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By Hisaaki Takada, Atsushi Yoshida, Kazuo Satoh, Norikazu Nanko, Naoshichi Higashi

Kamioka Mine of Mitsui Mining & Smelting Co., Ltd. is the largest lead-zinc mine in Japan and is composed of two mines, Tochibora Mine and Mozumi Mine, which have daily production rates of 5,200 metric tons and 1,800 metric tons of crude ore respectively. In the mines, there are many massive pyro-metasomatic deposits which have been derived from the replacement of limestone. The deposits are composed of skarn minerals which mainly contain hedenberite. The country rock is generally hard and fine-grained gneiss. These deposits have been mined by means of the sublevel stoping method, induced block caving method and sublevel caving method at Tochibora Mine and mainly by the cut and fill method at Mozumi Mine. Since the 19601s, the trackless mining system has been introduced successfully into both mines, and is still promoted to be applied over wider areas. The underground hauling system is simplified remark- ably and much improved by adopting trackless ramps to the existing vertical and horizontal underground framework. Moreover, through the combination of the trackless mining system with the mining methods stated above, a notable increase in efficiency has been achieved. This is due to the high performance of the introduced machinery, reductions in man power of miscellaneous jobs, and also has enabled a highly efficient performance through its mobility. In addition, as it becomes possible to realize a flexible development to meet the irregularly shaped deposits and also becomes much easier to recover the remaining pillars by secondary mining, the extraction rate of ore has been improved considerably. With the introduction of the trackless mining system, the development method has been changed, thus former hand-hold leg-drills are now mostly re- placed by jumbo-type drills. Repair shops for Load-Haul-Dump machines also have been provided with an established service system. Reinforcement and rearrangement of the ventilation system has been carried out.

Jan 1, 1977

By W. David Menzie

An inventory of the mineral resources of a region is a most desirable basis for planning their systematic development. In the absence of appropriate samples upon which to base a reliable estimate of this inventory, investigators have resorted to a number of indirect approaches; the unit regional value concept forms the basis for one such approach. The produced resources of a region are a function of the inventory multiplied by the degree of intensity (some fraction between zero and one) of development of the resources. A convenient means of expressing this amount is to accumulate the weight and value of resource and to prorate the totals over the area represented by the unit sampled; i.e., weight and value per unit area or tonnes/km.2 and U.S. 1967 $/km.2. When this approach is used for the U.S.A., South Africa and Rhodesia the average value of (log.) U.S. 67$/km.2 for the states of the U.S.A. and South Africa are similar ($55,176 U.S.$67/km.2 and $52,538/km.2 respectively); whereas, Rhodesia is relatively underdeveloped (10,301 U.S.67$/km.2). On the other hand if the individual commodities are used as a basis for comparison, the U.S.A. shows the greatest diversity (67 commodities out of a possible total of 75) with South Africa next (50 commodities) and Rhodesia last with only 26 commodities. Since it is known that area and value are not simply related perhaps diversity is directly related to area. Again the kinds of commodities which have contributed the greatest value to the totals differs, with fuels (petroleum, coal and natural gas) predominating in the U.S.A. totals; whereas, South Africa and Rhodesia obtain their greatest contributions from gold, diamonds (S. Africa) coal and asbestos. In each case the greatest value of resources is produced from sedimentary rocks. As a somewhat different kind of example, consider a single resource (petroleum, the most valuable in the U.S.A.) over a large area (number of sampling units) the U.S.A. by state. Furthermore, assume that the model frequency distribution of the amount of petroleum (tonnes/km.2) is log normal. Then the present production fails to match the model first because 17 states (34% out of 50) have not produced petroleum. Of the remaining 33 states, Louisiana has produced the most (15,177 tonnes/km.2) and the frequency histogram is still skew. A spatial analysis of the distribution of the amount of petroleum by state shows that the samples (i.e., states) are not random; the non-producers and producers tend to cluster. It remains to be seen if this is indeed a true representation of the incidence of petroleum or is a function of the exploration philosophy currently in vogue.

Jan 1, 1977

By Vincent Carlsson

A comprehensive investigation has been undertaken to clarify how pellets are affected by alkali circulating in the blast furnace. The investigation has been performed with acid and basic pellets in a special furnace. Experiments were carried out to ascertain the influence of potassium on swelling and reducibility when added at different stages of reduction. After that, the significance of the quantity of potassium added in the hematite stage was studied. A parallel experiment with sodium as the alkali component was also con- ducted. Besides these vaporization experiments the effect of alkali on softening and reduction characteristics at high temperatures was investigated. The results showed that alkali always increases swelling, especially when added in the hematite stage. The addition of alkali increases reducibility of acid pellets during reduction from wustite to 70 % reduction. The softening temperature is significantly lowered by the addition of alkali and is, in any case, lower for acid pellets than for basic pellets. The microscopic studies showed that alkali ferrites can be formed irrespective of the influence of alkali on the slag phase.

Jan 1, 1977

By Gordon C. Hicks

Prior to 1950 most fertilizer manufactured in the United States was produced in a nongranular form. In such form, the material caked when stored and was extremely dusty when applied in the field. About this time a wide interest developed in the fertilizer industry for the manufacture of a granular, high-analysis fertilizer of improved physical properties. Thus, TVA began work on fertilizer granulation about 1950 using both a pugmill (double-shaft paddle mixer) for a thick slurry of nitric phosphate and a continuous ammoniator-granulator drum for superphosphate-base mixed fertilizer. Granulation in these units was mainly by agglomeration. The liquid phase generated by the moisture and by the heat of reaction of ammonia with acidic materials, such as superphosphate and sulfuric or phosphoric acids, resulted in agglomeration of the solid ingredients. About 1956, TVA began studies of the use of a pan or disk granulator for production of ammonium nitrate or other fertilizers containing a large proportion of ammonium nitrate, such as 30-10-0 ammonium phosphate nitrate. This is the layering method of granulation. More recently, TVA has demonstrated pan granulation of urea from a highly concentrated solution and granulation of ammonium polyphosphate melts in a pugmill. The bulk of TVA studies throughout the years has related to use of the drum granulator. About 200 granulation plants in the United States have been licensed and built to use the TVA continuous ammoniator-granulator; it is estimated that more than half of the 20 million tons of mixed fertilizer used in the United States in 1974/1975 was produced in these plants. Some other granulation processes developed for use in the drum granulator include diammonium phosphate, monoammonium phosphate, urea- ammonium phosphate, ammoniated superphosphate, and most recently, NPK fertilizers by melt granulation using a pipe reactor.

Jan 1, 1977

By A. E. H. Bergmann

INTRODUCTION The Sachtleben Chemie GmbH in Duisburg, a subsidiary of the Metallgesellschaft AG, operates a new sulfuric acid plant that employs fluid bed roasting of pyrite concentrates. The plant produces about 300,000 tons per year of pyrite cinders from the fluid bed roasting unit. The cinder product consists of 58 percent iron and is about 80 percent by weight smaller than 50 microns. This cinder product was found to be a competitive source material for the cement industry as the iron-containing additive. However, the extreme fineness of the cinder and its dusting tendency were undesirable and an agglomerating technique became necessary. In order to keep the price of agglomerated pyrite-cinders at a competitive level, the agglomerating method must be chosen such a way the capital and operating costs are low. Initial experiments were carried out on a laboratory scale to make an appropriate choice of the agglomerating method. Major goals of agglomerating the cinders were to improve the transportation, storage, and proportioning and metering properties. Minimum specifications are put on the size, size distribution and shape of the product. Criterion for handling is that a minimum of minus one mm. fines are produced after several handlings, while for storage, it is also desirable for the agglomerated product to survive several months in open air. Thermal agglomeration processes such as sintering one known to produce excellent products, but are by far too expensive for our application. For the same reason, granulation, balling, and pelletizing tests with addition of organic binding agents, such as tylose, starch, sulfite wash, molasses, etc. were not continued. The costs for the binding agent was considerable, which is probably due to the high pore volume of our cinders (35 %). Furthermore, the pellets or granules

Jan 1, 1977

By Henry U. Ross

The behaviour during reduction of iron-ore pellets and sinters was investigated. Several methods for the preparation of agglomerates and their reduction were tried. Commercial agglomerates from world-wide sources as well as experimental samples were tested. The effect of coke additions to pellet and sinter plant feeds was given special consideration. An analysis of the test results has helped to explain many of the phenomena associated with the reduction of iron-ore agglomerates such as swelling, loss in strength and wear resistance, changes in porosity, changes in mineralogy and the formation of metallic iron and slag. A double-layer pellet with all of the coke concentrated in the core proved particularly interesting. Although large quantities of coke showed that partially reduced agglomerates containing metallic iron could be produced in the laboratory, the problem of producing reduced pellets and sinters by the existing agglomerating processes still remains.

Jan 1, 1977

By Charles L. Hosler

My function here today is not to illuminate any particular subject but simply to welcome you to Penn State and to the College of Earth and Mineral Sciences. Our college is, of course, dedicated to the same thing to which most of you have dedicated your lives--the exploration of the earth, the extraction of materials from it, and the production of useful things from those materials. We have about 2,000 students engaged in studying in preparation for service in these activities at the present time. Like other colleges of our type, we've undergone a great expansion just at a time when university budgets are contracting. This creates an interesting situation as to how we can best use our resources. This, of course, is the thing a lot of you are going to be talking about here--how we can best use the world's resources. As you well know, the expectations of the people of the world are rising, and, with the numbers of people increasing and with finite resources, there never was a time in history when it was more important that we become "quantitative" in our discovery, estimation, extraction, and utilization of those resources. I think it is admirable and very timely that you are gathered together to discuss your various approaches to this particu¬lar problem of quantifying and making most efficient use of the resources of the world. Yours is sort of a hidden profession, not just because you actually go underground, but because the public in general is not aware of where the materials they use come from. If you are successful in your professions the public will continue to be unaware. Only if you fail will your essential function become patently obvious. I wish you success both in your professional pursuits and in this particular meeting.

Jan 1, 1977

By William Y. Mo

The OPEC oil embargo and the subsequent higher prices for oil have drawn public attention to the critical problems associated with security of supply of oil and other key industrial materials, especially nonfuel minerals. This concern has stimulated the interest of decisionmakers in analyzing policy options to cope with the emergency situations resulting from a sudden foreign- induced supply interruption or a cartel price increase. Several policy options are available to counteract foreign-initiated embargoes or cartel price actions. The type of response will differ depending on the commodity action intiated. A mathematical model that measures the impact of foreign-induced commodity actions on the domestic economy is formulated. The paper also presents a computer method that can be used to determine the optimum policy response to counteract such actions.

Jan 1, 1977

By Joseph S. Young

During 1975, the Reclasource Corp. constructed and started up a plant for the recovery of mill scale, coke breeze, blast furnace dust; blast furnace sludge; and TOC dust, at the site of Crucible Steel, Inc., Midland, Pa. The Reclaform Process was employed as the criteria for plant design. This process takes the solid wastes (as listed above) which are commonly found in integrated steel mills, sizes them, forms them through the use of a carbonaceous binder briquetting system, and fixes the binder through a final heat treating step. Blast furnace tests have been performed on 15,000 tons of Reclaform briquets. This paper gives a brief history of the program, and describes the process and the raw materials involved. The blast furnace campaign and its major conclusions are discussed.

Jan 1, 1977

By Keith C. Hendrick

The mining industry of Canada, stretching from coast to coast and reaching into the most remote regions of the country, is of fundamental importance to the national economy and the well being of many communities outside the main urban areas. The production, processing and transportation of a host of mineral products provide employment for about 9% of the country's labour force; and their shipment to export markets provides an important contribution to the balance of payments. In 1976 Canada's metal and mineral production had a value of $5.24 billion, of which zinc and lead accounted for $862 and $129 million respectively, or 19% of the total. By all standards the Canadian zinc and lead industry is large and, therefore, important to the country as a producer and the world as a supplier. This report will review the development, describe the present status and discus current problems and future potential of the industry. The discovery and successful development of the major lead-zinc deposits at Kimberley, British Columbia, provided Canada with a solid base from which to grow. The breakthrough in metallurgical technology using differential flotation to separate the lead and zinc sulphides and the refining of high purity metal by electrolytic methods not only helped Canada to compete with other world producers but also provided a new source of these metals at prices and qualities that encouraged the development of new end uses.

Jan 1, 1977

By Schrade F. Radtke

The future of lead and zinc, as with any material, will relate directly to their capability to remain competitive; that is, to demonstrate cost-performance ratios that are superior to those of competing materials. These cost-performance ratios are not static; therefore, it is necessary to develop improvements in products or processes to maintain present markets or to penetrate other markets. Perhaps the surest way to achieve these goals, if they can be achieved at all, is through research. The world lead and zinc producing industry established ILZRO as its cooperative research function to carry on both fundamental and applied research and development efforts aimed at the stated objectives. Current research efforts in the fields of die casting, galvanizing, finishing, chemicals, architectural applications, ceramics, and batteries are reviewed and potential impact assessed, some projections are given of possible new areas of research. Environmental research and its impact on future uses of lead and zinc are also discussed.

Jan 1, 1977

By K. V. S. Sastry

This paper summarizes recent research on the kinetic aspects and process behavior of agglomeration in balling circuits. The physical concepts underlying agglomeration, the mechanisms responsible for size changes during agglomeration, and a generalized population balance model for agglomeration systems are summarized. Experimental techniques for investigating the batch balling behavior and for simulating the balling- circuit operations are reviewed. Further, the effect of such operating variables as feed moisture, bentonite content, and the rate of feed addition are discussed. An approach to the computer simulation of the agglomerating circuits is shown and the importance of such models in process engineering is discussed.

Jan 1, 1977

By J. A. Cordier

USINOR has conducted four blast furnace tests with formcoke made from marginal coals in the pilot plant of HBNPC ("H. B. N." process) in four different blast furnaces of various sizes and with medium and high grade burdens. The tests in which up to 30% of the blast furnace fuel burden was replaced by HBN formcoke yielded good results on furnaces ranging in hearth diameters from 5.6 to 9.5 m. The tests demonstrated that: - the slight increase of pressure drop in the stack did not prevent smooth operation at record production rates with the same blowers - the total coke rate was not significantly affected, but there was a slight increase of the calorific value of the top gas - the hot properties of the formcoke are satisfactory as seen from the samples withdrawn at the tuyeres and tapholes. At the end of the two months test on BE nº 2 of Dunkerque, the hearth was as permeable and clean as with good standard coke. Our conclusion is that HBNPC formcoke made from lean coals is an adequate substitute for conventional coke in the range of 20 to 40% replacement, which is of interest to USINOR.

Jan 1, 1977

By Gerard A. Flierman

INTRODUCTION There is a lot of discussion about the relative merits of sinter and pellets as components of a BF-burden. Many people claim that sinter is to be preferred and that the percentage of pellets in the burden must be restricted to 20%. During BF-trials in IJmuiden various amounts of pellets having various basicities were tried. It was concluded that there were no significant differences in furnace performance. Consequently the choice between sinter and pellets must be based on the local manufacturing costs (1). Table 1 gives a summary of the pellet experience in IJmuiden. [ ] Because the BF-trials were relatively short, a survey of published BF-operating data has been undertaken to investigate if differences between a sinter and pellet based BF- practice could be found. The comparison of BF-operating results has been restricted to coke rate and productivity.

Jan 1, 1977

By Dominique François-Bongarçon

A new method for open-pit design has been devised by G. MATHERON and the writers: it replaces the search for an optimum contour by the determination of a parametrizing function. The isovalue curves of this function give the optimum pit design corresponding to varying economic parameters; The method is described and indications are given about the corresponding program. Simulated data have been processed by the program and by a standard program using LERCES-GROSSMAN graphical method: the comparative results are described.

Jan 1, 1977

By Michel L. Bilodeau

The objective of delineation drilling is to provide a data base for the tonnage and grade estimates required to evaluate the economics of mine development. As drilling information is accumulated, geological risk is reduced and more reliable estimates of tonnage and grade are obtained. Investment in drilling is justified by the benefits which result from improving the reliability of the economic criteria evaluated. These benefits are subject to diminishing returns, i.e. as drilling information is accumulated the reliability of the economic criteria evaluated is improved but at a decreasing rate. At the same time, costs are incurred -- the direct investment cost associated with additional drilling and the time cost of delaying possible production revenues. The economic sampling limit is de- fined by the point at which the marginal benefits from drilling investment just balance the marginal costs. The paper describes the formulation of an economic model to optimize investment in delineation drilling. The model is applied to a simulated mineral deposit to illustrate the economic effects of a sequential drilling program.

Jan 1, 1977

By Andrew R. Swanson

An experimental study of the process parameters controlling the selective agglomeration of raw coal slurries is described. Particular attention has been paid to the influence of input variables on agglomerate size and process kinetics. These factors were considered to be of paramount importance as they determine the selection and sizing of the process equipment. The variables studied include oil addition, pulp density, agitation rate and particle size of the feed. The results have been qualitatively interpreted in terms of a classical reaction kinetic model.

Jan 1, 1977

By Alan English

INTRODUCTION During the Bicentennial Year in the United States of America, recognition should be given to the fact that 20 years ago the first large-scale commercial pelletizing plant was started and attained rated capacity. This was the beginning of a new industry. Twenty years ago the total production of pellets was principally from pilot plant facilities and totaled in the thousands of tons per year. At the present time the world production is slightly in excess of 280 million tons per year. This truly is a tremendous growth for any industry. Such a production growth obviously is accompanied by a similar growth pattern in the development of process, equipment, and facilities. During the growth and development period, different materials became more adaptable for processing. For example, initially the pelletizing of iron ores revolved around the magnetite concentrates where the heat of reaction constituted a very important part of the process fuel. During this growth period, specular hematite, earthy hematite, mixtures of hematite and magnetite, and even non-ferrous type materials were pelletized, a function previously thought not practical. The demand for the use of pellets has also broadened their concepts. At first they were made to replace the high-grade iron ores used in blast furnaces. Nowadays, not only have they replaced iron units, but they have had a major influence on the design of larger blast furnaces and have contributed to production rates in excess of 10 000 tons per day from a single furnace. They have also been used in the manufacture of steel, principally for coolants in the BOF practice. More recently, with the improved beneficiation techniques that have been developed over the same period of time, pellets have been used for the direct reduction process and can be used directly

Jan 1, 1977

By J. A. Ryder

TRANSIM II is a general purpose mining-oriented transport simulation program. It features the accurate modelling of locomotive tramming systems involving interferences and queue build- ups, as well as inter-level transport facilities linking bunkers of finite capacity. Features of the program are described, and a number of practical applications briefly reviewed including studies of optimal train capacities, pulling schedules, tip and bunker capacities, and operation of simple traffic-light systems.

Jan 1, 1977

By Heinrich A. Kortmann

Specifications on the chemical, physical and metallurgical properties of the blast furnace burden are steadily becoming more stringent, especially in those countries where higher raw material and energy costs can be overcome only by improved technology. This paper describes the test methods for the relative predetermination of the criteria where the effects of temperature, gas composition and physical load in the blast furnace are duly considered. Data are presented to show the correlations between burden material tests and blast furnace results. Possible test methods for the direct reduction process are also discussed.

Jan 1, 1977