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By N. Yamazaki

The supply of clean copper ores, which have high copper concentration and low impurities like arsenic, has declined year by year. Therefore, both mine and smelter sides have to consider how to remove impurities like arsenic. We focus herein on arsenic as an impurity because it is an extremely important issue from the environmental point of view. Approximately 150,000 t of arsenic is input into the copper industry every year. A small part of it is mainly treated in the smelting side. For instance, Ministro Hales Limited, which is a mining corporation in Chile, has performed the calcination process to remove arsenic from ore with high-arsenic content. In the process, flue gas is washed by water, and the final residue is treated by a hydrometallurgical process. Many processes for arsenic removal in various stages have been proposed, and several bottlenecks exist to achieve it. One of the difficulties encountered is getting an assessment of the process, which depends on the countries and/or areas of operation. The standardization of the assessment procedure will be desired in the near future to keep the same environment standards all over the world, and now is the time to start making discussions on this matter. This will be the first step in making an international assessment procedure for arsenic treatment in the copper industry. INTRODUCTION Using the term “sustainable development” without any scientific basis can give people a false sense of security. Engineers and scientists must analyze the total mass flow of energy and materials and estimate local drain on the environment as well as the global impact of a particular industrial activity to ensure sustainability on this planet. The operations of the mining and smelting industries have a strong effect on the environment even if they provide useful materials for human beings. The copper mining and smelting industries have brought about serious environmental problems in the past. For example, the Ashio mine pollution caused big damage to the agricultural sector near the Ashio area in Japan in the late 19th century. One of the most serious problems at that time was SO2 emission because copper ore is sulfide, and the smelting process basically results to sulfur oxidation. The resource balance from a copper smelter in a year, assuming a total production of 16 million tons, can be summarized as follows: discarded minerals, 30 billion tons; sulfur, 16 million tons; iron oxide, 8 million tons; additional smaller amounts of other metals, electricity, and fuel.

Jan 1, 2019

By Bryon Cerklefskie, Michael Schulte

"This case study explores the usage of polymer ducting as a replacement to curtains and FRP for face ventilation in two coal mines. There are two mines looked at, one is the highest elevation underground coal mine in North America, the other is the gassiest mine in North America. The paper details the trials of both mines switching from FRP and curtain respectively to polymer ducting. The results discuss the ability for the mines to not only achieve consistent airflows and keep them in compliance but the unexpected positives. Mine A was allowed to do longer cross cuts due to increased air volume at the face. This drastically cut their costs of mining down due solely to modification of the ventilation cycle. Mine B saw economic benefits due to longer cuts between place changes. Both mines have documented lower dust, methane, noise, and improved wear and tear on their equipment as a result.INTRODUCTIONThe emergence of longwall mining in underground coal operations has resulted in new ventilation challenges. Numerous production crews strive to complete their development sections with enough time to adequately prepare for the upcoming longwall panel. Continuous miners will cut out two or three entry development sections per their ventilation plan, that is approved and controlled by MSHA (Mine Safety and Health Administration), which will drive amount of footage that can be mined at a time prior to installing roof support. At this moment the continuous miner, hereafter referred to as the CM, will back out of the entry and moves to the second entry to complete a similar cut. Typically, a roof bolter crew will pull in to the finished cut section and install ground support. This is called a place change style of production coal mining. There is an alternate method that includes a miner/bolter combination as well but that was not featured at either test site in this case study. Ventilation has to be provided to sweep the working face of each entry to control dust and gasses. Each task will have an MSHA prescribed ventilation requirement dependent on the dust levels and methane emissions of the rock for that particular mine. The CM, roof bolting and unused headings will each require constant ventilation but at different volumes. Since each working face is changing throughout the mining cycle the ventilation requirement in a working heading is never static and is changing with the working task.Traditional Ventilation ControlsTraditionally face ventilation for coal mining operations has been completed thru the usage of a curtain system and\or using auxiliary fans and ventilation tubing. Room and pillar mining systems typically utilize curtain systems, which use curtain walls that are installed by the miners by erecting wood framing and covering it with brattice curtain. This splits the drift width to allow fresh air to sweep the face and take the contaminated air and dust behind the curtain to the ventilation exhaust\return area of the mine. This method is difficult to adjust the airflow from entry to entry during changing cycles and requires that a wider drift is mined out in order to have enough room for the brattice wall. In operations that require roof bolting, this method limits the length of the cuts from the CM prior to advancing and can lead to not providing enough ventilation to keep dust and methane levels below compliance requirements."

Jan 1, 2019

By Andrew Dobson, Cheryl Allen, Enrique Acuña

"Totten Mine return air raise was designed with two parallel fans equipped with silencers to reduce the noise emitted from the outlets into the environment. As development and production of the mine progressed through the past years, the silencer system needed to be upgraded, and additional maintenance strategies have been necessary to meet the regulatory noise limits enforced by the province of Ontario. The current mine plan will require the fans to reach the upper limit of their capacity by Q1 2019. To achieve this operational target, additional silencing capability has been required and Totten Mine has explored alternatives to further extend the noise silencing capacity available considering the current constraints at the mine site. The alternatives included a new silencer baffle design and a new layout that have allowed doubling the length of the silencer system. Using acoustic measurement data collected on several occasions, this paper presents and discusses the performance of the various silencing systems which have been installed on the return air fans at Totten Mine.INTRODUCTION Vale Canada Limited’s Totten Mine is a base metal, underground mine extracting nickel and copper, situated in the Sudbury Basin of Ontario. The mine initiated operations at the end of 2013, and is equipped with two main return air fans and two main fresh air fans located on surface. Both fresh air and return air fans are set in a parallel arrangement to operate as integrated units and are equipped with variable frequency drives (VFDs) to allow for the remote modification of their operating set point, usually between 600 to 880 rpm, depending on the mine’s requirements. The main return air raise (RAR) fans are also equipped with dissipative baffle silencers to attenuate the noise emitted to the environment. Approximately four years ago, acoustical measurements conducted to verify compliance with the applicable regulatory criteria, and respond to noise concerns from neighboring residents, concluded that the sound emissions of the main return air raise exceeded the noise design parameters. The acoustic tones of the fans were audible offsite, at a residential location, approximately 9 km northeast of the mine site. The elevated sound levels and offsite audibility was due to degradation of the original discharge silencers from moisture and particulate being drawn from underground workings and passing through the silencer baffles. The audibility was also due to an outlet directivity pattern which directed noise towards the residential location."

Jan 1, 2019

By Bin Tang, Suping Yao

In the last decade, the copper industry in China has developed rapidly and attracted the world’s attention. The production capacity of refined copper has grown remarkably from 4.578 million tons in 2010 up to 9.029 million tons in 2018, accounting for about 40% of the global refined copper production. And now, China has become the biggest refined copper producer in the world. This paper summarizes the application of modern copper metallurgical technologies such as Outotec flash smelting/converting technology, Cyclone smelting technology, TSL (ISA/Ausmelt) smelting/converting technology, Jinfeng side blown smelting and Baiyin side blown smelting technology, Chifeng side blown smelting and continuous top blown converting technology, SKS bottom blowing technology, Dongying two-step smelting technology, copper electrorefining with high current density, etc. in China’s copper industry, analyzes and compares the characteristics of those technologies and presents the great efforts of China’s copper smelters in adapting to the increasingly strict emission standards and improving economic benefits of copper smelters. INTRODUCTION China has been the biggest refined copper producer in the world for many years. China produced million tons of refined copper in 2018, accounting for 40% of the copper smelting production in the world, and of which, roughly, 70% of the copper concentrate was imported, mainly from Chile, Peru and Australia. ICSG (International Copper Study Group, 2017) shows clearly the position of top 20 countries of copper production and copper mine production (Figures 1 and 2). Blast Furnaces, Reverb Furnaces and Electric Furnaces dominated China Copper Smelting for quite long time till 1980s. The first modern copper smelting technology (flash copper smelting) was introduced into China in 1980s, then followed by Noranda, Ausmelt and ISA. Since then, China copper smelting technology stepped into modern time. Since 2000, old processes (Blast Furnace, Reverb Furnaces and Electric Furnaces) were phased out and replaced by modern smelting technologies. China Copper Production has been increasing dramatically (Figure 3).

Jan 1, 2019

By P. H. Agson Gani, T. Sitorus, N. P. Widodo

"PT ANTAM UBPE Pongkor underground mine use blasting to develop its tunnels which will cause poisonous and dangerous gases trapped inside mine. To analyze this case, a study of mine ventilation, the dispersion of carbon monoxide (CO) gas concentration and diffusion coefficient is commenced. At the end, the re-entry time formula will be determined. Results indicate that this study is site specific and could only be applied in the place this study executed. The aim of this study is to be further developed by applying Principal Component Analysis (PCA) to find a universal re-entry formula. KEYWORDS Mine Ventilation, Re-Entry, Smoke Clearing, Diffusion Coefficient, Carbon Monoxide Gas, Gas Dispersion INTRODUCTION Pongkor underground mine is using cut and fill as its mining method. Thus, its development and production processes require blasting to develop its tunnel. This process caused poisonous and dangerous gases spread and trapped inside the mine, one of them is carbon monoxide (CO) gas. CO is formed in an unbalanced reaction of explosives detonation and could be the cause of headache, blackout and death to people who inhale CO at certain concentration (McPherson, 2011; Hartman, Mutmansky, Ramani, & Wang, 2012). Mine ventilation system is installed in the mine to resolve this problem. Mine ventilation play an important role to disperse CO gas by absorb the poisonous/dangerous gases and deliver clean air into mine. The important parameter is diffusion coefficient, because diffusion is affecting particulates or gasses spreading from its sources throughout the mine. Diffusion coefficient is the total diffusion in axial direction of turbulent flow mainly by convection of bulk motion, advection and eddy diffusion, while the effect of molecular diffusion is appreciably negligible (Widiatmojo et al, 2015). Taylor (1953, 1954) develops a theory about the dispersion by inducing a slow stream of solvent into a capillary tube. Taylor used Reynolds assumption of radial diffusivity to be analogous with the transfer of the matter in turbulent flow as well as the transfer of momentum and heat. Then, Taylor proposed the formula of diffusion coefficient, D (m2/s), against pipe diameter and turbulent shear velocity are as follow:"

Jan 1, 2019

By S. Dominguez, E. Gebrehiwot, S. Richardson, S. Sandoval

Copper electrowinning/electrorefining (EW/ER) is powered by direct current (DC) rectifiers that typically generate 30,000 to 70,000 amps and a bus-bus voltage of 200 to 500 volts DC. Tankhouses are designed so that DC current flows through “cell lines” which contain individual EW/ER cells electrically connected in series. Electrolyte composed of copper sulfate and sulfuric acid in water forms the “liquid conductor” that connects the metallic conductors in this circuit. In this setting, stray current is a DC current that strays from and therefore bypasses the tankhouse circuit by finding a path to ground, often through the electrolyte in pipelines that feed into and discharge from the cells, or through dried electrolyte (i.e. sulfate), which is also electrically conductive. Tankhouse workers can be exposed to shock hazards if they become part of a stray current path to ground. This presentation details examples of stray current shock hazards in electrolytic tankhouses and provides voltage and amperage measurements associated with stray current in these examples. A review of critical safety controls in EW/ER tankhouses that will mitigate the risk of employee shock from stray current is also provided. INTRODUCTION Electrolytic tankhouses are designed to deliver relatively large amperages of DC current to a series of electrolytic cells in which copper is plated out of solution using the classic anode-cathode pair geometry within each cell. Electrolyte is the “liquid conductor” that transfers current in between the metallic conductors of the cell. The metallic conductors include inter-cell copper bus bars and the anodes and cathodes themselves. It is sometimes forgotten that electrolyte as a conductor is capable of delivering DC current outside the designed circuit of a tankhouse. Stray current is a DC current that strays from the tankhouse electrical circuit by finding a path to follow other than the designed path. Safety becomes a concern when there is a risk of an employee becoming part of an accidental stray current path, thereby suffering an electrical shock. In 2016, Freeport-McMoRan (FMI) suffered a fatality at one of its copper electrowinning tankhouses. The forensic analysis concluded that stray current from the tankhouse rectifier contributed to the fatality. An employee accidentally fell into contact with a metal flange at the end of an HDPE pipe that was collecting cell overflow electrolyte from the tankhouse. DC current passed through the employee to ground, creating a shock that was judged to contribute to his death. The situation was exasperated because the employee was unconscious, and therefore was exposed to the stray current for several minutes before being found. In addition, the employee’s clothing was saturated with liquid, and the employee was found kneeling in puddled liquid on the ground. FMI immediately began an investigation into the root cause of the stray current that was measured at the scene. Sufficient electrolyte had accumulated in the HDPE pipe such that a continuous path was formed between it and electrolyte that was continuously overflowing from energized electrowinning cells. The metal flange on the pipe was the metallic conductor that carried the current to the employee from the electrolyte inside the pipe. Current then flowed through the employee to ground. Because of this incident, FMI undertook an extensive review of the hazards of stray current in EW/ER. FMI’s tankhouse workforce received a Tankhouse Electrical Safety training course developed in- house to insure worker understanding of stray current hazards. Tankhouse design changes were implemented to better insulate workers from stray current. Personal protective equipment (PPE) standards were also reviewed and changes made.

Jan 1, 2019

By Ruipeng Qian, Pengfei Wang, Guorui Feng, XianJie Du, Jun Guo, Yuxia Guo, Tingye Qi, JinWen Bai

"A numerical modeling was conducted to describe the behavior of overlying strata on the longwall top coal caving face for exploitation of a 16.8 m thick coal seam. Three typical structural models, including the Cantilever Structure (CS), Lower Cantilever and Upper Hinged Arch Structure (LC&UHA), and Lower Arch and Upper Voussoir Beam (LA&UVB), were developed. Based on mechanical analysis of the different structures of the key strata, and considering the behaviors of the broken igneous rock strata, a method was proposed and applied to estimate the structures of the overburden strata. The results had been verified by a field micro-seismic monitoring test. The paper provides a foundational method to determine the shield loadings for the top coal caving longwall face.INTRODUCTIONLongwall top coal caving (LTCC) is a highly productive underground mining technology which has been widely applied to the exploitation of the thick coal seams in China and other countries due to its high efficiency (Ju and Xu, 2013; Ju, Xu, and Wang, 2011; Liu et al., 2009). In recent years, a large amount of research on mining pressure forecast, strata control, and mechanical equipment improvement of the LTCC technology has been carried out, which greatly advances the field application of the technology (Liu et al., 2009; Yu, 2016; Dou et al., 2014; Feng et al., 2011; Chen and Li, 2011; Yin, Yan, and An, 2008). In 2006, the LTCC technology was first applied to the exploitation in a 20 m thick coal seam at the Tashan Coal Mine in China (Yan et al., 2011). Ten years of mining at the Tashan Coal Mine has highlighted the importance of the support management in controlling the roof strata on the extra-thick LTCC face. The mining pressure is closely related to the structural features of the overlying strata and its movement laws (Yu, 2016; Dou et al., 2014; Feng et al., 2011). However, the distributions of three zones—caving zone, fracture zone, and deformation zone—on the fully mechanized caving longwalls changed significantly with the increase in thickness of the coal seam (Chen and Li, 2011). The behavior changes of the roof strata led to abnormal pressure in the mining face and resulted in the difficulty of surrounding rock control (Yin, Yan, and An, 2008; Liu et al., 2009; Yan et al., 2011; Gong and Jin, 2008). Therefore, the theoretical research focused on the behavior of overlying strata to reveal the laws of mining pressure has important theoretical significance and practical value.Many classical studies (Qian and Shi, 2003; Feng, 2010; Yu, 2015; Yu, Yan, and Liu, 2012) had been done to describe the behavior of overlying strata in the mining process. It has also been reported that magma intrusion causes an important effect on the surrounding rock, coal, and methane (Wang et al., 2005; Liu et al., 2007). On the one hand, the property and structure of the coal seam was obviously changed by the magma intrusion and resulted in a potential danger of a gas outburst during the mining process (Chen et al., 2012; Wang et al., 2014). On the other hand, the hard igneous strata and the joints occurred with the magma cooled, causing an abnormal behavior of overlying strata and resulting in a series of dynamic disasters during mining (Xuan, Xu, and Lu, 2014; Lu et al., 2016). In fact, many coal fields in China are intruded by igneous sill, including the Datong, Shuozhou, Huainan, and Xuzhou coal fields (Chen et al., 2014; Wu, 2011). The 3–5 coal seam at Tashan Coal Mine in Datong coal field is very thick and is intruded by a large area of layered lamprophyre rock. Face falls and shield failures occurred frequently during the face retreat."

Jan 1, 2019

By N. Sinclair

"In open pit dozer bulk push operations, the material left resting against the highwall after blasting poses an issue. This is because dozers cannot physically get in behind the waste to begin the bulk pushing process. Instead, an excavator can be used to side-cast this waste for the dozers to access. An alternative technique is to have the dozers ‘side-cut’ the material, which involves the dozers running parallel to the wall, digging out the material, and eventually rotating their blades to begin bulk pushing. Industry practices suggest the latter technique is less productive and economical than using an excavator. However, such excavator sidecasting ‘economic viability’ assumes that smaller/ancillary type excavators are used (i.e. less than 23 m3 bucket capacity). So, what happens if some mine sites are restricted to using relatively larger excavators (> 23 m3 bucket) that are preferred for higher priority digging tasks? When can they avoid using their excavator? This paper explores multiple scenarios that have been designed and developed to simulate data results, which identify conditions in which the dozer side-cutting technique becomes more economically viable than excavator side-casting in terms of decreased unit cost per loose cubic metre. IntroductionOptimizing the cost of waste removal operations is important for the profitability of opencast coal mines. In the past decade, dozer bulk pushing has emerged and taken over from traditional waste removal operations such as dragline and truck-and-shovel methods at various sites around the world (Beatty, 1994). In a typical bulk push operation, once the bench has been blasted, waste is left resting against the highwall, which can either be cleared using a loading unit or by having the dozers ‘side-cut’ the highwall.Dozers perform most effectively when slot dozing side-by-side, perpendicular to the highwall. However, when dozers are required to remove material off the highwall, they must push parallel to the highwall, rather than perpendicular, hence ‘side-cutting’ the material to ensure a clean face. While dozer sidecutting is possible, it has been found that the majority of mine sites use a loading unit in this situation to avoid dozer inefficiency. Other perceived issues with dozer side-cutting include higher maintenance requirements and safety risks to dozer operators working in close proximity to the highwall."

Jan 1, 2019

By Z. Zhang, M. S. Gonzalez, M. de P. Bueno, P. Holopainen, S. Luukkanen

In an extremely competitive mining industry, onsite experience is a big advantage. Mining education at the universities is mostly focused on theoretical studies without a possibility of practical training in mining sites. Hence, experimental mines suitable for practical education are needed to provide a platform for systematic research and education in industrial scale and for training in real mining conditions. Yet, this kind of mine sites is rare worldwide. Thus, a new educational research project, namely MINETRAIN is introduced in this paper evaluating the transition of the Pyhäsalmi mine in Central Finland from an active base metal mine to a research, educational and training underground facility. The uniqueness of MINETRAIN compared to other test mine programs is that the existing state‐of‐art infrastructure in Pyhäsalmi enables research and training facilities among all disciplines related to the overall mine value chain. Though all the above sound interesting in the context of research and education purposes, in practice Pyhäsalmi will have to become an experimental mine that can be sustainable in the future. Accordingly, a prefeasibility study is being conducted and some preliminary results are presented in this paper. INTRODUCTION Despite being a field of studies that requires practical knowledge and experience, mining engineering education follows the same pattern in most mining universities around the world; consisting of theoretical courses and laboratory-based practical modules (Mischo, 2015). The possibility of having practical training in real mining conditions on actual mine sites or processing plants is limited to none, while the only contact that undergraduate students have with mining operations during their time of studies is usually through short-time internships or visits in the context of educational trips. Yet, real integration between universities and the mining industry may be scarce, which does not help students to observe the actual processes, and thus understand the whole picture of mining operations. Indirect practical training is also possible nowadays that technology is shifting from mechanical to digital, and the use of virtual reality -in the context of Mining 4.0- can provide additional experience to the learning process. However, virtual reality is limited to the visual impression and is also limited in actions (Binder et al, 2018). In any case, when there is not a proper pragmatic view of how the different disciplines link to each other and especially if there is a lack of communication, unfortunately the results could be seen at a later stage in the mines as a poor performance of professionals and workers. Another major challenge for educating specialists in the mining sector is that experimental mines suitable for practical education, where the skills and know-how could be developed and/or enhanced are rare worldwide. Such research and educational (R&E) facilities are practically former metal ore mines that have been transformed into experimental sites. Besides being limited in number, not all facilities of this kind serve both a research and educational purpose.

Jan 1, 2019

By Ricardo Dr. Chavez, Mathieu Lachamp, Rob Dr. Farnfield

Pueblo Viejo is an open pit gold mine in the Dominican Republic which is always looking forward to implement the newest technology in the industry to improve all processes. Focusing on one of the pillars of the department and our company, digitalization, we’ve been looking for the technologies that allow us the automation of data generation, supervision and process innovation. That’s where a new Drill and Blast software takes place, helping to integrate the process from the beginning to end, right after the pattern is designed until it’s blasted, allowing us to track results like vibration, fragmentation, performance, cost and inventory of each blast in a single platform. The software helps engineers to generate back analysis by blast, bench, pit, month and many other ways, in a timely friendly manner. Therefore, we can catch business opportunities and improvement for the drilling and blasting process.

Jan 1, 2019

By J. Dilbeck, J. K. Ratliff, T. Petrov, Z. Brown

"In efforts to improve dust control during deep cut continuous mining a supplemental atomizing spray system, mounted on 14CM15 continuous miner, has been designed and successfully implemented in a U.S. coal mine. The mine is 2.1 m (7-ft) high and uses a blowing curtain face ventilation system with 1.1 m (3.5-ft) curtain offset from the rib. The face ventilation design parameters were set to 9.4 m3/s (20,000-cfm); 4.2 m3/s (9,000-cfm) line curtain flow rate, and 3.8 m3/s (8,000-cfm) scrubber capacity. The performed in-mine measurements, before and after the implementation of the atomizing spray system, showed a significant decrease in the respirable dust levels at the operator place as well as at the return. The paper describes the supplemental water spray system design and performance supported by three-dimensional computational fluid dynamics (CFD) simulations and in-mine test data.INTRODUCTIONThe work on this project have started in 2015 with a study of the conventionally applied face ventilation layouts. The specific behaviour of the face ventilation system have been analyzed trough in-mine measurements and computer modeling of typical cut scenarios. An computer modeling methodology have been developed for estimation the respirable dust concentration (RDC) using tracer gas to RDC contour mapping, calibrated by a single point value, provided by in-mine measurement. Utilizing the results of this study the engineering staff of the mine designed and implemented a supplemental atomizing spray system to improve the dust control during the deep cut continuous mining. Today the atomized spray system is successfully applied demonstrating steady performance and a significant decrease in respirable dust concentration on the working places of the continuous miner (CM) and coal transporters (CT) operators as well as at the return air stream. Information about the applied type of spray nozzles provided by other researchers (Cheng, 1973; Dick et al., 1996; Organiscak & Page, 1998; Pollock & Organiscak, 2007) and spray system manufacturers (Spraying System Co, 2011–2018; Steinen Mfg., 2016) have been used in this project. CFD code and simulation approach validated in a study conducted in 2000-2014 have been applied (Turner et al., 2002; Wala et al., 2004, 2007; Petrov, 2014)."

Jan 1, 2019

By L. Figueroa

Electrochemical methods have potential to treat waters impacted by mining, while simultaneously producing a recoverable metal product to off-set treatment costs. Mining-impacted waters may present challenges with electrochemical treatment due to low concentrations and complex solutions of numerous dissolved metals. This paper presents an evaluation of the potential strengths and limitations of abiotic electrowinning of mining-impacted waters. In particular the impacts of chemical composition on metals removal are evaluated. Results of bench-scale experiments demonstrate the potential to remove metals on the cathode (copper, cadmium, lead), as well as the anode (manganese). Pre-treatment for iron and aluminum may be needed and post-treatment pH adjustment would be necessary. INTRODUCTION Due to continually increasing demand for metals, new technologies and innovative applications of existing technologies are needed to recover metals from mining-impacted waters. Electrochemical methods have long been used for metallurgical processes with solutions containing high concentrations of the target metal. However, electrochemistry also has potential to treat waters with lower metal concentrations, while simultaneously producing a recoverable metal product to offset treatment costs. Electrochemical water treatment may have several benefits over traditional alkaline treatment for acid rock drainage (ARD). Sludge produced from alkaline treatment has high water content that is difficult to dewater, even for treatment plants producing a relatively high-density sludge. For example, the Argo Tunnel Water Treatment Facility (Argo Facility) in Idaho Springs, Colorado uses hydrated lime to produce a high-density sludge with a solids content of 20 to 25 percent and filter cake with solids content from 30 to 35 percent [1]. Furthermore, costs for managing the sludge are significant, approximately $90,000 per year for treating approximately 150 million gallons of water [1]. Although not the case for the Argo Facility, sludge produced from alkaline treatment of ARD has potential to be classified as hazardous. Disposal of sludge also opens up the potential for future liability depending on the sludge’s chemical stability and methods of disposal. In contrast to alkaline treatment, electrochemical treatment produces metals in elemental and other highly-dense forms on the cathode. If metals concentrations and flow rates are sufficiently high, the metals recovered may help offset overall treatment costs. In addition, sludge production would be reduced, if not eliminated altogether, thereby reducing both disposal costs and potential future liabilities as well.

Jan 1, 2019

By S. S. Klima, J. A. Organiscak

Researchers at the National Institute for Occupational Safety and Health (NIOSH) performed laboratory testing to examine and improve airborne dust capture and methane removal performance of flooded-bed scrubbers on continuous mining machines using a blowing face ventilation configuration to reduce respirable dust exposure to shuttle car operators. Several testing conditions were examined to minimize shuttle car operator dust exposure without adversely affecting continuous miner performance and production. Curtain-to-face setback distance of 9.1 m versus 15.2 m (30 ft versus 50 ft), face ventilation airflow of 226.5 m3/min versus 339.8 m3/min (8,000 ft3/min versus 12,000 ft3/min), and the use of side-body-mounted blocking sprays (on versus off) were the three primary parameters compared. Scrubber airflow was set and maintained at 198.2 m3/min (7,000 ft3/min) throughout testing. An examination of slab cuts versus box cuts and the location of the shuttle car (present behind the continuous miner versus not present in the entry) was also performed to demonstrate the effects of these constantly changing scenarios on scrubber performance. Results show that the best blowing face ventilation setup for minimizing shuttle car operator dust exposure for the tested parameters uses a 15.2-m (50-ft) curtain-to-face setback with 339.8 m3/min (12,000 ft3/min) face ventilation while operating the side-body-mounted blocking sprays. INTRODUCTION Coal mine worker overexposure to respirable coal dust continues to be a problem in U.S. underground coal mining operations, potentially leading to coal workers’ pneumoconiosis (black lung). The U.S. Mine Safety and Health Administration (MSHA) requires that respirable dust exposure to coal mine workers does not exceed a 1.5 mg/m3 average over the actual working shift (79 Fed. Reg. 24814 (2014)). Although using a blowing face ventilation configuration on continuous miner (CM) sections is beneficial for removing methane emissions from the mining face, it can be detrimental for dust control for shuttle car (or ram car) operators and any other workers on the return ventilation side of the CM when compared to exhausting ventilation. Even with machine-mounted scrubbers on CMs, shuttle car operators still have some of the higher dust exposures with blowing face ventilation systems (NIOSH 2011, Beck et al. 2015). Although scrubber discharge air is not completely clean, dust being blown around the scrubber inlet and therefore not being captured by the scrubber can further increase these dust exposures (Goodman 2000). Dust control problems are also caused by inadequate face ventilation quantities causing scrubber face airflow recirculation issues (Schultz et al. 2010). In order to minimize respirable dust exposures on blowing face ventilation sections, ventilation, water spray, and scrubber parameters were experimentally examined to improve operating ranges for both dust and gas control. Several blowing face ventilation factors were examined with respect to CM spray systems and scrubber operation. Curtain-to-face setback distance and side-body-mounted blocking sprays were previously examined in the laboratory for dust control on a full-scale CM model using a scrubber on a blowing face ventilation system (Goodman 2000). The blocking sprays produced larger dust reductions at the CM’s rear corners and return for a 6.1-m (20-ft) curtain setback distance as compared to a 12.2-m (40-ft) curtain setback distance with equal face and scrubber airflows of 169.9 m3/min (6,000 ft3/min). Because face ventilation airflow quantities, shuttle car operator locations, and tracer gas concentration gradients were not previously examined during these experiments, additional research was required to determine improved operating parameters for blowing face ventilation systems.

Jan 1, 2019

By G. Q. Zhou, H. C. Liang, X. D. Zhao

"This study describes the strain behavior in vertical shaft lining (VSL) embedded in thick soil deposits and its application in assessment of concrete deterioration. The observed strain in VSL continuously decreased companied by a sinusoidal fluctuation due to the influences derived from negative skin friction (NSF) and temperature. The increase in strain increment between peak and trough at each year and compressive strain level as the servicing time continued and VSL depth increased implies that the concrete strength was attenuated, and this attenuation was significantly dependent on the existing compressive strain level in VSL. The reliability of the proposed approach was validated by Schmidt Hammer Technique (SHT) – based concrete strength, and is applicable in concrete assessment and then fracturing prediction of VLSs in thick soil deposits.Concrete strength, Field monitoring, Strain behavior, Vertical shaft liningINTRODUCTIONOver 100 VSLs in Southeastern China subjected to an unpredictable fracturing as shown in Figure1, and there are over 1,000 VSLs embedded in thick alluvium su?ering from challenges of damaging and potential fracturing (Cheng, Yang, Zhou, Li, & Hu, 1993; Zhou, Cui, Lv, Huang, & Chen, 1999; Li & Li,2005). Therefore, a reliable assessment of these VSLs is significant to the normal servicing of mine shafts and the recycle of underground space when these mine shafts were closed.The continuous increasing of NSF induced by the drainage of water–saturated deposits well interpreted such extensive fracturing phenomenon, and it is universally regarded as the governing indicator to determine the VSL stabilization (Cheng et al., 1993; Zhou et al., 1999). Based on this recognition, the fracturing prediction and VSL strengthening according to the field monitoring on hydrogeological characteristics, servicing environments, and mechanical behaviors of VSL were carried out (Zhao, Zhou, Zhong, Zhu, & Liang, 2009; Liang et al., 2009; Xie, Lv, & Wu, 2014). As known, the compressive strain level in VSL and the in–situ strength of VSL concrete were the main factors to perform such fracturing prediction. However, the existing studies in literatures were limited to the strain accumulating or releasing behaviors (Zhao, Zhou, Zhao, Kuang, & Hu, 2017), and lack of considering the VSL concrete strength and its attenuation. In this reported study, the in–situ monitoring data on the strain in typical VSLs and the VSL elevations between 2004 and 2014 were initially analyzed. Then, an observed strain behaviors–based approach was developed to quantitatively evaluate the VSL concrete deterioration."

Jan 1, 2019

By J. E. Nesset, E. R. Bobicki, K. L. Bilaniuk

The introduction of froth flotation technology in Canada, and in particular, in British Columbia, began not long after it was successfully applied in the Broken Hill mining area of Australia which began around 1905. It proved to be a revolutionary and transformative technology that resulted in marginal operations in copper, lead and zinc becoming profitable in spectacular fashion. The paper presents the technology of both oil flotation and froth flotation in the context of the challenges of the time and its early application in British Columbia at the Le Roi No.2 mine (1903), the Britannia Copper mine (1912), and at the Allenby concentrator of the Copper Mountain mine (1918-19). New-found archival documents indicate the Britannia application to be the first production application of froth flotation for copper ore outside Australia, a claim that is currently made by the Braden mine (now El Teniente) in Chile. Flotation was initially an add-on process following gravity methods but was rapidly shown to be far superior method for the bulk and selective recovery of metal sulphides. Flotation proved particularly successful for the recovery of zinc sulphide (the so-called ‘zinc problem’) which was considered a contaminant at the time. The ‘copper problem’ related to the poor recovery of fine copper sulphide particles that were not amenable to gravity methods. The success of flotation led to changes in both the scale and methods of mining, concentration and smelting in a manner that allowed integrated mining companies to flourish. Many are still with us today. INTRODUCTION The advent of froth flotation in the early 20th century was truly a revolutionary technological development, not only for the mining and metallurgical industries, but arguably more so for business and society overall. The Canadian technology historian Jeremy Mouat stated (1996) “The development of flotation was the greatest single metallurgical improvement of the modern era...it is not overstating the case to claim that flotation was of central importance to the smooth functioning of the global economy”. It should, therefore, be a story of interest to us all. The aim of this paper is not to retell the full story, that has been well covered by others (Hoover, 1912; Rickard, 1916a; Hines & Vincent, 1961; Lynch et al., 2010) but rather to add some Canadian perspective and the key role played by companies and individuals in those early days, focusing on events in British Columbia’s copper industry. EARLY DEVELOPMENTS During the later half of the 19th century, a number of flotation-related patents were issued. These include the 1860 patent (Britain) granted to William Haynes for a process to separate sulphides from ground ore by mixing it with oil (1-10% wt) followed by a separation process in a water-filled vessel; the 1877 patent granted to Georg and Adolph Bessel (Germany) for a process involving the mixing of oil and graphite ore followed by boiling in water to produce a high grade graphite froth (>90% carbon); and the 1885 patent granted to Rebecca ‘Carrie’ Everson for the separation of sulphides by mixing sulphide ore with small quantities of oil, and adding water followed by sulphuric acid. These processes are more properly referred to as bulk oil flotation due to the relatively large quantity of hydrocarbon used.

Jan 1, 2019

By P. C. Holloway, A. Tshilombo, T. Xue, M. J. Collins, R. Lopetinsky, I. Mihaylov, I. M. Masters

The Voisey’s Bay deposit contains a trace amount of cadmium, which reports to solution during pressure leaching of the nickel concentrate at Vale’s Long Harbour Hydrometallurgy Plant, and must be removed to produce high quality nickel cathode. In 2006, Vale approached Sherritt Technologies to collaborate on the development of a process for removing cadmium to low levels (<1 mg/L) in the nickel raffinate. Following successful bench scale and pilot plant testing at Sherritt’s laboratories, the cadmium removal process was then moved through engineering and construction, culminating in the successful commissioning and startup of a cadmium removal circuit at the Long Harbour Hydrometallurgy Plant in 2017. This paper presents the results of this collaboration and the challenges that were encountered through each stage of development, as well as current results from operation of the commercial cadmium removal circuit. INTRODUCTION Vale’s Long Harbour Processing Plant, with a nameplate capacity of 50,000 t/y nickel, began operation in 2014. In addition to electrolytic nickel rounds, the plant also produces electrolytic cobalt rounds and copper cathode. The Long Harbour Processing Plant uses a unique hydrometallurgical process developed by Vale Base Metals Technology Centre, as shown in Figure 1, to treat a nickel sulphide concentrate produced at the Voisey’s Bay mine and mill located in northern Labrador (VBN concentrate) (Stevens et al., 2009).

Jan 1, 2019

By K. C. Sole, G. Robinson, M. S. Moats, W. G. Davenport, S. Sandoval

Global practice in hydrometallurgical production of copper cathode by electrowinning is reviewed, based on individual plant operating data for 2018. Data from 29 plants were collected, representing 38% of world cathode copper production. Similar surveys were carried out in 1997, 1999, 2003, 2007, and 2013. This survey includes analysis of historical and current data. Evolving trends in operating conditions and performance, as well as equipment design and process technology choices, are analysed and differences in operating practices with location are assessed. Examples of recent technology and operational choices to increase productivity, improve copper quality, and decrease electrical energy consumption are discussed. Significant project expansions, particularly in Africa, and the consolidation of numerous small Chinese operations are also presented. INTRODUCTION Global trends and operating practices in copper electrowinning (EW) in 2018 are reviewed and evaluated. Similar world and African surveys were carried out in 1997, 1999, 2001, 2002, 2003, 2007, and 2013 (Robinson, Davenport, & Jenkins, 1997; Jenkins, Davenport, Kennedy, & Robinson, 1999; Davenport, Jenkins, Robinson, & Karcas, 2001; Robinson, Garbutt, & Davenport, 2002; Robinson, Davenport, Jenkins, King, & Rasmussen, 2003; Robinson, Davenport, Moats, Karcas, & Demetrio, 2007; Robinson, Sole, Sandoval, Moats, Siegmund, & Davenport, 2013). Contributing operations included sites from the USA and Mexico (9), Chile and Peru (6), Laos (1), Kazakhstan (1), and Africa (9). Despite fewer contributions compared with past experience, this survey nevertheless represents 2018 copper EW cathode production of 1.76 Mt, or about 38% of world production of 4.64 Mt (International Copper Study Group, 2017). This drop in permission to contribute is attributed to the more competitive nature of the industry and unprecedented production pressures; furthermore, several operations in Australia have shut down, while large operations that are currently commissioning or ramping up to full production in Africa and Asia declined to participate. Of the Chinese operations, which represent an increasingly important proportion of global electrowon cathode copper, particularly in Africa, only Tenke Fungurume (Democratic Republic of Congo; DRC) participated in this survey.

Jan 1, 2019

By Francisco Sena Leite, Pedro Brito, Gean Frank, PhD Soeiro de Carvalho, Jose, Vinicius Miranda

The consequences of rock blasting with explosives are directly related to the accuracy of drilling and, because they have an effect on fragmentation and ground level, they should be controlled to ensure a problem free production, increase work safety and reduce environment impact. Safety control is one of the most important processes in detonation, since it can compromise the worker security on site and, eventually, neighboring communities. Due to the technology advancements, it is possible to build a hole deviation control device with “of the shelf” parts, and for that reason the authors decided to evaluate the possibility of measuring hole deviation by creating a portable prototype using an electronic sensor capable of measuring the acceleration on objects, that is, to measure the own acceleration of a system, known as "accelerometer" and a micro-controller to handle and treat data. The main idea behind this paper is to validate the power of the Euler method, given the stepping limitations of the sensor and micro controller in order to reproduce of the hole shape. A case study was carried out, comparing the measurements of borehole deviations made by a traditional equipment and the prototype. A mobile application was also created in order to recover and treat and display the data to the user. For validation of the prototype, several holes were measured using the two devices. A residue analysis was used to validate the data obtained. After analyzing and confirming the effectiveness of the new equipment, the normality tests prove a symmetric distribution with null expected residual mean and minimum variance. Consequently, the accuracy of the prototype is evidenced. Thus, the authors aspire to emphasize the potential of using these sensors allied to a traditional numerical method for analysis of hole deviation.

Jan 1, 2019

By Kevin Andrews, Terry Hamric, Scott Nelson

"Mining conditions in underground coal mines are dictated by the environment in which the coal seams were geologically deposited. Depositional features can change rapidly, significantly affecting mining conditions. Mine geologists understand factors affecting mining conditions, predict future conditions, and provide guidance to mine management. A case study demonstrates how a mine in Appalachia merged an understanding of depositional environments with mining conditions and drilling data to make informed decisions as the mine encountered geologic anomalies. The assessment included drilling, mapping of geologic hazards and mine productivity, and creation of a conceptual depositional model. Metallurgical coal quality and clean tons per foot served as incentives for continued advance. Mining in the south was historically favorable, with good production and advance rates. As mining advanced north, changing geologic conditions caused the upper seam split to abruptly disappear. The mine ramped down into the lower seam split. Mining in the north area encountered unfavorable conditions, including transition roof, “horsebacks,” sandstone intrusions, roof rolls, and bony floor, resulting in low rates of mining advance. The mine geologist characterized the features and created a predictive model for future mining. Most of the adverse conditions were attributed to the coal in the north being part of an incised, transgressive valley fill environment, as compared to the favorable conditions in the south resulting from a floodplain depositional environment. Geologic conditions, low productivity, and unfavorable future predicted conditions in the north ultimately resulted in mine closure and reallocation of resources to a new mine with better forecasted conditions.INTRODUCTIONThe role of a geologist in assisting coal mining operations to understand and predict the impact of varying geological factors on mining productivity is a critical one, especially when management decisions must be made about the future prospects of a mine operating in difficult conditions. Chase, Newman, and Rusnak (2006) provide a very thorough discussion of the evolution of the role of the coal mine geologist and emphasizes the importance of understanding geology with regard to mine management decisions. Using actual mining performance data to determine which geologic factors are the most critical for mining is a powerful tool for making informed mine management decisions. For example, Nelson, Mullennex, and Miller (1988) provide a case study of analyzing the geologic factors impacting productivity of a Kentucky longwall mine to predict future mining conditions for the operation. In that case, the difficult geologic factors for longwall mining were prevalent across much of the remaining permit area and, in response, mine management converted the operation from a longwall operation to a continuous miner (CM) operation to better adapt to the geology. In another example, Keim and Miller (1999) evaluated geologic conditions impacting a West Virginia longwall mine. In both examples, significant geotechnical and geological information was available, including the opportunity to compare predicted mining conditions against actual conditions as mining progressed. Numerous examples of advanced Geologic Hazard Mapping (GHM) methodologies have come from government agencies and academia. For example, development of the Coal Mine Roof Rating (CMRR) system (Molinda and Mark, 1994) provided a standard means for geologists and engineers to communicate quantitatively with regard to mine roof conditions, and the introduction of the Stability Mapping System (SMS) provided an efficient means for analyzing numerous factors affecting coal mine stability (Wang and Heasley, 2005)."

Jan 1, 2019

By K. Parameswaran

This paper builds on presentations made at the Conference of Metallurgists (COM) 2015, COM 2017 and Extraction 2018 and associated papers published in the respective conference proceedings. Based on the classic Brundtland Commission definition of sustainable development as “development that meets the needs of the present without compromising the ability of future generations to meet their own needs,” the paper describes how metal mining can be compatible with sustainable development and how sustainability considerations have been applied in the primary copper industry, using several examples of sustainable mining practices from ASARCO LLC operations. Finally, the paper discusses how these considerations might be used in the future by discussing the need for developing a sustainable development strategy and how this strategy can be aligned with the United Nations Sustainable Development Goals. INTRODUCTION The primary copper industry comprises: mining (also referred to as “extraction”); mineral processing (also referred to as “beneficiation, “milling” or “concentration,”) which includes leaching, solvent extraction (SX), crushing, grinding, froth and flotation operations; and metallurgical processing which includes smelting and converting; refining, which includes fire-refining or anode refining and electro-refining; and electrowinning (EW). There are two routes for producing refined copper: hydrometallurgical and pyrometallurgical. The hydrometallurgical route comprises mining (open-pit and underground), mineral processing (crushing and grinding — for heap leaching only; leaching and SX) and metallurgical processing (EW). The pyrometallurgical route involves mining, mineral processing (crushing, grinding and froth flotation) and metallurgical processing (smelting, fire refining and electro- refining). The primary copper industry is capital, water, resource and energy intensive with the potential for significant environmental impacts, if the environmental aspects are not properly managed. ASARCO LLC (Asarco) was organized in 1899 as the American Smelting And Refining Company. Originally a consolidation of several lead-silver smelting companies, it evolved over the years into an integrated producer of primary non-ferrous metals, including copper, lead and zinc and associated co-products. Grupo México, S.A.B. de C.V (Grupo México) acquired Asarco in 1999. Today, Asarco is a vertically integrated producer of primary refined copper and associated co-products such as gold, silver, selenium and tellurium. Asarco operates three open-pit mines and mills, two leach, SX-EW plants, a copper smelter in Arizona and a copper electrolytic refinery in Texas.

Jan 1, 2019