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By III Sadler

Processing bauxite and clay ores to reduce Iron content to levels low enough for the ores to be suitable raw materials for such products as refractories and abrasives has long been regarded as a diffi9ult problem. Standard magnetic separation processing of the untreated ore has been attempted by previous investigators with only limited success due to the finely divided state and weak magnetic susceptibility of the iron minerals (hematite, geothite, etc.) present in these ores. The new process described in this paper consists of calcining the finely crushed ore at 500 to 800 C and then reducing (with hydrogen, carbon monoxide, etc.) the iron oxides present to magnetite or elemental Iron. The magnetic susceptibility of iron in these forms is enhanced 40-to 100-fold over that of hematitie and is readily removed by simple magnetic separation. Starting with a 2.7% Fe20s Alabama bauxite ore, a 1.5% Fe20s product was produced in one pass through a Davis tube magnetic separator with 95 + % recovery of the iron-free bauxite fraction and a 20% Fe20a magnetic product. These findings suggest that with the addition of light calcination, reduction and magnetic separation steps to the conventional refractory grain production process, the large U.S. reserves of high-iron bauxites could be used.

Jan 1, 1990

By D. H. White

The term "block caving" as used in this text includes panel caving and mass caving as described by Julin and Tobie (1973). This method reportedly was conceived in 1895 when a block of ore ranging up to 200 ft (61 m) in width was undercut at the Pewabic Mine on the Menominee Range in Michigan (Bucky, 1956). Over the years this method has evolved largely as a consequence of trial and error in which operators became acutely aware of what nature would allow and what it would not. Today block caving remains somewhat of an art rather than a science where experience often dictates what needs to be done. With the plunging prices of base and specialty metals in the early 1980s caving mines sought to reduce operating and development costs in order to return to profitability. For some this became an impossible task given the design, grade and operating costs of the day and closure became the only alternative. One lesson learned from the experiences of the 80s is that survivability depends on cost competitiveness and this implies the efficient use of resources and technology. To this end applied rock mechanics serves as a useful tool. The purpose of this paper is to show how Geomechanics can be used? in block caving to facilitate sound decision making and how this equates to dollars saved. Features of mining method selection, design and operation are discussed as related to this theme.

Jan 1, 1990

By T. E. Durney

In the Fall of 1987 The Wellmore Coal division of The United Company installed a fines separation circuit in its #20 plant near Big Rock, Va. The addition of the fines circuit included a bank of classifying cyclones and two flotation units; one a conventional 4 cell, 34 m3 Wemco cell, the other an 2.4 meter diameter by 7.6 meter tall, 28.3 m3 column flotation cell. The new fine coal separation circuit is depicted in Figure 1. The column flotation cell is manufactured by the Deister Concentrator Company, Inc., under the trade name Flotaire. The Deister Flotaire column cell utilizes a counter current flow arrangement and a different means of generating air bubbles than that of conventional mechanical flotation cells found in coal processing plants. Other features include diffusers for additional air supply and a froth washer. This cell is one of the few commercial scale column cells processing coal.

Jan 1, 1990

By Y. C. Kim, M. Preston, F. Martino

Because of the high cost of obtaining coal washability samples, it has been difficult in the past to obtain washability variograms. As a result, it could not be determined if the geostatistical prediction tool known as kriging can be applied to predict in situ coal washability characteristics. This paper presents the obtained variogram models for the Upper Freeport coal seam in western Pennsylvania. Variogram model parameters are presented for a total of 27 models. They are for four different variables: float- weight, ash, sulfur, and Btu, at seven different specific gravities: 1.275, 1.300, 1.325, 1.400, 1.600, 1.800, and 1.80,Sink. Based on the obtained variogram results, it can be con¬cluded that all attributes of coal washability show definite spatial correlation structures, and, consequently, geostatistics can be used to predict the in situ coal washability characteristics.

Jan 1, 1990

By O&apos

Southern Ohio Coal Company (SOCCO) and the U.S. Bureau of Mines have identified techniques to optimize the use of scrubbers on continuous miners. The techniques provide maximum respirable dust control while maintaining a high output. The use of radio remote control and scrubber help to achieve greater advance between lifts by locating the operator in fresh air during the mining cycle. He is also kept away from newly exposed roof, which is not supported. An alternative to fan-powered scrubber was also evaluated at SOCCO. A high-pressure water-powered scrubber system eliminated the noise associated with fans, and achieved an intrinsically safe system. Experience in the use of these scrubber systems and remote control at SOCCO are discussed.

Jan 1, 1990

By Stephen Hoffman

The Environmental Protection Agency (EPA) is investigating approaches to control non-coal mining wastes. In May 1988, the EPA's Office of Solid Waste (OSW) released a document that outlined an approach to manage non-coal mining wastes and materials. This document was called Strawman I. It was a staff-level approach designed to aid the continued participation of interested parties and to enhance EPA's understanding of mining waste issues. EPA has been working with states, public interest groups and the mining industry to gather information and to solicit input on waste management approaches. The involvement of the states in the Strawman process has been coordinated by the Mine Waste Task Force of the Western Governors' Association and the Interstate Mining Compact Commission. Involvement of public interest groups has been coordinated through Colorado Trout Unlimited. And the participation of the mining industry has been managed principally by the American Mining Congress. In May 1990, EPA released Strawman II. It was based on comments submitted to the EPA on Strawman I and on information given to the EPA by interested parties since 1988. Strawman II is again a staff-level approach to protect human health and the environment from wastes and other materials associated with non-coal mining. In September 1990, meetings were held with public interest groups and the mining industry to discuss their comments on Strawman II. By early 1991, the EPA expects to make a decision on how to proceed with program development.

Jan 1, 1990

By S. G. Malghan, V. K. Pujari

Detailed characterization of all the powder constituents during powder processing is necessary for the reproducible manufacture of ceramic components that will perform reliably in intended applications. In this paper, selected physical and surface chemical techniques for characterization of silicon nitride powder are evaluated. The characterization data are discussed in the context of how these data, through their influence on powder processing unit operations, can affect the final microstructure. In the forming of ceramics, some of the major variables of injection molding are evaluated. Accurate measurement and control of these variables is emphasized for manufacture of Si3N4 ceramics with a high degree of reliability.

Jan 1, 1990

By J. F. Ziegler

The Silver Chert jasperoid, Mercur District, Utah, records a complex history or silicification and tectonic activity.

Jan 1, 1990

By G. J. Goldberg

Through the early 1980's, surveying at Bingham Canyon required a great deal of repetitive and manual work. The advent of total station surveying equipment provided an opportunity to improve the speed and accuracy of surveying work while reducing manpower needs. An evaluation of total station systems and their ability to meet the surveying requirements of Bingham Canyon culminated in the purchase of a total station system as the mine re-opened in 1986. This paper presents the procedure for evaluating, implementing and using the total station survey system at Bingham Canyon.

Jan 1, 1990

By A. W. Khair

This paper presents an engineering approach to solve a complex ground control problem at reduced cost, allowing the mine to be operated safely and economically. The mine has experienced serious and complicated cutter roof problem in the entries. This cutler roof problem has delayed the advance of the entry development considerably and cost of these entries is very high due to the requirement of very heavy artificial supports. The analysis includes assessment of the cause of cutter roof and step by step action taken to improve the entry condition through appropriate longwall panel entry design and roof support system. The approach for solving the problem was two-fold: 1) to apply yield pillar concept in order to reduce the effects of in-situ horizontal stress in the roof strata and 2) to find an effective way to reinforce the roof strata and to support the fractured roof and avoid caving.

Jan 1, 1990

By J. J. Scott

As a Rock Mechanics investigator, the author has, Over his career, attempted to use his best knowledge in developing better rock control fixtures. Based on the experience of nine years of development of friction rock stabilizers, in 1980 he decided to launch a new investigation to develop a unique roof support fixture which would fit the coal mining market. The largest single user of roof bolts in the world is the American coal mining industry, historically using up to 100 million fixtures per year. In 1989 they used approximately 82 million fixtures.

Jan 1, 1990

By R. L. Grayson, Y. J. Wang

An integrated approach to the management of underground coal mine production and cost is presented. A conceptual model for objectively analyzing an underground mine to obtain lower cost and higher productivity from operations is outlined. The model is designed to provide mine managers with a quantitative, decision-assisting methodology that can be used in formulating timely responses to fluctuations in operations. It consists of a productivity fore- cast component, routine use of current resource consumption factors, a linear programming scheduling component, a manpower loading analysis, and an inventory control component. The model is applied to an underground coal mine.

Jan 1, 1990

By Philip L. LeHoux

In recent years, much work has been done to explain the nature of the gold-carbon adsorption mechanism. The benefits of a sound theoretical basis has the obvious application to gold adsorption and elution industrial processes. Unfortunately, the lack of a clear agreement on the mechanism has provided no clear direction towards process innovation and optimization. Jones' (1989) work has gone a long way towards clarifying the specie of gold adsorbed (and thus the chemistry required to remove it). Since the development of hot caustic and cyanide elution, the kinetics have been accelerated by the application of pressure to increase elution temperatures beyond the boiling point at atmospheric pressure. However, the traditional reagent content of 15 g/L NaOH and 5-10g/L NaCN has remained largely unchanged. This is in spite of work that has shown that the presence of cyanide is not required for the elution process to take place (Adams, 1986; Adams; 1989; Jones, 1989). Adams (1989) has also compared NaOH elution rates with and without cyanide. He found improvement with the use of cyanide and a synergistic effect with the use of both. Others have found no difference in overall extraction (Jones, 1989

Jan 1, 1990

By Lawrence A. Taylor

The rocks and minerals of the moon will be included among the raw materials used to construct a lunar base. The lunar regolith, the fragmental material present on the surface of the Moon, is composed mostly of disaggregated rocks and minerals, but also includes glassy fragments fused together by meteorite impacts. The finer fraction (i.e., < lcm) of the regolith, the soil, is probably the most important portion of the regolith for use at a lunar base. For example, soil can be used in bulk as insulation against cosmic rays, for lunar ceramic and abodes, or for growing plants. However, beneficiation of the soil can provide other feedstocks. For example, the soil contains abundant solar-wind implanted elements, as we1 1 as various minerals, particularly oxide phases, which are of potential economic importance. These components of the soil are sources of oxygen and hydrogen for water and rocket fuel, helium for nuclear energy, and metals such as Fe, Ni, Al, Si, and Ti. The uses of the lunar materials only await a fertile imagination.

Jan 1, 1990

By S. Dawson

The Republic of South Africa has become a major producer of opencast coal in recent years. Opencast production commenced in 1970 and by 1977 some 10 million run of mine tonnes were being produced annually, Since then surface mine activity has increased to more than 60 million tonnes which represents approximately one third of the total annual South African? coal production. Whilst a substantial portion of this production is exported, the majority is used in the domestic market, The largest consumer, being the South?\ African Electricity Commission (Eskom), produces most of South Africa&apos;s electricity using coal fired power stations,

Jan 1, 1990

By B. M. Davis

Characterizing exploration prospect potential has aspects that differ from those encountered during ore reserve estimation. One problem is determination of the ore reserve potential prior to acquisition of significant volumes of hard data. The evaluation is subjective and data are usually sparse and of uncertain quality. However, estimations of the ore reserve potential are commonly demanded by management before project funding will be approved. The estimations from several prospects, along with the uncertainties inherent to the estimation, are then used to compare and contrast the potential of several prospects, often with widely varying geologic models.

Jan 1, 1990

By E. M. Frizzell

An ongoing research program at the Spokane Research Center of the U.S. Bureau of Mines is directed toward investigating drilling parameters (thrust, torque, penetration rate, and drill revolutions) during the drilling of roof bolt holes. A system that measures these drilling parameters calculates the specific energy of drilling, and determines drill bit position has been developed by the Bureau and mounted on a roof bolting/drilling machine, through the use of a microcomputer, critical drilling parameters can be immediately interpreted and analyzed. This makes it possible to inform the operator of hazardous roof conditions. Initial results of this program are presented here.

Jan 1, 1990

By Jon C. Yingling

Techniques for optimization of mineral processing flowsheets are reviewed. Though not yet widely used in the minerals industry, approaches for chemical process optimization based on successive quadratic programming (SQP) algorithms may be employed to determine optimum unit design and control settings for a mineral processing flowsheet. Moreover, in certain mineral processing flowsheet applications, specialized techniques can be applied because of the nature of the system relations. These techniques offer advanta es in efficiency. Moreover, their capability exceeds that o f the SQP approaches since simultaneous optimization of circuit configuration and unit controls can be addressed.

Jan 1, 1990

By H. V. Fairbanks

The following processes were investigated using ultrasonic treatment in mineral recovery: (1) cleaning coal from coal slurry ponds, and (2) extracting precious metals from tailings and other sources. The treatment entails the production of a water slurry of the material containing the mineral which is made to flow over the vibrating surface of the ultrasonic treatment unit. The vibrations transmitted into the slurry break up particle agglomerates and also produce a scrubbing action on the surfaces of the particles. The treated mineral particles were found to have increased settling rates, better compaction, and more rapid water drainage.

Jan 1, 1990

By Steven B. Van Kouteren

Value added is a loosely used qualifier in the industrial minerals industry. What exactly does it mean? What does it take to make a value-added product? More importantly, how does a company maintain the value added to its products? Most people agree that value-added means the value of a mineral minus the cost to produce it. This is misleading, though, because producing value-added products does not necessarily guarantee the profitability of the products. In some cases, firms that make value-added products are not very profitable. It is important not only to understand how to make a value-added product but also how competitive forces in the market can erode the value added. Therefore, when looking at value-added opportunities, producers must understand how to obtain the value added and how to maintain that value. Four major factors limit a company&apos;s ability to add value to its products. This paper examines these factors. It uses the ground calcium carbonate and mica industries as examples.

Jan 1, 1990