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By R. G. Eggert

"A critical element, as the term has come to be used, provides essential properties to a modern engineered material and is subject to supply risk. The rare-earth elements became perhaps the most prominent of the critical elements in recent years because of their important uses in permanent magnets, advanced lighting, and military materials; the geographic concentration of production in China; and the dramatic run-up in prices in 2010-2011 followed by price collapse between 2011 and 2016. Yet criticality extends beyond the rare earths. What is critical depends on your perspective – who and where you are, and when you ask. This paper reviews the many perspectives on, or faces of, critical elements. It compares and contrasts perspectives of industry (General Electric), national or regional manufacturing sectors (Japan, European Union), emerging energy technologies (as seen by U.S. Department of Energy and, separately, Joint Research Centre of the European Commission) and the world as a whole (as evaluated by academics). This comparison reveals a diversity of not only perspectives but also methodologies and time frames of concern.INTRODUCTIONRare-earth elements appeared prominently in the news in 2010 and 2011 because of the dramatic increase in their prices; their important uses in permanent magnets, advanced lighting, and military materials combined with the geographic concentration of production in China, which reduced export quotas significantly. Rare earths became the most prominent of what have become known as critical elements or materials – that is, those that provide essential properties to modern engineered materials and yet are subject to supply risks.Yet criticality, the state of being both essential and subject to supply risks, extends beyond rare earths. What is critical depends on your perspective. This paper begins by reviewing a little history and presenting a general conceptual framework from which to think about critical materials. It then reviews the many perspectives on, or faces of, critical elements – corporate, national, and global, as well several that focus on emerging energy technologies. The paper concludes with thoughts on what to do to mitigate the potentially negative effects of the supply risks associated with criticality."

Jan 1, 2016

By L. D. Roper

"This paper introduces novel comminution flowsheet concepts involving a novel apparatus, eccentric-high-pressure-centrifugal-comminution (eHPCC), and forthcoming advantages to the international mineral processing community. eHPCC is one-machine synergising high-pressure-rolling surfaces, high-intensity-attrition and centrifugal classification. eHPCC has demonstrated: an absorbed power- intensity of 4 MW/m3; receipt of lump feed whilst producing 80% of product particles less than (p80) 120 µm (choke-fed, dry, open circuit without grinding media; an inert comminution environment); tramp metal tolerance, and a minimum embodied-free-energy saving of 15% as compared against conventional comminution (this comparison withstanding 133-times difference in throughput). Furthermore, this paper introduces: process design and operating characteristics of eHPCC (wet, dry, with and without grinding media); reline considerations (vertical-lift without confined-space). The international mineral processing community is invited to consider eHPCC as an alternative to conventional comminution circuits and/ or complimentary so as to enhance existing process flow sheets.INTRODUCTIONEccentric-high-pressure-centrifugal-comminution (eHPCC) was conceived in 2013 (Patents pending) and has the potential to eliminate the in-efficiencies and complexity of conventional tumbling mill circuits. During the development and testing phase eHPCC demonstrated improved energy efficiency and sustainability offsets.eHPCC will compliment any upstream feed source, be it run-of-mine (ROM), primary crushed rock, or any other conventional comminution stream such as tumbling mill oversize. Another novelemerging technology, Conjugate Anvil-Hammer Mill (CAHM) (Nordell and Potapov, 2011), receiving ROM, will be a complimentary open-circuit feed to eHPCC for very high throughput flow-sheets.eHPCC may compliment downstream process requirements through selective mineral liberation. Selective mineral liberation is entirely feasible as the ore is comminuted upon itself (autogenously) in the high pressure zone caused by the synchronous rotating components."

Jan 1, 2016

By Rob Farnfield, Ben Williams, Ashley Haslett, Diane Cartledge

Major accidents that occur within our industry are often tragic and expensive, damaging reputation and threaten the livelihood of the business. There isn’t anything in them that can be seen as positive for those that experience them. They undertake what are usually very painful, detailed and time consuming investigations to discover how the incident occurred and what needs to be done in the future to prevent similar incidents occurring. Many admirably choose to share the lessons learnt through industry organizations such as SAFEX International so that we can all have the opportunity of preventing similar incidents from occurring within our own organizations.

Jan 1, 2016

By S. Masambi, S. M. Bradshaw, C. Dorfling

The presence of iron in base metal leach solutions complicates nickel and copper recovery processes. Leach solutions are commonly purified by precipitating iron as hematite, jarosite or goethite. Fast oxidation of ferrous to ferric is an important step to remove iron by precipitation at low pH values. This study reviews the ferrous oxidation mechanism and reaction rates in chloride media using molecular oxygen. This work contributes to the development of a better understanding of iron precipitation processing steps, which continues to be an important matter in hydrometallurgy. The specific objectives were to investigate (1) the effect of key process variables (acid concentration, copper concentration, and temperature) on the rate and extent of ferrous oxidation by dissolved oxygen and (2) the oxidation mechanism by varying chloride and hydrogen ion concentrations separately. Batch oxidation tests were performed using synthetic chloride solutions containing 45 g/L Fe and 3 g/L Ni at 50 and 80°C, dissolved Cu concentrations (0.3 to 3 g/L) and HCl concentrations (2 to 4.6 M). Regression analysis indicated that the significance of the effect of different variables on the extent of oxidation achieved after five hours decreased in the following order: HCl concentration > Cu concentration > temperature. Increasing the HCl concentration from 4 M to 4.6 M caused the degree of oxidation achieved after two hours to increase from 58.3% to 98.1%. The catalytic effect of dissolved copper on ferrous oxidation was more significant at low acid concentrations. Experimental data suggest that rapid oxidation of ferrous is possible at high HCl concentrations for two main reasons. First, the formation of ferrous chloride complexes allows ferrous oxidation to proceed without the formation of superoxide as an intermediate product (the rate limiting step in dilute acid solutions). Second, the formation of ferric chloride complexes stabilises the oxidation product.

Jan 1, 2016

By Chris Ashton, Andreas Rädle, Taner Aydogmus

"The Contract C310 is part of the current biggest infrastructure project of Europe “Crossrail” which is a major new cross-London rail link project and comprises the construction of the North Woolwich Portal, Plumstead Portal and the twin tube Thames Tunnels with a length of approximately 2.6km. Two Mix-Shield TBMs (Diameter 7.12m) were driving through differing challenging ground conditions (Thanet Sand, Gravels, Flint and Chalk) below the ground water table. The two tunnels were underpassing several listed buildings, sensitive structures, operational railway tracks with low overburden and close to existing subway tunnels in an urban environment. Several additional measures as compensation grouting, micro piles and an intensive monitoring has been carried out to ensure a safe tunnelling process. PROJECT OVERVIEW CROSSRAIL Project Crossrail Crossrail is currently the biggest infrastructure project in Europe which has been developed to serve London and the southeast of England. The project includes the construction of twin-bore tunnels on a west-east alignment under central London and the upgrading of existing National Rail lines to the east and west of central London. The new rail track, as shown in Figure 1, starting in Shenfield/ Abbey Wood in the east of London and ending in Reading / Heathrow Airport in the west of London, includes the construction of nine central area stations, providing interchange with London Underground, National Rail and London Bus services, and the upgrading or renewal of existing stations outside central London.Altogether there will be 118km of new rail tracks, including 42km of tunnels and 40 train stations. After completion in 2018, Crossrail expects 200 million passengers per year (Tauriainen, Rädle, Ingram 2013)."

Jan 1, 2016

By E. L. Chanturiya

The research and characterisation for compositional, physicochemical, structural, electrical and flotation properties of various pyrite samples for a copper-zinc sulfide ore was carried out. Various methods were used during the research, such as optical microscopy, X-ray diffraction, electron probe micro-analysis (EPMA), phase emission analysis, routine chemical analysis, auger electron spectroscopy (AES), scanning electron microscopy (SEM), back-scattered electron images (BSE), potentiometry, and instrumental neutron-activation analysis, flotation. Analysis of obtained results established the interrelation between impurity structures and concentration of electric charge carriers in minerals, Butyl xanthate sorption and flotation yield of pyrite. The research concluded that pyrite samples differ by morphology, micro defects of structure, concentration of donor and acceptor impurities (Co, As, Sb, etc.) and conductivity parameters (thermo-electrical force, specific resistance and concentration of charge carriers The peculiarity of pentagon-dodecahedral pyrite is the high concentration of electric charge carriers (electrons) and the more negative surface potential (by 25–75 mV) in comparison to cubic pyrite. The surface of cubic varieties is more active, therefore it is oxidized in alkaline lime medium much faster, than the surface of pentagon-dodecahedral varieties. This phenomenon is caused by high reaction ability, irregular jointing and defects of cubic pyrite. This promotes the increase of calcium ion sorption on its surface and the decrease of Butyl xanthate sorption. According to this, an increase in alkalinity (lime medium) from a pH of 10.0–11.5 leads to an increase of gold content reporting to the tail of bulk flotation. Gold content is increased from 0.58 g/t (?? 9.5) to 1.9 g/t (?? 11.6), which represents an increase in gold recovery of 24.68 to 79%, respectively.

Jan 1, 2016

By L. Bam, R. Machaka, S. Chikosha, N. S. Muchavi

"Parts manufactured through power metallurgy (PM) typically contain pores that can be detrimental to the final mechanical properties. This paper explores the merits of 3D X-ray computed tomography over traditional microscopy for the characterization of the evolution of porosity in metal injection moulding (MIM) and direct powder rolling (DPR) products. 17-4 PH stainless steel (as-moulded, as-debound and sintered) dog-bone samples produced via MIM and Ti-HDH strips (as-rolled and sintered) produced via DPR and were analysed for porosity. 3D microfocus X-ray tomography (XCT) analysis on specimens from both processes revealed spatial variations in densities and the existence of characteristic moulding and roll compaction defects in agreement with traditional microscopic microstructural analysis. It was concluded that micro-focus XCT scanning can be used to study MIM and DPR parts for the characterization of the amount, position and distribution of porosity and other defects. However, the majority of the sub-micron sized pores could not be clearly resolved even at the highest possible instrument resolution. Higher-resolution scans such as nano-focus XCT could be utilized in order to fully study the porosity in MIM and DPR parts. IntroductionMetal injection moulding (MIM) is a novel process, which combines the advantages of powder metallurgy (PM) and plastic injection moulding. MIM has found widespread applications in the cost-effective production of high-sintered density small parts with complicated shapes and mechanical properties equivalent to those of wrought materials (German and Bose, 1977; Machaka and Chikwanda, 2015; German, 2013). There are four basic processing steps involved in MIM, namely; feedstock preparation, injection moulding, debinding and sintering. These steps are discussed in greater detail elsewhere (Machaka, Seerane and Chikwanda, 2014; German and Bose, 1977; Machaka and Chikwanda, 2015; German, 2013).Feedstock preparation involves mixing metal powder with a carefully selected composition of polymeric binder materials at a specific temperature. The feedstock is then granulated and injected into a predefined mould die with the desired shape. The part produced during the moulding step is referred to as a ‘green’ component. The green component typically contains no porosity since the spaces between adjacent powder particles are readily filled with the binder materials (German and Bose, 1977; Li, Li and Khalil, 2007). Debinding is the systemic removal of the binder components by chemical, catalytic, or/and thermal means while maintaining the shape of the component. The part produced after the debinding step is referred to as a ‘brown’ component. Debinding is known to be the source of porosity in brown components (Ji et al., 2001; Tsai and Cen, 1995). Finally, the brown debound part is sintered to full or nearfull density (Sotomayor, Varez and Levenfeld, 2010). The sintering step and associated densification closes up the majority of the pores. Sintered MIM parts are typically sintered to high density (95–99%) and retain an irreducible amount of residual porosity (Barriere, Liu and Gelin, 2003; German, 1990)."

Jan 1, 2016

By W. Jomaa, V. Songmene, O. Mechri, Laval Université, P. Bocher, J. Levesque

"A 2D finite element modelling (FEM), based on pure Lagrangian approach, is developed for studying the serrated chip formation during high speed machining (HSM) of 7075-T651 alloy. The solution was achieved using a commercial software package, ABAQUS/Explicit v6.13. The Johnson-Cooke (JC) constitutive equation is used to describe the work material behaviour. Moreover, the JC damage equation is implemented into the FEM to take into account for the shear localization during the serrated chip formation. Modified Coulomb friction model has been used to characterize the sliding/sticking effects on the tool-chip interface with the friction coefficient and shear flow stress determined by force calibration and machining data, respectively. The proposed FEM is validated using experimental data obtained in HSM of 7075-T651. The FEM was able to predict accurately serrated chip morphology. The intensity of chip segmentation was found to increase with cutting speed.INTRODUCTIONHigh speed machining (HSM) is one of the most used processes for manufacturing aircraft parts with aluminum alloys. For aluminum alloys, the use of HSM increases metal removal rate and reduces the formation of built up edges and burrs. However, it was found that serrated (also named segmented or sawtooth chip) and discontinuous chips can be produced during HSM of some high strength aluminum alloys, such as 7075-T6 alloy (Rao & Shin, 2001). Many parameters were found to affect the segmented/discontinuous chip formation during the machining of aluminum alloys.There are two cases in which the serrated chip can forms: the first is when machining hardened materials (Morehead, Huang, & Luo, 2007), and the second, when machining ductile materials with a cutting speed higher than a critical value (Barry & Byrne, 2002). Different theories and models were developed in order to explain the formation mechanism of such kind of chips. According to Astakhov (2006), the segmented chip formation is attributed to variations in stress and plastic deformation states, and resulting temperatures on the cutting zone. Liyao et al. (2013) stated that the segmented chip formation was mainly attributable to adiabatic shear instability/catastrophic strain localization. Others (Vyas & Shaw, 1999) suggest that the fracture/crack propagation mechanism is at the root of chip generation."

Jan 1, 2016

By D. Newman

"The U.S. stone industry is in a transition from surface quarries to single and multiple level underground stone mines. The factors driving this transition include surface quarries; ? reaching their economic stripping ratio, ? encroaching on the mineral reserve boundary where the remaining reserves are below the active pit, ? dust, noise, and blast vibration concerns as suburban neighborhoods and development move into formerly rural areas. Ground control is critical to the success of a safe and productive, mining operation. The primary focus of the ground control engineer in an underground stone mine is the stability of the roof or back, development and benched pillar stability, stability of the sill pillar between vertically adjacent mining levels, and floor stability. Roof stability begins with the selection of a stable back horizon based upon the presence of a thin shale parting, stylolite, or other discontinuities from which the production shot can easily ""peel"" away leaving a stable back stratum. Room width and the decision of whether to bolt the roof, the bolt length, bolt type, bolt diameter, and spacing of the support is controlled by the thickness, fracture spacing, jointing, and material properties of the back strata. Horizontal stress controls the header and crosscut azimuth as to avoid driving perpendicular to the maximum horizontal stress direction. Stable pillar dimensions depend upon the interaction of the; ? vertical stress resulting from overburden thickness and multiple level interaction of overlying level(s), ? mining height during development and the final mining height after floor shots are taken while benching, ? presence of faults, folds, or joints passing through the pillar, and ? stone lithology recognizing that the presence of oolitic bands, shale partings, and bentonite beds create zones of weakness that can destabilize an otherwise competent pillar. Floor stability is typically not a significant issue for underground stone mines because the bearing capacity of the stone exceeds the vertical pressure transferred through the pillar. However, floor heave can be a ground control issue where shale partings, moisture sensitive strata, weak stone bands, or horizontal stress is present. Roof stability and pillar stability problems can be initiated as the floor heave enables the pillar and roof to settle. The ground control issues for underground stone mines are most clearly presented through a series of case histories. The case histories presented in this paper are a mix of ground failures and successful mining. The focus is on the geotechnical data required for underground stone mine ground control for roof, pillar, and floor design and stability analysis."

Jan 1, 2016

By T. Sun, J. Kou, C. Sun, China Railway Resources Group Limited

"The polymetallic sulfide ore in Jiama county of Tibet contains 0.78% Cu, 0.046% Mo, 0.31 g/t Au and 17.9 g/t Ag in average. However, heavy loss of valuable metals was observed using high-pH process and Butyl xanthate as the collector. In this paper, the flotation was optimized through the adoption of a novel collector C-7, which is a mixture of xanthate ester and thionocarbamate. This collector showed better flotation performance under weak base conditions. The recoveries of Cu, Mo, Au and Ag increased to 93.24%, 84.60%, 78.13% and 75.41%, respectively, under 15 g/t of C-7 at pH of 8.0. The adsorption mechanism of C-7 was investigated by micro-flotation tests, zeta potential measurements, FTIR analysis and adsorption quantity measurements. Chemisorption of C-7 on chalcopyrite surface is demonstrated with adsorption density 3.8 times higher than on pyrite.INTRODUCTIONXanthates are the most commonly used collectors of strong collecting ability for separating copper sulfide minerals from gangue in froth flotation. However, the selectivity of xanthates themselves is poor to realize separation of chalcopyrite and pyrite whose floatability are quite similar (Heyes & Trahar, 1977; Chandraprabha, Natarajan, & Modak, 2004). High pH process with xanthates as collectors is proved effective in copper-sulfur separation and is widely used in treatment of copper sulfide ore flotation (Smith, 1996; Valdivieso, Cervantes, Song, Cabrera, & Laskowski, 2004). This method could get ideal separation results, but large amount of lime must be added, and could bring about increased cost, device corrosion and environmental pollution. In addition, there could also be high depression and heavy loss of associated noble metal such as Mo, Au and Ag. Consequently, a large amount of research has been conducted on substitutions of xanthates for selective flotation of copper sulfide ores under low pH conditions (Gholivand, Khodadadian, & Ahmadi, 2010; Li, 2010)."

Jan 1, 2016

By S. Hussien, P. Somasundaran, P. Patra

"Rare earth elements (REEs) are essential for many applications in electronics, energy harvesting, and defense. The common resources for economic extraction of REEs are oxides such as bastnaesite and monazite, which are scarcely available in the earth’s crust. On the other hand, REEs are available in many clay and phosphate ores where REEs substitute Ca or Si in the mineral lattices or as physically adsorbed cations at negatively charged sites on the clay surface. While REE oxides readily dissolve in acid, making the chemical leaching of REEs an economically viable option, adopting a similar approach for leaching of silicates and phosphate ores is unfeasible because of significantly low REEs content in these ore deposits. Bio-leaching approaches are environmentally benign and economically viable. We investigated the bio-leaching (Acidothiobacillus ferrooxidans (Af) and the fungal Aspergillus niger (An)) of REEs from a phosphate ore, and examined the factors governing the leaching processes. Based on the shake flask leaching studies, an increase in surface area combined with an increase in pulp density (1-15 wt. %) was found to lead to an increase in the amount of REEs leached. In contrast, an increase in the surface area by reducing the particle size from 75 to 35 led to a decrease in the amount of REEs leached. These differing attributes are proposed to be due to the poor bacterial growth/activity with high F- ions in the leaching media, F- released from the edge-sites of the smaller particles. On the other hand, several advantages that associate with the Af bacterial bio-leaching processes relate to the media composition (Mg2+ and (NH4)+) and phenomena occurring at the electrical double layers of the mineral and bacterial- water interfaces. These studies suggested that leaching of particles occur in a layer-by-layer manner.INTRODUCTIONRare Earth Elements (REEs) are essential for many important applications, such as in electronics, energy generation, and defense. The common resources for economic extraction of REEs are typically carbonates such as bastnaesite and monazite, which are scarcely available in the earth’s crust (Y. Kanazawa and M. Kamitani, 2006). REEs are abundantly available in many clay and phosphate ores where REEs substitute Ca or Si of the mineral lattices. Conventional acid leaching of REEs from oxides is not economically feasible for clay and phosphate ores because of significantly low REE content (parts per billion) in these ores (Tian, J., Chi, R., Yin, J., 2010a; Moldoveanu G. A. and Papangelakis V. G., 2013; WK Goyne, LS Brantley and J Chorover, 2010). In some cases, REEs could be extracted from these ores via chemical leaching routes as they constitute reasonable amounts of REEs (0.1 - 1% REEs). A major challenge faced in general in chemical leaching processes (Chi, R., 1988) is the loss of REEs in the phosphate/gypsum precipitates/crystals, which are overcome in a step-by-step manner by sequentially removing impurities such as fluorine and calcium, including steps carried out at elevated temperatures. On the other hand, bio-leaching approaches provide environmentally benign and economical alternatives. Acidophilic bacteria are currently being used for industrial scale bio-leaching of Au/Cu/Ni from low grade ores. Studies on bioleaching of REEs from red mud (Al2O3) using Penicillium tricolor and Aspergilus niger (An), and, of bio-leaching (lab-scale) of phosphate rocks using Acidithiobacillus ferrooxidans (Af) have been reported (Boon, M., Heijnen, J.J., 1993; Qu, Y. and Lian, B., 2013). We conducted bacterial (Af) bio-leaching of REEs from a phosphate ore in shake flasks and columns, while examining the key factors that govern leaching kinetics."

Jan 1, 2016

By Giorgio Höfer-Öllinger, Peter Pointner, Manfred Stadlober

"SUMMARY Investigations from tunnel face are part of risk mitigation measures during the excavation works. With the tunnel equipment, percussion drillings of up to 30-40m can be achieved. Core drillings are state of art method for investigation exceeding 50m. At Koralm base tunnel, up to 270m deep percussion drillings were performed with drilling rigs and accompanied by an intensive investigation program. These investigations consisted of monitoring during the drilling, field tests (with packer, using the preventer, borehole imaging) and in laboratory. Percussion drillings are cheaper and save time of interruption of the excavation progress. INTRODUCTION As part of a proper risk management, horizontal advance drillings during excavation of underground works can be seen as state of art and meet wide acceptance. Core drillings, deep and shallow percussion drillings can be differed. The selection of the type of drilling, meanwhile, causes intensive discussions. On the one hand, only a core drilling allows a direct investigation of the rock mass expected during later excavation works. On the other hand core drillings are expensive in both cost and time – if there is no excavation progress during the investigation measures – in construction time. Percussion drillings can be performed as rapid investigation measure with the excavation equipment (“Jumbo”) allowing two dimensional image of the ground around the cross section. There is some limitation concerning a reasonable depth of approximately 30m and a borehole diameter of 76mm. The applications of preventer, packer or borehole imaging are hardly applicable. By use of a drilling rig depths of percussion drillings of several hundred meters can be achieved relative easily and there is less limitation of the borehole diameter. Installation of a preventer is possible, as well as packer tests and borehole measurements (imaging, gyroscope, borehole geophysics). The gap of information between core and percussion drilling cannot be closed completely, but it can be reduced substantially and sufficiently by combination of an intensive program of measurements and analysis accompanying the investigation works."

Jan 1, 2016

By Xiqing Wu, Liang Dai, Tao Yue, Longsheng Yi, Ruifang Wang

Magnetic seeding flotation (MSF), i.e. adding magnetic seeds and pre-magnetization-flotation, is a new flotation technology especially for fine particles, which improves the flotation performance by enlarging the apparent size of the particles in a way of magnetic agglomeration. Both the fine coal slimes with a size of 66.68% –38µm and the pyrite slimes with a size of 73.95% –23 µm were investigated by the MSF, respectively. Flotation tests with variable of dosages of magnetic seeds and polyacrylamide were conducted, and some measurements, such as laser diffraction size analysis, magnetic susceptibility by vibrating sample magnetometer (VSM) and infrared spectroscopy (IRS), were also applied in order to probe the mechanism of the MSF. Based on the tests, measurements and calculations it was found that both the recovery of coal and the flotation kinetics of pyrite slimes increased with the additions of the magnetic seeds, and in the presence of polyacrylamide the coal flotation was further strengthened due to a synergetic effect of magnetic seeds and polyacrylamide on the flotation and a relatively larger apparent size of slimes after additions of magnetic seeds and polyacrylamide. The reason for the MSF lies in fact that the presence of the polyacrylamide intensified the adsorption of magnetic seeds on the coal particles and increased the coverage of the magnetic seeds on the coal surface from 0.2 to 1.3 wt%, resulting in increased magnetic susceptibility of coal particles from 9.13×10-9 to 22.17×10-9 m3/kg and thus a low magnetic field strength of pre-magnetization needed for the magnetic agglomeration among the coal particles from 602 to 24 mT prior to proper flotation. IRS shows that polyacrylamide chemisorbed on the surfaces of both coal particles and magnetic seeds, thus acting as the bridging media between particles and seeds.

Jan 1, 2016

By Jamal Rostami, Alireza Salimi, Christian Moormann

"Rock mass classification systems are often applied in many empirical design practices in rock engineering, some contrasting with the original intent and applications of these classification systems, for example, estimation of TBM performance in various ground conditions. While accurate estimation of machine performance is significantly impacted by rock mass properties, parameters used in many of the existing classifications are more related to ground support design and not rock mass boreablity. The results of many investigations on this issue have shown a weak correlation between TBM rate of penetration and rock mass classification. This limitation can be overcome by fine tuning the rock mass classification input parameters to represent influence of rock mass properties on TBM performance as has been the objective of RME or QTBM. This paper will offer an overview of the impact of rock mass on TBM performance and introduces an empirical equation for predicting performance of rock TBMs based on rock mass classification. The results of the preliminary analysis of a new model has revealed that the use of the proposed system can offer a reasonable accuracy for estimation of TBM performance in various rock masses. 1. INTRODUCTION Hard rock tunnel boring has become more or less the standard method of tunneling for tunnels of various sizes with lengths over 1.5–2 km. Estimating the performance of TBM is a vital phase in tunnel design, and for the choice of the most appropriate excavation machine. During the past three decades, numerous TBM performance prediction models for evaluation of TBM rate of penetration and advance been proposed. In brief, all the TBM performance prediction models can be divided into two distinguished approaches, namely theoretical and empirical ones (Rostami et al., 1996). The most common and recent works on this topic are summarized in Table 1. Currently, two models including Colorado School of Mines or CSM (Rostami and Ozdemir, 1993; Rostami, 1997) and Norwegian University of Science and Technology or NTNU (Blindheim, 1979; Bruland, 1998) models are the most recognized TBM performance prediction and prognosis models in use around the world."

Jan 1, 2016

By M. N. Pons, F. Ferrari, V. Houzelot, B. Laubie, A. Bani, Université de Lorraine-CNRS LRGP

"More than 400 plants in the world are able to accumulate nickel in their aerial parts at concentrations higher than 10 g per kg of dry biomass. Then, nickel (Ni) can be recovered from the biomass of these hyperaccumulator plants. Agromining is a chain consisting in growing such plants and recovering metal and has been developed thanks to the combined know-how of agronomy and hydrometallurgy. Plants can be grown on serpentine soils, containing rather high concentrations of Ni, on sterile heaps or on contaminated soils. This crop enables us to extract Ni from secondary resources, and to improve soil quality by lowering its metal content. For example, Alyssum murale can be grown at the field scale in the Balkans, at yields corresponding to 110 kg Ni per hectare.Hydrometallurgical processes have been designed from the lab scale to the pilot scale to produce nickel salts: ANSH (ammonium and nickel sulphate hexahydrate), nickel sulphate, acetate, etc. and so on. These salts are used for surface treatment and in the paint and chemical industry. Ni salts are prepared from ashes, after plant calcination. Processes are based on the conventional methods of hydrometallurgy: acid leaching followed by different precipitation steps. These processes will be presented, as well as the pilot scale design. A life cycle assessment has been performed and clearly shows the environmental interest of this approach as a potential part of an anti-erosion strategy. An economic assessment has proved process feasibility and the final step is the launching of a start-up. At the moment, the approach is widened to other metals (cadmium, cobalt) and rare earth elements (REEs)."

Jan 1, 2016

By G. O. Oniyide, H. Yilmaz

The South African platinum mines in the Bushveld Complex (BC) have unique features that distinguish them from the gold mines. They have a higher horizontal stress closer to the surface, lower occurrence of seismic activity (caused mainly by pillar failure), and are sited in an area of high geothermal gradient. One of the future challenges of platinum mining is the increasing temperatures as the mining depth increases. High temperatures invariably bring about higher ventilation costs and require different approaches to human factors and ergonomics. Excavation stability would also be another area of concern due to increasing stresses. In this investigation, the effect of temperature on the physical and chemical properties of selected Bushveld rocks (chromitite, pyroxenite, norite, leuconorite, gabbronorite, mottled anorthosite, varitextured anorthosite, granite, and granofels) was studied by means of optical microscopy and scanning electron microscopy using energy-dispersive Xray spectrometry (SEM-EDX). The rock specimens were heated in a temperature-controlled oven a rate of 2°C /min to 50°C, 100°C, and 140°C and kept at temperature for five consecutive days. Samples were allowed to cool to ambient temperature (approximately 20°C) before image capturing. Micrographs of the specimens were taken before and after heat treatment. All the SEM samples were also subjected to heating and cooling on alternate days for ten days in order to observe the effect of repeated heating and cooling on the rocks. The results of the optical microscopy analyses showed minor physical changes in the rocks. The SEM images revealed that cracks initiating at lower temperatures extend with increasing temperature. The chemical analyses showed that the temperature range considered in this research is not high enough to induce changes in the chemical composition of rock samples.

Jan 1, 2016

By Jose A. Jimenez

"Mining operations generate an enormous amount of data that is difficult to organize, analyze and act on. These data require an extremely broad range of experts to investigate and manage the cross-disciplinary information. The data collects in paper files, diverse databases, historians, stand-alone applications, and excel files. This collection of sources represents everything from monthly, weekly, or daily inputs to real-time feeds or sporadic unscheduled entries. With the operational complexities ever increasing and fewer engineers per mine, an efficient operation is becoming more and more challenging. Engineers are typically burdened with data collection, clean up, and administrative efforts leaving very limited time for engineering assessment and/or optimization analysis. Often optimization becomes limited to the analysis of equipment uptime through existing field automation systems. A great portion of the field data is tucked away in historians seldom reaching those engineers who might leverage the data. Few mine operators have the time or budget to re-architect their operations data collection or management practice, so solutions must enable improvements without requiring expensive or time-consuming implementation. This presentation highlights examples where the aforementioned challenges are addressed using a solution framework designed to enable: 1) data integration and connectivity, 2) monitoring and opportunity recognition, and 3) engineering workflow automation. The initiative extends the concepts and success proven in the automation market segment to all disciplines across the mine operations. INTRODUCTIONThe mining industry by its very nature spends a great deal of its capital on equipment maintenance and replacement. In addition, periodic shutdowns due to equipment failure are typically very costly in terms of interrupted operations. Keeping mining equipment running at peak performance and avoiding costly shutdowns can make a huge difference in the overall return from mining operations. Today, information can be make available that can go a long way towards spotting equipment issues and permitting timely intervention to avoid costly unplanned shutdowns. That said, gathering all of the information from numerous points on many different pieces of equipment necessary to enhance overall equipment effectiveness presents its own daunting issues."

Jan 1, 2016

By Alain Blouin, Mohamad Sabsabi, Aissa Harhira, Paul Bouchard, Greg Lithgow

"The objective of this study was to demonstrate the application of Laser-Induced Breakdown Spectroscopy (LIBS) to the continuous analysis of online monitoring of Al, Mg, Ni, Mn, Si and Fe in nickel ore limonite and saprolite slurry samples. Analysis was performed on slurry samples in air at atmospheric pressure. Two pure samples of limonite and saprolite were used. Mixtures of the two samples in varying proportions were used to build calibration curves, study the influence of solid/liquid ratio, and evaluate short and long term reproducibility. The LIBS measurement of these elements is independent of the water content (from 70-85%, the range allowed by our setup). Repeatability of the measurement and long term reproducibility (from day-to-day) were below 1.2 % and 2% respectively for all the elements studied in our conditions. The results obtained showed that an industrial LIBS analyzer could provide the chemical composition of the six elements Al, Mg, Ni, Mn, Si and Fe within 1-2 minutes.IntroductionThe metal-producing industry faces the major challenge of increasing productivity, reducing costs, and maximizing benefits from existing equipment. By pyrometallurgy, metal making involves the basic steps of charging the furnace, melting the charge and refining. By hydrometallurgy, the metal refining is carried out through the dissolution of the metal by chemical reaction and electrolysis. During refining either by pyrometallurgy or hydrometallurgy, it is critical that operating parameters be adjusted and controlled so that the chemistry of the melt or the solution is within predetermined limits. Presently, the complete turnaround time for sampling, sample transfer, analysis and communication of the results to the operators is often 30 minutes or more."

Jan 1, 2016

By C. -M. Katsari, G. N. Anastassakis

"Copper is considered one of the most important industrial metals because of its properties (conductivity, malleability) and variety of uses. Approximately 70% of the global copper is used for various electrical applications, with a significant part of copper originating from recycling, since copper can be recycled and re-used countless times, without any loss of performance and difference in the quality of recycled copper in comparison to that from ore. Copper recycling significantly contributes to natural resources conservation, waste minimization, energy saving, and overall cost reduction. Approximately, 35% of the globally produced copper originates from recycled copper.The objective of the current work is to investigate the recovery of copper from electric wire scraps using wet shaking table as an alternative to air separation methods that prevail over the wet ones in recycling processes. The tests were carried out using feed of correspondingly high- and low-grade in copper. In the first case, the wire scraps had been subjected to shredding only, prior to tabling separation; in the later, the low-content tailing of prior air separation was used as feed ?n table separation.In regard to testing, the following factors were examined: table tilt, water flow-rate, and reciprocating speed. The results of the tests clearly denote that copper wire separation from plastic polymer is feasible, as in most cases, table separation resulted in heavy products of high purity in copper and high recovery, and tailings of very low copper grade. The results of the current work clearly denote that wet tabling can be applied efficiently for the separation of recycled copper wire from plastic, as an alternative to air separation methods, as well as for the recovery of copper from the low-grade tailings derived from air separation methods."

Jan 1, 2016

By Simon B. Blancher, Malo Rousseau, Renato Contessotto, Thomas Wallmach

The Manganese division of the ERAMET group extracts manganese ore in Gabon and produces manganese alloys for the steel industry. ERAMET has an economic interest to maximize the ore throughput without reducing the lifetime of its manganese mines. This can be achieved by means of research and development leading to innovative ore beneficiation processes. For this purpose, the ERAMET research center has designed and constructed a new pilot plant for ore beneficiation by physical separation processes. This pilot facility was erected within an infrastructural and synergetic framework, including competencies in hydrometallurgy, pyrometallurgy, numerical modelling, analyses and mineral characterization that provide ideal research conditions. After laboratory scale tests, a pilot operation of beneficiation of low grade Mn ore (around 35% Mn) was carried out by jigging of the 1-10 mm fraction. This gravity separation process exploits density differences between the various Mn-bearing minerals such as pyrolusite and lithiophorite as well as gangue minerals such as silicates and iron-hydroxides. Enrichment leads to the production of a marketable product associated with a high mass recovery (53% for the jigging step). However, 20% of pyrolusite and 30% of lithiophorite are lost in the waste. Mineral characterization has shown microtextural complexities, but grinding the ore to approach the liberation mesh was not an option due to commercially defined constraints given by the ferro-alloy industry. Recovery of the Mn-bearing minerals or adjustments of the feed grain size (6.3-10 mm) are two potential areas of process improvements identified by means of Qemscan® mineral characterization. This paper details the process tested on a pilot scale (0.5 t/h), which has led to a significant increase in the beneficiation of a low grade Mn ore.

Jan 1, 2016