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By Tamas Kekesi, Gergo Rimaszeki, Tibor Kulcsar

The efficient purification of soldering waste material can be achieved in a single operational step by the electrolytic refining in pure hydrochloric acid - tin-chloride media. The complex formation of the ionic species may offer a beneficial level of natural inhibition. Using the PCR (periodic current reversal) technology, is efficient in affecting the morphology of the cathodic deposit. In order to optimize the process, the investigation of the solution stability and the electrode reactions is essential. The natural tendency of the Sn(II) oxidation and precipitation can be overcome by properly controlling the concentration of the main components and the ratio of Sn(IV)/Sn(II) in the electrolyte solution. Polarization curves were obtained for different concentrations tin and hydrochloric acid. Conclusions referring to the electrode reaction were derived from the overvoltage - current plots. The morphology of the deposit can be correlated with the exchange current density, also determined from the polarization curves. The cathodic current efficiency and the morphology of deposited metal are affected by the distribution of tin species and the principal electrolysis parameters.

Jan 1, 2011

By Alexey T. Kovalev, Irina A. Khabarova, Valentine A. Chanturiya, Igor Zh. Bunin, Elizaveta V. Koporulina

"The paper presents new theoretical and experimental results about mechanisms of disintegration of mineral complexes and structural transformations of the sulfide surface under high-power nanosecond electromagnetic pulses (HPEMP). The heated gas outflow from nanosecond breakdown channels of sulfide minerals under HPEMP is considered. It is shown that the gas outflow from channels can be an additional destructive factor in the processes of the electric pulse discharge disintegration of mineral complexes. It is shown that the effect of HPEMP changes chemical surface composition and, respectively, technological properties of pyrrhotite and pentlandite. Morphology and elementary composition of new micro- and nanoformations on mineral surface of pentlandite and pyrrhotite have been investigated using up-to-date methods of SEM/EDX and Scanning Probe Microscopy. Preliminary electropulse effect on mineral products before flotation allows producing optimal conditions for flotation separation of pentlandite and pyrrhotite owing to forming the new nanophases and defects on the surface of sulfides.IntroductionThe effectiveness of High-Power Nanosecond Pulses in the disintegration and liberation of fine disseminated mineral complexes and the recovery of micro- and nanoparticles of precious metals from refractory ores was demonstrated in [1, 2]. Possible mechanisms of selective disintegration were considered in [1-3]. It has been shown both theoretically and experimentally that electric breakdowns can play an important role in the nanosecond pulsed treatment of milled minerals (e.g., semiconductor sulfides and quartz with particle sizes of 100 µm to 2-3 mm) that are carriers of finely disseminated gold and other valuable components. Electric discharges in such minerals are accompanied by a destruction of integrity in the form of breakdown channels and the formation of a system of cracks around these channels [3]. The development of the domains of induced cracks around the channels is determined by the pressure of evaporated material in the breakdown channel. Upon an instantaneous energy release in a channel (nanosecond discharges), the change in its transverse size and in the gas density and pressure in the channel is determined by (i) the radial motion of the evaporation wave, (ii) the radial expansion of the channel, and (iii) the heated gas outflow from the channel. The evaporation wave moves with a speed on the same order of magnitude as the speed of sound (or greater) and travels a distance of around the initial channel radius, i.e., a much smaller distance than the breakdown channel length."

Jan 1, 2011

By Jr. Blanchette, Claude Bazin, Paul Blatter

"Reporting of the gold production during a month implies to estimate the mass of gold that is processed by a mill, recovered as dorés, lost to the tailings and the change of gold inventory within the plant equipments. Carbon in pulp and/or carbon in leach tanks may contain gold inventory as large as 72 000 g (2 200 troy oz) of gold which needs to be estimated from measurements obtained from sampling the material contained in a tank. Sampling and analysis introduce measurement errors that could be systematic and/or random. This paper examines the effect of measurement errors on the estimation of the gold inventory and on the variation of the inventory in the carbon in leach tanks of the Agnico-Eagle Mines Limited Lapa concentrator. Results of the analysis demonstrate that the inventory is measured with ±10% reproducibility, while the variation of inventory used for mass balance is known with ±300% reproducibility.INTRODUCTIONThe preparation of a production report implies to reconcile measured data with the constraint of material balance over the considered period of production. The sampling and data reconciliation problems were recently reviewed by Morrison (2008) and Jansen (2009a; 2009b). Typically a production report is prepared to cover a period over which the mass conservation hypothesis can be considered valid. In gold processing plants, the change of inventory can seldom be neglected and plays a significant role in material balance calculations. This is particularly true for circuits using carbon adsorption, where the complete cycle of carbon is measured in days.In a 2000 t/d gold ore processing plant, the inventory can be as large as 140 000 g of gold in gravity concentrator bins, carbon in pulp tanks and in the electrolysis circuit. This is equivalent to the mass of gold that fed the circuit during 10 days of operation with 7 g/t feed assays. The change of inventory may therefore strongly impact the production figures and especially the plant recovery at the end of a week or a month. Despite the financial impact associated with gold inventory, few publications are devoted to the subject. Bruington (1991) and Morrison (2008) discussed the problem and stressed the need for the development of reliable methods to estimate the gold inventory in carbon in pulp or carbon in leach circuits."

Jan 1, 2011

By M. R. Khalesi, S. Bellec, C. Bazin, D. Hodouin

Batch grinding tests conducted on a gold ore indicated that gold is not randomly distributed within the size fractions of the ground ore. Since gold leaching performances were found to be dependent of the size of the gold carrying particles an integrated gold ore grinding-leaching simulator should incorporate a method to predict the gold size distribution of a ground ore. The paper describes the results obtained from batch grinding tests showing the non random distribution of gold within the size intervals of a ground ore and the initial developments of a grinding model to predict the gold size distribution in a batch grinding product.

Jan 1, 2011

By O. Rielo, A. Pascoal, P. Katsabanis

The dynamic parameters of two different granites have been obtained using Hopkinson bar experiments. One series of experiments were conducted using a Hopkinson pressure bar apparatus with an explosive source to provide the compressional wave. This wave would travel along the granite bar and would be reflected at the free end. Strains were obtained along the bar to examine the process. Using relatively long bars of rock, approximately 300mm long and 18mm in diameter, the separation of the compressive and the reflected tensile pulses was possible. If the net tension exceeds the strength of the material, spalling is witnessed. By properly selecting attenuation materials and explosive sources, single spalls were created, making results easier to interpret. Numerical modelling enabled the calculation of the propagation of the stress wave along the bar and its reflection at the free end. Knowing the location of the spalls, critical stress levels for rock failure under tension were obtained. Dynamic tensile strengths were also obtained, at different strain rates, using a Split Hopkinson Bar Apparatus. The results provide a measure of the increase of the dynamic strength at high strain rates, relevant to blasting applications. They are useful for the calibration of blasting models and the characterization of rocks for blast modelling, but also provide answers to the basic question of what is the rock strength for blasting applications.

Jan 1, 2011

By M. W. Grabinsky, B. D. Thompson

ABSTRACT: Use of cemented paste backfill (CPB) offers economic and environmental advantages over other backfill methods. However, many operations have limited knowledge of how their CPB behaves in situ. Therefore, to avoid over-pressuring containment barricades, backfilling strategies necessarily tend to be conservative. In situ monitoring at Barrick Gold Corporation’s Williams Mine and Inmet Mining Corporation’s Cayeli Mine has been conducted and factors controlling barricade pressures are demonstrated, including rise rates, binder content, stope geometry, and tailings properties. The application of barricade pressure monitoring on a stope-by-stope basis can increase backfilling efficiency and, thus, reduce stope cycle times, while maintaining optimal safety.

Jan 1, 2011

This work illustrates the potential of two welding processes for joining AA1100-16 vol.% B4C metal matrix composite: laser welding process using a 4 kW Nd:YAG laser and Friction Stir Welding. A comparison is made between these two welding techniques in terms of microstructure and mechanical properties of welded joints. A large amount of brittle needle-like phases, together with some residues of B4C particles were observed in the fusion zone of laser welded joints. The use of Ti filler can improve the microstructure and increase the joint efficiency from 63% to 75%. On the other hand, the friction stir welding process being a solid state welding technique is interesting as it avoids the formation of brittle intermetallic phases. In addition, the breakage of B4C particles and the grain refinement of the matrix were observed in the weld zone. Consequently, FSW joints show much better mechanical properties than laser welded joints. Up to 100% joint efficiency can be achieved by FSW for annealed AA1100-16 vol.% B4C materials.

Jan 1, 2011

By R. L. Virta

Ball Clay -- Four companies - H.C. Spinks Clay Co. Inc. (owned by Lhoist Group), Imerys Group (formerly Kentucky-Tennessee Clay Co.), Old Hickory Clay Co. and Unimin Corp. - mined ball clay in four states during 2010. Production, based on preliminary data, was 910 kt (1.11 million st) with an estimated value of $42.9 million. That was a 10-percent increase in tonnage from 831 kt (916 million st) with a value of $37.7 million that was produced in 2009. Tennessee was the leading producer state with 61 percent of domestic production. It was followed by Texas, Mississippi and Kentucky. About 70 percent of production was airfloat, 20 percent was crude and 10 percent was water-slurried.

Jan 1, 2011

By Mariane Costalonga de Aguiar, Carlos Mauricio Fontes Vieira, Sergio Neves Monteiro

"This work evaluates the effect of incorporation of an ornamental rock waste into an industrial clayey body used for roofing tiles fabrication. Formulations with 0, 10, 20 and 30 wt.% of waste were prepared by replacing the sand in the industrial clayey body. The plasticity of the formulations was determined by the Atterberg limits. Specimens were fabricated by 18 MPa press-molding and then fired from 850, 950 and 1050°C. The specimens were tested to determine the water absorption, linear shrinkage and three points bending flexural strength. The results indicated that the waste improves the extrusion performance of the clayey body by decreasing its plasticity. The use of the waste was beneficial to the water absorption and mechanical strength of the fired clayey ceramic at 1050°C.IntroductionOrnamental rock is a natural resource available in the municipal area of Santo Antonio de Padua and located 150 km from the city of Campos dos Goytacazes, northe of state of Rio de Janeiro, Brazil. Intense industrial activity related to ornamental stones, especially gneisses, is traditionally occurring in the region. After mining, the flagstone is submitted to sawing to obtain blocks and then, after a manual operation, the final products are small flagstones [1,2]. During the sawing operation, a sludge composed of water and fine particles of rock is generated. A monthly production of 1000 tons of ornamental rock waste is estimated to be produced at Santo Antonio de Padua. The final disposal of this waste has brought serious environmental problems. Since most industries do not have an adequate sludge treatment, the waste is contaminating the soil and underground waters as well as obstructing rivers and lakes.Ceramic bodies industrially fabricated in the municipal area of Campos dos Goytacazes, 280 km from the city of Rio de Janeiro, are still empirically elaborated using a mixture of local clays. These clays are predominantly kaolinitic mineral, associated with high plasticity. Due to the excessive plasticity of the ceramic bodies, it is common to have dimensional defects in the final products after the drying and firing processes. Moreover, the kaolinitic structure and the presence of aluminum hydroxide confer a refractory behavior to the local clays. This impairs sintering during the firing operation. In the case of clay ceramics for civil construction, this results in greater porosity associated with elevated values of water absorption [3,4]. To avoid this problem, it is necessary to reformulate the ceramic body composition. The addition of both non-plastic materials to reduce plasticity and fluxes to condition the refractoriness is a possible alternative."

Jan 1, 2011

By Jun Zhu, Jilai Xuel, Tao Li

"Coal gangue is industrial waste containing Al2O3 and SiO2 with great recycling and reuse values. This work is aimed at extracting Al2O3 content in the coal gangue by a process of carbonthermal reduction - alkaline leaching. The Al2O3 and SiO2 contents first became a mixture of SiC and Al2O3 in the process of carbonthermal reduction, and then Al2O3 was separated by leaching in NaOH solution, thus producing the sodium aluminate solution for Al(OH)3 precipitation. The products generated at various stages in the process were inspected using XRD and chemical analysis. The effects of parameters such as reduction temperature, carbon ratio, NaOH concentration, leaching time, leaching temperature, stirring speed, etc were investigated in details.IntroductionCoal gangue is an industrial residue resulted from the process of coal mining and washing, accounting for 100 - 150 kg with 1 ton raw coal mined. The existence of coal gangue in large quantities has become a serious problem for environment pollution. On the other hand, the chemical compositions of coal gangue are Si02 and Ah03 primarily. In China, the accumulation storage capacity of Ah03 in coal gangue is not less than 600 million ton at a rough estimate, which should be considered as an abundant second resource [1]. If the alumina can be recycling and reused effectively from coal gangue, it will not only reduce the imperilments caused by coal gangue, but also yield good economic returns.Generally, the processes of extracting Al2O3 from coal gangue can be divided into acid leaching (vitriol or hydrochloric acid) and alkaline leaching (mostly NaOH) [2]. The acid leaching processes have many problems, such as lower leaching ratio, corroding the equipments, recycling the spent acid hardly, etc. The primary matter of alkaline leaching process is silica dissolving with alumina, which brings perplexing desilication process, alumina loss seriously and higher energy consumption."

Jan 1, 2011

By Jerry C. Tien

China?s remarkable levels of economic growth during the past three decades have lifted almost 300 million people out of poverty. This amazing achievement has placed an increasing demand on energy and minerals, especially coal, which supplies 68.7 percent of China?s energy (June 2011). It is estimated that China mined more than 3 Gt (3.3 billion st) of coal in 2010, three times as much when compared to merely 10 years earlier. Such an impressive achievement does not come without major costs ?? including concerns with mine safety and an increasing number of occupational illnesses due to fast growth. This article reports on one of the major safety concerns in China?s coal mining, dust and dust control practices, and known cases of caol worker?s pneumoconiosis affiliated with prolonged exposure to excessive coal dusts. The exact size of China?s mining industry is not known, but it is estimated the coal industry is at least five-million people strong, and the metal and nonmetals industry probably employs another three million people. To meet increasing energy demand, China mined more than 3.1 Gt (3.4 billion st) of coal in 2010 from its 15,000 plus coal operations1, most of which are small- to medium-sized operations with annual coal productions ranging from a few thousand tons to 300 kt (330,000 st). These small coal operations are typically in remote areas, inadequately engineered, poorly ventilated and still using rudimentary drilling and blasting mining methods employing antiquated mining equipment and, presenting safety concerns, i.e., methane and dust explosions.

Jan 1, 2011

The SART (sulfidisation, acidification, recycle, and thickening) process is an effective way to separate copper and cyanide from each other in the waste stream of gold processing plants using cyanidation. Factorial experimentation has been conducted to create models of copper recovery, cyanide recovery, acid addition, and oxidation I reduction potential during SART. Economic analysis of the resultant models showed that SART is best operated with a sulfide to copper molar ratio of around 0.56, a pH of 4, and a minimised cyanide to copper molar ratio. The experiments also showed that thickening time may have drastic impacts on SART performance.

Jan 1, 2011

By Jérôme Girard, Shiu Kam, Sue Longo

"Historically, tailings management in a northern climate has involved the deposition of tailings into the Tailings Management Area (TMA) as conventional slurry. This type of system is obviously viable but presents challenges that are difficult to manage as circumstances change over the life of mine. These issues can include:? Increases in mill throughput, and? Life of the TMA for the life of mine.This case study will present how thickened, high-density, non-segregating tailings are used as an alternative to conventional slurry disposal to achieve greater storage capacity and enhanced environmental performance for a gold tailings facility in a northern climate. This paper will focus on how this change in deposition strategy accommodated the increased throughput of the mill and the increased life of mine. Specifically, the paper will discuss the addition and integration of new processes to the exiting mill system to accommodate the tailings management issues. It will highlight the challenges from laboratory testing to pre-feasibility to the engineered design of the thickened tailings system implemented at Musselwhite Mine.BACKGROUNDGoldcorp Canada’s Musselwhite Mine, in Northwestern Ontario (120 km north of Pickle Lake), is an underground gold mining operation that began production in 1997. The current mill throughput is about 4000 tpd (1.4 Mtpa). Gold extraction is based on a CIP process with cyanide destruction.The existing tailings management area (TMA) is located about 2 km southwest of the mill complex. The TMA is contained by high ground to the north and to the west and flanged by a moraine ridge along the south side. A number of dams have been constructed along this ridge. The dams were first built in 1996 and subsequently raised in 2000 and again in 2005. Excess tailings pond water is discharged to a polishing pond then released to the environment via a wetland.The TMA was originally designed to contain 13.7 Mt of tailings under a ponded surface for closure. The water cover was to inhibit adverse long-term environmental effects because the tailings contain pyrrhotite and other sulphide-bearing minerals that are potentially acid generating. The design was modified during Stage 3 Construction in 2005 to expand the storage capacity to 17.3 Mt (Golder, 2005). As of end of 2009, over 16 Mt of tailings had been deposited in the TMA. The slurried tailings were historically deposited at 50% solids."

Jan 1, 2011

By M. Botz

Alacer Gold Corporation is constructing the Çöpler Gold Mine in eastern Turkey. Mining commenced in the fourth quarter of 2009 and gold production started in the fourth quarter of 2010. The mine is a 15,500 t/day oxide heap leach with three-stage crushing, agglomeration, carbon adsorption and electrowinning for final metal recovery. Leach solution copper levels are expected to be relatively low during the first two years of production, but will increase in later years due to higher copper content in the mined and processed ore. Over the mine life, approximately 40 Mt of ore will be placed on the leach pad, which will contain about 35,000 t of copper. Metallurgical testing indicates copper extraction will vary by ore type and, if controls are not implemented, may lead to copper levels exceeding 1,000 mg/L in pregnant solution. High copper levels in leach solution have the deleterious effect of increasing cyanide consumption and potentially overwhelming the ability of the carbon circuit to effectively adsorb the principal economic metals, which in this case are gold and silver. Using data obtained from laboratory leach column testwork, the heap leach facility was modeled using METSIM process simulation software to estimate the build-up of copper in leach solution over the life of the mine. Laboratory testwork was also performed to evaluate process conditions for treating a portion of pregnant leach solution via sulfide addition to precipitate saleable copper as copper sulfide (Cu2S).

Jan 1, 2011

By V. I. Lakshmanan, R. Roy

Base metals and PGMs are currently recovered from sulfide concentrates using pyrometallurgical processes. These processes suffer from several limitations such as being capital intensive, scaling problems, S02 emissions and long delay in value recognition. Alternative hydrometallurgical technologies have so far not been successful and currently total pressure oxidation and partial pressure oxidation hydrometallurgical technologies are being evaluated. Process Research ORTECH has developed a unique hydrometallurgical process to recover base metals and precious metals using mixed chloride technology. In a first stage leach, base metals are recovered and elemental sulfur is liberated from hydrogen sulfide formed during this leaching stage. During second stage leach, precious metals are recovered using proven separation technologies. Some of the advantages of the process are the recovery of elemental sulfur from sulfide sulfur, recycle of the chloride lixiviant thereby eliminating effluent treatment steps and use of excess energy from the Claus reactor for the pyrohydrolysis step.

Jan 1, 2011

By M. Abdellatif

The Mintek Thermal Magnesium Process (MTMP) process is based on DC open arc metallothermic smelting of calcined dolomite at normal pressure and temperatures of 1650?1750°C. The process was demonstrated at the pilot scale in the period 2000?2004. Major changes to the MTMP pilot plant were made throughout the development period, which lasted for about five years. The changes included design and installation of new equipment, modification of existing equipment, changes in the metallurgical approach in terms of feed rates, feed recipes, furnace operating temperatures, cold and hot dolime feeding, and steady and systematic changes in the operating procedures and maintenance of the plant. As a result, the performance of the pilot plant gradually improved from one campaign to the next, in terms of availability and in particular the condensation efficiency. In Run 10, the process was successfully demonstrated over an 8-day campaign. Keywords Magnesium, condensation efficiency, DC arc furnace, silicothermic reduction.

Jan 1, 2011

By Dale Dean, Bill Hancock, Raul Mondragon, Carlos Aguilar, Chris Martin

"In 1942, commercial mining operations began in what is now the Lucky Friday Ag/Pb/Zn mine in Idaho’s Silver Valley. Wholly owned since 1962 by Hecla Mining Company, the mine has produced more than 145 million ounces of silver and has been a mainstay producer in Idaho’s Silver Valley for over 70 years.However, by the early 21st century, the mill had fallen, technologically, seriously behind the rest of the industry. Accordingly, starting in 2005, the current mill management team set to revitalizing the milling operation. This paper will describe how the mill was systematically evaluated and the aging infrastructure replaced with more current technology. Driven by internal mill review studies supported by QEMSCAN mineralogical balancing, the mill has in recent years been through waves of upgrading – from the installation of new mechanical and column flotation equipment to the introduction of on-stream analysis, a technology well-accepted around most of the industry but alien to this technologically conservative mining district.The experience at Lucky Friday is a testament to the need for ongoing structured mill optimisation and technology upgrading in established mining operations. This paper will describe engineering experiences associated with upgrading equipment in an operating mill, contained in a confined building. Experiences in teaching the team new ways of operating a mill, and finally the metallurgical rewards that have been reaped will be described.INTRODUCTIONMining in Idaho’s Silver ValleyIdaho’s Silver Valley is a 64-km long valley flanked by the US Northern Rocky mountains, seldom more the 3-km wide, and stretching across much of Idaho’s northern panhandle, roughly 150 km south of the Canadian border. Mining has been continuously active in the area for more than 140 years, during which time, the Silver Valley has become one of the richest silver producing districts in the world, and as of 1985 had out-produced the 500 years of production from the famed Potosi district in Bolivia. Since 1885, almost 100 deposits have been discovered and worked in the district (Chapman, 2000)."

Jan 1, 2011

By V. Aprahamian, T. Cheng, M. Tangen, R. Beauprie

The Royal Canadian Mint has implemented significant process additions since 2005. Installation of a whole new highly automated silver refining circuit has allowed recovery of physical silver from gold and silver dorés . To complement this change, a small Top Blown Rotary Converter has been in operation. On the gold refining side, a new hydrometallurgical process to recover precious metals from Miller Chlorination slag has been developed. Finally, new systems have been put in place to improve treatment of waste water, wet and dry fume and dust.

Jan 1, 2011

By D. D. Southworth

In 1987, the Bureau of Mines initiated a mineral assessment of the 5.7 million-acre Valdez Creek Mining District (VCMD). Following a literature search and interviews with persons knowledgeable about deposits within the district, limited on-site field visits were made to various deposits. Present within the district are the industrial minerals limestone, argillite, granite, basalt, perlite, zeolite, and sand and gravel. At least six limestone deposits of potentially economic size and grade are known to exist within the district. Adjacent to the Parks Highway and marginal to the district, a limestone deposit is currently being mined as a source of agricultural lime. A perlite occurrence near Yacko Creek was evaluated but proved not to be of industrial grade. The sand-and-gravel resources of the district are vast, but high silt content renders many of the glacial deposits unsuitable for use in construction applications.

Jan 1, 2011

By E. Asselin

Passivation of Fe-Ni-Co alloys during the Caron leach process is thought to result in low cobalt recoveries in ammoniacal ammonium carbonate solutions. A brief review of the available thermochemical data for the (Fe, Ni, Co)-NH3-H2O systems has been undertaken. The stability of the Co(II) and Co(III), Ni(II) and Fe(II) am-mines was examined through the use of speciation and Pourbaix diagrams at 298 and 333 K and at 6 M total ammonia. Increasing the temperature reduces the stability fields of the ammines and generally constrains the thermodynamic window for the leach. The Fe(II) ammines are only thermodynamically stable under reducing conditions. Polarization experiments show that these ammines are unlikely to form if oxygen is present. Fe-Ni-Co alloy passivation may be alleviated by careful management of potential.

Jan 1, 2011