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By H. C. L. Reemeyer

"The mining industry faces increasing economic, environmental and social challenges, as easier deposits deplete and ores become more difficult to mine and process; head grades decline; projects migrate to increasingly remote and difficult geographies; and the industry faces more stringent environmental and social standards. While these factors increase costs and risks, they also present opportunities for a more integrated approach to mining, processing, materials handling and waste management. Two key areas of risk are in tailings and water management. As mining and processing tonnage rates continue to increase, the disturbance footprints, water and energy consumption and scale of tailings storage facilities also rise. These factors can be mitigated by more selective mining, ore sorting and pre-concentration, and more intensive tailings dewatering. Such alternatives must be considered in conjunction with the selection of mining method, metallurgical flowsheets, major equipment selection, and key process design criteria. For example, increasing the grind size of a concentrator reduces energy consumption and eases tailings dewatering, but may cause challenges with metal recovery. Emerging technologies will be reviewed, and economic and environmental trade-offs for eco-efficient alternatives will be presented for metal sulfide mines.INTRODUCTION The metals mining industry faces significant challenges that can affect its financial viability and social license to operate. There has been a consistent decline in ore grades and a relentless push towards larger operations to capture perceived economies of scale. With these larger operations, the environmental footprint of mines has increased. Water and energy consumption, and resulting GHG emissions have also risen. In recent years, two issues have raised special concerns for stakeholders and companies: • Water scarcity, particularly in drier regions of the world such as Northern Chile, SW USA, Southern Africa and Australia • Tailings risks, following the high-profile failures of the Fundao tailings dam in Minas Gerais, Brazil in 2015 and the Mount Polley tailings dam in BC, Canada in 2014"

Jan 1, 2017

By B. Kyslinger

"In underground mining, machine design is predominantly dictated by mine conditions and individual customer desires. In partnership with Foresight Energy, J. H. Fletcher & Company was tasked to design and manufacture a new roof bolting machine with six independent drilling apparatus on board capable of drilling and bolting the roof and ribs with material handling. This is the first Fletcher® six head machine to be designed and built for the mines in the United States. The machine is intended to work in the Illinois Coal Basin. The objective was to produce a machine capable of drilling and installing six bolts simultaneously with a limited number of operators. The goal of the mine is to decrease the time to bolt a cut to improve the safety level of the current roof bolting method, improve efficiency and to improve the bottom line cost of entry development. The customer wanted four mast feed drills at the front of the machine dedicated to installing roof bolts and then another two mast feed drills behind them dedicated to rib bolts. This dictated the requirement of latched controls, which would allow the operator to start drilling one hole and then latch the controls to be able to move on to the next. To accomplish this, we developed a unique hydraulic latch circuit to maintain operator safety and compliance. Guarding was added to prevent an operator from coming into accidental contact with a latched drill. The result of the design is a machine with a single platform and six independent masts with drillheads: four masts strictly for drilling and installing roof bolts on the front of the platform and then two masts on the back of the platform for rib bolts. The feed and rotation controls at each operator’s station include a latch control for drilling. The latch control will allow the operator to lock in the feed and rotation once the hole has been collared, allowing the operator to move on to the next hole. The rear of the machine is equipped with material handling. There are two material pods with winch controls as well as a mesh rack that includes mesh lift, mesh tilt and mesh sump. The six-head roof bolter allows fewer operators to drill and install roof and rib bolts, which in turn lowers the miners’ roof exposure per cut. This design reduces the operator’s exposure from the inherent pinch points and rotary hazards once he has engaged the latch drilling. Therefore the machine will help to decrease the time to bolt a cut, improving productivity while enhancing the ability to operate the machine safely. INTRODUCTION When mining underground it is necessary to support the roof quickly to prevent it from collapsing after an area has been mined. Since the 1950s, the primary method for supporting the roof has been the installation of roof bolts. Roof bolting is one of the most basic functions yet one of the dangerous jobs in the underground mining operation (1). The Mine Safety and Health Administration’s (MSHA) Health and Safety Accident Classification injury database showed an average of 660 roof bolter operator accidents per year over a 5-year period (1999-2003) (2). The numbers show that roof bolting is the most hazardous machine-related job in underground mining. It represents 39 percent of all machine-related accidents in underground coal mines. In 1993, the U.S. Bureau of Mines conducted a study that has shown the activity of drilling as the most hazardous job task performed by a roof bolter operator, accounting for 31 percent of all roof bolting injuries (3). Almost half (46%) of these drilling injuries were due to falling rocks or coal from the roof. All of these injuries occurred under supported roof. The majority of these injuries (about 99%) are not caused by a major roof collapse but from falls of smaller rock from the immediate roof. This type of roof failure has also been termed “skin fall.”"

Jan 1, 2017

By Peter Hayes, Evgueni Jak, Taufiq Hidayat, Gary O’Connell, Denis Shishin, Jeff Chen, Francis Letarte

"Knowledge of slag properties is required for the optimisation of smelting operations. The phase equilibria and viscosities of the Al2O3-CaO-FeO-Fe2O3-MgO-MnO-NiO-Cr2O3-SiO2 slags at conditions of interest to Koniambo Ni-laterite smelting operations have been investigated. High-temperature re-equilibration phase equilibrium experiments of industrial slags followed by rapid quenching and direct measurement of phase compositions using electron probe X-ray microanalysis (EPMA) have been undertaken in the olivine and pyroxene primary phase fields at temperatures between 1475 and 1600°C and SiO2/MgO weight ratios between 1.57 and 2.09. Phase equilibria predictions were performed using FactSage thermodynamic software. A slag viscosity model available in the FactSage thermodynamic package has been used to calculate the viscosities of the liquid slags. The Einstein-Roscoe equation combined with the predicted phase equilibria data have been used to estimate the viscosities of the slag slurries (slag + solids). The information provided can be used to assist in the evaluation of the furnace performance, to assess further optimisation of slag composition and to explore possibilities of targeted feed changes.INTRODUCTION One of the key steps in the production of ferronickel from nickel laterite ore at Koniambo Nickel SAS involves reduction and smelting of pre-dried nickel-bearing saprolitic ore (high Mg and Si) in an electric furnace at temperatures up to 1650°C. The characterisation of the slag properties as functions of key operational parameters, such as, temperature and composition, including liquidus, the proportions of solids and viscosity, is essential for improving control and optimisation of the operations. The slag produced in the smelting process is a complex oxide system with the major chemical components including Al2O3, CaO, Cr2O3, “FeO”, MgO, “MnO”, “NiO” and SiO2. Characterisation of these multi-component systems using a solely experimental approach becomes increasingly complex as the number of components is increased."

Jan 1, 2017

By Zhikai Wang, Wensheng Lyu, Peng Yang

"To better understand the mechanical behavior of the compression deformation of backfill under high stresses corresponding to large depths, consolidation compression tests were performed for cemented tailings backfill with a cement-sand ration of 1:10 and 30% water under confined conditions. After applying different loading stress functions from 0.5 MPa to 32 MPa, the final axial deformation of the test specimen of backfill was obtained, and the micromorphology of backfill was studied before and after consolidation by scanning electron microscopy. Additionally, fitting analysis was performed for backfill confined compression deformation data and device model constitutive equations by the minimum square law. The constitutive model was revised according to the analysis results. The research results indicate that, as the load increases, the void ratio e obeys the functional relationship e=alnt + b (where a and b are fitting constants and t is compression time). Under the high-stress conditions of confinement, the constitutive model of backfill consolidation and creep can be used to describe the creep behavior of the backfill. Under high-stress conditions, after the consolidation of the confined backfill, the space between the tailing particles diminishes, the particles becomes more compact, and particle slippage occurs. INTRODUCTION With the depletion of shallow mineral resources, the mining industry has gradually shifted to deep mining (Zhang, Li, An, and Huang, 2010). Furthermore, with the continuous introduction of sustainable development policies regarding development and utilization of mineral resources, the mining industry must protect the limited available land and make full use of mineral resources as much as possible (Sijing, 1994; Zhihua, 2009). Backfill mining technology offers an unparalleled advantage in fully recovering mineral resources, controlling pressures, and improving environmental protection. As a result, this method has been widely used in various countries in the world (Burd, 2002; Benzaazoua, et al., 2008). Of the underground mines in the world, 45% of the large and medium-sized non-ferrous-metal mines and 37% of the gold mines use backfilling (Fuhrman, et al., 2014; Khaldoun, Ouadif, Baba, and Bahi, 2016). In addition, 45% of underground non-ferrous-metal mines and 37% of the gold mines use the filling method (Mchaina, Januszewski, and Hallam, 2001). According to incomplete statistics, more than 80 metal mines operate at a depth of more than 1 km; the depths of several typical deep mines are shown in Figure 1 (Burd, 2002; Fall, et al., 2009)."

Jan 1, 2017

By S. N. Dixon

"Maximizing the value of each tonne of processed ore is the goal for all operations. Cyanidation processing of gold-copper ores has been challenging since its first use in 1889. The current practice treats a bleed or the total flow of mill solution to recover copper as copper sulfide (by sulfidization, acidification, recycling, and thickening), or to recover the cyanide (by acidification-volatilizationneutralization). The process presented uses the adsorption of copper cyanide by carbon and the selective elution of copper from carbon to concentrate copper into a smaller stream. Copper contained in the smaller stream is precipitated as copper cyanide.RÉSUMÉ Toutes les exploitations ont pour objectif commun d’optimiser la valeur de chaque tonne de minerai traité. Depuis sa première utilisation en 1889, la méthode de traitement par cyanuration des minerais aurifère et cuprifère s’est révélée complexe. La pratique actuelle traite la saignée ou le débit total d’une solution de traitement du concentrateur pour récupérer le cuivre sous la forme de sulfure de cuivre (par sulfuration, acidification, recyclage et épaississement), ou pour récupérer le cyanure (par acidification, volatilisation et neutralisation). Le procédé présenté dans cet article utilise l’adsorption sur charbon actif de la solution de cyanure de cuivre et l’élution sélective du cuivre depuis le charbon pour concentrer le cuivre en un plus petit jet. Le cuivre contenu dans ce plus petit jet est précipité sous forme de cyanure de cuivre."

Jan 1, 2017

By Janaka J. Kumara, Takashi Kurashina, Yoshiaki Kikuchi, Takahiro Yajima

"The inner frictional resistance of open-ended piles depend heavily on the degree of soil plugging. Many factors including pile diameter, relative density and end conditions of the piles influence the degree of soil plugging. In this paper, the effects of inner sleeves attached at the pile base on the inner frictional resistance are discussed. The experiments were conducted on a medium-dense sandy ground using smallscale model piles. The results suggest that the inner frictional resistance is influenced by sleeve height for 50 mm diameter piles although it is independent for 30 mm diameter piles. The results also indicate that soil plug height is influenced by the sleeve height. The results of the incremental filling ratio (IFR) showed that penetration of non-sleeved piles is closer to unplugged state than the sleeved piles. The results of the IFR also reveal that the degree of soil plugging is affected by the sleeve height for 50 mm diameter piles although the variation is very limited in 30 mm diameter piles. The results on the coefficient of lateral earth pressure suggested that it increases from 1.08 – 1.75 when the sleeve height is increased from 10 – 100 mm for 50 mm diameter piles.INTRODUCTIONPrevious studies have shown that the behaviour of open-ended piles is different from closed-ended piles (Szechy, 1961; Randolph et al., 1979; Paikowsky and Whitman, 1990). Open-ended driven piles are widely used for deep foundations, in particular in offshore deep foundations. Generally, it is accepted that a short open-ended pile produces a smaller bearing capacity than a similar closed-ended pile (Nauroy and Tirant, 1983). However, a long open-ended pile can produce a similar bearing capacity as a closed-ended pile due to a large inner frictional resistance mobilised between the inner pile shaft and inner soil (Lehane and Randolph, 2002). The ultimate bearing capacity of an open-ended pile, Qu consists of three components as given in Eq. 1."

Jan 1, 2017

By Deborah A. Peacock

"Outer space technology and exploration have reached a tipping point, so that mining and mineral processing in outer space is now a certainty and not a dream. Several competing companies worldwide are on the way to building spaceships to land on the Moon and eventually mine the Moon and asteroids for volatiles, rare earth metals and Helium-3.The Google Lunar XPrize offers a $30 million prize1. China has recently landed a spacecraft on the Moon. The European Space Agency, with cooperation from the United States, has landed a spacecraft, Philae, on a comet. And, Mars One is planning a one-way trip to establish a settlement of humans on Mars.How and why are the Moon and asteroids and their resources of interest to private space industry companies? Why are the Moon and asteroids viewed as a potential business venue?Geology of the Moon and asteroids — Why do we want to mine there?Space enterprises are actively working toward establishing and operating lunar and asteroid mining locations for resource extraction, resource processing, conversion to salable products and distribution of the products and services in space and to Earth and beyond2.Forty-five years ago, the Apollo manned missions to the Moon returned rocks and regolith to Earth, which were studied and analyzed. What they found was that the Moon contains valuable minerals and resources. These minerals are largely due to meteor and asteroid impacts, which have, over eons, created this mineral-rich regolith. These impacts have occurred on Earth as well, for billions of years, particularly early on in the history of the solar system. However, on Earth, wind, water and vegetation have erased most of these impacts. On the Moon, in contrast, the only weathering is caused by subsequent impacts and the solar wind."

Jan 1, 2017

By N. Katsikaros, A. Lewis-Gray, P. Richards

"To optimize gold recovery in complex leach-to-electrowinning processes, Gekko Systems developed the Gekko resin exchange column (G-REX) as an intermediate step, using a highly gold-selective resin to isolate contaminant metals. The AuRIX®100 resin produced by Purolite is licensed exclusively to Gekko, with the G-REX column designed specifically for this resin. Operational experience has been gained at the Castlemaine Goldfields Ballarat gold mine. In near-continuous operation since 2008, the Ballarat plant treats unclarified concentrate leach solution. The extension of this technology to higher throughputs and more complex chemistry is discussed.RÉSUMÉ Afin d’optimiser la récupération de l’or dans des procédés complexes impliquant la lixiviation suivie de l’extraction électrolytique, Gekko Systems a développé la colonne Gekko de résines échangeuses d’ions (G-REX) comme étape intermédiaire, à l’aide d’une résine hautement sélective pour la récupération de l’or qui permet d’isoler les métaux contaminants. Gekko détient la licence exclusive pour la résine AuRIX®100 produite par Purolite, et la colonne G-REX a été spécifiquement conçue pour cette résine. C’est à la mine d’or Ballarat de Castlemaine Goldfields que l’expérience opérationnelle a été acquise. L’usine de Ballarat, en exploitation quasi-continue depuis 2008, traite une solution concentrée non clarifiée de lixiviation. L’extension de cette technologie à des capacités supérieures et à une chimie plus complexe est examinée.AURIX®100 RESINAuRIX100 resin is a crosslinked polystyrene alkaline resin developed by Henkel (Virnig, Mackenzie, & Adamson, 1996). The resin beads are off-white in colour and spherical, with a nominal size of 100% +600 µm. This resin is highly selective for gold and silver over many metals, by way of extracting precious metal–cyanide complexes from leach solutions with a pH of less than 11.5. The higher end of the pH scale produces the best selectivity according to the order of preference: Au > Ag > Hg > Zn > Ni > Cu > Co > Fe. Purolite produces the resin and Gekko Systems maintains licensing of AuRIX100 resin for use in its G-REX column, as part of its unique suite of gravity gold–handling equipment.Significant cost savings over carbon-in-solution (CIS) systems are realized with AURIX100 resin: approximately 4–12% in capital savings and 27–40% in operating costs (Virnig, Mackenzie, Katsikaros, & Gray, 2004). Additionally, AuRIX100 resin is not susceptible to fouling; that is, the resin does not load with inorganic salts or organic compounds that would affect the loading and extraction of precious metals. To counter any potential for fouling by inorganic salts, a dilute acid wash is periodically conducted in service on the resin to unblock resin pores."

Jan 1, 2017

By M. A. Gomez, V. Yahorava, J. A. Strauss

"It is accepted widely that pressure oxidation (POX) is the most appropriate technology for processing of arsenic containing refractory gold ores. However, studies on the stability of various iron-arsenic precipitates formed during POX are limited. Since the behaviour of these phases could have significant practical implications for gold processing plants, it is important to study them in isolation. This paper compares two synthetic precipitates, basic ferric arsenate sulphate (BFAS) and basic ferric sulphate (BFS) in terms of their formation, behaviour during hot curing and cyanidation, as well as their environmental stability. BFS and BFAS were synthesised hydrothermally at 205°C and their mineralogy was confirmed using various techniques. During synthesis, the addition of H3AsO4 into an aqueous Fe2(SO4)3-H2SO4 mixture significantly decreased the iron yield to BFAS in comparison to BFS under equimolar initial iron and acid concentrations. The BFAS dissolution kinetics was slightly faster, as compared to BFS, during subsequent hot curing. Cyanidation test work on the washed synthetic precipitates indicated that the lime consumption of BFAS was three times lower in comparison to BFS, while cyanide consumptions were comparable. Fresh BFS and BFAS precipitates, as well as their cyanidation residues, were found to pass the respective environmental tests in terms of arsenic release.INTRODUCTION Pressure oxidation (POX) is generally viewed as the most appropriate technology for the processing of arsenic-containing refractory gold ores due to the stabilisation of arsenic in the leach residue (Dutrizac & Jambor, 2007; Gomez et al., 2008; Harris, 2003; Collins, Berezowsky, & Weir, 1988). Detailed laboratory studies indicated that several Fe(III)-arsenate type compounds may be formed under typical conditions of autoclave treatment of refractory gold ores (Swash & Monhemius, 1994; Dutrizac & Jambor, 2007; Gomez et al., 2008, 2010; Gomez, Becze, Cutler, & Demopoulos, 2011). The basic ferric arsenate sulphate (BFAS) phase (Gomez et al., 2008), also known as Type II ferric arsenate (Swash & Monhemius, 1994) or Phase 3 (Dutrizac & Jambor, 2007), is one of the most common arsenic-bearing products (Harris, 2003; Dutrizac & Jambor, 2007). BFAS precipitation is viewed as one of the best routes for arsenic stabilisation and performed equally well to scorodite during environmental stability tests (Harris, 2003; Swash & Monhemius, 1994; Dutrizac & Jambor, 2007; Gomez et al., 2008, 2011)."

Jan 1, 2017

By F. Liu, S. Rezaei, M. Muinonen, M. Barati, V. L. Lakshmanan, S. Marcuson

Canadian nickel-copper ore deposits have been a major source of nickel, copper, cobalt and precious metals for more than 100 years. The two main minerals of interest, pentlandite (Pn, (Ni,Fe)9S8) and chalcopyrite (Cp, CuFeS2), are usually accompanied by large quantities of pyrrhotite (Po, Fe1-xS). Until the 1950s, Po containing small amounts of nickel was routinely smelted as part of the valuable Ni concentrate. The rapid growth in Ni demand following the Second World War created impetus to treat the Po separately. This action would liberate a valuable smelting capacity for higher value Pn, allow for recovery of Ni locked in Po, convert the Fe to iron oxide or metallic iron pellets, and recover S as sulphuric acid or elemental sulphur. The roasting process also has the potential to produce energy due to the highly exothermic oxidation of Po. The Ni industry would then have a “waste-free” process. Both Inco (now Vale) and Falconbridge (now Glencore) developed processes and built large industrial plants for this purpose that operated with some success. But technical issues and tenuous economics were continual challenges. By the early 1980s these industrial operations were closed. Sophisticated froth flotation methods of rejecting Po were developed, and Po containing up to 1% Ni became a waste material reporting to the tailings stream. As part of a major study on possible processing methods of Po for both value recovery and waste remediation, this paper presents a historical perspective on Canadian Po tailings with regards to their generation, inventory, value, and attempts to process them.

Jan 1, 2017

By A. J. Monhemius

"This paper reviews the history of modern iron-control processes in hydrometallurgy. Attention is paid to processes developed in the electrolytic zinc industry for removal of iron from zinc sulfate leach liquors and the problems faced by the industry in the safe disposal of the iron residues produced by these processes. Past lessons learned are projected onto current efforts to develop hydrometallurgical processes for treatment of copper sulfide concentrates. It is argued that any attempt to create a “hydrometallurgical copper smelter” will fail, unless methods are developed that can recover iron in a form that can be directly used by the steel or pigment industries.RÉSUMÉ Cet article passe en revue l’histoire des procédés modernes de contrôle du fer en hydrométallurgie. Il accordera une attention particulière aux procédés développés dans l’industrie du zinc électrolytique pour l’élimination du fer dans les liqueurs lixiviantes de sulfate de zinc anhydre, ainsi qu’aux problèmes rencontrés par l’industrie en termes d’élimination sans danger des résidus ferreux générés par ces procédés. En projetant les leçons tirées du passé sur les efforts actuels, on pourra développer des procédés hydrométallurgiques pour le traitement de concentrés de sulfure de cuivre. Beaucoup prétendent que toute tentative de créer une « fonderie de cuivre hydrométallurgique » échouera à moins de développer des méthodes permettant de récupérer le fer sous une forme pouvant directement être utilisée par les industries sidérurgique ou des pigmentsINTRODUCTIONThis paper resulted from an invitation to the author from the CIM’s Historical Metallurgy Committee to give a presentation on the early developments of iron control in hydrometallurgy. This was to take the form of a plenary lecture at the 4th Symposium on Iron Control in Hydrometallurgy, which formed part of the 28th International Mineral Processing Congress, held in Quebec City in September 2016.I was naturally flattered that the invitation was to give the lecture at an IMPC, the prestigious conference series that has been held since the 1950s. That this particular IMPC was to include the 4th Symposium on Iron Control in Hydrometallurgy, a conference series held only every 10 years, made the invitation even more appealing and appropriate. This was because I had been co-chairman of the First Symposium on Iron Control, together with my erstwhile colleague, John Dutrizac, which was held 30 years ago in Toronto."

Jan 1, 2017

By M. R. Khalesi, Y. Kianinia, A. Seyedhakimi, F. Soltani

"The feed ore to Agh-Darreh gold processing plant (Takab City, Iran) contains 2 ppm Au, 7 ppm Ag, and 120 ppm Hg. After cyanide leaching of the feed at pH 10.4, 80% of the total mercury (in the form of cinnabar and metacinnabar) goes to the tailings dam. In this research, separation of mercury from the tailings by flotation was investigated. The effects of collector type and dosage, pH, and the number of cleaner stages were studied. The results showed that after two stages of cleaning a 40–62% recovery of Hg at a grade of 14.3% Hg is attainable. Recycle water from a test in which 50 g/t amyl xanthate and 30 g/t pine oil was used in the flotation stage showed no adverse effect on the leaching and adsorption of gold onto activated carbon.IntroductionMercury, most commonly found in the nature as the mineral cinnabar (HgS), is a hazardous substance because of its mobility and toxicity (Kyle et al., 2012). Roasting is the wellestablished treatment method for mercury ores, in which the sulphur is burned and volatilized and mercury recovered subsequently by cooling and condensation. However, for low-grade ores, flotation is mainly applied for primary concentration due to its comparatively low costs, low environmental hazards, and flexibility regarding feed variations (Bulatovic, 2007). Particularly, cinnabar can be easily recovered by flotation using pine oil and a collector such as xanthate (Bulatovic, 2007; Crozier, 1991). Floatability of cinnabar is reduced due to surface oxidation when it is exposed to the atmosphere after crushing. This problem can be eliminated by adding copper sulphate and lead nitrate or acetate. The best pH for cinnabar flotation is in the range of 6.5 to 8.5 according to Erspamer and Wells, (1954), who reported that cinnabar and stibnite can be floated with long-chain xanthate collectors and an alcohol frother, with cumulative recoveries of 97.8% and 94.7%, respectively. Lead acetate was used as an activator."

Jan 1, 2017

By O. M. Arafat, J. A. Finch

"The Functional Performance Equation calculated from a plant grinding survey defines two distinct ball mill circuit efficiencies and how they relate to total production rate through the target grind size. The survey data are also used to calculate a complete ball mill size distribution model, represented by the energy specific grinding rates, not just through the target grind size, but through all the size classes. Cyclone separation performance is represented by individual size recoveries to underflow. When these two unit operation performances are entered into the circuit modelling program (Streamline™), along with the circuit feed rate and size distribution, all the circuit survey size distributions and mass flows are perfectly regenerated by the program. The many issues associated with the historical Epstein (breakage-selection) models are eliminated. Once the circuit program is populated, pump and cyclone performance changes can be evaluated using a step-by-step procedure in order to maximize Classification System Efficiency. Mill water use and media sizing opportunities are also diagnosed in order to maximize Mill Grinding Efficiency at the size of interest. An example is provided. This circuit analysis and modelling system, and related training, is provided through a web-based application.IntroductionSince its development (McIvor, 1988), the Functional Performance Equation for ball milling has facilitated new understanding of industrial circuit cause and effect relationships, leading to significant strides in operational performance. Success stories of this refreshing approach to plant circuit performance improvement are now too numerous to list. Finch and McIvor (circa 1986) also discovered that the Functional Performance “Mill Grinding Rate” at the size of interest was the same cumulative grinding rate that is calculated from mill feed and discharge size distributions using a first-order rate equation. By calculating these cumulative grinding rates for all screen sizes, a complete ball mill model is generated (as used by Finch and Ramirez, 1981). Others in industry, Hinde and Kalala (2009), for example, have noted the same. Lacking the complexity needed to maintain their interest, most researchers have ignored this model, broadly opting instead for Epstein’s (1948) characterization of grinding as a chemical reaction, combining “selection rate” and “breakage size distribution” functions. The much simpler ball mill model presented here has previously been incorporated into a proprietary circuit modeling program (McIvor, 2005) and used for plant improvement work (for example, see McIvor and Finch, 2007, and McIvor, 2014). Now, by combining this extremely business-friendly ball mill model with optimization criteria from Functional Performance Analysis, a circuit modeling system (including the needed supplementary steps to assure successful plant implementation of circuit design changes) is at the disposal of every plant metallurgist, grinding equipment/material provider, and circuit designer."

Jan 1, 2017

By Alessandro Bertero, Dylan Pearson, Wesley Schmutzler, Matteo Bertoni

"The SR 83/US 331 highway is located in the Florida panhandle, where it connects the Walton County beaches to the I-10 corridor. The roadway is of vital importance to the economy of the area as well as its safety since it represents the primary hurricane evacuation route from southern Walton County. The Florida Department of Transportation (FDOT) decided to increase the number of traffic lanes from two to four and improve the geotechnical properties of the moderately deep, very loose foundation soils, that had affected the highway rideability for years. The soil mixing was selected as the method to meet the unique deep ground improvement challenges of the project. The design required that Shallow Mixing Method (SMM) be used to build a 10-foot thick platform that transferred axial load to the bottom soil layers through a series of Deep Mixing Method (DMM) columns. Upon completion over 8,300 SMM columns and 1,500 DMM columns had been installed, with no remedial work required. Also, only 1% of the almost 1,500 specimens tested did not meet the specification requirements. This paper will describe the challenges encountered and provide valuable information that may be useful for other future projects, including details not previously published.INTRODUCTIONThe counties of Walton and Okaloosa have been a very popular vacation destination for many ears. The 50-mile long coastline boasts beautiful, sugar-white beaches and waters the color of emeralds. The popularity of the area has been growing even further, over the last few years. A consequence of this phenomenon is a fast-paced increase of the traffic flow on the SR83/US331 highway, especially at the bridge that connects the Walton County beaches across Choctawhatchee Bay (Fig. 1) to the heavily traveled I-10 corridor. The highway plays a very important role for the area also as a commercial link and as the primary hurricane evacuation route from southern Walton County. The increase in traffic has produced higher travel time, when not a complete traffic paralysis, and exacerbated the issue of ground settlement where accelerated wearing of road foundation occurred due to the presence of very loose, moderately deep, soils, that had afflicted the highway for several years. The Florida Department of Transportation (FDOT) decided to put an end to these issues by increasing the number of traffic lanes from two to four and improving the geotechnical properties of the foundation soils. The Design-Build Maximum Price Request for Proposal (RFP) issued for the expansion of the Choctawhatchee Bay Bridge saw the participation of numerous D/B teams which produced various technical solutions. Among them, the FDOT selected the Skanska/Parsons Brinckerhoff (General Contractor) proposal which provided for the use of soil mixing as the ground improvement technology. The design/build team assigned Foundation & Geotechnical Engineering (Designer of Record) the ground improvement design which Treviicos South (Specialty Contractor) would execute."

Jan 1, 2017

By Yeruva Ramanareddy, Sohail Wajid, Ahmed Shaz, K. Bhavani

"CP-06 is an NATM cross passage which connects up-line and down-line metro tunnels near Kilpauk Medical College, Chennai. It lies completely in loose silty sand to dense sand with water table almost touching the ground surface after Chennai floods. Pre-grouting was done before excavation to seal the area and to ensure no-loose pockets. The heading was excavated successfully but while benching excavation huge water ingress started seeping out. Sand also permeated along with water which became unstoppable due to cavity formation and caused the up-line tunnel to sink considerably. A large grouting exercise was carried out with different grout materials and techniques both from the ground surface and inside of tunnel to stop the water ingress and stabilize the tunnel. This paper describes the chronology of events that occurred in the tunnel during CP-06 issue. It elaborates all the different grouting techniques involved in the whole process of the tunnel stabilization. It includes a finite element analysis using Rocscience RS2 9.0 software showing the possible cause of sand incursion with water from the CP invert which lead to the tunnel settlement. This paper also describes the after effects and the lesson learnt from the whole incident.INTRODUCTIONConstruction of Metro Rails has become the latest alternative to cope up with the transportation demand of the growing urban cities population. L&T SUCG JV constructed Chennai Rail Metro Phase II Contract UAA-04 which included design and construction of approximately 4 km of route length of underground mass transit railway including 3 underground stations. This package also includes 12 cross passages which are NATM tunnels connecting upline and down-line side of TBM tunnel for safe evacuation of passengers in case of emergency. As per NFPA guidelines, this is a mandatory structure and there should be atleast one cross passage in 244m tunnel length.CP-06 is a cross passage connecting upline and downline tunnel between Pachiyappa College Station and KMC Station, in Chennai Metro. During the construction of CP-06, heavy water seepage of around 450 liters per minute was encountered during second round of benching excavation after full heading was excavated. An inflow of around 12-15 cum of sand and silt was also observed inside the tunnel along with the seepage water, which created piping inside the TBM tunnel causing it to settle continuously with time. A huge effort was made to stop the water ingress along with loose sand which was causing the running tunnel to settle, involving all possible grouting methods and temporary support installation."

Jan 1, 2017

By O. A. Ojo, N. Esmaeili

"The effects of brazing and use of composite powder mixture as interlayer material on hot corrosion resistance of brazed IN738 superalloy were studied. Brazing was observed to result in significant reduction in the hot corrosion resistance of the superalloy. However, application of composite powder mixture, which consists of additive superalloy powder, enhanced the hot corrosion resistance of brazed samples. It is also found that although the use of composite powder mixture increased hot corrosion resistance of brazed alloy, if the additive powder completely melts, which is possible during brazing, it can significantly reduce the hot corrosion resistance of the brazed joint. Elemental micro-segregation during solidification of the joint with completely melted powder mixture produces chromium depleted zones and consequently reduces hot corrosion resistance, since a uniform distribution and adequate chromium concentration is necessary to combat hot corrosion. This has not been previously reported in the literature and it is crucial to the use of composite powder mixture for enhancing the properties of brazed superalloys.INTRODUCTION Superalloys have been developed in response to the increasing demand for materials with higher resistance to corrosion and creep and also with higher mechanical strength at higher temperatures (Smith, 1981). Ni-base superalloys are predominantly used in manufacturing hot sections of gas turbine engine components. This is due to their high strength and corrosion resistance in extremely high temperature service environments which is typical for hot sections of gas turbine engines (Miglietti, 2009). The continuous demand for higher efficiency and output has resulted in the use of higher operating temperatures and gas pressure in modern gas turbine engines (Jahnke & Demny, 1983). Consequently, this has caused thermal and mechanical stresses which result in severe degradation and damage of gas turbine engine components due to creep, fatigue and hot corrosion (Zhang, Feng, & He, 2006). The decision to replace or repair damaged parts depends on the overall repair cost and expected life of the repaired components (Jahnke & Demny, 1983). However, in most cases, it is more cost effective to repair damaged parts rather than use a full replacement."

Jan 1, 2017

By Kodi Ranga Swamy, N. Sankar, M. Akhila

"Until recently, liquefaction-related studies concentrated on clean sands believing that only sands are susceptible to liquefaction. However, a few earthquakes like 1976 Tangshan earthquake, the 1989 Loma Prieta earthquake, the 1999 Kocaeli earthquake, the 2010 Chile earthquake, and the 2011 Christchurch earthquake, etc. showed that sand with fines could also liquefy. The research findings on liquefaction of silty soils are limited, and several structures constructed on such soil deposits are damaged during the past earthquakes. Some previous results of research on earthquake events show an increase of liquefaction resistance in silt soils with increase the fines content, but some report the opposite trend. This study presents the results based on undrained triaxial cyclic tests which were carried out on the fine sand with fines (0%, 10%, 20% and 40% fines). The samples were prepared at the required unit weight (Dr = 50%) and saturated by using back pressure and cell pressure increments. Each consolidated sample is subjected to cyclic loading with sinusoidal wave load form at a frequency of 1 Hz. The liquefaction resistance is evaluated in terms of cyclic stress ratio required to cause 100% pore pressure or 20% failure strain occur at 15 numbers of load cycles. Results are presented in forms of pore pressure build up and axial strain propagation plots. As the fines content increased, an increase in liquefaction potential was observed.INTRODUCTIONLiquefaction and related phenomenon have been responsible for tremendous amounts of damage all around the world. In general, the liquefaction may occur in fully saturated sands, silts and low plastic clays. When the saturated soil mass is subjected to seismic or dynamic loads, there is a sudden buildup of pore water within a short duration, and it could not dissipate which leads to reducing the effective shear strength of soil mass. In this state, the soil mass behaves like a liquid and causes large deformations, settlements, flow failures, etc. This phenomenon is called soil liquefaction. As a result, the ability of soil deposit to support the foundations of buildings, bridges, dams, etc. is reduced. Liquefiable soil also exerts a higher pressure on retaining walls.This lateral movement of soil could cause settlement of the retained soil. A sudden build-up of pore water pressure during quake also triggers landslides. Liquefaction damages of structures are commonly observed in low-lying areas near the rivers, lakes, and oceans."

Jan 1, 2017

By Brian M. Fraley

"Portions of the Catholic Total Abstinence Fountain in Fairmount Park in Philadelphia, Pa., were in “imminent danger,” according to a restoration services request for proposals (RFP) issued by the City of Philadelphia in August 2014. Open voids in the subsurface beneath the foundation were causing ongoing settlement of the fountain.The fountain was unveiled in 1876 as an ornamental drinking fountain for the Centennial International Exhibition, which celebrated the signing of the Declaration of Independence. Its creation was commissioned by the Catholic Total Abstinence Union of America, an Irish temperance organization that advocated for total abstinence from alcohol. Ironically, the fountain ran dry decades ago.The now-defunct fountain features a 100 ft (30.5 m) wide granite base with three steps in the shape of a Maltese cross. The centerpiece — enclosed by a 40 ft (12.2 m) diameter basin — is a 15 ft (4.6 m) tall statue of Moses perched atop an iglooshaped marble mound. Four subsidiary statues rise from granite pedestals at the tips of each arm of the cross, including Archbishop John Carroll, Charles Carroll of Carrollton, Father Theobald Mathew and Commodore John Barry.Natural and Man-Made DamageThe City of Philadelphia’s RFP called attention to three “high priority structural areas.” It was noted that Moses, Father Mathew and the steps surrounding the fountain had been documented as public hazards. The long-term effects of water infiltration had set in, eroding mortar joints and causing some stones to jut out. Furthermore, the stone base supporting the 16 ton (14.5 tonne) statue of Moses was in danger of collapsing. The statue of Father Mathew had been struck by lightning in 1910 and was repaired with an iron and metal pin anchor system, which had succumbed to corrosion. The city considered the statue of Father Mathew as the most threatened of the statues. Mike Miluski, P.E., vice president of Compaction Grouting Services (CGS), recalled “the fountain was in pretty bad shape” as he walked onto the site in August 2016 and immediately recognized the challenges ahead."

Jan 1, 2017

By D. B. Dreisinger, M. Rasouli

"Developing technology to address the environmental hazards associated with selenium in mine-impacted waters has been a serious challenge. Ion exchange (IX) has been identified as a potential treatment technology. This paper begins with a review on selenium adsorption with commercially-available basic anionic exchangers (BAS). It then looks at the use of resins for selenium removal via modification with the addition of -O, -N, or -S-containing chelating ligands and chelating polymeric ion exchangers pre-loaded with immobilized metal cations. The synthesis of chelating exchangers requires a final product with a highly stable metal in the ligand-metal complex. The nature, oxidation state, size, and affinity of the metal for the target oxyanions and the size, degree of protonation and space configuration of the oxyanion are among critical factors affecting the oxyanion uptake. There is a limited number of studies on the critical parameters affecting the selenium affinity for chelating exchangers. Such a study could fill in the gaps of our understanding of selenium-metal-chelating ligand interactions and assist in developing a new ion exchanger. In addition to commercial IX resins, layered double hydroxide materials (LDH) have received attention for oxyanion removal from waste water. The adsorption capacity of the LDHs are affected by the crystallinity of LDH, the nature of metal components, the ratio of metals, charge and type of anion, and the space between the layers. In particular, the Friedel phase (FP), a member of the LDH family, showed high adsorption capacity for selenate removal from synthetic solution. A study is currently underway at the University of British Columbia to investigate the effect of different synthesis methods and aging on the suitability of FP for selenium removal from mine waste water."

Jan 1, 2017

By G. Goodall, M. Muinonen, R. Pandher, R. Jabbar, S. J. Muinonen

"The implementation of a new and highly efficient converting practice at the Glencore Sudbury Integrated Nickel Operations Smelter has opened the possibility to further capacity increases by using larger ladles. To quantify the impact of increasing ladle sizes from 200 to 300 ft3, XPS constructed a detailed discrete event simulation using the commercial software package Rockwell Arena®. The challenges associated with implementing a model on an intricate and tightly scheduled process, and the solutions needed to derive meaningful results will be presented. The aisle capacity is predicted to increase by approximately 17 %, with a reduction in furnace tapping demand of 8 %. Arena modeling capabilities and the key factors contributing to the overall capacity increase at the Sudbury INO Smelter will be reviewed and presented.INTRODUCTION The Glencore Sudbury Integrated Nickel Operations (INO) comprises two Ni-Cu-PGM mines, Strathcona Mill, and the Sudbury Smelter. The Smelter has operated continuously since 1929 using different processes to produce nickel-copper Bessemer matte. Feeds to the Sudbury INO Smelter are a blend of concentrate from Strathcona Mill, Raglan concentrate produced at the mine-mill complex in Raglan, Quebec, as well as third party concentrate feeds shipped to Sudbury from around the world. In 2016, the Sudbury INO Smelter produced 75,900 tonnes of nickel and 20,000 tonnes of copper in Bessemer matte. The product matte is shipped to Glencore’s Nikkelverk refinery in Kristiansand, Norway where it is refined to produce nickel and copper cathode. A schematic of the Sudbury INO Smelter’s flowsheet is shown in Figure 1."

Jan 1, 2017