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By Eduardo A. Pérez, Alejandro R. Alonso, Rosa María Luna-Sánchez, Gretchen T. Lapidus

Rare earth elements have been widely used in various sectors, from the aerospace and steel industries, to electronic applications, particularly in displays and batteries for portable devices. The high demand for newer and better equipment, such as cell phones, tablets and lap tops, has increased the consumption of the rare earth elements and at the same time the need for its recovery from electronic wastes. For that reason, the recycling of batteries is important, principally the Ni-HM batteries, due to their elevated content of rare earths elements, in addition to the high concentrations of cobalt and nickel. The current processes are based on dissolution in strong acid solutions (sulfuric acid concentrations from 2 to 4 mol/L), and temperatures from 30 to 90°C. In the present work, electrodes from spent Ni-HM batteries were leached using 1 mol/L H2SO4, in the presence of ozone as the oxidant, where recoveries of 96% for La, Ce and Nd were obtained at room temperature. The separation of Ni and Co from the leach solutions was performed using an electrochemical reactor, after which rare earth elements were precipitated, obtaining a mixture of its hydroxides with impurities below 1%, according to EDS analysis.

Jan 1, 2014

By B Mohanty

Currently there exist several explosive quantity-distance (Q-D) rules variously exercised by most countries to protect personnel and property against the effects of accidental explosions. These regulations apply to manufacture, transport and storage of explosive products. This paper reviews the technical basis behind these regulations, as they apply to commercial and military explosives. The characteristics of a blast wave and missiles issuing out of an explosion site and their role in determining the level of damage to a target are discussed. The need for further research on the effect of detonation of charges of non-standard geometry, and under confined conditions such as tunnels is discussed. The challenge in estimating the net quantity of explosives involved and calculation of its TNT-equivalency is also highlighted.

Jan 1, 2014

A new method, localized uniform conditioning (LUC), was proposed in 2006 for modelling grades of small blocks of ore when data spacing is too broad for their accurate modelling by the linear regression based techniques, such as kriging (Abzalov, 2006). It represents a modified uniform conditioning (UC) technique that calculates the grade distribution functions for the large panels. LUC uses partitioning of the panels onto the small blocks and then ranks them in increasing order of grade. Based on the block ranks, a single grade value can be deduced for each block from the UC model of the gradetonnage relationships of the corresponding panel. After being first presented in 2006, the LUC method has been implemented in ISATIS© (commercial software) and became one of the common approaches for grade estimation when data spacing is broad in comparison with the estimated block size. Several years of study on the LUC method and its application to different geological environments, have allowed identification of the strengths and weaknesses of the method, which are as follows: ? The method produces accurate grade-tonnage functions, which are in a good accordance with a volume-variance relationship principles ? An initial ranking of the selective mining unit (SMU) blocks can be made by direct kriging from the sparse data grid. Therefore, the LUC method can be particularly useful at the early stages of exploration and mining project evaluations when sparsely distributed data is often the only available information ? Accuracy of the local estimation depends on the SMU ranking techniques. When ranking performed by direct kriging of the SMU blocks their spatial distribution is approximate. When the variogram of the studied variable is characterized by a large nugget effect, the block ranks produced by kriging can significantly differ from their ?true? distribution ? Block ranking can be improved using auxiliary data, either geophysical or geochemical. This allows use of the LUC method for integrating different data sets. In particular, LUC can be used for grade control in open pits by integrating resource definition data (e.g. drill-hole assays) and blast-hole assays. The latter are used for the block ranking.

Jan 1, 2014

By Thomas Mütze, Michael Klichowicz, Mathis Reichert, Holger Lieberwirth

"Self-similarity is proofed to be a common feature when brittle material is comminuted, either in particle bed or single particle mode. Appropriate test work is well documented for particle sizes less than 7 mm in several publications. In contrast, almost no research has been done for coarser particles. The aim of this paper is to show that the fracture pattern of coarser material also tends to be self-similar. Hence, single particles of quartzite, granodiorite and dolomite were comminuted under compressive load. The focus was set on three different size fractions -3.15 +2.5 mm, -31.5 +25 mm and lumps -300 mm. According to the wide range of particle sizes, three different piston-die presses were used with a maximum compressive force ranging from 5 kN to 4000 kN. The force-displacement curves were recorded in order to calculate the specific comminution energy. Additionally, the -31.5 +25 mm size fraction was crushed in a laboratory scale jaw crusher and a roll crusher. Some authors report that the energy-size-reduction relationship of self-similar materials can be approximated by a linear function, which is independent of the comminution equipment. In their charts the slope can be seen as a product-size-independent grindability measure. Our tests show a self-similar breakage behavior when particles in a range of -300 +3 mm are comminuted in single particle mode. Furthermore, the products of the piston-die-presses and the roll crusher are similar to each other in a self-similar representation of the particle size distribution. The jaw crusher product, however, is not self-similar compared to the piston-die-press products. Finally, the linear energy-size-reduction relationships are confirmed for each fraction, but show size dependent slopes."

Jan 1, 2014

By J. Rivoirard

Historically, linear and lognormal krigings were first created to estimate the in situ mineral resources of blocks. Nonlinear geostatistics and indicator kriging were subsequently developed to evaluate also the portion recovered when applying a cut-off on selective mining units (SMUs) within blocks. In practice these methods are generally based either on the Gaussian model with a transformation generalizing the lognormal case or on the indicators above cut-offs. Very often the indicator approach is simplified by kriging separately each indicator, and when starting from a continuous variable, a practical advantage of the discretization into classes lies in the easy treatment of a zero effect and of the high values. However, a number of so-called isofactorial models have also been developed for a discrete or continuous variable, where the full cokriging of indicators (i.e. disjunctive kriging) simplifies to the separate kriging of factors. Moreover, these models are equipped with a change of support, allowing a consistent estimation of recoverable resources on SMUs. Min-Max Autocorrelation Factors (MAF) analysis of the indicators offers a new approach for indicator modelling. In particular the first factor, the one with the highest spatial continuity, can help in choosing the type of model. For example a monotonic experimental first factor can be used directly as the basis of a discrete diffusion model, unless a continuous diffusion model such as the Gaussian model can be used on the original variable. This approach is illustrated on a uranium deposit mined selectively: estimates of recoverable resources by discrete disjunctive kriging and uniform conditioning in a Gaussian model are compared locally to short-term estimates based on two areas densely drilled.

Jan 1, 2014

By S. Steinlechner

"Today the common recycling technologies of automotive catalysts are either energy intensive pyrometallurgical processes generating huge amounts of residues or hydrometallurgical ones which have to cope with effluent problems. Next to that, other valuable metals beside PGMs such as rare earths from the wash coat are not recovered.Therefore, the present paper introduces a hydrometallurgical concept developed in cooperation with the company Railly & Hill for the recovery of the PGMs as well as cerium from the wash coat of the catalysts in a closed loop. Next to the process concept, the required parameters for the different steps are discussed, including the chemical reactions, leaching efficiencies and mass flows, which form the basis for an economic estimation of the concept.Contrary to the pyrometallurgical recycling where the monolith is completely melted down to slag which is typically dumped, in this process the remaining monolith forms an utilizable product for the ceramics/refractory industry. As a result of the closed loop of the leaching media an environmentally friendly process was developed from which nearly no new residues or effluents are generated, with a sustainable usage of chemicals."

Jan 1, 2014

By G. J. Ackland, K. Saksl, F. Brunke, M. Kohnke, B. Tegner, C. Siemers

The application of titanium alloys is limited to 550°C due to their poor oxidation resistance. It is known that the addition of niobium decelerates the oxidation of titanium alloys whereas elements like vanadium do not improve titanium’s oxidation resistance. The underlying mechanisms are not yet well understood. In the present study, different binary titanium-niobium and titanium-vanadium alloys as well as commercially pure titanium were investigated. Oxidation experiments were carried out at 800°C up to 288 hours followed by metallographic analyses to study the oxide layer morphology as well as the microstructure at the interface. Energy-dispersive X-ray spectroscopy mappings were used to identify possible changes in the distribution of the alloying elements. In addition, micro-focused hard X-ray experiments were performed to layer-wise analyse the phase composition in selected samples. As expected, the niobium containing alloys show a better oxidation performance compared to commercially pure titanium and the titanium-vanadium alloys. The oxide layer consisted of TiO2 and Ti2O3. Depending of the niobium content, a niobium-rich layer developed below the metal-oxide-interface minimising oxygen diffusion into the titanium matrix. Based on these results, the minimal niobium content needed for improved oxidation resistance was identified so that alloys of technical relevance can now be developed.

Jan 1, 2014

By Joseph D. Lessard

A process simulation of the conversion of molybdenum disulfide concentrates into molybdenum dioxide via the Looping Sulfide Oxidation process has been performed using HSC 7.1 thermodynamic software. By decoupling molybdenite conversion and molybdenum oxidation, Looping Sulfide Oxidation changes the paradigm by turning molybdenite processing into an energy generator while producing a molybdenum dioxide, which has a lower vapor pressure and lower oxygen content than molybdenum trioxide. The Looping Sulfide Oxidation process selectively produces molybdenum dioxide over molybdenum trioxide. This process uses a stoichiometric mixture of oxygen and molybdenum trioxide as oxidants in the conversion of the molybdenum sulfide to the molybdenum oxide. The model simulates the two reactor scheme required by Looping Sulfide Oxidation and incorporates thermodynamic equilibrium simulations performed in FactSage 6.3.1 thermodynamic software. Energy capture is also maximized with heat exchanger systems to transfer heat released in reactions to preheat air.

Jan 1, 2014

By A. Mainza, I. Govender, J. Waters

"The study of the properties of mineral processing suspensions is important in understanding how a circuit might behave. As soon as the predominantly dry ore enters a wet milling stage the ore properties undergo changes as a ‘slurry’ is created. Slurries can be classified in terms of their physical properties (particle density, solids concentration, particle size and size distribution, particle shape), and their flow properties such as rheology. Slurry flow regimes are classified into true homogeneous, pseudo homogeneous, heterogeneous and fully segregated, and only true homogeneous and pseudo homogeneous suspensions can be characterized by their flow structure. A class of the heterogeneous regime are the so-called dense phase or settling slurries - those which result in a clear water surface on standing, although they may approach a pseudo homogeneous state if suspended for a sufficient period of time. They are usually extremely difficult to characterize by their rheological properties alone and the rheological characterization of these slurries has always posed a problem, especially at higher concentrations. Previous rheological studies have focused on the individual concentrator units dealing with milling, classification, pumping, flotation, fine grinding, thickening.In this work an attempt was made to characterize two ore types (copper and a Platreef platinum ore) using a custom built Paterson and Cooke tube rheometer, at concentrations up to 43% by volume. After applying a turbulence correction, results showed Bingham plastic behavior. A conventional vane rheometer was then used to compare the rheological behavior of platinum concentrator streams. A size criteria was used to identify any rheologically dominant streams."

Jan 1, 2014

By Liu Fan, Shang Yanbo, Wang Zhongming

"Besides valuable metals of Cu, Sn, WO3, Zn, there are S, Ag, CaF2, In and so on in a complex ore deposit in south China (which belongs to Hu Nan Shizhuyuan Non-ferrous Metal Limited Liability). Although it proved reserve amounts to 3.5×107 ton, its crystal character limits its utilization in large-scale. It features complex relationships between valuable minerals, finest crystallized particle size, low-graded valuable metals (Cu 0.30%, Zn 0.5-0.7%, Sn 0.2%, W<0.1%). If only tungsten minerals are considered, it means WO3 grade is too low (the cut-off grade of WO3 is 0.1% in China). Only Cu and Sn minerals are recovered from 2006 and Cu recovery is less than 70%, Sn 15-20%. Other valuable metals of W, Zn, S and CaF2 were lost in the tailings. To make good use of the ore, the technology of fully recovering Cu, Sn, W, Zn, CaF2 and rare metals are in urgent need. After systematic researches, the flow sheet of "bulk flotation of Cu-Zn minerals at first, then Cu-Zn separation, then recovering sulphide by flotation, then recovering iron minerals by magnetic separation, then bulk flotation of Sn-W minerals after desliming" is developed. Furthermore, specific Sn-W collectors of BK411 and BK412 are applied into the processes and better indexes are obtained. The industrial indexes are listed as followings: the content of Cu, Zn, Sn, WO3 of ROM ore is 0.31%, 0.65%, 0.13%, 0.03%; Cu and Zn recovery are 82.23% and 37.79% respectively; 63.76% of Sn and 34.34% of WO3 go into the Sn-W bulk concentrates. Economic benefits are remarkable."

Jan 1, 2014

By P. Condori

In spite of the importance of the slurry transport and discharge in autogenous and semiautogen-ous (AG/SAG) mills, it is evident that a more comprehensive and useful model is still required. Semi-empirical models used up to now have many limitations and cannot be used beyond the ranges in which they were developed. The breakage of particles as they are transported along a mill com-plicates the experimental analysis and the modelling of the transport process within the mill. The interaction of the grate discharge and the pulp lifters, with the added issue of backflow from the pulp chamber into the mill, makes the discharge modelling process difficult. In order to overcome these difficulties, a mechanistic approach has been applied. The general transport and discharge model was subdivided into four independent models: Flow through the charge, flow through the grate, flow in the pulp lifter, and flow-back. This paper gives an overall description of the modelling approach and discusses in particular the modelling of transport of fluids through the charge. In order to evaluate and calibrate the model, experimental work was carried out. To evaluate the gradient pressure under different conditions of charge packing and flow rate, a specialised experimental rig with a highly sensitive pressure gauge was used. Preliminary results identify the differences of the charge and grate on the restriction of flow. The existence of a dynamic voidage in our particular system was more evident and as a result, a semi-empirical correlation for the voidage was developed. In general, results show that the me-chanistic model derived from Ergun?s equation for flow through a packed bed can be satisfactorily adapted.

Jan 1, 2014

By C. Y. Wang

Based on Slurry Electrolysis, and combined with the problems of extraction antimony, lead and their separation from complicated antimony-lead concentrate, a series of tests have been done in this paper. Using Slurry Electrolysis to treat complicated antimony-lead concentrate, antimony and lead can be separated in one step. And 2# metal antimony can be achieved in cathode directly at the same time. Lead in concentrate is restrained still in the residue at the form of PbCl2. After converting the residue with ammonium carbonate and removing sulfur with kerosene, the high quality of lead concentrate (Pb is above 45%, S is below 15%) and pure sulfur can be achieved, respectively. The recovery of all in Slurry Electrolysis process is as: Sb 95%, Pb 95%, Ag 80%, S 60%.

Jan 1, 2014

By H. Huang, R. N. Gow

Acidic treatment of enargite (Cu3AsS4) dissolves both arsenic and copper from the mineral and then attempts to separate them in the leach solution. The reactivity of enargite was examined in acidic to neutral solutions, over the pH range 1-7, to determine a potential range for co-dissolution. Enargite mineral samples from Butte, MT and Quirivilca, Peru were used as working electrodes in a cyclic voltammetry corrosion cell setup, which were then cycled multiple times over -1000 to 1000 mV. Surface reactions and transitions were characterized using in-situ Raman spectroscopy, which were then compared to updated EH-pH diagrams for the copper-arsenic-sulfur-water system from a previous study done under alkaline conditions. The region of co-dissolution is limited to > 600 mV vs. SHE and pH < 1 under the proposed diagram.

Jan 1, 2014

A processing scheme is presented to use one single chemical that has multiple functions to re-duce the use of chemicals and achieve more efficient mineral flotation and solids dewatering. Sti mulisensitive polymers which display hydrophilic/hydrophobic transitions in response to changes in temperature or pH have been found to be useful as such multiple function reagents. They can cause the mineral particles to be either hydrophilic or hydrophobic at one stimuli condition and the opposite at the reverse stimuli condition. Therefore, both particle surface wettability and inter-particle interaction forces are reversibly controllable. When the surface is hydrophilic, particle dispersion is achieved by repulsive inter-particle forces whereas when the surface is hydrophobic, particle aggregation is induced by inter-particle hydrophobic attractive forces. In addition, the hydrophobic surface condition allows for the attachment of particles to bubbles. Flotation and solid settling tests have been conducted with a silica suspension treated with the temperature-sensitive polymer poly (N-isopropyl acrylamide) (PNIPAM). The results indicated that PNIPAM can be used to induce a transition between hydrophilic and hydrophobic surface character at temperature lower or higher than its critical solution temperature (CST around 32oC). Thus, both effective silica dispersion or hydrophobic aggregation and flotation without adding any additional collector have been demonstrated. In tailings treatment, rapid silica settling was obtained with hydrophobic aggregation at temperature above the CST and further sediment consolidation (and water release) occurred at temperature below the CST. Contact angle measurements confirmed the hydrophilic/hydrophobic transition induced by PNIPAM.

Jan 1, 2014

By R. L. Castro

The extraction of ore in panel caving operations also involves the coextraction of non-economic material, known as dilution. Forecasting, avoiding, and understanding the mechanics of dilution is critical to longterm planning. The models of dilution that are currently in use in panel caving operations are those by Laubscher (1994), who postulated that dilution is due to gravitational flow and depends on the height of interaction, the column height, and the draw uniformity. This paper presents a back-analysis of extraction and dilution behaviour at Codelco?s El Salvador and Andina Divisions, which use panel caving as a mining method. This analysis was conducted in order to review the existent dilution entry mechanisms and calculation methods. Three sources of dilution were identified. The first source is ?gravitational dilution?, which is due to gravitational flow and mixing as dilution migrates by gravity from a sector located above the panel under analysis. The second source of dilution is ?caving dilution?, which occurs when an air gap is formed in a large area and a sudden propagation of a hang-up occurs, inducing early ingress of waste into the production level from a level above. The third mode observed is ?lateral dilution?, which occurs when the panel is located next to an exhausted sector and the broken material enters the draw column early during draw. In the last two cases, dilution could migrate large distances horizontally. The mine data indicated that draw and caving strategy are key for long-term planning of large panel caves.

Jan 1, 2014

By Enrique Ibarra, Manuel J. Mendoza

"Abstract: This paper describes the current state-of-practice for the design of cast-in-place drilled shafts in granular soils under axial loading, addressing recent advances that take into account the surrounding soil grain size distribution and their behavior. The important role of the gravel content in the shaft response under axial loading is emphasized. Usual design approaches in Mexico are described, and the results of load tests from different sources are discussed. The analysis emphasizes the primary contribution of the lateral area of shafts to their axial bearing capacity, raising doubts regarding the common local idea of “point bearing shafts”. Finally, some lines of research are noted to permit advances in the important field of deep foundations. 1 INTRODUCTIONIn Mexico, cast-in-place drilled shaft foundations are widely used to support various structures in the west area of Mexico City, where alluvial and volcanic deposits predominate. Deep foundations are also used in modern construction works located in other major cities of Mexico. In fact, the use of drilled shafts for tall buildings and overpasses in the center of Guadalajara as well as in transportation works related to the Metro and roadways in Monterrey is well known. It is worth mentioning that these same structures have been applied in road bridges throughout the country.Procedures for pile construction in Mexico have been basically the same for the past 20 years (Paniagua et al., 2005); however, modern equipment has been incorporated into the construction industry, including innovations in sludge-drilling technology, control and the quality of the castings. In addition, novel and efficient procedures such as construction with continuous auger displacement piles have been implemented (Auger Cast in Place, ACP) and have begun to be used locally with success (Schmitter and Paulin, 2006).However, it can be argued that the technological developments that have resulted in more efficient construction procedures have not included a breakthrough in the full understanding of the phenomena or basic mechanisms of load transfer from piles to the surrounding subsoil and therefore in supported, tested and practical design methods. This is particularly true when seeking to determine the unit side shear strength of shafts drilled in granular media with gravels, where it has been observed that the commonly used calculations developed for sands underestimate the load-bearing capacity by frictionin a most important way. Due to the above reasons, it seemed appropriate to present in this paper a review of the current stateof- practice in Mexico for the design of cast-in-place drilled shafts, particularly in granular media, highlighting some recent advances and research that takes into account the grain size distribution and behavior of granular soil."

Jan 1, 2014

By Bruce Mathema, Steven Huynh, Terry Cheng, Gerry Gomez

"The use of PM40N, a specialty precious metals promoter in conjunction with a standard Xanthate based collector was extensively investigated in the flotation of a complex, silver-bearing, lead-zinc ore containing naturally occurring graphitic gangue. The ore, considered difficult to treat with conventional reagents, was tested at plant scale to determine the impact of the promoter on silver recovery, lead grade and also on the amount of zinc misplaced to the final lead concentrate.Initial laboratory-scale rougher flotation testing implied significant improvements in the recovery of silver and lead with a marginal amount of zinc displaced. Subsequent mini pilot flotation tests further revealed that a gain in selectivity and recovery could be achieved by adjusting PM40N promoter dosage and incorporating a cleaner flotation step, further improving rejection of sphalerite. Plant trials resulted in an improvement of 3% in Silver recovery coupled with a 2% increase in recovered lead whilst maintaining lead grade in the lead circuit.To date, the use of PM40N as a promoter has enabled the processing operation to significantly increase its plant economics. The partial replacement of the standard Xanthate based collector has also reduced the overall quantity of Xanthate required in the standard circuit by approximately 10% - which is a positive impact on the environment. It is envisaged that further optimization of plant parameters will favor stable operation and continue to boost revenues generated by subsequent improvements in silver metallurgy."

Jan 1, 2014

By C. L. Xiao

With reference to the test report carried out by Guangzhou Nonferrous Metal Research Institute in 1983, the mineral process flow sheet of Yichun Tantalum-niobium mine is determined based on the characters of ores and successful experiences in light of the problems in the existing flowsheet: The ore is desilted before crushing; the primary slime is separately treated; the staged grinding process used while the fine slime is collectedly treated with tantalum and niobium as the main recoveries and lepidolite and feldspar powder as the secondary. The flowsheet is featured by comprehensive recovery, low investment and low energy cost.

Jan 1, 2014

By Kevin Galvin, James Dickinson

"The Reflux Flotation Cell (RFC) consists of an inverted fluidized bubbly bed, located above a system of parallel inclined channels. This novel arrangement enhances the hydrodynamics of flotation in a number of ways. Firstly, the free-surface of the flotation cell is enclosed via a fluidized bed distributor, ensuring uniform application of wash water to promote desliming. Secondly, foams can be variable in their stability and lack permeability. Hence this system is preferably operated in the absence of foam, instead opting for a bubbly zone of high bubble volume fraction through the use of a very high gas flux and/or wash water flux. Discharge of the product proceeds upwards through a central port of narrow cross-sectional area. Thirdly, the system of inclined channels increases the segregation between the bubbles and the water, ensuring the bubbly zone remains contained within the upper vertical zone, and the liquid flux reporting to the overflow is low. The expanded operating regime of the RFC was investigated by covering a very broad range of gas fluxes, up to 5.5 cm/s, and wash water fluxes, over 2 cm/s. Both laboratory and pilot plant performances were quantified by the recovery of hydrophobic particles and rejection of the hydrophilic particles, using model and industrial coal feeds. The new system hydrodynamics was found to offer significant advantages in flotation kinetics, desliming, and particle recovery across a broad particle size range. Bubble interfacial flux reached as high as 600 m2/m-2s-1. The upper system consists entirely of a high volume fraction of bubbles, which provides a "safety-net" to protect against the detachment of coarse particles, and a highly permeable zone for counter-current washing of the flotation product. Under relatively extreme conditions selective stripping of the product is observed, resulting in grade recovery values beyond those achievable using the tree flotation method."

Jan 1, 2014

By N. Johnson, J. Quinteros

With the general trend across all commodities towards the treatment of lower grade ores, it is becoming increasingly important to develop efficient protocols for comprehensive mineralogical characterisation to allow the development of the most appropriate strategies for processing an ore. In the case of silver, there are more than 200 known silver bearing minerals which can make it challenging to identify them. Knowledge of the deportment of silver within an ore is one of the factors used to determine an appropriate processing strategy. Automated SEM-based tools are commonly used for mineralogical characterisation but the low-grade together with the large number of minerals that are potential hosts for silver means that often, complementary analytical tools must be used in order to properly account for the silver. The work presented in this paper is a demonstration of the approach that should be taken when identifying the deportment of silver in complex ores. Three complex, low-grade silver ores were characterised using the approach. The insights from the mineralogical characterisation were then used to inform the metallurgical testing that was undertaken. The results from the batch flotation testing clearly demonstrate the importance of understanding the mineralogy in order to select the most appropriate metallurgical processes.

Jan 1, 2014