Search Documents

By D. Diekman

Perlite is not a trade name but a generic term for naturally occurring siliceous volcanic rock. A distinguishing feature which sets perlite apart from other volcanic glasses is that when heated to a suitable point in its softening range, it expands 5 to 20 times its original volume. This expansion is due to the presence of 2% to 6% combined water in the crude perlite rock. When quickly heated above 1600°F (871°C) crude perlite pops in a manner similar to popcorn. The combined water vaporizes and creates countless tiny bubbles in the heat softened glassy particles. It is these tiny glass sealed bubbles which account for the amazing lightweight and other exceptional physical properties of expanded perlite. The bulk densities of the expanded perlite generally range from 3 pounds per cubic foot (48 Kg M3) to 10 pounds per cubic foot (160 Kg H3).

Jan 1, 1985

By P. A. Rittenhouse

Reserves of potash are more than adequate to meet future world demand for this primary fertilizer nutrient. The bulk of both reserves and current production is located in only a few countries. Recent attention has focused on potential development of smaller reserves to supply local markets in developing areas of the world. However, most new capacity in the next decade will be built in countries with large current production and reserves. The paper reviews current and future projects that will add to the world supply of potash.

Jan 1, 1985

By William F. Daly, William H. Hansmire

Installation of initial tunnel support is often the most uncertain element of work in the design of, and a contractor bidding on, construction of a rock tunnel. The risks the construction contractor and owner assume are delineated to a great extent in the technical specifications portion of the contract documents. It is intended that this paper identify current practices for specifying initial tunnel support and the impacts each case has on the assignment of risks associated with providing the initial tunnel support. Examples of recently completed tunnel designs are given.

Jan 1, 1985

By N. J. Themelis

It is a pleasure to introduce this session on frontier technology and present an overview of pyrometallurgical technology, as it is today and where it may be heading. While there have been many advances in hydro-metallurgical processing in our times, pyrometallurgy has not been still, and more novel processes have been introduced in the last four decades than in all previous ages of humanity put together. As a result, pyrometallurgy has managed to remain the predominant mode of producing metals from ores and concentrates: over 95% of the world primary metals production, including iron, manganese, copper, lead, chromium and nickel, is obtained via the high temperature route. Some of the characteristics of pyrometallurgy, along with the corollary industrial advantages are shown in [Table 1]: [ ] On the other hand, the necessity of operating at high temperatures also entails special problems and it is unfortunate that research on how to overcome these problems has not, in most cases, kept up with the development of these wonderful novel processes. We shall first speak of the important developments in pyrometallurgy which have brought us to the current state of the technology, and subsequently on the problems still encountered and the kind of research and development that will be necessary to bring pyrometallurgy on a par with other late twentieth-century technological developments.

Jan 1, 1985

By D. A. Lowrie

Environmental concerns and increasing mine development costs have created a need for early information on gold recovery from its host environment. The habit, association, and approximate abundance of minerals which contain unacceptable metallic ions which may be released during process of concentration of gold should be identified in exploration drill core. One case of a "clean" gold orebody is described to show that early petrographic studies contributed to a rapid decision to mine a small deposit by open pit and to custom mill the ore in an already restricted effluent environment. A second example describes identification of an undesirable mercury content and resulting action taken.

Jan 1, 1985

By A. T. Yu, K. A. Young, Ronald M. Hays, Sanford Terry, D. R. Campbell, J. K. Lovrien, W. L. Price, C. W. Matthews, W. R. van Slyke, S. P. Cole

Storage and transport systems are essential for mineral processing. Section 10 includes systems for storage and transport of dry bulk materials, slurries, and water necessary for operation of mineral pro¬cessing plants. All aspects of these systems are presented, including material characteristics; dry material placement in and reclamation from storage stockpiles and bins; dry material conveyance; hydraulics (liquid flow and pumping); slurry characteristics; slurry storage and reclaim, slurry flow (distributors, launders, and pipes), and pumping; water (primary and secondary process, reclaimed, fire, cooling, and domestic) supply, transport, and storage; equipment selection and sizing; power transmission; controls; and health and safety. The mate¬rials considered include crude ore; process and other water supplies; initial, intermediate; and final in-plant materials; finished materials; and tailings and other waste products. Section 10 is a compilation of practical operating data for engineers, technicians, and plant opera¬tors. For the design of mineral processing plants, including selection and sizing of equipment, the design engineer should consult with equipment manufacturers, suppliers, engineering firms, and plant op¬erators with specialized experience in particular materials handling methods. When unusual conditions are encountered, actual pilot or full scale testing may be required to insure adequate design. Operation of mineral processing plants is dependent on the proper engineering and construction of storage and transport systems for dry bulk materials, slurries, and water. It is obvious that processing plants cannot produce the required quantities of semifinished and finished products unless these material can be transported adequately to, through, within, and from the plant. Costs of storage and transport systems may exceed 50% of the total capital and/or operating costs. Considerable attention must be given to the design, layout, and engineering of these systems. These systems are interrelated with the mineral processing method and it is necessary to determine the best combination of mineral processing method and storage and transport systems. Storage and transport systems perform a major supportive func¬tion to mineral processing. The final selection of these systems depends on the final selection of the processing method and related systems (environmental control, tailings and waste disposal, etc.). The process¬ing method determines the characteristics of materials to be stored and transported; distances, elevations, flow rates for transport; and storage requirements. Flowsheet After selection of the processing method and related systems, a flowsheet must be developed. This flowsheet should indicate produc¬tion rate, percent solids or moisture, and specific gravity for all initial, intermediate, and final products or product flow streams. It also may be necessary to know the size analysis, chemical analysis, abrasiveness, and other physical characteristics of various product flow streams. The flowsheet provides basic information for plant layout, storage requirements, and selection and sizing of process and transport equip¬ment. Storage and transport systems often function improperly be¬ cause of inadequate flowsheet data or process revisions, resulting in improper equipment selection and sizing. Further details on plant design are presented in Section 33. After selection and sizing of process equipment, it is necessary to select the type of material transport equipment to be used for in¬plant materials handling as well as crude ore, tailings, and final prod¬ucts. The storage and/or surge requirements, including capacity and location, then are determined. Storage and/or surge capacity is neces¬sary for leveling production rate fluctuations due to variations in material characteristics; production scheduling; equipment mismatch¬ing, failure, or breakdown; and scheduled maintenance downtime. Variations in ore grindability will cause fluctuations in throughput or production rate for grinding mills and variations in ore grade will cause fluctuations in production rate for concentrating equipment. Variations in material moisture content and percent solids can have serious effects on the capacity of material transport equipment. In some cases, a blending system may be desirable or necessary to reduce variations and to obtain uniform production and/or metallurgy. Storage capacity often is needed because of different production schedules for various phases of the mining and mineral processing complex. As an example, the mine and coarse crushing plant may operate on a one- or two-shift-per-day schedule while the fine crushing plant and concentrator on a three-shift-per-day schedule. This would require storage between the coarse and fine crushing plants. Another example would be load-out storage where unit trains are used to haul concentrate or final products. The concentrator could be operated on a three-shift-per-day schedule while only I to 2 hr may be scheduled for unit train loading. This would require adequate load-out storage so that the concentrator can be operated continuously. Process equipment with mismatched capacities requires storage or surge capacity between the mismatched equipment to achieve oper¬ating efficiency. As an example, the fine crushers may have greater capacity than the rod mills. Storage between the fine crushers and the rod mills permits both the crushers and rod mills to be operated at optimum capacity with the crushers actually operating or running a lesser number of hours per day. Mismatched capacities for process and transport equipment also may require storage or surge capacity. Mismatching of equipment capacities most often occurs because of the difficulty in equipment sizing. Thus, the design engineer must anticipate where in the flowsheet these mismatching capacities are likely to occur while making every effort to assure that equipment is selected and sized properly. Equipment breakdown can cause major operating difficulties and lost production. These breakdowns can be reduced with adequate scheduled maintenance. Lost production due to nonscheduled down¬time caused by equipment breakdown can be reduced further by standby equipment and storage and/or surge capacity ahead of essen¬tial mechanical and electrical equipment. As an example, standby pumps and conveyors often are available as part of the in-plant trans¬port system. Storage and/or surge bins and tanks often serve dual functions, such as dewatering, mixing, and smoothing production rate fluctuations.

Jan 1, 1985

By Richard D. Lang

The paper provides an overview of the activities which culminated in the decision to construct a major diamond mine in the north west of Australia. It presents a broad summary of the geological, mining, processing and marketing work which has been required to bring the project to the construction phase. The implications of the development for the world industrial diamond market are also discussed.

Jan 1, 1985

Terminology. The term potash originated in "pot ashes" produced by burning wood to ashes in iron pots and then leaching out the soluble salts, chiefly potassium carbonate, from the residue. In modern usage potash is a generic term for various potassium salts used in agriculture and industry. More specifically, it denotes the oxide of potassium, K2O, and the content of potassium in ores and products is stated as weight percent of K2O present. Its salts are commonly referred to as muriate of potash, sulfate of potash, etc. The presence of an adequate supply of available potassium in the soil promotes the health and improves the quality of the plant. insures greater efficiency in photosynthesis, increases resistance to certain diseases, offsets the effect of an oversupply of nitrogen, and helps the plant to utilize soil moisture more advantageously. ("Soils and Men," U.S. Dept. of Agriculture Yearbook 1938.) Occurrence. Potassium ranks seventh among the elements in abundance. It is estimated to constitute some 2.6% of the lithosphere and is found in soluble forms in the oceans, lakes, rivers, and subsurface waters. It is also an important constituent of plant and animal life. Commercially significant accumulations of potassium salts occur in underground deposits formed in past geologic times by evaporation of ancient bodies of saltwater, inland drainage basins, and shallow sea lagoons. The potash content of such waters was the end result of weathering and leaching of insoluble potash-bearing aluminosilicates, such as feldspars, micas, leucitcs, and others. The concentrations of potassium salts in the natural brines of some lakes in the arid and semiarid regions of the continents are also important as sources of potash; the brines of the Dead Sea in Asia Minor, the Great Salt Lake in Utah, and Searles Lake in California typify such concentrations. Every continent has major potash deposits as listed in Table 1 adopted from Cawley.1

Jan 1, 1985

By Douglas J. Cork

Biohydrometallurgica1 processes in the areas of coal desulfurization (Hoffman, M.R., et al., 1981) and recovery of metals from metal sulfide ores (Lundgren, D.G. and Malouf E.E., 1983) are well known. In addition other areas of potential interest to the mining industries have been outlined (Spisak, J.F., 1979). For instance, scientists involved in this interdisciplinary field have endeavored to apply microorganisms to the problem of effluent sulfate disposal. This chapter assesses the feasibility of utilizing a particular two stage anaerobic microbial process to convert effluent sulfate to orthorhombic sulfur. Strong emphasis is given to the possibility of substituting this bioprocess for alternative gypsum synthesis and disposal methodologies commonly practiced by companies which emphasize sulfuric acid or ammonium sulfate leaching processes.

Jan 1, 1985

By L. D. Bowerman

The topic of the presentation will be the excavation of 25,000 IF, 11-foot 0-inch diameter, hard rock tunnel using a Robbins boring machine on the Terror Lake Hydroelectric Project on Kodiak Island, Alaska. This tunnel was completed on a tight construction schedule under some unusual conditions. The tunnel was mined through hard massive granite with faults and high water flows up to 7,000 GPM encountered at the heading in some areas. New innovations in equipment and cutter design were used.

Jan 1, 1985

By D. H. Davidson

The basic principal in the ISL process involves the recovery of metal values by moving fluids through rock instead of moving rock. The process combines surface and sub-surface operations, with the economic performance controlled by four major factors; rates of fluid injection and production from wells; the rate of mineral solubilization; the volume of rock swept by the fluid; and the volume of solution processed through the system. This paper discusses various technical and economic parameters affecting these four factors and how they impact project costs.

Jan 1, 1985

By Fred Breu, Ronald E. Heuer

INTRODUCTION The Point Lepreau nuclear generating station was constructed in the late 1970's and early 1980's by the New Brunswick Electric Power Commission. Point Lepreau is a small peninsula on the north shore of the Bay of Fundy, about 55 km west of St. John, New Brunswick. Cooling water for the plant was to be obtained from and discharged into the Bay of Fundy by the system of shafts and tunnels illustrated in Fig. 1. The design engineer for the cooling water system was Albery, Pullerits, Dickson and Associates, Ltd., Toronto. Ferrera-Resco Ltd, Windsor, Ontario, was contractor for construction of the cooling water shaft and tunnel system, which was done between 1976 and 1979. The senior author was project manager for Ferrera-Resco, the junior author served as consultant to Ferrera-Resco on evaluation of certain geotechnical questions which arose during construction. SITE CONDITIONS Geology Except for limited overburden soils at the onshore shaft sites, the tunnels and shafts were constructed entirely in Triassic conglomerate, sandstone, and siltstone, with some shale interbeds. The bedding strike averaged about N6°E, The dip was to the west at about 30° along the Discharge Tunnel and 40° along the Intake Tunnel. Rock along the Intake Tunnel was mostly sandstone and siltstone and more thinly bedded, with RQ D generally in the range of 50 to 60%. Rock along the Discharge Tunnel tended to be coarser sandstone and conglomerate and more thickly bedded, with higher RQ D averaging about 80%. In addition to bedding joints, two other joint systems were identified

Jan 1, 1985

By Gene Mattila

Each installed rock bolt costs in excess of 520.00. High cost in conjunction with the primary purpose of safety makes it only logical to install the highest quality anchors possible. Each bolt has designed support capabilities in axial, shear and fluctuating ground condition, if installed to manufacturers recommendations. The quality of anchor is not; however, only affected by material specifications, but by transportation, handling storage, installation procedure, machine performance and geology. The quality is not only affected by many variables, but reliability should be assured. Non-destructive methods of testing reliability are only available for several types of bolts.

Jan 1, 1985

By Francis G. Stehli

Though sedimentary rocks comprise only about five percent of the volume of the continental crust, they cover about 80% of its surface, serve as important reservoirs for fluids, contain reserves of non-metallic minerals, and have in general been extensively drilled. However, most drilling has been shallow in comparison to the thickness of the crust and such deep drilling as has taken place is very strongly localized in sedimentary basins. This may be seen by reference to Figures 1 and 2 which show the location of wells that drilled deeper than 15,000' [=] 4.6 km. (Figure 1) and those that drilled below 20,000' [=] 6.15 km. (Figure 2). It is apparent that, even in regions of sedimentary cover, direct exploration below six kilometers has been very restricted. In the case of the metamorphic and igneous rocks which make up 95% of the volume of the crust, direct exploration has been much less extensive in terms of both area and depth. The present state of our knowledge of the crust below a' thin surface layer stands in marked contrast to our growing present need for raw materials and the needs of future generations. It also stands in contrast to our need for enhanced, scientific knowledge of the deeper crust, its configuration, its present state, its hydrothermal systems,-its evolution, and its materials. Lessons learned in exploring the third dimension of the sea floor, the vigorous prosecution of seismic profiling, the development of testable models for hydrothermal systems and mineral deposits, the need for better understanding of heat flow, state of stress, earthquake mechanisms, and a host of other phenomena all suggest that it is time to launch a national program for scientific exploration of the crust which uses drilling to test important hypotheses developed on the basis of indirect evidence.

Jan 1, 1985

By P. Raffinot, C. H. G. Bushell, S. Hodgson, E. F. Milner, H. J. Bosshardt, N. Draper, D. E. Pickett, Edwin T. McKnight, J. Prieto

Zinc ranks third and lead fourth in world nonferrous metal conumption. In 1972 the free world consumed 3,333,000 mt of refined lead and 4,422,000 mt of refined zinc. The lead tonnage was divided into the following end uses: storage batteries (42%), lead allows (7%), pigments and chemicals (11%), cable sheathing (9%), gasoline additives (13%), pipes and sheets (8%), and miscellaneous uses (10%). The corresponding distribution of zinc uses in 1972 was galvanizing (39%), die casting (26%), brass (15%), rolled zinc (8%), oxide excluding American Process zinc made directly from concentrate (6%), and other uses (6%). The pattern of usage of lead and zinc varies considerably from country to country. During 1972 in the USA 49% of refined lead was consumed in storage batteries, 19% in gasoline additives, and only 3% in cable sheathing, whereas in the United Kingdom 28% of the lead was consumed in batteries, 14% in cable sheathing, and 14% in gasoline additives. For zinc the major US uses were die casting (41%) and galvanizing (37%), with about 3% consumed as rolled zinc; corresponding usages in the same applications in France were 12, 28 and 28% and in Australia 12, 67, and 3%, respectively. The outstanding resistance of lead to corrosion, its density, and

Jan 1, 1985

By Paul J. Lauricella

This presentation will summarize the basic safety components of an underground safety program. The program will begin with the first ingredient to a successful safety program, top management support, and continue through emergency services. Particular attention will be devoted to top management support for the safety program.

Jan 1, 1985

By E. P. Deliac

The aim of this joint work between the French Coal Board and the Paris School of Mines is to be able to practically model the behaviour of a transverse drum cutting rock with picks. First a theoretical approach leads to the concept of cutting curves, giving forces and torque against penetration per drum revolution. Then experimental evidence, from full scale and reduced scale testing, validated and confirmed the theoretical shape of the curves. Finally practical applications are given, to improve the design or use of a shearer (or continuous miner). A micro-computer program is being developed to predict the cutting performances of a machine in certain conditions.

Jan 1, 1985

By Louis A. Sandbak

Drift excavation by boom-type roadheaders in the San Manuel and Kalamazoo sulfide copper ore bodies has been successfully demonstrated. Geomechanical rock classification in conjunction with detailed geologic mapping has been necessary to assess roadheader performance, and to predict advance rates in the varied rock classes in the San Manuel block caving mine. Rapid excavation and less fractured ground are obvious advantages of roadheader drift excavation over conventional drill and blast techniques. The geomechanical system of Engineers International (1984) can be an effective roadheader performance and ground support tool.

Jan 1, 1985

By Pieter Barendsen, Olivier Dubugnon

INTRODUCTION There are three fronts on which development efforts are being concentrated to extend the application domain of Tunnel Boring Machines (TBM), which is potentially very large - Assessment of a reliable prediction method, including machine-rock interaction and geological characterisation, so that the boring system can be designed properly and the costs remain in the predicted range for each given tunnel project. - Development of lighter, more flexible and more controllable machines to be applied in shorter, deeper tunnels or roadways, such as required in mining. - Reduction of cutter and machine costs when excavating hard rocks or difficult grounds, in developing improved tool materials, cutting geometries and tunnelling systems. The above three lines of development have a common, critical requirement: to have a reliable set of design rules to optimize the machine specifications from the knowledge of rock and geological parameters and working requirements. This optimization can only be done if a model sufficiently sophisticated is made available, able to take into account the numerous factors influencing the TBM advance , and being interactive enough to achieve the optimization.

Jan 1, 1985

By A. T. Yu

As a nation, we have been known as perhaps the most wasteful in history. From the perspective of engineers and builders on the other hand, planned obsolescence and demolition did beneficially pave way for growth and provided environment for new businesses. Recent economic recession and intense competition from overseas, however, have drastically changed the economics. The high cost of capital and the demise of indiscriminate plant expansion have totally altered the way we conduct our business and run our operations. As a response to increasing demands for better efficiency with little or no funding available, everyone is forced to make do and do better with whatever little he has. Today it nay not be an exaggeration to state that modification of existing facilities may have finally emerged as a way of life. This paper will outline examples of how several companies have effectively modified existing facilities to do more and do it efficiently without having to demolish everything and/or to spend a fortune.

Jan 1, 1985