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By Xiaoxu Sun, Jianchao Yao, Jiancheng He, Shijie Lu, Hongxi Zhou

"With the trend of increasingly more mineral resources turning low-grade and refractory, more and more new ore bodies being developed worldwide are more finely grained, which drives the rapidly development and application of techniques related to tower mills (vertical spiral stirred mills). However, the lacking in fundamentals of fine grinding, as well as standard procedures for equipment selection and scale up, seriously restraint high efficient application of tower mills. Taking grinding media motion characteristic and grinding intensity as a breakthrough point, this paper studies mechanisms behind how critical parameters affect grinding efficiency of tower mill, including ratio of screw pitch and diameter, agitator rotation speed, grinding media size. Several sets of orthogonal test are conducted on the quartz ore using the grinding system of KLM-3 tower mill. All the tests are under the same character of feeding mineral and undergo the consistent sampling for at least 60min grinding time. The input power is measured by a torque measurement system and the grinding products are analyzed by the laser particle size analyzer. The test results show the influence of parameters on grinding efficiency. Among the three important parameters, the effect of grinding media diameter is the biggest, followed by the agitator tip speed, and finally the ratio of screw pitch and diameter. For the different particle size of grinding products, the best combination of grinding parameters is different, with the mineral size becoming finer, the ratio of screw pitch and diameter become smaller, the diameter of grinding media become smaller, while the agitator tip speed does not change too much. The conclusions of the study help us to improve the grinding efficiency of the tower mill, to assist in the selection and optimization of working parameters, establish new scale up method on the basis of grinding model and eventually provide theoretical basis of rational selections of structural and media physical parameters within tower mill."

Jan 1, 2018

By Armin W. Stuedlein, Youssef Bougataya

Early stage design of driven piles primarily relies on static analysis based on one or a combination of total and effective stress approaches, the latter known as the method to estimate axial capacity. A database of 85 piles driven in the Puget Sound Lowland region and monitored at End of Driving (EOD) and Beginning of Restrike (BOR) was compiled along with capacities estimated using the CAPWAP procedure. Established soil profiles based on borings with standard penetration tests (SPT), cone penetration tests, and geologic maps were matched with their corresponding unit shaft resistance profiles from the CAPWAP procedure and resulted in more than 1,200 observations. In this study, eight new models were developed to predict the coefficients at EOD and BOR, based on the corresponding USCS categorization. Each coefficient model is formulated using a three-parameter exponential function, calibrated to capture the profile of coefficients with depth. These models could benefit the designer by providing them with a simple, empirical model that accounts for soil type and setup in a smooth, continuous function with depth. A parallel analysis was performed to assess the accuracy and variability of the formulated prediction models to facilitate implementation in load and resistance factor design (LRFD). INTRODUCTION The design of the axial capacity of driven piles during the planning stages of a project is typically based on a static analysis approach. The goals of this approach are to predict the components of capacity, consisting of the shaft and toe bearing resistances, and to assess project concept feasibility and preliminary lengths. In most cases, this analysis is based on empirically-developed methods, such as the total stress method, also known as the method (Tomlinson 1987) or the effective stress method known as the method (Esrig and Kirby 1979; Fellenius 1991). Many other methods, such as those based on in-situ test results exist and rely on correlations of blow counts from the standard penetration test (SPT), and cone tip and sleeve friction resistance from the cone penetration test (CPT), to shaft and toe pile resistances (Schmertmann 1978; Meyerhof 1976; Nottingham and Schmertmann 1975; Nordlund 1963; Eslami and Fellenius, 1997; De Ruiter and Beringen 1979). Although these methods were generally developed using data from specific geological regions, they are often recommended in national design manuals (e.g., FHWA, Hannigan et al. 2006).

Jan 1, 2018

By John Floyd, Maria Rocha, Benjamin Cebrian

Wall control blasting is needed in most metal mining operations in terms of increasing mineral reserves and assuring the safety of the operation. This type of blasting has the goal to achieve a clean, stable rock wall in the shortest distance from a well fragmented, easy to excavate, blasted rock mass. This can be done with a variety of blasting techniques, all of which decrease the explosive energy towards the final wall. Each technique needs to suit the geology: modified production blasting, buffer blasting, pre-split and line drilling of empty holes. Pre-split is the most expensive technique, and allows final steeper bench face angles while modified production blasting is the least expensive but needs wider berms.

Jan 1, 2018

By Polezhaev S. Yu, I. V. Ukraintsev, Boduen A. Ya, Saburbayeva L. Yu

"Comparison studies of different technologies are performed when selecting optimum option for gold ore and concentrate processing. Methods of ultrafine grinding, oxidizing roasting, bacterial leaching and pressure oxidation are used to extract gold from refractory ores and concentrates. Refractory gold flotation concentrate produced from pyrite-arsenopyrite ores of Bestobe deposit is a case study in this paper. The results of the experimental tests of the direct leaching of flotation concentrate and pre-oxidation products using different methods (oxidizing roasting cinder, pressure oxidation and bacterial leaching cakes) are the following: - cyanidation of original flotation concentrate provides recovery of Au at 46.6 %; - oxidizing roasting increases gold recovery from 46.6 % to 85 %; - BIOX increases gold recovery up to 86 %; - preliminary pressure oxidation of flotation concentrate ensures steadily high Au extraction in the follow-up cyanidation at 94.9-96.5 %. Pressure oxidation and bio-oxidation has changed dramatically the strategy of refractory gold ore processing. These solutions provided for development of ore deposits that considered earlier non-commercial. However, refractory ore processing has a complex character in terms of developing process flowsheet and requires large amount of studies to be performed for each new project. Gold extraction is the basic but not the only criteria to technology selection for gold ore and concentrate processing. Opex and capex, ore reserves, regional geography, developed infrastructure and skill personnel should be considered. Process studies and feasibility study of the developed technology shall be provided for each specific gold ore deposit. INTRODUCTION Due to changes in available feedstock and depletion of easy-to-process ores, refractory ores containing finely disseminated gold and silver in sulphides (primarily, in pyrites and arsenopyrites) are more and more involved into processing. Experts say that such ores amount above 40 % of the world’s gold reserves. Conventional technologies of gold extraction from refractory ores include flotation, roasting and cinder cyanidation (Fraser etal., 1991). However, today’s best available practice for refractory gold ore processing are bacterial (BIOX) and pressure (POX) oxidation."

Jan 1, 2018

By E. V. Koporulina, E. L. Chanturiya, M. V. Ryazantseva, E. S. Zhuravleva

"The morphology of the surface of sphalerite, galena and chalcopyrite and the adsorption of butyl xanthate under conditions of preliminary treatment of minerals by the products of water electrolysis were studied using atomic force microscopy (AFM) and Diffuse Reflection Infrared Fourier Transform Infrared Spectroscopy (FTIR). It was determined that practically all types of treatment by electrochemically modified water (a product of non-diaphragmatic treatment, anolyte and catholyte) lead to an increase of surface roughness of the studied minerals due to formation of small rounded shape particles. In contrast to that, after treatment of chalcopyrite by anolyte, its surface becomes smoother. Various effects of treatment by the water electrolysis products on the adsorption of chemical and physical forms of butyl xanthate on the studied sulfides were established. As a result, the efficiency of the complex of AFM and FTIR methods, as one of the ex-situ approaches for monitoring the surface state of sulfide minerals and direct investigation of BKx adsorption products was demonstrated.INTRODUCTION In mineral processing, copper-zinc sulfide ores are one of the most complex products in view of their mineral composition, fine dissemination, complex inter-growth and the proximity of the technological characteristics of copper, zinc and iron sulfides. For the most complete disintegration, fine grinding of ores to a size of 0.074-0.044 mm is necessary. Consequently, the main method for processing of such ores is flotation, which bases on the difference in physical and chemical properties of the mineral surfaces, in particular, degree of wettability. The separation of copper and zinc minerals and their separation from ferrous and other sulfides, sulfosalts and rock mineral is a very difficult task (Chanturiya, 2000). For the successful separation of copper and zinc minerals in the appropriate selective concentrates, it is necessary to find conditions for the most complete liberation of ore and rock-forming minerals and for increase the contrast in physical and chemical properties of their surfaces. Despite significant progress in the processing of copper-zinc sulfide ores, the problem of the selectivity of the separation of the main ore minerals has not yet been fully solved and requires innovative approaches (Chanturiya, 2015). To date, various methods of preliminary energy processing of complex ores are used: magnetic pulse treatment, impact by high-voltage nanosecond pulses, electrochemical effects (including products of water electrolysis (Chanturiya et al., 2014; Bunin et al., 2015; Chanturiya et al., 2014a; Chanturiya et al., 2016), processing with flotation reagents, etc. Electrochemical treatment of water in various modes allows to obtain products of electrolysis with different oxidation-reduction properties: acid anolyte with a high oxidation potential and dissolved oxygen content, an alkaline catholyte with high reducing properties and a product of non-diaphragmatic treatment with enhanced reduction properties."

Jan 1, 2018

By C. Dorfling, C. A. Snyders

South Africa has extensive mineral processing and extractive metallurgy capacity and infrastructure for metal production from natural resources. Decreasing ore grades, increasing labor costs, and more stringent legislation have made economic metal production from primary resources challenging. Opportunities exist for metal production from secondary resources such as mining wastes and end-of-life consumer goods. The objectives of this study were to evaluate the current status of metal production from secondary resources in South Africa and to identify potential opportunities for further development. Two main classes of secondary resources, namely mining waste and electronic waste, were considered. Primary metal producers are dominating metal production from mining wastes; several of the gold, platinum and chrome producers operate low risk and low cost tailings retreatment facilities that contribute significantly to their overall production. Further opportunities exist in, for example, the treatment of more than 450 estimated gold tailings dumps in Gauteng, as well as metal recovery from slags and furnace dust. The majority of companies involved with electronic waste recycling in South Africa focus on collecting and disassembling; only a few perform preliminary physical processing, with the recovered fractions then being sent overseas for metal recovery. Projections are that the rate of waste generation will increase significantly and that treatment will become critical to comply with more stringent environmental legislation. Projects related to process development, techno-economic evaluations and environmental impact studies for metal recovery from batteries, printed circuit boards, and fluorescent lamps are underway. South Africa is ideally positioned to further explore opportunities for synergistic relations between metal recyclers and primary metal producers. Processing of electronic waste for production of technology metals, for which limited natural resources exist in South Africa, would be a key enabler for local manufacturing industries and expansion of the value chain.

Jan 1, 2018

By S. M. Bradshaw, V. Rocher, L Kabondo, B. Combrink, C. A. Snyders

Media losses are a significant contributor to the operational cost in a dense media separation (DMS) circuit. Of these losses, up to 80 wt% can occur on the drain and rinse vibrating screens. Although these screens are an integral part of any DMS circuit, surprisingly little work can be found in open literature regarding the effect of aperture configuration on the drain rates (draining water and medium). To establish the effect of slot aperture size, experiments were conducted on a 0.6 x 1.2 m vibrating screen with polyurethane (PU) panels at slurry densities between 1.6 – 2.8 kg/L, and volumetric flow rates of 19 – 25 m3/h for both ferrosilicon and magnetite. Results showed that an increase in the volumetric flow rate led to an increase in drainage rate, moisture content and medium carryover. Once an optimum volumetric flow rate was exceeded, a further increase in flow rate resulted in a decrease in drainage rate with a sharp increase in moisture and medium bypass to the oversize stream. An increase in ferrosilicon slurry density led to a decrease in drainage rate with an increase in moisture and medium bypass with each of these rates increasing as the slurry density increased. For magnetite, a gradual decrease in drainage rate was observed with increase in slurry density and volumetric flowrate beyond the screen optimum point. It was found that an increase in aperture size from 0.63 x 8.8 mm to 0.8 x 8.8 mm to 1.0 x 13 mm resulted in an increase in ferrosilicon drainage rate of between 1.3 - 1.8 m3/m2/h depending on the flow rate and slurry density with a reduction in moisture and medium carryover of between 1.0 – 1.2 % and 14.1 – 20.2 kg/t/m respectively. For magnetite, the drainage rate increased between 1.0 - 1.4 m3/m2/h as the slot width increased from 0.63 x 8.8 mm to 0.8 x 8.8 mm while an increase in slot length from 0.63 x 8.8 to 0.63 x 12 mm only resulted in an increase in drainage rate of 0.1 - 0.5 m3/m2/h.

Jan 1, 2018

By Xingshi Yang, Ghislain Bournival, Seher Ata

"Particle-laden interfaces are a fundamental research topic in froth flotation since the process involves particle-coated bubbles in both the pulp and the froth phase. In most experimental studies the characteristics of the particle layer in multi-bubble systems are poorly defined. An experimental setup has been developed based on a Langmuir-Blodgett (L-B) trough. The modified trough allowed introducing an air bubble beneath the particle monolayer formed at the air-water interface which made the study of the interaction between the bubble and the monolayer under various pH values possible. The monolayer characteristics of the particles were also studied and compared in terms of surface pressure (?-A) isotherms and packing factor. On compression, the particles formed branched structure at high pH whereas a uniform monolayer was formed at lower pH. Observations related to the behavior of particles during compression and expansion cycles, and the coalescence of a bare bubble with the flat particle laden interface were provided and the implication of the results for flotation process was discussed.INTRODUCTIONFroth flotation is known for its versatility and ability to concentrate low-grade, complex ores. It is considered a physico-chemical process in which particles attach to air bubbles, depending on their hydrophobicity as well as other factors, and are carried to the surface to form a froth layer. Reagents are used to stabilize bubbles and the froth layer (Pugh, 1996). However, particles, which are carried by the bubbles or entrained, significantly contribute to the stability of the froth phase (Ata et al., 2003; Zanin et al., 2009; Bournival et al., 2015a). Their relevance in mineral processing has led to a number of fundamental studies on the effect of particles and their properties on the process of froth flotation.Flotation systems are particularly difficult to characterize due to the broad range of properties of particles (e.g. size, liberation, hydrophobicity, etc.) and inconsistent operational conditions (e.g. changes in water quality, reagent addition, etc.). Several studies have made the use of well characterized particles in laboratory conditions. Such studies allowed the finding of an optimal contact angle for the stabilization of the froth phase (Johansson and Pugh, 1992; Ata et al., 2002). Froths have a large number of bubbles so that individual interactions are not observed. The study of two bubbles allows to determine the stability of the bubbles, with particles, and to some extend the stability of the bubble-particle aggregate (Gourram-Badri et al., 1997; Bournival et al., 2015b). The removing of particles between two bubbles may also be studied from a Scheludko cell (Johansson and Pugh, 1992) or by observing a bubble with a flat interface (Sethumadhavan et al., 2002). However, these systems provide limited information on the arrangement of the particles."

Jan 1, 2018

By Morgan M. Sears, Gamal Rashed, Jim Winfield, Brent Slaker

"Over the past decade, ground falls have resulted in five fatalities, representing over 40% of all fatalities occurring in underground stone mines in the United States. In conjunction with recent high-profile pillar collapses, the need for further ground control research in the nation’s stone mines is evident. Ground conditions are growing more difficult. Therefore, this research is focused on deep cover, steeply dipping, and multi-level underground nonmetal mines. The objective of this paper is to introduce a geomechanical study of pillar development in a steeply dipping limestone deposit. To accomplish this, a numerical model was developed using input from modified laboratory test data and in situ stress measurements provided by the mine to simulate the development of a pillar under these conditions. The model was then verified against field observations and stress mapping. The calibrated model was then used to calculate the estimated stresses in the pillar and immediate roof as development progresses around an instrumented pillar.INTRODUCTIONGround falls represent a significant hazard in the nation’s underground stone mines. In response to recent large-scale pillar collapses, as well as stakeholder interactions, researchers from the National Institute for Occupational Safety and Health (NIOSH) are currently conducting detailed investigations into the complex loading conditions at mines operating in challenging operational environments. These include deep-cover, steeply dipping, and multi-level mines where there is the potential for an increased risk of ground failure. The Pleasant Gap Mine, shown in Figure 1, operates in the Valentine Formation, which is typically light grey, extremely fine-grained limestone, and approximately 21.3 m (70 ft.) thick. The Centre Hall Formation makes up the immediate and main roof members and is approximately 9.1 m (30 ft.) thick, consisting of medium-dark-gray limestone (Murphy et al., 2018). Situated in a syncline, the top of the Valentine Formation dips at approximately 19° with a strike of approximately N54E in the area of interest (see Figure 2)."

Jan 1, 2018

By A. Pirson, J. Souza, A. Araujo, M. Barbosa, F. Guimarães, J. Lima

"Although a large number of processes have been developed and applied to the separation of barite from other minerals, there is a lack of information in the literature about the separation of barite from iron ores. Nowadays, there are millions of tonnes of iron ore disposed as a waste or tailings given its high content of sulphur in the form of barite. In order to effectively separate barite from iron ore and ensure that mining business is truly creating economic and sustainable values, this paper provides a greater understanding of barite properties, the origin and occurrence of this barium-bearing mineral, and the employed beneficiation processes. A test work is conducted in a barite bearing iron ore from a deposit located in the Republika Srpska (Bosnia and Herzegovina) in order to separate the barite and check if a marketable by-product can be produced by drawing upon rich barite tailings. INTRODUCTION The exploration of iron ore containing barite results in a large amount of unrecovered material. The main difficulty in processing and using barite bearing iron ores is given by their high content of sulphur, silica and barium, which are unwanted chemical compounds in the subsequent processes in iron industry. As a result, millions of tonnes of iron ore are discarded every year into tailings or as a waste, which results in production losses, higher operation costs and environmental impacts (Praes et al. 2013). Therefore, the separation of barite from iron ores not only means reducing the environmental impact, but also an opportunity to generate income and beneficiate society. The beneficiation of barite bearing iron ores is a subject which requires a deeper investigation to solve the challenges faced by the iron industry. There are only a few studies that describe flowsheets proposed for the production of barite concentrate of iron ores. The most likely reason for this gap is that barite is frequently exploited commercially as a primary product rather than a by-product. In order to effectively separate barite from iron ore and ensure that mining business is truly creating economic and sustainable values, this paper provides a greater understanding of barite properties, the origin and occurrence of this barium-bearing mineral, and the employed beneficiation processes. A test work is conducted in a barite bearing iron ore from a deposit located in the Republika Srpska (Bosnia and Herzegovina) in order to separate the barite and verify if a marketable by-product can be produced by drawing upon rich barite tailings."

Jan 1, 2018

By S. L. Gubin, T. V. Ignatova, A. V. Levshin, D. O. Sharkovsky

"Flotation process applied for concentration of unoxidized ferruginous quartzites by PJSC Mikhailovsky GOK (MGOK) is based on wet magnetic separation of strong magnetic minerals. However quality of the resulting concentrate (Fe65-66%) is insufficient for production of metallics. Quality upgrade of magnetite concentrate via flotation has been implemented by MGOK to produce premium quality magnetite concentrate.Flotation is a challenging process due to sensitivity to varied amounts of reagents, fine and coarse mineral ratio, particle contact (retention) time and temperature of feed. Tomah’s PA-14 reagent (USA) has proven efficient for application in flotation of MGOK’s magnetite concentrate.Objective of this work is to select and prove applicability of selective agents for flotation upgrade of magnetite iron ore concentrate.Series of flotation tests has been carried out with application of new highly selective collecting agents produced by Akzo Nobel (Sweden), Clariant (Germany) as well as Akzo Nobel’s and Tomah’s cationic collector mix to improve performance efficiency of flotation process. Tomah’s flotation agents and Akzo Nobel’s Lilaflotproved to be the most effective for purposes of concentrate quality upgrade to Fe69.0% via flotation.Testing Method: Following scientific research methods were applied for testwork: system analysis, mathematical statistics, observation, comparison, trial (experiment).To determine key process factors a series of pilot tests was carried out. Most of the testwork was performed by PJSC Mikhailovsky GOK’s Central Process Laboratory.Work Results:-optimized flotation performance modes were defined to ensure production of three types of low-silica concentrate, i.e. containing SiO25%, SiO24% and below SiO23% by weight. Most efficient selective agents applicable for flotation have been defined. Mixture of higher aliphatic amines has proven to intensify selective flotation of quartz. It enables higher yield of chamber product maintaining desired quality of concentrate.Achieved process operation and performance factors have been revaluated.Value for Advancement and Expansion of Mineral Processing:Flotation of concentrate has enabled expansion of PJSC Mikhailovsky GOK’s production capacity, improved production quality, helped to maintain sustainability and competitive advantage of the company."

Jan 1, 2018

By Bob Coutts, Matt Martin, Dan Lynch, Dan Payne

"The Broadmeadow punch longwall coal mine in Central Queensland Australia has experienced significant highwall movement associated with the effect of longwall subsidence when the longwalls approach their final position close to the open-cut highwall. In response to this movement, Broadmeadow employed two types of broadscale highwall monitoring (radar and laser scanners) to provide full coverage measurement throughout three consecutive longwalls approaching the highwall. This was to attain a better understanding of the mechanism causing the movement and potentially enable prediction of instability. Results from the monitoring found the highwall is displaced to magnitudes unlike those typically measured in open-cut mining and in direct contrast with typical longwall subsidence behaviour.This paper discusses the ground movements measured, monitoring methods used, safety measures established, as well as theorising the failure mechanism. Recommendations are made for mine and pit designs for future punch longwall layouts. The paper shows how the movements measured are more aligned to some measurements made during stream valley closure studies previously presented at the ICGCM and challenge the mechanisms suggested by previous literature.BACKGROUNDThe mining of longwalls under or adjacent to large voids (e.g., stream valleys, escarpments, or cliffs) is commonly associated with heavily vegetated or steep surface areas. In areas of extreme topographic variance, access to traditional survey pegs and stations or even new radar or laser technologies is limited. In addition, seldom have the longwall layouts aligned themselves parallel or perpendicular to the surface feature, making interpretation of any available surface movement data more complicated.The punch longwall layout (Figure 1) is also quite uncommon (only undertaken at a small number of longwall mines in Australia) but creates the perfect configuration to enable a somewhat controlled study of the effect of longwall subsidence on a steeply dipping surface feature (an un-vegetated, evenly excavated open-cut highwall). The relatively recently developed radar and laser scanning technology has also enabled near continuous, real-time, sub-millimetre monitoring of a full 500m wide x 100m high highwall. Because the punch longwall enables access and a clear view, the technology could be easily deployed as compared to the highly vegetated and variable topography of stream valleys."

Jan 1, 2018

By Andrew Malinak, William Perkins

Seattle’s Elliott Bay Seawall protects the 1½ miles of downtown waterfront between South Washington and Broad streets. The seawall supports the urban waterfront and infrastructure, including the Alaskan Way Viaduct and Alaskan Way, access to historic waterfront piers, and numerous essential buried utilities. Most of the original seawall was constructed between 1916 and 1936 over soft/loose non-engineered fill, estuary, and beach deposits. The majority of the original seawall was a pile-supported timber relieving platform that extended up to 60 feet behind the face of the wall (Figure 1). With maximum spacing between the timber piles of 3 to 5 feet, a virtual forest of timber piles were driven for the original wall.

Jan 1, 2018

By S. Mitra1

"This study aims to investigate coarse particle detachment mechanisms (particle diameter > 150 ?m) utilising both experimental and numerical technique. Two mechanisms were studied – (i) interactions of bubbleparticle (BP) aggregate with vortices and (ii) coalescence of bubble-particle aggregates. On the first mechanism, interaction behaviour of coherent vortex structures with a BP aggregate (bubble diameter db = 3 mm, particle diameter dp = 0.3 mm) was studied using a CFD model in the Reynolds number range of 100 to 1000. Effect of surface hydrophobicity on the BP stability was examined using a range of contact angle boundary conditions. To address the second mechanism, interactions of bubble-particle aggregate (db ~ 4 mm, dp ~ 0.4 mm) with both free gas-liquid interface and individual bubbles were investigated using high speed imaging. Both rebound and coalescence outcomes were observed to be responsible for BP instability leading to particle detachment.INTRODUCTIONIt is widely known that flotation process performs excellent mineral recovery for base metal ore particles that are typically in the range of ~ 20 to 150 µm in diameter (Jameson, 2010). More specifically, higher recoveries are usually reported for particles in the size range of ~20 to 70 µm while outside this spectrum, generally the recovery diminishes significantly. It would be highly desirable to improve the recovery of particles at the coarse end of the flotation size range spectrum which has significant economic benefit (Jameson, 2010). However, it is essential that insights to particle detachment phenomenon, the primary impediment in coarse particle flotation caused by the underlying hydrodynamic factors are first obtained at a greater depth.In an ideal quiescent liquid medium, due to inertia, coarse particles deviate substantially from the fluid streamlines and collision efficiency with bubbles decreases which can only be augmented by increasing turbulence level in the medium sufficiently to make random physical contacts with bubbles. Nonetheless, even if successful contacts are made, it is difficult for these large particles to remain attached to bubbles in a turbulent shear flow environment. There are two major mechanisms postulated for particle detachment – interaction of turbulent flow structures (eddies) with BP aggregate and coalescence among surrounding aggregates. Earlier work of Schulze (1982) theorised a vortex acceleration component to characterise turbulence effect on BP aggregate instability in flotation machines. Wang et al. (2015) investigated bubble detachment behaviour from a stationary particle in a nearly homogeneous and isotropic flow field. Using PIV (particle image velocimetry), it was shown that the local maximum energy dissipation rate for the case of bubble detachment was significantly higher than the no detachment case, and was also higher than the critical value for bubble detachment calculated using Schulze’ theory (Schulze, 1982). Later, Wang et al. (2017) also visualised the BP aggregate instability in a cavity flow leading to particle detachment which was attributed to bubble coalescence, bubble surface oscillation and particle deceleration phenomena."

Jan 1, 2018

By M. Surracco, M. C. Tilocca

"Mineral comminution is often a costly process which also requires high level of energy. In the course of the studies carried out by the researchers of the Department of Civil-Environmental Engineering and Architecture at the University of Cagliari, aiming at the optimization of the reduction processes, it has been experimented, among of others, the effects of high-speed water jets on minerals grinding. As far as coal is concerned, some of the solutions initially adopted are presented in this paper, which essentially relied on the water jet power only, with secondary use of mechanical actions, to reach the most modern solutions that envisage the use of mechanical energy, normally used in traditional grinding machines, in synergy with hydraulic energy transferred by water jet.INTRODUCTION Mineral comminution can be rather expensive and demand a high-energy consumption, especially for fine sizes (Austin, 1979). Further interesting perspectives in this area may be offered by comminution means aided by high pressure water jets (Ciccu 2007), whose crushing potential is currently used for several operations such as cutting different materials, rock digging and industrial cleaning. The crushing action of water jets may induce a traction stress in materials where substances of a mineral nature, especially if characterised by permeable porosity, oppose a minor resistance (Griffith, 1920). The first solutions to this purpose essentially relied on the sole energy of water jets, with a secondary use of mechanical actions (Ciccu, 1993). Results were encouraging, despite the high values of specific energy for the low capacity of treatment. However, due to the difficulty in making the techniques mainly based on hydraulic energy practically applicable to solids comminution a solution was experimented, with some interesting results, consisting in the combination of mechanical energy, normally used in traditional grinding devices, with hydraulic energy transferred through water jets, in a synergic relationship (Ciccu, 1998; Tilocca, 2016)."

Jan 1, 2018

By M. Yekich, W. R. Reed, G. Ross, M. Shahan

"Canopy air curtains (CAC) on roof bolting machines have been proven, through laboratory and field investigations, to protect miners from respirable dust, preventing dust overexposures. Another desired application is to develop a CAC that is mounted in the compartment of a shuttle car to protect the operator from dust. The challenges faced with this design include mine ventilation rates in tandem with the shuttle car tram speeds, causing cab airspeeds that may exceed 600 fpm, as found in this study of a central Appalachian underground coal mine. Prior research and laboratory testing indicate that successfully protecting a miner in high air velocities is difficult to achieve because the clean air from the CAC is unable to penetrate through the high velocity mine air and make it to the breathing zone of the operator. During this investigation by researchers from the National Institute for Occupational Safety and Health (NIOSH), dust concentrations of the shuttle car operator were measured. Also, air velocities experienced by the operator were measured using a recording vane anemometer. Results from the survey indicate that the highest exposure to respirable dust (2.22 mg/m3) occurred when the shuttle car was loading at the continuous miner, where there was an average airspeed of 157 fpm. While tramming, the operator was exposed to 0.77 mg/m3 of respirable dust with an average airspeed of 203 fpm. This study indicates that a CAC system can be designed to greatly reduce an operator’s exposure to respirable dust by providing clean air to the operator, since the majority of the operator’s dust exposure occurs in air velocities less than 200 fpm. INTRODUCTION NIOSH has issued a contract (#200-2015-63485) with Marshall University and J.H. Fletcher & Co. (Salem et al., 2016) to develop a canopy air curtain (CAC) for coal mine shuttle cars. The proposed design maintains a similar design to the roof bolter CAC by providing filtered air via a blower over the operator. The plenum, which will provide the uniform airflow over the operator, is anticipated to be built into the shuttle car canopy. One of the main interferences with a CAC is ventilation airflow perpendicular to the plenum airflow [Engel et al. 1987]. This ventilation airflow, if the velocity is significantly high, can shear the downward flow from the plenum. The shear caused by the ventilating airflow can reduce the effectiveness of the CAC by either disrupting the downward flow or allowing contaminated mine air into the CAC zone of protection."

Jan 1, 2018

By G. Segaetsho

"Conventional blasting rules of thumb used to develop blast designs are based on parametric ratios, with insufficient consideration of the rock mass factors that influence the achievability of final wall designs. At a hard-rock mine in Botswana, catchment berm designs were frequently unachievable, which exposed the mining operation to safety hazards such as local wallrock failure from damaged crests, frozen toes, and rolling rockfalls from higher mining levels. Increased standoff distances from the highwall reduced the manoeuvring area on the pit floor and the extraction factor that was safely achievable. Application of rock mass classification and the Blastability Index (BI) as a means to improve wall control was investigated. Zones were defined according to rock types forming the western highwall rock mass, and distinguishing rock mass classification factors were used to establish the suitable wall control designs. The approach combined rock mass classification methodologies such as the Geological Strength Index and the Rock Mass Rating, and related them to the BI and discontinuities of the rock mass to produce a design input tool that can be used to develop objective wall control designs. The designs driven by the tool inherently take into account the rock mass characteristic factors at the centre of the rock mass classification methods mentioned above, and significantly reduce the dependence on rules of thumb. It was found that this approach produces designs with explosive energy measures that are consistent with the required rock-breaking effort and the behaviour of discontinuities, while preserving perimeter walls.IntroductionBlasting is the first step in the comminution process. Various coordinated inputs contribute to its success, and in turn to the efficient execution of processes that lie downstream from the blasting step. Primary to meeting production and operational objectives of a mine, as well as the protection of human life and the mineral resource, is the achievement of highwall design specifications and competence. To this end, this study investigated the use of existing tools and knowledge for the achievement of highwall control goals at a hard-rock mine in Botswana."

Jan 1, 2018

By Kym Runge, Wei Huang, Fengnian Shi, Christian Antonio

"This paper presents an emerging High Voltage Pulse (HVP) technology for ore pre-treatment. Unlike previous studies where HVP was utilized as a crusher to pulverize ore particles to micron size ranges for downstream processing, the researchers at the Julius Kruttschnitt Mineral Research Centre (JKMRC) use HVP to enhance ore processability. Application of relatively low levels of HVP energy to selectively break mineralized particles from barren rocks, followed by size-based screening separation enables the feed ore to be split into high grade and low grade products. During HVP treatment, cracks/micro-cracks are generated which results in pre-weakening of the treated ore particles, which ultimately results in energy savings in the downstream comminution processes. HVP treatment followed by conventional grinding also results in improved liberation of the valuable minerals in comparison to that achieved with traditional conventional comminution, subsequently improving downstream separation efficiencies. The three major improvements in ore processability through HVP pre-treatment have the potential to facilitate rejection of low grade ore prior to processing, increase production rates, reduce the energy required for comminution and improve flotation separation recoveries. This paper summarizes the major research outcomes of HVP pre-treatment demonstrated using ores from various mining operations conducted by the JKMRC. It also discusses the barriers that must be overcome before it can be adopted by industry with confidence in a continuous high tonnage rate application.INTRODUCTIONThe challenges of declining ore grades and increased plant throughput rates, resulting in higher energy consumption and operational costs, require the mining industry to adopt new technologies to make future ore treatment economically viable. Over the past 50 years, many researchers have engaged in investigating novel comminution techniques. Since Yutkin (1955) first demonstrated the potential to generate shock waves with pressures exceeding 103 MPa via electrical breakdown of water, several applications of electrohydraulic crushing by shock waves have been reported (Curley-Macauly, 1968). Interest in this technique was bolstered when Andres (1977) demonstrated that electrodynamic fragmentation results in superior liberation of mineral grains as compared with conventional grinding techniques. Despite mounting laboratory-scale evidence of the efficacy of electrodynamic fragmentation for mineral liberation, development of the technology for full-scale operation has stalled, primarily because the energy required to achieve desirable mineral liberation is approximately two to three times that of mechanical comminution, amounting to approximately 100 kWh/t for typical mineral ores (Andres et al., 2002)."

Jan 1, 2018

By K. Ihara, R. Akiyoshi, Y. Takaki, S. Kang, H. Shishido

"Tensile tests and scanning electron microscopy-electron backscattered diffraction (SEM-EBSD) analysis were performed in an Al-Mg-Si alloy to clarify the effect of annealing and cold-rolling reduction on the texture formation. The hot-rolled specimens were cold-rolled with the reduction of 58-75%(CR1), followed by annealing at 773 K for 5 min(IA). The secondary cold-rolling(CR2)for the IA specimens with the reduction of 33–66%, followed by the solution heat treatment(ST), were performed. Focusing on the CR1 and CR2 specimens, the average r-values increased with higher primary and lower secondary cold-rolling reduction, respectively. This was considered to be due to the increase of r-values measured in the direction of 45 degree with respect to rolling direction, caused by the formation of the ß-fiber components (Brass {011}<211>, Copper {112}<111> and S {123}<634>) with high density. Based on the texture analysis of annealed specimens it was suggested that the high density of the ß-fiber components after IA and the small amount of stored strain energy of CR2 introduced by the lower cold-rolling reduction remained the ?-fiber components even after solution treatment.INTRODUCTION Al-Mg-Si alloys have been applied to automobile body applications, due to their excellent paint-bake hardening (age-hardening) and corrosion resistance compared to other aluminum alloy. On the other hand, the mechanical properties and deep drawability of Al-Mg-Si alloys are inferior to those of steels. Thus, it is important to improve the mechanical properties and deep drawability in order to expand the application components. One of the best methods to improve the deep drawability is to increase the Lankford coefficient (r-value). Previous studies reported that the increase of the average r-value ( ) improves the deep drawability. The relationship between the r-value and texture of the alloy is also well known. Inoue et al. reported that the ß-fiber components, such as Brass ({011}<211>), Copper ({112}<111>) and S ({123}<634>), increase the r-value measured in the direction of 45o with respect to the rolling direction. r"

Jan 1, 2018

"Longwall shearers are widely employed in underground coal mines. The reliability of such machine has significant importance for successful mining operations. This paper aims at studying reliability of a longwall shearer using failure data recorded for a year. Data was pre-processed, sorted and selected for analysis. Selected data is then examined using statistical models. Distribution fitting of time-between-failure (TBF) and time-to-repair (TTR) are accomplished using three different models. Goodness-of-fit criteria is used to ascertain the best fitting model. Reliability in terms of mean-time-between-failure (MTBF), and mean-time-to-repair (MTTR) are calculated using the model which best represents the failure data. Exponential distribution best represents the time between failure and lognormal distribution the time to repair data. A well-known risk management technique Failure Mode Effect and Criticality Analysis is used to evaluate the critical breakdowns. Critical system/parts, experiencing regular failures is delineated based on this analysis. INTRODUCTION Mining is a capital intensive process, and huge monetary investment is required to develop and operate a mining project. Heavy and expensive equipment’s are employed in development and operation of these projects. In order to ensure timely completion of set milestones, it is mandatory that equipment’s perform their required task productively. Delays are not unusual owing to breakdown of these equipment’s. Breakdown or failure experienced by any of the equipment pose heavy financial burden. Moreover, frequent times, companies have to employ and dedicate additional resources to make up for such delays. Delays in project is not only detrimental to company’s image in market, but it also interrupts customer commitments. Mines having history of not fulfilling their promise usually get lower commodity price. Penalties are also imposed on the companies defaulting its obligations. Especially, in today’s world where competition among the companies are growing, success means keeping up the commitments in a timely manner. Heavy machinery and equipment are instrumental in success of any project. These machinery and equipment’s have to reliable in a sense that they can perform the set task in given time period. Reliability of these equipment plays a pivotal role in success of any project. The reliability analysis of mining equipment has long history. Many researchers have applied different statistical models for analyzing the reliability of mining machines (Samanta, Sarkar [1]. Kumar and Klefsjö [2] demonstrated the use of the power law process model for reliability assessments of repairable mining machines. Barabady and Kumar [3] performed the reliability analysis from failure data of the crushing plants."

Jan 1, 2018