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By Steve Karl, Rock Jenkins

The mining industry appears to be slowly rebounding. But many individuals and company officials are still smarting from the beating they received during the recent recession. As a result, companies have taken the "lean and mean" approach. As pointed out at the Oct. 24-26, 1984 SME-AIME Fall Meeting in Denver, CO, companies are placing more emphasis on optimizing their operations through more efficient mining and processing technologies and equipment. Empathizing with the mining industry's woes was the meeting's welcoming luncheon speaker, John D. Withrow, Jr., executive vice president product development for Chrysler Corp. Withrow paralleled Chrysler's problems of a few years ago with the current problems facing the US mining industry. He said Chrysler's come-back centered around its engineering and technical personnel, who regained "their seat at the head table." "In short," Withrow said, "we had lost the competitive edge. By cutting costs and people and improving our products we got everybody to believe we could." The 2700 participants at the Fall Meeting attended technical sessions geared toward turning mining back into a productive and profitable industry. Sessions and symposia included papers on precious metals extraction, crushing and grinding innovations, geomechanics, environmental control, health and safety, and various commodities. This article briefly highlights some of the papers presented. To order preprints of these technical papers, see ME, December 1984, pages 1620 and 1621. Computers Gain Mining Acceptance High tech has reached mining. As evidenced by many papers, computers have become valuable tools in many applications. These include tailings ponds operation and waste management; truck dispatching; mine design, simulation, and scheduling; monitoring; and reclamation. Mine planning is generally labor intensive and requires a considerable amount of the planner's time. P. K. Chatterjee, X. Chung, and Y. Jianjy described a computer-generated interactive graphics approach to under-ground coal mine planning that lessens the manhours involved in producing plans. The computer program examined exploratory borehole information. This included coal seam thickness, tonnage, quality constraints, and the nature of their distribution. Layout designs were then initiated and a probabilistic simulation performed to determine production levels of different extraction strategies. The interactive graphics approach gives planners the ability to quickly evaluate several layout alternatives and select the best one. For surface coal mines, M. A. White, of Arch Minerals Corp., explained several computer programs that aided in his company's surface mine plans. Several drill hole database and modeling pack¬ages are available. But Arch tech¬nicians developed specific pro¬grams for model strip areas. They were used to form long-term pro¬jections for various area and semi¬area stripping operations. They also generated reports on yard¬age, tonnage, quality, and ratio in¬formation. The information is used in budgeting, to compare mine plans, and to analyze acqui¬sition candidates. While computer-based truck dispatching systems have been used in mining for some time, earlier systems were run on ex¬pensive mainframe or high per¬formance minicomputers. As such, computer-based truck dis¬patching systems have been too expensive for all but the largest mines. Recently, however, a microcomputer-based system, af¬fordable to smaller mine opera¬tors, has become technologically feasible. Y. C. Kim and W. E. Kolb re¬ported on a simulated microcom¬puter system that uses strategi¬cally placed signposts in the pit area to automatically detect truck movements. A microprocessor in the signpost sends information to the microcomputer. The computer determines the truck's assign¬ment and alerts the dispatcher. He radios the driver his assign¬ment. In addition to the technical pa¬pers, an introductory short course on microcomputers was offered at the meeting. L. M. Kass and J. P. Stone, from the US Bureau of Mines, walked participants through the uses of microcom-

Jan 1, 1985

By J. E. Moyle

Introduction In October 1983, Rio Algom Ltd. decided to develop the East Kemptville tin deposit. This decision was the result of intensive geological and metallurgical evaluation work, as well as careful studies of environmental and marketing aspects. The property is located about 54 km (34 miles) northeast of Yarmouth, Nova Scotia, near the village of East Kemptville. Geology The geological setting is a granitic intrusive at the contact with metasediment. The tin mineralization is in the form of cassiterite (SnO2), which is about 80% tin. Sulfides are associated with the deposit containing silver, copper, and zinc, which are recoverable as byproducts. The mineralization is associated with quartz veins and greisen alteration. In the center of the deposit, the zones are so close together they have the appearance of a massive or porphyry type deposit. Ore Reserves The mine plan is based on 56 Mt (62 million st) at 0.165% tin. Up to the ninth year, mill feed will average about 0.2% and lower grade material will be stockpiled. In later years, the average grade will be 0.16% tin. A 0.08% cutoff grade is planned for the entire 17 years of production. East Kemptville is a relatively low grade tin deposit, and only a combination of favorable circumstances has made it economic. • The ore body is situated at, or very close to the surface, permitting mining by open-pit methods at a very low stripping ratio. • The tin occurs in relatively large crystals that allow for good recovery by gravity techniques. • It is ideally located in a well-settled area, with all essential infrastructural requirements already in place. • The positive and cooperative response from various governmental agencies involved are encouraging. Mine Plan The mine plan incorporates an initial pit, followed by three expansions to the ultimate pit. Mining will be at 14 kt/d (15,000 stpd) and will include 9 kt (10,000 st) of ore plus 5 kt (5,500 st) of waste and low grade. After five years, the mining rate will increase to 21 kt/d (27,500 stpd). It is planned to drill vertical 165-mm (6.5-in.) blast holes on a 6-x 6-m (20- x 20-ft) pattern. Bulk slurry explosives will be used to break the rock. Loading will be with hydraulic shovels into 70 t (77 st) haulage trucks. The trucks will deliver the ore to a 13 x 20 m (42 x 65 ft) gyratory crusher, where it will be crushed to 150 mm (6 in.). Secondary and tertiary cone crushers will be used to further crush the ore to 13 mm (0.5 in.). Process Design Tin extraction technology is practically unknown in North America, but Rio Tinto Zinc, which has a 53% ownership in Rio Algom, is involved in tin production in the UK. Rio Algom has used this experience and expertise in metallurgical evaluation work and in tin-related aspects of plant design. Mineralogical and metallurgical test work have been performed, both on laboratory and pilot plant scales. Mineralogical work was done largely in the UK, the laboratory test program was carried out at the Lakefield research facility in Ontario, and pilot plant work was conducted in Australia. This program has resulted in significant improvements in recovery and concentrate grades, over best projections that could be made before this work was carried out. Concentrating Process The concentrator is being designed to process about 9 kt/d (10,000 stpd). The first step is to reduce the size of the ore to -700 µm (-24 mesh) in a rod mill/ball mill grinding circuit. The ball mill will operate in closed circuit with high capacity banana-type screens. The screened product will be deslimed to 30 µm (560 mesh) with cyclones, then passed over the pri-

Jan 4, 1984

The Sandvik DE710 diamond core drill has become one of the most popular exploration drills available. It is operated on exploration and mining projects in locations around the world. The compact nature of the DE710 allows a small footprint on site. This has proven to be a great benefit in difficult access areas where site preparation can be limited. The DE710 drill is available in a range of con-figurations to suit global operational and environ-mental demands. It can be truck-mounted for greater maneuverability and ease of relocating the drill between sites. The drill can also be fitted to crawler tracks, powered from the rig hydraulic system, making it a small, self-propelled unit for areas with difficult site access. And the DE710 is available in a shack-mounted configuration for cold weather applications, ensuring a protected working environment for the drill crew. The DE710 is powered by a 6.7-liter engine that produces 141 kW (190 hp) at 2,200 rpm to power the rig hydraulic system. The engine complies with the Tier 3 emissions standards that are being introduced in many countries. The hydraulic system design for the Sandvik DE710 is based on the company?s philosophy of selecting the best available products to suit the application. The main hydraulic pumps and motors are the variable displacement design. This allows for greater fl exibility and precise control of critical drilling functions. The cooling system has also been designed for operation in ambient temperatures up to 50° C (122° F) to cope with varying global operational demands.

Jan 1, 2009

By Joseph T. Duncan, Syd Peng, Larry G. Stolarczyk

The mining business has numerous risks: equipment availability, labor disruptions, foreign exchange rate, etc., but one of the more important risks is assessing the geology. Improving the “intelligence” of geology can and will have significant positive effect on reducing mining risk and thus enhancing operational and financial performance. The use of the advanced Radio Imaging Method (RIM-IV) on coal seams and ore bodies can create useful two-dimensional (2-D) and three-dimensional (3-D) high-resolution images that provide mining engineers with additional intelligence to better plan and improve operations. Improved operational performance will reduce costs and enable mining companies to meet market and financial commitments. For the past decade the underground coal mining industry has been moving toward “super panels” in long-wall mining, and “super sections” for room-and-pillar mining. These mining conventions employ wider faces, longer gate roads, greater room-and-pillar density, and an increased scale in the amount and complexity of mining equipment. An obvious economy of scale exists: amortization of setup investments over greater volume of coal enables mine management to reduce fixed cost per ton. Restricted by equipment considerations, face widths have currently reached about 1,100 ft. Wider longwall panels are planned, with 1,400-ft widths, but this requires an incremental step in hardware that the original equipment manufacturers will soon bring to market. However, longwall panel length has not yet reached its limits, with some panels planned up to 25,000 ft. While longwall panel length is generally dictated by reserve size and extent, practical restrictions in mine planning also include seam thickness, ventilation requirements, or restrictions involving methane drainage. Super panels have certainly enabled the industry to keep pushing the limits of productivity improvement. However, important considerations in mine planning, now and especially in the future, will be driven in large part by geological factors. While larger developments improve productivity and capture economies of scale, the fact that super panels can contain at least four times the area or coal volume means that the probability of encountering serious anomalies is at least four times greater than with the “conventional” panels. Given the increased probability of encountering anomalies, improved assessment of geology is important for super panels and super sections. Proper due diligence requires a thorough and competent evaluation of a mining property and its ore reserve. Using improved geostatistical techniques is most important, and improving the base data for the analysis is equally important. The old cliché “garbage in, garbage out” certainly applies. Also, the quality of coal reserves is (or has been) declining, so, in the future, mining will be in deeper and most likely thinner seams—and these seams appear to contain greater anomalies that threaten efficient operations. To counter the impact of reserve deterioration, the industry is moving toward greater use of geophysical tools and services. Fortunately, tools such as the Radio Imaging Method™ (RIM-IV) system have been improved and can provide the industry with enhanced 2-D and 3-D images of coal seams and ore bodies. To identify and profile the best areas of a coal reserve, geologists, engineers, and mine managers need greater intelligence in the form of RIM-IV tomographic maps of longwall panels and room-and-pillar sections. These images have enhanced the understanding of in-seam features, which in turn has improved operational plans and performance.

Jan 1, 2005

Introduction The US mineral industry in 1983 participated in the recovery from the recent recession. Compared with 1982, the value of raw nonfuel mineral output rose 8% to $21.2 billion. The $218 billion worth of goods processed from this crude mineral output represented a 9% increase over 1982. Even in real terms, these figures reflect growth. Demand for nonfuel mineral materials, of course, depends on the overall state of the economy, which steadily improved each quarter in 1983. Of particular importance to the mineral industry were surges in key mineral-consuming sectors such as construction and automobile manufacturing. New housing starts rose one-third, to 1.7 million units, while automakers turned out about 35% more cars (6.8 million) and 25% more trucks (2.4 million) than in 1982. These are significant increases, even considering recent trends toward smaller, lighter vehicles, and multiple-unit housing. A comeback for the mineral industry, however, is bound to proceed unevenly, particularly at the beginning. Traditionally, the industry lags behind the rest of the economy during a recovery, and some mineral products respond to overall economic improvement more quickly than others. This pattern has been repeated many times and the industry is used to it. Mineral executives know it is best to be patient and cautious during the first stages of an economic upturn. Many experts say that it may take extraordinary toughness, patience, and caution this time around. Steel Improves Raw steel production - a major indicator of both material use and mineral production - rose 14% to 77 Mt (85 million st), stimulating a 7% rise in domestic iron ore production to 39 Mt (38 million It). Still, the iron ore industry operated at less than half capacity, with most major mines remaining closed for part of the year. Iron ore imports dropped 24% to 10 Mt (11 million st), so demand was partly met by withdrawals from stocks. Despite the increase in steel production for 1983, output remained far below levels of just a few years ago. For example, 1983 production was still 29% less than in 1981. Raw steelmaking capacity actually declined about 10% during the year to 122 Mt (135 million st). The industry continued to cite steel imports, especially those from developing nations, as a major cause of domestic capacity loss. As long as steel production remains weak, steelmaking metals suffer. Domestic producers of bulk ferroalloys of chromium, manganese, and silicon operated at about one-third capacity in 1983, with six of the 19 companies involved being closed all year. The US mined no manganese or chromium, and very little nickel, although the country's only nickel mine did resume production in November. Molybdenum production, at 13.6 t (15 st), was only about one-third as much as in 1982. The major molybdenum mines, Climax and Henderson in Colorado, remained closed all year. To meet demand, molybdenum stocks were halved to 19 t (21 st). Mine shipments of tungsten, another mineral tied to steel production, dropped 30% to 1.1 kt (1,200 st) of contained metal. One of the most positive responses to the general economic recovery came from the aluminum smelting industry. By the end of the year, it was operating at about 79% capacity, compared to 59% in January. Nevertheless, the 3.3 Mt (3.64 million st) of primary aluminum produced represented only a slight increase over 1982. Total bauxite imports were about 27% below 1982 levels. Production of magnesium metal rose 11% to 100 kt (110,000 st). But titanium was more typical of other

Jan 5, 1984

By J. M. Applegate, C. L. Morgan

Introduction In the same way that a blueprint communicates informa¬tion about a structure, a systems architecture should provide information that guides the construction and implementation of a computing system. Taking the blueprint analogy a step further, a plot plan can also show where, in the "bigger picture," a particular design fits (if in fact it does) and what a builder needs to know about the environment in which he or she will operate. In the context of business systems, a meaningful architecture should convey the following: • the primary purpose of computer-based systems rela¬tive to particular tasks or operations, • the relationship of the systems to each other and an indication of their interaction and dependencies, • the relationship of the systems relative to the organiza¬tion and its objectives, • indications of where IS/IT resources can best be allo¬cated to support the organization and • the overall context in which new systems and technolo¬gies can be assessed for both their impacts on current systems and on the organization itself. In theory, a well-designed systems architecture should allow an organization to focus its resources on those aspects of its business that matter most, thus, leveraging investments in information technology to a competitive advantage. In addition, the way that a computing systems architecture is represented should be un¬derstandable to non-IT staff, and it should be eas¬ily recognized by the people it supports. This pa¬per attempts to show that a meaningful systems model exists and that its applica¬tion to mining can achieve the desired results. The following discus¬sion is based on the au¬thors interpretation of a concept referred to as the computer integrated manu¬acturing (CIM) model, as developed by Allen-Bradley. An inherent strength of the CIM approach is that the model combines aspects of business-reporting structures with the manufacturing process itself. What results is a systems frame¬work that is aligned with relevant business processes and is, therefore, easier for non-IS/IT personnel to interpret. The successful application of the CIM model can be seen in a large number of both discrete and process-manufacturing facilities throughout the United States. This paper provides a brief overview of the CIM model and then describes how the model can be applied at a conceptual level to the mining industry. Finally, this paper proposes an extension to the CIM model that the authors believe will make it easier to understand and apply. CIM model As shown on Fig. 1, the CIM model begins with the most detailed levels of process equipment and works its way up to the highest level of consolidated financial reporting. Systems at each level are characterized by common attributes, users, time frames, etc., providing a clear picture of their interac¬tion. Further analysis of the relationships between systems and between levels provides insight into the opportunities for integration. Regardless of the industry or processes involved, the CIM model provides a framework in which the characteristics of systems and the data they manage can be predicted based on the nature of the business function they support. In general, as data moves upward from the lower rungs of the CIM model, it changes from de¬scribing the physical na¬ture of a process to describ¬ing its financial aspects (e.g., from productivity to cost). The time frame to which data applies also transitions from a very short duration, perhaps only milliseconds, to financial or regulatory reporting time frames that may span years. In a simi¬

Jan 1, 2000

By S. W. Swerson

25.1-THE PURCHASING FUNCTION The word "purchase" means "to obtain by paying money or its equivalent; to buy for a price." This definition is all too simple to properly describe the word "purchase." One should consider the basic objectives of purchasing-to procure the right material, of the right quality, in the right quantity, at the right time, from the right source at the right price. Here it should be noted that in purchasing it is recognized that the best quality or grade of materials may be the only grade to purchase for a specific job. However. there are other jobs where the medium, standard or poor grade of materials is the right quality, as the lesser grade will perform adequately. In some companies the purchasing department makes the decision as to the right quality, while in others this function is shared with other departments. Years ago in business the owners controlled the purchase of required materials and services by performing the task themselves. The owners obtained the type materials and services they needed and paid the price demanded. This function was performed along with all the other duties requisite to the owner of a business, namely, clerical, hiring and firing of personnel, financial management, etc. As companies grew in size, clerical duties were assigned to other personnel and the owner usually retained the purchasing authority. This same division exists today in many small companies. However, in the larger companies, the purchasing function has been assigned to a separate department. Importance of the Purchasing Function-The larger the company the greater the need for a separate department to perform the purchasing function. Today the purchasing agent for most larger progressive companies has policy-making authority. Therefore, it is reasonable for him to report to the president or vice president of his company. Studies of several hundred companies show the purchasing department head reporting to top management 87.5% of the time. This fact in itself is indicative of the importance of recognizing that effective purchasing requires a department staffed with specialists in the field of procurement with knowledge and experience sufficient to perform in today's complicated business atmosphere. In the manufacturing field it is a common axiom that usually half of the company's dollar expenditures are for materials. If a purchasing department functions properly and the right product or service is purchased and a savings accomplished, the contribution to the net profit of the company is much greater, as opposed to sale dollars, where only a small portion is carried forward to net profit. Thus, the importance of the purchasing department and the contribution it can make to the success of the company are obvious. 25.1.1-THE PURCHASING FUNCTION 1. Responsibilities of the Purchasing Function-The purchasing agent in performing his function is acting as an agent for the company and others in the company requiring materials and services. Accordingly, he is committing the company for materials and services subject to certain limitations which the board of directors may stipulate. In view of this, the purchasing agent,'^ position must of necessity he

Jan 1, 1973

Power cable costs are only a small part of total mining costs. So many mine operators consider power cable failure and resultant downtime as part of the cost of doing business. But, viewed in terms of lost production, these costs can be quite significant. Now one company, Cablec, seeks to cut cable costs by upgrading the polymer compounding process used to make cable insulating and semiconducting materials. Cablec is the leading manufacturer of electrical power cables in North America. And with about a third of the market, Cablec is the largest supplier of power cable to the mining industry in the United States. To improve its products, Cable has entered the polymer compounding business. In July, it began producing insulator and semiconductor polymer compounds at its plant in Indianapolis, IN. "This new facility provides a quantum leap over conventional compounding methods," said Harry C. Schell, Cablec's president and chief executive officer. "The Cablec polymers plant is producing a dramatically higher standard of polymer compounds that provide significantly higher levels of performance and improved life cycle costs for power cable." Cablec faces tough foreign competition in the wire and cable business. Competing on price alone is difficult, particularly when foreign producers are state subsidized. So Cablec feels the best way to compete is to establish new quality production standards. The company's new polymers plant is one way to do this. By increasing purity control and uniformity in polymer compounding, Cablec says its power cables will last longer and fail less often. A typical medium voltage cable consists of a conductor, conductor shield, insulation, insulation shield, metal shield, and jacket. The conductor shield and the insulation shield are conducting polymers. Contaminants and imperfections can occur within the insulation, at the conductor shield/insulation interface, or at the insulation shield/ insulation interface. Over time, these contaminants and imperfections can decrease the electrical strength of the cable or cause premature cable failure. The effort to minimize the number and size of any possible contaminants begins with pure polymer compounds mixed in a clean facility. However, most power cable manufacturers manually handle raw materials, use ethylene/propylene (EP) in bulk bales, and mix polymercompounds in open Banbury mixers. The quality and uniformity of polymer compounds is also impacted by temperature variations in the mixing process. This results in wide gradations of product consistency from batch to batch and ultimately contributes to power cable failure. Cablec says the improved polymer compounds from its state-of-the-art plant will be the purest and most consistent insulating and semiconducting materials available. The plant itself RCA spent $18 million to build Cablec's Indianapolis plant. RCA used the facility to mix specialty polymer compounds used to make video disks. RCA had two considerations in mind for the plant, cleanliness and uniformity of the compounds. However, when the video disk market failed to materialize, RCA sold the 46.5 dam 2 (50,000 sq ft) plant to Cablec for $3.1 million. Cablec invested an additional $3 million for modifications and increased production capabilities. Today's replacement cost for such a facility is estimated at $30 million. Cablec says the plant will set a new standard for performance and be economically difficult to duplicate anywhere. One of the essential elements of the plant's clean process environment is the air intake system. It filters contaminants greater than 2 um, less than one-fiftieth the current industry standard. All material handling and conveying areas in the facility are air-locked. This keeps out contaminants such as smoke, dust, and pollen. Banks of pneumatic pumps move polymer components through the system and continually filter the air. The plant also has a backup air intake system. No process downtime due to pump failure here. From the time raw material enters the plant, it is stored, transported, and processed in filtered air by an airtight stainless steel system. The stainless steel resists rust and corrosion. This further eliminates the danger of contamination from paint or rust particles in the conveyance network. A computer system allows a single operator in a central control room to monitor every aspect of the compounding process from air quality to line speed. The computer

Jan 12, 1988

By Priscilla P. Nelson, Francis L. C. Fong

Introduction Fracture mechanics is the study of the behavior of cracks and their modes of propagation. During cracking, energy is consumed in creating new surface area. The more energy a material absorbs, the higher is its fracture resistance. This fracture energy is provided either by work done externally, by the release of elastic strain energy within the cracked body, or by a combination of these two effects. Fracture resistance is measured in terms of either the stress intensity factor, K, or the energy release rate (also referred to as crack driving force), G. For linearly elastic materials, these two quantities are related by the following equation: [ ] where [u] is Poisson's ratio and E is the modulus of elasticity. Both K and G are direct functions of the applied force and the crack length. The process of rock cutting with full-face tunnel boring machines (TBMs) involves the indentation of a rock surface by rolling disc tools. Excavation occurs as fractures, extending from the locus of chip indentation, propagate between concentric disc grooves and liberate rock chips from the intact rock face. Since disc cutting is achieved by a fracture process, it is logical to anticipate that differences in cuttability of a variety of rocks should be related to the variation of fracture material properties among the rocks. Such a relation has been demonstrated between the performance of full-face TBMs and the critical crack driving force for excavation in relatively high strength, brittle, low porosity, isotropic rock (Nelson et al., 1985). The objective of this paper is to report on the results of a continued investigation of the relationship between fracture material properties and the effectiveness of disc cutting. Additional reliable data on full-face TBM performance is difficult to obtain, so that the results of disc linear cutter tests performed by the Transport and Road Research Laboratory (TRRL) (U.K.) are utilized in this study. Fracture Material Property Evaluation If a crack tip is subjected to a perfectly plain strain condition, many materials will behave in a brittle manner, and the material resistance to fracture is constant during crack growth. This resistance is referred to as the plain strain fracture toughness, believed to be a material property. The standard testing procedure for this parameter is given in the American Society for Testing and Materials (ASTM) test designation E399. To ensure plain strain conditions, acceptable specimen geometries are specified. Unless these geometric specifications are adhered to, the measured fracture resistance is regarded as the apparent fracture toughness, and a subscript Q is used, as [ ]. The methodology adopted by ASTM E399 is within the framework of Linear Elastic Fracture Mechanics (LEFM). This approach assumes that material resistance against cracking is developed instantaneously, without initial stable or subcritical crack extension. Prior to crack advancement in rock, however, much of the crack driving energy is absorbed in a localized volume in front of the crack tip, referred to as the plasticity or microcracking zone. This capability for energy absorption substantially increases material resistance, and a crack may be arrested unless an increased crack driving force is applied. The LEFM or plain strain assumptions would underestimate the actual fracture resistance of such a material. Such a conservative approximation may be desirable in the design of structures against fatigue or brittle failure. In mining or tunneling, however, an underestimation of crack resistance can lead to the selection of underrated excavation equipment and a decrease in production efficiency. The development of fracture resistance in rock is best described by the material resistance curve, or R-curve, which is a plot of fracture resistance as a function of crack extension. Typically, peak resistance is only reached after a finite amount of subcritical crack growth. The

Jan 1, 1986

By L. Diels

About 45% of the contaminated sites are dealing with heavy metal problems. Metals are spread in the environment by mining activities, surface treatment and non ferrous processing. As heavy metals can not be degraded, removal or immobilization (leading to bioavailability reduction) are the only risk reducing measures that exist. The currently best available technique for remediation of heavy metal contaminated groundwater is to pump the contaminated water and to treat it in a wastewater treatment plant installed on the surface. Next to this often used, but expensive, pump and treat technologies, heavy metals can be immobilized by inducing sulfate reducing bacteria (SRB) to transform the sulfates, that are very often present in the same groundwater (due to the metal mining or processing activities), into sulfides. These sulfides will precipitate the metals as insoluble metal sulfides. At the moment several studies have demonstrated the feasibility of this In Situ Bioprecipitation Process (ISBP) for the removal of heavy metals from ground-water as well at lab scale (batch and column tests) as at field scale. However, some questions arise concerning the continuation of the process, the efficiency and the sustainability of the precipitates. The presented study will try to answer these questions. The study is based on more than 10 different studies, all done by the same authors, on different groundwaters and aquifer samples. The presentation will give an overview of the guidelines necessary for a correct and successful bioprecipitation process with stable metal sulfide precipitates. An important question in the ISBP is related to the sustainability of the heavy metal precipitates. It could be observed that the interruption in the carbon source delivery also stopped the in situ bioprecipitation process. Depending on the metal also some release from the precipitate could be observed. It was shown that release can occur with Co and Ni. Aquifers, on which the metals precipitated during the ISBP, were treated in a sequential extraction process under an-aerobic and aerobic conditions. It could be shown that especially under the anaerobic conditions the Zn and Cd precipitates changed from the leachable and the exchangeable fraction to the organic or Fe-Mn fraction (i.e. from the unstable to the stable fraction). The same could be observed for Co and Ni but still some fraction was present under a more available form. On the other hand it could be shown that large differences were observed concerning the heavy metal speciation on the aquifer in function of the used carbon source during the ISBP. The molasses treated systems showed a much more available heavy metal fraction on the aquifer compared to the lactate or HRC® treated groundwater. The different speciation forms based on the use of different carbon sources will be discussed in detail. It will pay attention to the influence of the carbon source, the efficiency of the induction of the bioprecipitation process, the influence on the competence between sulfate reducers and methanogenic bacteria and the influence of low pH on the ISBP. It seems that acetate, which is also a degradation product of fermentation of some carbon sources, can inhibit some sulfate reducers. Also the relation between slow release compounds and immediately available compounds will be explained. Finally a pilot study will be presented showing the problems that can be encountered during this process. Focus will be put on the induction of the process, the keeping on of the process and the follow up of the process by the installation of in situ mesocosm socks. These results will allow the correct implementation of the ISBP with an eye on longevity and sustainability of the process and present the ISBP as a much more sustainable alternative to the pump and treat technology as measure for heavy metals contaminated groundwaters.

Jan 1, 2006

By Wolfgang R. Wawersik, Charles M. Stone

INTRODUCTION Hydraulic fracturing was applied in horizontal drill- holes in the Salado salt formation near Carlsbad, New Mexico. Tests were performed approximately 650 m be- low surface to validate the design of a Waste Isolation Pilot Plant (WIPP) for the disposal of radioactive waste from defense activities of the United States. Hydraulic fracturing was performed primarily to determine whether the virgin in situ stress state at the WIPP site is isotropic and whether the magnitude of the virgin in situ stresses corresponds to the weight of the overburden. Beyond these limited objectives, however, measurements are now being reviewed to evaluate the usefulness of hydraulic fracturing in salt formations in general. Such measurements are desirable to determine stresses induced by mining and to monitor time-dependent stress changes around underground excavations in salt masses. Hydraulic fracturing was chosen because it is the only technique that can be readily applied in virgin ground far from existing mine openings. The method also appeared to yield directly the magnitude of the least compressive principal stress, regardless of the mechanical properties of the rock mass. A knowledge of the least principal compression was deemed sufficient to establish the isotropic character of the virgin in situ stress field under two conditions: (1) the Salado formation was mechanically isotropic, i.e., the fracture toughness did not vary normal and parallel to bedding so as to permit preferred fracture paths, and (2) pressure measurements were combined with determinations of the orientations of hydraulic fractures and, more generally, with observations of the characteristic hydraulic fracture patterns. The latter was possible by locating the drillholes for hydraulic fracturing along the axes of drifts that were mined several months later. The success of general stress measurements by hy- draulic fracturing of salt subjected to anisotropic stress conditions was and remains less certain. While the smallest in situ compressive stresses should still be equal to instantaneous shut-in pressures, there may not exist any unique relationships between the greatest and intermediate in situ principal stresses on one hand and the primary breakdown and fracture reopening pressures on the other. This problem would be a consequence of stress relaxation due to salt creep around any drillhole in which hydraulic fracturing tests are conducted. Moreover, lab- oratory measurements suggest that creep and stress relaxation could be so rapid that it might not be possible to interpret the measurements for anisotropic stress conditions even if hydraulic fracturing were performed as soon after drilling as possible. The primary objectives of the stress measurements in the WIPP were met by combining hydraulic fracturing tests with finite element analyses of the effects of salt creep, observations of hydraulically induced fracture pat- terns, and laboratory hydraulic fracturing tests on oriented core. In situ hydraulic fracturing tests in long drillholes were preceded by several trial tests to establish the best test methods and to demonstrate that salt could be fractured. The resolution of anisotropic stresses and special problems, e.g., in the identification of instantaneous shut-in pressures, are currently being addressed in hydraulic fracturing tests in a mine pillar, in tests following different delays between drilling and fracturing, and in tests with different frac fluids. This paper will review the main results of the analyses above and of one group of hydraulic fracturing tests at different distances from existing excavations. The paper will conclude with a brief description of the geometry of the hydraulically induced fracture patterns. Because of space limitations, it will be assumed that the reader is familiar with hydraulic fracturing or will first consult other sources (e.g., Cleary, 1980; Gronseth and Detournay, 1979; Zoback and Haimson, 1983; Nemat-Nasser et al., 1983; Kim et al., 1984)

Jan 1, 1986

By W. J. Atkinson, E. M. Anderson

FOREWORD This paper is based on the authors' experience gained in the environmental assessment of major uranium projects in the former Department of Science and the Environment and Department of Home Affairs and Environment of the Australian Government. The authors gratefully acknowledge assistance received from colleagues within the Department of Home Affairs and Environment in the preparation of this paper. Special thanks go to Mr K.E. Thompson of the Department's Environment Division for his valuable comments and criticism. The views expressed in the paper are those of the authors alone and not the Australian Government or Dames & Moore. INTRODUCTION Uranium has been mined in Australia since 1954. A number of small scale mining and milling operations were active in the Northern Territory, in South Australia and in Queensland in the late fifties and early sixties. However, in the late sixties there was an increase in exploration activities in the expectation of an upsurge in world demand for uranium Substantial new resources were delineated in the Northern Territory, Queensland, South Australia and Western Australia. The most significant deposits were located in the Northern Territory, in what is called the Alligator Rivers Region located approximately 200 km east of Darwin. The Region is in the latitude of 13° South and thus lies within the Australian tropics (Figure 1). It consists of approximately 2.3 million hectares of natural wilderness containing much spectacular and attractive scenery. The area is noted for its abundant wildlife, particularly the waterbirds that gather on the flood-plains. Much of the vegetation is diverse and interesting. The Aboriginal population still maintains elements of the traditional way of life, and the spectacular Arnhem Land escarpment contains many of the best surviving examples of Aboriginal rock art. Numerous rich archaeological sites provide evidence of continuous human habitation for tens of thousands of years. Climatically, the Region is of the tropical monsoon type with a dry season from may to September and a "wet" from November to March. High intensity short period rainfall is characteristic, and the average annual precipitation is in the order of 1 350 mm. The monthly mean temperature ranges from 25° to 30°C throughout the year. The development of regulatory controls on uranium mining in the Alligator Rivers Region has been affected by the political status of the Northern Territory. While Australia is a federation, established as an independent self-governing country in 1901, it was not until 1978 that the Northern Territory became to any real extent self-governing. Prior to 1978, the Territory was administered through a special department of the Commonwealth (ie. the Federal Government). Under the Northern Territory (Self Government) Act 1978, administrative powers similar to those possessed by the Governments of the six founding Australian states were provided to the Territory Government. However, the Commonwealth government did not transfer to the Territory all such powers and functions, and in particular there has been, since 1978, a dual role for the Commonwealth and Territory Governments in the regulation of uranium development. Details of this role are provided later in this paper. RANGER URANIUM INQUIRY By 1973, major deposits had been discovered in the Alligator Rivers Region at Nabarlek, Ranger, Koongarra and Jabiluka. The estimated reserves and mine life expectancy of these deposits are given in Table I. Other radioactive anomalies have also been identified in the area but, as yet, they have not been delineated or evaluated. [ ] In 1974, an agreement was signed between the Commonwealth Government and Peko Mines Limited and the Electrolytic Zinc Company of Australia Limited for the joint development of the Ranger deposit. In July 1975, the Government announced a Commission of Inquiry under the provisions of the Commonwealth Environment Protection (Impact of Proposals) Act 1974, into the proposed Ranger development. The inquiry was known as the Ranger Uranium Environmental Inquiry or more commonly, the Fox Inquiry after the presiding Commissioner, Mr Justice Fox.

Jan 1, 1981

By Justus B. Deen, Randy Peterson

INTRODUCTION The General Chemical Soda Ash Operation located near Green River, Wyoming produces about 4.5 Mt of trona per year. In July 1989, Mine Ventilation Services Inc. performed a ventilation survey of this complex trona mine which had thirteen active panels spread over 36 square kilometers. The ventilation survey and subsequent study showed that the intake shaft air velocities were at their practical limits (Wallace and Rogers, 1987). The need for additional intake capacity was immediate. The ventilation network modeling delineated the best location for this new intake shaft as it applied to the 5 year ventilation plan. Unfortunately, this location, 6.5 kilometers from the soda ash processing plant, would make heating this intake air very costly. Presently, the intake air is heated by heat exchangers which use waste heat from the plant. Air heating during the winter months is necessary for miner comfort and to prevent potential freezing of water lines in the mine. It was decided to examine the feasibility of heating the air geothermally by coursing it through an old production panel. This method of air heating has been used in this region with good results at the Stauffer Chemical Operation (now Rhone-Poulenc) (Moore, 1985). In 1990, a geothermal heating study examined four different production shaft/panel configurations and a workable design was found. The operators at the General Chemical Soda Ash Operations acted on this design and began raise boring a ventilation shaft in the Spring of 1991. This paper describes the ventilation system, briefly, and the geothermal heating studies performed. Findings of the 1990 geothermal studies are then compared to field data acquired in the Winter of 1992. THE VENTILATION SYSTEM The ventilation system at General Chemical had four shafts serving the mining horizon in July 1989; three of these shafts are located at the Northwest end of the mine. The active work areas had progressed to the South over the past years and supplying ventilation has become increasingly difficult. The 6.1 meter diameter #3 Production shaft and the men and materials compartment of the 6.1 meter diameter #2 Split Shaft had reached their air velocity limits. Conversely, the 4.6 meter diameter #5 Exhaust Shaft was under utilized. Ventilation studies showed the conversion of the 3.7 meter diameter #1 Exhaust Shaft to an intake would provide adequate intake capacity for two years. The next option to improve ventilation was the addition of an intake shaft at the southeast part of the mine at the intersection of H Mains South(H-M-S)and J Mains East(J-M-E) (See Figure 1). A service shaft has been planned for the extreme Southeast end in the late 1990's. Ventilation network analyses showed this interim intake shaft would have to be at least 2.5 meters in diameter to postpone the service shaft construction beyond 1995. The greater the size of the borehole, the further the construction could be postponed. In October 1991, General Chemical commissioned the 4.57 meter diameter #4 Ventilation Shaft near the junction of H-M-S and J-M-E as shown in Figure 1. The L95 panel would be used for air heating as described in the geothermal heating section to follow. GEOTHERMAL STUDIES Geothermal heating studies were performed by MVS Inc. in May 1990. Using a modified code of CLIMSIM, an underground mine climatic simulation model, several different shaft/panel configurations were examined to see which would provide adequate air heating during the winter months. CLIMSIM simulates heat flow into a single underground airway. The program was used to evaluate the heat flow to and from the airway surface and to calculate the resulting change in dry bulb temperature of the ventilating air. CLIMSIM uses inlet air conditions, airway characteristics, and rock thermal properties input by the user to predict the variation of psychrometric and thermodynamic parameters along an underground airway.

Jan 1, 1993

By Glenn A. Shirey, Robert D. Stoessner, S. Gopalakrishnan

Under a contract awarded by the U.S. DOE-PETC, the Pennsylvania Electric Company and New York. State Electric and Gas Corporation are conducting a test program to evaluate and optimize the performance of a two-inch air-sparged. hydrocyclone (ASH) for cleaning fine coal. The test program is being conducted at the Homer City EPRI Coal Quality Development Center, utilizing Upper Freeport coal classified to minus 0.15 mm as the process feed material. A matrix of experiments has been conducted to establish the influence of significant design and operating variables (including overflow and underflow orifices, inlet slurry pressure, airflow rate, and reagent dosage) on the production of deep cleaned coal. Performance of the ASH is being compared to conventional froth flotation, utilizing advanced techniques and selected flotation reagents. This paper focuses on work completed to-date to optimize the performance of the air-sparged hydrocyclone for cleaning fine coal. INTRODUCTION The Pennsylvania Electric Company (Penelec) and New York State Electric and Gas Corporation (NYSEG) have been evaluating advanced fine coal cleaning processes for the production of compliance grade coal (1.2 pounds S02/million Btu). Laboratory bench-scale froth flotation results were compared with results of advanced flotation processes as performed by various organizations, utilizing the same coal feed. Among the processes evaluated, the air-sparged hydrocyclone (ASH) - developed by Dr. Jan Miller at the University of Utah - was considered to offer the best potential for retrofitting into an existing coal preparation facility because of the increased capacity per unit volume. The ASH has been shown to process over 100 times the throughput of conventional froth flotation cells. In May of 1988, Penelec/NYSEG was awarded a contract from the Department of Energy's Pittsburgh Energy and Technology Center (DOE-PETC) to optimize the performance of a five cm (two inch) ASH for producing compliance grade coal from raw classified minus 0.150 mm (1.00 mesh) Upper Freeport coal, and to compare its performance with conventional froth flotation utilizing advanced techniques and selected flotation reagents. The test work is being conducted at EPRI's Coal Quality Development Center (CQDC) in Homer City, Pennsylvania, utilizing a circuit processing 0.10 to 0.25 tons of coal per hour. Other members of the Penelec/NYSEG contract team include the University of Utah, Advanced Processing Technologies, Inc., Davy Dravo, Kaiser Engineers, Ebasco Services, and Management and Technical Systems. ASH DESCRIPTION AND OPERATION The ASH-2 System is a five cm ID (actually 4.76 cm) air-sparged hydrocyclone manufactured by Advanced Processing Technologies, Inc., under license from the University of Utah, for the purpose of research, evaluation and development. A schematic drawing of the air-sparged hydrocyclone is presented in Figure 1. Basically the air-sparged hydrocyclone consists of two concentric right-vertical tubes, a conventional cyclone header at the top, and a froth pedestal at the bottom. The inner tube is a porous tube through which air is sparged radially. The outer nonporous tube simply serves as an air jacket to provide for even distribution of air through the porous inner tube. The slurry is fed tangentially through the conventional cyclone header to develop a swirl flow in the radial direction. Air is sparged through the jacketed, inner porous tube wall and is sheared into small bubbles by the swirl flow. Hydrophobic particles in the slurry collide with these bubbles and, after attachment, are transported radially into a froth phase which forms on the cyclone axis. The froth phase is stabilized and constrained by the froth pedestal, thus moving towards the vortex finder of the cyclone header and discharged as an overflow product. Hydrophilic particles generally remain centrifuged in the slurry phase and are discharged as an underflow product through the annulus created by the froth pedestal.

Jan 1, 1989

By A. K. Mukhopadhyay, B. Sikdar, V. P. Arora

Introduction During the past several years, persistent concerns about an economic slowdown in India have tempered capital-expan¬sion plans. This has encouraged companies to find methods of increasing the capacity of existing production equipment. One of the more cost-effective methods of increasing produc¬tion capacity without major capital investment is to improve equipment maintenance to prevent needless machine down¬time. This can have a significant financial impact because of reduced maintenance costs and increased machine availabil¬ity. The maintenance program employs different techniques, but the analysis of the vibration behavior of machine compo¬nents to assess their condition was found to be the most accurate technique for monitoring various machine disorders. A dragline that handles overburden in open pit mines is one of the more capital-intensive pieces of production equip¬ment. It is imperative that the machine be run at its optimum capacity under the prevailing environmental conditions. Condition monitoring of the various components of the dragline through vibration analysis not only improves the machines availability but also ensures a long operation time free from sudden failure. This paper describes the application of vibration monitor¬ing and analysis techniques to assess the components of a W2000 dragline. The paper reveals that condition monitoring through vibration analysis can be as valuable in failure prevention as it is in failure analysis. Finally, the paper presents an approach to a knowledge-based expert system to the quick and correct diagnosis of mechanical faults in a dragline. Equipment A dragline is an intermittent-discharge-type excavator having a long boom at one end. Unlike other excavators, the bucket is not rigidly held by the frame structure. In favorable geomining conditions, the intensive operation of these exca¬vators is the least-expensive means of overburden removal. The basic working elements of this equipment are the hoist system, the crowd and retract system, the wing mechanism and the propel mechanism. The walking dragline is accepted as the most economical machine for stripping overburden at depths of up to 60 m (200 ft). They are electrically powered and the various motions are effected by individual drives. The Ward-Leonard system is used to provide the optimum flexibility in controlling different dc-drive motors. To mini¬mize the cost of mineral extraction, the largest such machine in India has a 24-m3 (850-cu ft) bucket with a boom length of 96 m (315 ft). Draglines are very costly, and considerable financial penal¬ties may arise from sudden stoppages due to component fail¬ures. Thus, operational reliability is of the greatest importance. Active measures are now being taken to minimize downtime by adopting condition-based maintenance techniques. Though a number of techniques come under this scheme, it has been observed that assessing the health of the dragline by measuring vibration is the best method of determining the dynamic behavior of its various rotating components to avoid any catastrophic failure. Based on criticality, the vibration-behav¬ior of the following components are studied: • motor-generator unit, • exciter unit, • hoist motor-gearbox unit, • hoist drum-gearbox unit, • drag motor-gearbox unit, • drag drum-gearbox unit and • swing motor unit The approach Increases in the vibration levels in different subsystems of the dragline were observed due to the presence of faults such as unbalance, misalignment, looseness and bad bearings. A vibration behavior study included the measurement of vibra¬tion level, trend analysis of time-domain vibration signals and vibration frequency analysis at bearing points of the components. A vibration meter, a vibration analyzer and a data collector are used. Vibration-level measurement. When the dragline was assembled and put into operation for the first time, vibration data were collected to generate baseline data for the equip¬ment (based on International Standard ISO 2372). After¬wards, the vibration levels were recorded regularly using a vibration meter. The measurements were taken at all bearing

Jan 1, 2000

By Dwane K. Johnson

INTRODUCTION The small mining company faces the dilemma of how to finance the development of its properties because it doesn't have the financial resources to pay for the development costs from its own funds and doesn't have the financial strength which will enable it to borrow the money needed for development. However, with a little imagination and the right set of circumstances, a financing can be arranged for the small mining company. This paper is an attempt to describe the fundamental steps on how such financing can be obtained --in other words--what is required to provide ad- equate capital at a low cost for developing and bringing a mining property into production. Innovative financing follows from this. The basic keys for building and maintaining a successful mining company are "the four M's": Management, Market, Mine, and Money. The writer believes their order of importance is as presented and each is a building block required in order to obtain the type of financing that best suits the borrower and lender. MANAGEMENT Management must be experienced, highly organized, realistic, able to take advantage of opportunities and fulfill promises. Mine financing requires a variety of skills and concentration on the part of management. Management should have a thorough understanding derived from experience in geology, construction, mining and metallurgy and environment, marketing, and financial matters. Management must realistically visualize what will be produced at what cost and truly evaluate the risks associated so the proper security can be correctly designed. Since risk cannot be eliminated, the objective of management is to identify the risk which will be present in a given venture and assess the level of that risk which will be acceptable to the firm. Generally the risk which is present is subject to little or no modification. After management identifies and measures the acceptable risk the firm will proceed in a way that it will be least exposed. Management must determine its long-term objectives and strategies within the context of a constantly changing world. This question must be addressed before examining the sorts of risk which affect the development and operation of a specific property. The compilation and interpretation of "hard data" by competent people is good to a point but the experience and instinct of seasoned individuals are the important factors in management choosing a long-term direction for the corporation. The attitude towards risk greatly affects the goals of the corporation. Major risks in a mining project can be placed in four categories: 1. Market - Price, demand, substitution. 2. Costs - Capital, operating, financial. 3. Regulation. 4. Taxation. The feasibility study for a project is the fundamental tool used in the management of risk. Management should employ an experienced team with an established and well-understood set of ground rules for the preparation and assembly of a feasibility study. The necessary degree of realism is built into all levels of the study and if the project is technically feasible, the company's hurdle rate is then used to discount the base-case project cash flow in order to determine its financial viability. Understanding the geological significance of the mineral deposit is critical. There should be strong interplay among the pure regional geologist, the detailed mine geologist, the mining engineer, and the metallurgical engineer. The collaboration among these different disciplines will yield a feasibility study that is more reliable. The essence of this work must be appreciated and understood by the executives planning the financing. It is vital that they thoroughly understand the risks and make the proper risk assessments to cope with our rapidly changing market environment. Projecting future revenue values is paramount and is subject to much estimation. One way to mitigate fluctuations and the risk of falling prices is by selling production for future delivery. MARKET Since mining is a worldwide industry it is mandatory that bankers be aware of what is occurring in the marketplace, both foreign and domestic. The marketing of the production is a very important facet when considering financing for the small

Jan 1, 1987

By Richard Stahura

The longtime rule-of-thumb for conveyors was that only one cleaner was needed to solve carryback problems and help keep belt replacement costs under control. That is now being rethought. Belt-cleaning systems manufacturers, designers, and users are shifting to the view that multiple cleaners, placed at key locations on the conveyor and properly maintained, are necessary to solve today's material build-up (carryback) problems. There are still not many statistics on conveyor belt cleaning. But some recent studies support this belief. One study contends that the plant maintenance engineer's biggest problem is keeping the conveyor system running efficiently. The study also said the conveyor itself is responsible for most plant shutdowns. An unscheduled conveyor shutdown can cost more than $100,000/hr and run into millions in lost production in a given year. Other studies pointed out that belt replacement is the greatest single cost of the conveyor system. These studies allude to an important fact: cleaner belts lead to reliability and longer belt life. They showed that a critical relationship exists between characteristics of material being moved and the design of all major conveyor components. In practically all situations this relationship is keyed to belt cleaners, which have long been considered "add-ons" or "accessories." At the Fifth International Coal Utilization Exhibition and Conference, the Sammis Station-Ohio Edison Co. said it installed four belt cleaners on each problem belt. The company found that under certain conditions, when the coal is wet and sticky, carryback can be so heavy that it will flow over two cleaners. Before installing the cleaners, it was necessary to schedule a cleanup crew of four men each day and rent a large vacuum truck for an eight-hour shift. In addition, the company dredged the harbor three times a year, to remove coal spillage. Once the cleaners became operational, however, cleanup costs were reduced to a few days labor every third month. Renting the vacuum truck crew was also eliminated, and harbor dredging became necessary only once each year. In addition, the Mechanical Handling Engineers' Association (MHEA) in London pointed out that standards for cleaners are sorely lacking in the industry. MHEA called for instituting such standards in the future. They also reaffirm using multiple belt cleaners for increased efficiency. MHEA pointed out that some conveyor belts can be cleaned by one device, provided that it is correctly installed and adequately maintained. But MHEA recommended that a system approach be adopted, since this has proved more effective in practice. There are two main reasons why one belt cleaner fails to solve most carryback problems. First, management often reasons that the design of the current cleaner has probably been around for years, so it "must be good." This logic leads to a continued investment in keeping the current model operating, which includes pouring substantial sums of money in "housekeeping" manpower hours because the cleaner does not clean. Second, most single-belt cleaners are specified too late in the design process (indeed, some after the system is operational). This complicates matters since cleaning efficiency is directly proportional to when they are specified: the later the specification, the less efficiency. Cleaning equipment should be taken into consideration before the conveyor's structure is designed and fabricated. Otherwise the space available to install adequate cleaning equipment at the head pulley may be inadequate. Instead of matching conveyor with proper cleaner (as would occur during the design of the conveyor itself), designing a cleaning system "after-the-fact" becomes a matter of matching cleaner to conveyor. This limits choices in cleaners and, therefore, overall cleaning effectiveness. This is why after-the-fact designs of single belt cleaners are costly and rarely successful. While it is always best to specify belt cleaners during early design stages, the multiple-cleaner systems approach makes the timing of cleaner installation less critical. Because of flexible mounting hardware, a well-designed system can lead to 99% efficiency in cleaning and put an end to carryback even after a system is operational. Multiple-Cleaner Systems Approach In a multiple-cleaner system approach, the first step is to achieve a thorough understanding of the material to be moved under the worst conditions. With such un-

Jan 4, 1984

By Mark A. Krall, Robert L. Geddes, James C. Frost

Introduction The Conda Partnership's Dry Valley phosphate mine is a thinly bedded, multiple seam open-pit mining operation where selective mining techniques are used to recover phosphatic shales. The mining methods used are truck/shovel and scraper/dozer operations. Ore is shipped 32 km (20 miles) by rail to a beneficiation facility. The ore is upgraded by washing and calcining. The mine and beneficiation complexes are owned by the Conda partnership. It is a joint venture between Beker Industries Corp., of Greenwich, CT, and Western Co-Operative Fertilizers (US) Inc., of Alberta, Canada. The Partnership operates as a separate entity of the two partners. The Dry Valley mine is located 48 km (30 miles) northeast of Soda Springs in Caribou County in southeastern Idaho. The mine is situated on the Caribou National Forest. Mining operations take place between 2 and 2.4 km (6400 and 7900 ft) in elevation. It is accessible partly by 32 km (20 miles) of paved roads and 16 km (10 miles) of dirt roads. The winters are long and severe, and the summers are short and mild. This article describes the history, geology, exploration, mining, and reclamation that makes this mine Idaho's largest producing mine and the western US' leading phosphate producer. History and production In the mid-1950s, Western Fertilizers of Salt Lake City, UT, drove an exploratory drift in Maybe Canyon. A large bulk sample of phosphatic shales was analyzed for phosphate content and processing characteristics. No large scale mining or processing operations were undertaken. In the late 1950s, the Dry Valley property was sold to Central Farmers of Chicago, IL. No major operations took place. In 1964, Central Farmers sold the property to El Paso Products Co. of Odessa, TX. El Paso Products supervised the mining operations of Wells Cargo Mining Co. from 1965 through 1967. During this time, El Paso Products built a beneficiation facility and a fertilizer complex in Conda. A 32-km (20-mile) railroad was also constructed from the mine to this facility. From 1968 through 1972, the mine was shut down due to a depressed fertilizer market. In 1972, El Paso products sold its ore reserves, beneficiation plant, and fertilizer complex to Beker Industries Corp. In 1979, Beker Industries sold 50% of its ore reserves and 50% of its beneficiation plant to Western Co-Operative Fertilizers (US) Inc., of Alberta Canada, forming the Conda Partnership. It has operated the mine and beneficiation plant since January 1979. From the mid-1950s to the mid-1960s, no substantial production took place. From 1965 to 1967, El Paso Products stripped 3 Mm3 (4 million cu yd) and mined 2.3 Mt (2.5 million st). From 1972 through 1983, 50 Mm3 (66 million cu yd) were stripped and 18 Mt (20 mil¬lion st) were mined. Geology The Wells Formation forms high ridges and hillsides in the Dry Valley area. It is best exposed along the west face of Dry Ridge. It forms the imposing wall on the east side of Dry Valley. The formation is divided into two members. The lower member, about 213 m (700 ft) thick, is dominantly thin to medium-bedded limestone and silty limestone. It contains nodules and stringers of chert and minor sandstone. The upper member is composed principally of thick-bedded to massive cross-bedded, light-gray to orange-yellow, fine grained sandstone. There is some interbedded brown to light-gray limestone. This member varies from 369 to 457 m (1300 to 1500 ft). Recent investigations indicate that the upper Wells is of Permian age. Under some conditions, the Wells may be water-bearing. Otherwise, it has no apparent economic significance. Grandeur Member (Park City Formation) Overlying the Wells Formation is a distinctive light-gray to white dolomitic fossiliferous limestone. This unit has been identified by the US Geological Survey (USGS) as the Grandeur Tongue Member of the Park City Formation. This member is sometimes absent due to its contact with the Meade Peak Member of the Phosphoria Formation. It is easily detectable by its color, hardness, and fetid odor. Phosphoria Formation The Phosphoria Formation of Permian age was named from Phosphoria Gulch, Bear Lake County. The formation has been studied extensively and developed for its economically valuable phosphate reserves.

Jan 11, 1985

By Robert F. Reeves, Stephens A. Avary

Introduction People, systems, methods, and organization make up maintenance productivity. Methods promote efficiency in operations, systems ensure consistency and continuity, and organization maintains direction and control. The common denominator in these techniques, though, is people. Management systems can be technically correct, but fail to work because management systems do not work by themselves - people make them work. Therefore, the foundation for mine maintenance productivity must begin with the people involved. Traditionally, the emphasis placed on mine maintenance, as opposed to production, is not proportional to the impact that maintenance has on a mining operation. The performance and productivity of mine maintenance substantially affects the operating costs, revenues, and profits of the mine. The mining industry has recently experienced a period of economic depression. While it has created financial problems in all segments of the industry, it has caused the industry to focus on the need for improved productivity. Mining companies that have made investments in productivity during this period will have a competitive edge during the recovery, and mine maintenance may be the best place to put that investment. Future lost production and maintenance cost problems can be avoided if mine management has the foresight to seize the opportunities that now exist. Background Technological improvements over the last 30 years have been dramatic in the industry. Before these changes, mining equipment was not very sophisticated. So maintenance needs were not very sophisticated. Maintenance people were not required to have any formal training in mechanical or electrical skills. At many mines there was no formal maintenance organization. The mechanic was a part of the section crew and received direction from the face boss. Mine maintenance was not a function, it was a task. Technological change in mining came about in response to an expanding economy and greater demand for mined products. The past 20 years brought about a change in the kind of individual needed to mine ore and coal, and an even greater change in the person needed to maintain equipment. Equipment went from mechanical and pneumatic to complicated electrical and hydraulic. Maintenance progressed from being a task to being a function. Types of Mechanics Mine maintenance workers can be grouped into three categories based on experience: mechanics with more than 20 years, five- to 10-years, and less then five years. These groupings have influenced mine maintenance productivity. The 20-plus mechanic has been the foundation of the maintenance force. He had no formal training and his skills were acquired on the job. As new equipment was introduced, he learned to repair it by trial and error. Not all of what he learned was correct. Personal initiative and conscientiousness are characteristics of this group. They have experienced the bad times and the good, and appreciate the opportunity to work. The five- to 10-year group worked with the older, more experienced mechanics to acquire maintenance skills. These mechanics came in during industry boom times, and many progressed quickly by being in the right place at the right time. Many in this group have difficulty with diagnostic trouble-shooting, and depend on changing out parts to identify problems. This group is generally more mobile and less apt to have a strong work ethic. Mechanics with about five years experience have vocational training, some formal education or basic skills training. Like the five- to 10-year group, these miners are mobile and tend to move readily to satisfy their changing needs. These two younger groups are less apt to feel any loyalty to the employer or obligation to be productive. Their attitudes and abilities reflect the influence of their general age groups, and has a definite impact on mining productivity. Past Requirements In the 1960s, the basic requirements for a maintenance supervisor was that he be a top mechanic, get along well with the men, and be a hustler and improviser. He learned the details of new equipment as repairs were needed. Oftentimes, this individual would be the only person on the property with the ability to read prints, use diagnostic testing equipment, and troubleshoot using an analytical approach. This approach to maintenance is sufficient when the equipment design is reasonably uncomplicated. Management Changes As technology progressed, organized labor gained strength, government regulation increased, and the job of supervising and managing people had to change. The environment has changed and

Jan 11, 1983

By Warnie Flint

According to statistics compiled by the National Safety Council, US Bureau of Mines, American Medical Association, and other agencies, accidental injuries cause more deaths than all the leading diseases. No one is immune to an accident. Probably the best way to describe an accident is to say that it is an unexpected happening. The automobile driver is not expecting a terrifying crash, the electrician does not expect to be electrocuted, nor is the coal miner expecting the roof to fall on him. All personal injuries will not result in death. There is a multitude of victims who are living proof of what accidents can mean to an individual-victims who are blind, paralytic, missing arms, legs, etc. In most instances the earning power of these individuals is gone, and they are utterly dependent upon family or welfare. For many years there seemed to be an attitude that prevailed in industrial America that accidents were inevitable, and that so many fatalities and injuries should be expected. This, of course, was utter nonsense. Since the birth of such organizations as The National Safety Council, American Society of Safety Engineers, and. the US Bureau of Mines, much progress has been made in reducing accidents. The enactment of compensation laws greatly contributed to the progress that has been made. Does this mean that all accidents can be prevented? Unfortunately, it does not. Human psychology indicates that men will work unsafely or perform unsafe acts for the following reasons : 1) Lack of knowledge or skill. 2) Conflicting motivations, such as: (a) to be more comfortable, (b) to save time or effort, (c) to be accepted by a group. 3) Physical or mental condition. Nearly everyone desires his own safety, but not all individuals are willing to do what they know to do to insure their own safety.

Jan 1, 1981