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By Rory Cameron, Chuck Edwards

"Stringent environmental performance criteria and regulations, and the desire to minimize water use have made membrane-based treatment and separation processes an attractive option. This has lead to many advances in all aspects of the technology. Membrane separation processes have found application in sea water desalination, brackish water treatment, decontamination of ground water, and wastewater treatment. Development of membranes with better resistance to harsh feed conditions has created new opportunities for the broader application of membrane separation technologies to mineral processing streams. There are examples in mineral processing operations, including treatment of acidic drainage, pre-concentration of pregnant leaching solution in heap leaching operations, separation of acids and metals from waste streams and intermediate process streams, as well as gold and cyanide recovery from a heap leaching operation. This paper provides a brief overview of membrane technology principles, followed by a discussion of current membrane technology applications relevant to the mining and mineral processing industry. The paper further explores the potential for the application of membrane separation as an integrated component in mineral processing operations.INTRODUCTION Increased regulatory pressures, emphasis on water conservation, and scarcity of water in arid regions have resulted in substantial changes in industrial practices in recent years. As a result, many industries have become more open to adopting innovative technologies such as membrane separation. The mining industry, which is typically very conservative, has adopted membrane separation as an effective end-of-pipe solution for effluent and acidic drainage (AD) treatment; however, its use as an integrated component in plant operations has progressed more slowly. With increasingly stringent environmental regulations coupled with the desire for low- and zero-discharge operations, the use of membrane separation technology for achieving acceptable environmental performance may be unavoidable in the future. The relatively small footprint requirement, versatility, and modular construction of membrane separation units facilitate their introduction into existing processes with a suitable feed stream. Membrane separation is not a stand-alone process that provides the ultimate solution to water and wastewater treatment; however, it can often be economically added to conventional waste treatment plants to increase throughput and/or decrease contaminant output (Mortazavi, 2008). Although membrane separation technology has become an established separation technique that is widely used in drinking water production and other industries, it is still considered an emerging technology within the mining and mineral processing industry. This technology offers many potential benefits such as clean water recovery from wastewater, significant reduction of volume requiring conventional treatment, decreased usage of reagents, and acid recovery, all of which lead to increased treatment efficiencies and lower reagent consumption. This could translate to smaller and more efficient plants with lower capital and operating costs and lower environmental impacts. Plant expansion may be facilitated by incorporating a membrane separation unit operation in order to utilize existing treatment systems at higher throughputs."

Jan 1, 2012

By Manqiu Xu, Songtao Yang, Zongfu Dai, Robert Pelton

"Hydrophobic polystyrene nanoparticle suspensions were evaluated as potential flotation collectors for pentlandite. Experiments involving both clean model mineral suspensions and complex ultramafic nickel ores confirmed that conventional water-soluble molecular flotation collectors such as xanthate could be partially or completely replaced by hydrophobic nanoparticle flotation collectors. The ability of nanoparticles to induce flotation was demonstrated by floating hydrophilic, negatively charged glass beads with cationic polystyrene nanoparticle collectors. Electrostatic attraction promoted the spontaneous deposition of the nanoparticles on the glass surfaces raising the effective contact angle sufficiently high to promote the adhesion of beads to air bubbles. As little as 10% coverage of the bead surfaces with our most effective nanoparticles could promote high flotation efficiencies, whereas conventional small molecular flotation collector requires ~ 20% or higher coverage for a good recovery. Surface functionalized nanoparticles enhanced the ability for nanoparticle collectors to selectively deposit onto surfaces of the desired mineral particles in the presence of gangue. For example, poly (styrene-co-vinylimidazole) nanoparticles were designed to selectively deposit onto nickel mineral (pentlandite) in the presence of Mg/Si slime. Flotation tests of ultramafic nickel ores at Vale with these nanoparticle collectors have shown improvements in both pentlandite recovery and selectivity. On-going work includes attempts to identify specific applications where nanoparticle flotation collectors might be cost effective.INTRODUCTION Most mineral processing operations include multiple stages of froth flotation to concentrate and isolate the desired product. Before flotation, chemical collectors are routinely added to ground ore slurries, selectively binding to mineral-rich particles, increasing their hydrophobicity thus promoting selective flotation. (Fuerstenau, Jameson, & Yoon, 2007) Conventional collectors are surfactants with a short hydrocarbon tail and a head group, such as xanthate. A typical conventional collector is potassium amyl xanthate (PAX), which is a small molecule with an extended molecular length of about 1 nm. Critical characteristics of a good collector include the ability to selectively adsorb onto desired mineral surfaces and to lower the water/mineral surface energy. Despite the extensive role of flotation in mineral processing, some ores are difficult to process by flotation. For example, ultramafic nickel sulfide ore containing both valuable pentlandite and large quantities of unwanted Mg/Si slime [primarily serpentine, (MgFe)3Si2O5(OH)4] responds poorly to flotation. (Mani, Xu, Quinn, & Stratton-Crawley, 1997) Fibrous hydrophilic Mg/Si slime usually masks the surface of pentlandite (known as “slime coating”) due to electrostatic interaction (Edwards, Kipkie, & Agar, 1980) and dramatically depresses pentlandite flotation. Consequently, new approaches are required for processing these difficult ores."

Jan 1, 2012

By R. I. Kraydenko, A. N. Dyachenko

"The possibility of SiO2 5N production by staged purification of ammonium hexafluosilicate (NH4)2SiF6 is discussed. High-purity silicon dioxide can be obtained with fluoridation of quartz concentrate by solid NH4F at 100 °C, with further sublimation of the product at 320 °C, its dissolution, ammonia hydrolysis, filtration and drying of SiO2•nH2O. This is accompanied by regeneration of the processing reagent - NH4F.INTRODUCTIONProduction of high-purity silica-5N (SiO2 content over 99.999%) is an important and urgent task of the modern chemical industry. This material is used in the manufacture of optical glass, optical fibers for internet cables, silicon for solar power and electronics.Quartz concentrate is raw material for the production of silicon dioxide. The existing technologies of synthetic silicon dioxide were introduced in the mid-twentieth century. These methods are energy-consuming, multi-step and do not meet stringent environmental requirements. In fact, as some conventional technologies became obsolete; it became necessary to develop new methods for the production of synthetic silica. We believe that the fluoride technology of processing of quartz materials by ammonium fluoride is the most promising direction.In industry, silicon dioxide marked ""Silica White"" is obtained by liquid-phase method. The method consists of the precipitation of amorphous silica from sodium silicate solutions with acids. The resulting product is filtered, washed and dried. Depending on the deposition conditions and nature of the coagulant the ""Silica White"" is acidic, neutral or alkaline. The dry product is subjected to grinding. The degree of dispersion and porosity of the particles of Silica White depends on the nature of decomposition agent (a substance that decomposes the silicate) and coagulant, conditions of sedimentation, filtration and drying. During the drying process the silica particles are sintered into aggregates of a few millimeters."

Jan 1, 2012

By Yeonuk Choi, Gus Van Weert

"In regular CIL circuits, activated carbon is used for two purposes: avoiding solid/liquid separation after cyanide leaching, and minimizing gold losses in the tails. The carbon distribution and gold profiles in the successive CIL stages are operating variables, not objectives. When the CIL feed contains a preg robbing constituent however, such as native carbon, there will be competition for gold cyanide and this conflicts with minimizing of losses of gold to CIL tails. This paper examines some of the limitations of activated carbon in CIL circuits handling preg robbing Carlin Trend ores.INTRODUCTION Carbon-In-Leach (CIL) has been a great success treating regular gold ores, but the technology is still challenged by preg robbing feedstocks. Little information is available in the gold milling literature on CIL gold extraction from “free” milling gold ores which are preg robbing, or on autoclave discharge (POX’ed) slurries of double refractory ores. Neither feedstock is readily available for experimentation. No literature reference could be found describing deliberate modifications to CIL operations or CIL circuits due to the presence of two types of carbon: “native” and activated. There is some literature on the gold cyanide adsorption activity of native carbons (Schmitz, Duyvesteyn, Johnson, Enloe & McMullen, 2001). Various tests have been devised to measure this activity, commensurate with CIP and CIL practices (Tretbar, Arehart & Graves). In this paper, the term “native” carbon indicates (severely) preg robbing carbonaceous materials found in gold ores. There is considerable literature on the gold cyanide adsorption activity of man-made “activated carbons”. Various tests have been devised to measure this activity, commensurate with CIP and CIL practices. These tests are comparative, i.e. results relate to a standard carbon and depend on the test methodology and carbon history. The test results are equilibrium oriented, hence of limited value to CIL circuit designers or plant operators handling preg robbing solids; in CIL circuits most carbons are not loaded to capacity. Information on gold cyanide adsorption and desorption kinetics might be more relevant and that is one subject explored in this paper."

Jan 1, 2012

By B. Dubé, R. Friedman, J. Oliver, R. Aubertin, M. Burson, G. Panneton, M. Hamilton, J. Ayer

"The Detour Lake gold deposit is located within the northwestern limit of the Archean Abitibi Subprovince of the Superior Province. Mineralized zones are hosted by a sequence of pillowed and massive flows, hyaloclastite units, and altered ultramafic rocks, and are commonly oriented parallel to a series of high-strain zones that are co-planar to the regional-scale Sunday Lake Deformation Zone. Early in its kinematic history, the Sunday Lake Deformation Zone placed older (2.72 Ga) volcanic rocks of the Detour Lake Formation over younger (2.70 Ga) sedimentary rocks of the Caopatina assemblage. Gold mineralization is also parallel to the position of a laterally persistent siliceous rock unit, the 2.725 Ga ‘Chert Marker Horizon.’ The Chert Marker Horizon coincides with the boundary between the mafic-dominated upper Detour Lake Formation and the ultramafic-dominated lower Detour Lake Formation. Stratigraphic and geochronological data suggest that the Chert Marker Horizon is a deformed felsic volcaniclastic unit. At a cut-off of 0.6 g/t Au, the Detour Lake deposit contains 17.26 million ounces of Au within 445.9 million tonnes of rock grading 1.20 g/t Au. Gold occurs in shear-hosted and extensional vein arrays within rocks of the upper and lower Detour Lake Formation and within the Chert Marker Horizon. The Detour Lake deposit has many of the characteristics of a greenstone-hosted, quartz-carbonate vein deposit; its very large size may be attributed to large-scale rheological controls resulting in the formation of dilatant sites in permissive rock units."

Jan 1, 2012

By J. Seidel

In 2009 Newmont Mining Corporation’s annual global spend on grinding media reached $94M USD, having doubled in the five years since 2004. The major contributing factor to the spend escalation during this period was unit consumable price, with total media consumption also rising as a function of annual ore tonnes milled. In an effort to better understand and manage the growth of this expenditure a significant supply chain management program was implemented. This was complemented by a series of technical initiatives focussed on grinding media specifications, quality management and the prediction of grinding media wear rate as a function of physical ore characteristics. This paper discusses the methodology and outcomes of these activities.

Jan 1, 2012

By T. Grammatikopoulos, SGS Canada Inc.

"The Nechalacho rare metal deposit, located in the Northwest Territories, Canada, is currently being taken through Feasibility Study by Avalon Rare Metals Inc. QEMSCAN analysis and supplementary electron microprobe analysis were utilized to identify and quantify the mineralogy of the deposit, and determine REE distribution among the minerals. QEMSCAN mineralogy was performed to provide textural information on the mineralization, determine the variability of the ore and identify REE domains, and the liberation and association of the REE minerals. The sample matrix consists predominantly of silicate minerals. The REE minerals include allanite, monazite, synchysite, columbite, fergusonite, and bastnaesite. Zircon is present in considerable amounts and is a REE carrier. Fergusonite and zircon account for most of the HREE, and monazite, allanite, synchysite and bastnaesite the LREE. QEMSCAN mineralogical data is extremely valuable in assessing the mineralogy of the ore. The data are implemented to define the mineralogy of the ore body, support metallurgical test work, and predict recoveries and grades.INTRODUCTIONThe term rare earth elements (REE) is used to describe the 15 lanthanide elements or metals and, more recently, the metals yttrium and scandium, which display similar physical and chemical properties.Economic and potentially economic REE deposits form two main groups, a more commonly occurring “light rare earth element” (LREE) group containing lanthanum, cerium, praseodymium, neodymium, and samarium and a less commonly occurring “heavy rare earth element” (HREE) group which, in addition to the LREE, contains elevated concentrations of the more valuable REE, europium, gadolinium, terbium, dysprosium, holmium, yttrium, erbium, thulium, ytterbium, lutetium and scandium. The first group is hosted primarily by carbonatites and the second by highly alkaline (Na + K > Al) silicate igneous rocks. The LREE are produced mainly from bastnaesite, monazite, etc., while HREE are produced almost exclusively from low-grade secondary ion adsorption clay deposits in which the REE are adsorbed onto the surfaces of kaolinite and halloysite, clay minerals produced by the weathering of granite and sediments. HREE are also found in fegusonite, zircon, xenotime, etc but are not produced presently from these minerals. China is responsible for 97% of the World’s production of the REE, mainly from the giant Bayan Obo, carbonatite-related deposit and from the clay deposits mentioned above.Quantitative automated mineralogy is increasingly being applied to ore deposits. It helps users to understand and improve mineralogical parameters for geological and metallurgical purposes. Data include textural characterization, to quantification and distribution of ore and gangue minerals, liberation and association of the REE minerals. The data can be used to define mineralogical domains and predict the metallurgical response of the ore (Gunning, de Souza, & Grammatikopoulos, 2009)."

Jan 1, 2012

By C. J. K. Purdy, H. E. Jamieson

"The comprehensive assessment of the environmental impacts of mining rare earth element (REE) deposits depends on a sound knowledge of the mobility of REEs in low-temperature aqueous environments. Temperature, pH and water chemistry are important factors controlling the aqueous mobility of REEs, while REEs are known to readily form complexes with both inorganic and organic ligands, and it has been shown that sorption and colloid formation may play an important part in dictating REE transport in the low temperature weathering environment. Ore and host rock mineralogy is also a key factor controlling the extent to which REEs are leached from mine waste. INTRODUCTIONThe aqueous mobility of rare earth elements (REEs) has commonly been explored in the past due to their potential application as tracers of geochemical processes in aqueous systems. REE mobility in low-temperature solutions has been shown to be dependent on the pH, temperature, ionic strength, and solution chemistry. For example, the aqueous transport of REEs can be modified by complexation with organic and inorganic ligands (Johannesson & Zhou, 1999; Klungness & Byrne, 2000; Luo & Byrne, 2004; Schijf & Byrne, 2004; Tang & Johannesson, 2010; Wood, 1990, 1993), or through sorption to suspended particles and colloids (Bau, 1999; Quinn, Byrne, & Schijf, 2004, 2006a, 2006b, 2007; Sholkovitz, 1995). Here we review the coordination chemistry, sorption behaviour and potential colloid association of REEs with respect to low temperature aquatic settings.RARE EARTH ELEMENT CHEMISTRYREEs include lanthanum to lutetium of Group IIIA in the periodic table. All share very similar chemical and physical properties. Often included in REE studies is another Group IIIA element, yttrium owing to its similar properties, and occasionally scandium, although its considerably smaller ionic radius makes for different properties and will not be discussed further here. The REEs are often subdivided into the light REEs (LREE), La to Sm, and the heavy REEs (HREE), Eu to Lu, which also usually include Y (hence are often referred to as YREE). The REE may be subdivided further into the LREEs, middle REEs (MREEs), and HREEs, in which case each classification includes La-Nd, Pm to Ho, and Er to Lu as well as Y, respectively, although definitions vary throughout the literature."

Jan 1, 2012

By G. J. Kipouros, W. Judge

"The prevalent metal extraction processes for most reactive metals are fused salt electrolysis and metallothermic reduction. The feed material for both of these processes is the anhydrous chloride of the metal under consideration. Dehydration of the feed material is then a critical step in the production of most reactive metals and requires rigorous thermodynamic analysis. Thermodynamic data for most of the reactive metal chloride hydrates have not been measured. Improper dehydration of the metal chloride may lead to a prohibitive amount of hydroxychloride, oxychloride, and oxide. To prevent hydrolysis a certain pressure of hydrogen chloride is required. An estimation and prediction model is presented for the vapour pressures of reactive metal chloride hydrates in an attempt to deduce the conditions necessary for dehydration to proceed without hydrolysis. Thermodynamic data including heat capacities, standard entropies, and standard enthalpies are estimated/predicted for all conceivable intermediate hydrate compounds. Estimations are based on published data as well as trends proven in similar systems. The thermodynamic estimations and predictions are presented for the magnesium, neodymium, praseodymium, and dysprosium chloride hydrates. INTRODUCTIONThe high reactivity of metals such as the alkalis, alkaline earths, and lanthanides prevents their reduction by traditional pyro- or hydrometallurgy. In their elemental form, these metals are raw materials in the manufacture of intermediate products such as alloys and electronic components. Currently the only two viable metal production methods are fused salt electrolysis and metallothermic reduction. Various feed materials have been proposed for these processes. Using the chloride of the metal as a feed material offers advantages in separation and purity of the final product, as well as lower energy input. Chlorides, however, are hygroscopic and must be dehydrated before use. Improper dehydration will lead to a prohibitive amount of oxychloride which will lower efficiencies and contaminate the final product.Optimum conditions for proper dehydration of MgCl2•6H2O to produce pure MgCl2 without hydrolysis have been calculated from existent thermodynamic data and have been reported previously (Kipouros, 1987; 2001). Calculations were also performed for the case of production of pure anhydrous NdCl3 from NdCl3•6H2O (Roy, 1997)] and the mechanism of dehydration was elucidated. Some thermodynamic studies on the dehydration of chlorides of the rare earths have also been conducted (Sundstrom, 1997; Hong, 1997; Aschcroft, 1968; Haeseler, 1965; Ukraintseya, 1989)."

Jan 1, 2012

By J. P. Grau, J. Z. Lu

"Thickeners/clarifiers are widely used in coal preparation plants, potash processing and other mineral processing facilities. Thickeners play a very important role in slurry treatment systems to accomplish solid/liquid separation. The demand for larger plants and the increased thickener handling capacities sometime require thickener diameters as large as 200m. The development and use of high capacity thickeners makes it possible to increase the handling capacity of these thickeners by several to more than 10 times compared to conventional thickeners. Hence, for a given slurry rate, selection of a high capacity thickener will significantly reduce the footprint of the thickener. Much higher handling rate, higher concentration of underflow, clearer overflow and lower capital cost are obvious advantages of high capacity thickeners; however, some process requirements and the concerns of operational cost, especially the flocculant cost of a high capacity thickener operation, keep some engineers selecting conventional thickeners and staying away from the high capacity thickeners. Forty years after the first high capacity thickener was developed, there are still arguments in the selection of conventional thickeners or high capacity thickeners in mineral processing. The arguments will continue unless there is a clear picture of capital cost vs. operational cost for each of the thickener types. The purpose of this paper is to analyze these costs and to provide guidelines for selection of thickeners. INTRODUCTIONThickeners/clarifiers are widely used in various slurry treatment systems. For mining and mineral processing, thickeners are an integral part of the solid/liquid separation system. The feed to the thickeners are processing slurries. The fundamental mechanism for the solids/liquid separation is for the solid particles in the slurry to gravity settle inside the thickener tank. The clear water overflows from the top of the thickener tank and is typically reused in the processing circuit, and the concentrated underflow is discharged to different downstream process systems depending on the application of the thickeners. The general requirements for a thickener operation include high density of underflow and clear overflow. Since thickener operation consists of continuous feeding, overflow and discharge of underflow, the solid particles will gravity settle against an upward flow with its velocity dependent on the feed rate and the underflow discharge rate. Higher feed rates to a given thickener produce higher upward velocities. Underflow discharge is typically relatively small compared to the amount of overflow. The upward flow tends to take particles up to the overflow. Only those particles having a settling velocity greater than the upward flow velocity will possibly settle out. Hence, thickener feed rate has to be controlled so that the required overflow water clarity can be achieved."

Jan 1, 2012

By J. R. Levin, E. J. Schelter

"We present some of our recent efforts in the development of predictive, directed oxidation chemistry of cerium(III) complexes under non-aqueous conditions. The electrochemistry of cerium(III)- alkali metal heterobimetallic aryloxide complexes is reported and compared with cerium aryloxide complexes that are kinetically stabilized by hydrogen bonding cations that span between the complexed aryloxide ligands. Comparative electrochemical measurements reveal differences between the heterobimetallic complexes and the hydrogen-bonded complexes.INTRODUCTIONThe rare earth elements comprise the lanthanides, La–Lu, and the element yttrium (Aspinall, 2001). Rare earth ores such as monazite, LnPO4, and bastnäsite, LnFCO3, typically bear mixtures of light rare earths: La–Sm while monazite, LnPO4, contains mixtures of heavy rare earths (Eu–Lu) (Cotton, 2006). Pure rare earth elements typically are isolated using a liquid-liquid separations process.(Bautista, 1995) The hydrometallurgy of these elements is a difficult problem because the separation factors between neighboring rare earths, which are predicated on the small differences in the sizes of the trivalent ions, are quite small (Cox, 1992). The element cerium, with its 4f1 electronic configuration in the trivalent state, is unique among the rare earth elements due to a relatively accessible 4f0 electronic configuration. The accessibility of the 4f0 configuration underlies the chemistry of cerium(IV), the only rare earth ion with molecular chemistry in the tetravalent oxidation state (Cotton, 2006). Cerium is trivially separated from mixtures of light rare earths by making use of its unique oxidation chemistry. In an effort to extend separations chemistry by oxidation reactions to other rare earth elements such as terbium and praseodymium, the solution electrochemistry of well-defined cerium complexes is of interest."

Jan 1, 2012

By Kurt Tischler

This paper presents the field experience of Siemens with regard to Gearless Drives in the mining industry ? We consider the elapsed production hours of Siemens Gearless Drives to be extensive enough to provide a reliable estimation of availability calculated on the basis of data representing repair time, downtime, and operating time. The users of Siemens Gearless Drives confirm an availability of more than 98% after exclusion of some major issues. The paper addresses all of these major issues of Siemens Gearless Drives, describes successfully applied corrective measures, explains the influences on the design of the drives, and lists the downtimes associated with each of these issues.

Jan 1, 2012

By T. G. Joseph, M. J. Bolster

ABSTRACT This paper explores passive seismic measurement as an alternative, nonintrusive approach to conducting annual brake testing on surface mine sites. Dictated by the test site location, this evaluation adhered to the brake testing procedure as per British Columbia occupational health and safety regulations. Results showed excellent correlation to those reported via conventional practice: Comparing stopping distance, time, and velocity for the proposed instantaneous passive seismic versus conventional approaches, less than a 0.5% variance was evident. A viable alternative, the passive seismic approach, allowed an entire fleet of trucks to be sequentially evaluated for annual brake testing without disrupting operations by installing mechanical testing equipment.

Jan 1, 2012

By Freislich. M., Y. Gordon

"In the changing global market scenario for raw materials for the steel industry, a number of novel iron- and steelmaking process technologies are being developed to provide the steel companies with economically-sustainable alternatives for iron- and steel-making. In addition, the steel industry is also focusing on reduction of energy consumption as well as green-house gas (GHG) emissions to address the crucial subject of climate change. In this context, it is important to assess these critical issues for the alternate iron- and steelmaking technologies that have been developed. This paper presents a comparative evaluation of energy-efficiency and GHG emissions for some selected iron- and steelmaking technologies that are being considered for implementation. In this work, Hatch’s G-CAP™ and En-MAP™ tools that were developed with the main objective of quantifying and qualifying the potential energy savings and CO2 abatement within the iron and steel industry, were employed in the evaluation conducted. INTRODUCTIONThe iron and steel industry continues to transform itself and evolve in the ever-changing global market place – the raw material scenario is constantly changing with respect to quality and quantity (availability), there is stiff competition in both global and local markets, and there is increasing pressure to address global climate change issues, especially since the steel industry is highly energy- and carbonintensive. There is growing importance of steel production in developing countries such as China and India – this means that the steel industry in these countries will play an important role in defining and shaping the future of the industry.Climate change is expected to present new risks to the steel industry with respect to ensuring a sustainable business. Legislators are proposing to limit GHG emission by placing an implicit price on CO2 emission - market-based “cap and trade”, carbon tax etc.. In this scenario, it is important for the steel companies to reduce exposure to climate-related risks and at the same time, find business opportunities within these risks. Thus, there is a need to strategically manage the climate change risks; the key steps to strategically manage climate change risks are presented in Table 1[1]."

Jan 1, 2012

By L. M. Southwick

"The history of extractive metallurgy is replete with examples of commercializing new processing technologies. The successes are widely reported, but failures seldom are. This is unfortunate, for usually we can learn more specifics on how to succeed in technology development by studying and thoroughly understanding their failures. Frequently one encounters a red herring that caused the whole effort to fail. A thorough and objective due diligence up front would have identified those red herrings and prevented the pursuit of a bad idea and the resulting destruction of capital. Due diligent analyzes performed before construction of three such bad ideas will be discussed. One is an EAF dust process, which pursued the red herrings of a poor understanding of the business, a naïve view of past experience, and false confidence in the technology. Another will examine the effort to commercialize a new pressure copper leach process that followed the red herrings of inadequate testing of the raw material, application of processing conditions that were inherently unsafe, and an improper assessment of the inherent advantages of past developments. The last is an alternative iron-making process, where the red herrings were incomplete and superficial assessment of prior pilot plant and demonstration plant tests, an assumption that the commercialization model of “build it and we will make it run” was viable, and a technology whose technical fatal flaws had already been identified. Unfortunately, capital destruction often also closes the window to more intelligent pursuit of technology development. TECHNOLOGY COMMERCIALIZATIONThe development and commercialization of new technology is a vital part of keeping industry profitable, able to deal with new sorts of feed stocks and current with economic, product, operational and environmental requirements. This is a difficult task in the best of times, and can be compounded when the developers become enamored of a particularly favorable characteristic of the project or of the product. These “red herrings” divert project focus away from the arduous path to success and, in the end, result in project failure."

Jan 1, 2012

By M. A. N. Rosa, L. C. R. Machado, R. A. Fonseca, A. M. Mendonça

"Sossego Mine was the first Vale SAG mill operation to process copper-gold ore. It is located in the state of Para, in the south-eastern Amazon region of Brazil. In the first six years of continuous operation, Vale investigated different alternatives for improving circuit performance by investigating operating conditions, mainly focusing on the SAG mill.Today, after a steady increase over five years the annual production rate seems to have stabilized. It is hoped this work will show how the SAG operating practice have been perfected with time and as new data are collected. Historical data of mill grind-outs and crash stops helped create operation curves depending on the ball charge volume and total charge volume. Also noted were impacts on throughput due to the effect of reducing liner weight and the ore type characteristics."

Jan 1, 2012

By J. D. Clucas, D. B. Dreisinger

"The Starved Acid Leach Technology (SALT) has been developed by Search Minerals to extract nickel and cobalt VALUES (from nickel laterite ores (saprolites) and Caron plant residues. The technology consists of sulfuric acid atmospheric leaching of the ores or residues followed by neutralization and recovery of nickel and cobalt. The acid addition is carefully controlled to maximize nickel and cobalt extraction while minimizing overall consumption of acid by various gangue reactions. The final recovery processes can be tailored for maximum economic benefit. The use of resin-in-pulp processing is advocated as the most cost effective method for initial recovery of nickel and cobalt from lower grade materials. INTRODUCTIONCommercial processes for laterite ore treatment vary according to laterite type and local conditions. The two general categories of laterite ore are saprolites and limonites.Saprolites are generally treated by pyrometallurgical processes for reduction of nickel to matte or ferro nickel alloys. The high cost of drying, chemical reduction and electric furnace smelting requires that the saprolite grade for economic processing is of the order of 1.8% nickel or higher. There are of course large amounts of saprolite that fall below this “cut-off” grade that are not currently economic.Limonites can be treated by the Caron Process which involves drying of the ore, a reduction roast of the whole ore to reduce nickel and cobalt (and some iron) to the metallic state followed by ammonium – ammonium carbonate solution to leach nickel and cobalt. Nickel and cobalt recovery are low (70-85% for Ni and 20-50% for Co). The Caron plant tailings therefore contain high levels of unrecovered nickel and cobalt. Relatively few plants have used the Caron Process and new installations are not anticipated due to the high energy cost of drying and reduction roasting. Nevertheless, plants in Brazil (Niquelandia), Australia (Yabulu) and Cuba continue to operate.The high pressure acid leach (HPAL) process was pioneered at Moa Bay in Cuba in the 1960’s in the treatment of limonites. In the 1990’s the HPAL process was touted to revolutionize the nickel industry with low capital and operating costs for new installations. Murrin Murrin, Cawse and Bulong in Australia were started and in each case the technical difficulties of operating at extreme temperature and pressure conditions and the challenges in “ramping up” a complex hydrometallurgical facility conspired to cause these plants to fail economically. At present, Cawse and Bulong are closed and Murrin Murrin continues to operate after undergoing a financial restructuring."

Jan 1, 2012

By R. Khanna, K. Hyun Ko, A. J. Berkovich, J. Hook

"The co-pyrolysis of synthetic polymer polyethylene terephthalate (PET) and agricultural wastes (naturally occurring polymer-macadamia nut shell) was investigated in the temperature range 473K to 1273K using a horizontal furnace with an aim to understand their thermal degradation under isothermal conditions. In-depth characterization of pyrolysis residues was carried out using x-ray diffraction (XRD) and solid state nuclear magnetic resonance (NMR) for carbon structure, and through determination of the concentration of unpaired electrons using electron paramagnetic resonance (EPR). In previous studies, it has been found that PET thermally decomposes ~ 650K-700K, releasing (~80 wt % of initial weight) gaseous products due to random chain scission. In the case of macadamia nut shell, three types of byproduct can be obtained from pyrolysis: char, tar and gaseous products. In the co-pyrolysis of macadamia nut shell with PET in 50-50 wt% ratio, total product weight ratio could be modified with the addition of PET acting as a hydrogen source. This is because a recombination of thermal cracking products of cellulose could be suppressed by hydrogen from PET, which will later lead to an enhancement of tar formation. In addition, pyrolysis around 673K is sufficient for bond cleavage to occur in cellulose and lignin leading to the formation of negatively charged activated carbon with high surface area, providing bonding sites for volatiles evolving from PET. Therefore the co-pyrolysis may be able to enhance the product yield (tar/char/solid carbon residue) along with a reduction in the release of gaseous products. During the co-pyrolysis, temperature was found to have a significant influence on the kinetics of thermal degradation and solid residual by-products after co-pyrolysis.INTRODUCTIONPlastics are being used worldwide in a wide range of applications in the modern society; their usage has resulted in increasingly a massive waste problem. The production of most synthetic plastics requires hydrocarbons that are produced from petrochemicals derived from fossil oil and natural gas, a non-renewable source (Speight 2011). Currently, plastic manufacture utilizes ~4% of world oil and gas production, and it is expected to drive further increases in petroleum demand by 1-2% due to their large volume of manufacture (Hopewell, Dvorak et al. 2009). Landfilling and incineration of plastic waste are the two main routes to plastic waste management (Encinar and González 2008). In Australia, only 10% of waste plastics were recycled in 2006 (White and Hyde 2011). This means that large amount of fossil fuels from plastics has either been simply burned for energy recovery or buried in the ground. There is an urgent need for developing alternative avenues for recycling waste plastics. Our group at UNSW has carried out extensive research on the recycling of waste polymers as carbon resource in steelmaking including slag foaming and carbon dissolution from waste plastics into liquid steel at 1600°C; the effect of basic plastic characteristics such as chemical composition, structure, bonding network etc. was examined (Sahajwalla, Rahman et al. 2009)"

Jan 1, 2012

By Dayang Datu Khalil, Charle Amoah, Fred Kock

Abosso Goldfields Limited has been optimizing the comminution circuit at the Damang Mine Operation for the treatment of 100% primary ore. The optimization process started at a base rate of 343 tph when treating primary crushed primary ore, and was increased to above 600 tph with partially crushed primary ore. Abosso Goldfields engaged Orway Mineral Consultants (OMC) to assist with the optimization process in 2009 and the two companies have been working together since, to further refine the process. Continuous improvement was achieved through crushing circuit modifications, changes in operating processes and grinding control system utilization. This paper discusses the improvements developed for the increase in milling capacity and improvements in final product size.

Jan 1, 2012

By Cosmin Carpinisan, Erich J. Hofmann, Stephen J. Hall

"Since presenting a technical paper regarding their unique capabilities in Forged Steel Mill Gearing at the SAG-2006 Conference, Australian heavy engineering company Hofmann Engineering has pioneered a number of new manufacturing processes and design concepts for components of large comminution equipment. These include: 1. Novel design improvements for HPGR Rolls with forged steel tyres and a unique patented tungsten carbide insert designed to improve wear life, enhance autogenous layer build-up, and to reduce breakage & chipping under load. 2. Development of forged fabricated Mill Heads using rolled & welded high-tensile steel plate as alternatives to cast conical mill heads. 3. Insitu Girth Gear measurements for profile and wear via portable 6-axis CMM. 4. Gear and Pinion designs to AGMA-6114 for SAG mills of 38’-40’ diameter to 24MW and for Ball Mills of 26’ diameter to 18MW. The paper presents case studies from the Australian heavy manufacturing facilities of Hofmann Engineering, combined with news of their new gear manufacturing and gearbox overhaul facility in Canada."

Jan 1, 2012