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By Esteban M. Domic

"T.L. Leaching ProcessCommercial PerformanceSociedad Minera Pudahuel Ltda. (SMP) has been innovating in the copper producing field with the commercial application of the Thin Layer (T .L.) leaching process in its two operating division s: Lo Aguirre and La Cascada. Since November 1980, SMP' s Lo Aguirre Division has been producing high-purity copper cathodes at a nominal rate of about 16,500 metric tonnes / year, by mean s of the new route of T.L. leaching, followed by solvent extraction and electrowinning (TLlSX/EW). This has been the first commercial application on T .L. technology in the world, and the only commercial application in Chile for solvent extraction and electrowinning.By mid -1980, SMP acquired Sagasca Mining Co., renaming it as La Cascad a Division. The existing vat leaching facilities were modified to apply T.L. in the same old vats. The existing scrap iron cementation recovery circuit was kept running for the continuing production of copper precipitates. The modifications in the leaching circuit allowed shorter treatment cycles with a lower acid consumption and consequently, copper product ion increased from a previous historical high of 12,000-13,000 metric tonnes /year to a new level of about 22,000 metric tonnes/ year . These changes have been in operation since March 1981.T.L. Leaching commercial performance, both at Lo Aguirre (TL / SX /EW) and at La Cascada (TL/cementation), has been presented in several recent publications. Real operating parameters and process requirement s were reviewed in detail. A breakdown for TL / SX/ EW economics was also published based on Lo Aguirre' s performance during 1982(41."

Jan 1, 1986

By Noel N. Moebs

Coal mine roof failure is categorized according to character, trend, or pattern of occurrence. Two principal categories of failure are proposed--geology related and stress related. Geology-related failure includes both lithology and structure. Each of several subcategories reflects the probable cause of failure and thereby provides a basis for the selection of appropriate techniques for reducing the incidence of failure. These control techniques, depending on local conditions, may include supplementary support, destressing, reduction of mine air humidity, or a change in the customary support methods.

Jan 1, 1986

By G. W. Elger

The Bureau of Mines investigated the conversion, at both laboratory and pilot plant scale, of a low-grade ilmenite to chlorination-grade feedstock that could substitute for imported rutile used to produce titanium tetrachloride. The concentrate was derived from the Tahawus, NY, lode deposit of ilmenite-magnetite in rock that contains anorthosite and gabbro. Charges of the ilmenite concentrate, containing 46.6 wt pct Ti02 blended with soda ash, were carbothermically reduced in an electric arc furnace, which separated most of the iron and left a high-titanium slag. However, the slag contained Ca, Mg, and Mn constituents that rendered the material unsuitable for continuous chlorination by causing plugging problems. After being ground and pelletized, the slag was reacted with S02 and air at 7000 to 9000 C, which selectively converted the harmful impurities to soluble compounds that were removed in a subsequent water or dilute HCI leach. In laboratory tests, the combined levels of harmful impurities were decreased from 5 to as low as 0.5 wt pct in leached slags. In pilot plant tests, leached slags sulfated at a rate of 10 lb/h averaged 85.5 wt pct Ti02 with pertinent impurity levels averaging 1.86 wt pct. The leached slag was successfully chlorinated in a laboratory fluidized-bed reactor at 9500 C to extract titanium as TiCI4.

Jan 1, 1986

By B. Pollack, L. G. Stevens

INTRODUCTION In other chapters of this volume many of the important technical aspects in the design of concentration and dewatering circuits have been discussed. This chapter will deal with the steps necessary to bring that information together in order to produce the specifications necessary to purchase the equipment and complete the design. It deals with the plant as a whole rather than just concentration and dewatering, since the steps are essentially the same. Prerequisites to Engineering Design Feasibility studies will have been completed and design parameters established prior to the start of the engineering design stages for a metallurgical plant. The data base for the feasibility studies will have included laboratory and/or pilot plant test work, historical data, proposed plant site data such as climatology, topographic mapping, geological and geotechnical information. These studies will have established the general project design criteria as well as the process design criteria leading to the preparation of preliminary flowsheet ( s) and/or alternative process flowsheets. These will have incorporated metallurgical and material balances, allowing identification of major equipment items, and development of preliminary plant site plot plans. Preliminary technical and economic assessments and recommendations will have been prepared during this phase for Owner's review and evaluation of the technical, physical, and cost effectiveness of the overall project and its component process, process facilities, and supporting facilities elements. After Ownert s approval and decision to proceed, the engineering design can be initiated, using the above information as the basis. Engineering Design Phase The engineering design of metallurgical plants and their elements are generally developed in two sequential stages, namely: (1) Basic ("Front end") Engineering Design (2) Detail Engineering Design Figure 1 relates these engineering stages to the entire program from feasibility through construction.

Jan 1, 1986

By Paul S. Goodman

This report examines the feasibility of Employee Assistance Plans for the coal industry. Three issues are examined in detail. First, the prevalence of off-the-job factors such as alcoholism, drug abuse, and marital problems are examined in a sample of miners from the eastern, midwestern, and western underground coal fields. Then data were presented that examined the link between these off-the-job factors and behaviors critical to the mines such as absenteeism and turnover. Lastly, we examined the effectiveness of the major Employee Assistance Program in underground coal mining--the HELP Program. The report contains recommendations on whether coal mining companies should implement these programs and how these programs should be designed.

Jan 1, 1986

By Z. T. Bieniawsk, C. A. F. F. Santos

The effects of artificial weathering on the mechanical properties of the Loyalhanna sandstone have been investigated. Weathering was simulated in the laboratory by subjecting cylin- drical specimens of rock to alternate cycles of wetting and drying (in distilled water at 2O0C 2 5OC and in an electric oven at 105OC t 1°C, respectively). The total number of cycles was 100 and the geomechanical characteristics of the altered material were determined through uniaxial compressive and indirect tensile ("Brazilian") tests, with the determination of axial and trans- verse strains and monitoring of acoustic emission activity (rate and total event count). Moisture content and weight loss data were collected after each cycle and the mechanical parameters (unconfined strength, indirect tensile strength, young's modulus, Poisson's ratio, permanent set and AE/MS activity) were determined for unweathered specimens and after 10, 20, 50 and 100 cycles of wetting and drying. Hypotheses for the effect of weathering on the geomechanical properties of the Loyalhanna sandstone are proposed as reinforced by petrographic analyses carried out for the different stages of artificial weathering. A methodology for assessing the degree of physical weathering of rocks is proposed based on the number of wetting and drying cycles.

Jan 1, 1986

Holla has given a good background to the various methods of subsidence control in the coalfields around Sydney.The present writer notes that in many cases, especially with wide longwall panels, there is not the flexibility to alter the mine layout as there is to some degree with the various pillar extraction methods. For this reason it may not be possible to plan the workings to minimise subsidence and some damage to structures may occur. The cost of repair or the cost of subsidence provisions to minimise damage may be small in relation to the tonnages of coal which would otherwise have to be sterilised. One method of subsidence control which has been in use in the Newcastle area since 1970 is the panel and pillar layout (partial extraction layouts with stable pillars). An extracted panel width of 0.6 times the depth of cover resulted in a maximum subsidence of 115 mm for an extracted seam thickness of 2.2 m.As Holla points out, the extracted panel widths in relation to th depth of cover depend on the particular geological setting. His Fig. 3 shows that the subsidence over a panel width of 0.3 times the cover depth in the Southern Coalfield is the same as over a panel width of 0.55 to 0.6 times the cover depth in the Northern Coalfield.Selective pillar extraction and longwall mining can both be used in the panel and pillar layout. Holla's Figs 2 and 3 are used to estimate the maximum subsidence over an extracted panel of known geometry. Maximum subsidence is related to seam thickness. What provision is made for a reduction in subsidence due to the coal which remains behind in a pillar extraction panel if the pillar recovery is poor? The writer suggests that an effective seam height could be used, based on the actual mining height reduced by a factor to account for the percentage recovery of coal from an extracted panel.

Jan 1, 1986

By Scott K. Palm, Neil D. Pearson, Jr. Read

"Uncertainty is an important feature of many investments, but it is especially important for mineral properties. Mine properties often entail large investments and fixed commitments. Managers in the mining industry often view price uncertainty as undesirable, due to the possibility that the price of the mined commodity will fall to a level that prevents the firm from recovering its investment and fixed costs. This paper identifies pitfalls in conventional valuation methods and outlines a new approach to valuation based on option pricing theory and dynamic programming. In the process, it identifies generic strategies for organizing mine production in ways that allow the owner to benefit from the uncertainty in mineral prices. IntroductionRisk is pervasive in the mining industry. The operation and maintenance of a mine may involve high, and unavoidable, fixed costs. A mine owner can only begin to recover these fixed costs if the price of the mined commodity is greater than the incremental cost of production. But the prices of many minerals are extremely volatile. The price volatility of copper has been significantly higher than the price volatility of a typical stock, for example. A mine owner cannot be sure that the price of the mineral product will remain high long enough for the firm to recover its capital and fixed costs.Mine owners are able to minimize their losses during periods when the output price is below the incremental cost of production by temporarily closing operations. During these periods they incur only fixed costs. While shut-downs help minimize losses, the y do not help the firm recover its initial investment. If output prices remain low long enough, the fixed costs and original investment may never be recovered. High fixed costs, therefore, lead to substantial downside risk."

Jan 1, 1986

By T. J. Yeomans

"The Kidd Creek metallurgical site is situated twenty-six kilometres east of Timmins, Ontario. The site consists of a 4.5 niillion tonne per year concentrator, a 127,000 tonne per year electrolytic zinc plant and a 79,000 tonne per year copper smelter/refinery complex.The concentrator commenced operations in 1966 and was expanded to its present capacity in 1978. The zinc plant commenced operations in 1972, and the copper smelter/refinery in 1983.The concentrator tailings, and both liquid and solid waste products from the other plants are disposed of within a 1215 hectare tailings disposal area. Here, a method known as centraljzecl thickened discharge is used to form a stable cone-shaped hill. A low permanent perimeter dyke structure encloses the cone and directs cone run-off and thickener overflow to a treatment pond. After treatment with lime slurry, this neutralized effluent is recycled to the metsite and also discharged into the Porcupine River system.The tailings system has been in operation in its present form since 1972, upon completion of dykes and a 110 metre thickener unit. Underflow densities were continuously increased until thickener overloading became a serious problem. This necessitated the construction of a second 110 metre thickener, which was completed in 1983. Target densities have been achieved without difficulty since then.This paper discusses the operation of the tailings system, reviews past performance, and outlines future operations."

Jan 1, 1986

By George E. Aiken, B. R. Jr. Waples

INTRODUCTION In this paper the author will attempt to bridge from the paper work of design and engineering to the reality of implementation. Certain facets of construction are constant to a successful project, no matter the level of technical complexity. Basic to timely, low cost construction are the people assigned to the project. Construction is not accomplished by robots, computers, or speeches; but rather by people. People do however require the avail- ability of equipment and communications to properly complete the work. ORGANIZATION Good organization is the basic requirement of a well implemented construction project. For this paper the author will suggest an organization chart as well as an activity listing that together support the construction activities. There is little difference in the activities or functions needed to construct a small plant or a large one. It is a matter of how much time an individual has to spend on an activity that determines the structure of an organization. The difference between a large and small plant construction job is often described as the multiple hat versus the single hat philosophy. As an example, a resident construction manager on a small job might be the manager, the field engineer, the scheduler, the estimator, and the procurement manager. At some time during a construction

Jan 1, 1986

By F. F. Langford

"The Athabasca Basin occupies about 100,000 km2 of the northwest corner of Saskatchewan with its western margin extending about 50 km into Alberta (Fig. 1). The basin is filled with a Helikian sequence of predominantly fluvial sandstones up to 1600 m thick. The sandstone beds are generally flat-lying, and rest unconformably on a crystalline basement which consists mostly of granitic intrusive complexes and quartzfeldspar- biotite gneisses. The basement rocks represent Aphebian sediments and Archaean basement rocks that were metamorphosed and remobilized to varying degrees during the Hudsonian Orogeny (ca 1800 Maj.Since 1968, three mining camps and several substantial unconformity-type uranium deposits have been discovered in the area (Figs. 1 and 2). These deposits lie along the unconformity surface, partially enclosed in sandstones, and partially in the basement rocks. The major deposits have elongate, pencil shaped orebodies that are parallel to the strike of underlying graphitic biotite gneisses. The total tonnage of uranium is in the order of 150,000 to 200,000 tonnes and mining grades range from 0.5 to 2.5 per cent U3O8.IntroductionUranium exploration started in Saskatchewan in 1945 when Jolliffe and Murphy headed field parties to investigate uranium occurrences on the north shore of Lake Athabasca (Kupsch, 1978). Their investigation lead to the development of the Beaverlodge camp in the following years. Some of the early prospectors were impressed by the fact that the uranium occurrences at Beaver lodge were centred on a thick sequence of unmetamorphosed arkosic redbeds which are now called the Martin Group. This sequence was referred to as the Athabasca Series by Christie (1949), and although some occurrences of uranium were found near Stony Rapids and Black Lake, the vast expanse of Athabasca sandstones south of Lake Athabasca was generally regarded as unpromising."

Jan 1, 1986

By D. A. Stokes

"In October of 1980, Fording's 15 000-ton capacity clean coal silo was put into operation. The silo was unique in that it was designed to allow the mass flow of material, coupled with a sophisticated computer-controlled dynamic loadout/weighing system.On May 1, 1982, an explosion, attributed to a methane buildup, devastated the top of the silo. .As a contingent plan to minimize the effect of the production loss the conveyance to the silo top was reconstructed and the silo' was back in operation by mid-June 1982, although the silo top was left open to prevent further methane buildup. As dust emissions occurred during loading ofthe silo, an extensive study was undertaken to establish dust control for the silo, while at the same time providing methane detection and control.The study, conducted for Fording by the Cambrian Engineering Group of Calgary, involved an extensive search and investigation of existing coal silos. The study concluded that there IS no universally accepted method of controlling methane emissions in coal silos.The study also produced a unique conceptual design for handling methane, while at the same time, protecting the environment . Fording's Clean Coal SiloThe silo, located at Fording Coal's Fording River metallurgical coal operation, is utilized for the storage and load out of cleaned thermally-dried metallurgical coal.The silo was constructed in 1979 and 1980 to reduce unit train loadout times and to facilitate the handling of “special shipments"" of coal. The silo went into operation in October 1980, under manual control and utilized computerized, automated loading by February 198I.The silo is 21 m in diameter and 76 m high, with a nominal capacity of IS 000 live tonnes. The coal storage portion of the silo is 21 m in diameter and 48 m high, utilizing 2 steep-angled hopper outlets allowing mass flow of the stored coal during train loading. Each hopper has a control gate and a discharge chute, one chute for bulk loading, the other for trim loading of coal into the rail cars."

Jan 1, 1986

By Jon Holder, Brann Johnson

Pore-fluid/rock chemical interactions on both short and long time scales can produce significant pore structure and mineralic changes that can markedly alter transport properties, such as fluid permeability. The introduction of the chemical factor requires modification of experimental systems and methodologies developed for measurements in which chemical effects are minimal. Particular attention must be given to temperature effects, fluid chemistry, fluid/rock reactions and kinetics, fluid flow rate, and fluid/experimental-system reactions. The ability to obtain very low, steady flow rates at constant fluid pressure is important for study of some fluid/rock systems. Minimization of metal corrosion is of paramount importance and requires choice of proper metals, such as titanium, and certain Ti-alloys and Ni-alloys. In this paper, we briefly discuss the relevant chemical factors affecting system and experimental design. The primary focus, however, is on the characteristics of highly corrosion resistant metals, thermal and chemical resistant jacketing materials, and the attributes and limitations of various flow-rate and back-pressure control systems and flow-rate measurement systems.

Jan 1, 1986

The value of domestic raw nonfuel mineral output in 1985 was estimated at $23.7 billion, 2% above the 1984 value of $23.1 billion. This crude mineral output was the basis for approximately $244 billion worth of processed materials of mineral origin. [ ] A U.S. company permanently closed its alumina plant in St. Croix, U.S. Virgin Islands, reducing domestic alumina capacity by 10%. Another U.S. company sold its 26% interest in an alumina plant in Jamaica to its two U.S. partners. On completion of the purchase agreement, the two remaining partners promptly closed the plant for an indefinite period, citing a world oversupply of alumina and unacceptably low prices.

Jan 1, 1986

By James R. Boyle

The value of Alabama's nonfuel mineral production in 1984 was $409.8 million, and established a new record high for value of nonfuel minerals in the State, at 13.4:% over the previous high of 1983. Output of nearly all nonfuel minerals increased; phosphate rock was one of the exceptions, with no recorded output in 1984. Cement, crushed stone, lime, sand and gravel, and clays were the major commodities produced in Alabama. Alabama led the Nation in the production of crushed marble; was second in bauxite; third in fire clay and kaolin; fourth in bentonite, ferroalloys, and dimension marble; fifth in masonry cement, lime, and recovered sulfur; and sixth in portland cement. Alabama ranked 22d in the Nation in value of nonfuel minerals produced.

Jan 1, 1986

By Mark R. Pettitt

The charter of this investigation was to identify and promote the application of noise control technology to future longwall mining machinery. Intensive noise and vibration data were acquired on a typical longwall shearing machine, and the highest noise levels were shown to radiate from the cutter drums. Shearing machine cutter drum noise control techniques that take advantage of the nature of the dynamic forces generated during coal cutting were developed. These include both structural redesign and force isolation techniques. A reduced noise cutter drum was developed that achieved a 5 to 6 dBA system noise reduction at the operator's position. Its operational performance was verified by a six-month long in-mine test. It was evident from the data that additional noise reduction could be achieved by treatment of the shearing machine hydraulics. Noise control of secondary sources was also investigated. A method of reducing full or empty stage conveyor noise (and continuous miner conveyor noise) by 5 to 10 dBA was demonstrated through isolation techniques. Underground mine durability testing, however, is yet to be demonstrated.

Jan 1, 1986

This briefing was sponsored by the Bureau of Mines to summarize ongoing and recently completed chromium-chromite research and resource assessment activities by the Bureau. Through the series of 18 presentations compiled herein, Bureau personnel covered a wide range of topics including U.S. chromite and chromium trends and usage patterns; foreign and domestic resources; and research activities on mineral characterization and beneficiation, chemical and pryometallurgical processing of chromite and chromium-bearing wastes, new low-chromium alloy and coating substitutes, corrosion- and oxidation-resistant stainless steels, and chromium-containing refractories.

Jan 1, 1986

By John M. Popovich

Disposing of coal mine waste at the surface has been and continues to be a problem which has yet to be resolved within the coal mining industry. A possible solution to this problem is to return the refuse back into the operating underground mine generating the waste material. It is believed that the approach described will provide an inexpensive and pratical solution to the problem. The designed system is installed and operable at the Millers Cove Energy Company, Inc. property in Lee County, Virginia. This system limits surfact facilities to a minimum size. It incorporates state-of-the-art hydraulic transport and backfilling technology and equipment to systematically backfill areas within the active mine. It maximized the benefits of reducing treatment of coal wasts while it minimizes environmental impacts on groundwater. The system approaches the problem in a manner to maximize benefits and minimize risks. The cost of returning coal waste back underground at the Millers Cove site is estimated at $0.67 per ton of marketable coal (1982 dollars), which is slightly higher than their surface disposal cost of $0.61 per ton of marketable mat (1982 dollars). The underground disposal costs do not include cost savings that should be realized within the preparation plant and treatment facilities at the surface. Preliminary tests of the system were conducted at the surface; funding restrictions prevented an in-mine trial. Efforts should continue to demonstrate the feasibility of solving the problem of refuse disposal. The installed system and plant at Millers Cove should provide the opportunity to test an underground disposal operation. This report contains guidelines to pursue this opportunity.

Jan 1, 1986

Research 86 highlights significant studies conducted during the past fiscal year at Bureau facilities and offices. Readers who want more information about the projects and studies summarized here can contact the researchers whose names and locations appear with each summary. General information on Bureau of Mines programs is available from the Office of Technical Information 2401 E Street, NW., Washington, DC 20241. A listing of principal officials, a location map of field facilities, and a selected bibliography of publications and patents issued on Bureau developments during the past 3 years are provided.

Jan 1, 1986

By M. E. Adam

This report describes the construction and testing of large (30 ft high by 55 ft wide) stopping and overcast structures in an oil shale mine. The work was undertaken to develop construction techniques and cost data, and to measure leakage rates on full scale structures in an oil shale mine. A design data base was developed by reviewing industry practice, oil shale industry plans, and technical literature. Alternate layouts for room and pillar mining were examined to find ways to reduce the size and number of ventilation control structures. Six full size stoppings and one overcast were built in the Colony Pilot Mine. Leakage rates were measured using both SF6 tracer gas techniques and the ?brattice window? method. The leakage was measured both before and after a full scale face blast. Blast air pressures were measured across two of the stoppings. Cost and leakage data were used to evaluate the projected overall performance of various combinations of the stoppings in a two-panel oil shale mine.

Jan 1, 1986