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By F. G. Rinker

The world demand for metallized iron continues to increase, keeping pace with steelmaking requirements for lower cost hot metal. Virgin iron ore and in-plant oxide fines can be reduced to direct reduced iron (DRI) and hot briquetted iron (RBI). MR&E has developed an improved coal-based process for cost-effective production of either DRI or HBI. Starting with dry compaction, the process combines the latest technology for material preparation, rotary hearth furnace construction and environmental control. Coarse iron ore fines are blended with pulverized non-metallurgical coal to produce a highly metallized (>90%) product. This paper presents production and installation cost data based on operating and under-construction iron oxide reduction facilities.

Jan 1, 1999

By M. S. Klima

This paper will detail the work that has been done in 1990 and 1991 at the Pittsburgh Energy Technology Center (PETC) on the development of the U.S. Department of Energy's (DOE) patented Micro-Mag Process. This process entails the use of a micronized-magnetite (minus-10 microns) and water mixture for cleaning fine coal (minus-600 microns) in a cyclone, along with the production and recovery of the magnetite. Emphasis will be on the results from micronized-magnetite recovery testing using both conventional wet-drum and high-gradient magnetic separators in which several key operating conditions were varied including feed percent solids, magnetite-to-coal ratio, magnetite grade, and feed rate. Also presented will be selected results from testing done on a 76-mm diameter cyclone at a relative density of 1.50 showing the effects of operating pressure, magnetite grade, and medium-to-coal ratio on separation efficiency. In addition, two methods for producing micronized magnetite, along with the corresponding size distributions, will also be discussed.

Jan 1, 1992

By Stephen J. Navin

The Los Angeles Metro Red Line has installed high density polyethylene (HDPE) as a gas and water barrier around all subsurface structures. The paper reviews the geological setting and resulting need for the barrier. HDPE installation practices are outlined, as are the risks to the barrier, from normal placement methods. Testing and inspection methods used to assure a quality installation are described, and also the field tag method for recording deficiencies and their repair. Specifications and installation changes that will be incorporated into subsequent contracts to improve the quality of the installation are high lighted. The cause of the fire that destroyed part of a tunnel is reviewed as are the revised precautions put in place to prevent a recurrence.

Jan 1, 1991

By K. Katen

In another situation, Dave Zegeer, the Assistant Secretary of Labor for Mine Safety and Health, whom all of you know very well, would have taken the opportunity to talk with you. In his absence, however, I would like to reference some of his recent comments which may help us to see the issue of mine safety in historical perspective. Dave pointed out that this year is the eightieth anniversary of the Great Earthquake and Fire of San Francisco. The whole world heard about that disaster--it and the 452 people who died in it. In that same year, nearly five times as many people died in coal mines, but no one particularly noticed.

Jan 1, 1986

By I. D. Lindley

The Wild Dog vein gold deposit in East New Britain Province, Papua New Guinea, forms part of a recently discovered 26 km zone of auriferous quartz vein mineralisation. The deposit, which was discovered in July 1983, has no silt anomaly, and a panned concentrate anomaly and float train restricted to within 500 m and 800 m respectively, of the discovery outcrop. Discovery of the Wild Dog deposit was a result of the methodical followup of regional panning which, as followup progressed, was replaced in importance by float sampling. Of the sampling methods used during the exploration leading to discovery, panning and float followup provided immediate indications of the presence of mineralisation. This high degree of spontaneity of followup is not provided by geochemical techniques, and has obvious advantages in high cost exploration for precious metal deposits in remote locations.

Jan 1, 1988

By R. C. Moe

Pelletizing studies were conducted to find ways of improving the metallurgical properties of acid and fluxed pellets. In acid pellets, melting temperature was controlled by the formation of low melting temperature fayalite during reduction. Formation of a permeable metallic shell during reduction allows diffusion of reducing gas to the pellet core, decreasing fayalite formation. With fluxed pellets, slag chemistry had the main influence on metallurgical properties. Mineralogical, chemical and structural transformations that occur during reduction were studied at various intervals for a number of Mesabi Range pellet types. Six pellet types were selected for further investigation based on significant differences in softening/melting characteristics. Retention of porosity in the metallic shell was found to be the overriding factor in determining softening/melting behavior.

Jan 1, 1990

By R. B. Tippin

Great Salt Lake Minerals & Chemicals Corporation (GSL), a subsidiary of Gulf Resources & Chemical Corporation, is located on the east side of the Great Salt Lake, approximately 20 miles from Ogden, Utah. GSL processes brine from the north arm of the lake to produce potash, salt cake, salt and magnesium chloride brine. Potash fertilizer, in the form of K2SO4 is GSL's primary product. The GSL Sulfate of Potash Complex The GSL potash complex (depicted in Figure I) is divided into a solar evaporation pond system and the process plants. The solar,evaporation system consists of a 17,000-acre (68.8 Km2) ponding operation where the various salts deposit during the summer evaporation season, and a harvesting operation which recovers the deposits during the remainder of the year. The harvest is either preconcentrated in the flotation plant or processed directly in the chemical plant where sulfate of potash (SOP) is produced. The chemistry of the lake brine results in a solar deposit con¬taining primarily kainite (KCl-MgSO4.3H20), schoenite (K2SO4?MgSO4^ 6H2O), and halite (NaCI), with some carnallite (KCl.MgCl2.6H20) and epsomite (MgSO4.7H20). Other minor minerals may be deposited, depending upon the weather during the evaporation season. Each year, the solar deposit in the evaporation ponds will greatly depend upon the summer weather conditions, which have in the past proven to be quite unpredictable. Weather may alter both the quantity of the solar deposit and the composition of this deposit. During, a "short" evaporation season, the tonnage deposited decreases, but depending upon the short-term weather, the potash mineral content

Jan 1, 1977

By Michael DiMatteo, Michael D. Gardner, Eric F. Perry, John K. Felbinger, Robert S. Evans

A hydrologically isolated surface coal mine was reclaimed using acid material handling, alkaline addition and ground-water management techniques. Eight pit floor drains were installed during reclamation to intercept ground-water flow in the mine backfill and minimize water table buildup. All drains began flowing within six months of installation. Water quality and ground-water discharge have been monitored for four years after mine closure. A thin water table aquifer about five to seven feet thick has developed in minespoil about 20 to 40 feet thick. Ground-water flow direction is largely controlled by geologic structure and the drains. Median ground- water discharge is about 0.43 gallons per acre per minute, and varies an order of magnitude between wet and dry seasons. About 19 % of precipitation enters the aquifer as recharge. Seven of the eight drains typically discharge net alkaline water. Alkalinity is produced continuously and concentrations are highest during dry periods. Conversely, sulfate and acidity concentrations increase during wet periods as slugs of accumulated acid products are leached. Overall water quality is controlled principally by minespoil geochemistry and added alkaline material. The drains have successfully directed ground-water to a planned discharge area. Without the drains, a ground-water mound was expected to form against a buried highwall and discharge over a large area.

Jan 1, 2000

By Robert A. Jankowski, J. Drew Potts

By implementing various mining practices, mine operators can reduce the respirable dust exposure levels of the roof bolter and the continuous miner operators. The Bureau of Mines has developed a computer program, entitled AMP (Alternative Mining Practices), that gives a quantitative comparison of these reductions. The alternative mining practices and their corresponding reductions in dust exposure levels that are evaluated by the program include a remote control continuous miner, a half-curtain ventilation system, two auxiliary fan-tubing bypass ventilation systems, a modified cutting sequence, a comparison between single-split and double-split ventilation networks, and a comparison between exhausting brattice and exhausting tubing. Descriptions of each of these mining practices are included in the report. The report also includes a hypothetical case study to show how AMP enables mine operators to select the technique(s) that is best suited to their particular needs. AMP is a compiled basic program that has been designed to run on computers with a DOS version 2.0 or later operating system. It includes high resolution graphics (640 X 200 dot positions) designed to run with video boards that are functionally compatible with the IBM Monochrome/ Printer Adapter. Graphic screens are selected from menus, and can be bypassed if the computer is not equipped to handle high resolution mode. Their primary function is to show proper implementation of the mining practices evaluated by the program. This package requires a minimum of 256K bytes of RAM. (Reference to specific products does not imply endorsement by the Bureau of Mines.)

Jan 1, 1987

By J. Klemenic

This paper presents an analysis of gold production and prices over an extended period. Production patterns are provided for the world as a whole and for the five major producing countries. Gold prices as a function of interest rates, as measured by municipal bond rates, are given for the period 1947 to the present. World gold production has had a phenomenal increase since 1980, with the exception of South Africa, all major producing nations participated in this increase, even though the price of gold generally has been decreasing since the high level attained in 1980.

Jan 1, 1993

By R. C. Schmidt

The Mont Klahoyo magnetite deposit is located about 600 km northwest of Abidjan, Ivory Coast. During an exploration period ending in 1977 an international joint venture group investigated the deposit and proved reserves of 670 million tons grading 36% iron. The deposit, occurring at the northeast end of the Baoubly-Kiriao chain of Precambrian iron formations, is associated with amphibolites, pyroxenites and gneisses of the Liberian Shield. At Mont Klahoyo occur two separate iron formations of which the lower member is the ore body. This lower member consists of a highly metamorphosed - banded quartz-magnetite iron formation in which iron silicate bands alternate with beds of quartz-magnetite. mphibolite-pyroxenites and sillimanite-cordierite-garnet gneisses form hanging and footwall rocks. The iron formation has been folded into an elongated overturned "Z" shaped major drag fold with axes trending and plunging approximately northeast. Beds are vertical or dip steeply to the southeast. The ore zone has an average thickness of 130 m and outcrops intermittently over a distance of approximately 5.5 km. Based upon detailed studies of drill cores and the results of ore dressing test work, eight stratigraphic units, identified as K-1 to K-8, are recognizable in the iron formation. Four interbedded units are low grade silicate zones (silicate facies) with the remaining quartz-magnetite units (oxide facies) repre¬senting the important ore zones of the Mont Klahoyo deposit. The ore-bearing "K" units are subdivided further, based upon their specific lithologies, iron content and concentration characteristics, into eleven ore types. The identification of these ore types is considered particularly important to mine planning and flowsheet design. A cap of oxidized materials overlies the primary quartz-magnetite iron formation but no enrichment has occurred. It is proposed that the Mont Kalhoyo iron formations were deposited, possibly chemically, in a volcanic environment as a siliceous iron formation with volcanism providing the primary source of iron and silica. Metamorphism converted the siliceous iron formation to a relatively coarse-grained quartz-magnetite-silicate iron formation.

Jan 1, 1979

By Jeffrey A. Holcomb

INTRODUCTION The passage of Comprehensive Environmental Response Compensation and Liability Act (CERCLA/Superfund) as well as the Resource Conservation and Recovery Act (RCRA) and state laws, have placed added regulatory pressures on the mining industry. These laws which focus on the regulation of hazardous substances and wastes for the protection of the public health and welfare and the environment, present the potential for tremendous financial impacts and liabilities on existing mine operators and owners and/or potential mine operators/owners. This paper takes a brief look at these laws and presents an environmental audit procedure to identify environmental liabilities prior to mine land transactions. The environmental audit approach presented is an overview of the procedures that could be used to document, evaluate and inventory existing and/or potential environmental concerns. This audit procedure can be applied to developed or undeveloped properties and at active or inactive mining sites. REGULATORY OVERVIEW Mining environmental liabilities have been addressed in RCRA, Superfund, the Clean Air Act (CAA) and the Clean Water Act (CWA). Even though the U.S. Environmental Protection Agency (EPA) has determined that mining wastes will be treated as solid wastes under RCRA and not as hazardous wastes, these wastes could still bring about a great deal of financial liability under Superfund. The catch is if the mine wastes generated contain hazardous substances such as the heavy metals arsenic, beryllium, cadmium, chromium, copper, lead, mercury, nickel, selenium, silver, thallium, zinc and others as well as cyanide. Thus, it is not only important for a mine operator/owner or a potential mine operator/owner to know if the mine wastes generated are hazardous, but it is important to know if the wastes contain hazardous substances. Following is a brief overview of RCRA and Superfund and their potential implications. RCRA RCRA, which provides the basis for the regulation of solid and hazardous wastes, is applicable to active mining and milling sites. Within RCRA the definition of a hazardous waste is provided. This definition applies to owners and operators of mining and milling sites if the operator has stored, disposed or treated hazardous wastes on-site. If this is the case and if strict process control and waste management activities are not adhered to, environmental liabilities may be associated with the site. Superfund The 1980 Superfund law can be applicable to inactive mining sites or to inactive sections of an active facility. The provisions of Superfund call for the regulation of hazardous wastes and hazardous sub- stances disposal and release not only by the existing owner, but also for any previous owner. This concept of joint and several liability means that one party, as among many, can be held totally responsible for the costs of hazardous waste cleanup (Haller, 1987). Furthermore, liabilities under Superfund have also been applied back to past acts; thus, several mining properties, active or inactive prior to the 1980 Superfund law, are at risk of being placed on the EPA's National Priority List (NPL) for cleanup. Last years amendments to Superfund, known as the Superfund Reauthorization Act of 1986 (SARA), provided some significant developments for the mining industry. The major requirement of the amendments as it pertains to owners or operators of mining sites is that the EPA must revise its present Hazard Ranking System (HRS). This is important be- cause in most cases the primary reason for several mining sites having been included on the NPL was due to the large volume of wastes generated. As is typical at most mining sites, large volumes of low toxicity wastes are generated and the current HRS model prejudices against this. It should be noted that this provision only applies to sites that are not already on the NPL or have not been proposed for inclusion on the list.

Jan 1, 1987

By H. Dreissen

Upgrading of low-concentration ores is of growing importance today. The Heavy Medium Cyclone Process, thanks to strong centrifugal forces, effectively separates particles varying only slightly in specific gravity but widely in size. The paper discusses the separation efficiency, the method of assessing that efficiency, and the influence of such factors as medium solids. The operating results of nine heavy medium cyclone plants handling following minerals are reported: barite, wolfram, iron, magnesite, diamond, lead-zinc, fluorspar, rocksalt potash. Highlighted are an improved recovery system for heavy medium and some other developments, such as techniques for separation down to 0.1mm and the application in the field of recycling.

Jan 1, 1980

By Ben W. Burdett

The operation of an electrolytic refining tank house is an art as well as a science. If the electro-refining industry is to progress, a better understanding of the refining process is necessary. This would help to reduce the amount of training necessary to produce competent tank house operators who, in turn, would be able to increase both quantity and quality of the tank house product. To aid in understanding this process, quantitative relationships between the critical tank house variables must be established. The inherent major contributor to inefficiency in most tank houses is short circuits. By quantifying the effect of short circuits on each of the other variables in the system, as well as their effect on over- all system performance, better decisions regarding manpower allocation can be made. Current distribution under short circuit conditions, which has always been somewhat of a mystery, can be studied in detail. The relative importance of electrolyte balance, proper anode-cathode spacing, low contact resistance at points of electrical connection, and other system variables can be determined, With a better understanding of these variables, the steps necessary to increase current efficiency are more easily defined. Relationships between most of these variables are described in qualitative terms in the literature, but quantitative relationships between tank house variables have never been established. A realistic mathematical model of the tank house could be used to test the effect of variations in a single variable on other variables in the system, and thus define the quantitative relationships between tank house variables. It is not the purpose of this paper to establish these relationships, but to describe a recently developed model that can assist in their establishment. A computer program implementing this model has been applied to examine the effect of short circuits on overall current distribution. Some of the results are given here as examples of the utility of this program.

Jan 1, 1973

By H. L. Lovall

Huge banks of preparation plant refuse and other non¬saleable materials have accumulated over the years in all major United States coal producing areas. These banks, esthetically and commercially undesirable, can cause air and water pollution and land reclamation and mineral conservation problems for the industry and nearby communities Although some refuse banks have been reworked to recover saleable coal, all remain and accumulation continues. Even those previously processed continue as potential hazards. Among the several problems created by refuse banks, in situ combustion is most treacherous. Of the millions of tons of major accumulations, there are at least 450 refuse banks on, fire at this time Attempts to extinguish such fires are costly, impractical and generally unfruitful. Studies are in progress to evaluate the potential of processing such materials to eliminate the combustion capability and to yield usable fuel and nonfuel products. Aspects of the study now in. development for coal refuse include: (a) evaluation of characteristics (size, sink-float, ash, sulfur and calorific value) of the coal refuse materials which are known to be highly variable, (b) development of an ignition test having significance for in situ conditions, (c) study of processing capabilities (comminution for liberation, pilot plant washing tests), and (d) investigation of potentially significant properties of fuel and nonfuel products which could be altered to enhance their market potential.. Among the latter products are lightweight aggregate, fill for mine slushing operations, construction, etc: Plans are to extend the studies to include the design, erection, and test processing of refuse with a transportable plant,; which could provide basic economic and product utilization data from several locations

Jan 1, 1964

By Richard L. Ash

In many instances, blasting exerts the dominant control over the economics and safety of excavation, where the materials involved are too hard and tough to be fragmented efficiently by other means. However, associated with the fragmentation process other effects very often result that are not desirable and may even be hazardous, such as fly rock, air blast, excessive overbreak, and damaging ground virbrations. It has always been the desire of those concerned with blasting to better control the forces involved so as to improve the breakage of materials, but at the same time reduce, or eliminate if possible, the unwanted side effects. Until the last decade or two, little was known of the phenomena concerned with blasting. However, since that time many investigators have studied blast mechanisms produced from both chemical and nuclear explosions, with the result that general concepts of the principles have been developed. But, in general, it is assumed that the energy from the explosion would be propagated spherically throughout the material, the latter of which for convenience of analyses is considered homogeneous and isotropic, i.e., the properties are the same in all directions, However, rocks are not isotropic as a rule, and evidence clearly indicates blasting forces rarely function uniformly or in spherical form as theorized.

Jan 1, 1965

By John J. Sammarco, Alan G. Mayton, Elaine N. Rubinstein

Researchers from the U.S. National Institute for Occupational Safety and Health (NIOSH) developed the Saturn light that significantly improves illumination for roof-bolting machine operators while reducing glare. The existing roof-bolter lighting was the baseline and was compared to the Saturn at 100, 75 and 50 percent intensities. Discomfort glare and disability glare were measured by the De Boer rating scale and the Mars Letter Contrast sensitivity test, respectively. Thirty study participants were tested. Discomfort glare was reduced at least three levels with the Saturn luminaire. Visibility levels were four to 6.5 times better with the Saturn than with the baseline. The Saturn design is freely available for commercialization.

By L. A. Price

With increased stripping ratios and with dwindling ore content, the mining fraternity is increasingly turning to larger and larger equipment for profitable open pit operations. The availability of higher horsepower prime movers and increased capacity electric transmissions using either wheel mounted or axle mounted traction motors makes a reality of single axle, rear dump trucks having 150 to 250 ton capacity. The size of electric loading shovels is inherently geared to the size of haulage equipment. To work effectively with this new generation of trucks, the Harnischfeger Corporation has introduced its P&H Model 2800 with a capacity of 20 to 25 cubic yards and a working weight of nearly 1,500,000 pounds. The Model 2800, depicted in Figure 1 loading a 200 ton truck, has many new electric and mechanical features designed to give excellent production and low cost operation. Chief among the new features is the ELECTRO TORQUE* control system. ELECTROTORQUE is a completely static, solid state electronic system supplying controlled power both to the armature and to the fields of the d.c. shovel drive motors. It eliminates many major electrical rotating machines and their attendant maintenance. The system was developed jointly by ASEA of Sweden and Harnischfeger Corporation.

Jan 1, 1969

By David A. Holmes

After a century of variable government-supplied housing on their cold, windswept lands, and facing extremely limited natural resources and no timber, the Standing Rock Sioux Tribe has launched a study into alternative housing approaches for their people. Considering that they have little more than the soil and limited river aggregates under their feet, the Tribe has elected to consider adobe and earthen-wall construction. Earthen construction is no stranger to the Sioux lands. Smaller tribes, including the Mandan, Arikira, and Hidatsa, lived here among the Sioux in earthlodges for centuries. Such earthlodge structures were not unlike the Southwestern jacal style-a framework of upright branches and branches covered with mud-employed by the Anasazi about A.D. 700-900. Indeed, the Sioux people themselves evolved from earlier earthlodge dwellers. Indigenous peoples in New Mexico, Arizona, and neighboring Mexico have used earthen-wall housing for many centuries, reinforcing Sioux observations that this is today an earth-friendly, cost-effective, and practical approach. The Cheyenne River and Pine Ridge Sioux Reservations also recently have conducted studies on earthen- wall construction. This paper describes the search for and evaluation of potential raw-material resources for earthen-wall/adobe construction on the Standing Rock Reservation in North and South Dakota. Significant resources of clay/silt materials (8 million tons in the Striped Cloud clay bed) suitable as adobe binders and sand-and-gravel aggregate (2.5 million tons) that could support earthen/adobe construction have been identified throughout the Fort Yates Flat area on the Reservation. Also addressed is how adobe and rammed-earth construction could add to the diversity of reservation construction and address future Tribal housing and other building needs.

Jan 1, 1999

By Sam S. Arentz

Storm King Mines began with the concept that the resource potential of thick and steeply pitching seams of the Grand Hogback region of Colorado could be mined profitably. Two large tracts of private land (fee coal) were acquired; approximately 23.8 km2 near Glenwood and 16.2 km2 near Meeker. Figure 1. Although both properties have substantial coal reserves, one has several distinct advantages in developing a competitive mining operation. Table 1 illustrates these advantages. Among the most important considerations from an economical point of view are proximity to railroad, highway, labor force, quality of coal, seam thickness, and source of water. As can be seen, Storm King Mines' property is adjacent to the main line of the D & RGW Railroad, 1-70, and the Colorado River. The cities of New Castle, Glenwood Springs, Silt, Rifle, Carbondale, and Parachute are within short commuting distances and have available skilled labor.

Jan 1, 1983