Search Documents

By Terry S. Maio

In 1978, Ozark Lead Company made the decision to expand the capacity of its mine/mill complex by 33%. The objectives of the expansion were to (a) increase mine' production capacity by 1816 tonne/d(2000 TPD), (b) increase lead metal pro¬duction by 21,790 tonne/y (24,000 TPY) and to (c) construct new facilities and/or modify exis¬ting equipment to accomodate the increased pro¬duction. The intent of this paper is to give a brief explanation of the equipment installed and the overall production and metallurgical benefits-realized from this expansion. The expansion was completed in the second half of 1980 with all equipment debugging and fine tuning completed by the first' quarter of 1981. The concentrator modifications and improvements were basically restricted to four areas: (1) materials handling, (2) automation: of the mill grinding circuit, (3) the increase of flotation capacity, and (4) concentrate dewatering.

Jan 1, 1983

By Kadri Dagdelen

New underground coal mines have become increasingly expensive to open. A simple drift mine producing a raw coal product can cost as much as $50 million while a new shaft mine producing a washed coal product can cost up to $200 million. As a result, few if any speculative new mines are constructed. Normally, a long term coal supply agreement is needed to justify new mine projects. Negotiating a supply agreement prior to production start is difficult. Pricing must be based on estimated rather than historic costs and coal quality must be estimated from core hole samples versus actual shipments. Further in todays competitive coal markets, there is little margin for error in either price or quality.

Jan 1, 1983

By J. Kinkead, R. M. Sherman, E. M. Frizzel

A recent research study performed under US Bureau of Mines Contract No. J0199088 "Modular Irrigation Equipment for Reclaimed Strip Mined Lands" investigated the feasibility of irrigation as a reclamation tool in the arid and semi-arid regions of the Western United States. Review of mined land characteristics, evaluation of irrigation systems, and assistance from the mining industry resulted in the design of two strategies for the implementation of reclamation irrigation using solid set systems. It is not the intent of this paper to suggest the generalizations made on the basis of a six state area can extend to the design of an irrigation system for a specific mine site. The purpose is to present two irrigation strategies that may be implemented with solid set irrigation in this six state area. The reader should note that the following is the result of research and, therefore, original concepts were presented. The ultimate validity of these concepts will be determined by future field tests.

Jan 1, 1983

By Robert F. Conley

Attrition milling, once employed exclusively for the dispersion of pigments, has in recent years found a host of new applications in the area of mineral processing and mineral-pigment production. Broadly categorized, attrition milling is divided into two classes, as defined by the machinery's function, vibratory milling and rotational milling. Each mill type has been defined as a variation on ball milling and the terms, "vibratory ball mill" and stirred ball mill" appear in the literature. The primary design differences between attrition and ball mills are: (1) a stationary canister (or shell) (2) smaller grinding media (3) grinder energy is motor limited rather than gravity limited (4) strong media/feed size dependance.

Jan 1, 1983

By S. J. Rodgers

This report presents guidelines on methods of dust control in conventional coal mining operations. The normal mining cycle and equipment used in a room and pillar conventional section are described. Main ventilation, section ventilation and face ventilation are discussed in detail. Proper installation of line brattice, maintenance of proper air flows at the face and split ventilation are stressed. The effects of maintaining the end of the line brattice near the face are described. The advantages and disadvantages of blowing and exhausting face ventilation are presented. The use of water sprays on cutter bars and loading machines is described. The design of a nonclogging water spray system developed under a Bureau of Mines contract is presented. Other methods of reducing dust exposure are discussed and include alternative procedures for shot firing and administrative controls.

Jan 1, 1983

The U.S. economy showed further strength during the third quarter of 1983, continuing the upward trend discussed in the last two issues of Minerals and Materials. The National Association of Purchasing Management composite index increased to a 10-year high of 67. 1 in July. (A value of 50 or greater indicates expanding industrial activity.) The index, a weighted composite of new orders, production, employment, vendor performance, and inventories, is derived from a survey of purchasing agents for about 250 industrial firms. Investment and Other National Economic Indicators The strong consumer surge of second quarter 1983 was reinforced during the third quarter by the performance of private investment. Because of this, many analysts became more optimistic about the strength of the recovery and its potential for being sustained. Capital investment growth, negative since 1980, was positive for every investment component in the third quarter of 1983. Preliminary estimates indicate a real increase of $1.4 billion (at an annual rate) in private investment expenditures on nonresidential structures, an increase of $4.3 billion (at an annual rate) for producers' durable equipment, and an increase of $4.8 billion (at an annual rate) in real inventory levels. The second quarter 1983 increase in expenditures on producers' durable equipment was the first indicator that investment recovery would occur during the rest of the year (table 1). Corporate profits in total manufacturing increased $6.5 billion from first quarter to second quarter 1983 (table 2).

Jan 1, 1983

By Ralph W. Barbaro

In the mineral industry, the objective of a mining venture is to extract, process, and market a mineral commodity in such a manner that the profit of the venture is maximized. In a mining venture, a company normally has control over mine production scheduling, the selection and location of processing facilities (mineral beneficiation plants, smelting plants, refineries, or blending facilities), processed ore blending, and the selection of markets. The flexibility of the above factors provides many alternatives to satisfy the needs of each market with regard to quantity and quality of ore. The purpose of this paper is to present a mathematical model for determining the alternative that yields the maximum profit. Production planning is generally concerned with the best utilization of fixed resources, more specifically, with the determination of production and inventory levels to meet fluctuating demand requirements. A mine can be any source of ore such as an entire mine, a production unit within a mine, or an independent supplier. The objective of production scheduling is to determine the times at which each mine will be used and to allocate a required level of production. Production planning and scheduling problems are intimately associated with the location of new and existing mines and processing facilities. Although the location of the mines is usually fixed, there can be considerable flexibility in locating new processing facilities, in the selection of the processing plant, and in blending the ore before and after processing.

Jan 1, 1983

By L. R. Verney

A number of interrelated factors influence the economics of the sulphide smelting of copper, lead, zinc and nickel. This paper discusses these factors, mainly from a US point of view, and shows how they affect the cost of construction and operation of new and existing plants. The paper shows how metallurgical plant construction costs and the consumer price index have increased at a much faster rate than metal prices thereby making some metal mining and production operations within the USA, Canada and the EEC less profitable than operations elsewhere. This in turn inhibits new "grass roots" metallurgical developments. It is explained how retrofit of existing pyrometallurgical plants can be a more viable development than the construction of "green field" plants, especially if such retrofit improves, energy efficiencies, overall operating costs and reduces emissions of sulphur and other toxic wastes. Some aspects of metallurgical plant operation are examined, especially for copper and nickel, to show how changes in operating practices may develop in order to improve overall smelting economies, especially when developed in conjunction with objective retrofit. The paper also examines some financial aspects, especially insofar as the disparity between terms for loans offered to third world countries and the USA and the EEC are concerned and also comments upon the need, especially within the USA, for legislation to permit rapid depreciation of capital. Specific comments are made about environmental aspects, including the lack of uniformity of pollution control legislation and how environmental considerations may have some bearing of the location of future smelting operations.

Jan 1, 1983

By Robert J. Greaves

High-resolution seismic reflection profiling can be used to evaluate detailed struc¬tural and stratigraphic features of coal pros¬pects. Since most coal prospects are relatively shallow (less than six hundred meters deep), the vertical and lateral resolution of seismic data can be significantly improved by high sampling rates in space and time. The case study present¬ed shows the effective use of seismic data in evaluation of the Wyodak coal at a prospective coal gasification site. The data were used to map the detailed structure and thickness of the coal and to search for lateral discontinuities, such as pinchouts and. faults. An important find was a paleochannel cutting across the base of the coal seam, which was later confirmed by drilling.

Jan 1, 1983

By Brant BA, Lewandowski R, Trendle M, Haughton D

There is a vast amount of geotechnical data, which can be obtained during exploration programs at new and existing mine sites. Additional information on the performance of the in-situ rock mass can be obtained from bore cores, which are usually only geologically logged and then stored. A computer based data management system for storage and retrieval of geotechnical data has been developed to access and manipulate such data.

Jan 1, 1983

By Peter N. Calder, G. H. Blackwell

The development of an open pit slope monitoring system, from equipment selection and justification to complete computer data storage and analysts, Is described. Methods of overcoming the Limitations of the electronic transit/distance measuring device and survey system selected are discussed. Results of the monitoring program showed that blasting was a major cause of Instability, and, after much experimentation, suitable blast patterns for mine production and pit wall integrity were designed. The experiences gained with double benching 'and wall cleanup procedures are discussed . The monitoring program also indicated that water was a contributor to instability, and methods of dealing with water In a rock with a low storage coefficient and transmissibility are described. Because of the danger of falling rock, photogrammetric methods are used for joint mapping and analysis, this work being contracted out. Joint strengths are measured on-site using a portable shear tester. Finally, a discussion of a complex failure is given.

Jan 1, 1983

By P. M. Brown

The Bureau of Mines is investigating a dewatering technique for coal-clay waste that uses a flocculant, polyethylene oxide (PEO). This flocculant forms strong stable flocs that can be dewatered on a static screen. A field test unit (FTU) using this technique was operated at approximately 400 gal/min, using a waste stream from the flotation circuit of a coal preparation plant. Consolidated coal-clay material con-taining 55 to 60 pct solids was produced when the flotation circuit slurries of 2.7 to 8 pct solids were treated with 0.1 to 0.3 Ib PEO per ton of solids. The FTU was also operated at 64.5 and 87.5 gal/min using a portion of the underflow slurry from the preparation plant's thickener. Consolidated coal-clay material containing 55 to 60 pct solids was produced when the thickener underflow slurries of 19 to 24 pct solids were treated with 0.08 to 0.2 Ib PEO per ton of solids. PED-treated materials continued to dewater when placed in a pit.

Jan 1, 1983

By Mark E. Gershon

The development of long term plans and schedules for strip mines now faces many companies, especially those developing large properties in the West. The rule of mining the lowest strip ratios first, while delaying equipment acquisitions and recouping investment the fastest, creates the situation where stripping ratios are too high in the latter years of mining operations. A program concept taking life of mine return on investment into account is developed in this paper to optimize mine scheduling and equipment acquisition. In addition, quality considerations (heat content, ash, sulfur, washability) can be considered by including the appropriate blending constraints to meet contract requirements.

Jan 1, 1983

By Benjamin W. Haynes

Analytical procedures are described for the quantitative determination of 16 elements (As, Ba, Be, Cd, Co, Cr, Cu, Fe, Mn, Mo, Ni, Pb, Sb, Se, TI, and Zn) and 7 ionic species (NH4, C032-, CI-, F-, NO3-, P043-, SO42-), identification of major and minor mineral components, and measurement of physical properties associated with manganese nodules and nodule processing reject waste materials. Compound identification methods discussed include X-ray diffraction, infrared spectroscopy, scanning and transmission electron microscopy, selective area electron diffraction, and optical and reflected light microscopy. Methods for elemental analysis include atomic absorption spectrophotometry, inductively coupled plasma emission spectroscopy, neutron activation analysis, fluorescent X-ray spectrography, and ion chromatography. Thermal gravimetric analysis, ultraviolet-visible spectrophotometry, ion specific electrodes, and standard wet chemical procedures are briefly discussed. Physical properties determined in manganese nodule materials include grain size distribution, specific gravity, triaxial shear, permeability, maximum density, Atterberg limits, and slurry density. The results of a round-robin analysis of an ammonia process waste material and manganese nodule standards demonstrate the applicability of the discussed methods. Tests discussed for the evaluation of the waste materials for disposal options include the Environmental Protection Agency (EPA) EP toxicity test, the ASTM shake extraction test, and the U.S. Army Corps of Engineers EPA seawater elutriant test.

Jan 1, 1983

By R. J. McClincy

The potential techniques for the direct smelting of copper sulfide concentrates to blister copper were evaluated from the standpoint of commercial application. Many existing smelters are adaptable to direct smelting practice but only with improved control of metallurgical performance. Modified and innovative procedures for slag cleaning and metal refining, prerequisites to direct smelting, are presented and discussed. The ability to smelt directly to blister copper using existing equipment and eliminating the need to convert matte offers ,significant advantages to traditional smelting practice from the viewpoint of cost, 'S02 control, and process simplicity.

Jan 1, 1983

By R. J. Sweigard

Three case studies were undertaken to investigate the role of land use potential evaluation in reclamation planning and to determine the impact of regional differences on the evaluation process. The three surface mines studied were representative of operations in the Appalachian, Interior, and Northern Great Plains provinces. The scope of the investigations included a survey of regional characteristics, a detailed investigation of the mining operations and site conditions, and an assessment of local land use planning activities in the area of the mine. Special attention was given to key factors that presently determine the use of reclaimed land. Also, for each case study, the postmining land use potential was evaluated using site planning principles. Specifically, the environmental, economic, and social impacts of several potential postmining land use plans were considered.

Jan 1, 1983

By Claus Becker

At the RETC 1979 in Atlanta/Georgia it was reported about the beginnings of the Hydroshield system and the first site experiences. Since that time over 10 miles of tunnels in various diameters have been built with that system, and the discussion of the two most interesting projects will be the main topics of this paper. AURELIA TUNNEL, ROME In Rome, the railway system is going to be completed and modernized. Therefore, it is necessary to tunnel through the Roman hills. Part of the new railway system is the Aurelia Tunnel, located some 100 feet below the famous Via Aurelia Antigua, close to the Vatican. The double track railway tunnel has an internal diameter of 9.44 m and a length of 2.410 m. It runs through completely differing soil conditions. (Fig. 1) The first 1000 t are situated in watertight clay, the rear part in water bearing loamy, clayey sands with interlayers of loamy clays. The figure shows the soft change-over from clay to sand. The groundwater head is between [ ]

Jan 1, 1983

By Eduardo M. Sacris

The performance of the grinding circuit, from the initial stages of operation to the present, is discussed. The mill efficiency as measured by the Bond grindability data and the operating work index is presented. The objective has been to produce a sand cyclone overflow containing not more than 6% +65 mesh. However, this has never been attained even at low milling rates. On the other hand, significant improvements in throughput were achieved by instituting some equipment changes and process modifications within the grinding circuit. The latest approach to solving the coarse grind problem is also discussed.

Jan 1, 1983

By J. A. Eisele

The Bureau of Mines is investigating the recovery of alumina from domestic nonbauxitic resources, including anorthosite. The United States has large reserves of anorthosite, but its aluminum content is less than 50 pct soluble in acid, unless a source of fluoride is added to the acid. A flowsheet that includes leaching with HCl and fluoride followed by crystallization of AlC13.6H20 from the pregnant liquor by HCl gas injection was designed. Approximately 90 pct of the aluminum values were recovered from the anorthosite when a ratio of 0.14 mole of fluorine per mole of aluminum was used. Sodium chloride is cocrystallized with the A1C13.6H20 but is removed by water washing of the Al203 product. A material balance is given based on results of laboratory studies of the unit operations.

Jan 1, 1983

By Ross. C. Barkley

A computer program has been written to simulate ground vibrations induced by multiple-hole surface blasts. The program is an inexpensive and relatively easy to use tool for predicting the principal blast vibration characteristics that determine damage and annoyance potential: peak particle velocity, frequency content and pulse duration. The program generates a complete ground motion history by superposing, at any surface position, the vibrations induced by each individual explosives charge. It requires specification of (hence allows accounting for) the blast geometry, initiation sequence (including random delays), position with respect to blast, pulse characteristics induced by each charge, and propagation laws. A methodology is outlined to determine the necessary variables either on the basis of site investigations (e.g. velocity, attenuation, pulse), or by backcalculation from measured blast vibration records. The latter procedure has been applied to blasts from two coal strip mines. Main difficulties are backcalculating individual pulses, propagation (especially dispersion) parameters and delays. A normal distribution of delays, based on published results, has been shown to influence the results and the response of a single degree of freedom structure significantly. Broadening of the wave types included and additional verifications with field results are required.

Jan 1, 1983