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By Mark S. Stagg, Stephen A. Rholl, Steven G. Grannes

A method of determining the fragment size distribution of rock quarry muckpiles using photographic and digital-image processing techniques has been developed by the Bureau of Mines. To assess the fragmentation, photographs and video tapes were taken in both the laboratory and in the field and then digitized for analysis. The fully-automated process uses specially written image-interpretation software which had been developed previously by Bureau researchers to measure irregular taconite ore shapes. The advantages of photographic assessment in comparison with other methods include speed and cost.

Jan 1, 1993

By Theodore A. Christensen

Besides the moral responsibility for ensuring worker safety, today's blasting contractor has a major financial incentive for establishing an effective safety program: on-the-job accidents have a direct impact on a very sensitive cost area - Workers Compensation. Within specific parameters, a good safety program can reduce WC costs by lowering the Experience Modification Rate.

Jan 1, 1993

By J. Alton Burks, James P. Rider

The ability to accurately predict the sound field is essential for the estimation of probable worker noise exposure. For this reason, the U.S. Bureau of Mines is researching computer- based analytical techniques specifically geared to calculate the spatial variation of sound pressure levels within common mining environments. Initial modelling efforts describing the user interface, the simulation of energy acoustics, and the graphical representation of sound pressure levels are presented in this paper.

Jan 1, 1993

Although auriferous beach and fore-dune sands at Five Mile Beach south of Okarito township had been intensively mined by hand and primative mechanical methods drilling of the sandspit by the Gold Development Corporation in 1929 indicated that the grade and quantity of undisturbed black and grey sand below the water table was sufficient to support a mining operation. Worked sand above the water table also contained fair prospects. The Okarito Five Mile Beach Gold Dredging Co Ltd, was formed and an hydraulically powered, bucket ladder, sluice box dredge built. In 13 years of operation (1931 - 1943) the dredge returned 556.39 kg (17 890 oz) of gold at a recovered grade of 225.4 mg/m3. A total of ú42 000 was distributed as dividends on the ú30 000 capital investment. Recent drill and bulk sampling at the northern end of the beach has confirmed that reworking of the historic tailings by a modern gravity recovery plant would not be economic.

Jan 1, 1993

By George S. Kalamaras

Coal strata strength is included as a vague term in most of the pillar design formulas, either as a questionable fraction of the intact coal strength or a size-dependent relationship for scaling down a laboratory value to the in situ strength. In order to introduce a coal mass strength criterion which would be compatible with current design trends, the Rock Mass Rating (RMR) system was revised to incorporate factors governing coal seam behavior under load. A number of adjustment factors have been proposed but, the most significant change, is the introduction of a parameter representing the heterogeneity of the seam. When developing a rock mass strength criterion, it is necessary to find the constants of appropriate intact rock strength criteria and to establish a correlation to scale down these constants as a function of the RMR. For four intact rock strength criteria, the constants for coal were found using the Nelder-Mead method. To correlate the constants of the strength criteria with the coal seam quality values (RMR), a procedure was developed based on finite element modeling of in situ large scale tests for which the RMR was known. A new coal strata strength criterion is proposed, in a principal stress formulation, for modeling coal pillar behavior when the stress field in a pillar is known. A linear relationship is also given, to be used when empirical pillar strength formulas are used to design pillars. The proposed criteria have been evaluated in a case study.

Jan 1, 1993

By Eugene M. Trisko

Presentation Overview State-Of-The-Art Scrub/Switch Analyses > Allegheny Power System > PSI Energy UMWA Phase I Coal Interests > 16 Phase I Scrub Plant Coal Profiles > Coal Price/Emission Allowance Interaction Southern Company Case Study > 2+ Million Ton Phase II Allowance Purchases > 10+ Million Ton Phase I Coal Switch > Georgia PSC Proposed Fuel Price Cap > Shift/Avoid Georgia Scub Costs Through System Allowance Purchases

Jan 1, 1993

By Lynn B. Hales, Randy A. Ynchausti

There is a large economic driving force associated with improving metallurgical performance in mineral processing plants using process control. Because of this and other benefits, control systems of the future will develop towards more sophisticated user friendly computer based systems that use powerful software analysis and control techniques. Auto-tuning, adaptive control and process models will gain expanded use because of their transparent availability to the system designer. Control of individual unit operations will be optimized and coordinated through expert systems that monitor economic conditions and management directives and direct operations accordingly. Plant areas, considered cost centers for years, will be integrated into plant-wide control systems for economic control and optimization. New control hardware, process sensors, control strategies and software development tools will be presented, as well as an overview of the economics driving the continued development of advanced process control systems.

Jan 1, 1993

By B. A. Filas

Stabilizing fine coal refuse ponds for reclamation at Monterey Coal Company's No. 1 Mine has been difficult. Entrained water in the stored refuse causes liquefaction as reclamation caps are placed, resulting in additional material requirements than originally projected to stabilize the pond surface. Laboratory results indicate that in-place refuse densities may be substantially improved at No. I Mine by converting from a single-point to a managed slurry distribution system. Increased densities result in improved storage efficiency, less entrained moisture and a more stable refuse mass, thereby providing an improved working surface for reclamation and improved post-closure cover stability.

Jan 1, 1993

By A Bagchi, Nabiullah, Jagdieh

"A number of coal mines in India are affected by fire. Most of coking coal reserves in the country are located in Jharia coalfield where more than 18 sq. km is in the grip of fire. Generally such fires are confined in areas near to our crops. About 37 million tonnes of coking coal are lost in recent yearsdue to fire and another 48 million tonnes are blocked in fire areas. Preventive measures adopted to control fires were only partially successful and the cost of such measures was exorbitant I Temperature of blast holes in fire area varies between 60 and 300° C or even more. Even after thorough quenching of holes with water, it become difficult to bring down the temperature below SO"" C. For blasting hot holes primary need is to select safe and suitable commercial explosives and detonating fuse and to measure hot hole temperatures. VWiOUs types of commercially available explosives including Nitro Glycerine bare, slurries, site mixed slurries (SMS), emulsion5 ,detonating fuses and detonators were tested to determine their thermal behaviour at elevated temperatures under field simulated conditions in the Copyright © 2000 International Society of Explosives Engineers 1993g - Studies on Safe Blasting Technique in Fire Area of Coal Mines laboratory and in hot blast holes in field . More than 50 round of blast were conducted in fire areas. NG base compositions and detonators were found unsafe at temperature above SO0 C andtherefore, they are not permitted to be used in hot holes. Slurries and emulsion are stable upto 1200 c. For blasting at temperature exceeding SO0 C a heat resistant gel/ solution was developed by the authors and is being used in number of fire areas."

Jan 1, 1993

By Zervoudis J

Limitations of current touch-up solders for galvanised steel include coating thickness control problems and poor corrosion and abrasion resistance as well as health and environmental concerns due to toxic constituents such as lead. This paper reports on progress in ILZRO-sponsored research to develop an improved touch-up solder. Encouraging results were achieved in torch soldering trials with experimental zinc-tin-based alloys. Mouldability and coating thickness control were achieved over a practical working temperature range in which the solders consisted of a viscous mixture of solid primary zinc phase particles in a liquid zinc-tin eutectic matrix. The mouldability was dependent on the microstructure of the solder sticks, and optimum structures could be obtained through control of casting solidification rates and by the addition of small amounts of copper. Hardness, abrasion resistance, adhesion and corrosion tests on experimental Zn- (40 - 50 per cent) Sn-I per cent Cu also showed improved performance over lead-tin-zinc solders and compared the effects of tin content within this range. Atmospheric corrosion testing and optimisation of alloy composition and methods of solder stick production are continuing.

Jan 1, 1993

By Y. Topkaya, R. E. Johnson, B. R. Palmer, Bruce E. Kurtz, Anatoli Omelian, John I. Choi

This paper relates to hydrometallurgical studies on the recovery of soluble aluminum values from aluminum-bearing ores, i.e., Georgia clays. At least 50% of the soluble alumina values were recovered by leaching the calcined clays from aqueous solutions, comprising simultaneously contacting a stream containing an effective amount of a reducing agent such as sulfur dioxide and a stream containing an effective amount of an oxidizing agent such as chlorine gas for a time sufficient to dissolve alumina. The recovery of alumina from this aqueous slurry of the calcined clay by leaching with sulfur dioxide and chlorine gas showed much better results than that by leaching with concentrated sulfuric acid and/or concentrated hydrochloric acid at 100O C. The leaching reactions between the aqueous slurry of the calcined clay, chlorine gas, and sulfur dioxide were strong exothermic reactions for several hours, requiring no external heating.

Jan 1, 1993

By H. Maleki

Roof falls continue to affect productivity and safety in U.S. coal mines in spite of significant increases in support utilization in recent decades. To minimize roof stability problems while controlling support effectiveness, the U.S. Bureau of Mines is conducting research on support and ground monitoring techniques. Practical implementation of this research is presented in this paper. Instruments to monitor rock mass deformation, support loads, and microseismic emissions have traditionally been used to assess roof stability. Controlled-source seismic surveys are being used as well. In this paper, measurement techniques are reviewed, and the effectiveness of deformation measurements is demonstrated. This is achieved by an analysis of deformation history from four case studies in room-and-pillar retreat mines. In spite of differences in geologic, geometric, and support conditions in these mines, roof behavior is shown to have been similar prior to failure. The rate of roof movement is suggested as a reliable indicator of roof stability.

Jan 1, 1993

By J L. Jethwa, A G. Gaithankar

The paper deals with a software method developed to design the optimum blast parameters for tunnels and mine roadways for a given set of geo-mining condition without any major discontinuity. The application of the software is presently limited to 8 D-ahaped excavation where inclined hole cut or four-section parallel cut is used with smooth blasting technique.

Jan 1, 1993

By Z. Y. Xie

The visualization techniques were employed for the analysis of computer simulation studies of dislocation core structure in ordered alloys. Atomistic computer simulation was used for the study of the local configuration of the material in the vicinity of the dislocation. Stresses were applied in the simulation in order to study the necessary stress level for the dislocation to move and onset plastic deformation of the material. The results were analyzed in terms of the strain tensor as a function of the position (x, y) in the material with the dislocation located at (0, 0). Various visualization packages are used to plot the invariants of this strain tensor and to visualize the changes that the dislocation core undergoes under stresses until it finally moves.

Jan 1, 1993

By Alan R. Buehler

The Bureau of Mines conducted a mineral investigation of the 10,500-hectare Cache Peak study area in 1992; the area had been proposed as wilderness. Bureau personnel examined and sampled prospect workings; 14 rock and 20 placer samples were taken during the investigation. The study area is centered about 40 km south-southeast of Burley. Idaho, in the Sawtooth National Forest. There were seven mining claims located inside the study area, and one additional historical mining claim location. Gold, silver, copper, lead, zinc: Possible resource, poor exposure precludes estimate. Marble: Several million tonnes may be suitable for a variety of uses; markets too distant to favor mining. Sand and Gravel: Several million m3, but markets and transportation costs do not favor mining. Quartzite: Several million tonnes may be suitable for metallurgical purposes; however, markets are too limited to mine. Slabs have been quarried at three localities adjacent to the study area, for decorative stone. Production: In 1979, two tonnes of ore were produced and a plan of operations was submitted calling for approximately 5 km of access road for the Last Chance mine. Decorative stone production was not recorded.

Jan 1, 1993

By Yu. A. Polozov, V. A. Lagunov, O. Yu. Lushinkova, Yu. I. Svirskiy, Eh. Ya. Kipko, Roy A. Williams

The integrated grouting method, as developed in the USSR, can be applied to multi-purpose operations that in¬clude the construction of shafts, drifts, and tunnels. In the USSR it has been used extensively for primary and final grouting of underground excavations in mining engineering and civil engineering projects. It has been applied in projects where the primary objective was waste contain¬ment. It has also been used to control subsidence beneath buildings located over mined out openings and to eliminate the flow of ground water beneath and around dams. This chapter considers several industrial applications in the form of case histories. The word integrated means that grouting activities were integrated with other activities. 9.1 CASE HISTORIES OF GROUTING FRACTURED ROCK WHEN SINKING VERTICAL SHAFTS The integrated grouting method has been applied most widely in the sinking of vertical shafts in fractured, satu¬rated rock. As explained previously herein, grouting oper¬ations preferably are carried out from the ground surface where they are integrated into the schedule of the setting up of the shaft excavation and construction equipment. Such integration reduces significantly the length of time required for preparation of shaft construction and the time required to sink the shaft. The increased efficiency is achieved by the elimination of cementing operations from the working face upon the penetration of each aquifer. Concomitantly, labor and energy consumption during shaft sinking are minimized because the more complicated and labor-intensive work is carried out at the surface section. Table 9.1 presents the essential parameters for the pri¬mary grouting of saturated fractured rock carried out by the integrated method when sinking vertical shafts. 9.1.1 NAGOL'CHANSK MINE NO. 1-2, VENTILATION SHAFT NO. 1 The integrated method of grouting saturated fractured rock through holes drilled from the surface was employed for the first time during the sinking of vertical shaft No. 1 at the Nagol'chansk mine No. 1-2 in the Don Basin. The shaft had an inside diameter of 6 m. The grouting operations commenced by using cement grout with a density of 1.7 to 1.8 g/cm3. Clay-based grout with cement and other addi¬tives was used only for grouting the aquifers where cement grout proved to be ineffective. By the time of the grouting of ventilation shaft No. 1, hydrodynamic analytical methods were well in hand and a preliminary method for designing isolation curtains had been developed. A method for designing and drilling ori¬ented directional drillholes whose natural curvature re¬flected the characteristics of the fracturing had been devel¬oped. The majority of the necessary equipment had been developed. Clay-based grouts were considered ready for the first industrial application. The hydrogeologic environment at the Nagol'chansk mine No. 1-2 contained many prolific aquifers. According to monitored drillhole data, the total expected inflow into ventilation shaft No. 1 without grouting was 425 m3/hr. This large ground water inflow rate was supported by in¬formation obtained during the sinking of the main shaft and from the auxiliary shaft of the "Nagol'chansk" mine No. 1-2. The construction contractor at the site began sinking ventilation shaft No. 1 to a depth of 217 m by cement grouting from the working face of the shaft. As a result of the cement grouting operations, the inflow of water was reduced from 105.4 to 40 m3/hr over this 217 m interval. However the residual inflow rate caused the shaft to become functional at the depth of 217 m. At this point all grouting operations were transferred to SPETSTAMPONAZHGEOLOGIA (STG) in an effort to improve the operation. In order to carry out preliminary grouting from the sur¬face, seven drillholes were installed and designed for re¬ceiving grout. Drilling was implemented by the ZIF-1200A rig to the design depth of the shaft. The geometry of the principal fracture system that would be encountered by the shaft was estimated while breaking ground using informa¬tion from other shafts. The drillholes were arranged so that they cut through the aquifers uniformly around the shaft. Some preference was given to intercepting the aquifers that were located along the rock dip above the shaft bottom because it was established that the ground water in the aqui¬fers flowed downward along the dip into the cone of de¬pression of the shaft. Investigations in the drillholes using the DAU-3M flowmeter described in Chapter 3 showed that all of the nine aquifers were penetrated by the time a depth of 690 m had been reached. The flowmetric information showed that aquifer numbers [1 and 2], [4, 5, and 6], and [7 and 8] had practically identical hydrogeologic characteristics; so it was decided to connect them into combined stopes and inject the grout using five stopes instead of nine. Table 9.2 shows the results of the grout injection into the aquifers. The volume of grout pumped into the separate intervals through single holes varied from 204 to 15 m3. The trend of grout consumption showed a reduction of grout consump

Jan 1, 1993

By D. A. Stanley, B. J. Scheiner

The U.S. Bureau of Mines has thoroughly investigated the flocculation of phosphatic clay waste with polyethylene oxide (PEO). The studies included both theoretical and applied aspects of the flocculation sequence. The screen dewatering technique developed by the Bureau was field tested at four different Florida phosphate mines. The results of these field studies are presented. Also, to determine the mechanisms of the interaction of PEO with montmorillonite clays common to the phosphatic clay waste, a number of theoretical studies were conducted. An empirical equation was developed to describe the amount of PEO needed for flocculation. Infrared, ion exchange, and rheology techniques were used to study the interaction of PEO with Florida clays. The results of these studies are also presented.

Jan 1, 1993

By I. D. Reznik

The flowsheets of converter matte production from sulphide copper - nickel and oxide nickel ores on Severonickel and Yuzhuralnickel integrated ,;corks are given. The cobalt behaviour in electrosmelting and autogenous ore smelting, converting and converter slag cleaning is observed. A list of acticles published in the 80 th is given.

Jan 1, 1993

Worldwide minerals exploration slipped in 1992 from 1991 levels. Although industrial production figures showed the US economy emerging from recession in early 1992, it was not until February 1993 that the lagging indicator of unemployment dropped to 7%. Most other industrialized countries are still in recession. Preliminary data for 1992 showed industrial production dropping in Japan (5%), Germany (1.4%), the United Kingdom (0.5%) and France (1.4%). The slowdown in industrial production led to reduced mineral demand. This resulted in lean cash flows from mining operations, which squeezed exploration funding. Although mineral prices were steady during most of 1992, some mineral commodity prices began falling in late 1992 and early this year. Exploration 1991-1992 According to Metals Economics Group (MEG), planned 1992 exploration expenditures were down by about 5%. Geographically, the leading exploration target was the United States with 21 % of the expenditures, followed by Australia (19%), Canada (18%), Latin America (15%), South Africa (9%) and the western Pacific (7.5%). The remaining 10% was split between Europe and Africa. There were absolute increases in exploration expenditures in the United States and Latin America. Latin America showed the largest increase. The change in the Mexican mining law allowing foreign ownership of mines should result in the inflow of direct foreign investment in Mexico's mining industry.

Jan 1, 1993

By M. H. Moys, J. A. Engelbrecht

"Large-diameter flotation columns are subject to severe axial mixing which has reduced column recovery and has generally limited it to cleaner applications. It has been assumed that columns with diameter greater than 1 m should be baffled to reduce axial mixing, but little work has been reported quantifying the effectiveness of baffling. Tests were done on a 0.2 m by 2 m column fitted with baffles of different geometry. It was generally found that the inclusion of baffles in the column worsened rather than improved mixing conditions in the column. This is explained in terms of a model for the effect of poor gas distribution on the behaviour of the column; this showed that under typical conditions a 16% excess of gas flux in the one compartment of a two-compartment column could result in one of the compartments being ""dead"" (i.e. with no net flow of slurry through it), resulting in a substantial loss of performance. The quality of mixing in the laboratory column was only reliably improved when the baffle was raised so that its top was positioned above the froth-slurry interface level. It should be possible to increase column recovery substantially with this configuration. The improved residence time distribution also means that columns can be used more effectively in roughing and scavenging applications. IntroductionFlotation columns have generally been used in cleaner applications, starting with their dramatic success at Mines Gaspe(1). Their lack of applications as roughers and scavengers is probably due to their poor residence time distribution (RID) when compared to the conventional cells they would replace. Espinosa-Gomez et al,(2) recently used them in rougher applications but installed three columns in series, presumably to cope with this disadvantage.Dobby and Finch in their seminal papersl(3,4) on the scale-up of flotation columns were the first to quantify the impact of axial mixing on the performance of industrial flotation columns. Laplante et al.(5) collected further data from the literature for column diameter D, ranging between 5 cm and 183 cm, gas superficial velocity Jg ranging between 0.7 cm/s and 2.8 cm/s and per cent solids in the feed S ranging between 3% and 52%. These data were analyzed with reference to the axial mixing model using the boundary conditions for closed vessels (the latter are more appropriate for flotation columns but the model is more difficult to use because analytical solutions for the RID are not available). The data were correlated by:"

Jan 1, 1993