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By I. Gombköto, G. Földing, G. Mucsi, B. Csoke, J. Faitli, B. Kovács

This paper summarizes the main achievements of our previous project entitled "Development of a technological system producing quality guaranteed fly-ash based binder". Furthermore, this study deals with the laboratory experience of lignite fly ash utilization for two different goals. On the one hand the fly ash was tested as a binder; on the other hand it was investigated as an underground mine backfill material. Considering the first goal, the utilization of a mixture of mechanically activated fly ash and lime for producing an independent binding composition has been assessed involving determination of relationship between the degree of activation of fly ash and the strength of the obtained concrete. The results confirmed that this hydraulic binder is suitable for construction of stabilization and capping layers or base layer. Regarding the backfilling application, this paper presents laboratory experiments, their results including settling tests, hydraulic permeability and strength measurements and dense slurry technology related results.

Jan 1, 2011

By S. Geerts, J Davidson

The purpose of the experiment was to determine detonation characteristics of various improvised explosives. The test consisted of detonating a pipe filled with an explosive compound inside of a plywood arena. The pipe will be located in the center of the arena to ensure even distribution on the witness panels. Details on pipe dimensions, weights of the pipe and explosive, and the density were recorded prior to testing for use in the model calculations. The same size pipes were used throughout to minimize the variables inherent in testing. The plywood witness panels will capture the fragments so that penetration data was obtained, primarily the surface area of impact and depth of penetration. Through the use of the penetration data in conjunction with a mathematical model the original fragment velocity was determined. The mathematical model was developed to measure lethality of fragments from explosives and was modified to determine the original fragment velocity instead. From this model other variables such as the Gurney velocity were calculated. This test was done with an explosive compound that was commonly found, and numerous improvised compounds. In order to guarantee accurate data all of the explosives used for testing were cap sensitive, to eliminate the need for a booster charge which would introduce many unknown variables. The one common explosive compound that was used was C-4 which has known data in order to show accuracy of the model and calculations. The other 5 compounds chosen will not have this data as they will primarily be improvised mixtures.

Jan 1, 2011

By M. Tangstad

Keywords: Pyrometallurgy, ROMA, Norway, furnace, fines The ROMA project is a competence project on optimizing the usage of raw materials and energy in the ferromanganese, silicon, and aluminium industries. One of the items investigated in this project is the effect of fines on the furnace, and the usage of agglomerates versus lumpy ore. From lab-scale experiments it is shown, that for the charge to agglomerate in the furnace, the charge has to be exposed to a temperature higher than about 1200°C, independent of fines content. The fines less than 1 mm also showed higher agglomeration properties, compared to 2?4 mm, which showed no agglomeration property at all. The properties of agglomerates are very dependent on the pre-treatment of the agglomerate. Sinter and pellets, which have been heated to high temperatures, show a better strength, but also a lower CO reactivity. Sinter also shows a lower melting temperature compared to the ore.

Jan 1, 2011

By H. M. Chikashi

Keywords: Pyrometallurgy, furnace, bath agitation, regression analysis, entrainment This paper presents the results of linear regression analysis of the influence that each component of slag has on the losses of copper in slag-cleaning-furnace slag. Data used for the analysis are actual plant data collected over the past two years of operation. Facts obtained from the study will be helpful for smelter management to control these components in the flash smelting furnace feed and slag, to levels which will enable better control of copper in slag, and smoother operation of the KCM slag-cleaning furnace.

Jan 1, 2011

By R. Gordon, J. Palich, W. Qian

The EarthProbe DCIP system deploys tightly spaced electrodes connected to a centralized data acquisition system that enables arbitrary selection of current and potential electrodes through relays. Rapid data collection (approximately 1000 readings per hour) and advanced signal processing allow for efficient use of conventional and novel arrays and the removal of natural and cultural noise. What is unique about the system is its electrode and borehole cable design, which allows seamless integration of borehole and surface measurements. EarthProbe operates in four configurations - surface, borehole, borehole-to-borehole, and surface-to-borehole (a variant of the borehole-to-borehole configuration).

Jan 1, 2011

By M. Botz

Anatolia Minerals Development Limited (AMDL) is constructing the Çöpler Gold Project in eastern Turkey and commenced mining in the fourth quarter of 2009 with gold production scheduled to begin in the fourth quarter of 2010. The project is a 15,500 tonnes/day oxide heap leach with three-stage crushing, agglomeration, carbon adsorption and electrowinning for final metal recovery. Leach solution copper levels are expected to be relatively low during the first two years of production but will increase in later years due to higher copper content in the mined and processed ore. Over the mine life approximately 40 million tones of ore will be placed on the leach pad, which will contain about 35,000 tonnes of copper. Metallurgical testing indicates copper extraction will vary by ore type and, if controls are not implemented, may lead to copper levels exceeding 1,000 mg/L in pregnant solution. High copper levels in leach solution have the deleterious effect of increasing cyanide consumption and potentially overwhelming the ability of the carbon circuit to effectively adsorb the principal economic metals, which in this case are gold and silver. Using data obtained from laboratory leach column testwork, the heap leach facility was modeled using METSIM process simulation software to estimate the build-up of copper in leach solution over the mine life. Laboratory testwork was also performed to evaluate process conditions for treating a portion of pregnant leach solution via sulfide addition to precipitate saleable copper as copper sulfide (Cu2S).

Jan 1, 2011

By Z. Zhang, Cuihuan Huang, Zongshu Zou, Nan Wang, Xueqian Xin

"Vitrification is considered as an attractive procedure for municipal solid waste incineration ash, which can realize the volume reduction and innocent treatment of incineration ash, as well as reuse of bottom ash. The main oxide components of molten ash slag are CaO, Al2O3, SiO2, Fe2O3, MgO, and Na2O, accounting for more than 90% of the total mass. The phase relations and thermodynamic properties of the CaO-Al2O3-SiO2-FeOx-MgO-Na2O oxide system is highly required, and is of great scientific significance for optimization of vitrification processing and sustainable resource utilization of melting slag. A study on the equilibria phase relations of CaO-SiO2-MgO-FeOx system was done by using CALPHAD method based on FactSage in this paper. The modeling parameters for the thermodynamic properties of liquid phase in CaO-SiO2-MgO-FeOx system were established and the equilibrium phase relations of MgO-SiO2-FeOx and CaO-SiO2-FeOx-MgO systems were calculated for different temperatures and oxygen partial pressures.IntroductionThe main oxide components of vitrified bottom ash slag are CaO, Al2O3, SiO2, Fe2O3, MgO, and Na2O, accounting for more than 90% of the bottom ash by weight [1]. During slag processing and modification, the knowledge of thermodynamic properties and liquidus temperature in the related slag system is highly required [2-5], which is not yet available. Through literature survey [6-9], it is clear that the systematic information on the concerned complex slag system is scarce. Most binary subsystems except FeOx-Na2O have been investigated well. Among ternary subsystems, few phase relations of the Na2O-MgO-SiO2 ternary system are available. For the phase relations of the system Na2O-MgO-Al2O3, all the studies are focused on the Al2O3-rich region. Investigation on the CaO-Al2O3-FeOx system is limited to Fe2O3-containing system with relatively higher oxygen potential. Most quaternary systems are not studied well except the CaO-MgO-Al2O3-SiO2 system, mainly due to their metallurgical importance. Figure 1 demonstrates the research status of the vitrified bottom ash slag with almost zero effort [10]. The effort here is defined based on the published literature by considering the number of publications, the investigated composition ranges, and the research details. So far the engineers in the field have to make assumptions of the thermodynamic properties of the simplified oxide system, without taking into consideration the interactions of the different oxide components, which hinders the development of the slag valorization and utilization. In order to provide thermodynamic properties for the application of the vitrified bottom ash, the six-component oxide system (CaO-MgO-Al2O3-SiO2-FeOx-Na2O) will be investigated through both experimental approach and computer modeling."

Jan 1, 2011

By Bingguo Liu, Daifu Huang, Jinhui Peng

"The conditions to prepare U3O8 by calcination from ammonium diuranate were optimized, and the response surface design method was applied to analyze the influence on the total uranium and U+4 of calcination temperature, calcination time and mass of sample. A quadratic equation model for the total uranium and U+4 of U3O8 was built and the effects of main factors and their corresponding relationships were obtained. The analysis of variance shows that calcination temperature and calcination time significantly affected the value of total uranium and U+4 of U3O8. The optimal calcination conditions were as follows: calcination temperature 931.83 K, calcination time 24.32 min and 43.89 g. Under these conditions the value of total uranium and U+4 of U3O8 was 84.78% and 28.02%, respectively. The validity of the model was confirmed experimentally and the results were satisfactory.IntroductionNuclear energy is clean, effective, and a sustainable from of energy. It plays an important role in overcoming the impending global energy crisis, and in reducing energy vulnerability. In addition, nuclear energy is a possible cheaper and cleaner source of energy compared to fossil fuels, with no not really, mining of uranium produces CO2 contribution to green house gases [1]. Uranium dioxide, one of the most important fuel pellets used as nuclear fuel in light water reactors, is manufactured by calcining ammonium diuranate to triuranium octaoxide, followed by its reduction to uranium dioxide using cracked ammonia at 700°C [2]. Earlier attempts to optimize the important calcination process through several common techniques have not yielded desirable results [3]. These techniques either rely on the classical one parameter at a time approach that ignores the combined interactions between physicochemical parameters, or are theoretical in nature. Furthermore, these techniques also require large number of experimental data to be generated [4]. In order to produce triuranium octaoxide in an optimized manner, which considers the interaction of different process parameters [5], there is a need to adopt a multivariate statistical technique."

Jan 1, 2011

By R. Renzoni, S. Belboom, F. Tourneur, A. Léonard

"Construction is a field which is concerned by environment. Tools as environmental product declarations are increasingly often used to compare several products and to take account of the environmental sphere in the choice. Environmental declarations of Belgian bluestone and sandstone products were realized in accordance with the ISO standards and following the standard NF P 01-010. The main goals of these studies were to obtain Belgian environmental product declarations to strengthen existing databases and to provide defences against Asian competition. Indeed, competition with China for bluestone products and with India for sandstone pavement is very important due the fact of the very competitive prices for foreign products. The impacts on climate change, resources and acidification of the sole transport were taken into account for foreign products"

Jan 1, 2011

Ground falls (roof and rib) have historically been responsible for nearly 50% of all fatalities in bituminous underground coal mines. In recent years, the number of some annual ground fall fatalities has approached zero, indicating that significant progress has been made. On the other hand, the twin disasters at Crandall Canyon in 2007, in which nine miners perished in violent coal bumps, provided a stark reminder that complacency is premature. One important success has been a great reduction in the number of miners killed inby roof supports. Throughout the 1990s, these accounted for nearly half of all roof fall fatalities, but there have just been two inby incidents since 2005. Progress has also been made in pillar recovery, where there has been just one fatal incident since 2005. On the other hand, more than 300 miners continue to be injured each year by rock falling from between supports and 100 more are injured by rib falls. Together, these two categories also account for a large percentage of recent ground fall fatalities available technologies such as roof screen, rib bolting and inside control roof bolters could reduce injury and fatality rates if they were used more widely. Further advances in these areas will likely be the next big advance in ground control safety.

Jan 1, 2011

The structural design of a mine haul road involves the determination of cover thickness requirements above the in-situ or sub-grade material. The specification of these layerworks is a critical component in the overall road design process. Poor design often leads to premature failure of the road, safety is often compromised and productivity and equipment service-life will certainly decrease. Historically, the California Bearing Ratio (CBR) cover-curve design method has been widely applied to the structural design of mine haul roads. More recently, established mechanistic design principles have superceded the CBR approach to haul road design, using a multi-layer model to represent the various road structural layers. The structural design and associated layer thickness requirements are then determined following a maximum strain criterion. This paper develops a case-study evaluation of the CBR cover-curve and mechanistic design methodologies and through a comparative analysis of layerworks and materials, highlights how improved structural design can be achieved mechanistically.

Jan 1, 2011

By G. Kolosay, J. Rajala, G. Deschênes, A. Romanov

ABSTRACT: The Kupol project, located in Far East Russia, treats a high-grade, free-milling ore containing 25.5 g/t Au, 298.3 g/t Ag, and 0.5% pyrite,with a P70of 53 microns. Most of the gold occurs as elec-trum and the silver is predominantly present in the forms of acanthite, stephanite, pyrargyrite, andproustite. The mill reached the design throughput of 3,000 tpd six months after start-up. AKnelson con-centratorrecovers10.4% gold and 0.5% silver. Leaching (14.5 hours pre-treatment and 116 hours cyanidation)of gravity tailings is performed with the CANMET Enhanced Leach Process (CELP),using only 490 ppm NaCN (cyanide consumption of 1.1 kg/t). The precious metals are recovered by counter-current decantation and the Merrill-Crowe process. Calcium hypochlorite destroyscyanide and thiocyanate. Overall, gold and silver recoveries for 2008 were 95.4% and 85.6%,respectively (2.8% and7.5% higher than targets). In the first eight months of 2009, gold and silver recoveries were 95.0% and82.6%, respectively. By August 2009, the mill processed 1.42 million tons of ore with production of 1.1 million ounces of gold and 11.3 million ounces of silver. CELP performance was not affected by changes in feed grade and ore mineralogy. Additional modifications to the leaching strategy allowed further reduction in cyanide consumption and effluent treatment costs.

Jan 1, 2011

By T. Tafi

The Ute-Ulay project area is located approximately five miles west of Lake City, in Hinsdale County, Colorado. The Ute-Ulay Mine site is approximately one mile east of the project area. The elevation of the site is 9,200 feet and is adjacent to Henson Creek (Figure 1) [ ] The Ute-Ulay Mining complex is an inactive gold, silver, and zinc mining/milling operation, that operated from the 1880?s until the 1970?s, and sporadically into the late 1990?s. The mining complex comprises several levels of underground mines, a flotation mill, and an abandoned town site. Due to the narrow, steep sided canyon, milled tailings were pumped upstream one mile in a sluice box to a wider section of the canyon, and deposited into five tailings impoundments and one berm located between the impoundments. An estimated 9,000 cubic yards (yd3) of fine grained tailings were located in the impoundments adjacent to the creek. The Ute-Ulay project area consisted of the mill tailings impoundments located upstream from the historic mine.

Jan 1, 2011

By S. N. Monteiro, C. M. F. Vieira, A. P. N. M. de Sa, J. P. D. Vitorino

"This work has as its objective to characterize an ash waste and to evaluate its incorporation into a clay to produce bricks and roofing tiles. The waste is a type of fly-ash resulting from the incineration of a selected part of urban garbage, which is basically constituted of organic matter and plastics. The waste was submitted to mineralogical and chemical characterization. Compositions were prepared with incorporation of the waste in amounts of up to 20wt.% into athe clay. Rectangular specimens were prepared by extrusion and fired in a laboratory furnace at 900°C. The physical and mechanical properties evaluated were: linear shrinkage, water absorption and flexural rupture strength. The results showed that the waste is predominantly composed of quartz and calcium compounds. The incorporation of the ash was deleterious to the evaluated properties of the clay. It is suggested that the incorporation should be made in amounts below 5wt. % to avoid deleterious effect in the mechanical strength and water absorption of the clayey ceramic.IntroductionThe world attention has turned to a subject of great concern today, the production and disposal of large amounts of industrial wastes as well as wastes of various sources. When deposed in an unsuitable place, these wastes can cause considerable harm to human health and to the environment. Our planet suffers with air pollution, groundwater and soil contamination as well as silting of rivers and lakes with the growing amounts of our society wastes.The recycling of waste materials is of great interest to the industries, mainly due to the environmental agencies legislation. One of the practices for correct disposal of these wastes being investigated is to incorporate into red ceramics, such as bricks and roofing tiles. The natural variability of the characteristics of the clays associated with the relatively simple processing techniques and also the low performance required for the products allow the presence of relatively high levels of impurities in clayey ceramics."

Jan 1, 2011

By Graham Cooke, Abhishek Lahiri, Animesh Jha, E. Jeya Kumari

"CO2 reduction by alternative energy devices such as wind-power, electric vehicles utilize rare-earth elements (REE) in several forms; such as in piezo-electric devices, batteries and magnetic materials. In 2010, the 95% of Rare Earth supply is controlled by China, compared to USA being dominant supplier in the 1980s. The dependence upon a single source of lanthanides has prompted the utilization of lower grades of titaniferous mineral concentrates, which often have rich seams of REE. We propose a new methodology, which utilizes the low-grade minerals for the extraction of synthetic rutile and also significant quantities of REE. We demonstrate the alkali roasting of lower grades of mineral concentrates and subsequent leaching in an aqueous medium for preferential flocculation of REE during the extraction of synthetic rutile. Changes in mineral structure during alkali roasting and leaching determine flocculation of REE and permit their separation at the front end of unit process.The physical chemistry and crystal structure of minerals in equilibrium with alkali and aqueous medium play an important role, which we explain by demonstrating the changes in the crystal structure. The quantification of separation of RE oxide via chemical analysis suggests that it may be possible to separate rare-earth oxides between 50 and 80% of the initial concentration in the non-magnetic fractions of ilmenite, for example. The microstructural and X-ray diffraction analysis points out that the presence of alumina and roasting with potassium based alkali enhances the separation and flocculation of rare-earth elements at the front end of the process after roasting. The process allows the recovery of CO2 generated by recycling into the process for the regeneration of alkali."

Jan 1, 2011

By Osvaldo A. Bascur, Curt Heftier

The lack of integrated information including the Energy/Utility Suppliers with sufficient detail for analysis causes inefficient operation in metallurgical complexes including the Energy/Utility Suppliers . Defining the right context for information use is essential for sustainable operations. This being said, what are we doing to enable people to act upon information and to be aligned to optimize the use of resources like raw materials, energy, water and consumables for an entire metallurgical complex? Collaboration between all company entities is a key component of improving efficiency. Evolution of web technology and object modeling of enterprise assets enables collaboration across the whole business. Operational troubleshooting occurs more quickly as the organization acts on issues to reduce wasteful operation. This paper presents a real time software infrastructure with tools that give users the ability to sift through available data, transform data into information for business continuous improvement and optimization. We will introduce a new technology for analyzing real time data, information and events using multidimensional analysis of information to detect anomalies based on the statistics of the data classified by time events to reduce the information into action. A new paradigm for collaboration at a local and strategic level is proposed to enable the enterprise to become proactive in dealing with wasted time and products. Three examples from the industry will presented and their benefits highlighted.

Jan 1, 2011

By I. Mihajlovic

This paper investigates a potential method for arsenic removal from copper concentrates using hypochlorite leaching. The problems concerning pyrometallurgical processing of copper concentrates with high arsenic contents are discussed. A possible solution to the problem by leaching of natural enargite crystals with sodium hypochlorite under alkaline oxidizing conditions, with enargite converted into crystalline CuO and the soluble arsenic forming AsO43-, was experimentally investigated and results are presented. Kinetic parameters were calculated for enargite leaching, using a model-free approach. Advanced isoconversional methods were used to investigate the dependence of activation energy (Ea) on reaction rate (a). Keywords Enargite, copper concentrate, isoconversional method, kinetics, activation energy.

Jan 1, 2011

By E. Keskinkilic

In this study, sulfide-type inclusion morphologies of a Ca-treated hot-rolled wheel steel, Grade-X, were investigated. The specimens taken from the hot-rolled products of Grade-X heats were studied. The size and distribution of elongated sulfide inclusions were examined for the heats of different S levels. Elongated sulfide inclusions were either not observed or rarely encountered when ladle analysis S content was below 50 ppm. The size and relative abundance of sulfide inclusions were reported to increase markedly when the S composition was greater than or equal to 70 ppm and the Ca/S ratio was less than 0.50. The effect of Ti addition (0.010?0.020% Ti) on sulfide-type inclusion morphologies was then investigated for heats having a sulfur content higher than 50 ppm. Addition of Ti was found to have a partial effect on decreasing the size of sulfide-type inclusions under real steelmaking conditions. Keywords Sulfide inclusions, Ca-treatment, titanium.

Jan 1, 2011

By D. J. de Beer

South Africa had a late start with rapid prototyping (RP), with the first system being available in 1991. Up to 1994 only three systems were available in SA. Through active research participation from the CSIR and a number of universities, supported by technology transfer programmes and industry awareness workshops, adoption of RP technologies started to grow. Internationally, RP grew to the extent that several country-based member organizations were formed, and an initiation meeting of the Global Alliance of RP Associations (GARPA) took place during the SME Rapid Conference in Dearborn, USA in 1998. South Africa (SA) was invited under the auspices of the Time Compression Technologies Centre (TCTC) launched by the CSIR, and received an invitation to become a member of GARPA through the launch of a national, inclusive organization. The latter gave rise to a RAPDASA planning/launch meeting held at the University of Stellenbosch, which culminated in the first RAPDASA international conference held in November 2000 at the CSIR, and the election of a first RAPDASA management committee, also at the 1st AGM held during the conference. RAPDASA has been a pillar of strength since then, with an annual international conference being presented. As South Africa?s RP awareness grew through the RAPDASA and independent activities, so did the availability of RP platforms in SA.SA also became a benchmark for other countries/late adopters to follow, as slowly a position of following became a position of leading through innovative applications. The paper highlights SA?s development approach and history, together with the discussion of case studies in various fields. Contribution to the light metals industry will also be discussed. Keywords Rapid prototyping, additive manufacturing, product design, rapid tooling, rapid manufacturing, medical product development.

Jan 1, 2011

By C. C. Clark

The national Institute for Occupational Safety and Health (NIOSH), Office of Mine Safety and Health, Ground Control Engineering Branch is investigating the use of shotcrete in weak rock mass mines with the objective of reducing fatalities and injuries resulting from rock fall accidents. When shotcrete is used as part of a multi-element ground support system, it is necessary to know when the material has developed a compressive strength of approximately 1 MPa (145 psi), the early threshold for safe re-entry of miner and machine into shotcreted mine workings at this value, the material has developed enough strength to be self-supporting and to allow for installation of other ground support components that require drilling of the shotcrete layer without degradation. NIOSH researchers have developed methods and portable test equipment to measure shotcrete strength on site in the first six hours after application using a partial beam test standard, a STM C 116-90 (1990). These advances were demonstrated in tests with five commercially available shotcrete mixes, sprayed as dry shotcrete using field expedient methods and equipment. The strength values from these tests allowed for real-time identification of the early strength threshold and were consistent with strengths reported using laboratory-type equipment. Measuring the early strength properties of shotcrete directly at the mine site can improve mine safety by identifying appropriate re-entry times and providing a convenient means of conducting on site quality control during shotcrete applications.

Jan 1, 2011