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By James F. McConnell, Charles W. Statler

Pennsylvania's existing large coal-fired units are limited to 2.0, 1.8, or 0.6 lb of sulfur per million Btu fired, depending on site location. Multi-stream coal preparation can be employed on system basis to extract the highest quality fraction of coal for use in units requiring the lowest sulfur. The middling fraction can be directed to units permitted higher sulfur. General Public Utilities Corp. has concluded that it is feasible to advance the state-of-the-art of heavy media coal preparation to produce an intensively cleaned primary product of 1.3 sp gr of less than 0.6 lb of sulfur per million Btu for the new unit and a middling product of 2.0 lb of sulfur per million Btu for existing units.

Jan 1, 1977

By Kiyoshi Sugasawa

At Sumitomo Metal Industries, technologies for manufacturing metallurgical coke have been developed, under the names of Sumicoal System and DKS formed coke processes. Sumicoal System is the process utilizing approximately 70% conventional fine coal, 30% briquettes charge, and 2-3% caking substance. This technology was industrialized in 1975, and now the blending ratio of non-coking coal has reached up to 20%. On the other hand, a large scale demonstration plant using the DKS process was constructed and operated over one year. As the result of that test, it is thought that the DKS process has also reached the stage of industrialization. This paper will describe these new coking technologies.

Jan 1, 1977

By Clark A. Sumner

An apparatus for agglomerating fine particles was developed in 1969 as a joint effort of Stauffer Chemical and O’Brien Industrial Equipment. Commercial sized units were built for agglomerating home dishwashing detergents. Recently, as a result of further pilot development, variation of bed depth and cage configuration has resulted in a means of controlling the amount of internal classification from a minimum, producing small agglomerates, to a maximum, producing compact rounded agglomerates. Little or no external classification of discharged agglomerates is needed. At maximum internal classification the agglomerates roll on a bed of fine particles rather than the shell resulting in increased agglomerate size.

Jan 1, 1977

By Carlos Kovacs-Figueroa

Complying with air pollution regulations created the need to dispose of increased sulfuric acid production by the Morenci smelter. As a result, a two-module leaching plant was constructed to leach Morenci flotation tailings. The leaching plant was equipped to perform the following operations: leach feed pumping, agitated leaching, two-stage countercurrent decantation, neutralization of leached tailings, and copper precipitation. Ancillary facilities were provided for neutralizer and flocculant preparation as well as precipitant handling and recovery of precipitates. Plant control is automatic from a central control panel supervised on a shift schedule by one operator and two helpers. Construction of the first module was initiated in April 1973 and leaching of tailings commenced in November 1974. Construction of the second module began in January 1975 and was completed in November 1975.

Jan 1, 1977

By J. A. Herbst, J. L. Sepulveda, J. D. Miller

Effective bismuth removal from flue dust residues has been accomplished for flue dusts from both zinc and copper smelters. Selective dissolution of bismuth, with respect to silver and lead, can be achieved by the proper manipulation of temperature, sulfuric acid addition and sodium chloride addition. Optimum levels of these variables were determined using a response surface technique to maximize the objective function: Y = %Bi/(1 + %Ag). In the case of the flue dust residue from a zinc smelter, which contains bismuth as an impurity (0.05%), 86% bismuth removal can be realized with less than 1% combined silver and lead dissolution. Similarly, in the case of flue dust from a copper smelter, which contains bismuth as a primary constituent (3.3%), 93% bismuth removal was obtained with little dissolution of silver and lead values.

Jan 1, 1977

By Charles J. Haas

The effectiveness of rock bolts in resisting shear displacement along preexisting fracture surfaces or slip planes was determined in the laboratory with full-scale bolts and large-scale shear test equipment. The system variables were the type of bolt, orientation of bolt relative to shear surface, and normal pressure on the interface. Results showed that, in general, both conventional bolts and resin- grouted reinforcing bars significantly increase the shear resistance along a fracture or bedding plane when the average normal compressive stress on the plane is in the order of 25 psi and when the bolt is oriented such that it tends to lengthen as the shear progresses. An increase in shear resistance is also noted at the higher normal pressure of 250 psi; however, the increase is small compared to the corresponding shear resistance without a bolt. Conventional bolts oriented such that they lose tension as shear displacement occurs added no shear resistance since the tension drops to zero at very small shear displacements.

Jan 1, 1977

By Harold J. Bennett

A comprehensive knowledge of the availability of mineral resources to evaluate and assure a dependable supply is a prerequisite in establishing and maintaining a viable national economy. Since no nation is self-sufficient in all its mineral needs, its prosperity depends to a great degree upon its developing and maintaining an effective national minerals policy. This must be preceded by a systematic inventory of mineral resources that may be available to that nation. The U.S. Bureau of Mines is implementing a mineral deposit inventory program of domestic and foreign mineral occurrences, with initial emphasis on the domestic. In order to provide an in-depth appraisal of minerals availability, the approach includes not only realistic estimates of quantity and quality, but other essential factors such as costs, technology, environmental constraints, and development-time requirements. Analysis of this information provides usable relationships of quantity, price, time, and associated degrees of confidence of the occurrence of identifiable mineral resources. Keeping pace with a changing minerals industry and handling the large volume of information required in this undertaking demands that computer methods be employed.

Jan 1, 1977

By Charles J. Lipton

Third World countries have lately taken a variety of actions to improve their revenues from the development of their mineral resources. Increasingly, their governments seek to negotiate production agreements on the basis of feasibility studies and discounted cash flow projections. Developing countries are now more selective in giving incentives to encourage investment in the mining sector. They recognize the value of their contributions to mining projects by way of guarantees and the provision of infrastructure. Third World governments now seek to participate in the basic decision making which determines profitability, such as loan-equity ratios, plant capacity, and processing and sales arrangements. They are alert to the benefits of large-scale development and appreciate their risks. They seek to increase their benefits from foreign exchange earnings and the multiplier effect of mining projects. New forms of arrangements are being used to insure that the mining sector is developed in harmony with the national objectives of the Third World.

Jan 1, 1977

By Robert A. Melton

Since many of the easily mined, continuous, thick coal seams in the Appalachian Region have been exhausted, new exploration and mining is being directed toward less continuous seams that are under more cover and are more difficult to mine. The direct results of this are that more money and time and more expertise and data are needed to plan and open new coal mines today. It is also becoming apparent that the old methods of assimilating and preparing information needed for mine planning are inadequate to meet the needs of today's modern mining engineer, especially in the areas of data gathering, storage, retrieval, preparation, and interpretation. The system described here allows assimilation of old and new core data in a relatively quick, accurate, and efficient manner. The system is a set of computer assisted procedures consisting of the following four basic steps: 1) raw data collection, computer input, storage, and graphic preparation, 2) geologic profile correlation and establishment of seam continuity, 3) computerized data posting of important seam parameters, 4) geologic and planimetric analysis for mine planning.

Jan 1, 1977

By Wayne D. Gould

Cities Service Co.'s Pinto Valley concentrator was designed to eliminate excess capital costs without loss of efficiency. The result is a workable plant with some important innovations. These innovations, the equipment used, and plant processes are outlined. Particular attention is paid to the work efficiency and wear of the six ball mills, the largest wet ball mills made. For experiment purposes, four designs of liners were installed. The effectiveness of each design is discussed.

Jan 1, 1977

By John D. Siddle

Efficient energy utilization in the electrolytic zinc process, relative to other zinc processes, is one of the reasons for its wide adoption in recent years. Designers and operators of electrolytic zinc plants have pioneered process improvements, new equipment, and operating techniques to conserve energy. As energy costs advance still higher in the future, and competitive pressure against the less efficient producers increases, these or alternative energy-saving methods will be looked upon as a necessity for economic survival. Estimated energy savings which may be achieved by various equipment and techniques are included.

Jan 1, 1977

By James Marsh

INTRODUCTION Economists have long expressed suspicion of the economic theory of natural resource exhaustion, even in writing articles which have contributed to it (1). Indeed, the gap which separates the pure theory from practical management seems unusually wide. It is doubtful whether a mine manager could possibly know enough about the relevant parameters of his mine to steer it along the optimal paths described by the theorists (2). Nevertheless, enough faith in the theory remains that mine managers are suspected of being a separate breed whose behavior must be studied in special courses using specialized text-books, collections of readings, and journals (3). The implied hypothesis, that mines and natural resource firms are managed differently than other firms, is the subject of this paper. In the next section the theory is developed and analyzed. In section III, I discuss the implications of the statistical results that have been obtained. Finally, conclusions are reserved for section IV. THE MODEL A key difference between the traditional theory of natural resource production and that of other forms lies in the set of variables which ire assumed to jointly determine the quantity of output the firm will produce. Output, in the non-resource case, is assumed to be a function of k clearly definable and distinguishable inputs or factors of production, viz., y = f(xl, x2, ..., xk), (1) here

Jan 1, 1977

By R. K. Young

This paper describes a computer-based Data Acquisition System which provides efficient data logging and retrieval, control of on-line gas chromatographs, and instantaneous calculation of material and energy balances.

Jan 1, 1977

By M. T. Abasov

The work suggests an approach to the problem of optimally planning the drilling and development of gas fields. The approach is based on systems analysis and allows a joint optimal choice of the total number of wells in the field, their spacing in the reservoir, the diameter of production tubing, drilling dynamics, the number and spacing of drilling platforms and well pattern schemes for each plat- form as well. The optimal solution satisfies the set of technical- economical requirements and provides a minimum value of discounted total expenditures (capital costs plus operating costs). A mathematical model of the problem is presented. This work represents an extension of the authors&apos; previous investigations that formulated and solved problems of optimal drilling of oil and gas deposits by directional wells [1] and problems of optimal control of the number of active wells in multi-reservoir oil and gas fields [2], [3]. For construction of the mathematical model we choose a range (Nmin, Nmax) of possible values of the total number of wells, N, which should be drilled in the deposit. Here Nmin, Nmax are minimum and maximum numbers of wells correspondingly, that should be drilled into the reservoir. N[€](Nmin = N1, ... N[o], ..., Nm = Nmax). For simplicity a one-reservoir gas field is considered. It is assumed that: (a) wells are spaced in the reservoir uniformly, (b) there is a certain algorithm providing a uniform spacing of the given number N[o] ([0]=l, . . . , m) of wells in the reservoir, (c) the diameters of the production tubing for all the wells are the same. The relation Qz (x), i.e. the dependence of the cumulative output of gas from the cumulative "well-years" of operations is constructed for each diameter dZ from the given range of diameters d1< ...< dr.

Jan 1, 1977

By James L. Sweeney

The Project Independence Evaluation System (PIES) is a complex evaluation, forecasting, and analysis system which represents the U.S. energy production, conversion, transportation and consumption activities. The system includes various models: An econometrically estimated energy demand model, used to evaluate the final demand functions for energy commodities ; A collection of supply models, used to evaluate the cost curves or supply curves for domestic crude oil, natural gas, coal ; An integrating model used to describe energy conversion and transportation activities and to calculate prices which equate energy supply and demand in each market. PIES has been used to generate conditional forecasts of the 1980, 1985, and 1990 states of the energy system--forecasts conditional upon the world oil prices, the energy policy environment, and other uncertainties. Scenarios have been structured to separately examine conservation initiatives, domestic energy supply enhancements, an extensive electrification strategy, and oil and natural gas well -head price regulation. This paper presents the basic model, discusses its use for examining policy options, and describes several forecast results. The paper draws heavily upon work completed for the 1976 National Energy Outlook, published by the Federal Energy Administration.

Jan 1, 1977

By Daniel T. Hegyan, Thomas B. Zugates

Continuous vacuum disk filters are increasingly being used to filter refuse from the fine-coal washing circuits as it becomes important to close the water circuits and eliminate sludge holding ponds. This paper discusses our past experience filtering refuse, effects of solids concentration in the filter feed, use of polymer flocculation aids, effect of flocculation devices, and effects of particle size and ash content on the filtration rate. Detailed tests were performed on existing installations utilizing coal refuse filters to determine optimum flocculant dosage, solids concentration, and disk rotation speed to form a dischargeable cake. Information was also obtained showing effect of flocculant addition on the moisture of the filter cake.

Jan 1, 1977

By Richard B. Greenwalt

INTRODUCTION Direct reduction of iron ores has unquestionably become established as an important step in the worldwide steelmaking industry. The history of this development has been long and fraught with difficulty. In 1800, Champlain suggested the direct reduction concept using carbon and a shallow hearth vessel. Roughly 100 years later, Jones attempted a commercial process using carbon and producer gas in a rotary kiln. During the early years of this century, numerous attempts were made to start commercial direct reduction plants using such processes as Hoganas, Wiberg, Krupp-Renn, and others. Most of these were short lived, being abandoned due to a variety of technical and economical factors. Today, however, a new generation of direct reduction processes has emerged. We enter 1977 with at least 40 commercial plants in operation using 15 processes in 14 countries. These plants have combined total annual capacity of roughly 10 million tonnes of direct reduced product. Many articles have been written, and projections made, concerning the future growth potential for direct reduction. As is al- ways the case with projections, the numbers vary, but the outlook does not. Anyone who participated in the years of effort that have gone into this field of endeavor should be excited and justly rewarded by noting the shape of the curve in Figure 1.

Jan 1, 1977

By Charles Rich, Robert Munson, Leonard Obert

Improved methods of predicting the caving characteristics of ore bodies is discussed. Experiments were conducted at Climax mine, Climax, Colo., on varied rock compositions. The cavability of adjacent areas, as well as seismic energy absorption proved to be good factors in determining cavability. Seismic velocity, core recovery, and rock quality designation (RQD) were found to be not as reliable.

Jan 1, 1977

By James M. Townsend

INTRODUCTION The first stage in planning any mining venture is to determine whether the reserves are of sufficient quantity and quality to warrant commencement of mining activities. In addition to total reserve values a modern mining operation requires information on possible support problems, various pillar sizes, and an estimate on recoverable reserves. To achieve this goal in U. S. coal mines, up-to-date computer methods have been applied to existing ground control technology to provide the mining engineer with a reasonably accurate method of determining such figures. The purpose of this paper is to present a mine planning suite comprised of three computer programs, CONTUR, RESERV-COAL and RAMPLAN, created to accomplish this task. These programs were developed at VPI under the sponsorship of the Office of Coal Research (now Energy Research and Development Administration), and are currently available to the mining industry. A basic assumption in the construction of the CONTUR program is that a coal seam is variable in nature. The data available to the mining engineer comes from randomly spaced points, namely boreholes and sampling points, on outcrops or in adjacent mines. These randomly spaced data points are used in the CONTUR program to estimate numerical values at evenly spaced grid points and to provide approximate contour plans. Given the necessary gridded data, RESERV-COAL calculates raw and clean coal tonnages and then provides breakdown on the quantity of coal within specified ranges of ash, sulfur, BTU and reject. RAMPLAN (Rock Mechanics Applied to Mine Planning) also uses gridded data to calculate mining dimensions and estimate recoverable reserves, thereby

Jan 1, 1977

By F. W. Hillnhutter

In plant tests with a 9.7 m hearth diameter high top pressure blast furnace the influence of disintegration of sinter during low-temperature reduction on blast furnace performance was evaluated. The blast furnace burden during the test period consisted of 74% self-fluxing sinter with a basicity of CaO/Si02 = 1.3, 15% pellets, 6% lump ore, and 5% recirculated slags. The sinter for the test was produced in a modern sinter plant. By changing the fuel rate and/or the MgO content at a constant basicity CaO/Si02 sinters with different low-temperature disintegration properties could be produced. The blast furnace was equipped with pressure monitoring devices at medium height of the furnace stack wall. This device provided in addition to the normal operating data readings of pressure losses in the upper and lower part of the furnace. The basic physico-chemical factors determining low-temperature disintegration are explained. The testing devices and the extent of quality control measures of sinter during the test period are outlined. Conclusions are drawn from the plant test in relation to sinter properties.

Jan 1, 1977