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By R. Wirth, B. Orberger, C. Wagner, A. Tudryn, B. Baptiste, S. Miska, Université Paris-Sud

Banded iron formations (BIFs) comprise complex textures and mineralogy, which result from fluid-rock interactions related to high and low temperature alteration. The initial iron oxy hydroxide mineralogy and associated phases such as carbonates, quartz, apatite and phyllosilicates were transformed leading to an upgrading of these BIFs into the world’s largest source of iron ore. In low-grade BIFs, a large part of the iron is related to micro- and nano- metric iron-bearing inclusions within micrometric quartz and/or carbonates (mainly dolomite). We studied laminated jaspilitic BIF samples from a drill core containing 26.71 wt.% total iron, 0.2 wt.% SiO2, 0.32 wt.% MnO, 15.46 wt.% MgO, 22.32 wt.% CaO, 0.09 wt.% P2O5, < 0.05 wt.% Al2O3, 0.15 wt.% H2O and 34.08 wt.% CO2 (Aguas Claras Mine, Quadrilatero Ferrifero, Brazil). Bright rose coloured dolomite and quartz bands alternate with massive specular hematite bands. Raman spectroscopy, X-ray diffraction and FIB-TEM analyses reveal that the micro- and nanometric inclusions in dolomite are mainly hematite and minor goethite, partly occurring as clusters in voids. Curie Balance analyses were carried out at different heating steps and temperatures on whole rock samples and a synthetic mix of decarbonated sample and pure dolomite. X-ray diffraction on the products of the heating experiments shows that that hematite is stable and new phases: magnesioferrite (MgFe2O4), lime (CaO), periclase (MgO), portlandite (Ca(OH)2) and srebrodoskite (Ca2Fe2O5) were formed between 680°C and 920°C. These finding gives hints to optimizing the beneficiation process, as the presence of hydroxyl ions bearing goethite micro- and nanoinclusions lowers the sintering temperature. Prior separation of coarse hematite and barren dolomite and quartz, followed by lower temperature sintering of the inclusionbearing dolomite/quartz leads to transformations into phases with higher magnetic susceptibilities (such as hematite and magnesioferrite). The entire Fe and Fe/Mg oxide feed (the priorly separated fraction added to the sintered fraction) can then pass through wet-high intensity magnetic separation after crushing.

Jan 1, 2016

By Olli Haavisto, Lauri Koresaar, Navid Khajehzadeh

In recent times sustainable minerals processing is an important topic in research. Sustainable mining is linked with efficient use of energy and human resource in all process stages including beneficiation of the ore. Controlling and optimizing the recovery while preserving the grade of the concentrate is extremely important in flotation plants. This development requires new technological solutions and has given rise to the multitude of application areas for lasers. X-ray Fluorescence (XRF) and Laser-Induced Breakdown Spectroscopy (LIBS) are currently two of the predominant non-contact and direct analysing methods in industry. LIBS and XRF measurement techniques both have high capabilities for measuring elements. LIBS has a very simple and easy-to-implement spectroscopic setup, wider range of elements can be detected with online LIBS and measuring light elements is simpler by LIBS compared with XRF. It is of great interest to extract mineralogical information from the elemental results with no modification on the measurement setup. In order to achieve this, more advanced interpretation of the elemental peaks of LIBS spectra is required. Therefore, the major focus of this research is about measuring mineral concentrations from the elemental lines of LIBS spectra using advanced statistical methods. This accomplishment provides knowledge about mineral concentrations from the real-time assay data of the slurry LIBS analyzer. Consequently, this paper first discusses an analytical method called partial least squares regression leading to rapid mineral identification from the elemental contents of the LIBS technique. Then the technique is employed to analyze the mineral contents quantitatively through the information acquired from an on-stream LIBS slurry analyser. This can lead to many benefits such as rapid control of concentrate quality, enhanced recovery, saving time, energy and manpower.

Jan 1, 2016

By Grant Small, Jessica Kinal, Christopher J. Greet

"The conversion from an electrochemically reactive grinding media (forged steel) to a more electrochemically inert alloy (high chrome white iron) not only reduces the wear rate of the grinding media, but also has an impact on the grinding chemistry. Typically the grinding chemistry becomes more oxidising, with less reducing Eh values and more dissolved oxygen in the pulp. There is also a decrease in the EDTA extractable iron, which is an indication of the change in the media corrosion. These changes are indicative of alterations in the surface chemistry of the minerals that the operator is trying to separate. For porphyry copper ores the changes in the pulp and surface chemistry not only affect the copper sulphide minerals, but also impact the iron sulphides (i.e. pyrite and pyrrhotite). Generally, with more oxidising pulp chemical conditions during grinding there is an increase in the oxidation of the iron sulphides which renders their surfaces hydrophilic, thereby depressing flotation. This leads to improved selectivity for copper sulphides against iron sulphides.INTRODUCTIONPorphyry copper deposits are the dominant source of copper that is mined today to satisfy global demand. These style of deposits typically contain one percent copper mostly as chalcopyrite, but may contain other copper bearing minerals (for example, bornite, chalcocite, azurite, malachite), small quantities of pyrite and quartz. Porphyry copper deposits also contain economically significant quantities of gold, silver and molybdenum. Interestingly, the majority of the world’s porphyry copper deposits are concentrated along tectonic plate boundaries (Figure 1)."

Jan 1, 2016

By Kazutoshi Haga, Batnasan Altansukh, Yasushi Takasaki, Mohd Yazid Bin Abdul Razak, Atsushi Shibayama

"In this study, the volatilization behaviour of arsenic (As) and antimony (Sb) from arsenicantimony bearing minerals such as tennantite (Cu12As4S13)/tetrahedrite (Cu12Sb4S13) in copper ore was investigated using a roasting process. Specifically, the thermal decomposition of tennantite and the arsenic volatilization were investigated under nitrogen and air atmosphere. The roasting experiments were performed at temperatures ranging from 500 to 1,200oC and different retention times using a laboratory electric furnace. The results indicated that over 95% volatilization was achieved at 700oC. On the other hand, when the temperature increased to 1,200oC, volatilization rate of Sb reached to 90%. Therefore, volatilization of Sb requires high temperature compared to As. It suggests that As and Sb can be separated using temperature difference. Selective removal of As is possible at 700oC, subsequently Sb can be recovered as a volatilized product by increasing the temperature to 1,200oC. Meanwhile, volatilization of Cu and Fe was not observed on these conditions. The content of As and Sb in the residues obtained from roasting at 700 and 1,200oC was less than 0.3 and 0.75 mass%, respectively. The Cu content in solid residue at 1,200oC increased to 34 mass%. The clean copper concentrate with lower amounts of arsenic and antimony was obtained from the process. INTRODUCTIONRecently, arsenic (As) and antimony (Sb) contents in copper (Cu) concentrates are increasing year by year. Arsenic and antimony are present with Cu minerals such as enargite (Cu3AsS4), tennantite (Cu12As4S13) and tetrahedrite (Cu12Sb4S13) that associate with copper sulfides [chalcopyrite (CuFeS2) and bornite (Cu5FeS4)]. They are normally concentrated by flotation and treated in copper smelters. However, treatment of copper concentrates containing high amounts of arsenic and antimony by a smelting process is difficult due to environmental implications of toxic arsenic and antimony. As demand for copper continues to grow, the need to source copper from several types of resources including those that contain high levels of As/Sb becomes necessary. Therefore, a novel processes for the treatment of As/Sb bearing Cu concentrates are required. Reviews on copper resources such as enargite, tennantite and tetrahedrite containing high amounts of arsenic and antimony are covered widely in literatures by many researchers (Padilla et al., 1998; Welham, 2001; Vinals et al., 2003; Guo & Yen, 2005; Balaž & Achimovicova, 2006a; Filippou et al., 2007; Mihajlovic et al., 2007; Lattanzi et al., 2008)."

Jan 1, 2016

By Mark F. Sindelar, Yi Luo, Hua Jiang, Michael T. Shook

"Convergence of roof and floor in underground mine openings is a common occurrence. This convergence not only adversely affects the ability of workers, equipment and supplies to travel through the mine, it also reduces the effectiveness of the mine ventilation system, which is essential for the dilution of methane gas and airborne respirable dust. While installing secondary standing supports to control floor and roof convergence, such supports, by nature, partially obstruct a portion of the airway. These added obstructions inhibit the ability of the ventilation system to operate as efficiently as it could by increasing the resistance in and reducing the cross-sectional area of the airway.This study introduces and demonstrates the benefits of The Eye CAN™ standing roof support, which controls floor and roof convergence and is less obstructive to air flow than conventional wooden cribs. Laboratory findings show that the normal resistance of a supported lined airway is reduced by using this new product from Burrell Mining Products, Inc., while providing the same roof support characteristics of an established product-The CAN®. Load vs. displacement curves generated from laboratory tests demonstrated that this new product behaves with the same roof support characteristics as others in The CAN product family. Ventilation data gathered from a simulated mine entry was then used for computational fluid dynamics (CFD) modeling. The CFD analysis showed an improvement with The Eye CAN versus other accepted forms of standing roof support.This proof-of-concept study suggests that, when using this new product made by Burrell Mining Products, Inc., not only will the convergence from the roof and floor be controlled, but airway resistance will also be reduced.INTRODUCTIONOne of the basic elements of underground mining is the necessity to support the mine roof. It is well-known that easier reserves have been mined so that today's underground mines present challenging conditions. Factors influencing roof support decisions include mine depth, mining method, overburden composition, and agency regulations. Mining engineers, therefore, have to balance three objectives: safety, engineering, and cost. While safety is obviously paramount, and engineering often complements safety, the cost effectiveness of any product, method, or device warrants additional consideration in today's harsh business climate. Avenues for adaptation and improvement are found at the intersection of the three objectives."

Jan 1, 2016

By Sylvie Lévesque, Frederic Couët, Laura Pérez-Barnuevo, Cory Hennessey

Determining mineralogical characteristics of samples throughout the iron ore concentration process – from drill core samples up to the concentrate – is critical to process improvement and remediation. However, assessment of mineral proportions, liberation, and texture, although essential, can be time-consuming and costly. Thus, a mineralogical study is often not performed or only restricted to a limited number of samples. New iron ore deposits or new ore zones in active mines will bring new challenges as they are known to be problematic due to their lower grades, complex textures and presence of mineral impurities. In those cases, applied process mineralogy will be necessary to understand and to diagnose potential processing issues. To take full advantage of mineralogical information along the iron ore concentration process, new tools are being developed to provide mineralogical data based on texture, composition and liberation. In an early stage at the mine, the automated identification of drill core textures could provide essential information for the prediction of ore concentrability and grindability. In a later stage, the automated modal tool, combining the knowledge of the iron ore mineralogy of a specific deposit and the results of chemical analyses, can quantify the mineral proportions of the ore; results show good agreement between mineral estimation via chemical analysis and modal analysis using a Mineral Liberation Analyser. A bulk mineralogical analyser allowing semi-quantitative evaluation of the liberation of iron oxides is being validated. The results from the bulk mineralogical analyser will eventually be linked with the mineral proportions issued by the automated modal tool to provide complete mineralogical characteristics of iron ore samples. Ultimately, these mineralogical tools could provide valuable and timely insight for predicting concentrators’ performances or troubleshooting gravity separation processes.

Jan 1, 2016

"Decreasing gold-in-ore grades is one of the main drivers of poorer productivity and rapidly escalating unit costs. Grinding costs, water use and reagent consumption are all intimately related to the ore grade processed. Various pre-concentration technologies have been developed that can be applied at various stages of crushing prior to ore grinding. This paper will review the amenability of ores to coarse particle barren gangue rejection for fine crush sizes in the pumpable particle size range (i.e., particles between 5 mm and 0.3 mm in size). The liberation of oxide gangue achieved during crushing is evaluated by proxy using sink-float analysis and the deportments of gold, sulfur, and arsenic into sinks and floats are monitored. Amenability of gangue rejection by continuous gravity separation is evaluated after various crushing modes (vertical shaft impact crushing, cone crushing, and HPGR crushing). The potential to identify coarse particle mineral association and liberation using three-dimensional x-ray computed tomography will be discussed.INTRODUCTIONThe aim of research in this area is to explore some of the attributes which make some ores amenable to preconcentration, or rejection of a significant component of the feed mass to tailings at a coarse liberation size. Characteristics such as ore type, mineralogy, breakage pattern, particle shape, and liberation characteristics may need to be examined to identify amenability to pre-concentration amenability.It is intended to focus on continuous gangue rejection in the pumpable size range (0.3–5.0 mm) as this remains one of the key opportunities to reduce processing costs through a combination of techniques including screening (for mineral differentiation rather than size classification only) and gravity separation (using jigs). This is to be contrasted to conventional preconcentration as performed with automatic ore sorters."

Jan 1, 2016

By M. G. Maruma, L. A. Mampuru

"Mill liner wear is a major cost item in the mining industry and there is continuous research to prolong the life of the liners. Over the years it has become apparent that even though high-chromium white cast irons are highly efficient as abrasion-resistant materials, a combination of wear resistance and fracture strength remains difficult to achieve. Increasing the hardness of the high-chrome white cast iron (HCWCI), which improves the resistance to abrasion wear, is often accompanied by a deterioration in fracture strength. Operational conditions inside the mill require that the liner should be made of highly wear-resistant material with some fracture strength. Vanadium additions ranging from 0.2 to 3 wt% were made to HCWCI in an attempt to refine the microstructure. It was found that an increase in vanadium content promotes grain refinement. A content of 1.5-3 wt% gave the best results as measured by the maximum breaking strength.IntroductionOver the years it has become apparent that even though high-chromium white cast irons are highly efficient abrasion-resistant material, a combination of excellent wear resistance and fracture strength remains difficult to achieve. The exceptional wear resistance of highchromium white cast iron (HCWCI) is attributed to hard chromium carbides embedded in an austenitic/martensitic/pearlitic matrix. When the chromium contents exceed 12 wt%, interconnected MC3-type carbides of conventional cast irons are replaced by rodshaped and isolated M7C3 carbides (Powell, 1980), leading to an improvement in the impact toughness, ductility and fatigue resistance. However, the main M7C3 carbides in HCWCI are hard and brittle and can provide an easy path for crack propagation. This limits the applications of HCWCI, particularly in severe impact conditions. Most operations involving HCWCI are in crushing and grinding and the life of a part/liner is limited by its wear resistance. However, improving the wear resistance of HWCI comes at the cost of a significant reduction in fracture strength. Concerns about premature failure of HCWCI mill liners in the mining industries prompted a study to improve the wear resistance and mechanical properties of HCWCI."

Jan 1, 2016

By Maryam Sadeghi, Jonathan Roy, Claude Bazin

"The operation of mineral processing equipments is intimately related to the mineral composition of the ore. However unit performances are usually characterized in terms of metal contents or recoveries as this data is easier to obtain than the mineral contents. This paper describes a method that combines the operations of material balancing and estimation of the mineral contents of the ore. The estimated mineral contents can be used for process analysis and diagnosis of operating problems.IntroductionThe ore that is feeding a concentrator is made of minerals that condition the energy requirements for the ore comminution and the performances of the subsequent separation circuit. Indeed a change in the mineral composition of the ore may lead to lower grinding mill throughput as well as lower recovery or grade of the economical products. Despite this relationship is recognized the mineral composition of the ore is seldom measured or estimated to provide regular information for the diagnosis of operating problems. Some methods such as the QEM-SCAN (Whiten, 2008; Lamberg and Vianna, 2006) are available to measure the concentration of the minerals in ore samples but the method is time demanding and plant operators usually base their evaluation of the plant performances on chemical assays of metals or elements since this data is easier to obtain from ore samples.Usually samples of the streams of mineral processing plants are collected on a daily basis to be assayed for strategic elements. The obtained concentrations are balanced to produce coherent data with the material conservation constraint and then used to characterize the day to day operation of the plant in terms of recovery of valuable metals and grades of the marketable concentrates. The behavior of contaminant elements can also be monitored from this data allowing the operators to explain for instance a lower zinc concentrate grade by a more important contamination of iron. However such diagnosis is only partial as the contaminant element can be transported by different minerals. Indeed the iron contamination of a zinc sulfide concentrate may be caused by an inadequate depression of pyrite or due to another iron carrying mineral. A possible way to answer the question is to determine the concentrations of the various minerals in the ore and produced sealable concentrates. Since measuring the mineral contents of the ore could be a demanding task one should consider to estimate this data from the daily chemical assays of the sample collected on the main streams of the circuit. Some authors have already investigated the problem. Whiten(2008) described a method to estimate the mineral contents of an ore sample. Lamberg and Vianna(2006) proposed a method to do a sequential mineral reconstruction followed by a material balance. Few of these methods account for the mass conservation of the reconstructed mineral contents."

Jan 1, 2016

By Brandt Porter, Lawrence K. Nordell, Alexander Potapor

"Improving comminution efficiencies with better machine geometries and motions, improved nip angles, rock movement control, and voids regulation among rocks are some of the next steps to better machine performance. Recent gains (~30%) using high pressure grinding rolls (HPGRS) and vertical roller mills, in theory and practice, are based on Prof. Klaus Schönert’s academic studies (1979–1996) on rock breakage physics. More recently, University of British Columbia Prof. Bern Klein’s studies (2006–present) via the Ph.D. thesis of Z. Davaanyam (2015) further validate theory with practice from laboratory measurements used in this paper.They demonstrated ideal rock compression breakage, within HPGR and vertical roller mill machines using a piston-die apparatus. Similar rock size range is used. The piston-die confine rock breakage behavior. However, these studies do not extend to larger rocks (> 75 mm), and do not demonstrate the influence of rock voids among bifurcation of rocks during comminution. Further, machines fed with larger rock sizes, such as gyratory, jaw, and cone crushers, are not designed or evaluated for geometry nip angle efficiency.Herein we illustrate a performance gain of a new comminution machine, the conjugate anvil-hammer mill (CAHM), first presented at SAG 2011 (Nordell, 2012). The CAHM machine digests rock sizes 400% larger than HPGR, improves rock grip/nip geometry, better improves rock voids, improves surface wear life > 500%, and improves rock containment and slippage during compression. In all, the CAHM machine shows 22 potential improvements over the HPGR. Most importantly, CAHM shows a 50% kWh/ton improvement compared to the HPGR. Our studies use an advanced Discrete Element Method (DEM) computer program called ROCKY. ROCKY simulates moving boundaries, surface wear mechanics, and incorporates rock breakage physics based on the fundamentals of JKMRC T10 protocol [×] with tuned A × b breakage parameters.We calibrate rock breakage in our DEM code to mimicking both UBC laboratory piston-die and HPGR comminution measurements. We then model CAHM with these known ore and machine properties. Differences are illustrated using DEM techniques on each machine, including key points of when each: use geometry; initiate bifurcation breakage; provide a map of particle size distribution by location; illustrate the importance of controlling voids to minimize agglomeration after breakage; machine performance limits; and kWh/ton benefit."

Jan 1, 2016

By Pierre De Pasquale, Aquilino Antonio Alvarez-Castro

Greenhouse gas emissions are now an essential issue for extractive industries. Actually, lowering of quarry energy consumption and CO2 emissions participates to answer both environmental and financial issues. The “EE-Quarry” European project, supported by the European Commission (EE stands for Energy Efficient), develops a new and highly effective modelling and monitoring Energy Management System technique to improve Energy Efficiency and move to a low CO2 emission rate in the nonmetallic mineral industry.

Jan 1, 2016

By Enguang Zhu, Kangning Zhang, Yang Li

"Due to the use of outdated mining technology or room and pillar mining process in small coal mines, the coal recovery ratio is only 10% - 25%. In many regions of China: the damage area caused by the small coal mines amounted to nearly one hundred square kilometers. Therefore, special mining techniques must be taken to reclaim the wasted resource in disturbed coal areas. This paper focuses on the different mining methods by analyzing the longwall panel layout and abandoned gateroad (AG) distribution in in the abandoned area of Cui Jiazhai Coal Mine in northwestern China. On the basis of three-dimensional geological model, FLAC- 3D numerical simulation was employed. The abutment pressure distribution was simulated when the panel face passed through the disturbed areas. The proper angle of the inclined face was analyzed when the panel face passed through the abandoned gateroads. The results show that the head end of the face should be 13-20m ahead of the tail end. The pillars on both sides of abandoned gateroads had not been damaged at the same time, and no large-area stress concentration occurred above the main roof. Therefore, the coal reserves of disturbed areas can be successfully recovered by using underground longwall mining. INTRODUCTIONDuring the 70-90's, there were a lot of small coal mines in China. Due to their disordered mining, most of the small coal mines left a great many abandoned gateroads (defined as AG in this paper) and a large area of damage coal seam. In these type of coalfields, there exist many mining risk issues, including nonuniform stress in the overburden, flooding and hazardous gases accumulated in the gob. So how to lay out a longwall panel and successfully mining under this type of abandoned small mines is a big issue nowadays in China.As mentioned above, longwall panel is being performed in the damaged coal seams in order to increase recovery of coal reserves (Wang, 2009). However, the abandoned geteroads intersect to each other all around the area. So a series of production issues arose while the panel face is passing through these AG. Gang and Gong (2015) analyzed the roof stability and abutment pressure distribution during the face was passing those AG that were parallel and inclined to the faceline. Xie, et al. (2015) proposed the ground control mechanism by passing the AG in top-coal caving longwall mining. He recommended to stop the face advance until the roof is over, using high strength bolts and cable bolts, and grouting consolidation. This paper studies the different mining methods by analyzing the longwall panel layout and AG distribution in damage coal seams. Theoretical analysis and field observation were conducted to determine the overburden movement when the face was advancing under the AG. The pillar between face and parallel AG changes from elastic to plastic and eventually to the residual supporting status. All these three status was combined with the roof structure to establish the theoretical model to calculate the shield support capacity. Numerical modeling was employed to simulate the pillar stability and determine the abutment pressure distribution as the face inclined to the AG during longwall mining."

Jan 1, 2016

By Pier Francesco Paglini, Gian Luca Menchini, Pier Francesco Boschi

"PROJECTThe “Caltanissetta” Tunnel is part of the ANAS S.p.A (National Autonomous Roads Corporation) $ 1.3 Billion Highway 640 Caltanissetta-Agrigento (Sicily, Italy) Rehabilitation Project, consisting in upgrading of 62 km (40 miles) of highway. The Italian multinational construction company Cooperativa Muratori & Cementisti di Ravenna, is the General Contractor for the design and build contract. The highway S.S. 640 starts from Porto Empedocle, to the intersection with the Motorway A 19 Catania-Palermo.The entire project, double carriageway designed for speed 70-120 km/h and maximum longitudinal slope of 4.2%, is divided into two sections. First Section: just finished and opened to traffic. Second Section: mainly involving the province of Caltanissetta, length about 28 km (18 miles), works started in 2013. This second section includes the most challenging work of all the project, the “Caltanissetta” tunnel consisting of two separate tubes, each with 3.9 km length and inside diameter of 13.50 m, in order to host 2 traffic lines and an emergency line. HORIZONTAL AND VERTICAL ALIGNMENT - GEOLOGY AND HYDROGEOLOGYThe plan alignment of “Caltanissetta” tunnel is formed by two tubes which are located at a minimum mutual distance of 22 m to a maximum of 63 m, with n. 9 pedestrian and n. 4 road cross passages; ventilation shafts are not provided. Overburden over portals area is about 5 m till a maximum of 120 m. Tunnel sections have variable longitudinal slope from 2.6% to 0.5%, transversal slope of about 3.5%. Right tube length is 3,992 m, left tube length is 3,877 m."

Jan 1, 2016

By S. Mostaghel, Fariba Azgomi, Steven Goodman, M. Oliazadeh

"It is known that copper loss to the slag phase can be in the forms of chemical dissolution and mechanical entrainment. The contribution of each mechanism to the total Cu-loss depends on different parameters and may vary significantly. To reduce emissions to the atmosphere and to shorten the converting cycle, most industrial processes are aiming at production of high matte grades. Increased oxygen-to-sulfur potential, required by these processes, results in a highly oxidized slag, which in turn leads to an increased concentration of the chemically dissolved copper in the slag phase. Hence, slag cleaning processes are becoming increasingly important for economic viability of the smelting operations. Hydrometallurgical, pyrometallurgical, and mineral processing routes have been used for copper recovery from slag. The current article reviews a trade-off study evaluating two of the commonly used methods (namely flotation and electric slag cleaning furnace) by comparing the technical pros and cons, operability/maintenance requirements, and capital/operating costs of the operations.INTRODUCTIONLarge volumes of smelter and converter slags are produced by copper smelters around the world. It is estimated that for production of each ton of metal 2.2 tons of slag is produced (Gorai, Jana, & Premchand, 2003). Considering the current pressure on the mining and metals industry for “zero-waste, sustainable and environmentally friendly” extraction of metals, it is absolutely essential for metal producers to improve their efficiencies in order to remain competitive. To meet these objectives, almost all metal producers, from steelmaking plants, ferroalloys, base and precious metals producers, are trying to reduce their metal losses to the slag phase. In particular, copper producers are aiming to produce higher matte grades in their smelting furnaces to reduce the converting time and improve their overall throughput. Copper smelters need to minimize their copper/precious metal losses to the slag phase before final landfilling/use of slag. The current article, therefore, briefly reviews the copper loss to the slag phase, methods of metal recovery from the slag and then presents a trade-off study conducted for a green field flash smelter of the sulfide concentrates. A comparison was made between two of the major process routes for metal recovery from slag, namely slag cleaning furnace and flotation."

Jan 1, 2016

By B. R. Neufeld, M. G. Heximer, S. J. Roach, W. G. Van Luven, D. G. Reynolds

"Teck Metals Ltd. operates an integrated zinc-lead complex at Trail, British Columbia, Canada. In the zinc plant, zinc concentrates are roasted to produce calcine, which is then processed in the leaching circuit for zinc recovery. Calcine is first dissolved at pH <2.0. This is followed by a precipitation stage using additional calcine that removes iron as a ferric hydroxide precipitate which is recycled to the lead operations. It is during this pH adjustment that impurities, notably arsenic, antimony and germanium, are co-precipitated with ferric hydroxide which is the primary removal phase for these elements. Recent processing conditions have resulted in lower iron inputs to the leaching circuit and this has resulted in insufficient co-precipitation of key impurities. This paper summarizes the influence of iron concentrations on impurity removal using laboratory and plant scale surveys, and emphasizes key specification limits for the primary iron removal circuit.INTRODUCTIONThe Sulphide Leach Plant (SLP) at Teck Metals Ltd., Trail Operations produces a zinc sulphate electrolyte from three different zinc bearing streams:1. Calcine, primarily containing zinc oxide, from the roasters2. Zinc electrolyte from the Oxide Leach Plant (OLP) is produced by leaching zinc oxide fume from the pyrometallurgical lead smelting operations3. Zinc slurry from the Zinc Pressure Leach (ZPL) autoclaveThe feed sources are blended and introduced to the iron removal process to precipitate iron in the form of a hydrolyzed iron precipitate which is recycled to the lead smelting operation. Along with iron, impurities, namely arsenic, antimony, germanium and silica, also co-precipitate; this process acts as the primary removal step for these elements. Following iron removal, the electrolyte is further processed in the zinc dust purification circuits. Cadmium and copper are removed in the cold stage circuit via zinc dust cementation, followed by cobalt cementation in the hot stage circuit."

Jan 1, 2016

By Thibaut Pannetier, Damien Rogat, Catherine Larive, André Regnard, David Chamoley

"INTRODUCTION For several decades, the use of fibre-reinforced sprayed concrete (FRSC) has been becoming increasingly widespread, either as a replacement for or in addition to traditional reinforcements. Macro-synthetic fibres appeared on the market at the same time as metal fibres (in the 1980s), but their use has developed more recently in France, starting in the early 2000s. While their properties are attractive for underground operations, their long-term performance remains the subject of some controversy, particularly with regard to the phenomenon of creep [1-5]. Unfortunately, the many differences of protocol among the studies carried out (materials, metering, spraying equipment and test methods, etc.) mean that, in general, the results cannot be compared. Although several methods have been developed to assess the bending creep behaviour of fibre-reinforced concrete, the majority of them test notched beams resting on isostatic supports. There are currently no standardised test methods adapted to FRSC on hyperstatic supports (as is the case for FRSC used for underground support). The Asquapro association has thus developed a new test specially designed for this type of concrete. Slabs of thickness 10cm, measuring 60 x 60 cm in plan have been sprayed and tested under bending stress according to a test procedure inspired by the standardised test of energy absorption capacity (NF EN 14488-5). An experimental campaign was launched in October 2014 to study the behaviour of seven types of sprayed concrete, manufactured using the same concrete matrix: six of them were reinforced with different metal or macrosynthetic fibres and the seventh with a welded wire mesh. Fourteen slabs were sprayed for each type of concrete and also for the non-reinforced concrete with the same matrix. The types of mechanical performances measured were the compressive strength and energy absorption capacity (at seven and twenty-eight days), in addition to the creep behaviour of these seven types of concrete, placed under stress on the seventh day. This article follows on from that published in the WTC 2015 congress proceedings [6]: the programme and the test methods are briefly described here and the results available at the time of writing are presented and discussed."

Jan 1, 2016

By Monique Pharand, Jeet Basi, Simon Hille

"High quality activated carbon is essential in the recovery of gold in Carbon-in-Leach (CIL), Carbon-in-Pulp (CIP), and Carbon-in-Column (CIC) circuits. Goldcorp’s Campbell complex at Red Lake Gold Mines (RLGM) experienced a period of low soluble gold (Au) recoveries during Q3 2013, during which time the processing plant saw higher than typical Au grades in the CIP tails solution stream. A technical review identified that the CIP circuit may be experiencing a carbon-fouling issue. To further understand the degree of fouling, and to troubleshoot the low recovery problem, samples of carbon were collected from the CIP, elution, acid wash, and regeneration circuits, and submitted for characterization test work. This paper summarizes the steps taken to remedy the carbon-fouling problem at RLGM resulting in increased overall Au recovery.Overview of Red Lake Gold MinesRed Lake Gold Mines is located approximately 450 kilometres northeast of Winnipeg, Manitoba, in Ontario’s western boundary region.All mining is carried out through underground operations, utilizing overhand cut and fill, underhand cut and fill, and long-hole mining methods. Ore types include: silica-replaced carbonate veins with free milling gold, siliceous replacement-type mineralization (rich with arsenopyrite) marginal to veins, broad disseminated sulphide mineralization along major shears, and some minor sulphidized chemical sediment-hosted ore. The operation is supported by two milling complexes: Red Lake, and Campbell.Process DescriptionThe Campbell processing plant's main unit operations consist of grinding, gravity concentrating, flotation, autoclaving, leaching, carbon-in-pulp (CIP), carbon elution and reactivation, electro-winning, bullion smelting/refining and cyanide destruction, and concentrate handling. A schematic of the plant flowsheet is shown in the figure below.BackgroundHigh quality activated carbon is essential in the recovery of gold at many CIP/CIL/CIC processing plants. At RLGM, gold-bearing ore is milled and cyanide is added to leach the gold from the solids into solution. The dissolved gold then comes into contact with activated carbon, and adsorbs onto its highly porous surfaces. Gold is then recovered by separating the activated carbon from the main slurry for further refining. As such, the characteristics and quality of the activated carbon have a significant and direct impact on overall gold recovery."

Jan 1, 2016

By John R. Poland, Benjamin Mirabile

"There are significant ground support hazards to both personnel and equipment when longwall equipment must mine through cross-panel entries. Backfilling support strategies are often cost prohibitive. Additionally, it is often very difficult to install backfill material in full contact with the mine roof in backfilled entries. This paper will demonstrate the use of fiber-reinforced concrete crib material as a method for standing support in longwall cut-through entries. Despite conceptions of poor performance in potentially high convergence environments, fiber-reinforced concrete crib material can be used in longwall support environments subject to high abutment loads and convergence. Central to the proper design of these supports is the use of yield material between crib layers and at the mine roof/crib interface. The placement location of cribs within the cut-through entry has a significant effect on the main roof behavior and associated ground conditions in the longwall abutment zones. It is particularly important to engineer the proper load displacement characteristics of the installed crib to support expected ground conditions. The cost of fiber-reinforced crib supports is less than 50% of backfilling methods.INTRODUCTIONThe design and execution of a longwall cut-through is perhaps one of the most difficult and risky endeavors in the field of ground control. The magnitude of abutment loads and potential for ground failure present a significant safety hazard to underground personnel. In addition, there is significant financial risk, with replacement costs of face equipment exceeding $200 million. Faced with these consequences, it is both advisable and common for an engineer to design ground support with a significant margin of safety. This paper outlines a robust support system that possesses a significant margin of safety along with significantly lower costs than most other support systems employed in similar conditions.SITE PARAMETERSThe mine site described in this study operates in the Herrin No. 6 seam in southern Illinois. The seam height is typically 76- 84 inches. Mining height in gateroads and mains is typically over 96 in, and typical mining height on the longwall face is 82 in. The overburden depth is 950-970 feet in the area of the longwall cutthrough."

Jan 1, 2016

"Use of the Bond Work Index to size industrial grinding equipment was widely known. Bond also described its application for measuring grinding circuit efficiency. Bond Work Index efficiency has been widely used by industry, but until now without concise standard methods, or a formal guideline, for doing so. The Bond Efficiency Sub-Committee of the Industrial Comminution Efficiency work group of GMSG has produced such a guideline, which follows. It covers the methods and provides examples of how to calculate the Bond Work Index Efficiency of most industrial grinding circuits. Bond Work Index testing equipment and methods are also provided. The next steps are: (1) to establish standard reference testing materials and one or more laboratories to serve as bases for reference testing; (2) to establish the accuracy of relative circuit Work Index Efficiency determinations; and (3), to develop and provide a public data base of industrial comminution circuit Bond Work Index Efficiencies. OUTLINE Introduction and Background Part 1. Determining the Bond Efficiency of a Grinding Circuit Method Demonstration/Example Calculations Bond Work Index Testing Equipment and Procedures Accuracy of Comparative Circuit WI Efficiency Determinations (under development) List of Symbols Part 2. Data Base of Bond Grinding Circuit Efficiencies (under development) References Annexes: A1. The Bond Crushing WI Test Equipment and Procedure for Bond Efficiency Determinations (Revised March 26, 2015) B1. The Bond Rod Mill WI Test Equipment and Procedure (Revised March 26, 2015) C1. The Bond Ball Mill WI Test Equipment and Procedure (Revised March 26, 2015) Introduction and Background Please see the references and slide presentation “Bond Efficiency SLC (rev3)-print.pdf.” This efficiency determination applies to most brittle materials in their naturally occurring (un-scalped) size distributions being treated in size reduction circuits down to a product sizing of approximately eighty percent passing 70 µm (see below). Unusually shaped materials (e.g. mica) should be regarded with caution. Part 1. Determining the Bond Efficiency of a Grinding Circuit Method In the plant: • Define the circuit for which the WI efficiency is to be determined • Procure samples of the circuit feed and product • Obtain the power draw of the size reduction equipment at the drive pinion(s) • Obtain the circuit throughput rate (dry tonnage) In the laboratory:"

Jan 1, 2016

By Houquan Zhang, Ming Li, Guimin Zhang, Bei Zhang

"The support quality of bolts in deep roadways is one of the important factors for efficient and safe coal production. A new kind of non-destructive testing technique and equipment was used to monitor the axial bolt load in real time in deep roadways. Based on the test results, the working status of bolt support in deep roadways was evaluated. The research results show that the variation characteristics of axial bolt load is consistent with the distribution characteristics of rock pressure no matter whether it is in the initial support stage or mining disturbance stage. The axial load of bolts located 20m outby the development face has an overall rising trend within 3-5 days after installation. Within a certain distance in the front abutment pressure zone in front of the face, the axial bolt load increases with the advance of coal extraction. When coal and rock in the abutment pressure zone yield, the axial bolt load is dropped correspondingly. This kind of non-destructive testing technique provides an advanced means of detection and evaluation on bolt support quality.INTRODUCTIONMany coal seams more than 800m deep are being mined in eastern China. Roadways of large cross-section are being developed in coal seams more than 600m deep in western China (Kang et al. 2014). Moreover, these roadways are commonly supported by roof bolts and have encountered many support problems, including soft rock strata, intense mining disturbance, and abnormal tectonic stress. The stability of its surrounding rocks is difficult to maintain, the roof bolt even fails before mining (Shen 2014; Jiang et al. 2015). Therefore, it is very important to develop an effective method to detect the bolt quality in real time and evaluate the bolt's safety status.During installation of roof bolt, the installation quality is heavily affected by installation equipment and tools, field conditions, and operators' skills (Li et al. 2005; Shan 2009). The anchorage length will be shorter than the designed one if the resin cartridges are pushed to the bottom of excessively long drill hole and stay there without being shredded and mixed. The support function of the bolt would be weakened by the shorter anchorage length."

Jan 1, 2016