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Jan 1, 1977

By P. J. G. du Toit

Coal has been mined by hydraulic means in various countries, i.e., the hydraulic excavation as well as the hydraulic transportation of coal has been practiced. The hydraulic breaking (excavating) of the coal dealt with in this report is done with a monitor directing a continuous jet of water against the coal, pressures of the water fed to the monitor range from 1500 to 2500 psi at 1000 to 2100 gallons per minute Transportation of the coal from the face is by fluming if a gradient exists in excess of 2 or, when a favorable gradient does not exist, the coal is pumped from the face by various types of pumps which can also provide a means of hoisting the coal to a higher elevation as required. This report presents: 1.) preliminary design and systems specifications of a demonstration miner (referred to in this report as a hydrominer), 2.) mining configurations showing good promise for typical U.S. thick coal seams in three seam pitch categories, (0° - 7° = Flat, 8° - 250 = Moderately pitching, 26° - 90° = Steeply pitching), along with cost and performance analyses for each system, 3.) a definition of a test program that will provide sufficient engineering data for the design of a water jet cutting head adequate to cut coal in those typical U.S. thick coal seams The cost analysis data showed hydraulic methods to be economically competitive with present thick seam raining methods. It was also obvious from studies of thick seam methods that the hydromonitor coal breaking techniques are more effective in removing most of the coal with its long reach of 60 ft. (or more), is a safer mining system, and produces very low coal-dust content in the air (usually less than 0.25 to 0.5 mg/cubic meter). It is recommended that the USBM sponsor a full fledged continuation of the hydraulic mining program: (a) lab, test, (b) preliminary field test, (c) full scale mine section demonstration.

Jan 1, 1977

By H. M. Coggin

The study summarizes the state of the art in rock mechanics, open pit and underground mining, leaching, geology, metallurgy and financial analysis Conceptual design of pit slope caving technique and analyses explore concepts for the exploitation of ore grade remnants in the walls and bottoms of open pit mines and the potential economics of the adaptations Several coded sites were examined for future studies where the feasibility of the method may be demonstrated. An extensive bibliography has been developed

Jan 1, 1977

By Robert G. Clarke

The production of natural abrasives varied in quantity and value compared with those of 1974. Output of tripoli-type materials and garnet both decreased in quantity and value. Special silica stone products decreased in quantity but in-creased in value. The production of emery increased 38% in quantity. The production of manufactured abrasive materials decreased for all types and the decreases were more in quantity than in value. [ ] FOREIGN TRADE Imports of abrasive materials were 15% less in value than in 1974, and exports plus reexports decreased in value 10%. Net exports, the excess of exports and reexports over imports, were $9.3 million, about four times that of 1974. The volume of all abrasive materials exported decreased and the value of nearly all decreased.

Jan 1, 1977

By A. C. Hawken, L. M. Strah

"The Report outlines the Conversion to Rubber Mill Liners and steel grinding balls from the old style Cobalt pocket liners and flint pebbles which had been used in 5'x22' Fraser-Chalmers tube mills for over fifty years. An outline of the past history and some of the plant modifications are mentioned as well.The details pertaining to considerations, modifications and repairs carried out on the mills are described. Factors influencing the rubber liner design are outlined along with the description of the rubber liner design.The performance and advantages to date are given and concludes with brief summary.HISTORYThe original amalgamation-cyanidation mill of Dome Mines Limited went into operation in 1912. Milling has been continuous since 1912, except for two periods; one of 17 months commencing in December 1917, and the other of about 12 months, when fire destroyed the plant in November 1929. Initially the capacity of the mill was 350 tons a day. In 1916 it was raised to 750 tons a day, following which there was a gradual expansion to 1,500 tons a day."

Jan 1, 1977

The Mascot-Jefferson City zinc mining district in eastern Tennessee has been a major zinc producer for over 60 years. The district lies within the Tennessee division of the Appalachian Valley and is underlain by folded and faulted Paleozoic rocks. The local formations are composed of limestones and dolomites with occasional shales, and sand- stones, and thin and scattered chert nodules. The regional structure of the district is unique in that it is complicated by irregular, distorted, and broken anticlines, synclines, domes, and major and minor post-ore folding and faulting.

Jan 5, 1976

Minerals are vital to any industrialized civilization. Annually, the United States uses more than 4 billion tons of new mineral materials, or about 40,000 pounds per person-about half being mineral fuels and the other half being metals and nonmetallics. Stable and economic domestic mining, mineral, metal, and mineral reclamation industries are essential to the economy. The value of United States energy and processed materials of mineral origin exceeds $200 billion annually. Although a number of minerals are imported, especially some designated as "strategic and critical," most U.S. mineral supplies are derived from the domestic mines and processing facilities that you will be seeing, reading about, and visiting as you use this visitor guide. We hope you enjoy your experiences. This pamphlet, a guide to mining and mineral operations that may be observed or visited and some other points of interest relating to minerals, is intended to aid tourists and students who are interested in mining. Some may wish to study our Nation's romantic past; others may plan to enter the minerals industry as a career; still others may have a primary interest in conservation practices. The pamphlet is also intended to aid State and local officials, Chambers of Commerce, and mining firms in answering some of the many questions of tourists and students.

Jan 1, 1976

By Lewis M. McNay

The strength characteristics of hydraulic sandfill modified by varying quantities of type III portland cement and two flocculants were investigated by the Bureau of Mines. Three different sand-cement ratios were examined using different percentages of flocculant. Two other experimental variables were curing time and weight-percent solids for hydraulic mixture. Results of unconfined compression tests with strain are discussed. Maximum strength was achieved with 0.5 weight-percent of ferric sulfate per ton of solids when the slurry mixture was 75 weight-percent solids. The bearing capacity of hydraulic sandfill is reduced by increasing the water content and decreasing the amount of cement mixed with sandfill.

Jan 1, 1976

By G. Bjorling

After complete dissolution of chalcopyrite concentrate in sulphuric acid in presence of nitric acid the excess of the latter is expelled by a surplus of concentrate and the last traces of nitrate removed in the mother liquor after crystallization of the copper and iron sulphates. Zinc accumulates in the mother liquor from which it can be removed by solvent extraction of zinc sulphate as a pair of ions. After dissolution of the sulphate crystals in water the neutral solution is oxidized in an autoclave at 140°C where iron sulphate is thermally hydrolyzed; the iron-free solution is taken to copper electrowinning and the cell acid after partial evaporation recirculated with the mother liquor to the leaching circuit. Total recovery of copper is about 96%; other metals like zinc and iron are concentrated in industrially usable products. At a copper price of about 70 c/lb, the method appears to be profitable also in a small unit.

Jan 1, 1976

By J. M. Singer

In this Bureau of Mines study coal and rock dust beds were entrained by airblasts generated by gas explosions at the closed end of a 0.61-m-diameter explosion tunnel, 49.7 m long. The system was designed to simulate entrainment of mine dust deposits by accidental gas explosion at the coal face of nonintersecting mine passageways. Full-scale mine explosion trials confirmed many of the results of the explosion tunnel experiments and indicated several new features of dust entrainment. Dispersal of 20.3-cm-long stepped dust beds located 35 m from the closed end always began during the early portion of the ascending gradient of the first transient airflow (and pressure) wave, and was usually completed before the end of the first quarter-wave period. Bulk quantities of dust were entrained simultaneously by longitudinal regression from the leading edge of the dust bed and by surface lifting of the top layer. Instantaneous threshold air velocities for bulk quantities of coal and rock dust beds in separate, mixed, and layered configurations were in the same range (5 to 30 m/sec) as previously found under steady-state velocity conditions. Selective lifting of coal dust layers from rock dust occurred when the threshold dispersal velocity of coal dust but not of the underlying rock dust was exceeded.

Jan 1, 1976

By Edward D. Thimons

The Bureau of Mines developed a stopping design that allows the stopping to be blown down by strong blast forces without incurring any permanent damage. Trials with the new stopping, dubbed the quick-fix blowout stopping, have been conducted in the Bureau's Safety Research Coal Mine at Bruceton, Pa., and in two New Mexico uranium mines. Results have been favorable in all cases. Compared with conventional brattice stoppings or wood bulkheads, the quick-fix blowout stopping is easier and less time consuming to install, is easier to maintain, and in most cases is just as efficient an air barrier. There is same indication that the shape of the stopping makes it more resistant to blast fore s than the fabric stoppings now in use.

Jan 1, 1976

By Sidney Katell

This study estimates capital investment, operating costs, and selling prices for four underground bituminous mines producing coal with annual production ranging from 1.06 to 4.99 million tons. It is assumed that the mines have a 20-year life. Wages and union welfare payments are considered as of December 6, 1974, under the Bituminous Wage Agreement of 1974, and costs for material and equipment are based on 1975 indexes. Initial capital investment ranges from $20,799,800 for the 1 .06- million-ton-per-year (MM tpy) mine to $84,027,500 for the 4.99-MM-tpy mine. Total capital investment ranges from $32,506,800 to $1 22,983,500 for the same mines. Corresponding selling prices for the coal range from $12.87 to $11.64 per ton, assuming a 15-percent discounted cash flow rate of return after Federal income taxes.

Jan 1, 1976

By C. Carlson, W. Muir

"The oxygen demand of the complex lead-zinc-iron feed at the Cyuro Anvil concentrator was determined denendent on the cyanide ion con-contration of the pulp. By redistribution of the cyanide [ ] the grinding circuit in direct proportion to the amount of surface area created, a more activated flotation feed in obtained.Monitoring the oxygen demand of the flotation feed and grinding mill discharge has proved useful in diagnosing metallurgical problems day to day operation."

Jan 1, 1976

The mineralogy of nickel slags from the flash smelter of Western Mining Corporation Ltd. at Kalgoorlie was studied. Residual magnesium silicates in the sulphide concentrates raise the melting point of the slag and result in the formation of magnesium-rich olivines. Addition of lime lowered the melting point, and, in slowly cooled slags, resulted in the formation of a pyroxene.Magnetite and sulphides were also present in all slags.The converter slags contained an olivine near fayalite in composition, together with wiistite, magnetite, and a little sulphide.Accretions from the hearth of the flash furnace were largely composed of magnetite with subsidiary olivine similar in composition to those of the flash furnace slags.Wall deposits, however, were largely composed of nickel ferrite and nickel-iron olivines.

Jan 1, 1976

To provide a faster means to open and close permissible electrical enclosures. Approach: An inspection and repair port with a multiple start thread which provides a permissible joint has been developed and tested. How It Works: The inspection port screw thread has a large pitch, which allows the port cover to be rotated from fully closed 10 fully open, in less than one revolution. See Figure 1. When the cover is screwed back in. it be-gins engagement within one eighth turn because the screw design has eight separate threads. To prevent Its unauthorized opening, the port cover has a bolt guarded by ears which accept a padlock. The threads are designed to tolerate a reasonable amount of grit without binding, although wipe-off cleanness is necessary during reassembly. Enclosures of two different sizes each fitted with the quick-access port, were

Jan 1, 1976

By James A. Powell

The theory of electromagnetic fields indicates such fields could be used to detect and locate trapped miners. To be useful, the hardware of the system must meet a number of requirements, including small size, intrinsic safety, and rugged construction. Such hardware has been built, and the system has been tested by the Bureau of Mines and its contractors. These tests indicate that the electromagnetic method provides a practical means to locate miners in emergencies.

Jan 1, 1976

By Sheridan J. Rodgers

The quantity and behavior of gases in metal and nonmetal mines were monitored to provide background information on feasibility of incipient fire detection systems. Monitoring was conducted during working and nonworking periods at intake air, return air and working places. Gases generated during diesel operations and shot firing were of particular interest. Gases which were monitored were CU, C02, N0, N02 and S02: submicron particulate concentrations were monitored also. Commercially available instruments were used and included nondispersive infrared, electrochemical and chemiluminescent types. The ratios of the various gases generated during diesel operations and shot firing were similar to those expected from an incipient fire, with the exception of the C02/NOx ratio, which is sufficiently different to be considered for early fire warning. Samples taken near leaking bulkheads showed high C02 levels and low C0 levels, the reverse of anticipated behavior in coal mines.

Jan 1, 1976

By Paul E. Richardson, Edwin E. Maust

Cyclic voltammetry and surface potential (photovoltage) measurements have been carried out on galena electrodes in sodium tetraborate solutions with added HC1 and NaOH to adjust the pH over the range 2 to 13. The first technique shows that the surface species formed on moderate anodic polarization and reduced on subsequent cathodic polarization are the same over the entire pH range. At anodic potentials, a soluble metal species and excess sulfur are formed; at cathodic potentials, sulfur is reduced to a soluble species. More importantly, excess surface sulfur is formed spontaneously under zero current conditions in alkaline solutions. This has been shown to occur on both polished surfaces and on virgin surfaces produced by in situ cleavage under the electrolyte. The photovoltage gives some insight into the charge and potential distribution at the galena surface. This is found to depend on past electrochemical history and the n- or p-type semiconducting character of the electrode and is interpreted in terms of changes in the surface stoichiometry that occur during reduction or oxidation. The effect of surface stoichiometry on subsequent xanthate interactions is discussed.

Jan 1, 1976

By Thomas A. Phillips

The Bureau of dines present, an economic evaluation of its process for the ferric chloride leaching of chalcopyrite concentrate. In this process, chalcopyrite concentrate is leached with ferric chloride solution to extract copper, which is precipitated from the solution by electrolysis while leaving sulfur in the residue. Spent liquor from electrolysis is treated with oxygen to regenerate the ferric chloride leach solution and the sulfur-laden residue is processed to recover the sulfur. A cost estimate was prepared for a plant capable of processing 600 tons of chalcopyrite concentrate per day, 330 days per year. The fixed capital cost, on an early 1.975 basis is $27,831,600 and the estimated operating cost is 9.9 cents, per pound of copper product. In comparison, the estimated operating cost of a smelter equipped with a citrate process plant to recover sulfur is about 13.6 cents per pound of copper product. No charge for chalcopyrite concentrate or credit for recovered byproducts has been included in either operating cost. The ferric chloride leach process, therefore, appears to be economically attractive.

Jan 1, 1976

By Guy Demers

"This paper defines the responsibilities and functions of the Maintenance Department, and its organization, physical and human assets, highlighting the unique operating problems. Due to the self-sufficient aspect of the Asbestos Hill Deception Bay project, the Maintenance Department cover-s fields that are numerous and very dissimilar: production, mobile, processing, service, power generation, fire protection, heating, water and sewage disposal equipment. Added to this, buildings, plant and camps, wharves and communications equipment all demand versatility, adaptability and expertise from maintenance personnel. Good maintenance practices are a necessity in this environment and are more critical than at southern locations; that is, high-quality replacement material, complete and well-controlled preventive maintenance, major repairs on a component-replacement basis, updated inventory, efficient training and permanent contacts with suppliers, combined with an equipment improvement program, updated specifications on lubricants, hoses, seals, filters, etc., are mandatory. The seasonal aspect of the operations applies a great deal of pressure on the maintenance team, as the production months do not permit major repairs. Short- and medium range planning and accurate evaluation of equipment conditions highly influence production efficiency. Maintenance control, planning and scheduling do not follow the accepted standard routines, as personnel turnover normally does not permit an accumulation of knowledge of the equipment history and condition by the •individual tradesman."

Jan 1, 1976