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By Michael D. Justason

"In January 2009, long-time competitors, Anchor Shoring & Caissons Ltd. of Toronto and Bermingham Foundation Solutions of Hamilton, joined forces to tackle one of the Greater Toronto area’s largest deep foundation projects: the West Toronto Diamond Rail Grade Separation. The two companies formed the “West Diamond JV” and succeeded in winning the contract from the Canadian National Railways. This deep foundations work was the first and most significant part of the $300-million-plus rail grade separation project. A big part of the job turned out to be dealing with local government regulations and citizens’ concerns with noise and vibration.The project is approximately 10 km (6 mi) northwest of downtown Toronto in an area of mixed-zoning including light industrial, commercial and residential buildings. The area is commonly called the “The Junction,” because of the heavy rail- traffic. The “West Toronto Diamond” refers more specifically to the railway junction where the North-South tracks of Canadian National (CN) Railway meet at a level crossing with the East-West tracks of the Canadian Pacific (CP) Railway. The goal for this part of the project was to convert the West Toronto Diamond into a grade-separated junction by depressing the CN lines under the CP lines, thus allowing commuter rail carrier, called GO Transit, intercity carrier VIA Rail, and CN freight trains to pass through the new underpass.Dawn Tattle, president of Anchor Shoring & Caissons says, “not only is the site in a densely populated area adjacent to homes and businesses, the crews worked adjacent to active rail lines with numerous trains passing daily. During the 7-hour working day, approximately 60 trains passed through the site in very close proximity to working crews.” Safety was paramount. While trains were passing through the site, it was a railroad requirement that all equipment and men stop working. In addition, at those times, all personnel were required to stay 6 m (20 ft) from the tracks and were required to face the tracks. For the faster commuter trains, this work interruption could last as little as 2-3 minutes, while interruptions caused by the slower freight trains could last as long as 25 minutes. The most disruption to the site occurred during the morning commute between 7 to 9 a.m., so work did not really get underway until after that time. Once work finally commenced the race was on to finish as much as possible before the afternoon commute – hence the shortened work day. The amount of disruption caused by the trains was a big unknown faced by the JV going into the project, but crews adapted quickly to the very unusual work environment"

Jan 1, 2012

By J. R. Kish, J. Dabrowski

"The susceptibility to intergranular corrosion modes is a major technical issue preventing widespread utilization of higher strength welded AA7xxx extruded beam profiles, in the peak-aged T6 condition, in automotive bumper assemblies. A study was undertaken to evaluate the relative exfoliation corrosion resistance (ASTM G85-A2) as a function of joint design parameters, namely the base alloy composition, heat-treated condition and beam orientation after exposure to a cyclic acidified salt spray test. This paper documents the major findings extracted from this study.INTRODUCTIONBumper systems play a predominant role in the passive safety of an automobile, since they are one of the main structures for absorbing the collision energy in the event of an automobile crash. Heattreatable AA6xxx-series (Al-Mg-Si) and AA7xxx-series (Al-Zn-Mg) Al alloys, with relatively high strength, toughness, energy absorption, weldability and formability, make it possible to design costcompetitive bumper systems to crush in a controlled fashion. In this context, Cu-lean AA7xxx extrusions, such as AA7003 and AA7108, which exhibit higher strength than AA6xxx extrusion, such as AA6082, represent an attractive light weight material from which to fabricate bumper assemblies (Clausen et al., 2000; Pedersen et al., 2008; Chen et al., 2009).Arc welding is a key joining process for AA7xxx alloys within the transportation industry. A major technological issue preventing widespread utilization of arc-welded AA7xxx joints is the susceptibility to severe localized corrosion (Kent, 1970, Reboul et al., 1985; Holroyd et al., 1987). It generally occurs as exfoliation corrosion within a heat affected zone (HAZ) a few millimeters from the weld bead, or a type of stress corrosion cracking (weld-toe cracking), which initiates at the weld toe and propagates into the interfacial region between the weld bead and the HAZ (so called “white zone”). In addition to the micro-galvanic cell activity induced by the intermetallic compound constituent and strengthening particles present, there is strong evidence that macro-galvanic cell activity between the weld bead and base AA7xxx alloy may be playing a controlling role. Electrochemical profiles taken across fusion welded joints, in cross-section, during exposure to saline solutions suggest that a significant potential difference exists across the AA7xxx arc-welded joint (Shumaker et al., 1967; Grauer and Wiedmer, 1980; Tuck, 1985, Onoro and Ranninger, 1993). These studies consistently show that the HAZ and base alloy are more electronegative with respect to the weld bead (arc-welded with AA5xxx filler wire). Despite this initial important work, the majority of the recent corrosion research effort on welded AA7xxx alloys has focused on the performance of friction stir welds (Lumsden et al., 1999; Wadeson et al., 2006; Hatamleh et al., 2009)."

Jan 1, 2012

The global mining industry will always face significant challenges. Some, though, are bigger than others. What do you consider the major challenges facing the mining industry as a whole and SME in particular? Without a doubt, the major issue in both coal and metal/nonmetal mining industries is the ?graying? of the workforce in all aspects of mining. As the baby boomers continue to age, valuable experience is being lost by industry, government and academia. And there is the potential for SME to lose some of its membership. Now with that said, I should note that, despite the aging of the workforce, SME membership continued to grow by 7.1 percent during 2011.

Jan 1, 2012

By Fabio Mielli

Encompassing between 20 and 40 percent of the typical mining operational costs, energy in mining operations is a growing concern for the industry. However, this concern is a complex, multi-faceted variable that involves government regulations, societal pressures, cost and competitiveness. Managing energy efficiency is becoming a keystone of successful companies. The suggested energy strategy in mining and mineral processing operations must follow a well-structured approach to include the following: ? Understanding where energy is being used and why. ? Recommending and implementing energy conservation measures. ? Driving visibility to targets and results. ? Leveraging the energy spent across the enterprise. ? Developing a robust energy and sustainability strategy. Additionally, it must ensure that all decisions support the financial and operational integrity of the business.

Jan 1, 2012

Slurry flow, including flow through the charge, through the discharge grates, along the pulp lifters and its discharge from the mill is an important contributor to the efficiency of the grinding process within a SAG mill. Poor transport of finer ground material can adversely affect grinding leading to excess energy consumption and over-grinding of fine material. This paper extends a 1-way coupled DEM-SPH method to three dimensions and applies it to a 1.8 m diameter by 0.6 m long AG/SAG pilot mill. This provides detailed information on the internal flow of slurry within a SAG mill, including the prediction of dry regions and of slurry pooling. Full 3D analysis also allows the pulp flow patterns into and out of the mill via pulp lifter chamber to be investigated.

Jan 1, 2012

By Antonio Mendoza

El presente texto describe el sistema de manejo de agua y aire, las actividades integradoras, preventivas, de análisis y ejecución realizadas para describir la respuesta a los retos del futuro inmediato para alcanzar los objetivos ambientales en la mina Antamina.

Jan 1, 2012

By P. Dinham, G. C. Summerton, N. McCulloch, S. Dowling, D. C. Craig

"Development of a process for the treatment of a nickel copper matte rich in the minerals heazlewoodite, chalcocite and bornite has demonstrated significant base metal recoveries and metal separation efficiencies. The determination of chemical and mineralogical changes occurring in the individual leaching stages in laboratory experiments has enabled a better understanding of the complex leaching chemistry. The chemistry and mineralogy of the piloting and laboratory processes are discussed.INTRODUCTIONThe nickel-copper sulfide ores of the South African Bushveld Complex are among the most important Platinum Group Metal (PGM) bearing ores, and contain the world’s largest reserves of platinum. The treatment used in the recovery of PGMs from these ores includes three types of processes, namely ore concentration using physical techniques such as flotation and gravity separation, concentration by pyrometallurgical means, hydrometallurgical extraction of the base metals followed by the PGMs. Following milling of the ore, flotation involves the separation of high value minerals from gangue by taking advantage of the differences in their hydrophobicity. These differences are generally maximized through the use of a surfactant or wetting agent. Concentrates are then thermally treated and melted which brings about physical and chemical changes that enable the recovery of base metals and PGMs. The main aim of the smelting and converting process is to separate and eliminate the valuable metals from the bulk of the unwanted gangue and essentially all of the iron and to concentrate the metal VALUES (into a high grade converter matte. The matte can be further enriched by magnetic separation, producing a PGM-rich magnetic fraction and a base metal-rich non-magnetic fraction. The magnetic fraction is treated by hydrometallurgical processes to produce a PGM concentrate which is further refined to separate and purify the individual metals. The non-magnetic fraction is treated to produce marketable metal VALUES (such as nickel, copper, cobalt and to a lesser extent PGMs. The principal objective of any hydrometallurgical extractive process is to leach the desired elements selectively into an aqueous phase so as to separate them from the bulk of the material. (Crundwell, Moats, Ramachandran, Robinson and Davenport, 2011; Hundermark, Mncwango, de Villiers and Nelson, 2011)."

Jan 1, 2012

By G. Van Weert, O. Wang

"As part of a general review of processing double refractory ores through Barrick Gold’s autoclaves / CIL facility at Goldstrike, blanking the preg robbing native carbon in the process solids with hard (m.p. 55 - 60 º C) paraffin wax was studied, specifically in relation to pressure oxidation. The improvement in CIL gold extraction was found to depend on the wax addition point, with hot, dry contacting of the ore in the presence of wax - prior to POX - yielding the largest, most consistent improvement in gold extraction.INTRODUCTIONDouble refractory gold ores present two barriers to gold extraction. The first is generally a physical barrier: the gold is encapsulated or dispersed in a matrix which is impervious to the gold lixiviant. In most cases, including Carlin Trend, NV, deposits, this involves a pyrite or arsenopyrite matrix, although minor gold may also be dispersed in competent silica (quartz) or iron oxides. Gold can be rendered accessible by oxidative destruction of such sulphide matrices. At Goldstrike this is practised by roasting and autoclave oxidation (Thomas, 1994). It is the latter route to which this paper refers.The second barrier refers to the actual gold recovery. Gold may be extracted from the pressure oxidized solids with cyanide, forming a gold cyanide complex. One characteristic of this complex is that it adsorbs on graphitic surfaces. This is taken advantage of on a large scale by gold millers, who use manmade activated, i.e., graphitized carbon particles to remove the gold from solution during leaching: the Carbon-In-Leach, or CIL process. The gold cyanide bearing carbon particles are larger than the ore solids and can be separately recovered by screening. Goldstrike uses the CIL technology to recover gold. The second barrier becomes problematic when the ore naturally contains graphitic orcarbonaceous material, hereafter referred to as native carbon (versus the man-made activated carbon). This material may also adsorb gold cyanide in competition with the activated carbon. Since the native carbon is ground with the ore it is much smaller than the activated carbon. Any competition between the two carbons may produce a loss of gold from the pregnant leach liquor to the process tailings. This phenomenon is called “preg robbing”. Goldstrike ores come from the Carlin trend, which is known for the occurrence of native carbon (Adams & Burger, 1998; Schmitz, Duyvesteyn, Johnson, Enloe & McMullen, 2001; Tretbar, 2004)."

Jan 1, 2012

By C. Liley

Open cut blasting at the Ernest Henry mine has the potential to cause damage to nearby underground workings. This paper is a case study of the blast vibration management project which was conducted to ensure pit blasting did not adversely affect the stability of upper production levels or cause damage to the underground primary fan units.

Jan 1, 2012

By Egbert Burchardt

The challenge of "ore bodies getting steadily harder and lower in grade" was brought to light during the first oil crisis in the 70's. Shortly afterwards, HPGRs appeared on the scene with the promise of saving energy. This combined with developments in wear protection for the rolls ushered in a period of trade-off studies that considered the HPGR as an option to improve project economics or to even make projects feasible at all. Since then, applications of HPGRs at Cerro Verde (Freeport), PTFI Grasberg (Freeport), Mogalakwena (Anglo Platinum), Tarkwa (Goldfields), Boddington (Newmont), Penasquito (Goldcorp), and others have contributed to the creation of a formidable basket of operating experience. Collected through years of successful operation, this information has been used to validate design criteria, scale-up factors and establishing a clearer picture of what "to do" and what "not to do". This paper compares results from various mining operations using HPGRs in their processing plants. Some of the lessons learnt in different operating environments are reviewed in order to support proper implementation and operation of HPGR's. Some of the development programs that have been initiated to improve wear life of the tyres and to reduce overall operating costs are reviewed. It is timely to summarize today?s experience and analyse its implications for existing and new operations.

Jan 1, 2012

By P. Amelunxen

It is well-known that the particle breakage mode that occurs in a semi-autogenous mill is significantly different from that which occurs in a ball mill, enough so to warrant very different lab scale breakage tests and scale-up models. This phenomenon, at the plant scale, leads to changing process constraints depending on the particular properties of the ore. For example, hard or coarse ores might bottleneck the SAG/AG mill throughput, while the ball mills might constrain throughput when milling soft or fine ores. Because the power draw of a ball mill is fairly constant compared to that of a SAG/AG mill, periods of SAG/AG mill bottlenecks lead to increased ball mill circuit specific energy consumption and a finer grinding circuit product size, which together constitute a loss of efficiency of the overall process. Because HPGR circuit throughput is less sensitive to changes in ore hardness, this situation is less common or severe in those circuits. Furthermore, the ball mills are somewhat decoupled from the upstream crushing circuits through the use of surge bins, which also helps to mitigate this effect. As a result, ore hardness variability constitutes a significant cost penalty that should be applied to SAG mill/ball mill/pebble crusher SABC circuits when evaluating the relative economics of different grinding circuit configurations. Nevertheless, the issue is by-and-large ignored, because most current HPGR trade-off studies are based on averaged ore hardness parameters. This paper provides an estimate of the magnitude of this penalty for a typical operation by using Monte Carlo simulation methods and plant data from Freeport-McMoRan?s autogenous, semi-autogenous, and HPGR-based comminution circuits. A case study from an in-house 96K t/d sulphide project is presented to illustrate the concept. It was found that by including variability effects, the trade-off NPV of the HPGR circuit over that of the SAG mill circuit increases to $84 million from negative $33 million, effectively reversing the original decision of selecting a SAG mill circuit for the fixed hardness case.

Jan 1, 2012

By F. Crundwell, N. Steenekamp

"The leaching of sulphide minerals generates a significant amount of energy. There are three systems that might be used to remove this energy. These are: cooling coils, quench water, and flash recycle. Flash recycle is the recycling of slurry from the autoclave to the feed tank. Heat is removed in this arrangement when the slurry at elevated temperature and pressure is flashed to atmosphere, releasing steam. The slurry is returned to the autoclave at lower temperature, resulting in cooling. The cooling is directly proportional to the steam released from the recycled slurry. Design equations and results for the flash recycle system are presented. A fourth proposal for removing heat is to recycle slurry from the back of the autoclave. These four alternatives not only remove the heat, but also have an effect on the leaching efficiency. Amongst the four alternatives, design calculations indicate that the flash recycle option is the optimal solution in terms of leaching efficiency and heat removal, and recycling product from the back of the autoclave is the worst. In spite of its efficiency in terms of heat removal and leaching, the implementation of the flash recycle system is limited to a few operations in the platinum industry.INTRODUCTIONIn considering ways to improve leaching operations, focus is placed on the chemistry, on the kinetics, the agitation and perhaps even on the gas mass transfer conditions. Attention is less frequently placed on the removal of energy from these reactors and how this might limit performance.The pressure leaching of sulphides releases a significant amount of heat. For example, the reaction for the leaching of chalcocite, Cu2S, given by"

Jan 1, 2012

By S. Marx

More than twenty years ago Sasol, ISCOR, and some parastatals played a major role in ensuring that South Africa had sufficient technical skills. When the economy became tight and business and government were pressurized to decrease costs, the first budgets that were reduced were the training budgets. It seemed to be too expensive and too time-consuming to train apprentices. According to Stacey2, this is a major strategic issue facing the mining industry in South Africa. Two factors added to the shortage of skills challenge: ? Skills erosion and job losses ? Artisans ? currently the economy produces 5 000 but the need is 12 500 ? Level of mechanization in South Africa less than 10 per cent ? Average age of operators and artisans is 50 ? Greater awareness of occupational health effects of hand-held drilling. ? Workplace challenges ? The impact of HIV/AIDS and other employee wellness issues ? Changes and challenges in workplace environment i.e. the mining industry.

Jan 1, 2012

By Lon Santis, Michael Swisdak, David Leidel, John Tatom

The Institute of Makers of Explosives (IME) and A-P-T Research, Inc (APT) have developed and released a quantitative risk management tool, IMESAFR (IME Safety Analysis For Risk), for the commercial explosives industry. Consequence algorithms in IMESAFR are considered state-of-the-art. Generally, they mirror those in SAFER (US Department of Defense Explosives Safety Board quantitative risk management software). The science behind the software has now been assessed for its maturity. Results have identified areas where additional test consequence data could improve predictions. To address these areas, full-scale testing programs to provide the needed data have been formulated. Proposed testing efforts include work to: (1) improve characterization of explosive articles now absent from SAFER, and (2) refine modeling of the Potential Explosion Site (PES) types, particularly small metal structures, also not found in SAFER. Goals of each program as well as requirements for conducting the tests have been established. Testing results are to be used to improve the algorithms and to further the state-of-the-art in risk-based explosives safety.

Jan 1, 2012

By Michael S. Moats, Alexander Derrick

"The Winand Diagram was developed and has been used for decades to illustrate the interaction between polarization, mass transport and inhibition on the resulting structure of a metal electrodeposit. Recently, Adcock et al. criticized the Winand Diagram and developed their own structural diagram based on nucleation and plating overpotentials. Their work was based on zinc electrodeposition using a galvanostatic staircase method. This work explores the nucleation and plating overpotentials for copper electrodeposition using conditions typical for primary electrowinning and the galvanostatic staircase experimental technique. Additionally, the effects of organic additives and plating substrate on these overpotentials are reported.IntroductionThe control of electrodeposited structures is critically important to modem electrometallurgy operations to insure proper quality and efficient energy use. Electrodeposition of base metals for primary recovery (e.g. electrowinning or electrorefining), while similar to plating for decorative or device manufacturing, differs in the need to produce deposits that cover large areas and grow to significant thickness. Thus, controlling nucleation and particularly growth of electrodeposits is critically important for base metal electrometallurgical operations.The control of nucleation and growth on an industrial scale is most influenced by five parameters - current density, temperature, metal concentration, electrolyte agitation and additives. The effects of these parameters on electrodeposition are interrelated. To describe their effects on the type ofelectrodeposits generated and provide practitioners with a useful tool, Winand developed what is known as the Winand Diagram [1-2]. An adapted version of the Winand Diagram is shown in Figure 1.Winand characterized electrodeposits using Fischer's classification [3] and plotted the various deposit types versus inhibition on a vertical axis and the ratio of current density to bulk metal concentration on the horizontal axis. Inhibition intensity is a complex parameter and is still not well understood even though Fischer introduced the term in 1960 [4]. Often, inhibition intensity is simplified to equal the concentration of organic additive at the deposit surface and is related to the inverse of the exchange current density of the metal being deposited. The ratio of current density to bulk metal concentration is used to represent the ratio of crystallization overvoltage to mass transport of the depositing ion. As such i/iL could also be along the horizontal axis, where iL is the limiting current density of the electrodeposition reaction."

Jan 1, 2012

By S. Kelebek, B. Nanthakumar

ABSTRACT The sensitivity of sulphide minerals towards oxidation depends on the mineralogical makeup and nature of sulphide ores. This paper focuses on chalcopyrite behaviour in a nickel-copper sulphide- ore matrix that was aged in the mine-site stockpiles. Results of collectorless, collector-induced flotation and recovery by size are presented following a discussion of XPS analysis that was used to gain insight into oxidative alteration of chalcopyrite’s surface chemistry. Chalcopyrite maintains its high flotation activity despite exposure to weeks of oxidative conditions. It is concluded that chalcopyrite is quite tolerant to stockpile oxidation due to various factors related to alteration of its surface chemistry.

Jan 1, 2012

By R. K. Rajamani

Discrete Element Method simulation of charge motion in ball, SAG and autogenous mills has become a standard for design of mill internals, power draft evaluation, etc. Both two-dimensional and three-dimensional codes are being used. The two-dimensional code dominates the user market since the code completes a simulation in one or two hours. On the other hand, three-dimensional codes have been in the domain of specialists who can handle the complexity of the code and have access to parallel computing hardware. For the first time, this barrier is overcome via computing with graphic processing units (GPU). Commodity graphics cards now allow parallel computation with hundreds of processors. It is shown that the computational time has been reduced by a factor of fifty using GPU computing. Hence, SAG charge simulation results in three dimensions are achievable in a few hours using affordable desktop machines. The GPU computing shown here enables the three dimensional simulation into a manageable daily task for mill designers and researchers. On the technical side, the simulations can be elevated to a higher level of complexity to simulate breakage and transport. First, the speedup factor of fifty is established for the Nvidia GeForce GTX 580 graphics card. Next, four simulation tasks, consisting of AG, SAG and ball mills are reported. The simulation of AG and SAG mills are completed in less than 8 hours. The ball mill simulation with 1.25 million spheres is completed in 27 hours. In the near future, as the graphic card hardware advances the compute time can be halved.

Jan 1, 2012

By Yuanbo Zhang, Daoyuan Zhang, Youlian Zhou, Guanghui Li, Tao Jiang

"Modified humic acid (MHA) has been developed by Central South University (CSU) and authorized in China. It has been reported that MHA is an effective binder for oxidized pellets prepared from specularite concentrates. In this research, effects of MHA binder on roasting behaviors of the specularite pellets are studied. MHA is an organic binder, containing much carbon, hydrogen, oxygen, etc. During the roasting, MHA can provide some heat because of combustion of hydrocarbon, which is beneficial for the recrystallization of Fe2O3 in the specularite pellets at high temperature. Simultaneously, part of hematite particles within the pellets are firstly reduced to magnetite, then, magnetite is oxidized into secondary hematite, which obviously improves the roasting performance of specularite pellets.IntroductionOxidized pellets have been widely used in steel production as a kind of high quality burden for blast furnace ironmaking [1]. In recent years, production of oxidized pellets is developing very fast. Therefore, the supply of high quality magnetite concentrates, which is the most suitable for pellet production, becomes scarce. It is imperative to pursue new alternative materials for oxidized pellet production [2]. Specularite concentrates have attracted widespread attention due to the advantages of high total Fe grade and low impurity content. However, due to the poor ballability and firing performance, specularite has not yet been widely applied into pellet production [3, 4]."

Jan 1, 2012

By Lawrence Nordell

A Conjugate Anvil-Hammer Mill (CAHM) has the potential to replace conventional crushers and SAG mills, with their respective conveyors and stockpiles, in a SABC circuit. It may improve comminution circuit efficiency by 100%. CAHM compresses rock in a more efficient way, similar to 19th century stamp mills, which follows the fundamental research of Schönert (1990 & 1996). CAHM efficiency is being proven through the use of ROCKY (2011) Discrete Element Method (DEM). ROCKY features allow it to simulate realistic comminution. CAHM is customizable with many geometries that are rock-property specific. ROCKY?s wear modeling compliments the structural integrity of the design.

Jan 1, 2012

In 2009 Newmont Mining Corporation?s annual global spend on grinding media reached $94M USD, having doubled in the five years since 2004. The major contributing factor to the spend escalation during this period was unit consumable price, with total media consumption also rising as a function of annual ore tonnes milled. In an effort to better understand and manage the growth of this expenditure a significant supply chain management program was implemented. This was complemented by a series of technical initiatives focussed on grinding media specifications, quality management and the prediction of grinding media wear rate as a function of physical ore characteristics. This paper discusses the methodology and outcomes of these activities.

Jan 1, 2012