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By J. Lindström, J. Hamuyuni, M. Lundström, J. Aromaa

"The rising demand for metals today, coupled with the scarcity of primary sources for raw materials threatens both technological advancements and industrial manufacturing. In order to meet the demand, metals and other resources trapped in waste streams, have to be harnessed. This philosophy supports circular economy, where metals and other resources are kept in a closed loop. The pickling acid recovery system of most stainless steel production is one such example where the dissolved metals such as iron, nickel and chromium are currently not completely recovered due to the limitations of the current technologies. The aim of this study was to assess the available metals recovery methods from extremely concentrated acids. The main aim is to simultaneously recover metals and keep sulphuric acid reusable in acid circulation process. From the available literature, the most promising methods were chosen for laboratory experiments. Based on experimental work, the results and observations of electrodeposition, solvent extraction, and freeze crystallization are provided. KEYWORDS Pickling acid, metal recovery, solvent extraction, cathodic polarization, Freeze crystallization. INTRODUCTION Pickling in stainless steel production is an essential surface treatment process (Regel-Rosocka, M. (2010); Agrawal and Sahu, 2009). It is applied for removing surface films such as oxides and chromium-depleted layers to improve the corrosion resistance and surface finish of steel (Regel-Rosocka, 2010). Whilst the process greatly improves the surface finish of the stainless steel, it generates large amount of used acid, containing dissolved metals including chromium, iron, and nickel (Agrawal and Sahu, 2009). Recovery of acid is common practice for most steel producing industries (Nyman and Koivunen, 1986). In this work, acid regeneration process is investigated so as to simultaneously reusing sulfuric acid and recovering the dissolved metals. Recovery of valuable metals even in very small amounts would also bring additional revenue to the steel production industry. At a time when metal production has also been challenged by lack of natural resources for raw materials, secondary sources for metals such as the acid pickling process therefore, have greater potential as supplements. From earlier studies, electrodeposition (Giovanardi and Orlando, 2011; Kuznetsov et al., 200; Rögener et al., 2012; Surviliene et al., 2006), solvent extraction (Alguacil and López 1996; Haghshenas et al., 2009; Kesieme et al., 2013) and freeze crystallization (Beyer et al.,2003; Hasan et al.,2017; Van der Ham et al., 1999) are some of the most established potential methods. Earlier studies have also shown that simultaneous recovery of acid and metals would require combination of different methods. This is primarily due to the nature of very stable metal containing complex compounds formed during pickling. These complexes must be broken down to free the metals for further recovery processes."

Jan 1, 2018

By Andrea Lisjak Bradley

Clay shales are currently being assessed as possible host rock formations for the deep geological disposal of radioactive waste. However, one main concern is that the favourable long-term isolation properties of the intact rock mass could be negatively affected by the formation of an excavation damaged zone (EDZ) around the underground openings. The goal of this thesis was to develop and validate a mechanically-based model of the deformation and failure process of a clay shale, namely Opalinus Clay (OPA), with particular focus on the influence of anisotropy on the short-term response of circular tunnels. To achieve this goal, a hybrid continuum-discontinuum numerical approach was developed in combination with new field measurements from the Mont Terri underground research laboratory. The response of OPA during the excavation of a full-scale emplacement (FE) test tunnel was characterized by geodetic monitoring of wall displacements, radial extensometers and longitudinal inclinometers. The deformation measurements indicated strong directionality induced by the combined effect of in-situ stress field and bedding planes striking parallel to the tunnel axis, with the most severe deformation occurring in the direction approximately perpendicular to the material layering. Computer simulations were conducted using a newly-extended combined finite-discrete element method (FEM/DEM), a numerical technique which allows the explicit simulation of brittle fracturing and associated seismicity. The numerical experimentation firstly focused on the laboratory-scale analysis of failure processes (e.g., acoustic activity) in brittle rocks, and on the role of strength and modulus anisotropy in the failure behaviour of OPA in tension and compression. The fracturing behaviour of unsupported circular excavations in laminated rock masses was then analyzed under different in-situ stress conditions. Lastly, the proposed modelling methodology was applied to the aforementioned FE tunnel to obtain unique insights into the EDZ formation process around emplacement tunnels for nuclear waste. The calibrated numerical model suggested delamination along bedding planes and subsequent extensional fracturing as key mechanisms of the damage process potentially leading to buckling and spalling phenomena. Overall, the research findings are already having a direct impact on the preliminary design process of an underground repository for nuclear waste in Switzerland.

Jan 1, 2015

By P. J. Mehrfert

"Recovery of mineralized coarse particles is notoriously low in conventional concentrators that treat copper porphyry ores. The application of coarse particle flotation techniques has the potential to achieve comparable metallurgical performance at significantly coarser primary grind sizings. ALS Metallurgy has been conducting both internal research and commercial test programs to investigate the potential of Eriez HydroFloatTM technology on copper sulphide ores. Test data indicates that significant improvements in the recovery of copper sulphide bearing particles between 200µm to 850µm can be achieved using Hydrofloat technology compared to conventional flotation techniques. This paper summarizes the results from a selection of test programs that includes recovery by size data from both conventional flotation and HydroFloatTM tests. An explanation of the apparatus and test procedure will be given. Mineralogical analyses of the test products and characteristics that limit metallurgical performance will be discussed.Description of Apparatus and Test ProtocolThe HydroFloatTM laboratory cell is a clear plastic column with an internal diameter of 14 cm. Water and air are introduced to the cell through a circular manifold located in the lower portion of the cell. The cell has a conical bottom which directs slurry to a pinch valve that controls the discharge of tailings. Feed solids are introduced to the upper portion of the cell in slurry form. The cell is operated in a manner such that the manifold water creates a teeter bed zone of suspended solids in the middle portion of the cell. Tailings exit the bottom of the cell at a high pulp density, and most of the introduced water overflows the top of the column and is collected in a launder. Particles with a hydrophobic surface may attach to air bubbles that percolate through the teeter bed, rendering them sufficiently buoyant to be transported to the overflow launder.Three significant features of this arrangement enhance the potential to recover coarse, low grade particles by flotation techniques. Firstly, the hindered settling conditions created by the rising column of water allow coarse particles to become buoyant once attached to a modest sized air bubble. Secondly, the flow conditions within the cell are relatively quiescent compared to a conventional flotation cell that utilizes an agitator. This allows particles that have limited hydrophobic portions of their surface, due to a low content of exposed sulphide mineral, to maintain a somewhat fragile attachment to air bubbles long enough for successful recovery to the overflow. Finally, the absence of a froth phase at the top of the cell allows particles attached to air bubbles to immediately exit the vessel, reducing the potential to drop back into the pulp phase as bubbles burst or coalesce."

Jan 1, 2017

It cannot be said that accurate and reliable ore reserve estimation is the fundamental of any mining operation success. Estimation techniques which are used to estimate the grade distribution of an orebody together with the assessment of uncertainty and risk have a vital influence on the success of any optimisation algorithm. Traditional estimation techniques such as kriging or inverse distance weighting are frequently used for assigning grade values to blocks. Various attempts have been made in order to compare geostatistical estimated methods for ore reserve estimation. This paper aims to evaluate the sensitivity of different estimation methods over changing the block dimension. For this reason, several block models with different dimensions were derived in Chador Malu iron ore mine which is located in 180 km northeast of Yazd in the centre of Iran. Each block model was estimated by different estimation methods such as nearest neighbours (NN), inverse distance (ID) and ordinary kriging (OK). The results of each estimation methods were compared against a control block file created by using the assay results of all blastholes drilled in the ore over four benches of the pit. The results signify that by estimating the large block size, no significant improvement occurred due to the employment of different estimation techniques. Furthermore, the grades estimated based on ID method is more reliable, but OK methods estimated more accurate tonnage.

Dec 6, 2010

By Peter Radziszewski

"Comminition process costs, which typically represent an important contribution to mining operating costs, can themselves be divided roughly between energy and liner /charge wear. As such, developing the ability of predicting mill wear will allow a more accurate estimation of wear costs and therefore their control. In this paper and based on the possibility of estimating energy dissipated in impact and abrasion by using a discrete element charge motion model for mill charge motion simulation, media wear will be investigated principally as a function of three wear mechanisms : impact, abrasion and corrosion. Experimental results will be used to identify a total media wear model. Model results will be compared with real mill data from three operating Australian mines. These preliminary results show for the cases tested that the overall average error, as compared with the observed cases, is 0 % with a standard deviation of 66.1 %. Results from the Bond abrasion index tests, for the same cases investigated, give an overall error of 73 % and a standard deviation of 192.5 %. Further work is in progress to improve test procedure, validity and confidence.INTRODUCTIONComminition process costs, which typically represent an important contribution to mining operating costs, can themselves be divided roughly between energy and line / charge wear. In Greenfield situations where the estimation of operating costs is critical in determining project feasibility, the level of confidence in such estimates becomes quite important. With regards to media wear, the Bond abrasion test currently serves as the standard media wear prediction device. However, as shown [l, 21 test results once compared with actual wear rates can vary greatly. Figure 1 shows test results as compared with 15 cases. Average error over this data is 73 % with a standard deviation of 192.5 %. As such, developing the ability of more accurately predicting mill wear will allow greater confidence in wear cost estimation and therefore their control."

Jan 1, 2001

By Robert A. Cummings, Madan M. Singh

In April 1984 a subsidence depression formed directly beneath a two-story frame residence, near Linton, IN, causing 2 ft of separation between the floor and walls, and damaging both the foundation and interior of the building. The Office of Surface Mining undertook the rehabilitation of the area under its emergency response program. This paper describes the investigation performed to determine the cause, severity, and extent of the problem. Abandoned mine workings were found approximately 55 to 60 ft below the house. Based on the findings, remedial measures were prescribed. An abatement program consisting of grouting the mine voids was recommended, and specifications prepared. These were implemented, and the area has been successfully stabilized.

Jan 1, 1986

By David Van Horsen

Big Creek Tunnel 2, constructed in 1912, is located in the Sierra Nevada Mountains of California, east of Fresno. It is horseshoe and circular shaped with a 3.6m (12ft) diameter and extends 6.6km (4.1mi). Historically, tunnel performance suffers from highly jointed rock and low cover. In 2003, leaks were observed surfacing through outcrops of highly jointed graniodiorite, and subsequently investigated by visual inspection, joint mapping, ground penetrating radar, and a water-tracing survey. Several grouting targets were identified as a result of these investigations. Cement grouting was used to fill void spaces, broken rock and open joints expected to exist behind the concrete and steel liners. Project work consisted of grout hole drilling through the existing concrete liners, and grout placement through squeeze packers supplied by standard grout hose and portable grout plants. Grout pressures were typically 20?30 psi. Grouting was completed in 16 days with a total of 1,550 sacks of Type II/III grout placed at the three likely leak source areas. No grout was observed exiting the tunnel and the leak was stopped.

Jan 1, 2008

By de Bruin J H

A method new to Australia was used for sinking a vertical shaft at Broken Hill in the development of Pasminco Southern Operations No 5 Ventilation Shaft. The 6 m diameter shaft of 820 m depth was planned with a construction method which allowed access for ground support as sinking proceeded by mechanical excavation.The vertical shaft boring machine, known as the V-Mole, was originally developed in West Germany. The machine operates in a manner similar to a full face TBM but vertically and the cuttings drop down a previously constructed raise. The raise is subject to stringent tolerance on verticality and must remain stable for the duration of reaming.

Jan 1, 1993

By E. Topuz, C. Patrick

Longwall face-to-face transfers can cost more than $100 per minute in lost production potential and $100,000 for personnel and supplies. Such high costs make extensive planning and control of the transfer process a critical necessity for the economic feasibility of longwall operations. Operations research techniques are used for the analysis and modeling of longwall face-to-face transfers. Transfer data has been collected from companies who operate, over 35%, of the total US longwall faces. Comprehensive sequence networks of existing longwall transfers were developed; simulation was used to generate models of transfers under Carving conditions; and the economic feasibility of tine-cost tradeoffs in the transfer procedure was investigated.

Jan 1, 1994

By Douglas E. Pollock

Recent NIOSH published information has shown an increase of rapidly progressive coal workers? pneumoconiosis (CWP) in the southern Appalachian coal region (SAR) of the U.S., despite the fact that compliance data indicates that most coal miners have been exposed to coal mine dust concentrations below the statutory limit of 2 mg/m³. While the exact cause of these elevated CWP levels in the SAR has not been established, several factors may be contributing to the increase in occupational lung disease among coal miners. The mining of high rank coal is known to lead to higher CWP rates, and this type of coal is mined in a portion of this region. Also, a high percentage of the mines in the region are on reduced dust standards because of the high silica content of the airborne dust resulting in miners possibly being exposed to excessive amounts of respirable silica dust. Exposure to excessive amounts of respirable silica dust can lead to silicosis, a disabling and potentially fatal lung disease. NIOSH?s Respiratory Hazards Control Branch has been investigating the possible causes that would account for the observed higher trends in disease progression through literature review, data analysis and in-mine surveying. The investigation to date has revealed that underground mines are faced with cutting large amounts of rock in order to maintain haulage clearances. Cutting rock not only increases the potential for silica exposure, it increases the requirement for machine maintenance, which was a concern observed during dust surveys conducted by NIOSH. Over half of the mines operating in the SAR are on reduced standards due to high silica content. Adequate face ventilation of the continuous miner and roof bolter and limited down-wind operations from the miner are also issues of concern and items that require the constant attention of miners operating in these conditions.

Jan 2, 2010

By D. E. Pollock

Recent NIOSH published information has shown an increase of rapidly progressive coal workers? pneumoconiosis (CWP) in the southern Appalachian coal region (SAR) of the U.S., despite the fact that compliance data indicates that most coal miners have been exposed to coal mine dust concentrations below the statutory limit of 2.0 mg/m³. While the exact cause of these elevated CWP levels in the SAR has not been established, several factors may be contributing to the increase in occupational lung disease among coal miners. The mining of high rank coal is known to lead to higher CWP rates, and this type of coal is mined in a portion of this region. Also, a high percentage of the mines in the region are on reduced dust standards because of the high silica content of the airborne dust resulting in miners possibly being exposed to excessive amounts of respirable silica dust. Exposure to excessive amounts of respirable silica dust can lead to silicosis, a disabling and potentially fatal lung disease. NIOSH's Respiratory Hazards Control Branch has been investigating the possible causes that would account for the observed higher trends in disease progression through literature review, data analysis, and in-mine surveying. The investigation to date has revealed that underground mines are faced with cutting large amounts of rock in order to maintain haulage clearances. Cutting rock not only increases the potential for silica exposure, it increases the requirement for machine maintenance which was a concern observed during dust surveys conducted by NIOSH. Over half of the mines operating in the SAR are on reduced standards due to high silica content. Adequate face ventilation of the continuous miner and roof bolter and limited down-wind operations from the miner are also issues of concern and items which require the constant attention of miners operating in these conditions. Disclaimer: Mention of any company or product does not constitute endorsement by the National Institute for Occupational Safety and Health.

Jan 1, 2009

The influence of varying amounts of magnesia, silica, and alumina in iron ore sinter on its mineralogy, reducibility index (RI), reduction disintegration index (RDI), physical breakdown (AI and TI), and production properties (coke breeze rate) were examined. It was found that the mineralogy of iron sinter can more easily be predicted from its chemical composition than from the RI, RDI, AI or TI. Anticipating the consequence that varying amounts of MgO and SiO2would have on sinter properties is complex, and not necessarily predictable. High concentrations of Al2O3in the sinter result in high concentrations of the SFCA phase, but with drastically deteriorated properties. This study also confirmed that the form in which fluxes are added to the raw material sinter mixture affects the mineralogy and properties of the produced sinter.

Jan 1, 2010

By T. Holmes, D. C. Russell, G. Jolly

"The AMEC Oakville office is involved in the design and construction of an iron ore concentrator located in Liberia. Currently, the site ships Direct Shipped Ore (DSO) to overseas customers. The DSO mine-site and port can experience heavy annual rainfalls. The IMSBC Code requires that cargoes are only accepted for loading when the moisture content of the cargo is less than its Transportable Moisture Limit (TML). The moisture content of the DSO has, on occasions, risen to near or above its TML. AMEC was asked to advise whether the concentrate produced from the new concentrator would or would not have the same problems with moisture content and ship loading as the DSO.INTRODUCTION Liberia was, at one time, the world’s sixth largest exporter of iron ore and used some of the most modern mining operations of their time. However, the country has not produced iron ore over the past seventeen years because of civil unrest. The return of stability to the country has allowed the redevelopment of the iron ore industry. ArcelorMittal Liberia (AML) obtained a concession for mining in the Nimba County area of Liberia (Figure 1) in December, 2004 and has studied the known iron ore deposits and former mining operations in this area. It began phase 1 operations in June 2011 with the direct shipping of high grade ore at a rate of up to 4Mtpa. The processing of the lower grade ore in phase 2 of the project requires additional processing capability to produce at the design rate of 15Mtpa. DSO and Concentrate The DSO in the first phase is selectively mined at an average grade of 60% Fe, and then crushed and screened to -10 mm with no washing or concentration. Testing of samples has indicated a size distribution that is finer than typical sinter feed material, although critical material below 0.10 mm is low in most cases, and overall the ore is coarser than typical concentrates or ultrafine products (Feasibility study report, 2011). The phase 1 DSO facility will cease operation after the phase 2 concentrator comes into operation."

Jan 1, 2014

By Charles Deacon

The mining industry is constantly taking greater cognisance of their operating costs as a strategy to counter the effects of falling commodity prices. As a result, optimal operating efficiency is more important than ever. One such operation is that of blasting. Considering the relative increasing costs of explosives and accessories it is desirable to optimise the number of blast-holes fired by maximising their individual output. This achievement may now only be possible following the advent of higher technologies in the form of modified explosives and electronic detonators. This paper reviews and introduces some techniques of blast monitoring, types of operations where each is most suited, resulting modifications to blast designs, and identifies some pitfalls to watch out for when analysing the results.

Jan 1, 2000

By Zhigang Liang

Investigation into the mixing of 150t ladle furnace by two-nozzle jetting was performed by a water model simulation of 1:4. The effects of nozzle arrangements including separation angle, radial position and asymmetry as well as tracer adding position on the mixing time were studied. The most favorable mixing is achieved when the two nozzles are symmetrically arranged at half radii in the ladle, with 45o separation angle. The empirical relationship between the mixing time and stirring power intensity has been established for two-nozzle jetting based on the present experimental results. In addition, the swelling above bath surface is also investigated with two-nozzle jetting.

Jan 1, 2009

By R. B. Krog

The use of belt air as an intake source at longwall operations has greatly changed over the past decades. The practical considerations for the use of belt air are controlled by a variety of factors including airflow quantity and velocity, coal methane content, methane desorption rates, coal mining rate, belt length, stopping leakage, and the number of gateroad entries. At longwall operations, the advantages and disadvantages of belt air are different for gateroad development and longwall panel extraction. During gateroad development, the use of belt air to ventilate the working section will reduce the leakage from the intake to the belt compared to the belt air being ventilated outby the working sections because of lower pressure differentials. A greater quantity of airflow will reach the last open crosscut with belt on intake than outby, given the same amount of pressure and airflow available at the mouth of the section. This paper will investigate the current ventilation practices regarding the use of belt air during gateroad development and longwall panel extraction. Operating considerations regarding air quantities and pressures to deliver the required airflow will be investigated using ventilation network modeling.

Jan 1, 2009

By Yunsheng Yao, P. Golledge, A. D. S. Gillies

In order to investigate the explosibility of sulphide mineral dusts, sulphide ore samples were collected from five underground metalliferous mines in Australia. The mineralogical and chemical composition of the dust samples was analysed by X-Ray Powder Diffraction and Atomic Absorption techniques. Simulated post detonation fumes were produced and used in dust explosibility tests to examine the influence of the fumes on sulphide dust ex- plosions. These tests were conducted in a 20 Litre Siwek Explosion Chamber with measurement and control system that is regarded as a standard testing system worldwide for dust explosion studies. The dust mineralogical composition and dust explosibility tests indicated that the content of sulphur can not accurately predict the explosibity of the sulphide dust. The percentage content of pyrite in the sulphide dust can be a relatively reliable diagnostic criterion in evaluating the risk of sulphide dust explosions in the mining of a massive sulphide orebody. The hybrid explosion tests demonstrated that the post detonation fumes from ANFO not only decrease the lower explosion limit of the sulphide dusts, but also increase the severity of the dust explosions. The explosion pressure reaches its peak value when the fumes content in the explosion chamber is about 20 per cent by volume

Jan 1, 1997

By Chi-Mun Song, Seok-Hyun Choi, Seok-In Hong, Han-Kee Jang

Accurate measurement and evaluation of hand-transmitted vibration from a power tool is an important issue for tool manufacturers, because they are obliged to develop low-hazard power tools for workers. The International Standard ISO 5349(1) dictates a systematic procedure for the measurement and evaluation of hand-transmitted vibration. However, the uncertainty in this measurement is too large for manufacturers to apply such data to the design and modification of power tools. There can be several sources of this uncertainty in such measurements; e.g., operator-dependent, power tool-dependent, and operational conditions (see Table 1). For a manufacturer to characterize the exposure of a power tool’s use to a given level of vibration, the relationship between these uncertainty factors and the measured vibration must be elucidated. In this study, we investigated the effect of several factors on the uncertainty in measurements. [ ] Methods In this study, some of the factors in Table 1 were selected for examination, and their effect on the measured variation was quantitatively investigated. Three tools from the same manufacturer were sampled at random in our experiments, and each of five of the same type of insert (disks or tips) was installed into each tool. Although each of the tools and inserts were of the same design and were made by the same production process, they differed from one to another, which can be a source of the variation in the measured vibration. Three human subjects participated in our experiments, which were carried out as stated in ISO 5349. The subjects were asked to maintain their posture, and the applied force was kept as constant as possible. The applied force was monitored using an indirect method, where vibration energy was displayed in real time during the experiment using a three-axis accelerometer attached to the work piece at a specified point. The appropriate range of the applied force was predetermined to cover the range of real work operations. The engineering tolerance between the inner diameter of a grit disk and the outer diameter of the tool shaft leads to an eccentricity of the mass at the center of the disk. The degree of eccentricity varies with installation, and this is another source of uncertainty. In our study, the effect of this eccentricity was investigated by carrying out repeated assembly and disassembly of an insert.

Jan 6, 2006

By O. Dojcar

The results of a laboratory investigation of rock fragmentation conducted with a model material were partially verified under field conditions. The object of the investigation was to study the qualitative and quantitative relations between the parameters of the primary blast and fragmentation to enable the planning of an economically efficient degree of disintegration with optimum utilisation of the blast energy. The three blast parameters that were considered were burden, specific charge and the ratio of spacing to burden

Jan 1, 1991

By N. Coli

The exhausted Santa Barbara open pit mine (Tuscany, Italy), owned by the main electric power company in Italy (ENEL S.p.A,) extracted lignite as a fuel for the Santa Barbara thermoelectric power plant. The mining activity led to the excavation of a wide slope (with maximum height of 200 m and a planar extension of about 1300 m x 500 m) in the Shale Limestone Chaotic Complex (SLCC) (Figure 1). Since the beginning of its excavation the slope underwent rotational landslides and diffuse instability phenomena. From a geotechnical point of view the SLCC represents a typical bimrock (block-in-matrix rock) (Medley 1994, Medley 2002, Medley 2007) characterized by a mixture of a highly sheared, scaly-fabric, clayey matrix and calcareous blocks ranging from a few millimetres to tens of metres in size. Since the geometrical properties of blocks (grain-size distribution, shape, orientation and volumetric proportion) have been proved to influence the mechanical behaviour of bimrocks (Lindquist & Goodman 1994, Goodman & Ahlgren 2000, Kim et al. 2004, Sonmez et al. 2006), the aim of the present study is to investigate the geometrical properties of calcareous blocks in order to properly characterize the mechanical behaviour of the SLCC bimrock and to further assess the stability of the slope. Block size-distribution and shape were investigated by means of advanced image analysis techniques of SLCC pictures taken in the field. Geostatistical semivariograms and variographic maps were also used in order to investigate the anisotropy of block spatial distribution. Finally, in-situ large sized sieving tests were carried out to investigate the volumetric block proportion within the clayey matrix.

May 1, 2009