Cu-S system is used as the basis for explaining the mass-balanced method of calculating EH-pH diagrams with the STABCAL thermodynamic equilibrium software. A breakdown of the Gibbs’ Phase Rule and how it is used in STABCAL to modify the diagrams is included. The methodology was applied to the aqueous Cu-As-S system, and resulting diagrams were compared against examples of those generated using the predominant-ion method. The complexity of such diagrams increases with every additional component, and competition between species becomes more apparent, as can be seen by curvature in the resulting mass-balanced diagrams. The complete diagram for enargite (Cu3AsS4) is shown. It compares well with spectroelectrochemical measurements from Raman spectroscopy and cyclic voltammetry studies.IntroductionInnovation in the field of processing arsenicbearing copper ores has been of particular interest. Copper arsenic sulfosalt minerals such as enargite (Cu3AsS4) and tennanite (Cu12As4S13) are now frequently prevalent in ore bodies as the oxide and easily leachable sulfides become harder to find. These minerals, unless pretreated somehow, concentrate in copper sulfide flotation processes, in turn concentrating the arsenic levels. Increasing environmental restrictions on arsenic content for smelters makes the hydrometallurgical processing of these concentrates more favorable. While enargite is considered one of the more refractory copper sulfides, more so than chalcopyrite (CuFeS2), there are still several methods, both industrially proven and in development, that are capable of processing these ore types. Alkaline sulfide leaching can be used as a pretreatment method to solubilize arsenic selectively (Delfini et al., 2003; Anderson and Twidwell, 2008; Tongamp, Takasaki and Shibayama, 2010a, 2010b), or the entire metal content can be leached using acid-type leaches such as acidified ferric sulfate (Dutrizac, 1981; Hackl et al., 1995; Klauber, 2008), or the chloride assisted, CESL (McDonald and Muir, 2007) or nitrogen species catalyzed (Anderson, 2003) processes can be used.As development of these leaching technologies proceed, it is also important to develop an understanding of the mineral thermodynamics. To date, there are numerous studies on the Cu-Fe-S-H2O system, particularly as it relates to chalcopyrite leaching, yet few studies have done on the Cu-As-S-H2O system. Computer-generated EH-pH diagrams have been employed to illustrate the importance of thermodynamic calculations in providing insight into such a system."

Jan 1, 2016

By V

"Recent regulations, as well as a general aversion to central dust collectors within the Powder River Basin Coal user’s community, have created a need for an alternate method for eliminating airborne dust. This paper addresses the capital expenditure as well as the cost of ownership of an integrated point source air cleaning system in comparison to a central collection system. This assessment was conducted by comparing the cost to purchase and operate a central dust collection system and integrated air cleaner system on a typical multiple transfer point application. The central dust collector consists of a negative pressure blower, a series of filter bags, a collection hopper, a screw conveyor to place collected material back into the material stream, and a series of ducts to pull air and dust from individual pickup points. The point specific integrated air cleaners consists of a negative pressure blower to pull dust and air from an application point through a bag-less filter media located at the application point. The agglomerated material is then redeposited into the material stream at point of use without the need for ducting or a central material hopper. The assessment yielded a 54% reduction in capital expenditure and a 26% reduction in operating costs for the same application when using individual dust filters as opposed to a central system. In addition to the lowered cost, there are reductions in risk associated with the elimination of ductwork and the central containment enclosure for collected explosive dust. By the conclusion of this paper, the reader will have a better understanding of the quantifiable differences between a central dust collection system and a set integrated air cleaner systems. BACKGROUND Spillage has always been a problem in the bulk solids handling industry. As long as there have been conveyors, there has been spillage. Spillage is material that falls off a conveyor belt and creates a hazard in the environment around a conveyor belt."

Jan 1, 2016

By Yoshinori Shimada, Oleg Kotiaev, Hiroaki Sakamoto, Toshihiro Asakura, Naotoshi Yasuda, Norikazu Misaki, Masahiro Shinoda

"To ensure that trains run safely, the performance of railway civil engineering structures is checked by periodic inspections. General inspection method has merits and demerits, but none of them offers the combination of high accuracy and quick inspection. In an effort to resolve this problem, West Japan Railway Company, the Institute for Laser Technology and the Railway Technical Research Institute jointly developed a remote laser sensing system as an alternative to the impact acoustics method for detecting defective concrete elements in tunnel linings. The proposed remote laser sensing system has two lasers, one to apply an impact to the concrete surface and the other to measure the vibration of the concrete generated by the impact laser. The impact laser is a high-energy pulse laser that induces vibration in the concrete. The detection laser has a signal beam and a reference beam. The signal beam reflects on the concrete surface and goes into the dynamic hologram crystal. The reference beam diffracts in the dynamic hologram and enters the detection sensor with the signal beam. The vibration of the concrete surface can be measured to detect the movement of an interference pattern. A prototype of the remote laser sensing system was developed as shown in Figure1. A vibration and acoustic insulators are equipped to remove a noise generated from a maintenance car or electric generator in this system. The proposed laser remote sensing system and the detection algorithm were verified with the help of field test conducted in a tunnel on the Shinkansen. An impact test using hammering was applied to obtain the accurate response acceleration on the surface of the concrete before application of the proposed method. In this test, the result obtained from the proposed method has good agreement with that obtained from the impact test by hammering. Consequently, it is verified that the proposed method can be used as an alternative to the standard impact acoustics method."

Jan 1, 2016

By Sandeep Upadhya, Marc Morgan, Baljinder Bassi, James Fletcher, Mike Deevy, Nishant Nayan

"In order to protect public safety in the event of a deliberate fire attack, underground rail authorities are increasingly considering the need to design for arson-initiated fire scenarios. Where typical design fires for modern rolling stock mean a peak fire size is reached after 12 minutes, an arson-initiated fire reaches its peak within 2-3 minutes. We present the innovations required to successfully incorporate this requirement on a recent design-build project. In stations 3D modelling is used to optimise smoke reservoir designs, smoke chimneys, station boxes and tunnel geometry to allow coordination with structural requirements. In tunnels, novel coupling of one dimensional network modelling and 3D Computational Fluid Dynamics (CFD) is used to improve assessment of complex fire scenarios. Finally, the impact on tunnel structures is assessed through comparison with standard time-temperature curves and risk of explosive spalling. INTRODUCTION An increasing regulatory environment and the appreciable influence that terrorist incidents have had on public safety policy have motivated the need to protect against large arson fires, especially in civil structures and public transport systems. With a greater reliance of a growing urban population on underground subway systems, design of such infrastructure is continually being reassessed and developed worldwide. Underground rail authorities are paying increased consideration to the design of fires - with properties beyond the upper regions of growth and intensity - amongst arson fire studies. Use of fire hardened materials on modern rolling stock means fires caused accidentally can be expected to develop relative slowly. However, recent experiments involving large initiating fires (as would result from an arson attack) have shown rapid fire growth rates and flashover leading to greater maximum heat release rates, Hadjisophocleous (2012), White (2010), and Lönnermark, et al. (2015). This paper describes the challenges and innovations required to complete a detailed design to control smoke from such aggressive super-fast growing fires. Computational modelling is used to demonstrate the required smoke control design by configuring the mechanical exhaust system combined with careful coordination with the architectural and structural design. The design objectives are to provide tenable egress paths in accordance with NFPA 130 (2014) and fire-fighting access. Finally, analysis of the design fire is used to inform the tunnel lining design, reducing the risk of explosive spalling, protecting the asset in the event of a severe fire."

Jan 1, 2016

By L. Magne, A. Pinto, M. Maldonado, J. A. Finch

Estimation of gas holdup from electrical conductivity measurements has been used in lab and industrial installations. The approach is based on the application of Maxwell's model, which relates the concentration of a dispersed phase in a continuous medium to measurements of the electrical conductivity of the dispersed phase, continuous medium and the resulting mixture (dispersion). When applied to inferring the collection zone gas holdup in a three phase system and to facilitate real-time on-line measurement, the slurry is assumed to behave as the continuous medium and gas bubbles as a nonconducting dispersed phase. This article derives an equation for estimating gas holdup in a three phase system, eliminating the assumption that the slurry behaves as a continuous medium but rather as a dispersion of non-conducting solid particles in water. In this formulation only water behaves as the continuous medium in the sense of Maxwell, and gas holdup in a three phase system is then calculated from the application of the Maxwell model twice: (1) to determine solid content in a two-phase system, and (2) to determine solid plus gas holdup in a three phase system. To validate the new equation and quantify the errors incurred by assuming slurry is the continuous phase a laboratory flotation cell was instrumented to continuously measure the conductivity of two and three phase dispersions with known solids contents. As the amount of gas in a lab flotation machine is difficult to measure directly or by another indirect technique such as using pressure signals, 2.5 mm dielectric plastic spheres having a density of ca. 1.3 g/cm3 were used instead of air bubbles for validation. Experimental results demonstrated that the continuous medium assumption underestimates gas holdup and that the resulting bias error increases linearly with the solid content and decreases with the magnitude of gas holdup.

Jan 1, 2016

By Daniel de la Rosa, Juan Manuel Mayoral, Damián Vital

"This paper presents a numerical study regarding the loads, and the corresponding damage, taken by the primary and secondary lining of a tunnel built in cemented fine-grained stiff soils. This study aims at establishing more rational design criteria that take into account explicity the lining performance. A 3.5 km long tunnel to be built in a densely populated northwest area of Mexico City, was considered as case study. Series of three-dimensional finite difference models, developed with FLAC3D, were used to simulate the tunnel construction, and to compute the ground settlements, internal forces, bending moments, and displacements acting both on the primary and secondary tunnel linings. Interaction diagrams were used to study the lining performance. Several advancement lengths, and tunnel covers were considered to establish their impact on the loads transferred to the tunnel lining. A practice-oriented damage criterion for tunnels was proposed based on the interaction diagram analysis. INTRODUCTION Lining performance during conventional tunnelling, CT, as defined by the International Tunnel Association, ITA (ITA 2009) is strongly affected by the construction procedure. Special attention must be taken in cemented fine-grained materials, such as those found in the northeast portion of Mexico City, due to the potential of fragile failure (i.e. the soil fails suddenly without important deformation) that these soils may exhibit. During CT, it is assumed that the ground strength contributes to the stability of the excavation, as long as the lining is built correctly. It is common practice to consider two structures, which together form the tunnel support: 1) A primary lining, which is a flexible support, which allows excavation walls to deform to mobilize part of its shear strength, and thus contributes to the tunnel self-stability, and 2) A secondary lining. Commonly, the primary lining consists of several layers of shotcrete. In this case the installation method guarantees perfect contact between the lining and the excavation perimeter. The secondary lining, if required, is used to withstand the load conditions in the long term and also has an esthetic function. This paper presents a numerical study aimed at establishing a performance damage criterion for the primary and secondary lining design in cemented fine-grained stiff soils. Due to the lack of data, the strength and deformation parameters were established through empirically-derived relationships. Three-dimensional finite difference models were developed to simulate the tunnel construction, and compute ground settlements, internal forces, bending moments and displacements acting both on the primary and secondary tunnel linings. Interaction diagrams, along with a damage criterion were used to study the lining performance. From the results gathered insight was gained regarding tunnel lining performance during CT."

Jan 1, 2016

By Yadong Xue, Fei Wang, Hongwei Huang, Yan Sun

"Increasing attention to subway tunnel maintenance is being paid with the high speed development of urban rail transit system in China. A novel moving tunnel inspection equipment based on machine vision is developed in this paper. High resolution image acquisition system is proposed for tunnel crack and leakage inspection. The main components of this image acquisition system includes high speed CCD cameras, linear lights and high performance computer. To inspect the crack less than 0.3mm with a 3-5km/h speed in subway tunnel, we need to consider resolution and line rate of camera, pixels of cameras, range of inspection and illumination intensity of lights simultaneously. The optimization design is proposed to make the equipment more convenient for tunnel use. Entire tunnel situation can be detected and recorded in a single inspection process. This equipment has already been verified in Shanghai subway tunnel for defects inspection.1. INTRODUCTION In China, the quantity of subway tunnel has reached a large scale in recent years. Until 2014, there had been more than 2300km of subway tunnel in China which accounted for nearly three quarters of Chinese urban railway system (Zhang Chen,2015). In some metropolises like Beijing and Shanghai, most of the metro tunnels has already run over 20 years which within maintenance phase. This has brought about plenty of inspection work and maintenance work to guarantee the tunnel under the serviceability limit states. The increase of running mileage of subway tunnels in China has been displayed in Fig 1."

Jan 1, 2016