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By David A. Monaghan, Kenneth R. Maser, Adi R. Gurdar, D. Randolph Berry

5. Development of Initial Probing System 5. 1 Introduction The preliminary evaluation of a variety of potential methods for initial probing showed that the optical system using closed circuit television (CCTV) and the sonar, or acoustic ranging, system were the most promising. The former is capable of pro¬viding a visual display of the mine passages in a clear, non-smoky environment, and the latter is capable of providing a map of the spatial location of the coal surfaces making up the entries, as well as objects, such as cribs, mining machines, etc., in the passages in both smoky and non-smoky environments. The sonar system used in conjunction with the CCTV in a clear environment can greatly assist in resolving the spatial distribution of objects seen on the TV screen. Further, in a smoky environment the interpretation of the sonar information could be facilitated if some visual information were also available. CCTV systems exist but require some modifications to suit this particular application. The Industrial Hazards and Communications Division of the Bureau has an ongoing program for the development of such a CCTV system. Rather than duplicate this effort in developing a CCTV system, it was decided to evaluate the possibility of utilizing their system for initial probing, while continuing with the develop¬ment of a system which would work in any environment, including the presence of dense smoke. The concept of using sonar for the initial probing of mine passages represents the application of new technology requiring development. The results of such a development effort undertaken during the course of this program are described in the following sections.

Jan 1, 1973

By J. Mothomogolo

Mining projects are capital-intensive and are also characterized by high technical and economic risks. These factors pose challenges to mining entrepreneurs when they seek to raise seed capital for mining start-ups. There are limited sources of mining investment funds in South Africa and each has shortcomings due to one reason or another. Another impediment is South Africa?s status as a developing economy, in which the standards of living ? which in turn influences the savings culture ? the limited GDPs and budget, the socio-political environment, and banking, mining, treasury and other regulations, determine the size of investments, particularly in mining ventures. The proposed funding mechanism was developed with the aim of filling the gaps identified in existing funding mechanisms that were developed by the government with the introduction of the Minerals and Petroleum Resources Development Act (MPRDA), 2002. The shortcomings identified were presented to the study participants as questions to obtain views that were used to define innovative ways of raising mining start-up capital. Most participants in the study supported the derived hypotheses and proposals, and these were used to refine the proposed mechanism for mining investment in South Africa. The proposed funding framework is aimed at encouraging interaction between mining entrepreneurs, government, and the investors to align goals and expectations when undertaking a mining investment.

Jan 1, 2012

By R Balusu, P Humphries

In combination with detailed field studies and goaf gas characterisation, computational fluid dynamics (CFD) models have been used to develop optimum and effective strategies for inertisation during longwall sealing operations to achieve goaf inertisation within a few hours of panel seal-off operation. This study has combined detailed analysis of the performance of various inertisation field trials together with CFD modelling results of different inertisation operations in order to develop the optimum inertisation strategies. A number of parametric studies were conducted on the base case CFD models that had been calibrated and validated based on the information obtained from previous inertisation studies and goaf gas monitoring. These studies included changes in inert gas injection locations, inert gas flow rates, seam gradients, and different inertisation strategies to investigate their effect on goaf inertisation. Studies indicate that the strategy of inert gas injection through the MG seal was not as effective as the alternative strategy of inert gas injection at 200 m behind the face. Innovative inertisation strategies have been developed and subsequently implemented at an underground coal mine in Australia. Further investigations have been carried out in the development and demonstration of proactive inertisation strategies with the objective to suppress the occurrence of spontaneous heatings in active longwall faces, in particular under unexpected scenarios such as during slow retreat/face stoppage due to difficult geological conditions. Initial trials at two Australian longwall panels have demonstrated the great potential of this practice to contain the onset of heatings in the goaf.

Jan 1, 2005

By Y. Tao

The professional status and characteristics of mineral processing were discussed along with the importance of innovative personnel training for mineral processing engineering. Reform ideas and models for the mineral processing engineering education system were suggested to formulate and implement new training program for the mineral processing specialty. It is suggested to strengthen engineering training practices, cultivate the culture of innovation, improve innovative education system and insisting on the combination of teaching with production and scientific research as the important means of training innovative talents for mineral processing engineering.

Jan 1, 2010

By M. A. Halim, V. I. Lakshmanan

Recycling is one of the key elements for sustainable process development for the recovery of value-added products and reducing environmental impact. Process Research ORTECH Inc. has developed several innovative and sustainable technologies, which minimizes the use of water, and chemicals for the recovery of gold, vanadium and gallium from secondary sources by maximizing the recycling of reagents, and reuse of water from process effluents.

Jan 1, 2015

Hindustan Zinc Limited (HZL) is one of the leading base metal producers in India. It operates a two-smelter Complex at Visakhapatnam, Andhra Pradesh. At this zinc-lead smelter zinc is manufactured by the conventional hydrometallurgical route and lead is produced by Blast furnace technology generating residues or wastes which contain substantial quantities of metal values. Disposal of such wastes is a problem in any non-ferrous industry. Both the stringent environmental regulations and the changing industrial scenario emphasise the need for industrial research to find economically viable and environmentally friendly technologies to recover the metal values from these waste materials. The in-house R&D Centre at Vizag Zinc Smelter (VZS) thinking globally re-engineered its activities and major thrust was given for converting waste to valuable metals and metal compounds. Basic analytical chemistry with the hydrometallurgical concepts has been adopted in developing these innovative technologies. In this paper attempts are made to provide a clear history of the different waste raw material, the process developed for each raw material and their superiority of over other parallel work. Most of the processes described here are pilot plant tested and under patenting. The process flowsheet, results obtained and advantages of each process are presented. This paper provides a consolidated approach through which the varied smelter waste materials can be processed with cost effective and eco-friendly innovative technologies. In-house R&D efforts at VZS with its contribution and achievement in converting æwastes into wealthÆ technologies are presented in this paper on the following the major thrust areas:recovery of zinc from liquid effluent; recovery of zinc from effluent treatment plant (ETP) gypsum sludge; production of highly pure electrolytic zinc metal powder from zinc bearing gypsum residue/sludge generated at the effluent treatment plant; hydrometallurgical recovery of copper as copper sulphate solution which can be used for CuSO4.5H2O, copper cathode/copper metal powder from copper-cadmium cement; recovery of manganese, lead and silver from anode mud generated at Zinc Cell House and 4-metal extraction/recovery of manganese, cobalt, copper and nickel from Indian ocean bed manganese nodules; recovery of zinc, lead, silver and sulphur values from silver concentrate residue generated at the froth flotation process; recovery of silver and lead as lead-silver sponge/lead-silver sulphide concentrate from lead bearing residues; recovery of lead, silver and copper from copper matte; recovery of antimony as antimony metal or lead-antimony master alloy from antimony bearing dross; and recovery of nickel and dimethylglyoxime from Ni-DMG complex.

Jan 1, 2000

By R R LARGE

In the past decade mineral deposit models have become an important tool for the exploration geoscientist. By combining genetic theories on the formation of particular deposit styles, with geological, geochemical and geophysical criteria relevant to ore location, it has been possible to more effectively focus exploration effort to the regions and local targets which have the best chance of success. However, such models have their limitations, and must be carefully and critically applied and continually updated as new technical and research information becomes available.

Jan 1, 1992

By R Heath, P Rose, L Coetser

A sustained eight-year major research effort has been undertaken in South Africa to develop integrated passive water treatment systems for the sustainable removal of sulfates, while simultaneously addressing the removal of metals and acidity. The research effort addressed the problem both at a fundamental science level and at the more empirical pilot plant level. Whereas there are numerous anaerobic sulfate reducing reactors in operation on mine waters that remove some sulfate together with metals and acidity, these are typically plagued by low sulfate removal efficiency and gradual reductions in overall reactor efficiency with time. The South African research effort has focused on understanding the fundamental microbiological and biochemical reactions that occur in anaerobic reactors filled with lignocellulosic material and subjected to high sulfate water. Hypotheses have been developed that differentiate the reactions occurring in such a reactor into groups that should be individually optimised and these hypotheses have been verified through rigorous laboratory and pilot scale studies. The results of this research are incorporated into a patented multi-stage integrated passive treatment system that is capable of sustained high rate removal of sulfates, metals and acidity.

Jan 1, 2003

By Thompson D, Burgess G. C

Subsequent to large scale trials in 1987, the installation of a submerged lance Sirosmelt furnace system was approved in late-1988 for the cupellation of retort bullion to dore silver. Commissioning work commenced in June 1990. During the process air is lanced into a molten slag bath contained in a cylindrical vessel to rapidly oxidise the granulated feed bullion from 15 - 25 per cent silver to rough dore grade. The process is now an integral part of the Precious Metals operation replacing the first stage reverberatory cupellation furnaces to achieve productivity improvements, lower silver inventory and increased silver Recovery.

Jan 1, 1992

By C. H. Bucknam

Metallurgical processing of gold ores in positive water balance environments has been facing decreasing discharge concentrations in permits and additional requirements to pass acute toxicity testing before discharges will be allowed to native fisheries. In response to the challenge to meet 0.005 mg/L free cyanide guidance for discharges to fresh water fisheries, the American Society of Testing and Materials (ASTM) International Cyanide Task Group has undertaken an interlaboratory study for the free cyanide method in the metallurgical processing cyanide detoxified reverse osmosis effluent to determine if the quantitation limit for the method could be lowered from the current 0.009 mg/L free cyanide (1) to less than the 0.005 mg/L guidance concentration. Results of the testing are presented below.

Jan 1, 2012

By Carlos A. Ferreira, Betina Hansen, Marco A. S. Rodrigues, Marcela P. Proença

"Nowadays, the concern with the reduction of industrial pollution has motivated researchers to found out new technologies for treatment of industrial waste. The clean technologies, as electrodialysis, are capable of treating these residues, minimizing the impacts when they are discarded directly on the environment. Membranes of SPS/HIPS, PAniCSA/SPS/HIPS, SPAN/SPS/HIPS were developed using chemical mixture method. Membranes were characterized by Infrared Spectroscopy (FTIR), Thermogravimetric Analysis (TGA), Dynamic Mechanical Analysis (DMA) and Scanning Electronic Microscopy (SEM). Membranes were submitted to electrical polarization and to electrodialysis at NaCl and KCl solutions, in order to determine ionic transport through the membranes. Results were compared with commercial membranes. The average percent extraction for Na+ ions obtained by membrane was beyond 20%.IntroductionThe high environmental impact caused by the galvanoplastic industries represents today a world concern(1). In the galvanoplasty, thin metallic layers are deposited on metallic surfaces(2) through chemical methods or electrochemical process. This industrial process presents some disadvantages that limit its utilization, as the generation of toxic effluents containing concentrations of heavy metals usually above the limits allowed for his release in receiving bodies(1), the production of galvanic sludge which is considered hazardous waste and that is very difficult to treat, beyond the high consumption of water (3).Stimulated by the development of new ion-exchanged membranes with high selectivity, lower electrical resistance, and improved thermal, chemical and mechanical properties, the use of electrodialysis in the wastewater treatment has recently gained a broader interest(5). The electrodialysis (ED) is a mass separation process in which electrically charged membranes and an electrical potential difference are used to separate ionic species from an aqueous solution(5). The technique permits the recovery and the reutilization of the waste products from the industrial process, avoiding the discharge of them on the environmental (acting as clean technology)."

Jan 1, 2008

By I. Kylmakorpi

In non-ferrous metal smelting, when the concentrate entering the furnace contains high levels of moisture, energy requirement for heating and drying increases and large volumes of exhaust are produced. To solve this problem, rotary dryers and flash dryers using direct heating, and also steam dryers using indirect heating have all been used for drying concentrate. The focus of this paper is to present the development and current applications of the Kumera Rotary steam dryer. The advantages of this technology are numerous, including reduced heating requirements, environmental friendliness, operation reliability and minimum maintenance needs; making it a top choice for drying concentrate.

Jan 1, 2008

By S. Liu

With the development of global economy, the demand of mineral?s quantity and quality are in-creased, valuable minerals are more and more finer and poorer, and the capacity of concentration plant are more and more high. Using large-scale flotation cells can obviously enhance the capacity of treating the mineral, reduce the cost, and increase the economic benefit and competitive ability for the enterprise. BGRIMM advanced advisable technical scheme with optimally parameter and route for the feature of dynamic in large scale flotation machine, and developed the KYF Large Scale Flotation Cells, which have used more than 400. The paper advanced the history, the design principle, the operating principle, the structure feature and the application of KYF flotation ma-chine.

Jan 1, 2014

By D. E. Walsh

With the exception of the development of large scale mining equipment (haul trucks, draglines, shovels, etc.), there are likely few other candidates responsible for the ability to exploit large tonnage, low grade deposits, than the development of large capacity comminution equipment and circuits; crushers and grinding mills. Ball mills are often the final step in the comminution process and are responsible for providing what should be the optimum particle size distribution of ore to subsequent mineral concentration steps in the flowsheet. Because comminution processes are such high cost centers for milling operations, both capital and operating costs, an enormous amount of research has been conducted to study and model their performance, in order to improve efficiencies (Kelsall, et al., 1969; Austin et al., 1984; Napier-Munn, et al., 1999; Powell and Smit, 2001). With respect to modeling ball mills, estimates of the breakage rates for individual size classes of ore particles are fundamental, as are the particle size class breakage functions (the progeny of particle sizes produced from breaking a coarser particle size class), also termed appearance functions. Fundamental research into particle breakage in tumbling mills focuses on how much energy is input into single particles versus how they break and what size distribution of particles results. Several test methods, including JKMRC?s well known dual pendulum test and drop weight test, have been developed for the breakage of coarse particles down to 6 mm in size (Napier-Munn, et al., 1999). Work on the breakage of finer particles is still an area of intense research and single particle breakage is being investigated as are multiple particle, fixed bed methods (Hoffler and Herbst, 1990; Bourgeois et al., 1992; Whiten, 2007).

Jan 1, 2011

A combination of highly structured, fissile stope hangingwalls and high ground stresses have caused difficult mining conditions in the Main Lode Deeps at Lancefield Gold Mine. Cyclic reviews of ground support and stoping techniques, coupled with geotechnical investigations, and the application of numerical modelling has led to the successful management of stoping operations.

Jan 1, 1995

By Seiji Mizutani, Hirofumi Taguchi, Makoto Yoshida, Hidenori Takahashi, Naotoshi Shinkawa, Kazuo Konishi, Yoshiyuki Morikawa, Masaya Kawata

"The lattice-shaped cement treatment method has been used to improve the seismic performance of liquefied sandy soil in Japan. The efficacy of the method has been confirmed by the huge earthquake in Japan. In the present study, a new method to improve sandy ground by using the lattice-shaped cement treatment method is proposed as a liquefaction countermeasure. It is the floating-type and lattice-shaped cement treatment method, where cement treated soil is not fixed to an un-liquefiable stratum. In this method, a fixed-type structure such as treated soil should be formed at the side of the floating-type treated soil to reduce its lateral displacement. In the study, one-dimensional dynamic response analyses were firstly conducted to confirm the mechanism of the new method. Secondly, a series of centrifuge model tests were performed to demonstrate the effect in a proto-type scale's stress condition. The analyses and model tests confirmed the effect of liquefaction countermeasure of the new method.INTRODUCTIONLiquefaction induced by an earthquake generates sand boiling and ground settlement. Other problems have also been reported, including a decrease in bearing capacity and an increase in the horizontal earth pressure against retaining walls. To prevent these problems caused by liquefaction of the ground, various countermeasures have been proposed, such as cement deep mixing and high-pressure jet mixing methods. These methods have the big advantage of being applicable to ground that contains soil with a fine-grain fraction. Furthermore, the unnecessary displacement caused by the construction can be reduced. In Japan, a lattice-shaped cement-treatment method has frequently been used at many construction sites to prevent liquefaction, where cement-treated piles are intersected to form a lattice, as shown in Fig. 1. The lattice-shaped walls can reduce the shear stress generated by an earthquake, restricting the liquefaction at that location. However, the construction cost of the cement treatment is relatively high compared to other methods such as the sand compaction pile (SCP) method, and needs to be reduced. Therefore, decreasing the total volume of the cement treatment is necessary to reduce the construction cost."

Jan 1, 2015

By Francesco Vegliò, Luigi Toro, Francesca Pagnanelli

"Different hydrometallurgical processes have been studied in order to recover manganese(II) from oxidised minerals such as MnO2 (Vegliò and Toro, 1994). An innovative acid reductive leaching carried out in soft experimental conditions was here considered using agro-industrial wastes containing carbohydrates as reducing agents (Vegliò et al., 1998).The leaching process was investigated from a kinetic and equilibrium point of view in order to optimize the experimental conditions and obtain high purity and concentrated MnSO4 solutions.The overall leaching process (not considering the complex network of intermediate oxidation reactions of the carbohydrates in hot sulphuric acid medium (Vegliò and Toro, 1994)) can be described by the following reaction:24 MnO2 + C12H22O11 + 48 H 24 Mn2+ + 12 CO2 + 35 H2O (1)A Shrinking Core Model (SCM) was modified by a variable activation energy term to take into account both the variable reagent concentrations and the reaction rate change with respect to the manganese dioxide conversion. The influence of the particle size in the kinetic model is discussed with the support of SEM analysis and BET surface measurements before and after leaching.Manganese extraction yield was maximised (170-190 g/L) using appropriate carbohydrates and acid excesses, while impurity concentrations were kept low (Fe<10ppm and Ca<300ppm) pre-treating the ores, using hydroalcoholic leaching medium and different combinations of down-stream processes. In particular precipitation, solvent extraction and adsorption onto active carbon were tested to eliminate Fe and Ca from MnSO4 solutions."

Jan 1, 2003

By Francesco Vegliò, Luigi Toro, Francesca Pagnanelli

Different hydro-metallurgical processes have been studied in order to recover manganese(II) from oxidised minerals such as MnO2. An innovative acid reductive leaching carried out in mild experimental conditions was here considered using agricultural and industrial wastes containing carbohydrates as reducing agents. The leaching process was investigated from a kinetic and equilibrium point of view in order to optimise the experimental conditions, develop a kinetic model and obtain high purity concentrated MnSO4 solutions. To study the leaching kinetic a Shrinking Core Model (SCM) was modified by a variable activation energy term to take into account both the variable reagent concentrations and the reaction rate change with respect to the manganese dioxide conversion. The influence of the particle size in the kinetic model is discussed with the support of SEM analysis before and after leaching. Manganese extraction yield was maximised (170-190 g/L) using appropriate carbohydrates and acid excesses, while impurity concentrations were kept low (Fe<10ppm and Ca<300ppm) pre-treating the ores, using hydro-alcoholic leaching medium and different combinations of down-stream processes. In particular precipitation, solvent extraction and adsorption onto active carbon were tested to eliminate Fe and Ca from MnSO4 solutions.

Jan 1, 2003

By Dawes C. A, Mitchell R. A

A process control strategy has been developed for the lead circuit of the lead- zinc concentrator at The Zinc Corporation, Limited (ZC), Broken Hill, Australia. The general aims of the control system were to produce a final concentrate with a zinc content below a certain limit and, at the same time, obtain the highest lead recovery possible. As presently arranged the system involves control of the cleaner feed mass flaw by cleaner diverter tray manipulation and control of xanthate addition based on per cent lead in feed. Generally this approach works well but for abnormal conditions such as very high or law pH the system requires further improvement.

Jan 1, 1983

By K. Oishi

We have developed a 76Cu-3Si-21Zn alloy "ECOBRASS®" containing no lead. When 3% Si is added to a 78Cu-22Zn alloy, kappa and gamma phases participate uniformly in the alpha matrix. When being machined, stress concentrates on these hard phases, namely kappa and gamma, and thereby lowering the required cutting force and yielding segmentalized chips without lubricant. Kappa and gamma phases transform into beta phase under high temperature, which makes it easier to extrude and/or forge the alloy. When 0.08% P and 50 ppm Zr are co-added, the grains of ECOBRASS® castings are refined significantly to become as small as several dozens of micrometers. The grain refinement by the co-addition of P and Zr improves castability, tensile strength and elongation of ECOBRASS® castings. Meanwhile, the lead leachate from an ECOBRASS® water meter, field-tested in pH 6.8 drinking water for one year, was less than 5 ppb without correction. No indication of dezincification corrosion was observed, either. ECOBRASS® is equally suitable for rods, forgings and castings, and makes it possible to produce a complete set of plumbing parts (valves, faucets, etc.) by its own. This way, not only improving recyclability, ECOBRASS® also realizes size and weight reduction due to its good corrosion resistance and high strength.

Jan 1, 2007