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By J. Grobler, J. Zietsman

"Understanding the influence of feed material mineral assemblage on spiral separation is paramount for the successful and consistent operation of a spiral plant. Plant stability is required to maintain high recovery of valuable heavy minerals (VHM). Standard material analysis methods used in the heavy mineral industry to evaluate spiral separation behaviour are unable to quantify performance differences in the case of large variations in feed assemblage. This study illustrates a systematic approach to evaluate spiral separation performance. This technique was applied on a four-stage spiral plant. The performance information was used in a circuit simulation to clearly illustrate the importance of correct setting of the spiral splitter position and resulting spiral mass loading to ensure optimal circuit stability and maximum VHM recovery.IntroductionHeavy mineral sands deposits generally consist of naturally fine-grained, free-flowing sand due to the way in which the deposit was formed. The size of the heavy minerals market is roughly 8 Mt/a of zircon and titanium combined (Iluka, 2013). If an average combined feed grade of 5% zircon and titanium and an average combined overall product recovery of 80% are assumed, the resulting run-of-mine feed tons that would require primary spiral beneficiation is 200 Mt/a. The number of spirals required for the processing of this material, assuming 6500 operating hours per annum, an average of 2 t/h per start, and the same number of rougher spirals as other duty spirals, is over 30 000 spirals for the heavy mineral sands business alone. These numbers clearly illustrate the importance of the spiral in the heavy mineral industry.The aim of a spiral plant in the primary processing value chain of a heavy mineral process is to reject non-valuable quartz (a light mineral) from various valuable heavy minerals (VHM). The product from the spiral plant is a heavy mineral concentrate that has a reasonable grade (more than 90% heavy minerals) at a reasonable heavy mineral recovery (greater than 90%). This benchmark is fairly easy to achieve if all the mineral particles are well liberated (as in the case free-flowing sand), the feed is properly deslimed (-45 µm fraction removed to less than 5% of the solids mass), and the spirals are fed within design solids concentration (water to solids ratio) and design spiral load (dry tons per hour per start)."

Jan 1, 2017

By Ryan Higbie, King Chin, Matthew Anderson, Mike Huggins, Rian Johnson, Dave Sinsheimer

"The Permanent Canal Closures and Pumps (PCCP) project is the capstone piece of New Orleans’ extensive hurricane risk-reduction system constructed following Hurricane Katrina. The project consists of three discrete pump stations and flood gates on the shore of Lake Pontchartrain which provide a storm surge barrier and pump rainwater from the City of New Orleans’ primary drainage canals. The depth of the pump station structures ranged between 39 and 45 feet below sea-level. USACE developed the PCCP project for design-build delivery; granting the project team latitude to develop innovative, cost effective solutions for the project. The use of OPEN CELLTM cofferdams to construct the pump station structures was one such innovation. OPEN CELL structures utilize the strength of the retained soil to anchor cellular sheet pile face arcs; allowing a free-field of construction within the cofferdam. This cofferdam design did not require ground improvement or dewatering around the perimeter of the cofferdam. The free-field cofferdams streamlined construction and large equipment installation within the structures with no encumbrance from internal bracing. Meticulous force-based design, soil-structure numerical modeling, and physical testing were all techniques used to present and gain USACE acceptance of the design on this vital element of the work.PROJECT DESCRIPTIONThe Permanent Canal Closures and Pumps (PCCP) project is the capstone piece of the City of New Orleans’ extensive hurricane risk-reductions system constructed following Hurricane Katrina in 2005. The project encompasses three separate pump stations and floodgate structures located at the mouths of three outfall canals (17th Street, Orleans, and London) on the south shore of Lake Pontchartrain. These three canals, running from the south to north, act as the primary conduits for discharging water from the New Orleans area. Prior to Hurricane Katrina, these canals were operated with pump stations two to three miles upstream of the mouths at Lake Pontchartrain. This left long stretches of levee on each side of the canals exposed to storm surges entering from the lake. Three levee failures occurred along these canals during Katrina; two at London Canal and one at 17th Street Canal. The failures resulted in major flooding of the surrounding neighborhoods, significant damages, and loss of life.Following initial canal levee repairs after Hurricane Katrina, USACE, in partnership with the Louisiana Coastal Protection and Restoration Authority (CPRA), took action to move the line of flood protection to the mouths of these three canals at the edge of the lake. By cutting off the storm surges from Lake Pontchartrain at the entrance to the canal, over ten miles of canal levee would no longer be exposed to storm surge water elevations, significantly decreasing the risk of failure."

Jan 1, 2017

By G. Mei

"This study explores froth flotation and selective flocculation methods to recycle waste phosphors containing several rare earth elements, namely, yttrium (Y), europium (Eu), cerium (Ce) and terbium (Tb). The effects of the presence or absence of collector and of flocculant and their dosages, as well as the pH, were investigated. Reverse flotation resulted in concentrates with grade of 27.03 percent and recovery rate of 71.36 percent, while flocculation resulted in concentrates with grade of 31.43 percent and recovery rate of 91.28 percent. The flotation and flocculation behaviors were further analyzed by X-ray diffraction analysis, zeta potential measurements, particle size distribution and other methods. The successful separation of rare earth minerals by flotation was attributed to the selective adsorption of the collector onto quartz, making it particularly recoverable by reverse flotation so as to be separated from the valuable materials. The analysis of the particle aggregation process indicated that its better flocculation performance was due to the selective adsorption of flocculants onto the unwanted materials, enlarging the flocculant sizes by forming aggregations and facilitating the separation of rare earth minerals from waste materials based on different settling rates. IntroductionBecause waste phosphors pose the problems of heavy environmental burden and high risk to human health (Hu and Cheng, 2012) as a result of containing heavy metals such as mercury and manganese (He et al., 2006; Lucas and Emery, 2006), they have received added attention as urban mining resources for extracting rare earth elements (REEs) like yttrium (Y), europium (Eu), cerium (Ce) and terbium (Tb).At present, chemical processes such as acid leaching, alkali fusion, roasting and extraction are the primary methods for recovering REEs from waste phosphors (De Michelis et al., 2011; Li et al., 2012; Li, 2010). With these strategies, phosphors can be effectively decomposed and their REEs extracted. After the removal of impurities, the REEs can be efficiently precipitated by adding an H2C2O4 solution (Porob et al., 2012). Although relatively high recovery rates are achieved, those processes entail high energy consumption and can cause severe environmental pollution."

Jan 1, 2017

By M. R. Dion, K. Frenette, R. K. Jonas, S. Simard, F. Robichaud

"In 2011, a site study indicated that the application of Honeywell’s Multivariable Predictive Control Technology (MPC) to the Goldex processing facility would provide significant opportunities for improvement. Grinding MPC was implemented in the SAG Mill in June 2015. This pilot application, called Phase 1, featured one of the first Multivariable Predictive Controllers to be installed in a Canadian mineral processing plant. Since the implementation of MPC, gold recovery from the gravity circuit has increased. MPC contributed to a decrease in flotation feed particle size (120 to 112 µm) and an increase in the SAG feed tonnage (8.5% increase). MPC also increased and stabilized the % solids of the SAG feed, which can have an impact on cost reduction (mechanical maintenance). Additionally, MPC increased productivity, providing grinding operators with more time to perform other tasks. Further anticipated benefits include the standardization of the grinding circuit operation from one team to the next, thereby minimizing circuit disturbances resulting from different operating philosophies. This paper will discuss the advanced control project development and justification, the technology and rapid implementation process, the performance results and the benefits obtained.IntroductionGoldex is an underground mine located near Val-d’Or that is owned and operated by Agnico Eagle Mines Limited (AEM). Between 2008 and 2011, mining focused on the Goldex Extension Zone (GEZ). In 2011, the project was halted due to geotechnical problems; operations ceased until late 2013. Goldex operations resumed in September 2013 with the M and E zones, for which there were 0.7M gold ounces of proven and probable reserves, 2.1M ounces of measured and indicated resources and 1.2M ounces of inferred resources, totalizing 4M ounces. Life expectancy was extended until 2024."

Jan 1, 2017

By T. Feroze, B. Genc

"The effect of some of the system variables in forcing and exhausting ducted fan systems on ventilation in an empty heading was investigated using computational fluid dynamics(CFD) and comparative analyses. The diameter of the duct, duct mouth to face distance, and the power of the fan (quantity delivered by the fan) were varied and their effect on ventilation determined through a comparative analysis of the flow rates calculated close to the face of the heading. Estimation models were developed, which can be used to calculate the flow rate close to the face of the empty heading for different settings of the system variables studied.The study showed that recirculation for a forcing ducted fan system can be reduced by increasing the duct diameter or increasing the duct mouth to face distance. For the exhausting ducted fan system, higher flow rates were achieved by reducing the duct mouth to face distance, andincreasing the fan design flow rate and duct diameter.The outcomes of this investigation will help ventilation engineers in deciding the optimum duct fan system required for sufficient ventilation.IntroductionThe ventilation of underground mines, irrespective of the type of mine and mining method, is divided into two broad branches, the primary ventilation and secondary or auxiliary ventilation. The primary ventilation is responsible for the total volumetric flow through the mine and the auxiliary ventilation is responsible for the ventilation of the development ends, production areas, and facilities disconnected from the main circuit with no through-ventilation connections. Auxiliary ventilation is the more difficult to achieve (Bise, 1996), and the disruption of this ventilation system is considered to be one of the primary factors contributing to methane and coal dust explosions (Creedy, 1996). A number of causalities have been recorded by many authors due to these explosions (Phillips and Brandt, 1995; Dubinski et al., 2011; Phillips, 2015). The ventilation of short headings, less than 10 m in depth, can be carried out without the use of any auxiliary equipment (Feroze and Phillips, 2015). However, for headings deeper than 10 m, auxiliary ventilation systems are required. These are generally classified into the three basic types, namely line brattice (LB) ventilation systems, ducted fan systems, and jet fans (Figures 1 through Figure 3 respectively)."

Jan 1, 2017

By A. Takala, B Nielson, J. Schunicht

"Pre-concentration in minerals processing presents clear advantages in energy efficiency, water efficiency, reduction of consumables and minimization of capital and operating costs. Outotec’s sorting solutions are powered by Tomra Sorting in order to achieve pre-concentration of concentrator feed in a variety of mineral processing applications. Sensor based sorting combines advanced sensors with rapid computational evaluation and mechanical separation of valuable material from waste and/or gangue. Modern sensor based sorting machines typically use fine air jets to propel individual rocks, thus optimizing recovery and minimizing “mis-sorting”.Gold is generally present in such low concentrations that sensors suitable for ore sorting cannot directly detect it. Therefore, in order to sort gold ore, properties of associated host rock are used. Free and sulphidic gold is often hosted on the quartz-host rock contact zone. Laser scattering effect can be used to detect the surfaces of quartz and composite quartz-host rock particles for subsequent sorting with very high recovery of 95 to 99%. In addition, ore often preferentially fractures along the quartz-host rock contact zone in the crushing circuit. This behavior helps because it liberates more quartz for detection.The feasibility of sorting is investigated for four gold projects in Northern Europe with similar mineralogy. This includes geometallurgical evaluation, amenability testing, small scale “mini-bulk” factory testing in full scale sensor based sorting. The results of the various tests are presented and basic feasibility demonstrated with information on flow sheet development. In addition, the amenability process is evaluated and recommendations made for future projects."

Jan 1, 2017

By G. Clarkson, M. Hitch, R. Clarkson

"A novel reagent-free method of extracting gold from gravity middling concentrates in the Yukon placer fields is presented in this paper. This method exploits the malleability of gold by submitting concentrates to grinding in a rod mill. Brittle waste minerals are effectively reduced, whereas malleable gold particles are flattened and are then extracted by classification through sieves. Recoveries in the field using a laboratory-sized rod mill regularly exceeded 90%, whereas correlation laboratory tests indicated recovery to be most sensitive to the mill charge size. This method has broad potential, including application to the gravity circuits of large hard-rock processing circuits.RÉSUMÉ Cet article présente une nouvelle méthode sans agents réactifs d’extraction de l’or dans les concentrés gravimétriques mixtes que l’on trouve dans les districts placériens du Yukon. Cette méthode exploite la malléabilité de l’or en broyant des concentrés dans un broyeur à barres. Les déchets miniers cassants sont bien réduits, alors que les particules d’or malléables sont écrasées puis extraites par classification au travers de cribles. Si les récupérations sur le site à l’aide d’un broyeur à barres de laboratoire excèdent 90 %, les essais de concordance en laboratoire indiquent que la récupération est très sensible à la taille de la charge du broyeur. Cette méthode présente un grand potentiel, notamment une application possible aux circuits gravimétriques des grands circuits de traitement des roches dures.INTRODUCTIONExploiting the high density of gold to separate it from waste materials is the oldest known mineral processing technique. This basic technique is still widely used in gravity concentration circuits today; however, gravity processing invariably results in high-value middlings, especially in the Yukon placer gold fields. In addition to having a uniquely high density, gold is also the most malleable metal. This unique malleability can be exploited to extract gold from otherwise inaccessible gravity middlings.The Yukon placer gold industry has been continuously ongoing since the 1860s, and today produces approximately 60,000 oz t (1.87 million grams) of crude gold annually, most of which is from the Klondike region near Dawson City (Van Loon & Bond, 2014). It is important to note that Yukon placer miners do not use any chemical extraction methods; rather, gravity upgrading methods are the sole processing techniques used. Placer deposits are typically coarse, well liberated, and naturally gravity concentrated and recoverable, thus making more expensive chemical extraction unnecessary (Mitchell, Evans, & Styles, 1997). Furthermore, a strict permitting regime, environmental concerns, lack of expertise, and fear of repercussions from regulators prevent miners from attempting more advanced processing methods, such as flotation or cyanidation. Even simple chemical extractions like mercury amalgamation have not been implemented for decades, with one observer noting that, as many as 30 years ago, “the art of mercury for amalgamating appear[ed] to be dying [in the Yukon]” (Osler, 1983)."

Jan 1, 2017

By S. Bradshaw, A. Mabentsela

"Physical and numerical modelling methods were followed to identify mechanism(s) for tundish slag entrainment in a bare tundish and one with a flow control device (FCD).The physical and numerical models made use of water and paraffin to model steel and slag respectively. Observations from the physical model showed that the steel-slag interface remains immobile in both cases. Entrained paraffin formed droplets approximately 1 mm in diameter. Results from both models (numerical and physical) showed that in both cases (bare and FCD case), areas of high entrained slag concentration exist near the inlet region. The entrained slag concentration decreases towards the tundish endwalls.Flow patterns and velocities tangential to the steel-slag interface from the numerical model showed that slag entrainment in both the bare tundish and tundish with a FCD possibly takes place via two mechanisms. First, the slag moves across the steel-slag interface via mass transfer; secondly small velocities tangential to the interface at depths greater than 10 mm below the interface carry the already ‘entrained’ slag into the bulk steel phase. These tangential flow patterns are dominant in the inlet region, hence the high concentration of entrained slag in this region. IntroductionThe tundish serves as the last metallurgical vessel through which steel passes before solidifying in the moulds. It is in the tundish that the last traces of non-metallic inclusions should be removed, otherwise the inclusions carry over to the moulds and cause defects in the steel product. In the tundish, the slag is less dense than the melt and thus resides on the top of the melt. The slag provides a sink into which the non-metallic inclusions float to and dissolve. The slag also protects the melt from air and heat loss. However, when slag is entrained in the melt as a result of increased turbulence or shearing at the steel-slag interface, slag can become a source of nonmetallic inclusions.Numerous studies on flow patterns in the tundish have been carried out since the introduction of the tundish. These studies were aimed at improving the flow characteristics in the tundish (Chattopadhyay, Isac, and Guthri, 2010; Cloete, 2014; Jha, Dash, and Kumar, 2001; Jha, Rao, and Dewan, 2008;"

Jan 1, 2017

By M R. Hettigner, J Nawrocki, C E. Johnson, P G. Cahill

This study evaluates the effects of both short inter-hole and intra-hole delay times on rock fragmentation and throw. Full-scale test blasts were analyzed at a granite quarry in Talbotton, GA. This analysis provides a representative understanding of timing effects on fragmentation in the field, different from previous lab scale studies that negate the effect of geology. Inter-hole delay times between 0 ms and 25 ms were tested on a series of 4 bench blasts and subsequently examined using photographic fragmentation analysis methods.

Jan 1, 2017

By S. Zhao, S. P. He, M. Y. Zhu, Y. Tao

"The effect of two refining slags (A: 1.0–1.8 CaO/Al2O3 ratio, 11–20 wt% SiO2; and B: 1.0–1.2 CaO/SiO2 ratio, 25–35 wt% Al2O3) on the inclusion morphology of a carbon structural steel (Q235B) was studied by controlling the balance between the steel and the refining slag at 1600ºC in a Si–Mo resistance laboratory furnace. The results showed that most of the inclusions in the molten steel balanced with slag A were formed by a lowmelting CaO–MgO–Al2O3–SiO2 system with a total oxygen content (T[O]) being fixed at 6–13 ppm. The inclusions in liquid steel balanced with the slag B were mostly formed by the CaO–MnO–Al2O3–SiO2 system, with T[O] controlled to 19–26 ppm. The overall size of the inclusions under balance conditions was higher in the steel reacted with the slag B than that reacted with slag A, with the latter showing more inclusions smaller than 3 um. In order to generate a large number of spherical CaO–MgO–Al2O3–SiO2 inclusions smaller than 3 ??m while decreasing the T[O] in the resulting steel, the composition of slag A should be used. This composition allowed improving the cleanliness of the slab, and is also advantageous for the castability of the molten steel. IntroductionThe sample used in this study was a typical carbon steel manufactured by CQ Steel. The galvanized, tinned, and plastic composite steel plates made of the original plates are used extensively for decorative panels, general dust pipes, drums, instrument cases, switchboxes, and train cars, among other uses. The target control composition is shown in Table I. The S and P contents are usually fixed during production below 0.020 and 0.025 wt%, respectively, with the aim of reducing longitudinal cracks on the slab surface."

Jan 1, 2017

By J. -F. Lepage, M. A. Tomlinson, K. K. Murray

"The Éléonore mine, located in the James Bay region of Northern Quebec, generates a gold bearing flotation concentrate rich in pyrrhotite. Direct leaching of the finely ground concentrate results in high cyanide consumptions and poor recoveries, so effective pre-treatment to passivate the pyrrhotite is required before leaching. Following a number of process upsets at the mine, test work was performed to better understand the requirements for passivation so a more effective operational strategy could be implemented. This paper outlines the testing and implementation of the new strategy at Éléonore.ÉLÉONORE CONCENTRATOR The Éléonore mine is located 800 km north of Montreal, in the James Bay Region of Quebec, Canada. The ore, containing gold disseminated in sulfide minerals and free fine gold in silicate gangue, is crushed in a two-stage crusher plant before being ground in a single 9,000 kW ball mill. The ball mill is in closed circuit, with about 25% of the cyclone underflow passing through a gravity plant with two, 48” Knelson concentrators. Gold recovery in the gravity circuit varies between 15 and 20%, with gravity concentrate leached daily in an Acacia intensive leach reactor. Cyclone overflow, at a target P80 of 65 microns, flows to the flotation plant where the gold bearing sulfide minerals, mainly pyrrhotite and arsenopyrite, are recovered to concentrate with a mass pull of about 5%. The flotation concentrate, typically containing between 80 and 120 g/t of gold, is thickened and finely ground using a 1500 kW Isa Mill. The finely ground concentrate is diluted, to generate a slurry with about 32% solids by weight, before feeding the leach plant. Initially the concentrate slurry is pre-treated with oxygen and lead nitrate, to passivate the sulphide minerals before cyanide is added for gold dissolution. Gold is recovered from the leached slurry using carbon-in-pulp (CIP). The flotation tailings are also thickened and gold is recovered in a dedicated leach-CIP plant."

Jan 1, 2017

By Natalie Zeleznik, Brian Hawkins, David Bradley, Rachel Gooding, Patrick Wilson

"The United States (U.S.) Department of Homeland Security (DHS) Directorate of Science and Technology (S&T), utilizes a probabilistic risk assessment (PRA) approach to explore the risks (anduncertainty) from chemical, biological, radiological and nuclear (CBRN) threat agents to the Homeland.This end-to-end risk methodology considers a broad range of hazards incorporating emergingtechnologies, available countermeasures and input from the Intelligence and Law Enforcementcommunities (IC/LE) to evaluate the acute risk to human health due to an attack on the U.S. homeland. The PRA generated output provides a mechanism to examine risk mitigation strategies, critical vulnerabilities, critical data and knowledge gaps and relative risk rankings of materials, targets, classes of compounds and scenarios."

Jan 1, 2017

By P. Kobylin, K. Haavanlammi, K. Valkama

"Base metals and precious metals can be recovered from a nickel matte or nickel concentrate using the Outotec nickel chloride leaching process. The raw material is leached with hydrochloric acid and the metals are recovered by solvent extraction, where ammonia is used to control the pH. Ammonium chloride is regenerated to ammonia and the side product of this step is calcium chloride solution. The regeneration utilizes either calcium oxide or calcium hydroxide. The calcium chloride solution is used to convert sulfuric acid into a hydrochloric acid solution while producing pure gypsum as a side product. The regeneration and reuse of ammonia and hydrochloric acid in this process will have a positive impact, from the point of view of both operating costs and environmental sustainability. This paper concentrates on the test work and technical concept development performed by Outotec to implement and develop chemical regeneration and recycling into a vital part of the nickel chloride leaching process.INTRODUCTION According to a nickel market analysis, the nickel market is expected to grow in the future. Main driver for this growth is the increase in stainless steel consumption as the living standards are equalizing globally. The expected increase in the amount of electrical cars and the need for nickel in the batteries of electrical cars also gives potential for the increased need for nickel in near future. At the moment the use of nickel in nickel-cobalt-manganese (NCM) and nickel-cobalt-aluminium (NCA) Li-ion batteries is in the range of 14 ktpa. It is estimated to increase to the level of 90 ktpa by 2025. In every era of the nickel industry, Outotec has been constantly developing new processes to create environmentally sustainable and economically viable processing routes. The Outotec® Nickel Matte Chloride Leaching process is a great example of a process that is flexible regarding raw material and could also treat nickel raw materials that are difficult for smelters. Outotec’s main options for pyrometallurgical nickel treatment include the Outotec® Direct Nickel Flash Smelting process (DON) and the Outotec® Ausmelt TSL process. The DON process is operated in Boliden Harjavalta Nickel Smelter in Finland. Ausmelt process is in use for example in Daye nonferrous plant in China. In the Outotec® Direct Nickel Flash Smelting Process, a sulphide nickel concentrate is processed in an Outotec Flash Smelting Furnace (FSF). Producing concentrates and processing them by Outotec Direct Nickel Flash Smelting to matte followed by hydrometallurgical refining offers a reliable route from concentrate to product. In the DON process, high-grade matte with low Fe content is produced in the FSF and the valuable metals in the slag are recovered in an electric furnace (EF). The Outotec® Ausmelt TSL process can use a large variety of raw materials (concentrates, secondary material and scrap metal) as feed. Fuel and oxygen are injected into the furnace through TSL (Top Submerged Lance) and this enables efficient smelting. Both Flash Smelting and TSL plants produce nickel mattes, which can be refined with Outotec hydrometallurgical processes."

Jan 1, 2017

By P. T. Bissert, J. P. Ducarme, J. D. Noll, C. C. Jobes

"There have been about 42 fatalities in underground coal mines between 1984 and 2015 where the victim was struck, pinned, or run over by a mobile machine (MM) such as a shuttle car, scoop, or battery hauler. MSHA has issued a proposed rule requiring proximity detection systems (PDS) on MMs in an effort to prevent future fatalities. Currently approved PDSs use electromagnetic (EM) technology to detect the presence of a miner and impose machine controls to prevent contact. The disadvantages of an EM-based PDS on MMs include the need for a miner-wearable component (MWC), environmental interferences, EM interferences from other devices, and low localization range and accuracy. NIOSH researchers are investigating alternate technologies that could improve the capabilities of the current PDSs. Many technologies were reviewed, and NIOSH researchers identified RFID, LIDAR, RADAR, ultrasonic detection, and computer vision as candidates for PDS development. The performance characteristics of each technology and its applicability to an underground mining environment will be discussed, along with international developments and implementations, and the concept of sensor fusion. INTRODUCTION PDSs provide safety to mine workers by detecting their presence (and in some cases location) around a machine. These PDSs provide a warning zone, which triggers an alarm, and a stop zone, which halts the machine before it contacts the miner. The Mine Safety and Health Administration (MSHA) issued a final rule requiring that PDSs be installed on all continuous mining machines (CMMs) on the working section, with the exception of full-faced machines, according to a phase-in schedule for newly manufactured and existing equipment [1]. The PDSs that were designed for CMMs have since been adapted to other mobile machines. Mobile machines include scoops, which are used as general utility vehicles, as well as coal hauling machines, such as shuttle cars, ram cars, and continuous haulage systems. MSHA has examined all accident reports from 1984 to 2014, and determined that 42 fatalities could have been prevented on mobile machines had a PDS been installed [2]. As such, MSHA issued a proposed rule that would require mobile machines on working sections (with the exception of longwall sections) to be equipped with a PDS. This rule would follow a phase-in schedule for newly manufactured and existing equipment. Currently available PDSs are based on electromagnetic (EM) technology. NIOSH researchers developed a shell-based magnetic flux density distribution model [3] for determining the position of a miner near a machine. A typical system would consist of four generators positioned around the perimeter of the machine. Each generator is a coil of insulated wire wrapped around a ferrite core. The magnetic field strength is proportional to the current running through the coil. Miners working on the section have an MWC, which is a transceiver that measures the field strength emitted by the generators and transmits a data packet over an RF link which contains the field strength reading to the PDS controller mounted on the machine. The magnetic field generators are pulsed sequentially such that the MWC can identify which generator’s field strength it is reading. This type of system utilizes the principle of magnetic flux density: the closer the MWC is to the field generators, the higher the field strength reading. Thus a miner’s presence can be determined once he gets too close to the machine, because his MWC will measure a magnetic flux density beyond a certain threshold. These thresholds are utilized on a per-generator basis to “shape” the fields for both warning and stop zones around a machine, as illustrated in Figure 1."

Jan 1, 2017

By K. D. Dill, S. D. Rosenthal

"This project analyzed the efficiency of incorporating the use of directional drilling technology into coal overburden blasting. Directional drilling is currently in use in the petroleum industry and it is believed that it will be a valuable asset in the mining industry. This project has shown that directional drilling can be a viable technology for use in the coal overburden removal process resulting in increased drill utilization and potential for cost savings. Future work regarding blasting and geotechnical evaluation should be performed to solidify the concept. INTRODUCTION Determine the Potential Drill Utilization Improvements and Rock Fragmentation Requirements Using Directional Drilling in a Coal Mining Overburden Highwall Application was a project funded by Atlas Copco Drilling Solutions (Atlas Copco) based in Garland, Texas. The project was developed and researched by Montana Tech of the University of Montana. This project was intended to show how the use of directional drilling can increase drill utilization, while decreasing costs, without sacrificing overburden blasting results. This paper discusses a review of the literature, the methods performed, conclusions and future work Background Atlas Copco theorized that an alternative approach to drilling a cast blast pattern would be beneficial to coal mining operations by increasing drill utilization and therefore, decreasing overall costs. Increasing drill utilization results in an increase in the amount of time the drill is being productive, more drill bit time in ground. Atlas Copco’s theory is that by incorporating directional drilling in the design of a cast blast pattern, a drill rig could drill multiple directional holes, which are the length of the cast blast, from a single drill set up. A drill goes through a series of steps to complete a blast pattern, these steps include: tramming to the hole location, leveling the drill, drilling the hole, cleaning the hole, and retracting the drill steel. This process is repeated hundreds of times until the whole pattern is completed. The most time intensive part of this process is drilling out the blast pattern. Integrating directional drilling into this process could decrease the overall time it takes to drill out a blast pattern by minimizing the amount of time spent tramming and setting up for each subsequent hole. Tramming and drill set up are two aspects of the drilling process where the drill tool is not engaged with the ground and, therefore, not being utilized. A cast blast pattern designed to utilize directional drilling will allow the drill tool to be “in the hole” longer and will improve drill utilization. This change in drill utilization was analyzed. Drilling and blasting is an integral part of the mining process, without it mining would be a slower process and less material could be mined. Drilling provides holes for explosives to be loaded and then blasted. Blasting has been found to be the most cost effective method of fracturing rock in mining for material removal. Blasting is also used as a low-cost method to move the rock in open cast mines, commonly referred to as cast blasting. A cast blast is a large blast designed to allow for the maximum amount of overburden to be removed using explosives in a single blast thereby uncovering more coal at a lower cost. Not all the material is blasted to cast-to-final, which requires that material to be moved with large mining machinery. Material that is considered cast-to-final is material that has been thrown far enough to never be moved again in the coal extraction process, therefore it is in its final resting place. A typical cast profile and cast-to-final area is shown in Figure 1."

Jan 1, 2017

By L. Cong, C. Liu, N. Zhang, W. Cao, C. Zhou, X. Fan

"The modes of occurrence of arsenic and the effects of low-intensity leaching-flotation on arsenic removal from coal slime from the Tanggongta Plant, Inner Mongolia, China were investigated. The coal slime was examined using hydride generation inductively coupled plasma optical emission spectrometry and X-ray diffraction to obtain the content of elements and the major minerals. The modes of occurrence of arsenic in minerals were determined using selective leaching, float-and-sink analysis, and polarized light microscopy. The results indicate that pyrite is the dominant carrier of arsenic in the coal slime, which predominantly exists in association with clay. Significant proportion of the arsenic is removed by a low-intensity leaching-flotation process, consistent with the data from selective leaching and flotation of gangue. The results show that low intensity leaching-alkali washing-flotation is more efficient than direct flotation and low-intensity leaching-flotation.IntroductionUnderstanding the occurrence of arsenic in coal and its removal is significant in optimizing coal utilization, because arsenic in the environment is viewed as a potentially toxic trace element (Finkelman, Belkin, and Zhang, 1999; Hall, 2002; Smith et al., 1992; Smedley et al., 2003; Zheng et al., 1999). Many studies on the modes of occurrence and concentration trends of arsenic in different coal and washing products have been performed (Diehl, Goldhaber, and Hatch, 2004; Kolker et al., 2000; Quick and Irons, 2002; Wang et al., 2006; Fan et al., 2016). Trace elements are usually preferentially associated with certain minerals and the form that these minerals take will influence the efficiency of removal during cleaning (Quick and Irons, 2002). Arsenic is mainly associated with minerals such as pyrite, carbonate, and silicate (Demir et al., 1998; Diehl, Goldhaber, and Hatch, 2004; Zhou et al., 2014). The existence of organically bound arsenic was also confirmed using X-ray absorption (Kolker et al., 2000). However, inorganic arsenic is the principal source of pollution because of its leachability and high concentration compared with organic arsenic (Fujino et al., 2004; Gao, Lu, and Wang, 2010; Jiang et al., 2008; Kolker et al., 2000)."

Jan 1, 2017

By Jinwang Zhang, Zhaohui Wang, Jiachen Wang

"Thick coal seams (seam height larger than 3.5 m) account for a large portion of the proven coal reserves of China, and underground thick coal seam mining provides about 50% of the Chinese annual coal production. Such seams are mainly mined using the longwall top-coal caving (LTCC) method. For safe and successful mining, a number of analyses on the stability of surrounding rocks in the LTCC face area have been extensively performed, and certain research achievements have been made. This paper introduces the main findings on rock pressure occurrence in the LTCC face during the last few decades and presents face and roof stability control techniques. INTRODUCTIONUnderground thick coal seams in China provide 1.8 billion tons of coal every year, which accounts for approximately 50% of the total Chinese annual coal production and 25% of the world, indicating that thick coal seams stand an important position in Chinese coal mining industry (Wang, 2005). Before the 1980s, thick coal seams were mined mainly by using the multiple-slice mining method. With the improvement of mining techniques and equipment in last two decades, longwall top-coal caving (LTCC) and high-seam, single-cut longwall are employed for thick coal seam extraction, offering advantages over multiple slicing from entry excavation and production perspectives (Wang, 2013).. The primary author of this paper introduced the most popular thick coal seam mining methods in China at the 30th ICGCM (Wang, 2015). This paper presents the stability of surrounding rocks in face area and ground control techniques for mining thick coal seams. For traditional longwall faces (seam height less than 3.5 m), the well-developed VoussoirVoussoir beam theory has been successfully used to analyze the movement of overlaying strata, which indicates that ground control techniques have become mature for this mining system. In such faces, the four-leg support with loading capacity of 4000–8000 kN is considered adequate for safe and successful mining. These faces normally have an annual yield of 1–2 million tons (Wang, 2007). For thick coal seams, however, the traditional support becomes inadequate and the ground control problem change to be more difficult and complex. Thus, development of large-scale mining equipment and ground control techniques for enlarged mined-out space and entries have been recognized as the most basic technical problems in mining thick coal seams."

Jan 1, 2017

By Matthew Clay, Colin Chambers, Susan Hookham

Opencast (quarries) and underground mines around the world use blasting methods to mine valuable ore. Traditional blasting systems use technologies such as electric delay detonator systems (developed in the 1950s) and non-electric detonator systems (developed in the 1970s) to initiate a detonation train to blast rock more effectively, and so retrieve valuable product more efficiently. However, the lack of precise control over blast timings with these approaches can result in undesirable outcomes such as significant flyrock, excessive ground vibration, uneven grade of rock and misfires (in which sections of the blast can remain unfired). The development of Electronic Initiation Systems (EIS), first used in the 1990s, introduced a higher level of control over the blast. These systems greatly reduce the negative issues associated with blasting. However, this precision introduces complexity, and with this complexity comes difficulty in demonstrating the predictability, safety and reliability of such systems.

Jan 1, 2017

By R. L. Miller

"Why should we care about diesel quality amidst the complexity of mining for minerals? Mining companies use a large amount of diesel fuel in their worldwide operations, both for moving ore from the mine to the processing mills or transportation hubs, and to generate power for onsite processing. This creates a large carbon footprint and poses both environmental risk with the production of emissions, and public perception of how those companies do their business as stewards of the environment while incurring a huge fuel expenditure. To improve diesel quality and create incremental value and greater environmental stewardship, the opportunity is broken down into several segments: 1. Mining industry diesel consumption 2. Fuel quality issues 3. Impacts on operations, economics, and emissions 4. Potential solutions 5. How improved fuel quality saves fuel expenditures 6. Economics of improved fuel quality 7. Recommended testing process 8. Fuel quality analysis checklist MINING INDUSTRY DIESEL CONSUMPTION The average grade of mined Australian ore bodies has halved, while the waste removed to access the minerals has more than doubled over the last 30 years, thus increasing energy consumption by 70%, (http://eex.gov.au/industry-sectors/mining/). Energy consumption and intensity in mining and mineral processing is rising at around 6% per annum. The mining industry is a huge consumer of diesel fuel worldwide, and the SRS Rocco Report of 4 August 2014 gives a better picture of recent trends. To better understand the reasons to reduce both fuel costs and consumption, we need to compare metrics on the amount of diesel consumed per each ounce of gold produced over the last decade. The rate of diesel consumption in gallons per each ounce of gold produced for the top five worldwide gold producers has doubled in the last 8 years from 12.7 gallons per ounce in 2005 to 25.8 in 2013 as shown in Figure 1 below.This is caused by 1) lower ore grades requiring more hauls to get same amount of finished gold product, and 2) haul trucks moving ore from deeper sources in open pit and underground mines. For one large multi-national gold mining company, the 2005 waste rock / production ratio was 52 metric tons/gold ounce; by 2013 that ratio had grown to 113 metric tons/gold ounce per the same SRSrocco 4 August 2014 report. Using the metrics above, the top 5 gold miners used over 591 million gallons of diesel fuel in 2013. The cost of diesel in dollars per ounce of gold has increased from $30.48 in 2005 to $101.14 in 2013, an annual appreciation of 16.2% as shown in Figure 2 below."

Jan 1, 2017

By M. Zhang, H. Ni, F. Zheng, M. Guo

"In the present work, we investigate the effects of roasting temperature and time on the transformation of the titanium (Ti)-bearing phase and magnesium aluminate spinel (MgAl2O4) phase in Ti-bearing electric arc furnace molten slag during the molten sodium hydroxide (NaOH) treatment process. With applied temperature of 700 °C for 60 min, and a mass ratio of Ti-bearing electric arc furnace slag to NaOH, or Rslag/NaOH, of 1:1.2, the conversion ratios of the Ti-bearing phase and the MgAl2O4 phase reached about 98.3 percent and 88.1 percent, respectively. Moreover, investigation of the reaction kinetics indicate that the conversion of these phases during the molten NaOH treatment process is a typical solid-liquid reaction, and it can be theoretically described by the unreacted shrinking core model. The conversion ratio of the Ti-bearing phase was found to be controlled by the chemical reaction step, with an apparent activation energy of 41.76 kJ/mol. The decomposition of the MgAl2O4 phase was found to be controlled by the surface chemical reaction in the early stage of 0 to 20 min from start of reaction, changing to diffusion control in the later stage of 20 to 60 min. The apparent activation energies of the process were determined as 55.88 and 22.72 kJ/mol, respectively.IntroductionChina has rich mineral resources of vanadium–titanium magnetite ore deposits, and the iron and steel industry in the country produces millions of tons of titanium (Ti)-bearing slag every year. The problem of how to dispose of the Ti-bearing slag has attracted much attention, and various approaches have been developed, including the acid process (Li et al., 2007; Zhang et al., 2011; Zhang and Nicol, 2010; Li et al., 2011), alkali fusion process (Han et al., 2012; Middlemas, Fang and Fan, 2013; Nayl, Awwad and Aly, 2009; Lasheen, 2008; Zhang, Qi and Zhang, 2009), carbonization and chlorination process (Liu et al., 2008; Tao et al., 2012; Fu et al., 2012; Liu, 2009), selective crystallization process (Lei and Xue, 2008; Li et al., 2011; Zhang et al., 2007a, 2007b). However, these processes have been beset by various functional, economical and ecological problems (Yu and Chen, 2010). With environmental protection regulations becoming increasingly rigorous, and demand growing for the comprehensive utilization of resources, the focus is on methods to treat Ti-bearing slag with high efficiency and mild reaction conditions (Nazari and Riahi, 2011; Wu et al., 2013)."

Jan 1, 2017