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By T. Marin, J. E. Seccatore, M. Cardu

The most energy-intensive process in the mining industry is particle size reduction – comminution. The first phase of this process is blasting to fragment the rock from the initial Boussinesq’s halfspace size. Scientific literature demonstrates that the output of a blast in terms of fragment size distribution can be manipulated by varying the specific charge (powder factor) and charge distribution. This study focuses on the influence of blasting on the internal resistance of the blasted fragments; in particular the influence of the spatial distribution of charges. Small-scale blasts were performed on 14 marble blocks using different powder factors and charge distributions. Three control blocks were fragmented by mechanical means for comparison. The results show the correlations between charge distributions and the specific energy of mechanical comminution. Opportunities for adjusting charge diameter and distribution in opencast blasts to improve the performancet of comminution circuits are discussed.

Aug 8, 2024

By Bora Okumusoglu, Devon K. V. Mothersille

"AnchorTest is an innovative software package, specifically developed for tablets, that permits ground anchor test data assessment and management in real time. The solution has two components: a front-end tablet app runs on the Apple iPad platform, and a back-end Cloudbased system running on Amazon Web Services with an online cross-platform website, which can be accessed from any PC, tablet or even mobile smartphone. This tool provides full data analysis and data management capabilities and portability to create greater efficiency in the anchor testing process. AnchorTest is programmed to accommodate the major international anchor testing codes and incorporates an intuitive user interface, which is revolutionary compared to conventional engineering software designs. The use of this tool creates an environment where the testing of ground anchors has effectively become a paperless exercise with greater efficiency and access to instantaneous feedback on the performance of anchors in relation to established acceptance criteria.Historically, project personnel record and analyze the results from anchor load tests using spreadsheets and a laptop computer and/or on predesigned paperbased test sheets (usually as a backup of the testing). In addition, the processing of the test results is not typically performed in real time as the testing progresses — the calculations and analysis are performed either afterward while still on site (if a field office is available) or after returning to the office. Undoubtedly, on larger projects containing numerous anchors where multiple anchor tests may be performed at the same time, processing, analyzing and accepting the load test data and results can be especially time consuming, which could cause delays to the construction schedule.DevelopmentThe need for a more automated and digitized approach to record, process and analyze the data from anchor load tests was highlighted at a deep basement project for a mixed-use development complex in Moscow, Russia. The diaphragm wall supporting the structure was approximately 1,970 ft (600 m) in perimeter length and about 148 ft (45 m) deep, with an excavated depth of about 82 ft (25 m), which required six levels of single bore multiple anchors (SBMAs). This project provided a challenge to recording, processing and signing off on the data generated from some 3,600 3-unit SBMAs. More specifically, for this project, three hydraulically synchronized stressing jacks were used to stress and proof test each 3-unit SBMA, which resulted in nearly 10,800 data plots of the load-extension tests being generated. This project served as the main impetus in the conceptual design and optimization of AnchorTest."

Jan 1, 2017

Optimising flotation designs and innovations is a complex process involving many parameters, one of which is ensuring sufficient testwork is carried out at plant level before these innovations are launched in the marketplace. This paper will describe how modern design tools are utilized, what are testwork phases at various plants and how results and observations have helped to validate and optimise flotation design innovations. Scale-up of equipment has long been the prevalent trend, but how long can it continue? Are there other means for pushing the boundaries of present technology? Some present challenges and future directions are given in the light of theoretical criteria for scale-up and how it has been applied in practice. Very large flotation cells of 300 m3 size have been installed in New Zealand, and relevant results from the metallurgical and mechanical aspects are presented and discussed. Utilization of the cell volume is also important. New innovations in the hydrodynamic domain are presented and discussed. Means to enhance flotation of coarse and fine particles are shown with results from plant testwork. Accurate control of large flotation cells is vital to optimize yields and grades. Froth image analysis and intelligent level control are presented ? again - with relevant plant results.

Jan 1, 2014

By C. J. Greet

Grinding with an electrochemically inert grinding media (i.e., high chrome white iron) shifts the pulp potentials to more oxidising conditions, increases the dissolved oxygen content and reduces the EDTA extractable iron concentration when compared with milling with electrochemically active grinding media (forged steel). These changes in pulp chemistry produce cleaner particle surfaces, reduce reagent consumption, and increase concentrate grades and recoveries. This paper presents a robust laboratory test program that not only demonstrates the changes in the pulp chemistry, but also provide an indication of the magnitude of the metallurgical improvements that are possible. While laboratory studies are interesting, the proof is in the pudding! So, the paper provides an overview of plant trials conducted at several porphyry copper operations around the world: Newmont’s Cadia and Red Chris Operations, as well as Evolution Mining’s Northparkes Operation. These successful plant trials clearly demonstrate that selection of the right grinding media alloy will yield savings in grinding media consumption and reagent consumption as well as increases in revenue through improved copper and gold recoveries. However, many of the porphyry copper mines on the Eastern Pacific are copper-molybdenum deposits. The paper presents laboratory test results for typical copper-molybdenum operations and extrapolate these numbers to what might be expected should a plant trial occur.

Feb 1, 2025

By Kevin R. Johnson, Matt Caskey, Bryan Plaskett

Working in urban environments presents unique logistical challenges beyond those typically associated with traditional geotechnical design and construction. These challenges can include constrained sites with limited access and laydown area, vibration concerns for adjacent structures, and the need to complete work within limited schedules. When challenging geotechnical conditions like variable bedrock elevations are present, the need to balance performance requirements with logistical constraints become the driving factor when selecting deep foundation systems. This paper focuses on the deep foundations used for a new elevated pedestrian bridge at a major health care facility in Tampa, Florida. In addition to the technical design requirements, the owner required a deep foundation system that could offer low vibrations, rapid production, and clean installation to limit impacts on their properties and the public roadway that separated them. The paper describes the project specific geotechnical and design conditions, describes Ductile Iron Pile design, and focuses on how installation of the system addressed the unique logistical challenges. In addition, the implementation of a full-scale load testing program to assess compression, uplift, and lateral design capacities is presented. This paper represents one of the few published references for Ductile Iron Piles on projects in the United States.

Oct 1, 2022

By F. J. Hrach, K. P. Flynn, P. J. Miranda

"ST Equipment & Technology, LLC (STET) has developed a processing system based on tribo-electrostatic belt separation that provides the mineral processing industry a means to beneficiate fine materials with an entirely dry technology. In contrast to other electrostatic separation processes that are typically limited to particles greater than 75 µm in size, the triboelectric belt separator is ideally suited for separation of very fine (<1 µm) to moderately coarse (300 µm) particles with very high throughput. The high efficiency multi-stage separation through internal charging/recharging and recycle results in far superior separations that can be achieved with a conventional single-stage free-fall tribo-electrostatic separator. The triboelectric belt separator technology has been used to separate a wide range of materials including mixtures of glassy aluminosilicates/carbon, calcite/quartz, talc/magnesite, and barite/quartz. Separation results are presented for selected industrial mineral sources. An economic comparison of using the tribo-electrostatic belt separation versus conventional flotation for barite / quartz separation illustrates the advantages of dry processing for minerals.INTRODUCTIONThe lack of access to fresh water is becoming a major factor affecting the feasibility of mining projects around the world. According to Hubert Fleming, former global director for Hatch Water, “Of all the mining projects in the world that have either been stopped or slowed down over the past year, it has been, in almost 100% of the cases, a result of water, either directly or indirectly” (Blin et al., 2013). Dry mineral processing methods offer a solution to this looming problem."

Jan 1, 2016

By Jr. D'Angelo, Michael M. Blendy, Shawn Downey

"A grouted helical pile was used to support new buildings in the reconstruction of a large residential development. Foundation options were complicated by urban fill underlain with variable alluvial soil. A driven timber pile and grade beam system was recommended to support the new buildings. Other foundation options are also discussed. The grouted helical pile was quoted as an alternate and ultimately won the bid based on the economics and performance of the system. Data from 8 load tests was used to develop an empirical site specific relationship for determining pile capacity based on both installing torque and installation depth. Design to incorporate tolerance on installed pile location is presented. With the three phases completed, 554 residential dwelling units supported by 3645 grouted helical piles had been constructed covering 18 city blocks on the 44 acre site. IntroductionThe Philadelphia Housing Authority reconstructed the Tasker Homes housing complex located in southern Philadelphia, Pennsylvania, adjacent to the Schuylkill Expressway in the Grays Ferry area. Keating Building Corp. and Pennoni Associates were the general contractor and the structural engineer respectively. The original Tasker Homes development was constructed from 1940 to 1941 and consisted of 44 acres of primarily two and three-story residential brick buildings. These buildings were supported by a timber pile foundation system. The structural condition of the buildings supported on the timber piles was generally good in comparison to areas outside the buildings. These areas had settled possibly up to 2-feet in places due to the heterogeneous nature of the urban fill."

Jan 1, 2005

By Keith G. Wallace

The effect of face resistance on ventilation air leakage through stoppings was measured in a twin development heading. Face resistance was varied by alternately tightening or loosening the face line brattice to change the line brattice leakage. Results indicated that tight brattice lines are necessary to maintain acceptable airflow at the face but result in higher leakage throughout the entire system, reduced overall ventilation efficiency, and higher operating costs. Conversely, a low face resistance which simulated an auxiliary fan/duct system gave reduced stopping leakage losses, higher quantities of air at the last open cross-cut and greater entire system efficiencies

Jan 1, 1984

By Z. He

Based on full investigation of the characteristic of sphalerite in the residue obtained from cyanidation leaching process and the study of the mechanism of the interaction between flotation reagents and sphalerite with the aid of electrochemical analysis, the reagent named YO was developed for eliminating the depression effect of CN- on sphalerite and reducing the dosage of CuSO4. The achievements have been used in commercial production for the treatment of the cyanidation residue to recover the zinc minerals, obtaining a zinc concentrate with grade of 56.49% Zn and recovery of 86.63% Zn.

Jan 1, 2014

By Sean Peterfreund, Grant Finn, Ty Jahn

For urban underground development involving tieback anchors for excavation support, authorities having jurisdiction typically require tiebacks to be de-tensioned before project completion. This paper updates “A Proactive Approach to Tieback Anchor De-tensioning” (by Peterfreund and Finn, published in the 2017 RETC Proceedings), which discussed a new method employed in a cut-and-cover transit station project. Since publication of that paper, 237 tiebacks were successfully and rapidly detensioned from using a small-diameter drill to cut strands from the surface. To the authors’ knowledge, this was the first intentional large-scale use of a drilling method for this purpose.

Jun 13, 2023

By K. Forsberg, Ş. Kaya, C. Dittrich, M. Svärd, E. M. Peters

Scandium can be recovered from waste streams of other metallurgical processes such as red mud from the Bayer process and titanium dioxide acid waste. This is accomplished by an integrated process comprising leaching using acidic media, solvent extraction using organic solvents and stripping of Sc from the organic phase using NH4F solutions. The precipitation of scandium as (NH4)3ScF6 from NH4F strip liquors has been demonstrated at lab-scale with recoveries and purities greater than 98% and 98.3%, respectively. It is desired to assess the possibility of recovering the solvents for re-use in the process to improve its economy and environmental friendliness. Investigations have been conducted to recover alcohol by simple distillation from strip liquor-alcohol mixtures containing about 50 v/v% alcohol. The mixtures were obtained after anti-solvent precipitation of (NH4)3ScF6 using an alcohol to strip liquor volumetric ratio of 1:1. The starting strip liquor contained about 2000 mg/L scandium in 3 mol/L NH4F solution. In the recovery of methanol, the first distillate product collected had a purity of about 87 v/v% and this decreased slightly with time over two hours. The methanol distillate collected in the first 30 minutes with a purity of ca. 85 v/v% was re-used in anti-solvent crystallisation of (NH4)3ScF6 from the initial strip liquor, and the scandium recovery attained was about 98.6 w/w%, almost similar to that of 99.2 w/w% obtained using 100 v/v% methanol. For ethanol recovery, the first distillate product collected was approx. 84 v/v% pure and the distillate collected in the first 30 minutes with a purity of about 75 v/v% achieved a scandium recovery of about 97.2 w/w% in comparison to 98.5 w/w% obtained using 100 v/v% ethanol during anti-solvent crystallisation. Keywords: Alcohol recovery, methanol, ethanol, anti-solvent crystallisation, (NH4)3ScF6

Jan 1, 2020

By Markus A. Reuter, Jacob Wood, Robert Matusewicz

Over the last 20 years, significant improvements in copper smelter productivity have been realized through the advent of continuous smelting processes. This progress has until recently however, not been carried through to copper converting. Peirce-Smith converting has been widely used by the copper industry for 100 years but is limited by its batch nature in achieving large scale of production. A logical next step is therefore copper converting on a continuous basis with its inherent environmental benefits. A number of continuous converting technologies are currently in use or being developed within the copper industry, the majority of these operating with calcium-ferrite slags. A notable exception however is the Ausmelt Continuous Copper Converting (C3) technology which has focused on operation with ferrous-calciumsilicate or loosely called olivine type slags. This paper discusses the merits of the Ausmelt C3 process and the advantages offered in terms of operational flexibility and process control arising from the use of lime modified iron silicate slags. It also examines the effects of key process variables pertinent to continuous copper converting from both a theoretical and experimental/operational perspective.

Jan 1, 2009

By S. K. Sharma

The Bureau of Mines has investigated the fundamentals of the flocculation process. The objective of this study was to determine the effects of various physico-chemical parameters such as shear rate, polymer dosage, and polymer concentration on floc growth and to determine the applicability of a model in predicting polymer flocculation behavior. A rapid in-line particle size analyzer was used to follow the progress of both the floc growth and the breakage as a function of time. A genetic algorithm (GA) was used to determine the unknown parameters in the model and to fit a curve to the experimental data. Results show that the model, using GA as a tool to determine the unknown parameters, reproduces the experimental data with only reasonable accuracy and was relatively insensitive to the parameters. Results of the flocculation study showed that increases in polymer dosage had greater effect on the time required to reach the maximum floc size than on the floc size itself. It was also determined that, given all the aforementioned parameters, the degree of slurry mixing during the flocculation process had the greatest bearing on the floc growth.

Jan 1, 1993

By S. G. Shabestari

In the metal casting industry an improvement of component quality mainly depends on better control over the production parameters. Thus, thermal analysis cooling curve of the alloy is used for process control in aluminum casting industry. Cooling rates of the alloy during solidification process affect microstructure, grain size, eutectic silicon morphology, and dendrite arm spacing (DAS). In this research, effect of cooling rate on the microstructure and solidification parameters of 319 aluminum alloy that is a widely used alloy in automotive industry, has been investigated by means of thermal analysis. Seven different cooling rates have been obtained by using CO2-bonded silica sand molds with two different wall thicknesses, hot-work tool steel molds (H13) with and without coating, thin-wall steel molds with different coatings. In each case, cooling curve and first derivative cooling curve have been plotted by use of very accurate thermal analysis equipment. Effect of different cooling rates on solidification parameters e.g. Nucleation temperature (TN,a), nucleation undercooling (ATN,a), recalescence temperature (TR,a), solidification range (AT,s), and total solidification time (t 0 have been studied in the liquidus region. Microstructural evaluation has been carried out and DAS were measured in all solidification conditions. A numerical equation was proposed to predict cooling rates via measuring DAS in 319 aluminum alloy. Nucleation process and the effect of cooling rate have been interpreted by using thermal analysis cooling curves and microstructural study.

Jan 1, 2004

By Hung-Kei H. Lam

Rubidium and cesium were discovered by Bunsen and Kirchhoff about 100 years ago. These two elements are by no means as abundant as sodium or potassium. Their occurrence in minerals is widespread, but usually as minor constituents. There is no known specific ore containing rubidium, but rubidium is found replacing the. other alkali metals in .some minerals.. Perhaps the highest concentration of rubidium found in one mineral is in lepidolite, KLi(OH,F)2A12Si3010, which contains from 0 to 3.5%*Rb20. 0n the average, lepidolite contains about 0.5% Rb20. Other sources of rubidium are carnallite, KMgCl3?6H20; pollucite, H20.2Cs20.2AI203.9SiO2; rhodizite, R20.2A1203-3B203; biotite, H2K(Mg,Fe)3A1(Si04)3; sea water, rivers, marine and fresh water organisms, soils, and plants. Cesium, even though it is the least abundant. of the stable alkalies, has a specific ore. Pollucites a hydrous cesium aluminum silicate, may con¬tain as high as 42.5% Cs20, although again, the average Cs20 content is about 25% among the handful of known deposits. Other cesium-containing minerals are lepidolite and carnallite. Rubidium and cesium are very much like potassium in chemical properties, consequently, they are hard to separate. Because of the difficulty in obtaining pure cesium and rubidium compounds coupled with the scarcity-of supply, prices were high and the two elements enjoyed little industrial use. Just before the Second World War, the world. supply of rubidium and cesium, from Germany, was a matter of tens of kilograms per year and prices were about

Jan 1, 1959

By Pingchao Ke

A crystalline polyferric sulfate (PFS) adsorbent was synthesized by oxidizing and precipitating ferrous ions under atmospheric conditions. The morphology, structure, composition and specific surface area (SSA) and adsorptive efficacy to As (III) of the adsorbent were characterized by SEM/EDS and TEM images, XRD patterns, FT-IR spectra, BET SSA analyses and adsorption experiments. The adsorbent presents as morphology of near-spherical aggregate and good crystallinity. A small amount of goethite co-precipitated with PFS in the case of the initial ferrous concentration of 1 mol/L and increased the SSA of the aggregates. The absorbent with co-precipitation of goethite showed good adsorption to As(III) and good filtering performance in the high As(III)-content solution of 10–100 mg/L under acidic, neutral and alkaline conditions (pH 2.09–9.01), and its maximal adsorption capacity and adsorption efficiency were 7911 μg/g and 96% separately. After Adsorption, the stability of the absorbents adsorbing As(III) were evaluated by TCLP tests, and the results indicated that the absorbents adsorbing As(III) were extremely stable, and the concentration of arsenic in all leaching solutions were less than 0.01 mg/L.

By Robert McIvor

The following is a summary of the Robert H. Richards Lecture on “Learning and Good Fortune on the Road to Discovery” presented at the Mineral & Metallurgical Processing Division (MPD) Awards Plenary Session on Feb. 23, 2026 during the MINEXCHANGE 2026 SME Annual Conference & Expo in Salt Lake City, UT.

Mar 1, 2026

By Trevor Saldanha, Stephen Grano

A key uncertainty in flotation modelling is determining, a priori, the proportion of each mineral which will develop a certain rate constant for different feeds of variable liberation and hydrophobicity. First and foremost is the ability to predict the proportion of minerals that will not be recovered, even at very long flotation times, and which therefore report to the tailing stream as the non-floatable fraction (i.e., having a zero rate constant). Recent empirical evidence has shown there are at least two factors which contribute to heterogeneity in flotation rates and, in particular, the appearance of a non-floatable fraction - heterogeneity in the distribution of adsorbed collector amount on a particle-by-particle basis, even for the same liberated mineral in the same size fraction, and the existence of a critical contact angle below which the bubble-particle union is unstable. In this paper, inferred measures of the critical contact angle for liberated particles are compared with stability model calculations. This has demonstrated that the dependency of the critical contact angle with particle size and mineral specific gravity are explicable by bubble-particle stability considerations. This argument is further extended to the flotation behaviour of composite particles, as a function of liberation class, in which the wetting perimeter of the attached bubble on the composite particle surface is constrained by the presence of a surrounding hydrophilic domain for the case of simple binary composites. Reasons for the different flotation behaviour of composite particles having different textures, as noted in the literature, are also discussed in terms of the stability of the bubble-particle union.

Jan 1, 2014

By Deborah A. Spotts

Researchers at the Bureau of Mines have developed a technique for re- generating chromic acid-sulfuric acid etching solutions used in metal surface treatment operations. The technique utilizes a diaphragm cell equipped with a cation-selective membrane to oxidize cr3+ to cr6+ at the anode and to remove copper, the major metallic contaminant, at the cathode. Normally, spent etchant is discarded after approximately 3 days of use. Using the electrolytic cell, the etchant can be used for a year without replacement, From data obtained from industrial-scale cells, the installation of a regeneration cell with a 1,000-gal catholyte- holding tank has been estimated to save at least $240 per day, The payback period for the investment is estimated to be about 10 mo or less. Because the magnitude of these cost savings will vary at different locations, several graphs are presented to aid in calculating payback for a specific site. Using these graphs and the capital costs presented in this study, the payback period can be determined for installing a regeneration cell with a 500- or a 1,000-gal catholyte-holding tank in an existing surface treatment plant.

Jan 1, 1983

By Jamal Rostami, Wei Hu

Efficient performance of EPB TBMs in clayey ground is primarily dominated by the flow capability of the excavated muck in the cutterhead and screw conveyor. Currently, Consistency Index approach is used to evaluate clay clogging potential, but it does not include the effects of surcharge pressure on clay behavior. In this paper, a macro-scale soil rheometer is introduced to assess the clogging potential under various water content and surcharge loading conditions. The results show that, in addition to water content, surcharge pressure has clear impact on clay clogging too. In practice, Consistency Index chart can be refined to incorporate the impact of face pressure to better simulate the EPB tunneling conditions.

Jun 13, 2021