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By Dale S. Preece

INTRODUCTION In 1975 Congress passed the Energy Conservation Act to establish a U. S. Strategic Petroleum Reserve (SPR) with a capacity of 750 million barrels of crude oil. The most economic storage medium was determined to be salt caverns leached in salt domes in Louisiana and Texas. Salt caverns existed at several sites when the reserve was created. These were obtained by the U. S. Department of Energy (DOE) and used to initiate SPR oil storage. In order to meet the storage capacity approved by Congress, new caverns also had to be leached. To support the resulting design effort, finite element computer programs have been used to determine the creep closure and structural stability of salt caverns Using site specific material properties including creep models, elastic moduli and fracture data, the finite element analyses have replaced earlier empirical approaches to cavern design. This report presents results of such finite element analyses to determine the best cavern roof shape and the minimum pillar to diameter ratio, P/D. These numerical predictions indicate that the current cavern design is safe. FINITE ELEMENT AND MATERIAL MODELING The finite element program used in this study has existed for approximately four years. Its theoritical basis (Key, et al, 1980) and application are well documented It was originally developed to predict the creep around mined openings In bedded rock salt for the Waste Isolation Pilot Plant (WIPP) The program was tested by modeling the creep of salt around a drift and by comparing the results with the predictions of eight other structural computer codes (Morgan, et al, 1981) Since then the program has had continual use for calculations to support the WIPP (Miller, et al, 1982) For about two years the

Jan 1, 1984

By Thomas M. Barczak

The resultant load vector is the representation of the forces applied to a longwall roof support element by caving strata into a single, quantifiable measure of support resistance. The relatively complex kinematics of the shield support prohibit a determination of support resistance simply by summation of leg forces. A method is being investigated by the Bureau of Mines to determine the resultant load vector by instrumenting supports with pressure transducers and strain gages to measure leg, canopy capsule, and lemniscate link forces. This concept has been laboratory tested in the Bureau's Mine Roof Simulator. Functional relationships among variables have been assessed, and confidence intervals have been established for prediction of the resultant load vector parameters.

Jan 1, 1984

By Philip D. Shelton

INTRODUCTION Traditional design of support for permanent underground mine excavations place great emphasis on the magnitude of the maximum radial load which a specific support or lining must sustain. However, this depends upon so many factors that reliable prediction in advance of excavation is very difficult except in strong-self supporting ground. Some of the factors affecting the loads acting on a support are illustrated in Table 1. [ ]

Jan 1, 1984

By J. M. Floyd

The theory, construction and applications of oxygen sensors employing high-temperature electro- chemical cells with solid electrolytes are briefly reviewed. The application of disposable probes to measurement of the oxygen potential in matte and slag baths in tin, copper, and nickel smelting operations is described. Examples discussed include end-point determination in smelting and slag-cleaning operations, pilot-scale investigations of process chemistry to assist in the development of smelting strategies, and measurements in operating smelters to improve the efficiency of operation.

Jan 1, 1984

By Lito C. Mejia

Diesel-powered equipment operating in a gassy underground mine could conceivably ingest a methane-air mixture from the mine atmosphere that could cause the diesel engine to overspeed, or exceed its rated speed. Engine overspeed, particularly if extreme (engine runaway), could result in personal injury, a possible mine explosion, and/or catastrophic engine failure. In this report, the Bureau of Mines reviews the literature on the potential hazards of methane-induced diesel engine overspeed. Also included are the Bureau's findings from consultations with representatives of the diesel engine industry to determine the specific engine behavior that could he expected under the overspeed condition. The report summarizes data on mine accidents involving methane, discusses results of tests on the compression ignition of methane in diesel engines, and examines fuel governors and intake-air-cutoff devices, two kinds of devices used to prevent overspeed. Analysis of the information gathered suggests that the conditions necessary to cause a diesel engine to overspeed uncontrollably are not likely to occur, particularly if the engine is equipped with flame-proofing devices. The available literature and lack of actual overspeed case histories suggest that the safety devices currently in use are sufficient to prevent diesel engine overspeed.

Jan 1, 1984

By K. Yatsunami

NKK has developed a new cold bonded pellet process. The features of this process are; 1) it is a continuous process with 10 hours curing. 2) Products can be used as materials for various metallurgical furnaces. 3) Various kinds of slag are used as binders if necessary. 4) The quality of products is excellent. The pilot plant completed in 1981 is now being successfully operated. We are also constructing a commercial plant at our Niigata works. We produced cold pellets containing carbon as material for ferroalloys (Si-Mn), by pilot plant and used them in furnaces. Consequently, considerable economic advantages were obtained.

Jan 1, 1984

By Van Groenou B

Traditionally mining and conservation have been regarded as opposing and mutually exclusive concepts of land use. Often problems are anticipated which cannot be substantiated by facts. In addition, an ill defined time-scale adds to potentially emotive issues. Examples from Australia and elsewhere are presented which illustrate the dynamic nature of the environment and accentuate sequence patterns in plant community development following natural and man-made disturbances. The mining industry generally appears to be aware of the environmental impact of mining and whilst endeavouring to minimise the disturbance, is still orientated towards maximum production.

Jan 1, 1984

By Robert R. Brookshire

Brush plating has been thought of by many as black magic bordering on alchemy. Actually it is a science that uses both electro-chemical and mechanical engineering skills and technology. We are not sure when brush plating was first used or by whom. I do know that many times when we would put in for patents on things we thought of as new and innovative, we would find that someone had done it many years before. It took World War I1 to get brush plating off and running. Now at this point, someone may be asking just what is brush plating? And why are we plating brushes? One way of describing what brush plating is, is by telling what it is not such as tankless plating. Brush plating-is an electro deposition of an electro-platable element or alloy onto a conductive surface. To do this a source of direct current is required; this can vary widely. I prefer stepless voltage control from 0-35 volts with a capacity depending on the size job to be done. This can vary up to 500 amps for normal applications. In one case we have used 7500 amps.. In the beginning a brush was actually used with a wire in the middle of the bristles and a jelly-like paste made up from tank plating solutions. The bristles were saturated with the gunk and the spot to be plated was muddled with the concoction at a potential which was the same as the applied tank Voltage. Metal was deposited but only thin coats were achieved. Today we use graphite wrapped or covered with cotton to form a Q-tip type anode. By using graphite rather than a specific metal we are able to either plate, de-plate or strip, electro- mill, electropolish, or anodize--all with the same equipment. Only the electrolyte needs to be changed.

Jan 1, 1984

By P. M. Yavorsky

Using a mine roof simulator press capable of duplicating the expected magnitude of vertical and horizontal forces experienced by underground mine roof supports, load capabilities of some roof support cribbings were measured. Comparative ultimate vertical support strengths are reported for cribs of old and new timber and nonreinforced and steel-fiber-reinforced (SFR) concrete blocks. In terms of load- bearing capability, cribs of new hickory and nonreinforced concrete blocks have about equal strength, and SFR concrete blocks are three times as strong. Wood aged 2 years underground lost 43 pct of its support strength. These data were obtained during the course of the initial familiarization exercise of the complex press.

Jan 1, 1984

The following notes have been compiled to assist authors in the preparation of papers for presentation to the Institute and for publication in the Journal. All papers must meet the standards set by the Council of the Institute, and for this purpose all papers are referred to at least two referees appointed by the Council. Although the worldwide readership of the Journal results in a preference for papers in English, the Council treats papers in Afrikaans on an equal basis, but, to meet the needs of the majority of readers, an English summary of some 5OO to 750 words should be provided.

Jan 1, 1984

By D. N. Sutherland

The cassiterite flotation circuit at the Renison concentrator has operated with increasing levels of automatic control since late 1981. The circuit operates at high levels of recycle which make it difficult to control manually so that the initial control strategy was to stabilize the mass flows around the circuit prior to circuit optimization. Control of the air supplies to the flotation banks was introduced to achieve this stabilization and initial results indicated that some success has been achieved, as indicated by improvements in the overall circuit performance and reduction in the stream variabilities. These improvements were gained through control of the major recycle to the roughing stage which dominates the circuit behaviour. Feed-forward control of collector addition has also been introduced successfully, but attempts to control the final concentrate grade have been less satisfactory. This work is continuing and the objective of current activity is to include the three cleaning stages in an overall circuit control scheme as a first phase of metallurgical optimization of the operation.

Jan 1, 1984

By Johan K. Rodenburg

A major bauxite belt was discovered and evaluated from 1969 to 1974 by P. T. Alcoa Minerals of Indonesia in West Kalimantan, Indonesia. The proven reserves of beneficiated bauxite are 800 million tons averaging 38.6% AA1203 and 3.0% RSiO2. Inferred reserves of washed bauxite are in excess of 2 billion tons. The bauxite occurs as capping of low lying hills which were formed during the post Paleogene peneplaination stage. The overburden varies from 0.6 to 3.8 meters and the nodular bauxite horizon from 2.2 to 5.2 meters. The deposits were formed by the in situ weathering of predominantly acidic and basic intrusive rocks.

Jan 1, 1984

The captions to Figs. 1 and 2 of the paper by B. J. Parry entitled 'High-strength cold-rolled steels' should read as follows:

Jan 1, 1984

By Gregg A. Scott

Upper Stillwater Dam is to be a roller-compacted concrete gravity structure, founded on nearly horizontally bedded sandstone and argillite rock. An overview of the testing and analyses used to evaluate the adequacy of the foundation relative to deformation, seepage, and stability is presented.

Jan 1, 1984

By David Sugden

Intense, tropical weathering of Cretaceous-Tertiary sediments has developed similar laterites in distant areas of the Amazon Basin. In two areas, Trombetas and Paragomina s, bauxites of commercial potential arc found. The bauxite comes mostly from the lower horizon of the three component laterite. The laterite is overlain by a clay cover, possibly an integral part of the weathered profile. The laterites are found on almost flat plateaus with individual areas of up to 80km2. There is a close relationship between the morphology and the ldterites. The process of lateritization is allegedly Pliocence but probably continues today.

Jan 1, 1984

By Kittitep Fuenkajorn

Ring tension tests, permeability tests, and microscopic fracture studies have been performed to investigate the damaged zone induced by drilling (diamond, percussion, and rotary) in the borehole walls. Specimens are drilled with three different hole sizes (38, 76 and 102 mm diameter) in Pomona basalt and Grande basaltic andesite. The thickness of the damaged zone ranges from 0.0 to 1.7 mm. A larger drill bit induces more wall damage than a smaller one. Different drilling techniques show different damage characteristics (intensity and distribution). Damage characteristics are governed not only by drilling parameters (bit size, weight on bit, rotational speed, diamond radius, and energy), but also by properties of the rock. The weaker rock tends to show more intense damage than does the stronger one. Cracks within grains or cleavage fractures are predominant in coarse grained rock (larger than 0.5 mm grain size) while intergranular cracks are predominant in fine grained rock (smaller than 0.01 mm grain size). The influence of the damaged zone on the permeability of the rock around the hole is investigated by permeability tests.

Jan 1, 1984

By Gary L. Hundley

The Bureau of Mines has devised and demonstrated a process for recovering Ni and Co from low-grade domestic laterites. The process consists of four major steps: (1) reduction roast, (2) ammoniacal leach, (3) solvent extraction, and (4) electrowinning. Several solid-liquid separation steps are required that affect the economics of the overall pro-cess. In this study, two techniques for solid-liquid separation, centrifugation and thickening, were investigated. This report presents the results of (1) laboratory and pilot plant studies to determine parameters for sizing centrifuges and thickeners and (2) an economic study of the two techniques, based on the requirements of a commercial-size (5,OOO-tpd) laterite processing plant. Sizing and other equipment-related recommendations, based on data from the Bureau's studies, were obtained from commercial manufacturers. The costs of thickening and centrifugation, including all the unit operations affected, were determined by the Bureau's process evaluation group. The total operating costs ~or separation using the two techniques (including depreciation on the capital cost of equipment) were found to be quite close: $17.26 per ton of laterite for centrifugation and $18.15 per ton of laterite for thickening. For centrifugal separation, the greatest cost was found to be the initial capital cost for the separation equipment; using thickeners, the greatest cost was for re-agent recovery.

Jan 1, 1984

The paper describes the reasons for the development and for the selection of systems which were finally adopted; further estima- tion and design engineering problems, as well as experience with large screens in operation. Advantages, disadvantages and the final li- mits of screen dimensions are indicated.

Jan 1, 1984

The ER&S Company operates a copper sinter plant, blast furnace and converter smelting complex at Port Kembla. Eighty percent of the smelter feed is dirty copper concentrates that contain some lead and zinc. The remaining twenty percent of the smelter feed is copper bearing secondary materials, some of which contain lead, zinc and tin. A predominately lead/zinc fume is produced during the smelting and converting of this feed mix. The composition and tonnage of fume produced at Port Kembla has varied over the years as the smelter feed sources have changed. The economic processing of the fume has always been dependent on the value of the metals contained in the fume and on the fume composition. Both pyrometallurgical and hydrometallurgical methods have been used to treat the fume for the recovery of some or all of the following metals - lead, zinc, tin, copper, cadmium, silver and bismuth. A detailed description of the treatment methods that have been investigated and used to process ER&S fume is given.

Jan 1, 1984

Crossroads for Students Students in their matriculation year, whatever their background, have reached a crossroads in their lives: behind them lie the relatively carefree years of childhood; ahead lies the whole of their working lives. Whether those working lives will be rewarding and interesting depends to considerable extent on whether they get 'a good matric' and carry on to some form of further education. IPMI awards 1985 Nominations for the 1985 Awards are now being accepted by the Awards Committee of the International Precious Metals Institute. THE DISTINGUISHED ACHIEVEMENT AWARD was established to recognize important career contributions to the advancement of precious metals, be it technological, economic, or business.

Jan 1, 1984