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Mining Science and Technology (Russia)

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Vol 9, No 1 (2024)
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BENEFICIATION AND PROCESSING OF NATURAL AND TECHNOGENIC RAW MATERIALS 

5-11 614
Abstract

The search for alternative sources of useful minerals is a pressing issue. One such possible source is the processing of lean gold-bearing ores, which previously did not seem feasible to exploit for subsoil users, leading to their disposal in off-balance ore dumps. Processing these resources becomes economically viable as gold prices rise and processing technologies improve over time. This paper presents the elemental and mineralogical composition of lean gold-bearing ore dumps from the Golden Pride Project (GPP) mining operation in Tanzania’s Lihendo district. This area contains an old dump of lean gold-bearing ores, weighing approximately 1.4 million tons. Extracting valuable components from lean mineral raw materials is a current priority. Sampling was conducted to study the dumps. Boreholes were drilled to a depth of 1 m, covering a total sampling area of 20 ha; 18 samples, each averaging 3 kg in weight, were collected. The results of X-ray fluorescence analysis (XRF) indicated the presence of Fe, S, Si, Ca, Ca, Mn, Cu, Al, Cr, Ti, As, and Ag in the collected samples. X-ray diffraction (XRD) analysis revealed that the main minerals in the dumps are muscovite, kaolinite, quartz, montimorillonite, and goethite. The average gold grade in the selected samples is 0.72 g/t. Studies of the grain-size distribution and gold distribution by grain-size classes after ore grinding demonstrated that the majority of gold (74%) is in the −75 μm class. In the initial mineral material of the dumps, the share of the +30-50 mm grain-size class is 81%. The paper proposes potential methods for processing lean dumps of gold-bearing ores. One such methods involves crushing the dump material, separating the −75 μm class, and subjecting it to direct leaching or leaching using “carbon-in-pulp” technique. Heap leaching appears to be the most promising method for extracting gold from such dumps in terms of technical and economic feasibility. Positive experience has been reported in applying this process to ores of similar mineralogical type.

12-20 445
Abstract

Complex processing of ash and slag waste is a supported directions for the development of environmental friendliness and performance in power engineering. The rational use of this waste in large-scale production processes has now been realized in the construction field. The development of up-to-date beneficiation technologies raises the possibility of extracting various useful components from ash and slag wastes. This study aims to investigate the potential for using energy-efficient ash beneficiation to produce a heavy metal-containing fraction and separate the magnetic fraction. To assess the feasibility of ash beneficiation and its rational use, the technical documentation of ash and slag dumps of PJSC “Magadanenergo” was studied, and semi-quantitative analyses of samples collected from these dumps were carried out. The data on the content of useful components and quantities of ash and slag enabled us to develop complex beneficiation flow sheets, assess their process efficiency, and evaluate their potential financial viability. The estimated volume of metals to be recovered includes 785 tons of Ti (me-1), 183 tons of Sr (me-2), and 4,867 tons of Fe (me-3). The performance indicators of the beneficiation and aggregated values of economic indicators for this project implementation on an industrial scale were calculated. The economic feasibility of the ash processing project showed good values for two out of three models over a ten-year planning horizon. Implementing the project also effectively improves the environmental situation by potentially processing up to 10% of the total volume of ash dumps, fulfilling one-fifth of the Energy Strategy of the Russian Federation’s requirements until 2035. While investigations of ash from the Magadan Cogeneration Power Plant (MCPP) are not new, they were not previously carried out within the framework of studying integrated processing of ash to obtain various useful components.

21-29 366
Abstract

One of the main challenges in processing fresh ferruginous quartzites is to obtain high-quality iron ore concentrates containing more than 70% total iron and less than 1.8% silica to produce DR pellets and hot Briquetted Iron (HBI). Currently, it is widely recognized that the most effective methods to achieve high-quality iron ore concentrates is through reverse flotation using cationic amine collectors in an alkaline medium. However, due to the very fine impregnation of magnetite in quartz, the insufficiently complete release of magnetite even with fine grinding, and the proximity of the flotation (surface) behavior of the separated minerals, high-quality concentrates are not always achievable in the flotation process. Consequently, exploring methods to enhance the efficiency of flotation separation of minerals and improve concentrate quality remains a pertinent issue. Historical studies have shown that electrochemical treatment can adjust the properties of reagents, enhance their effect on specific minerals, and thus control the flotation process. The efficiency of quartz and other silicates flotation by amines significantly depends on the ratio of ionic and molecular forms of the reagent in aqueous solutions of the collector and in the flotation pulp. Altering this ratio can impact the outcomes of reverse cationic flotation of iron ores. It is feasible to change the ratio of the amine forms through electrochemical oxidation or reduction of the reagent solution. Moreover, the electrochemical treatment facilitates the dispersion of the amine in the aqueous medium and its physical adsorption on minerals. Therefore, electrochemical pretreatment of amines can be considered a promising method for intensifying the reverse flotation of iron ore. This paper presents research results aimed at improving the quality of the oversize of the fine screening of ordinary magnetite concentrate from Mikhailovsky GOK, named after A.V. Varichev, through the use of electrochemically treated solutions of cationic amine class collectors in the process of reverse cationic flotation. The research findings confirmed the feasibility of using preliminary diaphragmless electrochemical treatment of reagents Tomamine RA-14 and Lilaflot 811M (esters of monoamine of different composition) for the targeted modification of their properties and for increasing the efficiency of reverse flotation. Consequently, the silica content in the flotation cell product decreased from 1.66–1.7% to 1.51–1.56, with the grade of total iron exceeding 70%.

30-40 313
Abstract

Kaolin (mainly composed of kaolinite, whose chemical formula is Al2Si2O5(OH)4), serves as a versatile raw material widely used in various industries including production of ceramics, paper, paints, cosmetics, pneumatics, building materials, and hazardous waste storage. In the northern part of Vietnam, due to favorable geological conditions, there are diverse deposits of high quality kaolin of different origin and scale. Decades of research indicate the diversity of kaolin sources in the region, with special attention paid to hydrothermally altered and exchange types of kaolin, the formation of which is associated with complex processes of weathering, hydrothermal alteration and reprecipitation. The aim of this study was to characterize three different types of kaolin derived from different sources in Northern Vietnam (from weathered pegmatites, weathered felsic effusives, and hydrothermal-metasomatic altered rocks). The main focus was to analyze the thermal behavior of these samples during calcination in the temperature range from 300 °C to 1,100 °C. The comprehensive characterization was performed by X-ray diffraction (XRD), FT-IR spectroscopy (FT-IR), thermal analysis (thermogravimetry / differential thermogravimetry (TG / DTG)) and scanning electron microscopy with energy dispersive X-ray spectroscopy (SEM-EDS). The results showed that kaolinite with particle size less than 2 μm was identified in all samples. Minor amounts of muscovite and montmorillonite are present in some samples, and pyrophyllite is present in a sample from the hydrothermally altered rocks. Kaolinite morphology in all the samples showed typical forms including hexagonal and pseudohexagonal. The main chemical constituents of the samples are SiO2 and Al2O3; in addition to these, K2O + Na2O, TiO2 and iron are present in smaller quantities. Thermal analysis allowed to reveal the formation of metakaolinite phase at temperatures around 494 °C and 507 °C in the two studied samples from weathered rocks, while the pyrophyllite-bearing sample undergoes this transition at a higher temperature of 653.8 °C. The onset of metakaolinization was observed at about 500 °C for the weathered rock samples and about 700 °C for the pyrophyllite-bearing sample. In addition, mullitization leading to the formation of mullite was evident at 1,100 °C. The study findings allow concluding that the studied kaolins can be used in traditional ceramics production.

SAFETY IN MINING AND PROCESSING INDUSTRY AND ENVIRONMENTAL PROTECTION 

41-52 258
Abstract

The study of airflow patterns at the ends of dead-end mine workings is crucial for optimizing underground mining ventilation systems. Understanding these patterns forms the basis for designing and implementing effective ventilation strategies.

Previous studies have shed light on the behavior of the main vortex and the formation of stagnant zones in such environments, but these insights remain fragmented and call for a more systematic exploration to integrate them into a comprehensive theory.

This paper presents the results of a thorough field investigation into the forced ventilation behavior in a dead-end mine working with a significant cross-sectional area (29.2 m2). We evaluated the impact of varying the setback distance of the ventilation duct’s end from the working face at intervals of 10, 15, 17, 19, and 21 m. The experimental design included precise measurements of turbulent airflow velocities at 25 carefully chosen points (in a 5x5 grid) for each setback distance, covering the area from the working face to beyond the end of the ventilation duct. This included additional measurements taken 1 meter and 10 meters past the termination of the ventilation duct, moving towards the entrance of the working area.

The fieldwork was carried out in a typical dead-end stope at the Kupol gold-silver mine in the Chukotka Autonomous District, created by drilling and blasting.

The volume of fresh air delivered to the working was maintained at a consistent rate of 17.4 m3/s across all scenarios, aligning with the mine’s standard air flow rate derived from the ventilation requirement for exhaust gases emitted by internal combustion engines of Load-Haul-Dump (LHD) machinery. With the duct’s terminal cross-sectional area at 0.8 m², this resulted in an inflow velocity averaging 21.75 m/s.

Additionally, we included insights from three-dimensional numerical simulations performed in ANSYS Fluent, focusing on steady-state air movement and developed turbulence within the dead-end space. A comparative review of both empirical and modeled data shows that the ventilation jet, for all tested setback distances up to 21 m, successfully delivered air to the working face, where it then dispersed and initiated reverse flow patterns.

These experiments led to the formulation of a linear relationship between the maximum relative velocity (compared to the initial jet velocity) at a distance of 1 m from the working face and a key geometric factor of the ventilation setup. This factor is the ratio of the duct’s setback distance to a characteristic dimension of the cross-sectional area, calculated as the square root of the cross-sectional area.

53-59 201
Abstract

The increasing complex geological and hydrogeological conditions ore deposit mining, deeper excavation sites, and ambitious business expansion strategies, necessitate the use of high-performance, heavy-duty self-propelled machinery and winning equipment. Such activities significantly strain mine ventilation systems and demand innovative safety measures during mining.

This study assesses the influence of interconnected production variables on the aerological safety of mining operations. It provides real-world data on emissions from diverse sources within mines. The analysis includes an examination of current methodologies for estimating the air volume needed to dilute exhaust gases from diesel-powered machinery. Through numerical simulation that accounts for changes over time, the study was able to predict how exhaust gas concentrations would disperse within mines. These theoretical findings were then confirmed through empirical observations made in actual mining setting The field studies conducted, alongside their thorough analysis, underscored the necessity for adopting new, more sophisticated approaches to calculate airflow requirements in mines operating ICE machinery. A particular methodology developed by the MMI of the NUST MISIS (hereinafter referred to as the Methodology) was put forward as the primary tool for this purpose. The Methodology’s precision and benefits were closely scrutinized, revealing its effectiveness in ensuring aerological safety in mines.

POWER ENGINEERING, AUTOMATION, AND ENERGY PERFORMANCE 

60-69 313
Abstract

The intensive implementation of variable-frequency drive machines and installations in underground mining processes necessitates addressing several issues, with a primary focus on ensuring the quality of electric power. Elevating the energy resource of mining machines and enhancing the energy efficiency of mining operations requires maintaining the rated indicators of electric power quality in mine power distribution systems. Achieving this involves assessing the level and composition of higher harmonic components in voltage and current within power circuits equipped with variable-frequency drives (VFD). Key objectives encompass the development of a simulation model based on the equivalent diagram of the power distribution system substitution with a scraper conveyor VFD to scrutinize the spectral composition of higher harmonic components in the power circuits of the mine power distribution system (MPDS). Additionally, the study involves analyzing the impact of harmonic filters (HFs), reactors, and sine filters on the quality of electric power in the VFD system of a scraper conveyor. Further analysis extends to the spectral composition of higher harmonic components in circuits related to insulation leakage and metering circuits of the residual-current device. Practical recommendations for improving electric power quality in the VFD system of a scraper conveyor are then developed based on the research findings. The established model of a variable-frequency drive system for scraper conveyors facilitates the assessment of the effectiveness of electric power quality improvement measures. The harmonic composition of voltage and current in the mine power distribution system is determined under maximum distortion conditions and in the presence of HFs, reactors, and sine filters. Research methods are chosen to unveil the spectral composition of voltage and current in symmetrical and single-phase modes of insulation leakage, as well as in metering circuits of residual-current devices (RCDs). It is noted that the harmonic composition of leakage voltage and current is primarily influenced by the parameters of the output voltage modulated by the autonomous frequency converter inverter. Considering the high level of harmonic components in voltage and current, adjustments to RCD settings, capacitive current compensator, and the protective shunting unit are recommended for electrical safety. The study emphasizes the importance of scientifically substantiating the rated indicators of higher harmonic components for leakage circuits and further exploring the physiological effects of higher current harmonics on the human body. The feasibility of installing a harmonic filter (HF) directly on the low-voltage supply section of a scraper conveyor should be technically justified. Interestingly, the presence of HFs, reactors, and sine filters does not significantly impact the harmonic composition or the magnitudes of coefficients of the harmonic components in the phase voltage of the system concerning ground and leakage currents through insulation. However, higher harmonic components induced in leakage current circuits may pose a potential hazard, leading to a violation of magnetic compatibility and posing risks in case of contact with live parts of electrical equipment.



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ISSN 2500-0632 (Online)