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By Alan K. Burton

Massive increases in the productive capability of open pit nines after World. War II were in a large part made possible by the introduction of ever larger trucks and the supply of a seemingly bottomless ocean of inexpensive and readily accessible oil. Over a period of about 25 years, a variety of technological developments permitted a tenfold truck payload increase, from about 32 tonnes (35 tons) to 320 tonnes (350 tons). There is no, doubt that this was a remarkable achievement resulting in impressive benefits of scale as well as the ability to control what would otherwise have become an intolerable traffic congestion problem in today's large open pit mines. It became fashionable and economically possible during this time to mine large quantities of low grade material and to tolerate very high stripping ratios. As tine has gone by and as easier to get at and higher grade deposits have been depleted, ore grades have tended to decline while stripping ratios have increased. The alternative to reduced revenues has been an ever increasing demand to step up production which in turn has led to a continuing demand for ever larger and larger trucks. While a larger truck has had the effect of reducing the cost of the operator per unit of material moved and of reducing traffic congestion, it has not specifically addressed the subject of fuel cost.

Jan 1, 1981

By Charles W. Daugherty

INTRODUCTION The Washington Metropolitan Area Transit Authority's (WMATA's) rapid transit system, Metro, ultimately will comprise 162.5 km (101 miles) of line divided among 10 routes. As shown in Figure 1, about 24 km (15 miles) of the system will consist of mined rock tunnels distributed along the A, B, C and K Routes. The structural construction contracts for all of the A, C and K Route rock tunnels are complete and trains are running in about one-third of them. A contract for construction of rock tunnel section B-9, the southernmost third of the B Route, was awarded on June 27, 1980. The final design of Sections B-10 and B-lla, the remainder of the rock tunnel portions of the B Route and the Metro system, are well advanced and should be under con¬struction by 1982. Of Metro's 87 stations, 11 will have been constructed by mining in solid rock, a not inconsiderable achievement, since each structure must be over 183 m (600 feet) long, wide enough to accommodate two trains and one or two passenger platforms, and high enough to achieve a stable arching action without encumbering columns. With the passage of years, some original priorities have been reordered, and ways have been sought to streamline and simplify this most complex of Metro structures without grossly violating the architectural standards that make it unique. This paper will summarize that search, and describe the design and construction aspects of the resulting product, the dual chamber rock tunnel station.

Jan 1, 1981

By Thomas R. Kuesel, Harvey W. Parker

INTRODUCTION This paper describes the use of a shield and compressed air for construction of a short section of a pair of twin single-track tunnels for the Metropolitan Atlanta Rapid Transit Authority (MARTA) transit system. Although only two blocks long, this section posed the greatest difficulties to both engineers and contractors, and is the most expensive section of line construction on the MARTA system. All this derives directly from its setting--these tunnels had to be constructed through mixed-face conditions. SETTING The Broad Street tunnels form a link between the Peachtree Center and Five Points Stations, in the heart of Atlanta's central business district (Figure 1). Peachtree Center sits atop a solid rock ridge, which inspired the design of a deep rock-mined station, as described in the 1979 RETC. Five Points Station is MARTA's hub--the intersection of the system's two main branches. It is located in the old railroad gulch, a filled-in erosional valley at the base of Peachtree Ridge, and was constructed by open-cut methods. The alignment and profile of the Broad Street tunnels were closely constrained by these two adjacent anchors, and in the six-block stretch between them there was very little room for maneuvering. Since the rock ridge petered out about in the middle of the section, it was evident at the outset that there would be about two blocks of rock tunneling at the north end, two blocks of soft ground construction at the south, and two blocks of mixed-face in between. It is this central two-block section that is the focus of this paper.

Jan 1, 1981

By Robert L. Marovelli

Organizational development that attempts to simultaneously deal both with training and with job design parameters as they relate to mine health and safety, productivity, and quality of life is one of several areas of research that the Bureau of Mines is pursuing. The Bureau sees potential in this particular effort for reducing accidents and injuries, improving worker satisfaction and health, and increasing productivity.

Jan 1, 1981

By P. E. Wingrove

The Kayford, Boone and Nicholas Division of Bethlehem Mines Corporation operates a modern coal preparation plant in Van, West Virginia. Since the start-up of the Van Plant in 1976 until the summer of 1980, the refuse handling system proved to be a costly maintenance problem and a material handling bottleneck. During the 1980 two-week miner's vacation the original system, which included two screw conveyors and a drag conveyor, was replaced by an installation utilizing two Flexowall steep angle belt conveyors. This paper describes the technical and economic analysis that led to the new installation and reviews its first year operating performance. The Van facility is a heavy media plant designed to handle 127 mm x 0 raw metallurgical quality coal from the Powellton seam at a maximum feed rate of 590 TPH (metric tons per hour). Depending on mining conditions, the clean coal recovery rate averages between 50 and 65%. The plant is set up with three types of cleaning circuits. Coarse material (127 mm x 12 mm) is cleaned in heavy media baths. Intermediate size material (12 mm x .5 mm) is cleaned in heavy media cyclones. Fine coal (.5 mm x 0) is cleaned in a hydrocyclone1 froth flotation circuit.

Jan 1, 1981

By R. E. Muller, L. G. Martin, J. M. Stonehouse

Erratic distribution of values in free gold ore bodies presents severe problems in sorting material in large scale open pit mining. However, an intense program of modern blasting techniques and less than modern gold panning results in good sorting at Houston International's Manhattan mine. Blasting technique is important. If the sample location cannot be relocated because of blasted material movement, information acquired while drilling is useless. So short benches are critical to minimize dilution. Though not very accurate, panning allows for rapid analysis. The more accurate fire assay does not provide the needed speed. Panning can be fairly accurate and errors made are mostly on the low side. Samples of mixed and broken stockpile material are used as checks on pit procedure and to develop stockpile content in¬formation. Added tonnages discovered offset the higher labor costs of this careful sorting technique. The mine is located in central Nevada's Toquima Range in the small mining town of Manhattan, 322 km north of Las Vegas. The mine has four epithermal stockwork ore bodies that are mined in two pits. The mine problem was that conventional ore control was not separating ore from waste. Assays of 6-m blast-holes were used on 5-m centers. The blastholes were relocated by stadia survey after blasting. Holes assaying above the cutoff grade were flagged and mined as ore. This system is practical and useful in high concentration ore bodies or in evenly disseminated mineralization. But it was not practical at Manhattan because of large gold particles and small ore pocket sizes. Ore pockets were often missed when drilling a grid area for blasting. Also, large gold nuggets made assay results unreliable. The probability of a nugget being contained in an assay charge is small. So most results were low, compared to actual grades mined based on stockpile samples. When a nugget found its way into a fire assay charge, the result would be far higher than the actual grade of material represented. In addition, disturbance by blasting created problems in relocating ore. Because of these problems, the grade control program was intensified in September 1979. It successfully separated ore and waste in blocked out ore areas and located more ore in "waste" areas. Known reserves mined to date have increased up to 50% on some benches. The methods used are modern blasting techniques, detailed assaying, and traditional panning of samples collected from active mining faces. These methods allow mining flexibility, to match the variable mineral occurrence in ore bodies. The united effort of the geology and engineering departments has been important to the program's success.

Jan 12, 1980

By Leroy O. Gieseke, John B. Begley

If the particles produced and transported in your plant are as chunky as rough crushed coal or as fine as cement, there are probably several conveying and elevating systems suitable for your operation. The problem is deciding which is most suitable in terms of space, energy cost, allowable product degradation, productivity, and angle of movement. Each conveying and elevating method should be fit to the products it can handle successfully, to desirable economics, and to suitability for the overall operating scheme. Matching along these lines will result in selection guides that should be useful for many years, although design evolution is expected for the materials handling equipment involved. There are several common bulk material handling devices for moving solids: belt conveyors, screw conveyors, bucket elevators, chain conveyors, and en-masse conveyors/ elevators. En-masse conveyor/elevator equipment is commonly compared and contrasted with the other devices. These comparisons often involve en-masse versus all others. En-masse has developed into a versatile technique because the machines can move materials horizontally, vertically, or in closed circuit. Such machines unload, elevate, store, reclaim, and distribute materials-all without ancillary equipment except for chutes and gates. Bulk material can be carried, as with a belt conveyor or bucket elevator; pushed, as with a flight or screw conveyor; bumped, as with a vibrating conveyor; blown, as with a pneumatic conveyor; fluidized, as with a dense phase pneumatic conveyor; or by applying internal forces to it to induce "en-masse" flow. Conveying en-masse is analogous to the flow of a fluid in an open channel, and elevating en-masse is analogous to the flow of fluid in a pipe. In the case of a fluid, flow is caused by a differential in pressure. With en-masse movement, flow results from resistance to shear induced by the movement of chain and flights.

Jan 12, 1980

By R. L. Loofbourow

In addition, dewatering is seldom complete because of aquifer irregularities and an operator's natural reluctance to start a costly study program, provision of wells, and pumping long before mining begins. In some cases, water pumped from the mine is used in treatment. This use is suggested as a way to minimize effluent effects. The true objective of water supply, however, is to provide water of satisfactory quality at the rate needed and at the least cost. Pumping to permit efficient mining isn't likely to coincide strictly with that objective during much of the mine life. The history of mining is replete with efforts, some highly ingenious, to control mine water. Methods that might be used to tackle the challenge Operators of wet mines are faced with both obvious pumping costs and some unquantified water costs. It is possible to reduce both types of costs, generally by reducing inflow to the mine area-and a surprising number of methods have been used to do this. Both the obvious and unquantified costs at a wet mine are now multiplied by: •Increasing costs of power, labor, equipment, and supplies; •Work at greater depth and, in some cases, in wetter ground; •Increasing use of hydraulic fill; and •Increasing zeal in protection of surface and groundwater quality. There are many easily overlooked ways in which mine water may add to hazards and costs (Loofbourow, 1973). As to their importance, consider these examples: •Increased maintenance of equipment, tires, roads, and ditches; •Increased difficulty in supplying proper ventilation; •Increased hazards from ice and use of electric power; • Loss of friable ore minerals and fines stuck on conveyances and in chutes; •Need to use more expensive methods and explosives; and •Decrease productivity of equipment and personnel. Expressed as cost per unit of ore produced, these unquantified costs can be high. Ideally, advanced dewatering should eliminate most of them. Advanced dewatering is a highly effective water control method, but it isn't problem free. Mines in ideal ground for advanced dewatering are most unusual. To be effective, water must be pumped at a comparatively high rate for a period longer than the life of the mine, from below mining depth. Effects on both groundwater and surface water are likely to be drastic. of increasing mine water costs are listed in the accompanying table. Ten groups of possible methods are cited. Most have been demonstrated in mining; two are known from industries other than mining.

Jan 12, 1980

By James M. Riddle

A discussion of frequently asked questions may help individuals trying to interpret subsidence regulations or prepare permit applications. The subsidence permitting process involves just one part of the mass of Surface Mining Control and Reclamation Act regulations. But of the 18 main SMCRA sections, subsidence is critical to the permitting process for coal operators. It's an area in which applicants have had problems interpreting regulations and preparing permit applications. Of 22 western states, only Wyoming, Montana, Colorado, and Utah heave thus far received approval for their mining and reclamation plans. The other states are now involved in the permit application process and will be dealing with SMCRA regulations for the next year or so. Some state programs, when approved, may differ substantially from the federal SMCRA program. But, to be approved, the state programs must be deemed equal to or more stringent than the federal regulations. SMCRA regulations apply to any coal operation "that exhibits surface effects." Thus they apply to surface strip mines as well as underground coal operations. The regulations do not apply to hardrock mining operations. Since August 3, 1977, the government, industry, and the public have wrestled with SMCRA. They have struggled through an initial program with the US Geological Survey; a new agency, the Office of Surface Mining Reclamation and Enforcement (OSM); an interim program; and a "final" permanent regulatory program. Even now, OSM is reluctant to publish formal program guidelines because: •The regulations are still in the process of judicial review. • Some approvable state programs will supersede the federal regula¬tions. • The flexible regulations are open to interpretation, which is desir¬able to maintain. •Guidelines could be misleading until regulations and interpretations are revised and finalized.

Jan 12, 1980

By Charles L. Allie

Since Reserve Mining Co. began commercial operations at Silver Bay, MN, some 25 years ago, major improvements in taconite processing technology have become available. In addition, significant new government standards have been imposed on industrial operations. By implementing a $370-million modernization program, Reserve was able to accomplish two major company objectives: the quality of concentrates produced from the Peter Mitchell mine has improved, and the operation meets both present and foreseeable environmental standards. Process modifications at Reserve were designed to: •Reduce the pellet silica content from 9% to 5%; •Increase the pellet iron content from 62.5% to 65.8%; •Implement a tailings disposal system utilizing "best available technology" water quality controls; and •Reduce air emissions by installing "best available technology" air emission controls. By adding dry cobbing, fine screening, and flotation to the concentrating process, pellet silica content has been reduced; the process reclaims and reuses all process waters; all tailings are stored in a zero discharge tailings basin; and all air emission standards are being met. Initial Beneficiation at Silver Bay Reserve's Peter Mitchell mine at Babbitt, MN, is on the eastern end of the Biwabik iron formation. The open-pit mine is approximately 16 km long, 0.8 km wide, and presently has a maximum depth of about 50 m. Principal constituents of the ore body are magnetite, quartz, and iron-magnesium silicates. The company's large commercial plant began operating at Silver Bay, 75 rail km from the mine, in 1955. Facilities have historically had the capacity to process 31.5 Mt/a of taconite, containing an average 24% magnetic iron, into 11 Mt/a of iron ore pellets. Reserve's initial beneficiation process-which existed up to early 1979-consisted of two crushing stages at the Babbitt mine site, two additional crushing and screening stages at Silver Bay, grinding in a conventional rod-ball¬regrind mill circuit, size classification with cyclones, and concentration with magnetic and hydraulic separators. Concentrate produced by that circuit assayed 65% iron and 8.5% silica, with a screen analysis of 94% -44 µm, and a surface area of 9300 cm2/cm3. Pellets produced from this concentrate assayed 62.5% iron and 9% silica (dry basis). Construction began in 1977 to modify Reserve's operation. Process modifications were designed from pilot scale operations that had been operated and researched by Reserve for more than 10 years. There were two design restraints imposed on the process: economic constraints that Reserve continue to use much of the existing processes and structures in the new operation; and a substantial number of government-imposed permit constraints. In effect, the tailings process was designed first and then a concentrating process was developed that would "fit" the tailings disposal system. Operation of the modified process began in June 1980. Crushing Remains Unchanged No changes in process flow were made at either the Babbitt mine and crushing plant or at the Silver Bay fine crusher. Gyratory crushers reduce run-of-mine taconite to -90 mm-diam at the mine. Taconite is then transported to Silver Bay by intra-plant railroad. There are 10 fine crushing lines. Each consists of a double deck screen, followed by a heavy duty short head crusher, a second double deck screen, and second short head crusher. All screen undersize material bypasses the crushing lines, resulting in an open circuit crushing process. Fine crusher product is approximately 98% - 20 mm, 80% -12 mm, and 50% -10 mm in diameter. Each fine crusher line processes about 400 t/h of crude taconite. Cobbing Provides Aggregate for Tailings Dams The first major process change was the addition of dry cobbing, a dry magnetic separation step between the fine crusher and concentrator. Dry cobbing serves two major purposes in the new process. Its principal function is to provide large volumes of dry coarse aggregate for use in construction of tailings dams. This process rejects about 20% of the fine crusher product as tailings with a size analysis of 98% -20 mm and 50% - 10 mm. These tailings are free draining and have high frictional shear strengths-two key requirements for dam building aggregates. Fine crusher product is conveyed to a new dry cobbing building. Here crushed ore is discharged into one of two 30-minute capacity surge bins. Crushed ore is withdrawn by 12 constant speed conveyor belts; each discharges 500 t of crushed taconite into a dry cobbing machine. Each machine consists of a 3-m-long riffle splitter and two vari-

Jan 12, 1980

"Lax, misguided, and dangerous" is Rep. James Santini's description of the official US position on strategic nonfuel minerals. Santini (D-NV), chairman of the House Mines and Mining Subcommittee, criticized the Interior Department for "its long record of benign neglect" regarding the domestic minerals crisis. Santini made his remarks at a news conference at the American Mining Congress convention in San Francisco, where he released his subcommittee report "US Minerals Vulnerability: National Policy Implications." The report-said to be the first major congressional study of the minerals issue by a committee of jurisdiction is the result of a two-year inquiry. The investigation was undertaken, according to the chairman, "because no person or agency in the executive branch of government fully grasps the critical importance of nonfuel minerals to the nation's economy, defense, and quality of life." The report also urges a larger role for the Department of Defense, which has "stood passively by for many years as a consuming by-stander," according to the report. President Carter's incomplete Non-fuel Minerals Policy Review also drew the committee's ire; Santini calls it "a tragic waste that cost tax-payers $3.5 million and the loss of some 13,000 person-days." The subcommittee examined the following issues for its report: • The US minerals industry's inability to meet national raw material needs under a "hodgepodge of contradictory, restrictive, and irrational" federal regulations; • Dependency on foreign sources of strategic minerals in times of "increasing resource nationalism" and "Soviet mineral expansionism;" • National security needs for foreign mineral resources that do not have effective substitutes; • The US government's approach to national minerals policy "amid a growing realization that such a policy does not exist." The subcommittee report includes an analysis of public and private studies on nonfuel minerals and discusses a series of policy problem areas that negatively affect domestic production. Capital formation disincentives, tax policies, antitrust enforcement, environmental laws, health and safety regulations, technical problems, and restricted access to federally-controlled public lands contribute to what Santini calls a "tragic irony." "The irony is that we are a nation vastly rich in mineral resources yet our own government chooses to stifle development of these critical raw materials and thereby increase offshore reliance. The tragedy is that we also are ensuring US vulnerability to severe economic dislocations and a weakening of our national security." In just six years, from 1973-1978, the US trade deficit in nonfuel minerals rose from $2 billion per year to $8 billion, according to the report. The country imports more than 50% of 23 critical minerals, including 100% of its manganese, chromium, cobalt and platinum. The US is promoting its dependence on foreign mineral sources at the very time the security of many of those sources is becoming less certain, the report notes. Santini said the subcommittee investigation revealed a vulnerability that may be more serious and pervasive than that of foreign oil. The US may be able to develop alternate energy resources, but there are no effective substitutes for many nonfuel minerals. The report also discloses that US stockpiles of critical and strategic minerals are of inadequate supply and quality. Holdings of some vital minerals are far below present objectives, and for some there are no holdings at all, according to Santini. To resolve the current crisis, the report makes the following recommendations: • Complete immediately President Carter's Interagency Nonfuel Minerals Policy Review; • Implement (throught the Interior Department) the 1970 Mining and Minerals Policy Act; • Create an Office of Energy and Minerals with the same stature, power, and oversight responsibilities as the Council on Environmental Quality; • Ease federal restrictions on mineral exploration and development on public lands and implement a complete review of public land use policies; •Fund for and fulfill US nonfuel minerals stockpiling objectives; •Increase federal funding for non-

Jan 11, 1980

Microprocessor-based balances are helping Keffler & Rose Coal Preparation Co. to test and ship coal faster than the competition. They provide a high level of accuracy in meeting Environmental Protection Agency standards and customer specifications .and help minimize "bad" coal. The combination of speed and accuracy has helped increase K&R's sales, while improving the company's reputation for meeting precise client requirements. The quality of coal that is assured by the company's testing-at an in-house lab using fast, precision weighing, and a computerized sulfur test-has assured K&R of a good price for its products. Recent EPA standards have strained the testing capabilities of coal suppliers. Companies involved with high-sulfur coal often use outside laboratory services that can take three to four days to report test results. Since the coal business moves much faster these days, some coal companies cannot afford that kind of time. Too much coal not up to specifications could be produced within a three or four day period. Keffler & Rose took a novel approach to this problem, installing its own in-house laboratory. The test situation immediately improved with this step. However, one bottleneck persisted for a time: the weight measurement procedure for ash, moisture, and energy content. The company first employed a mechanical balance that required time for setting up and taring. The balance provided readings on a conventional scale that was not very precise and allowed for error through subjective readings by the operator. The balance bottleneck was broken when K&R applied new technology to meet its needs: microprocessor-based weighing. The result has been a 75% reduction in weighing time and a sharp increase in accuracy. This has contributed to the test speed needed to keep up with 227-t/h production and precise K&R coal specs.

Jan 11, 1980

By Yoginder P. Chugh

The mining methods used at many opencast brown coal mines in Poland and the German Democratic Republic are not used in the US to any extent. Using bucketwheel excavators, bucket chain excavators, and mobile conveyor bridges, the mining techniques may offer efficient, economic alternatives for operators in the US. These mining methods were observed during visits to several open-cast brown coal mines in Eastern Europe over the past two years. Some of them may be particularly attractive for the large lignite mines being planned in North Dakota and Texas.

Jan 11, 1980

By Roshan B. Bhappu

Integrating a research and development department into an engineering company's corporate structure can be rewarding to the engineering division, the R&D group, and, most of all, the company's clients. Actually, the R&D department is a logical extension of the conventional processing group within an engineering organization-but the R&D group provides services as needed to the engineering department while it is carrying out regular testing, pilot plant, and preliminary feasibility studies. Backup Services Provided With an R&D group, the engineering division does not need a process engineering group as such. The R&D group provides project backup services for feasibility studies, preliminary and detailed engineering, construction, and startup. The R&D group, in turn, benefits from its close association with project engineers, draftsmen, estimators, and computer capabilities in the engineering division. The client also benefits from the arrangement because R&D and engineering skills are available to both departments on an as-needed basis without standby eost. To handle the integrated responsibility of R&D projects, as well as conceptual design and preliminary feasibility studies, the R&D staff must be carefully selected. These research engineers should: • have a good background in plant practice as a mill superintendent or chief metallurgist; • be capable of organizing and supervising a testing program or a pilot plant campaign; •be innovative and willing to accept new ideas and concepts; • be able to translate lab test results into a workable flowsheet through sound conceptual design and feasibility studies; and •be able to communicate with clients. In short, the R&D engineer must be a jack of all process-engineering trades to successfully take a project from concept to operating reality. Engineers in a metallurgical R&D organization should have experience in mining and processing all types of

Jan 10, 1980

By John V. Beall

A completed feasibility study executed by an independent agency can benefit a company in two ways. Inside the organization, it verifies the project staffs ideas and their concept of the facility. Outside the company, it can be utilized to obtain equity partners, debt financing, and other forms of credit. It is advisable to bring in a project execution contractor for the feasibility study. A project execution contractor is able to work with engineers to develop the project concept, process flowsheet, and best utilization of the site. By getting an early start on understanding a company's policies and working methods, a project execution contractor saves the company money since it does not have to go through the educational buildup twice. The contractor is a specialist in putting together a bankable document that can be taken to a financing source. It answers all the agency requirements on the first pass. In addition, the contractor can advise an owner on likely financing sources since he works on the worldwide market every day. A less obvious advantage of including the contractor in the study and predevelopment buildup stages is the importance of coordinating finance and technical input. The financing source influences equipment specifications, procurement, logistics, project schedule, cash flow, and liquidity. There are many surprises in store for any manager of a large international project involving worldwide financing and purchasing. The job does not have to be made more difficult by bringing in a contractor after all predevelopment steps are taken. The contractor can still work if the predevelopment steps have been done, even if he does not agree with them. But early contractor involvement is the preferable solution.

Jan 10, 1980

By Carleton K. Smith

Due to special job or client requirements, there will always be some variation in the philosophy of organizing and controlling construction under a project management contract. In typical cases, however, some standard procedures apply. Controls on a construction project are best described only in general terms. They should apply to the total job and can be most effective only when all pieces of the job organization fit together to support a control system for the entire project. Controls are more than a system of reports, schedules, and tabulations-they are the result of an integrated organization dedicated to getting a job done on time and within budget. One of the most important aspects of project control is the construction organization. It must include the right people, facilities, and site equipment, as well as the authority to do what's necessary to accomplish the work. This should be set up to function with as little involvement from off-site or the home office as possible. However, the jobsite construction group must work within established policies and guidelines and is subject to continuous off-site or home office monitoring. In other words, the job-site leaders need to have a clear definition of their responsibility, their authority, and the necessary people and equipment to make things happen. With that philosophy in mind, this is how Bechtel sets up a new job to be

Jan 10, 1980

By William Bogan, Mark Vaivoda, Richard Daniele

Many factors must be considered when performing engineering and construction work for a major minerals project. Dravo's Afton copper smelter in British Columbia illustrates some of the E&C factors considered when setting up this new operation. In March 1978, Afton Mines Ltd., a Tech Corp. subsidiary, began blister copper production at the world's first integrated copper ore mining, milling, and smelting operation to use Top Blow Rotary Converter (TBRC) process smelting technology. This key TBRC smelting element is licensed by INCO Ltd. to Dravo Corp. The TBRC process uses a single vessel of modular design. It rotates for mixing and provides complete processing capability, from concentrate through blister copper. The Afton facility is about 16 km west of Kamloops, a town in south-central British Columbia. To make its operation as economic as possible, Afton officials considered several options for the copper smelter, the first in modern times in the province. Inability to extract precious metals-primarily gold-from the concentrates ruled out hydro-metallurgical processes. The final choice was between a conventional electric furnace/ Peirce-Smith converter combination and the TBRC process. The TBRC process was chosen for its versatility in processing the various Afton concentrates and grades and its 40% lower capital cost compared to the electric furnace converter system. The TBRC smelter -including concentrate slurry receiving, drying, storage, smelting, off-gas cleaning, and copper casting-had an installed cost of about $25 million. In December 1974, a pilot program was conducted by Teck, Dravo, and INCO at INCO's Port Colborne, Ontario, research facility. The pilot program demonstrated the TBRC's ability to smelt, convert, and clean copper slags. After the successful pilot effort, Dravo performed additional research to find an effective fixation system for high grade, intermittent SO2 gases. Once the go-ahead was given, design and procurement for the Afton copper smelter was provided by the Denver Division, Dravo Engineers and Constructors. Commonwealth Construction, Vancouver, constructed all Afton facilities. Afton's single furnace smelter is designed to produce 25-kt/a blister copper in 363-408 kg cake form. The product is sold to England for electrolytic refining. The TBRC process is only one of several innovations proposed by Dravo and chosen by Afton to insure the most modern smelter in North America and meet all British Columbia's environmental restrictions. Conventional smelting methods use a separate furnace for each process step. The TBRC process employs but one furnace. The Afton TBRC vessel measures 6.4 m in length and 4.3 m in diameter. The furnace is supported on a set of motor-driven rollers. These permit the vessel to rotate at variable speeds to 40 rpm. Rotation provides good mixing, high reaction rates, and effective heat transfer from the refractory sides to the molten bath resulting in a low thermal gradient. The furnace can tilt through a full 360° for charging, firing, and pouring. Smelting at Afton is accomplished in sequential fashion. Flotation concentrate and limestone flux are initially charged to the hot, empty vessel. Using the water-cooled, oxy-fuel lance, the initial charge is smelted. Once sufficient molten bath is obtained and slagging completed, the metallic concentrate is charged. Materials are charged through the water-cooled, variable position additive chute mounted on the TBRC

Jan 10, 1980

By Edwin J. Connell, O&apos

Investment in mining and related process facilities will be more costly and complex in the 1980s than ever before. Interest rates and inflation are soaring; regulations are expanding; and in order to achieve economies of scale, plant facilities and mines are getting larger. As the pace quickens, the time/cost circuit closes around the resource owner or developer. Larger modern projects cost more money and take more time to build. The longer it takes to bring a project onstream, the more it costs in interest, escalation, and lost production. One solution to the time/cost squeeze is to take advantage of systems developed by major contractors serving the mining industry. These contractors have been serving clients in planning and executing large and small projects for many years. They have developed systems which, if applied at an early point in the project's life, can be a significant benefit in development of mineral resources. The systems involve performance of feasibility studies, economic evaluations, and the project installation itself. First the Feasibility Study Feasibility studies can minimize risk through systematic evaluations while progressing toward the ultimate objective-an operating plant. Normally, studies are initiated with a minimum amount of specific information and a maximum number of as¬sumptions. Through the course of the study program, assumptions are continuously confirmed, refined, or rejected by facts until a sound basis for decision is available. High on the list of cost effective tools for evaluation is the use of a geostatistically derived sampling program that provides a highly accurate ore reserve estimate for economic evaluation. When a predetermined sample of data from the drilling program and bench-scale or pilot-plant tests are received, a detailed feasibility study may be started. This study can involve design of the mine,

Jan 10, 1980

It doesn't take any special acumen to note that US engineering and construction firms are busier than ever with mining projects in this mineral conscious world. This special issue of Mining Engineering takes a look at E&C companies-their expanding role, their special capabilities, and their challenges and problems. ME sent a questionnaire to a representative sample of E&C firms. Information was sought about officers, ownership, and amount of business. ME also asked about types of projects and commodities dealt in as well as market distribution and forms of payment. The accomnanying charts show how the 17 responding E&C firms answered these and other questions. Other ME survey questions, and a review of company literature, yielded information about financing techniques and special challenges for E&C firms. Insights were gained concerning government impacts, customer-generated problems, and promising areas for development-including synfuels-in the minerals industry. These areas are discussed later in this article. Accompanying articles in the special issue discuss the E&C company's role in mining projects, research and development in E&C firms, one approach to contract work used by an E&C firm, and an E&C project case study.

Jan 10, 1980

By Jeffrey B. Smith

Introduction The gas shortage is going to be with us for some time to come. If we can set aside political and industry rhetoric (along with subjective personal opinions), we still are confronted by two serious "facts of life": (1) for almost a decade the U.S. has been consuming natural gas at a greater rate than we have been finding new reserves; and (2) there is a finite amount of natural gas present within the earth&apos;s crust. Much of the known and easily exploitable sources of gas (the so-called "conventional" sources, such as the high permeability sand reservoirs of the Tertiary sequence along the Gulf Coast) already have been developed; their production is declining rapidly. The total producible reserves from conventional gas reservoirs amount to only 216 Tcf, less than an 11-year supply. However, several large potential resources of natural gas remain to be developed. These "unconventional sources" have low permeability and/or peculiar producing characteristics. The DOE program for development of these unconventional sources of gas is called the enhanced gas recovery (EGR) program. The primary goal of this program is to provide a data base of resource characterization and production technology that will lead to commercial development. DOE will encourage and support industry participation in developing and demonstrating technologies needed to reach this goal. Unconventional Resources Four major unconventional resources of gas have a high potential for commercial development. There are other unconventional sources (such as gas hydrates) that are too poorly defined to warrant a major development thrust at this time. The four unconventional sources of gas currently included in the EGR program are: 1. The carbonaceous shales of Devonian age in the Appalachian, Illinois, and Michigan sedimentary basins are the targets of the Eastern Gas Shales Project (EGSP). 2. The low permeability, low porosity so-called "tight" gas sandstones of the Upper Cretaceous/Lower Tertiary in the Rocky Mountain areas constitute the resource target for the Western Gas Sands Project (WGSP). 3. The free methane trapped in coal beds of both the eastern and western U. S. constitute the Methane from Coal Beds Project (MCBP). 4. The abnormally high pressured, high-temperature saltwater aquifers of the Texas-Louisiana gulf coast are targets of the Geopressured Aquifer Project (GPAP). Basic implementation strategy for these EGR projects involve (1) assessing and characterizing the resource potential of the resource; (2) conducting cost-shared field testing with industry to improve, develop, and demonstrate various stimulation and production technologies; (3) coordinating EGR activities within DOE and with other federal agencies (such as the Bureau of Mines) to minimize duplication; and (4) aiming all projects toward commercial development of the gas resources. EGSP What type of "geological animal" is the EGSP dealing with? While gas undeniably is related to the occurrence of natural fracture systems within the shale, the overall producing mechanism and precise location of fractured, gas-bearing locales within each basin is still poorly understood. By developing reliable resource characterization techniques and applying effective stimulation technologies we intend to elevate the Devonian shale from the status of a potential gas resource to that of a proven gas reserve. Once we have done this the private sector can take over the large-scale commercial development of the Devonian shale gas resource. WGSP The second largest project (both in terms of complexity and level of funding) is the WGSP. The primary targets for this project are the low permeability (< 1 md) gas sandstones of the Piceance, Uintah, and Greater Green River basins and the Northern Great Plains Province. Project success in these four primary geologic locales will permit investigating additional low permeability sandstones in 16 other sedimentary basins. It appears that the only practical means of increasing permeability and resultant flow rates from these sandstones lies in the use of massive hydraulic fracturing techniques. Unfortunately, it is still too early to design such jobs with predictable results. MCBP The MCBP is to be involved in producing and utilizing methane derived from coal beds. The coal, like portions of the Devonian shale, is impermeable, highly fractured (termed "cleat" by

Jan 9, 1980