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By John E. Miller

Unit Rig & Equipment Co., manufacturer of Lectra Haul Trucks, is continually studying methods of reducing the operating costs of large haulage trucks. Reduction of haulage system operating costs is an important goal that equipment operators and equipment manufacturers constantly try to improve on. One of the most variable and important factors affecting operating costs is actual truck operating practices. An examination was centered on methods to optimize truck utilizaion. It was found that a very effective method of accomplishing this goal would be an Automatic Truck Control (ATC) system to automatically control a fleet of haulage trucks in a predetermined pattern. Economic studies were conducted which showed a very favorable reduction in mine operating costs by use of an ATC system. In 1970, Unit Rig & Equipment Company, in conjunction with SAAB-SCANIA began preliminary development of adapting for truck use a proven automated control system previously used for train systems, small trucks, and military target vehicles.

Jan 1, 1979

By Lorraine B. Yde

Successful implementation of computer systems deals with meeting final systems objectives and cost and schedule requirements, but the final success is dependent upon personal inter- action. This is a case history of the installation of responsibility reporting at The Anaconda Co.'s Twin Buttes operation, later to become Anamax. The study has been documented as it occurred in hopes that it will illuminate the "people" side of computer systems implementation. Systems implementation involves negotiating with people. "The cooperative approach to negotiation (Nierenberg, 1968) the approach which vostulates that all varties must come away having gained something is based on a simple but important premise. Negotiation takes place between human beings. You cannot negotiate with a computer." This is a look at the human side of a major system installation. An attempt is made to show how a reporting system enabled a company to take a new look at itself. It is also an example of statements made by Toffler (1970) in Future Shock. "As machines take over routine tasks and the accelerative thrust increases the amount of novelty in the environment, more and more of the energy of society (and its organizations) must turn toward the solution of non-routine problems. This requires a degree of imagination and creativity that bureaucracy, with its man-in-a-slot organization, its permanent structures, and its hierarchies, is not well-equipped to provide."

Jan 1, 1979

By Peter J. Tarkoy

The art of predicting rock excavating machine performance has become increasingly detailed and refined. Researchers using laboratory experiments and machine manufacturers using field observations have identified and defined mechanisms of failure, rock and tool interaction, and relevant design principles affecting them. Concurrently, practitioners have developed index tests which reflect rock properties relevant to machine performance. Empirical relationships between index properties and machine performance (penetration rate, cutter consumption, and machine utilization) have been established from past experience and are currently used throughout the industry. Contractors have used such relationships for estimating throughout the world. The detail in which geological, geotechnical, test, and project data, empirical relationships, and construction experience are utilized, is limited by time constraints imposed by the bidding period. To fully utilize all available data, methods of analysis, and construction experience, a simple computer program was developed for a microcomputer costing less than $7500. As a result, 1. machine performance predictions are detailed & reliable, 2. construction alternatives may be examined, 3. anticipated conditions & performance are graphically, documented & easily comparable to those encountered, and 4. results include a listing of assumptions & results of performance analyses & a graphic performance summary.

Jan 1, 1979

By Nathaniel Arbiter

The development of flotation machines since the first industrial use of the process can be divided into three stages. The first, up to about 1930, was marked by diversity in the means for contacting floatable mineral with the air/ water interface and for generating the interface, as well as in cell design. By 1927 Taggart (1) could list 170 patents covering flotation cells, and he mentioned dozens which were or had been in operation. He divided cells into eight categories according to design, type of separating interface, and where in the cell and how separation took place. These were: (1) Film or skin flotation with wet or dry oiling of surfaces; (2) pulp body process with bubbles generated chemically by pressure reduction, by vacuum or by boiling; (3) agitation-froth processes involving local supersaturation with air; (4) bubble column; (5) pneumatic; (6) cascade; (7) subaeration; and (8) combination and miscellaneous types and processes. Most widely used then were the agitation-froth, sub- aeration, pneumatic types. By 1943 a significant reduction in categories had occurred to the two main divisions of mechanical and pneumatic cells according to whether agitation and aeration were (a) by an impeller with or without compressed air, or (b) by compressed air alone. Cells at that time were still relatively small; the Morenci Concentrator completed in 1942 used 432 1.7m3 (60 cu ft) Fagergrens for roughing 45,000 and later up to 55,000 t/d.

Jan 1, 1979

By Brent W. Madsen

To assist in fulfilling the Bureau of Mines goals of maintaining adequate mineral supplies to meet national economic and strategic needs, and to minimize the environmental impacts associated with mineral-processing operations, a leaching-solvent extraction-electrowinning technique was compared with a leaching-cementation technique for processing low-grade copper ores. Large-scale laboratory column leaching tests (6 to 7 tonnes) were conducted on minus 37-cm chalcocitic ore using ferric sulfate leach solutions at 25° C. Two columns contained 11 percent minus 1.27-cm fines, and two columns contained 32 percent minus 1.27-cm fines. After 416 days of leaching ore samples containing 11 percent minus 1.27-cm fines, copper extraction was 48 and 51 percent for the leach-cementation and leach-solvent extraction-electrowinning procedures, respectively. When leaching ore samples containing 32 percent minus 1.27-cm fines, the leaching-solvent extraction-electrowinning technique extracted 60 percent of the copper after 568 days, whereas the leaching-cementation technique extracted only 48 percent of the copper. In the latter test, leach solution ponded on the ore, which reflected a decrease in ore column permeability. The decreased permeability was attributed to the generation of excessive amounts of iron salts during cementation; the salts precipitated on the fine ore particles and in the interstices, thus plugging the column. This decrease also lowered the available oxygen, resulting in poor aerobic bacterial activity which slowed the oxidation rate of ferrous ions to ferric ions. Sulfuric acid required to maintain a leachant pH of 2 was nearly halved when copper was recovered by solvent extraction and electrowinning rather than by cementation.

Jan 1, 1979

By Gordon R. Wicker, Peter V. Avotins, Steven S. Ahlschlager

Laterite ore slurries exhibit Bingham plastic behavior and can be characterized by the magnitude of their yield point and Bingham viscosity. These two parameters are affected by ore composition, solids concentration, and temperature and are used to predict the pressure drop in pipelines and heat transfer coefficients in shell-and-tube heat exchangers. In cycloning of laterite slurries, the calculated cut size is corrected by factors obtained from the rheological parameters.

Jan 1, 1979

By Nick Barton, Harald Hansteen

The deformations resulting from excavation of very large openings are compared using two-dimensional F.E. continuum analyses and discontinuous physical models (20,000 discrete blocks). Both the joint orientations and the model horizontal stress levels were varied. Some models were dynamically loaded to simulate earthquakes (0.2-0.7 g). Model deformations were recorded using photogrammetry. The changes in deformation when increasing the simulated spans from 20 m to 50 m were of particular interest. High horizontal stress caused surface heave when joint orientations were favourable for arch stability. Joint orientations also determined whether the pillars between parallel openings were in a state of compression or tension. INTRODUCTION The engineering performance of large rock caverns has traditionally been learned from mining and hydro power projects, where the depth below surface is often many times greater than the span of the openings. Deformations measured in the walls and roofs of hydro power caverns generally range from about 5-50 mm, though there is a documented case where a wall moved in 126 mm (1), and another where the arch moved down 147 mm (2). The chief objectives of the present studies of large near-surface openings were threefold: (i) to provide deformation data to compare with monitored data from planned engineering projects involving large span near-surface excavations, e.g. underground sports complexes, civil defense shelters, nuclear power stations,

Jan 1, 1979

By A. L. Mular

Steady-state material balances calculated from data measured at various locations around process units are useful for many purposes, such as metallurgical accounting, on-line control, and the development of mathematical models. Often it is possible to calculate material balances by several independent procedures when excess measurement information, i.e., redundant data, is available. Clearly, if the data were collected without measurement errors, a theoretical condition never found in practice, all material balances calculated from redundant data would be in agreement. The real situation is that error exists in practical measurements, so that the results of material balances determined from available optional procedures differ. Consequently, best fit computational procedures to improve the material balances by taking measurement errors into account have been formulated. Such procedures can be used also to judge whether measurements are grossly in error due to either faulty observations or defective data sensing devices. A variety of mathematical techniques are available which serve to adjust raw data. The adjusted data permit mass balancing that does not depend on the computational method. To illustrate the need for an adjustment procedure, Table 1 shows a raw data set acquired around the Brenda Mines Ltd. No. 4 grinding circuit shown schematically in Fig. 1. At least seven optional ways to calculate a circulating load ratio may be employed. These are shown in Table 2 where, depending upon the calculation [ ]

Jan 1, 1979

By Jose M. Milian, Raphael F. Matson

An intensive study was started in 1968 to determine the most economical process for winning nickel and cobalt from an extensive de- posit of complex, low grade nickel-cobalt ore (1.6% Ni, 0.10% CO) designated "the Greenvale ore." In 1974 the commercial plant at Yabulu, in Queensland, Australia, began processing the ore. In the interim, a great deal of laboratory and pilot-plant effort was applied to develop technical, process and commercial design data to demonstrate to potential financial backers and customers that a full-scale plant was feasible. The laboratory test work, pilot plant facilities and pro- gram are briefly reviewed in this paper.

Jan 1, 1979

By Mahmood B. Mirza

The geology of the Gulf Coast Salt domes has been extensively studied by Kupfer (1,2,3,4,5), Atwater (6,7), Balk (81, Hawkins (9), and Wharton (10). dominant geological feature of Southern Louisiana is the Gulf Coast Geosyncline. The axis of this geosyncline corresponds with the present day coastline of Texas, Louisiana, Mississippi, Alabama and Florida. This geosyncline has been continually subsiding since Cretaceous times and receiving large deltaic accumulations of sediments from Central North America. These accumulations progressively thicken toward the South. In the vicinity of the Coast, these sediments are reported to be about 40,000 feet thick. Another dominant feature of the region is the large number of salt domes scattered along the Gulf Coast (fig. 1). Typically, these domes are roughly cylindrical in shape, 1 to 5 miles in diameter, and extend to more than 20,000 feet in depth. It is hypothesized that these domes are derived from the thick Louann salt formation lying below the deltaic sediments. Due to its low specific gravity and buoyancy, the salt layer protruded upwards plastically and pierced the overlying strata. As a result of this upward flow, the adjacent strata are locally lifted upwards, creating excellent traps for petroleum accumulation.

Jan 1, 1979

By Ronald M. Hays

The White Pine Copper Division of Copper Range Company is a large copper producer operating an underground mine, mill, and smelter on Michigan's Upper Peninsula. Principal water discharges are from the tailings basin where these discharges are high in dissolved solids because of mine water pumped into the basin. Principal air emissions are from the smelter where SO2 emissions are uncontrolled. Although water discharges and air emissions have not had significant environmental impacts, environmental regulations could require additional control procedures. Because of low copper prices and poor profitability, cost of compliance with possible new environmental regulations could have serious impact on White Pine with no apparent significant beneficial environmental impacts.

Jan 1, 1979

By Usko Anttikoski

This article deals with the extensive geotechnical soil and bedrock mapping system maintained in the Geotechnical Office of the City of Helsinki since 1955.Soil maps have been prepared to scales of 1:500,1:2000 and 1:10 000, and most recently in 1978 a new type of bedrock map was printed to a scale of 1:10 000, which covers the whole city area and particularly serves rock tunnel construction. A map showing the types of foundation building in the central city area, which will also serve underground construction activities, is currently being prepared. Since the geotechnical mapping system has been well received in Helsinki and the drawing of similar maps has also been undertaken in other Finnish towns, this mapping method is believed to be of interest to foundation engineers and tunnel constructors elsewhere too. THE GEOTECHNICAL CONDITIONS IN HELSINKI The geological structure of Helsinki, and of all Finland, presents two types clearly differing in character and age; bedrock and soil. The solid bedrock is Precambrian, while the soil dates from the Pleistocene Age and has mainly been deposited during and after the Ice Age. Thus the history of Helsinki only displays very old and very young formations, but nothing in between. The ground level in Helsinki is +62 at its highest and the sea bottom close to shore is -15 at its deepest. The deepest rockhead has been found to lie at the -70 level.

Jan 1, 1979

By Vinton A. Garbesi

The construction involved in the Washington Metropolitan Area Transit Authority (WMATA), Contract No. lK0011 (K-1), encompassed some 2,621 meters of single track parallel tube rapid transit tunnels, 335 meters of cut-cover subway station and appurtenant ventilation structures at each end, and a fan shaft at approximately the mid point of the tunnels. The construction contract was awarded June 7, 1974 to a Joint Venture consisting of Intercounty Construction Corporation, Hyattsville, Maryland, and S $ M Constructors, Inc., Solon, Ohio. The former being responsible for performing the cut and cover construction, and the latter being charged with constructing the running tunnels and fan shaft at their mid point. (See Fig. 1) The problems of mining and supporting, the 183 meters of twin tunnels just east of Court House Square Station, by unique mixed face and soft ground mining methods is the main subject of this report, although a general review of the tunnels in their entirety, as well as the geology encountered in the excavations, is presented to give a better overall setting for the problems encountered. GEOLOGIC SETTING The tunnels for the K-1 contract are located in three general types of material; the first being fractured and metamorphosed ignious rock (quartz-hornblende-biotite gneiss), the transition zone between weathered and competent rock, and in ground consisting of the weathered

Jan 1, 1979

By Brian P. Canning

Ion exchange resin processes are receiving renewed attention in the mining industry for recovery;, of metals from solution. This interest has been inspired by the development of continuous countercurrent ion; exchange systems (CCIX) which are of much lower cost than the original, fixed bed contactor processes. With the countercurrent systems and new developments to process or upgrade the eluate product, ion exchange can now compete successfully with solvent extraction for treatment of uranium ores. The low concentration of U308 obtained in the CCIX strong eluate is generally upgraded by solvent extraction methods in sulfuric acid systems. Resin loadings of up to 120 grams per liter of U308, however, have been produced experimentally by recycling of eluate (HIM-IX process) and further developments may be expected in the near future. New developments in resin technology are bringing forth products of greater strength, loading capacity, selectivity and density. Densities up, to 1.35 spgr have been claimed by some suppliers. The process is not a new one and has taken years to advance to the present state of development. The earliest system to gain widespread acceptance was the resin-in-pulp system applied to uranium recovery. Ion exchange, however, later lost acceptance in favor of solvent extraction in the 1960's due to problems in resin degradation, resin contamination and resin-pulp separation, in addition to the development of improved solvent extraction reagents and techniques. The resin-in-pulp system continues to have application on high clay ores and has advanced in design. A number of other continuous ion exchange systems were also tried but never gained continued acceptance. In the current resurgence period the CCIX systems to gain acceptance were the Utah and Chem-Sep (Higgins Loop) systems. These processes are relatively simple in concept although require sophisticated controls. Fixed bed columns have also been designed into multistage systems in countercurrent operation but are not discussed in this paper. These systems remain competitive today for many applications. The most recent advancements however have been in the multistage contactors from,, which three are in current acceptance. These are the Himsley, Porter, and NIM systems. All industrial applications of these systems are relatively new, although pilot plant and in-plant development has been in progress over the last decade. Fur36ther developments should be expected in the near future.

Jan 1, 1979

By Heinz Kettling

Labor costs, which have rapidly increased in the industrial countries for several years, have forced the mining industry to develop new methods and cost saving systems. Also, because mining is basic to meeting the increasing requirements for raw materials, the mining industry is guaranteed a key position in cost cutting efforts. Although this report aims to describe major recent developments in the Federal Republic of Germany, it is restricted to a limited number of them in view of the wide variety of current innovations. The most important mining activities in West Germany are concentrated in the coal mines on the Rhine, Ruhr and Saar, in the lignite open-cast mines west of Cologne and in the potash and salt mining region in Lower Saxony and Hesse. This report will only discuss developments in the underground coal mines and the potash and salt mines, and focuses on projects of Salzgitter Maschinen and Anlagen AG (SMAG). HYDRAULIC DRILLS Drilling strata of varying strength One special difficulty faced in European coal mines is the varying of compressive strength of strata that occurs even over a few meters. The strata associated with the coal measures ranges from hard and tough sandstone or conglomerate to very soft carboniferous shale. It is often difficult to use continuous miners or roadheaders so that drifting by blasting still predominates. But the varying compressive strengths of the strata makes it difficult to choose the best method to drill the rock. For example, it is best to penetrate hard sandstone or conglomerate with heavy percussion drills. The soft carboniferous shale on the other hand, should be penetrated by high speed rotary drilling to obtain optimum performance.

Jan 1, 1979

By R. B. McCammon

Four areas have been identified as favorable drill-site locations for determining whether or not a suspected prophyry copper deposit exists in Rowe Canyon, Nevada. Favorability is based on the similarity to a deposit model constructed from geochemical data for the porphyry copper deposit near Ely. Favorability is defined as the coincident number of positive anomalies for the elements zinc, silver, arsenic, antimony and iron. The favorable areas coincide with an observed magnetic high and areas in proximity to major faults.

Jan 1, 1979

By Joseph B. Gillenwater

Miss Gertrude Carey lived next to us in Martinsburg, West Virginia for several years. She was a retired school teacher. She was also a cousin to Messers Dan and Joe Baker who owned and operated Standard Lime and Stone Company, a predecessor of Martin Marietta Corporation. She-was well acquainted with the Baker family and their history. Here is one of the legends she told my wife, Jean, and me. The Bakers were originally Tanners. They had a tannery near Frederick, Maryland. There were several boys in the family and when they were grown each man had specified responsibilities. Will Baker was assigned the duty of locating, buying, and transporting tanbark and lime. As he traveled through Maryland, Virginia, Pennsylvania, and West Virginia to locate and buy tanbark, he also talked the farmers out of some pieces of lime, which the farmers had produced in holes dug and filled with layers of limestone and wood. Will Baker took the lime and soaked a piece of hide in the milk of lime. If the lime did not spot the hide, Will Baker would get the farmer to burn some lime for him, and further tests would be made. If these tests were good - the Bakers bought the land. They eventually discovered that the limestone that would make lime that wouldn't spot the hide would also be suitable for producing steel. They began producing lime just outside Harpers Ferry, West Virginia in pots and upright kilns. That stone too small for the kilns was just perfect for railroad ballast. Now you know how "Baltimore Blue Bloods" got together!!

Jan 1, 1979

By Robert L. Randall

The mineral industries have a continuing need for market forecasting and analysis for a variety of purposes, among which are organization and control of the sales effort, financial and corporate planning, and evaluation of the anticipated revenue from investment in proposed projects. For anything beyond the simplest extrapolation, some kind of economic reasoning or analysis is called for, which may or may not be incorporated into a formal or quantitative model. The principles described here apply to most of the commercially significant minerals and metals. The examples are drawn largely from the copper market, as it is the one with which I have the most practical experience. Practical forecasting is the process of analysis and synthesis from three categories of knowledge: facts and statistics, theory, and practical knowledge and informed opinion. Although many attempts have been made to build forecasts on only one of these three pillars, none has been successful as an operating procedure because of the lack of balance. There are no facts about the future-only about the present and the past. Facts can illuminate the future, but the future can be described only in terms of probability or more or less likely states of affairs-not as a continuous extension of the past and present. Likewise, theory, although useful as an organizing discipline and for providing a methodology of analysis, is inadequate for the complexities of reality. This is especially so when there is feedback between plans and forecasts to produce a new outcome and when there are significant elements of unpredictable free will, such as presidential jawboning or foreign policy considerations. Such elements are difficult to accommodate in neat theories, although they must certainly be reflected in the forecasts. Pure opinion frequently suffers from both a lack of-disciplined reasoning and the presence of biases or self-interest. While the future is unknown, it tends to cast its shadow before it; hence, forecasting is the art and science of positioning oneself so that the shadow becomes visible to the forecaster.

Jan 1, 1979

By Richard Klimpel

A common problem in mineral processing and chemical engineering is the need to estimate flow rates and/or weight ratios involved with engineering operations for which it is inherently difficult to directly measure stream weights. Simple examples of this situation include stream separators (a classifier operating on a particle flow) and stream mixers (the mixing of new feed and circulating load in a ball mill circuit). Often in these types of operations, it is possible to sample the streams involved to get approximate component analyses (e.g. size distributions of solid streams, chemical composition of chemical streams). In this paper various formulae are developed which can be used to estimate stream flow rates or weight ratios given information on the stream components. The type and level of experimental error present in the stream component analyses does have an important bearing on the numerical values (and reliability) of the weight ratios calculated by the various formulae. A simple but theoretically sound method is shown for selecting appropriate estimation formulae for any given engineering operation. The derived formulae are applied to sets of experimental classification data for illustration purposes.

Jan 1, 1979

By C. C. Hatch

As part of a general project to simulate a concentrator, the Brenda Mines Limited secondary crushing plant, located near Peachland, B. C., was sampled during the summer and winter of 1975 to develop a digital crushing plant simulator specific to the Brenda operation. The purpose of this simulator was to study the influence of manipulable process variables on important responses and to permit study of alternative circuit configurations if desired. This paper describes the simulation methodology employed and presents the results of a computer study of the secondary crushing plant (1).

Jan 1, 1979