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By L. Scott, M. A. Goncalves

Effective communication is a sought-after non-technical skill in the health, safety, and environmental (HSE) function and is fundamental in achieving an organization’s safety objectives. While different channels are used to communicate HSE matters, many organizations employ posters, videos, and/ or signs containing images to convey information. Communication through signage and graphical hazard symbols has been regulated in standards, but vast sections of HSE communication are bespoke communications and exist outside the sphere of standards. Effective HSE communication through images requires an understanding of the organizational culture in which the images will be used, as well as an understanding of the semiotics of the images themselves. Creative interpretation within HSE communication can create situations where the message that was received is not the message that was intended, leading to confusion and misinterpretation. This paper is aimed at elucidating the semiotics of South African HSE visual content. It was found that the indexical mode of images was most preferred in visual communication, and text-only designs the least preferred. Senders and receivers of messages differ in their opinions on the complexity of HSE communication.

Feb 2, 2021

By Margreth Tadie, Chalwe Chibwe

Physicochemical properties of copper electrolytes are a strong fundamental consideration in electrodeposition processes during electro-purification and recovery of copper. Their influence extends to mass transfer as well as energy consumption during the electrodeposition process. In this study, the influence of electrolyte composition on electrolyte physicochemical properties was investigated to review the existing literature data. This review of data is considered necessary as more and more electrowinning models are being developed for process prediction and optimisation and a need of such data is required for accurate prediction of physicochemical properties. The major components of importance to the formation of smooth high-quality and high-purity copper cathodes at optimum current efficiency are considered the species in solution. These include Cu ions, Fe ions (major impurity), H2SO4, and a smoothing agent additive. A 5-factor, 2- and 3-level experimental design was employed to determine the effect of copper (35 and 45 g/l), sulphuric acid (160 and 180 g/l), iron (1, 3, and 6 g/l), polyacrylamide additive (2, 5, and 10 mg/ l), and temperature (45 and 55 °C) on electrolyte density, conductivity, and the diffusion coefficient in synthetic copper electrowinning electrolytes. The major species in a copper electrowinning electrolyte are found to be the most relevant for prediction of physicochemical properties. These results indicate that relatively simple empirical models are sufficient for modelling of the electrolyte domain in electrowinning, without the need for the generation of vast amounts of complex experimental data.

Feb 1, 2021

By CAIJUN CHEN, MING ZHANG, ZHENWEI WU, FENG ZHOU, BOQUAN LI, XILIANG ZHANG, ZHOU PU

Traveling grate is a widely used process for iron ore pellet production; however, the thermal state of pellets in drying section is still unclear. In this study, the temperature distribution of drying section was investigated using computational fluid dynamics (CFD). Based on the calculated results of airflow velocity, space temperature distribution, and the temperature change of pellets, it concluded that there is a coupling effect in drying section in traveling grate. The gas with higher temperature in DDD transfers heat to UDD through the gap of the insulation board, and the temperature gradient of the pellet bed changed before reaching the insulation board. The characteristics of pellet bed expected to appear in DDD was displayed in UDD in advance. Moreover, a contrast experiment was conducted to verify the model.

Feb 1, 2021

By Fan Yang, Meigui Yi, Lan Xiang, Zhuoying Yang

This paper reported the calculation of the reaction heat in titanium-bearing blast furnace slag (abbreviated as TBFS)-H2SO4 system based on estimation of thermodynamic data of CaTiAl2O6 by mechanical mixture model. The thermodynamic analysis indicated that CaTiAl2O6 was more stable than the corresponding ternary oxides as CaO·TiO2, CaO·Al2O3, and Al2O3·TiO2. TBFS-H2SO4 system was highly exothermic since all of the reactions involved in the system were exothermic. For example, the increase of temperature from 25 to 200°C led to the increase of the release of the reaction heat in TBFS (100.0g)-H2SO4 system from 181.28 to 189.73kJ. Eighty-five to 90%of the reaction heat in TBFS-H2SO4 system was contributed by the reactions among CaTiAl2O6, CaTiO3, CaMgSi2O6, and H2SO4.

Feb 1, 2021

By Cengiz Karagüzel, Ömer Canıeren

The mobility of gold and silver metals from refractory ores is very low due to free metal ions in their bodies that bind the transportable and free metal molecules or they are encapsulated in minerals such as sulfides, arsenosulfides, carbonaceous, and clayey materials which make it difficult to extract them. As known from the literature, the enrichment of oxide refractory gold, silver ores, Ag, and Au-rich flotation concentrated from sulfur refractory ores can be leached in the chloride-hypochlorite solutions. In this work, the leaching approach was studied to extract silver ions from refractory ores in the presence of hypochlorite media under high pressure. The mineralogical and scanning electron microscopy analysis of the sample indicated that the silver was encapsulated in barite and quartz minerals in fine sizes. In order to obtain the optimum leaching conditions for the silver ore, the effects of several parameters, namely, temperature, leaching time, NaCl and NaOCl concentration, solid ratio, and particle size on the leaching recovery were investigated in detail. The leaching experiments showed that the highest silver recovery of 62.35% was obtained under the following conditions: temperature of 150 °C, oxygen pressure of 1800 kPa, leaching time of 2 h, concentrations of 2 mol/dm3 and 0.4 mol/dm3 for NaCl and NaOCl, respectively, the solid ratio of 30%, and particle size (d80) 15 μm. The results obtained from this study indicated that the enrichment of refractory silver ores to extract the silver encapsulated in barite and quartz minerals could be possible in the chlorite-hypochlorite under high pressure, a relatively shorter leaching time compared to conventional cyanide leaching.

Jan 28, 2021

By LUIS ALBERTO TORRES-CRUZ

The assessment of liquefaction vulnerability is crucial to understanding the potential consequences of a tailings dam failure. The “Plewes method” is a relatively well-known and simple screening method to assess liquefaction potential based on results of cone penetration testing (CPT) which may be complemented with laboratory testing. The objective of the current work is to emphasise the screening nature of the method and its uncertainties when applied in tailings deposits. Specifically, the paper highlights the difficulties in assessing the intrinsic uncertainty of the method and the additional uncertainty that results from variations of the slope of the critical state line (λ10) along the depth of the CPT sounding. The results of the method are too uncertain for detailed characterisation of tailings even when a relatively low intrinsic uncertainty is assumed. However, the method characterises weaker soils with lower uncertainty (although still too high for detailed characterisation) than stronger soils. The uncertainty of the method is negatively affected by the relatively low λ10 values that are typical of nonplastic tailings. It is suggested that the results of the method should be presented in scatter plots in which the spread of the data is consistent with the uncertainty of the method.

Jan 28, 2021

By Yongjun Peng, Yufan Mu

Pyrite depression in the flotation of copper ores is difficult due to the activation of Cu2+ ions on pyrite surface. In this study, the radical chain reaction involving the redox cycling of Cu(I/II) induced by sodium metabisulphite (MBS) was exploited to selectively depress the flotation of copper-activated pyrite at pH 8.0. Electrochemical measurements revealed that the presence of Cu2+ and O2 was essential to the formation of SO•− 5 through sulphite oxidation, the main entity to convert the activating species Cu(I)S on pyrite to Cu(II)-hydroxide/sulphate, causing deactivation of pyrite. The depression role ofMBS on pyrite flotation was closely associated with the type of grinding media which affected the electrochemical conditions of flotation. When forged steel was used as the grinding media, a high dosage of MBS was required to depress pyrite, but a low dosage of MBS could almost completely depressed pyrite when high chrome steel grinding media was used. This is because high chrome steel produced a stronger oxidation condition with a higher amount of Cu2+ and O2 which promoted the formation of SO•− 5

Jan 26, 2021

By Harald Ulrik Sverdrup, Anna Hulda Olafsdottir

The long-term supply of nickel to society was assessed with theWORLD7 model for the global nickel cycle, using new estimates of nickel reserves and resources, indicating that the best estimate of the ultimately recoverable resources for nickel is in the range of 650–720 million ton. This is significantly larger than earlier estimates. The extractable amounts were stratified by extraction cost and ore grade in the model, making them extractable only after price increases and cost reductions. The model simulated extraction, supply, ore grades, and market prices. The assessment predicts future scarcity and supply problems after 2100 for nickel. The model reconstructs observed extraction, supply and market prices for the period 1850–2020, and is used to simulate development for the period 2020–2200. The quality of nickel ore has decreased significantly from 1850 to 2020 and will continue to do so in the future according to the simulated predictions from the WORLD7 model. For nickel, extraction rates are suggested to reach their maximum value in 2050, and that most primary nickel resources will have been exhausted by 2130. After 2100, the supply per capita for nickel will decline towards exhaustion if business-as-usual is continuing. This will be manifested as reduced supply and increased prices. The peak year can be delayed by a maximum of 100 years if recycling rates are improved significantly and long before scarcity is visible.

Jan 26, 2021

By Weiguo Xie, MARK LAPUTKA

The pyrometallurgical industry plays a vital role in producing metals for our modern life. With growing demand of metals and declining grade of mineable ore, innovations become critical for many mining companies. It is necessary to conduct a review of recent improvements to the pyrometallurgical industry on analytical measurement techniques, process and equipment improvements, and computer-based modeling/simulations. Many of those innovations tend to be applied to wider metals, and not be restricted by a specific metal. Therefore, we tried to cover the wide applications of many improvements to wider range of metals to reflect this trend. The challenge of a lack of robust measurement techniques under high-temperature conditions within a furnace hinders optimization of a pyrometallurgical process. Some future opportunities in the pyrometallurgical industry on analytical measurement techniques, computer modeling, and processes and equipment have also been outlined and discussed.

Jan 26, 2021

By Yi Luo, Jian Yang

Subsurface strata movements and deformations associated with longwall mining operations in underground coal mines could cause various disturbances to subsurface mine structures, ground water bodies, and coalbed methane reservoirs. In order to assess those disturbances correctly and to design effective and efficient mitigation measures, it is necessary to develop an accurate prediction model for subsurface strata movements and deformations. Decades of research have demonstrated that variations of stratification and lithology in the overburden have significant influence on the subsurface strata movements and deformations during ground subsidence process. The key strata theory states that the thick and hard key strata serve as the backbone of the overburden and control the movements of the thin and soft weak strata located above them. From an engineering standpoint, the overburden strata are subdivided into several individual groups by the key strata with each group consisting of a key layer at the bottom and weak layers overlying it. A new subsurface subsidence prediction model considering the key strata effects on subsurface strata movements and deformations has been proposed. In this method, elastic modulus, specific weight, tensile strength, and uniaxial compressive strength (UCS) of each layer are used to identify the key layers and to determine the needed subsurface subsidence parameters. The influence function method, proven to be accurate and versatile for surface subsidence prediction, was employed to predict the subsidence on each of the overburden layers from mining horizon progressively upward to ground surface with the assumption that the predicted subsidence on a given layer serves as the subsidence source for the layer immediately above. The enhanced subsurface subsidence prediction model has been demonstrated with an actual case to show its applicability and improvement.

Jan 25, 2021

By PETER ROBINSON, KEVIN BARBER, OLIVER WHATNALL

Investigation and uptake of filtered tailings continues to grow throughout the globe. This is driven by a wide range of site-specific considerations, which include such factors as tailings characteristics (e.g., amenability to filtration), production rates, climate, water availability, cost drivers, environmental requirements, and social factors. Despite the aforementioned technological growth, the currently available filtration technology is not able to meet the needs of many operations and projects that would otherwise adopt the technology. Experience with large-scale industrial filtration shows that vacuum belt filter systems meet the needs of many modern users, exceptions being the inability to effectively dewater tailings at altitude and/or with a fine particle size distribution: a potential fatal flaw. This paper presents a case study on the utilization of the patented Viper Filtration technology on gold tailings to overcome this challenge and shares the resultant full-scale plant design, highlighting the features designed to overcome cost and scalability deterrents. This technology is a novel mechanical process which complements the vacuum pressure in dewatering the filter cake as it travels along the belt filter. This project commenced with a pilot testing program, which successfully met the objective to rigorously test, measure and record any performance improvements achieved when engaging the Viper technology. Of the two tailings products tested, gross improvements of 4.2%w/w and 5.7%w/w were achieved when compared to the conventional vacuum belt filter operation. This pilot testing facilitated measurement of operating and design data, which forms the basis of the full-scale system design and resultant equipment supply of three vibration roller assemblies for retro-fitting on the existing vacuum belt filter.

Jan 25, 2021

By YUSONG MIAO, DI WU, XIANRONG YAN, YIPING ZHANG, JIE LIN, KEBIN LI

Rock fragmentation size distribution is often used as an important index to account for the blasting effect because it directly affects the subsequent loading, transportation, and secondary crushing. Due to the mismatching of explosive and rock wave impedance, high boulder yield often occurs which affects the blasting effect. In this study, methods of measuring rock acoustic impedance, rock strength point loading, and detonation wave velocity have been used to obtain more accurate input parameters. Then, in the watershed image segmentation technique, the Gates-Gaudin-Schuhmann and Rosin-Rammler distribution functions have been used to analyze and quantitatively describe the rock fragmentation size distribution in the existing muck-pile. Finally, taking the rock properties, explosive performance, blasting parameters, and system characteristic variable into consideration, support vector machine (SVM) regression model has been analyzed on the learning and prediction of samples. The results show that SVM has a good prediction accuracy, high precision, and strong generalization ability. The optimized matching coefficient of rock and explosive wave impedance K ranges from 2.50 to 2.58 times. This study has developed a series of simple, accurate methods for rock properties analysis, detonation wave velocity measurement, and muck-pile model image processing, and a basis for predicting and evaluating rock fragmentation size distribution and optimizing the matching coefficient before carrying out a blasting operation.

Jan 22, 2021

By S. K. Samal, B. Mishra, M. K. Mohanty, S. C. Mishra

Steelmaking industries consume the majority of chromium and manganese ferroalloys to impart several properties in steel and also for other purposes. The quality of ore governs the process kinetics as well as the process economy of the ferroalloy industry. The present study demonstrates the thermal transformation behavior of chromite and manganese ores with varying compositions. Simultaneous thermal analysis (DTA/TG) is employed for such ore samples where the transformation of mineral phases is correlated with the thermogram characteristics and quantified. Phase, microstructure, and compositional analysis results of individual ores corroborated with thermal analysis are in good agreement. Chromite samples are ferruginous with goethite and gibbsite contents, whereas manganese ores vary in composition and also exhibit multiple and/or overlapping transformations.

Jan 21, 2021

By Brenton Fletcher, Yongjun Peng, Wonder Chimonyo

As a cheap, renewable and non-toxic material, starch can contribute to the sustainability of the flotation process, albeit in a minor way as one type of reagent in systems involving materials with far greater impact. But the physical and chemical versatility of starch can help address another issue, namely, that of processing complex ores with decreasing grades of valuable minerals and increasing mixtures of gangue. This paper compares the results of two lab scale flotation studies where starches (native wheat starch (NWS), dextrin and two oxidised wheat starches) were used to depress two common gangue minerals, copper-activated pyrite and carbon (graphite), over a range of dosages. The oxidised starch with the larger molecular weight structures depressed copper-activated pyrite best, and the oxidised starch with lower molecular weight structures was better at depressing graphite. In both cases, the oxidised starches allowed greater recovery of chalcopyrite, pointing to selectivity potential. The extent to which the carbonyl and carboxyl moieties of the oxidised starches contribute to depressant performance is difficult to quantify, but it should not be discounted. Importantly, the results demonstrate relatively simple modifications of native starch by oxidation can yield structures suitable for depressing gangue minerals with diverse surface properties. The challenge remaining for greater application of modified starch depressants is being able to replicate the desired structures at scale in cold-water-soluble form.

Jan 18, 2021

By Viktor Lishchuk, Olof Martinsson, Tobias E. Bauer, Elena Haller

Freely accessible and non-confidential real-life geological data sets from mineral deposits are desirable for the wide range of applications in research and education. However, publicly available statistical data are limited in their number and quality—they contain reduced information about geological, geophysical, geotechnical, chemical, mineralogical, and other relevant properties of deposits. This makes such data insufficient for scientific purposes. However, the amount of geological knowledge obtained for a variety of deposits in the past allows the construction of an idealized synthetic ore body model using analytical approach. Such a model could be used for education purposes and testing basic scientific theories, e.g., visualization of deposit structure; teaching sampling strategies; testing new algorithms for mine planning; or comparing geostatistical modeling methods. This paper presents an analytical approach to simulate volcanic massive sulfide (VMS) deposits and shows how synthetic deposit model can be constructed and further used for studying sampling with drilling and simulating folding and faulting.

Jan 14, 2021

By A. A. Zatout, G. H. Sedahmed, T. M. Zewail, M. H. Abdel-Aziz, B. S. Ibrahim, E-S. Z. El-Ashtoukhy

In this work, the possibility of intensifying the cementation process in stirred vessels was studied by using the perforated baffles as turbulence promoters; the cementation reaction of Cu+2 on Zn was selected as a model. Zn was used in the form of a sheet lining the inner wall of an agitated vessel. Parameters considered are initial concentration of Cu+2, solution temperature, impeller rotation speed, and impeller geometry. Within the present range of parameters studied, the rate of cementation was found to increase with increasing initial concentration of Cu+2, solution temperature, and impeller rotation speed. At the same rotational speed, a flat turbine gave a higher rate of cementation than a 45° pitched turbine. The present suggested that baffles’ geometry gave superior performance in terms of mass transfer of copper cementation compared to the conventional baffle geometry. All parameters that affect the rate of cementation were correlated in the form of dimensionless equations suitable for the design and performance prediction of the agitated vessel. Potential applications of the obtained results in the field of hydrometallurgical processes and wastewater treatment were discussed.

Jan 12, 2021

By SUHAINA ISMAIL, NORLIA BAHARUN, SHAIK ABDUL RAHMAN, WAN NUR SYAFIQAH ANUAR, MOHAMMAD REZAEI ARDANI

Hypochlorite leaching system is a strong oxidizing solution for metal sulfides, which are naturally associated with gold extraction. This study evaluated the hypochlorite leaching of refractory gold ore by using the response surface method–central composite design (RSM-CCD) as a statistical approach in determining the optimum condition of gold extraction from refractory gold ore. The studied parameters for the gold recovery were pH (4 to 6), concentrations of Ca(OCl)2 (0.5 to 1.5 M) and NaCl (2.5 to 3.5 M) in the solution. It was found that the maximum gold extraction of 82.46% (13.85 g/t) was achieved at a pH of 4.0 with NaCl and Ca(OCl)2 concentrations of 2.93 M and 1.08 M, respectively. The statistical analysis also revealed that the amount of gold recovery in chloride solution was significantly depended on pH as the main factor, followed by concentrations of Ca(OCl)2 and NaCl.

Jan 8, 2021

By Liaqat Ali Shah, Muhammad Farooq, Zait Ullah Shah, Francisco Rolando Valenzuela-Díaz

Bentonite collected from Nowshera (Pakistan) was treated with NaCl, and the < 2-μm clay fractions were separated by sedimentation process. The textural changes in NaCl treated purified bentonite were compared with raw and physically purified sample. It was detected that the NaCl-treated purified bentonite and the sample purified by simple sedimentation, respectively, consist of sodium-montmorillonite and calcium-montmorillonite as a major clay mineral. The honeycombed-type morphology was observed for both the purified samples; however, the particles of NaCl treated purified bentonite were relatively in a compact form. The particle sizes of both the purified samples were found considerably smaller. The high volume percent of the fine particles was noticed in the NaCl-treated purified bentonite. This attributed that the sodium exchange has a valuable impact on the bentonite dispersion in aqueous media during particle size measurement. The relatively high mesopore area/volume and micropore area/volume and specific surface area (SSA) were detected in purified samples. The NaCl-treated purified sample showed relatively high mesopores area/volume than the sample obtained by simple sedimentation. These changes seem to be originated from either high montmorillonite contents and/or the smaller particle size, which might be produced after the layer rearrangement during the interlayer cation replacement by Na+ ions. The large SSA and high porosity of purified samples particularly the NaCl-treated bentonite suggest their potential use as adsorbents, catalysts, pharmaceuticals, and cosmetics.

Jan 7, 2021

By Ihsan Berk Tulu, Mark Alexander Van Dyke, Deniz Tuncay, Ted M. Klemetti

Bleeder entries are critically important to longwall mining for the moving of supplies, personnel, and the dilution of mine air contaminants. By design, these entries must stay open for many years for ventilation. Standing supports in moderate cover bleeder entries were observed, numerically modeled, and instrumented by researchers at the National Institute for Occupational Safety and Health (NIOSH). The measurements of the installed borehole pressure cells (BPCs), standing support load cells and convergence meters, and roof extensometers are presented in this paper in addition to the numerical modeling results and visual observations made by the NIOSH researchers in the bleeder entries. The results include the effects of multiple panels being extracted in close proximity to the instrumented site as well as over one and a half years of aging. As expected, standing supports closer to the longwall gob showed the greatest load and convergence. The roof sag appeared generally independent of the proximity to the longwall gob. The BPC readings were driven by both the proximity to the gob and the depth into the pillar. The results of this study demonstrated that the entry roof can respond independently of the pillar and standing support loading. In addition, the rear abutment stress experienced by this bleeder entry design was minimal. The closer the mine development, pillar, or supports are to the gob, the greater the applied load due to rear abutment stress.

Jan 7, 2021

By Mei Long, Tawum Juvert Mbah, Jianhua Zhang, Haiwang Ye

There have been many improvements and advancements in the application of neural networks in the mining industry. In this study, two advanced deep learning neural networks called recurrent neural network (RNN) and autoregressive integrated moving average (ARIMA) were implemented in the simulation and prediction of limestone price variation. The RNN uses long shortterm memory layers (LSTM), dropout regularization, activation functions, mean square error (MSE), and the Adam optimizer to simulate the predictions. The LSTM stores previous data over time and uses it in simulating future prices based on defined parameters and algorithms. The ARIMA model is a statistical method that captures different time series based on the level, trend, and seasonality of the data. The auto ARIMA function searches for the best parameters that fit the model. Different layers and parameters are added to the model to simulate the price prediction. The performance of both network models is remarkable in terms of trend variability and factors affecting limestone price. The ARIMA model has an accuracy of 95.7% while RNN has an accuracy of 91.8%. This shows that the ARIMA model outperforms the RNN model. In addition, the time required to train the ARIMA is than that of the RNN. Predicting limestone prices may help both investors and industries in making economical and technical decisions, for example, when to invest, buy, sell, increase, and decrease production.

Jan 6, 2021