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By Q. Li, X. -L. Lei

Accompanying global energy shortage and high energy prices, shale gas has been the focus of exploration and it has attracted great attention from both academia and industry. The combination of horizontal drilling and hydraulic fracturing enables the extraction of huge quantities of shale gas from impermeable shale formations. During the process of hydraulic fracturing, great amounts of water, sand and chemicals must be injected into the shale formation at a high pressure, which may trigger seismicity. Such events could occur due to the presence of faults or the reactivation of these potential faults. Shale is the main component of source rock in the Sichuan Basin, China, and has the greatest contribution to the natural gas of the basin. In order to investigate the fracturing mechanism of shale in the Sichuan Basin, China, a series of rock fracture tests under triaxial compression were carried out in the laboratory in order to investigate the hydraulic fracturing behavior in relation to the seismicity. Based on the high multichannel waveform recording system, the detailed spatio-temporal distribution of acoustic emission due to micro-cracking was used to examine the deformation and fracture behavior of shale. In addition, the effects of confining pressure on the deformation and fracture in shale under triaxial compression by acoustic emission monitoring and X-ray computed tomography were discussed in the paper. The experimental results indicate that the shale samples demonstrate brittle fracture behavior. The confining pressure has a great effect on the complexity of the fracture planes and the spatial distribution of acoustic emissions, but few contributions to the location of the major hydraulic fracturing plane. The foliation of shale plays a dominant role in the rupture process and the geometry of the major hydraulic fracturing plane. The high confining pressure increases the strength and restrains the deformation of shale during compression process. These results shed some light on the understanding of onset of hydraulic fracture initiation not only for shale gas exploration and production, but also for CO2 geological storage and underground energy storage.

Jan 1, 2015

By L. Magne, M. Maldonado, R. Varela

Real-time optimization of flotation circuits demands for accurate and reliable measurements to support the decision making process. The collection zone gas holdup is an important variable in this context as integrates the effect of machine and chemical factors on the bubble size and velocity distributions. It has been demonstrated that gas holdup not only correlates with bubble surface area flux, which defines the particle collection rate and recovery in the collection zone, but also with water overflow, a variable which has been related to the froth zone recovery. Therefore, on-line gas holdup measurements provide a reliable alternative to judge efforts leading to the optimization of flotation cells and columns. Estimation of gas holdup in flotation from electrical conductivity measurements has been proposed and extensively 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 conductivity of the liquid medium and of the mineral pulp with and without air bubbles included. These measurements require a conductivity cell which covers a representative volume of the flotation cell, and creates a homogeneous electric field throughout this volume that ideally is not affected by the conductivity of the medium. The development of such a cell in the limiting space and geometry of a laboratory flotation cell has been problematic, but a multi-electrode arrangement offers a promising alternative. Electrodes were installed in the flotation cell of a Denver unit; the results of preliminary testing are discussed with a focus on its performance in the measurement of two- and three-phase dispersion conductivity.

Jan 1, 2015

By K. Bartholomew

The Functional Performance Equation for ball milling circuits provides plant staff with a new means to improve circuit performance. However, successful execution of a plant processing performance improvement project, with verifiable improvements, requires a significant number of accompanying steps beyond using this equation. In order to identify and articulate all these steps, a study was undertaken with the metallurgical staff from two milling operations and process application specialists from a grinding media manufacturing company. “Task analysis” of improving plant grinding performance was carried out. This analysis identified the required steps, and ultimately yielded a “Plant Grinding Circuit Processing Performance Management/ Improvement System.

Jan 1, 2015

"Discrete Fracture Network (DFN) modelling has increasingly being used in many geotechnical and mining engineering problems, the authors believe there is an ever greater demand to provide updated guidelines that address the collection of discontinuity data in the specific context of DFN models. In general terms, the generation of a DFN model requires collecting information on i) fracture orientation, ii) fracture intensity, iii) fracture length and iv) fracture terminations. The International Society of Rock Mechanics (ISRM) suggested methods for the quantitative description of discontinuities in rock masses directly include most of these parameters. However, there are important differences engineers should be aware. To what extent discontinuities can be sampled and which limitations are inherently introduced in the analysis by the sampling methods being adopted represent important aspects that should drive the collection of discontinuity data for DFN analysis; this will require the introduction of a more appropriate set of guidelines bridging the gap between the current, very practical, ISRM methods and the data requirements imposed by the use of new DFN technologies.INTRODUCTIONThe last decade has seen a major increase in use of the Discrete Fracture Network (DFN) approach, both as a stand-alone tool or integrated within more complex geomechanical simulations (Rogers et al., 2014 and Elmo et al., 2014). In particular, the DFN approach offers the opportunity to maximise the use of fracture data collected from mapping of rock exposures and to construct synthetic rock mass (SRM) models. However, the potential of DFN based modelling is limited if there is insufficient care in collecting the necessary structural data at the required engineering scale. DFN models are also subject to the process of data calibration and validation (Hadjigeorgiou, 2012). With DFN modelling becoming an almost integral part of many geotechnical and mining engineering problems, the authors believe there is an ever greater demand to review the process of collecting fracture data in the specific context of DFN modelling.The value of the DFN model depends directly on the quality and quantity of available field data. For example, fracture length (persistence) is an important parameter in DFN modelling; however, this parameter is either seldom available at the pre-feasibility stage due to a lack of exposures (man-made or natural), or engineers have access to limited length data collected along exploratory drifts. Characterisation of rock exposures should also take into account limits of window/scanline mapping techniques with respect to both trace length bias and the effect of cut-off assumptions inherent in the mapping methodology."

Jan 1, 2015

By Y. Nara, N. Aramaki, M. Maruyama

Evaluation of three dimensionally non-uniform strain distribution in rocks under various conditions such as in water or under freeze-thaw cycles is of significant importance to understand their complex deformations and fracturing mechanisms. For this purpose, we developed an image analysis method which can evaluate or “measure” the three dimensional (3-D) strain distribution in rocks. The proposed method utilizes the 3-D images of rock under initial and deformed configurations, which are obtained by some imaging techniques such as X-ray computed tomography (X-rayCT). In the proposed method, the obtained 3-D images are divided into multiple sub-regions of interest. For each sub-region, the strain is evaluated utilizing 3-D affine transform with unknown coefficients to be determined. In the first step, 3-D voxel level displacements at multiple representative points in each sub-region are computed by 3- D digital volume correlation technique between the comparison images and the initial-guess of the transform coefficients are obtained. In the second step, referring to the initial-guess of unknown transform coefficient, they were optimized in sub-voxel level by finding optimum digital volume correlation between the comparison images, which can evaluate the transform coefficients with higher precision. From the calculated transform coefficients, the strain was directly obtained through the spatial derivative of displacement based on affine transform. In this paper, along with the description of the proposed method, the evaluation of deformation in a lignite specimen due to immersion in water was presented as an application example. As the 3-D imaging technique, micro-focus X-rayCT was applied. The result showed that the induced dilatational strain field due to the initiation and extension of cracks in the specimen was clearly captured. Therefore, authors believe that the proposed method can be applicable to various problems in rock mechanics.

Jan 1, 2015

By H. Utsunomiya, J. Su, K. S. Tamimi, S. Yue, M. Sanjari, L. Kestens, A. S. Kabir, R. Petrov

The recrystallization and texture evolution of AZ31 sheets obtained through two stages was investigated at different stages of post-rolling annealing. The specimens were rolled at the temperature of 100? and at a fast speed of 1000m/min and low speed of 15m/min with a reduction of 30% in one pass. The results show thatAZ31B sheets rolled at 15 m/min and 100 °C has fractured for reductions of more than 30% per pass. However, by increasing the rolling speed to 1000 m/min the rollability was improved significantly and the material can be rolled to reductions of more than 70% per pass. The high speed and heavily deformed materials are fully recrystallized even at 100 °C.

Jan 1, 2015

By D. Virely, M. Gasc-Barbier, J. Guittard

"The valleys of the Dordogne and the Vézère (France) have been inhabited since prehistoric times, as evidenced by the famous site of Lascaux. A few miles away, the village of La Roque-Gageac is also a very popular tourist destination (about 1.5 million tourists per year): The village is sandwiched between a massive limestone cliff and the Dordogne river. The collapse of a cave roof high above the village in January 2010 led us to characterize instability together for the cave and the whole cliff and propose a adapted instrumentation to monitor the fracture openings in the rock mass that are linked to climatic variations. Measurements have been going on and been recorded for nearly 4 years. They point out the role of thermal stress fatigue in the breakdown of the rock mass. In this paper we describe the site under study, the instrumentation and its main results. INTRODUCTIONThe phenomenon of thermal fatigue has been very little studied as far as rocks are concerned, whereas it is rather well characterized for other types of materials: Elsevier published a journal dedicated to fatigue (International Journal of fatigue). In the case of rocks, thermal phenomena and their impacts on mechanical behavior have been analyzed from a micro-structural point of view, and it is now well-known that an increase in temperature causes a dilatation of crystals (Arnould et al., 2004; Berest & Weber, 1998). This dilatation may lead to the development of inter-granular traction and compression stresses, and if those stresses are greater than fracture strength, inter-granular and intra-granular cracks may take place. On the other hand, the fatigue phenomenon (cyclic repetition of a temperature variation which is less extreme than the one that may lead to this inter-granular or intra-granular fracture) is a phenomenon which has not been much studied.The principal studies on thermal fatigue on rocks come mainly from the field of geomorphology, particularly in connection with the analysis of the evolutions of past climate that can explain the present shapes of those landforms: those studies remained essentially qualitative and not quantitative. Le Ber & Oter Duthoit (1987) proposed a thermal and thermodynamic approach to analyse the disaggregation of rock masses. This analysis is dedicated to the study of paleoclimates and was implemented to better understand the formation of slope deposits in order to propose transfer models permitting the reconstruction of the climactic conditions contemporary to their appearance. Since deterioration in the cliff only appears after several cycles, it means that it is a gradual and irreversible deterioration which leads to an increase of the « disorder ». Seen from a macroscopic system point of view, this irreversible evolution is quantified by the internal creation of entropy."

Jan 1, 2015

By Yihan Liu, Jintao Zhang, Chen Xiao, Xiaomeng Zhao, Guanglei Song

To estimate the performance of the inert anode materials based on NiFe2O4 spinel ceramic during it used for aluminum electrolysis, we investigated the wetting process of cryolite molten salt which is in composition of industrial aluminum electrolysis with carbon anode and NiFe2O4 based cermet materials, by means of determination the interface wetting angle between the molten cryolite electrolyte and the solid anodes interface. The results show that the wetting angle between the electrolyte and carbon anode is larger than 90 angulation, this means that they basically can not wetting; however the nickel ferrate spinel ceramics behaves much better. In regard to the NiFe2O4 matrix materials, their initial wetting angles is 76.9. The initial wetting angles for 1.0wt%MnO2, 2.5wt%TiO2 and 0.5wt%V2O5-doped samples are respectively 56.86°, 52.98° and 51.93°. However, after 50s later, all the wetting angles came down below 15°.

Jan 1, 2015

By A. McLean, M. Barati

In this paper, examples are presented of pyrometallurgical research and associated teaching activities during the past century within the Department of Metallurgical Engineering, now the Department of Materials Science and Engineering, at the University of Toronto. Throughout these years, pyrometallurgical research has been characterized by recognition of the importance of the interdependence of measurements and models as well as the development and application of sensors, for the generation, validation and practical implementation of new knowledge. The important role played in the delivery of lectures and participation in joint research by Adjunct Professors with strong backgrounds in the pyrometallurgical industry is described. Projects conducted in close collaboration with the industrial sector and opportunities for students to obtain practical experience working as teams on a "round-the clock" shift basis within an industrial pilot plant environment are outlined. These activities, together with the involvement of students in poster competitions and the presentation of papers at society conferences and technical meetings, are still vital elements in the development of pyrometallurgists equipped with the appropriate professional skills for subsequent employment within academia, government laboratories or the industrial sector.

Jan 1, 2015

By A. McLean, W. Q. Chen, W. Yan, M. Barati, Y. D. Yang

In order to maximally remove the harmful impurities phosphorus and reduce the loss of valuable elements from Si-based alloy for production of solar-grade silicon, thermodynamic properties of the Si-based alloy were studied. In this work a new model, the Molecular Interaction Volume Model (MIVM) derived from statistical thermodynamics, was successfully used in the Si-based and Si-Fe-based alloy. The calculation started from binary Si-Fe, Si-P and Fe-P systems, then the thermodynamic parameters of ternary systems could be derived based sub-binary systems. Using the activity coefficients of the elements in the Si-based alloys and the saturated vapor pressure of the pure substance of the components, mass fraction of P during vapor-liquid equilibrium can be calculated. The calculated thermodynamic parameters were compared with experimental data available in different publications, and it is found that the thermodynamic parameters calculated using MIVM model are in good agreement with the measured results. The calculated result shows that the mass fraction of phosphorus during vapor-liquid equilibrium of Si-Fe-P melt increases with the increasing phosphorus content and decreasing temperature. This is an important direction for experimental practice in vacuum or low-pressure EML refining of ferrosilicon for potential production of solar-grade silicon without significant vaporization loss of valuable element.

Jan 1, 2015

By C. Díaz, M. Barati

Prof. Torstein Utigard's untimely death, in the spring of 2012, put an abrupt end to a meritorious career in the field of high temperature chemical process metallurgy. As an academic in the Department of Materials Science and Engineering of the University of Toronto, Torstein made solid contributions to the advancement of knowledge pertaining to production and refining of both nonferrous and light metals, and to the development of inquisitive and innovative young people in extractive metallurgy. In this profile, the authors highlight aspects of Torstein's rich personality and of his contributions to his field of expertise.

Jan 1, 2015

By CIM Standing Committee

The CIM Definition Standards on Mineral Resources and Reserves (CIM Definition Standards) establish definitions and guidance on the definitions for Mineral Resources, Mineral Reserves, and mining studies used in Canada. The Mineral Resource, Mineral Reserve, and mining study definitions are incorporated, by reference, into National Instrument 43-101 – Standards of Disclosure for Mineral Projects (NI 43-101). The CIM Definition Standards can be viewed at mrmr.cim.org. Readers should be aware that reports written by persons issuing technical reports that disclose information about exploration or other mining properties to the public in Canada are governed by a number of securities regulations.

May 10, 2014

"The mining industry uses many types of mineral and metallurgical plants to produce saleable product from ore mined. Plant design history has left current operations with a mixture of manual operation and various forms of automated process controls. Consequently, we typically see high variability in the continuous operations together with a shortfall in the attainment of full capacity, or higher utilisation of consumables.At a level of best practice, ‘Operational Performance Excellence’ focuses on process control, using automation and control systems to deliver process optimisation. This more sophisticated delivery is a great deal more difficult than the first stage of equipment selection / installation. It includes the appropriate selection of the right instrumentation, control system, key process knowledge, individuals with a solid control engineering background / experience, and the essential backing / support of the operations management team together leading to higher value delivery. Robust solutions can be realised, considerably minimising process variation, thus leading to process optimisation. This approach results in an easier, efficient and safer process while providing considerable returns for the plant owners.How variable are your processes, and do you maintain optimised process performance with dedicated resources, modern instrumentation, ‘best practice’ control systems and performance monitoring tools? In this paper, these questions and their possible answers are discussed."

Jan 1, 2014

By Georges Houlachi, Akram Alfantazi, Maysam Mohammadi

Manganese ions in zinc electrowinning electrolytes form a protective MnO2 layer that ultimately decreases Pb contamination in the zinc product. In this study, the effect of dissolved Mn2+ on the electrochemical performance of Pb, Pb-Ca and composite Pb-MnO2 anodes was investigated. The properties of the MnO2 layer formed on these anodes were studied and compared. Potentiodynamic polarization and cyclic voltammetry experiments were performed in 180 g L-1 sulphuric acid to study the electrochemical reactions occurring on the anodes. The anodes were subjected to galvanostatic polarization at 50 mA cm-2. The morphology and uniformity of the MnO2 layer on the anodes were examined using scanning electron microscopy (SEM). Experimental results revealed that the MnO2 layer formed on the composite anode was more compact and uniform compared to that formed on the Pb and Pb-Ca anode. It was also observed that the cell mud formation rate, and consequently manganese ions consumption, depended on the anode type. Although initial formation of the MnO2 layer decreased the oxygen evolution overpotential, its growth might negatively affect electrocatalytic activity of the anodes.

Jan 1, 2014

By J. Smit, F. Parada, R. Parra, E. Balladares, M. P. Merino

"In this study, a two-step process was developed for recovering copper, molybdenum, zinc and iron (hematite). In the first step, grinded slags (-65 mesh) were sulphated with SO3 at 350-500ºC to form iron, copper and zinc sulphates. In the next step, the formed sulphates were decomposed to hematite, copper and zinc sulphates and oxysulphates at 700-750ºC. The generated SO3 was recirculated back to the sulphation step. The generated calcine in the decomposition step is leached with 25 gpl acid at 50ºC to dissolve the copper, zinc and molybdenum for further conventional separation and recovery. The hematite residue, of intense red color, can be used as pigment, in the ceramic industry or as pellet feed. The fine crystalline silica remains in the hematite residue."

Jan 1, 2014

By E. Sharifi

Advanced Process Control (APC) has been one of the most beneficial tools in the past decades available to minerals processing industry. Low capital cost together with significant improvements in process optimization have made APC an attractive investment option for nearly all mineral processing units. During economic downturns, importance of process optimization becomes even more relevant as metal producers tend to target de-bottlenecking and process efficiency improvements rather than large-scale capacity upgrades. APC project clearly has a lot of potential to improve process performance but there are also some pitfalls to be identified and avoided in order to achieve a desired outcome. Above all, APC project implementation is collaboration between the system vendor and user. Targets for the optimization must be agreed together with the customer and process performance must be defined before and after the optimization project. Most importantly, performance of the process must be monitored on a continuous basis during and after the project and potentially improved further. This paper discusses Outotec’s experiences from various concentrator optimization projects. Some examples are discussed in more details; however, the main target is to present general guidelines enabling a successful APC project implementation.

Jan 1, 2014

By V. A. Leão, M. L. M. Rodrigues, L. C. Sicupira, I. C. B. Rodrigues, T. C. Veloso

Brazilian sulphide ores can contain a significant content of chloride and fluoride, which are harmful to bacteria and thus bioleaching. This work summarizes a four-year research investigation on the effect of fluoride on both bacterial growth and sulphide bioleaching, supported by studies carried out with secondary copper ores. Firstly, the influence of fluoride on the kinetics of ferrous iron bio-oxidation with Sulfobacillus thermosulfidooxidans was addressed. Values as low as 10.0 mg/L F- fully inhibited bacterial growth, although fluoride toxicity could be overcome by the presence of aluminium, which reduced the concentration of hydrofluoric acid through the formation of aluminium-fluoride complexes. This required at least a 2:1 aluminium/fluoride molar ratio, which ensured bacterial growth rate values similar to that observed in the absence of fluoride ions. Subsequently, both batch and column bioleaching with mesofiles (30 ºC), moderate thermofile (50 ºC) or hyperthermophiles (67.5 ºC) of two secondary copper ore samples were analyzed with focus on the relevant effects of fluoride-containing minerals on the bioleaching of such sulphide ores.

Jan 1, 2014

By S. A. H Tyrrell, R. Rotzinger

"Taseko Mines Limited recommenced operation of the Gibraltar copper-molybdenum mine in 2004 and embarked on series of development projects to modernize the mine and increase throughput capacity. The Gibraltar Development Plan 3 (GDP3) project included a second stand-alone copper-molybdenum concentrator, a stand-alone molybdenum separation plant and associated services. Ausenco was contracted to commence the detailed design in 2Q2011, commissioning commenced in 4Q2012 and first ore was processed in 1Q2013. This paper discusses the design, implementation and commissioning of the GDP3 Concentrator.INTRODUCTION The Gibraltar Mine (Gibraltar) property is located in the Cariboo Region of south central British Columbia, approximately 360 kilometers northeast of Vancouver. The site is accessed via an 18 kilometer paved road from the town of McLeese Lake, which is located on the province’s main north-south highway between the cities of Williams Lake and Quesnel. Gibraltar was originally developed by Placer Development and commenced production in 1972. Gibraltar was acquired, while on care and maintenance, by Taseko Mines Limited (Taseko) in 1999 during a period of unusually low metal prices. Taseko recommenced operations at Gibraltar in 2004, and embarked on series of development projects to modernize the mine and increase throughput capacity. The 1972 Gibraltar process flowsheet incorporated two-stage crushing followed by rod and ball milling and flotation. In 2008 Gibraltar completed their first development stage that included the installation of a SAG mill, converting the existing rod mills to ball mills and adding additional flotation capacity. Gibraltar continued development with the installation of an in-pit primary crusher, expansion of the bulk regrind circuit, expansion of the cleaner flotation circuit, replacement of the tailings pumping system and replacement of the concentrate filters and dryer."

Jan 1, 2014

By S. Suzuki, C. Tokoro, S. Owada, T. Sakakibara

Acid mine drainage (AMD) has been actively treated by neutralization from about 80 abandoned or closed mines in Japan. More efficient and cost effective treatment processes has been demanded for AMD due to the government investment of billions of yen every year to protect the environment from these discharges. In this study, quantitative modeling was conducted for actual AMD to predict pH or residual concentration of toxic elements after neutralization/co-precipitation process. Simple chemical equilibrium calculation was not adequate for quantitative prediction of pH after neutralization, because residual concentration of major elements of AMD, such as Fe or Si, could not be quantitatively calculated. When oxidation rate of Fe(II) to Fe(III) and precipitation rate of kaolinite were added to the model, quantitative prediction of pH and Fe or Si concentration was achieved. Surface complexation at the interface between hydroxide such as ferrihydrite or aluminum hydroxide and AMD was the most important mechanism for removal of dilute toxic ions. When surface complexation model at the interface of ferrihydrite was added to the model, residual As (V) and Pb (II) concentration after neutralization/coprecipitation process was successfully calculated. On the other hand, surface complezation model of aluminum hydroxide was also necessary for quantitative prediction of residual Zn(II) concentration after neutralization/co-precipitation process.

Jan 1, 2014

By M. Y. Solar, W. G. Davenport

Most of the recent growth in nickel demand has been for the production of stainless steels and virtually all of it has been satisfied by new ferronickel and nickel pig iron projects. But "good" laterite resources are more and more difficult to find: Ni grades are decreasing while Fe contents are increasing and SiO2/MgO ratios vary from 1 to 3 and even higher if limonites are included. Predicting the smelting behaviour of such ores requires a more fundamental understanding of the thermodynamics of these systems in commercial operations. One valid question is thus whether these furnaces are at thermodynamic equilibrium or not. The present paper investigates this question, compares calculated and measured O2 partial pressures and mechanical/chemical slag loss ratios and concludes that ferronickel furnaces are not at thermodynamic equilibrium. This departure from expectation is actually to the operators’ advantage: the targeted ferronickel grades can be obtained at lower reduction potentials than calculated from pure thermodynamics.

Jan 1, 2014