Search Documents

By W. A. McCurdy, Joseph W. Leonard, William F. Lawrence

INTRODUCTION Utilization from the Point of View of the Preparation Engineer The primary interest of the coal preparation engineer is in process design, operation, and maintenance to produce an acceptable product that can be sold at the greatest possible profit. Because of emphasis upon these interests, attention to other potential values of coal is sometimes neglected. The intent of this chapter is to alert the preparation engineer to the utilization possibilities of the product as well as the tributary coal flow moving through a modern coal preparation plant. The basis for any unrealized potential derives directly from the coal seam itself. Most coal seams consist of coal bands and benches sandwiched together in layers that differ visually from each other in physical structure and luster. Randomly selected physical and chemical ranges determined from layers of coal in a single seam can easily differ by as much as 30 Hardgrove grindability indices, 0.30 of a specific gravity point, 20 percentage points of ash, 6 percentage points of dry volatile matter, and 10 percentage points of total su1fur.l Similar wide variations exist for calorific value, seam moisture content, and, undoubtedly, for any other conceivable coal test parameter that might be used for comparative purposes. These observations all point to the long-established fact that coal is not homogeneous, as conventional analytical methods might tend to indicate, but is instead a highly heterogeneous substance.

Jan 1, 1979

By Ed L. Reed

INTRODUCTION The most efficient development of a mine plan for in-situ leach (solution) mining must be based upon an understanding and application of the basic hydrologic characteristics of the aquifer containing the mineral values. Similar knowledge of the overlying and underlying aquifers is also required. This paper summarizes the hydrologic properties of a ground water system and describes some of the more important conclusions that can be drawn from a detailed hydrologic study. Basic to an in-situ leach mining operation is the flow of fluids through porous rock from place to place. The degree to which these movements of fluids can be predicted and controlled determines to a large extent the efficiency of the ore recovery operation. HYDROLOGIC CHARACTERISTICS The principal hydrologic characteristics of a porous medium (sand, intercrystalline or vuggy limestone, fractured basalt, etc.) influencing fluid flow are: Porosity Permeability Thickness Transmissivity Storage Coefficient Water Table or Piezometric Surface Hydraulic Gradient Briefly these parameters can be defined as follows: Porosity: the void space in a unit volume of rock. Permeability: the ease with which fluid will flow through a porous medium. Thickness: the height of the formation which contributes flow to a well. Transmissivity the product of permeability and thickness. Storage Coefficient. the volume of water released from the reservoir per unit drop in head. Water Table or Piezometric Surface: the level at which water will stand in a well: the top of the zone of saturation in a gravity aquifer; the height to which water will rise above the confining bed in an artesian system. Hydraulic Gradient the direction and rate of dip of the water table or piezometric surface. A properly designed pumping test will provide numbers for transmissivity, storage coefficient and the water table or piezometric surface. Drilling records or bore hole logs provide aquifer thickness data from which permeability can be calculated. Ground elevations applied to measured depths to water enable one to calculate the direction and rate of dip of the water table or piezometric surface. Porosity can be determined from core analyses or density logs; it can be estimated from grain size distribution curves in sands or sandstones and from, microscopic examination of drill cuttings derived from carbonate aquifers. CHARACTERISTICS OF FLUID FLOW The characteristics of fluid flow that are vital to an understanding of leach mining include: Velocity Direction Flow Path Radius of Influence The velocity of fluid flow is of paramount importance in planning and managing a leach mine operation. Velocity is directly proportional to the permeability and hydraulic gradient and indirectly proportional to the effective porosity The permeability determined from a pumping test is an average value for the interval stressed; therefore, the velocity calculated from data derived from a pumping test represents average conditions. Under actual conditions discrete portions of the aquifer open to the screen may have permeabilities several times as high as the average and minimum permeabilities only a fraction as much. An injection front will be irregular to the extent that the reservoir rocks are heterogeneous An important consideration is the direct relationship of velocity to head. A reservoir which would provide a velocity of 0.05 feet per day under conditions of equilibrium would allow fluid flow of 36 feet per day under typical leaching operations, i.e. 12-foot injection head, 12-foot pumping level and 50 foot five-spot pattern. The direction of fluid flow is also vital both inside and outside the mine area. In the pattern area the direction of flow is determined by the geometry of the well field and can be approximated by mathematical modeling techniques. Outside the well field, the direction of flow is influenced by both natural conditions and the degree to which production and injection volumes are balanced. Flow directions (and velocities) are critical to an understanding of leachate excursions and their control.

Jan 1, 1979

By W. E. Foreman, James A. Redding

INTRODUCTION Screening is a mechanical process that separates particles by size. Modern coal preparation is made possible by efficient sizing. Sizing of coal is defined in terms of the opening through which an individual particle will or will not pass, or as two openings, the larger of which passes the particle and the smaller of which retains the particle. Screening accomplishes sizing by passing coal of a wide range of sizes through a series of screens, each of a decreasing size. The individual screen discharges are then directed into different screen products for subsequent sale or processing. Screening in modern preparation plants is done for the following reasons: 1 ) Removal of fine coal before a size reduction step. 2) Size separation of the coal into a coarse and fine fraction for sized products or processing in coarse and fine coal circuits. 3) Recovery of heavy media from heavy media coal cleaning circuits. 4) Dewatering. 5) Rock and trash removal by handpicking on a screen. Fig. 8-1 is a generalized flowsheet of a plant showing the use of screens in the coal preparation process. Table 8-1 shows the vibrating screen equipment utilized in Fig. 8-1

Jan 1, 1979

By R. H. Cox, A. S. Allen, James Paone

The southwestern Illinois communities of Belleville and Maryville lie within the greater metropolitan area surrounding St. Louis. Missouri. They also lie within that part of the Illinois coal basin where the Number 6 coalbed has been mined for more than a century. About half the coal was left as pillars to support the ground surface. Years later, however, damaging movements are affecting buildings, streets, and public utilities in some areas. They are generally believed to be related to abandoned mine workings. The threat of continued or increasing incidence of damage raises the need to explore other subsidence-control measures for protecting affected areas with high population density. Because of experience gained in a subsidence-control program of backfilling abandoned coal mines in the Applachian region and in Rock Springs, Wyoming, the Bureau of Mines was called upon to investigate the subsidence occurrences at Belleville and Maryville, and recommend protective measures. Funds ware appropriated for the Bureau to initiate subsidence-control projects at two residential sites in Belleville and one in Maryville. Subsurface investigation of the sites by diamond core drilling revealed two conditions that differ from those encountered at most sites of previous subsidence-control projects. The mine workings were found to be dry and the mine floor consisted of soft underclay which characteristically loses strength with increase of moisture. It had been anticipated that water would have percolated into the mine workings at one .or more of the sites through cracks resulting from subsidence. Under such conditions Bureau engineers believed that injection of mine waste by the pumped; slurry technique3 would provide support and stabilize any movements initiated by the softening of the clay. With discovery that the underclay deposits at the three sites have apparently not been exposed to water since the mines were operating, hydraulic backfilling of any type was considered inadvisable on the basis of present knowledge. To avoid introducing water, a portable pneumatic system is being devised for injecting minus 0.01 27 m (1/2 in.) mine waste into the mine workings. Machines for pneumatic backfilling have been used in Europe not only for subsidence protection but also for strata control, for reducing spontaneous combustion and methane accumulation, and as a means of waste disposal. The Bureau experimented with a pneumatic machine in the Northern anthracite field of Pennsylvania in the 1950's. Previously pneumatic machines have been installed in active mine workings discharging from horizontal pipelines which conveyed air- borne material into rooms to be filled. In the present adaptation to abandoned mines, the machine and air compressor will be operating at the surface, to impel material vertically down injection boreholes with sufficient air pressure to disperse fill material laterally in mine workings at the base of injection holes. Large diameter access and ventilation boreholes will be provided at one site for entry into mine workings to observe backfilling progress. The Belleville and Maryville projects are part of the Mined Land Demonstration Program of the Bureau of Mines. The Illinois State Geological Survey and Department of Mines and Minerals are furnishing technical support.

Jan 1, 1979

By Thomas R. Couzens

This chapter covers certain aspects of open pit production planning based on experience, pointing out approaches to planning that may help produce a realistic picture for evaluation and operation The subjects discussed are roads, preproduction stripping, dump planning, dewatering, the relationship of production planning to equipment selection, and computer methods for the short-range or operational pit planning process Actual determination of ore limits, pit design, and production schedules are covered in other chapters This discussion is somewhat general. Specific problems that occur in mine planning are extremely varied, and it is not possible to cover many of them in a chapter, therefore, only some of the principles that are important in the approach to open pit production planning problems will be discussed.

Jan 1, 1979

By Nathaniel Arbiter

INTRODUCTION Almost seventy-five years ago problems in the recovery of sulfides from then designated slime fractions were the impetus for the development of flotation. The fall-off in recovery by gravity methods below about 200-mesh, and the shift from coarser vein deposits to more disseminated ores, particularly for copper, provided the background for flotation's rapid advances. Although the ensuing years have witnessed major improvments both in flotation reagents and in flotation machines, many problems are still with us. And since, with the exception of the unique leaching of chalcocite ores at Inspiration, flotation is still the exclusive mainstay for primary recovery of all base metal sulfides, the solution of these problems as they arise is vital to the well-being of the mining industry. Before considering the problems themselves, it will be useful to review the current status of sulfide flotation in the United States. The last comprehensive survey by the Bureau of Mines in 1975 (1) showed sulfide ore tonnages treated from 1960 to 1975 as summarized in Table 1; Table 2 gives similar data for the flotation of all non-sulfide ores. Noteworthy is the leveling off in sulfide ore tonnages in 1970-1975, with a probable further decline in the past three years, and the sharp drop in the number of plants floating sulfide ores. In contrast, the tonnages of non-sulfide ores floated, as well as the number of individual plants, has continued to increase. In spite of these trends, two-thirds of the total tonnage of the ores to which flotation is applied is still represented by sulfides. Average grades of sulfide ores in 1975 were: about 0.6 percent for copper; near 5 percent for lead; and near 3 percent for zinc. Recoveries averaged in the low 80's for copper; about 95 percent for

Jan 1, 1979

By Howard I. Epstein, John R. Buzek

Thickeners are simply large tanks, usually circular in shape, which are designed to allow settling of solids and to operate with continuous overflow of clear water and underflow of thick pulp. The dimensions of the thickener are usually such that dewatering of very fine pulps may be accomplished while still overflowing clear water. Some thickeners such as the Center, Hardinge and Hydrotator types combine thickening with filtering2 while others such as the Dorr type are pure thickeners. l .2 , 3 A schematic diagram of the traction type Dorr thickener is shown in [Fig 1]. This type is appropriate for tanks over 15 m (50 ft) in diameter. This tank employs a rotating raking mechanism which moves the settled material toward the central discharge. For this and other thickeners, it is common to have a shallow conical tank bottom in order to conform to the geometry of the raking mechanism, and it is often desirable to elevate the tank for ease of access to the product. When the tank does not rest on the ground, the forces resisted by the cone are large, and thick plates must be employed. The fabrication of these tanks requires temporary supports in order to erect the cone. A flat-bottomed tank could also be used because the settled material would soon form a hardened conical surface. However, because of the presence of large bending forces, even larger plate thicknesses are required than for the conical bottom. Significant cost savings often can be realized by the use of a scalloped-bottomed tank such as the one partially shown in [Fig. 2]. The particular scalloped bottom discussed in this paper employs radial beams forming the outline of the cone-shaped bottom. These beams are supported directly by columns. Cone segments are hung between adjacent beams. The exact geometry of these segments depends upon the cone angle and radius, the number of radial beams, and their inclination. The geometry is chosen to satisfy certain clearance restraints and to utilize the material as efficiently as possible. The resulting thickness of these segments is significantly less than that of the equivalent plate for the tank with a conical bottom. This result, along with the simpler fabrication procedures required, accounts for the cost savings associated with this design. The raking mechanism employed may be the same as for the conventional conical bottom since the settled material soon forms a conical surface. Determination of the internal force mechanism for the scalloped bottom leads to designs that utilized material efficiently and thus maximize the cost savings. The complicated geometry of these bottoms along with the difficulty in analyzing the structure are factors which may have limited the use of scalloped-bottomed tanks to date. When such tanks have been built, the uncertainties associated with the internal forces have led to designs that are somewhat inefficient. In this paper, equations relating the geometric parameters are presented along with simplified closed-form solutions for the internal forces in the cone segments, from which the loads applied to the beams and the loads carried to the cylindrical tank shell can be deduced. An example is presented to show the magnitude of the savings which may be realized with this configuration.

Jan 1, 1979

By I. R. M. Chaston

Radial layout’s guiding principle is the grouping under one roof of the operating processes which require continuous supervision. Separate treatment sections are isolated by outside stockpiles fed with radiating conveyors. Hence the name ‘radial’ layout. Many plants are designed with ‘linear’ layout where successive operating stages are dotted like beads along a string of conveyors. [Figures 1 through 5] show the development of the radial concept in the layout of heavy-media diamond recovery plants over

Jan 1, 1979

By James K. Hallenburg

INTRODUCTION The delayed fission neutron, or DFN technique for uranium ore body analysis uses the first down-hole method for detecting uranium in place quantitatively. This technique detects the presence of and measures the amount of uranium in the formation. DFN TECHNIQUE DESCRIPTION The DFN technique depends upon inducing a fission reaction in the formation uranium with neutrons, resulting in an anomalous and quantitative return of neutrons from the uranium. Since there are no free, natural neutrons in formation, a good, low noise assessment may be made. There are several methods available for determining uranium quantity in situ. The method used by Century uses an electrical source of neutrons. This is a linear accelerator which bombards a tritium target with high velocity deuterium ions. The resulting reaction emits high energy neutrons which diffuse into the surrounding formation. They lose most of their energy until they come to thermal equilibrium with the formation. Upon encountering a fissile material, such as uranium, these thermal neutrons will react with the material. These reactions produce additional neutrons, the number of which is a function of the number of original neutrons and the amount of fissile material exposed. The particular source used, the linear accelerator, has several distinct advantages over other types of sources: 1. It can be turned off. Thus, it does not constitute a radioactive hazard when it is not in use. 2. It can be gated on in short bursts (6 to 8 microseconds). This results in measurements free of a high background of primary neutrons. 3. The output can be controlled. Thus, the neutron output can be made the same in a number of tools, easily and automatically. There are several interesting reactions which take place during the lifetime of the neutrons around the source. During the slowing down or moderating process the neutron can react with several elements. One of these is oxygen 17. This results in a background level of neutrons in any of the measurements which must be accounted for in any interpretation technique. These elements are usually uninteresting economically. The high energy neutrons will also react with uranium 238. However, the proportions of uranium 235 and 238 are nearly constant. Therefore, this reaction aids detection of uranium mineral and need not be seperated out. Upon reaching thermal energy the neutrons will react with any fissile material, uranium 235, uranium 234, and thorium 232. At present, we do not have good techniques for seperating out the reaction products of uranium 234 and thorium 232. However, uranium 234 is a small (.0055%) percentage of the uranium mineral and thorium 232 is usually not present in sedimentary deposits. When the uranium 235 reacts with thermal neutrons it breaks into two or more fragments and some neutrons. This occurs within a few microseconds after the primary neutrons have moderated and is the prompt reaction. One system uses this; the PFN or prompt fission neutron technique. We don't use this method because the neutron population is low and, therefore, the signal is small and difficult to work with, accurately. Within a few microseconds to several seconds the fission fragments also decay with the emmission of additional neutrons. Now, with a long time period available and a large neutron population we gate off the generator and measure the delayed fission neutrons after a waiting period. These neutrons can be a measure of the amount of uranium present around the probe. Thermal neutrons are detected with the DFN technique instead of capture gamma rays to avoid some of the returns from other elements than uranium. LOGGING TECHNIQUE The exact logging technique will depend, to some extent, upon the purpose of the measurement. However, the general technique is to first run the standard logs. These will include: 1. The gamma ray log for initial evaluation of the mineral body and for determining the position of the borehole within the mineral body, 2. The resistance or resistivity log for determining the formation quality, lithology, and porosity. 3. The S. P. curve for estimating the redox state and shale content, and measuring formation water salinity, 4. The hole deviation for locating the position, depth, and thickness of the mineral (and other formations), and 5. The neutron porosity curve. The neutron porosity curve is most important to the interpretation of the DFN readings. The neutrons from this tool are affected in the same way by bore hole and formation fluids as the DFN neutrons are. Therefore, we can use this curve to determine effect of the oxygen 17 in the water. Of course, this curve can be used to determine formation porosity. It can also be used to calculate formation density.

Jan 1, 1979

By Kenneth K. Humphreys, J. W. Leonard, T. S. Spicer

INTRODUCTION Reasons for Thermal Drying The continuing increase in the percentage of - '/4 in. ( -6.3 mm) coal produced as a result of the increased use of mechanical mining methods has, over the years, tended to shift considerable portions of the work of producing salable coal to the fine coal cleaning section of the preparation

Jan 1, 1979

By Gary E. Parish

TABLE OF CONTENTS Contents I. Introduction II. Purpose of the Paper III. Historical Perspective A. Existing Sources B. New Sources (NSPS) C. Hazardous Pollutants (NESHAPS) D. Enforcement/Judicial Review 1. Title I Enforcement 2. Title III Enforcement 3. Information Gathering E. Summary IV. The Clean Air Act Amendments of 1977 (1977 Act) A. SIP-Related Provisions 1. Section 107(d) - Geographic Boundaries 2. Section 108 - Air Quality Criteria 3. Section 109 – NAAQS 4. Section 110 – SIPs 5. Section 122 and Sections 402 and 403 of P.L 95-95 – Unregulated Pollutants 6. Emission Offsets – Interpretive Ruling (I.R.) B. PSD Provisions - Part C. 1. Regulations Under the 1970 Act 2. The 1977 Act 3. Regulations Under the 1977 Act C. Visibility Protection - Part C, Subpart 2 D. Non-Attainment Provisions - Part D E. Monitoring and Modeling F. NSPS G. NESHAPS H. Enforcement/Judicial Review 1. Title I 2. Economic Enforcement 3. Title III Enforcement/Judicial Review (a) Section 304 (b) Section 307 4. Summary V. Special Problems and Opportunities for the Uranium Industry A. End Use B. Transportation C. Milling/Processing D. Extraction E. Exploration/Discovery F. General VI. Conclusions Appendix A Footnotes

Jan 1, 1979

By Richard D. Call

Data obtained from development drilling provide the basic input for open pit mine planning and design. Development drilling is defined as delineation of the size, mineral content, and disposition of an ore body by drilling boreholes (Thrush, 1968). The objectives of development drilling are: ( 1 ) determining the geometry of the mineralization, ( 2 ) determining the grade and tonnage, , ( 3 ) obtaining samples for metallurgical testing, and ( 4 ) obtaining geotechnical data for mine design. To accomplish these objectives, an appropriate drilling plan must include the number of holes, the spacing and orientation of the holes, and a suitable data collection program. The data collection program covers sample collection, hole logging, and data presentation. This chapter will present some guidelines for development drilling and data collection techniques. The operational aspects of drilling will be covered in an- other chapter.

Jan 1, 1979

By R. H. Heinen

Introduction Drilling is the initial operating step In open pit mining. It goes hand-in-hand with the blasting operations to ensure adequately broken material for the excavation equipment employed. The drilling effectiveness is highly dependent on the quality of the drill evaluation. This discussion will center on the parameters that are needed to evaluate drill requirements for a new mine The procedure that is generated can, however, be used to evaluate whether to expand existing operations and replace existing equipment. Methods of breaking ground, other than blasthole drilling and blasting, such as ripping, will not be discussed. The importance of correct drill evaluation extends to the other facets of open pit mining. Inadequate fragmentation, the direct result of poor drilling and blasting techniques, results in oversized, hard digging for the excavating equipment. The result is higher secondary blasting costs, reduced excavation efficiencies, higher excavation costs, higher road repair costs, and higher haulage equipment costs. The main objective of evaluating drill fleet requirements, therefore, is to determine the equipment needed to minimize the operational constraints, caused by blasthole drilling, on other facets of open pit mining at the lowest cash flow costs.

Jan 1, 1979

SULFURIC ACID U.S. 4,070,260 - Sulfuric acid leaching of willemite, hemimorphite, or other zinc silicate ore. Ore is leached with at least a stoichiometric amount of a IN to 6N sulfuric acid solution at a temperature near its boiling point to form a gelatinous mass of hydrated silica and zinc sulfate, the water in the mass partially evaporated to crystallize all of the silica, the mass treated with hot water to dissolve substantially all of the zinc sulfate, the suspension filtered, and zinc values recovered from the filtrate by electrolysis. N. Dreulle, assigned to Compagnie Royale Asturienne des Mines. Jan. 24, 1978. 3 pp. (204-119). Filed: 2-10-76 (656,966) . Priority: France, 2-14-75 (75/04594) .

Jan 1, 1979

By Thomas W. Healy

Particles present in mineral processing systems that are termed ultrafine are those that are small enough to be unaffected by gravity or the flow conditions imposed on the pulp. As such, their interaction with one another and with other larger particles are controlled by specific attractive and repulsive colloidal or surface interactions. Electrostatic repulsion between ultrafines is dominated by surface potential, double layer thickness and specific adsorption potential effects - controlled by pH, salt and complexing ion concentrations. Attraction due to van der Waals interactions must be assessed in terms of bulk and surface coating effects and of particle size and shape. The net effect of attraction and repulsion must finally be related to the average kinetic energy of particles in the real system.

Jan 1, 1979

By L. V. Wade

US Bureau of Mines efforts under longwall research programs to develop the capability to predict support requirements for longwall/shortwall support systems are discussed. Ground control studies are being conducted in conjunction with several longwall/shortwall demonstration projects. Geologic, support performance, and strata behavior are being documented on these projects. A hypothesis is presented for the prediction of support requirements.

Jan 1, 1979

ALKALINE LEACHING; SODIUM HYDROXIDE U.S. 4,091,071 -In the alkaline digestion of bauxite containing goethite, boehmite and/or diaspore, the process is accelerated by adding to the digestion mass an optimum proportion of calcium oxide and divalent manganese ions, advantageously in the form of a calcium carbonate-containing manganese oxide ore, whereby goethite is transformed into hematite, the alumina yield increased, and loss of caustic soda values minimized. J. Boros, assigned to Femipari Kutato Intezet, Aluterv Alumiumipari Tervezo Vallalat and Almasfuzitoi Timfoldgyar. May 23, 1978. 7 pp. Filed: 12-23-75 (643,670). Priority: Hungary, 12-24-74 (AU 330). Same: British 1,528,146, dated Oct. 11, 1978.

Jan 1, 1979

By Benjamin C. Koskiniemi

Introduction When evaluating any ore body, one of the first questions concerns the ore reserves. In the case of an open pit mine, this is not possible to answer reliably until the ultimate (final) pit limits have been established. Techniques used in designing an ultimate pit are classed as (1) manual, (2) computer, and (3) combined manual-computer. This chapter will describe how manual techniques can be utilized in designing an ulti¬mate pit Certain economic and design criteria must be established before the actual design begins In order to begin designing an ultimate pit, it will be assumed that the engineer already has the following data available (1) vertical sections, (2) horizontal sections for each level, (3) stripping curve, (4) bench height, (5) bank slope angle between levels, (6) level berm width, (7) roadway width, (8) pit slope angles at ultimate pit limits (estimated average including roads and ramps and between roads and ramps), and (9) minimum width of pit bottom

Jan 1, 1979

By R. B. Muter, W. C. Grady, T. D. Wheelock, D. G. Chedgy

INTRODUCTION Topics of special interest, such as preparation plant flowsheets and noise pollution, are described in this chapter along with a discussion of non- state-of-the-art processes such as chemical cleaning, high intensity magnetic separation, and bacterial oxidation. PREPARATION PLANT FLOWSHEETS by RICHARD B. Muter In determining the layout or combination of unit operations to be utilized in a modern preparation plant several factors must be taken into account.

Jan 1, 1979

By Walter W. Fisher, Samuel Rudy

Secondary treated sewage effluent was substituted for normal process water in laboratory tests simulating froth flotation recovery of copper and molybdenum sulfides. Sewage effluent caused significant detrimental response in the flotation process. First, a voluminous, uncontrollable froth was generated, even in the absence of a frothing agent, that has little mineral carrying ability. Second, sewage effluent caused a small loss in copper recovery and a large loss in molybdenum recovery. The detrimental effects of sewage effluent on flotation were partially overcome by tertiary treatment of the effluent by activated carbon adsorption and anion exchange. The frothing problem was significantly reduced after treating the sewage effluent by foam fractionation. Dilution of the effluent with normal process water resulted in a significant improvement in metal recovery. In addition, the large loss in molybdenum recovery was overcome by using a secondary collector in a combination reagent schedule. However, the secondary collector caused an appreciable loss in copper recovery.

Jan 1, 1979