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By S. D. F. Rocha, A. L. A. SANTOS, E. M. A. BECHELENI, R. M. Papini, P. R. M. Viana, F. P. C. Silvas

The kinetics of atmospheric sulfuric acid leaching from a Brazilian nickel laterite ore was assessed using distinct reducing agents and ore mineralogy. This transitional ore contains 1.63% Ni distributed as 1.27% in coarse size (− 500 + 150 μm), mainly as silicates (lizardite and chlorite—28.6%), and 2.06%in the fines fraction (− 75 μm), mainly as iron oxy-hydroxides (goethite and hematite—49%). The effects of temperature, acid concentration, reducing reagent type, and concentration were evaluated. The − 75 μm fraction limited the leaching efficiency and the use of reducing media with thiosulfate improved leaching and Ni-Fe selectivity. However, at constant Eh of 626–743 mV and a pH range between 0.2 and 1.1, no substantial rise in metals extraction, except for Co and Mn, has been observed. In order to determine the process control at 95 °C, two regions in the extraction curves were used in combination with the shrinking core model. Control by porous diffusion was observed and the kinetic constant was found to be in the order kFe<kNi<kMn<kCo<kMg for atmospheric leaching without Eh control. In reducing media for the first 15 min of leaching, the kinetic constant was found to be kFe<kNi<kMg≅kCo<kMn as derived from Ni disseminated into iron oxides structures.

Oct 7, 2020

By Khushaal Popli, Vanessa Roeland, Brian Hall, Carl Diederichs

Highland Valley Copper (HVC) has embraced an integrated Mine to Mill approach to comminution since the late 1990s. Previous blasting optimization was carried out through adjustments to blast pattern geometry (i.e., reduction of burden and spacing). This approach proved very effective and HVC reduced the burden and spacing of high energy ore blast patterns to what was considered the practical limit that still allowed for efficient drilling and bulk truck loading operations. While mining in the bottom of the Valley pit near the end of the previous pushback, HVC encountered high static groundwater conditions which enabled the transmission of elevated inter-blasthole pressures that had the potential to exceed safe operating limits for initiation products. This risk was mitigated through an expansion of burden and spacing for the high energy ore patterns, reducing the application of blasting energy and increasing the average particle size in Mill feed.

Feb 6, 2023

By S. Tandon

Equilibria studies of selenium distribution for sodium-borate slags were initiated at 1473k under reducing condition as a function of slag composition and alloy composition. The Se distribution coefficient (% Se in slag/% Se in metal) increased from 0.4 to 2.9 with increase in basicity (0.53 to 0.86) for Cu-0.446% Se alloy. However, the results are not very useful from industrial application viewpoint. Therefore, in order to improve the distribution of Se, CaO (10% to 50%) was added to the sodium-borate slag of basicity 0.864. On addition of 502 CaO, the distribution coefficient increased roughly by 100% for slag composition - 44.5% Borax, 22.2% Na2C03, 33.3% CaO and Cu-0.44677 Se alloy. Further, the value of this distribution coefficient has been found to increase by an additional 80% on addition of 20% CaF2 to the above slag for all Cu-Se alloy compositions. Also with increase in initial concentration of Se, the distribution coefficient has been noted to increase.

Jan 1, 1992

By K. V. Raj, A. Miller

"Workers at mineral processing facilities are often exposed to high levels of dust generated when ores are processed. Crushing, grinding, screening, and other processes generate large quantities of dust, which can exceed the threshold VALUES (prescribed by the Mine Safety and Health Administration (MSHA). Many ores contain quartz (silica), which has been known to cause serious health problems in workers over time. Given the structure of mineral processing plants, the airflow regime is not coherent inside the building, which may lead to multiple recirculation zones. These recirculation zones can trap dust, and concentrations of dust can then rise over time. Therefore, there is a need to understand the airflow phenomenon that occur inside of mineral processing facilities and how these occurrences interact with the dust generation processes to identify zones of potentially high dust concentration. Computational fluid dynamics (CFD) modeling can give a better understanding of the airflow and help recommend designs and methods to mitigate the high dust concentrations in a mineral processing plant. This paper presents the CFD modeling of airflow inside of a mill building to demonstrate airflow patterns that will affect the generation and subsequent dispersion of dust due to crushing, grinding, and other activities. This study was conducted by researchers from the National Institute for Occupational Safety and Health (NIOSH). INTRODUCTION In a mineral processing facility, minerals go through various mechanical processes in order to reduce their size for separation of economic minerals from gangue minerals to produce a final marketable product. This research, conducted by the National Institute for Occupational Safety and Health (NIOSH), focuses on ore mills in metal and nonmetal mining (MNM) operations, but the applicability of the approach will be valid for any large structure where workers are exposed to airborne contaminants. The processes of crushing, grinding, cleaning, drying, and product sizing in these facilities generate a large amount of dust, creating hazardous conditions for the workers in these facilities. This is highlighted by the fact that MSHA sampling data for the years 1997–2012 indicate that 12.3% and 15.9% of the gathered samples were over 100 µg/m3 for silica for metal and nonmetal mills, respectively [1]. Mineral processing operations typically use some type of engineering control to address their most significant dust sources. Engineering controls include such approaches as bag-house-type dust collectors, scrubbers, and electrostatic precipitation [2]."

Jan 1, 2018

By D. M. Morrison

"The most important factor in Canadian mining is not the operating cost of current projects but the availability of capital for future projects. The future of mining at depth will be producing ore from the top of the orebody working downward with very effective, tightly controlled mining methods, i.e. either selective mining or bulk mining with well controlled dilution and fragmentation. The key characteristics of future mines will be smaller access excavations, more effective ground support, very precise blasting techniques and more efficient and reliable materials handling systems. Equipment will be smaller and designed for high efficiency and low maintenance, reducing both the capital and operating cost. This means there will be fewer scoops, more continuous mucking machines and conveyor belts, both lateral and vertical.Orepass failures have become accepted and the resultant redevelopment and retramming has become common. The capital investment in so-called permanent ore passes and crusher stations becomes questionable, particularly when crushers are only necessary for less than 10% of the ore going through the system. The best way to solve the chronic instability of ore passes is, as with all of the stability problems at depth, by reducing the excavation size rather than increasing ground support. Smaller access drifts would reduce the capital cost and increase the rate of development as well as reduce the amount of waste to be handled, reducing the ground support and the ventilation requirements. Large drifts and ore passes are essential only for the equipment needed to handle large pieces of ore and the productivity of scoops is very expensive when the requirements for ventilation and large access drifts are taken into account. The key issue is the fragmentation generated by primary blasting.The future of mining in Canada will depend on simple and robust technology geared to the environment in which it will have to operate. Its survival will depend on some-thing much more fundamental and difficult to accomplish than a technological advance — it will require a dramatic change in the way the mining process is managed, how work is organized, how effort is rewarded and how costs are measured — a complete change in mind-set."

Jan 1, 1996

By J E. Wheeler, S B. Valine, L G. Albuquerque

It has long been known that closed circuit grinding with a classifier improves grinding efficiency, reduces unit specific power consumption, and reduces over grinding. The classification device removes material from the circuit that has reached the desired size and returns coarse material back to the mill for further grinding. The efficiency of the classifier is an important factor in the overall performance of a grinding circuit. The classifier affects the capacity of the grinding circuit and the metallurgical performance of downstream operations. A review of historical research and modern case studies is used to demonstrate the benefits of high frequency screens for classification in grinding circuits.CITATION:Valine, S B, Wheeler, J E and Albuquerque, L G, 2012. Applications of fine screens in grinding circuits, in Proceedings 11th AusIMM Mill OperatorsÆ Conference, pp 389-394 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 29, 2012

By Michael Hood

High-volume, low-pressure water jets have been employed for erosion of loosely consolidated rocks for centuries. This excavation method finds application in specialized circumstances even today. The use of high-pressure, low-volume water jets for rock cutting is more recent and was made possible by the development of high-pressure water pumps. Despite the benefits often claimed for these systems, high-pressure water jets still have not found widespread application. In this report, the U.S. Bureau of Mines has reviewed the various methods that have been employed using water jets to break rock and has focused on one method, termed "jet-assisted cutting," which was determined to be the closest to commercial development. The current state of knowledge based on laboratory and field experiences using this cutting method is reviewed, and possible future developments for this approach to excavation are assessed.

Jan 1, 1990

By Larry Gsellman

This report presents the results of a benefit/cost analysis of the Bureau of Mines&apos; Coal Extraction RCD Program for the period FY 1977 through FY 1982. The analysis is an update of the analysis performed on the Coal Extraction R&D Program for EY 1975 - FY 1980 and presented in a MITRE report, MTR-7225, published in May 1975. Major changes included: new production scenarios and an update of R&D cost estimates.

Jan 1, 1977

By Chris McKee

Quartz has been of interest in occupational health for years because it can cause silicosis after prolonged exposure. New OSHA regulations (Air Contaminant; Final Rule) list perlite as a nuisance dust. They conclude that perlite is nontoxic when air-borne total particulate concentrations are 15 mg/m3 or below and when quartz content is less than 1% crystalline silica. OSHA has established an 8-hour PEL of 15 mg/m TWA for total perlite dust containing less than 1% quartz. OSHA has established a 5 mg/m3 TWA PEL for respirable perlite. These limits will protect workers from significant risk of eye, skin, or other physical irritation. This regulation is based on a Group 2A classification as a probable carcinogen in humans, at the 0.1% crystalline silica level, by the International Agency for Research on Cancer (IARC 1987a, b). IARC found sufficient evidence for carcinogenicity of crystalline silica in animals and limited evidence in humans. Perlite is not listed as a carcinogen by OSHA or the National Toxicology Program.

Jan 1, 1990

By T. Beamish, I. Vasilev, T. Nikolov, E. Marinov, D. Kirilov, P. Barrios

In April 2005, Umicore Copper de-merged from Umicore Group and created a new independent Copper company called Cumerio. As a separate company, Cumerio is a major European copper smelter and refinery and a leading producer of copper products such as wire rod, billets, cakes and specialty rod with a total production capacity of copper products in excess of 500,000 tpy with production plants in Belgium, Italy and Bulgaria. The Pirdop Smelter is the only state-of the-art smelter in South East Europe and it makes Pirdop the natural hub for the copper industry in the region. In order to be competitive in the international market the main challenges facing Cumerio are to maintain its low cost structure and to achieve higher production volumes while reducing its impact to the environment and striving for continuous improvement of the production process. Cumerio&apos;s state-of-the-art smelting facility in Pirdop has recently increased the anode production capacity to 250,000 tpy by the installation of the third evaporative cooler on the converters section that allows operating with three-hot converters. In April 2007 a general shut-down for repair and modification on the Flash Smelting Furnace and Waste Heat Boiler is envisaged. At this time a revamp of one of the existing Sulphuric Acid Plants is planned, resulting in a further copper capacity increase to 275,000 tpy with modest Capex. In 2005 Cumerio received from the Bulgarian Ministry of Environment and Water the Complex Permit under the EU IPPC criteria. Accordingly an Environmental Compliance Program was defined targeting a large reduction in the secondary emissions. The system will be commissioned in May 2007. In order to better integrate the smelter and refinery in Pirdop and to respond to the growing demand for cathodes in the region, a new state-of-the-art Electrolytic Refinery with an installed capacity of 180,000 tpy will replace the existing refinery. The new refinery is expected to be fully operational as from early 2008. This paper describes the challenges and the projects.

Jan 1, 2007

By H. Salamanca

Recently, the mining industry has become one of the leading target markets for the technology industry as they need to innovate in their productive processes in order to boost productivity, reduce operation costs, increase operation safety, and improve the quality of life of their workers. This work presents the technological developments that HighService has done in different stages of the mining productive processes to include robotic manipulators in their automation solutions as well as the development of new equipment and sensors. The robotic technology integration is presented in different applications such as handling and selection of cathodes in E-W machines, automation of base plate maintenance, automation of cathode stripping machine, and multi-tools handler for liner bolt replacement in SAG mill liner maintenance activities. The proposed solutions show technical and economical viability with low initial investment and short implementation period of six (6) to ten (10) months. The results have been validated in plant, obtaining higher production rates and availability.

Jan 1, 2007

In the pursuit of commercial solutions for environmental issues, individual problems are often identified, considered and resolved in isolation from other environmental matters and always at the end of the cycle û after the problem has been created. Inter-relationships are neglected if they are not seen to obviously impact on a specific problem and the issue at hand is plucked from the environmental landscape and dealt with in total isolation to all else. In a Zero Waste approach to environmental matters, all outputs are pursued as potential inputs. Industrial processes are viewed as a variation on natureÆs theme and opportunity pursued above all else. When viewed from this perspective, industry appears to have forgotten its origins. It has forgotten that it is principally about people. The juggernaut of global trade has forgotten that it is a small part of a big landscape and that its principal participants, people, cannot exist without healthy soil. Commercial activity in all parts of the world relies heavily on the ability of agriculture to produce the necessary inputs for industrial production. The care and nurturing of our soils is fundamental, not only to the survival of humanity, but also to the economic systems that support that humanity and to the industry which profits by it. Actual levels of domestic recycling in many countries around the world seldom reflect the 90 plus per cent desire to recycle recorded in surveys conducted by local authorities in almost every country. If the desire to recycle is far removed from the end result, why is it that the systems provided are so ineffective? It is obvious that what we do need is a recycling system that both engages and rewards the participant and stimulates the innate desire to support the environment. A recent trial in New South Wales, Australia, demonstrated that by giving individual households credits for recycling organic wastes, not only will contamination levels fall dramatically, but increased yields, improved soil structure, improved land values, reduced fertiliser costs and increased water use efficiency give the farmer good economic reasons for purchasing and applying quality composted product. By underpinning and securing the agricultural community, we secure the future of industry. The æCity to SoilÆ project linked the economic on-farm benefits of compost use with reduced contamination through the provision of rewards paid for by the purchase of product by the farmer.

Jan 1, 2006

By J. Tomlinson

Shuttle car trailing cable splices were tested for resistance to failure upon being subjected to repeated bending, abrasion, and tensile shocks using a new testing method that closely simulates shuttle car induced stress. The results show that under normal stresses, splices can be made to withstand the equivalent of three months of operational use. Restoring the tensile strength to the conductors is found to be as critical as restoring flexibility. Splices in which the conductors are of slightly unequal length did not present as serious a workmanship problem as previously thought since test results show that the conductors tend to equalize when longer cables, in contrast to short cables employed in previous testing methods, were used. Dynamic recordings of cable tensile stresses are presented for a shuttle car and the new simulated testing method. Two simple but effective methods for removing insulation using a knife and a pair of pliers are described. None of the designs tested for a sacrificial splice covering were satisfactory.

Jan 1, 1979

MIM Holdings Limited has acquired a reputation for the successful application of R&D to develop break-through technologies for the mining industry. The Isa Process tank-house technology has been licensed to copper refineries throughout the world, and almost 40 per cent of the worldÆs copper is refined using this technology. Isasmelt copper and lead smelting technology is either in use, or is currently being installed, by eight companies in eight countries around the world. Jameson Cell technology is widely used in the coal mining industry and increasingly in the base-metal industry. The IsaMills developed at Mount Isa and McArthur River made it possible to develop the McArthur River and George Fisher orebodies. This paper will address the need for innovation and then discuss the development of the IsaMill and Isasmelt technologies. It will conclude with some comments about why MIM has been so successful in developing such technologies.

Jan 1, 2002

By Michael B. Mooiman, David J. Kinneberg, Philippe Cettou, Leo W. Simpson, Pierre Ramoni

"The demand for high purity precious metals began with certain industrial applications having uncompromising requirements for quality and performance. As industrial uses proliferated and as the jewelry industry became increasingly sophisticated, the demand for high purity gold has reached the point where 99.99% is now the standard in the marketplace. A similar evolution is expected for other precious metals.In this paper, we examine both the production and use of high purity precious metals, specifically gold, silver, platinum and palladium. After defining what is meant by ""high purity"", we discuss the various analytical techniques used for measuring impurity concentrations. Next, we review process strategies employed by extractive metallurgists to produce high purity precious metals. Lastly, we describe some of the principal applications for high purity materials including thick films, thin films, bonding wire, thermocouples and jewelry manufacture.Precious metals have unique physical properties that, despite their expense (and the ever-continuing search for more economical alternatives), make substitution difficult if not impossible. These physical properties are dramatically affected by small concentrations of certain impurities. As long as manufacturers continue to demand quality and performance, there will be a need for high purity precious metals.IntroductionIn the precious metals industry, the qualifier ""high purity"" describes any specification over and above commodity grade. High purity specifications delineate lower limits on overall metal purity or upper limits on individual impurities or both. Sometimes, if these special requirements become commonplace, either because of improved refining technology or because of market pressures, yesterday's ""high purity"" material becomes tomorrow's commodity. This transition is now occurring with gold bullion and probably will soon occur with platinum and palladium as industrial use of these materials grows."

Jan 1, 1998

By T Sparks

The Collie River catchment, located approximately 200 km south of Perth, covers an area of around 2830 km2 and is the source of run-off to the Wellington Dam, an important irrigation water resource for the Collie Irrigation District. The salinity of the Wellington Dam has increased due to historical clearing and irrigators currently use water with salinity levels approximately twice that of the Murray River in South Australia (Water and Rivers Commission, 2001). The Collie River Salinity Situation Statement (2001), released by the Water and Rivers Commission (now the Department of Water), identified realistic actions that could achieve the salinity reduction target. Subsequent benefit-cost analyses and prefeasibility studies recommended the diversion of the most saline flows in the Collie River away from the dam as an immediate intervention (URS, 2003). The East Branch of the Collie River above the locality of Buckingham (20 km east of Collie) contributes around half of the salt that flows into the Wellington Dam and the diversion and storage of the saltiest flows from the East Branch at Buckingham was identified as a viable option for reducing salinity in Wellington Dam. The proposal had one problem û the water could not be disposed of as quickly as it was diverted. However, in the vicinity of the diversion site were a number of coal mine voids and after preliminary discussions, the Government/Griffin Coal alliance was formed and from this the opportunities have continued. Diverted water would be stored temporarily in an adjacent mine void (Chicken Creek 4 void) and then disposed of to the sea. The disposal options included Western Power CorporationÆs saline discharge pipeline from Collie Power Station, or a new pipeline. The diverted water was also identified as a potential raw source for treatment and use in industry. This has opened up opportunities including desalination, water efficiencies in the power stations, increased reliability of water supply for the power stations, water for new industries, wastewater disposal options and extra water for PerthÆs water supply. In the process of solving the water storage problems the project introduced a range of mine water quality problems û heavy metals and pH û and the Department of Water (DoW) is now working with the mining industry and the Centre for Sustainable Mine Lakes (CSML) to develop treatment and management technologies. The project has received support and funding through the National Action Plan for Salinity and Water Quality (NAP) and it has been possible to accelerate and enhance this project as a result of NAP. The DoW has developed the proposal to an advanced stage and gained approvals for the capital diversion program to go ahead. The partnerships have expanded to include the second mining company, Premier Coal, the Water Corporation, Western Power and the Harvey Irrigation Cooperative. The proposal could feasibly result in a $90 million integrated water management initiative for Collie using the latest technology, mining operations and providing water for value adding industries in the local area. The DoW is not a mining company; however, our experience in managing water in times of shortage, environmental water quality criteria, competition for water and managing community expectations will have the same success factors:consultation and knowing your community and stakeholders, sharing issues and working in partnership can provide results far greater than the initial issue, even brackish water has value, every sector is in competition with each other and has to have a share of the water, an integrated approach can provide opportunities for development in areas of water shortage, and never think of water as wastewater.

Jan 1, 2006

By Michael J. Friedel

As part of an investigation aimed at improving the health and safety and competitiveness of the mining industry, the U.S. Bureau of Mines evaluated the application of common offset radar profiling, using a 250-MHz ground-penetrating radar (GPR) system, for the detection of fractures in igneous rock. A series of radar reflection surveys were conducted to detect and delineate the extent of fracturing at various granodiorite and gabbro quarries and outcrops located in Minnesota. The application of radar profiling for detecting joints, sheeting fractures, shear zones, and depth to water table was demonstrated to be feasible with minimal processing. Radar reflection interpretations were verified by visual inspection of the rock mass and field mapping of local structure. The radar reflection section provides a simple, rapid, and cost-effective means for mapping of shallow (less than 10 m) small-scale fractures (greater than 0.25 cm) in igneous rock masses (characteristic of velocities between 0.061 m/ns for gabbro and 0.125 m/ns for granodiorite). Depth or distance estimates to fractures are within 10 pct of the actual, and time-shift compensation is necessary only when topographic irregularities exceed 30 cm.

Jan 1, 2010

By J. S. Becker

Technology developed and first implemented in the United Kingdom enables very low grade aluminum scraps containing oils, organics, plastics and ferrous metals to be directly charged, without pretreatment, into a unique melting furnace. The system has been in full scale production for over three years. The oxy-fuel-based furnace design incorporates internal afterburning in the furnace&apos;s hot zone, producing excellent thermal efficiency and very low emissions. The furnace is inherently low in NOx. This paper will provide both theoretical background and extensive operating results for this new melting concept. Applications describing both purpose built new furnaces and retrofits of existing reverberatory furnaces will be presented. Extensive operating emissions data will be presented.

Jan 1, 1996

By Zhiqing Zhang, Changyun Chen, Qing Liu, Lin Lin, Zhihong Jia, Guangjie Huang, Lipeng Ding

The effect of interrupted quenching (IQ) treatments on natural aging and bake hardening response of Al-Mg-Si alloy was investigated by hardness measurements, tensile test, differential scanning calorimetry (DSC) and transmission electron microscopy (TEM). The results show that interrupted quenching at 100oC could effectively suppress natural aging and improve bake hardening response. The optimized interrupted quenching treatment is 100oC for 45min, which gives the alloy a relatively low T4 temper strength and higher bake hardening response. The formation of highly dense cluster(2) during the interrupted quenching could be the reason for suppressing the natural aging and accelerating the precipitation of ß? phase during the paint bake treatment. In addition, interrupted quenching at higher temperature (170oC) results in unfavorable properties in both T4 temper and paint bake treatment. The formation of large precipitates is responsible for these undesired effects.

Jan 1, 2015

By Green A. D M

The establishment of the Imperial Smelting Furnace at Sulphide Coporation Pty. Limited for the smelting of zinc and lead made it necessary to design and install sintering capacity to produce approximately 500 t.p.d. of zinc-lead sinter. The updraught sintering process installed is a recent development and the plant was designed with adequate flexibility and equipment to enable operating staff to investigate the process and achieve maximum production under optimum operating conditions.Sulphur dioxide gases from the sinter machine are passed to a contact acid plant for the manufacture of sulphuric acid.

Jan 1, 1964