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By Avula Rajashekar Yadav, Sreenivasa Rao Islavath

Barrier pillars and gateroads play a vital role for the safe exploitation of coal from the panel in the longwall workings. The barrier pillars and gateroads are subjected to the front abutment and side abutment loads during the retreat of the panel. These structures may fail if the developed load on them is higher than their strength. The stability of the longwall structures such as barrier, gateroads and face is paramount in extracting the coal from the panel safely. For this, a deep longwall mine in India is chosen for the study using a 3D numerical modelling technique. In this paper, three critical conditions such as scenario 1 (no side goaved-out panel), scenario 2 (with side goaved-out panel) and scenario 3 (with two side goaved-out panels) are taken. For each scenario, five retreat distances such as 100, 125, 150, 175 and 200 m are considered for detailed investigation. The development of vertical displacement in gateroads, vertical stresses on barriers, vertical stress concentration factor, abutment zone and yield zone for longwall face are extracted and analyzed. Also, the safety factor of the barrier and longwall face is estimated considering the Hoek–Brown rock mass failure criterion. From the study, it is observed that the maximum vertical displacement of 121 mm in TG3 at scenario 3 for a retreat distance of 200 m and a minimum vertical displacement of 33 mm in TG2 for a retreat distance of 100 m at scenario 2. The development of vertical stress on the barrier is found to be between 8.78 and 13.40 MPa, and the safety factor of the barrier lies in between 1.56 and 1.80. The study also revealed that the yield zone at the longwall face lies within 2 to 3 m.

Dec 29, 2023

By T. A. Vivian

The use of heavy media organic solvents to recover coal from its attendant gangue is hardly new. DuPont built a pilot plant using pentachloroethane in 1936 at Weston Coal Company, Weston Breaker, Shenandoah, Pennsylvania. That's almost half a century ago. Since that time, it has become common practice to utilize similar classes of chemicals in laboratory separations of coal samples. It is the objective of this paper to discuss some specific separations on both pilot and laboratory scale on samples representing different classifications of coal. These separations have been carried out on coarse (+4 M), middling (4 x 20 M), and fine (-20 M) coal samples. The coal samples tested include Pennsylvania anthracite; Pennsylvania, Indiana and Colorado bituminous; Wyoming sub-bituminous; and Texas lignite. Other chlorinated solvents were used to vary the specific gravity of separation.

Jan 1, 1984

By P. Michael

Proponents of geomorphic mine land reclamation have criticized current reclamation practices in the coal fields of steep-sloped Central Appalachia as too narrowly focused on civil engineering principles and neglectful of the functional and aesthetic benefits of reclaiming mine sites in ways that mimic natural landforms and drainage patterns. They observe that current mining and reclamation practices are radically transforming the mountain-and-valley terrain into gigantic flat plateaus and, in doing so, disrupting the beauty and ecology of the natural landscape. Instead of designing and constructing linear or planar surfaces and unvarying slope gradients during the reclamation process, they recommend ?landforming,? i.e. the adoption of curvilinear, compound slope forms that blend well with the surrounding physiography and represent the result of naturally stabilizing geomomorphic processes. The authors feel that the concept of geomorphic mine land reclamation is sound, however, its application to the Central Appalachian coal fields faces significant--albeit not insurmountable--challenges. They include: (1) existing reclamation enforcement regulations that are focused on civil engineering principles and not explicitly supportive of geomorphic methodologies; (2) regulatory agencies? current intent to limit the down-gradient reach of excess spoil fills in order to allay disruption or burial of natural streams; (3) actual or perceived increases in reclamation costs; and (4) the challenge of designing and constructing ?natural? landforms that are mature and stable in an otherwise youthful, erosional landscape.

Jan 1, 2010

By Earl Gardiner, Michael Grenier, Stephen Hardcastle, John Vergunst

A prototype, self-contained mine refuge station air supply sys- tem was tested in an underground metal mine to verify it's ability to keep oxygen and catbon dioxide levels at acceptable concentrations in an emergency situation. In this test, 25 volunteers were assembled and sealed in a functional underground refuge station for a period of 24 hours, without the benefit of the standard com- pressed air supply. The prototype system was designed to: 1) operate on a self-contained power supply for a period of at least 27 hours; 2) supply oxygen at a metered rate; and 3) remove car- bon dioxide by re-circulating refuge station air through soda lime scrubbing beds. During the test period, the catbon dioxide concentration remained at an average of 2500ppm and oxygen concentration stayed between 20.2% and 20.6%. The volunteers found the prototype easy to use and seemed confident in its ability to provide a safe atmosphere. The test showed that this technology could become part of an underground mine's refuge station emergency equipment.

Jan 1, 1997

By A. Anani

The goal of hot mix asphalt (HMA) design is optimal material blending to meet Superpave specifications. HMA cost minimization has being modeled as linear programing (LP) (Awuah-Offei et al 2011) and mixed integer LP problems (Brown et al, 2012) and solved with commercial software such as LINDO and CPLEX. Often these software, which are designed to solve general optimization problems, have licenses that cost thousands of dollars. The objective of this study is to develop a novel solution algorithm to the HMA optimization problem presented by Brown et al. (2012), which will negate the need for expensive commercial packages and is specific to this problem. This novel algorithm is based on the branch and bound algorithm for solving mixed integer problems. The algorithm is incorporated into a software package with an easy-to-use graphical user interface. The developed algorithm is validated using a real-life HMA problem. Using this solution algorithm will save companies thousands of dollars, otherwise used to purchase software licenses.

Feb 23, 2014

By G. R. Coonan

A number of famous studies have shown that house damage relates better to peak particle velocity than to acceleration or displacement. The relationship is true but doesn't go far enough. Why, for example, can construction shots go well above 1.0 or 2.0 inches per second without reportable damage? Recent studies have shown that vie must look at frequency and duration of an event in addition to amplitude. The complexity of measuring frequency, duration, and amplitude makes the average blaster in the field shudder. An even more excruciating problem is the need to obtain such data inside the building or residence in order to accurately predict the damage potential or human response to nearby blasting. The author reviews current research programs and suggests new areas of research necessary to help maintain a balance between complicated research requirements and simple field measurements.

Jan 1, 1980

By J. Tavares

It is no mystery why the mining industry has such lofty safety standards. In dealing with Mother Nature and gravity, the combination of the two can create significant hazards from high wall and tunnel collapses to huge landslides. The loss of production from a major disruption could be enormous. The price tag on the loss of human life is immeasurable. The evolution of geotechnical instruments and software has been ongoing for years. But the biggest innovations have occurred during the era of cell modems, internet, and wireless networks, allowing for real time data and alarms to be delivered globally anywhere and anytime to one?s computer, laptop and smartphone. Yet in some ways you can thank the urban construction projects for developing much of the technology in use by today?s mines. Due to the density of population and the billions in dollars of structures and infrastructure in cities throughout the US and the world, urban projects have faced intense scrutiny for years. Out of this scrutiny was born the necessity of real time automated monitoring of instrumentation and sensors, a defence against catastrophic failures, and real time early warning systems through alarms that can and do saves lives. It is also possible to identify areas of concern with subsequent remediation prior to failure.

Feb 23, 2014

By I. K. Gilmore

Texasgulf Inc. currently operates an open pit phosphate mine in the central coastal plain of North Carolina. The area of phosphate deposition lies within the Aurora Phosphate district which consists of an embayment which is in the center of the Neogene phosphate deposition. A variety of solid and liquid fertilizer products are produced at the Texasgulf complex. One of these products is known as North Carolina Natural Phosphate (NCNP). New potential for use of unacidulated natural phosphate, now exists in regions with acid soils due to the discovery of the findings from recent research, cost advantages, and moves to reduce chemical inputs.

Jan 1, 1995

Introduction Agrico Mining Co.'s Florida mining division has three surface mines and employs nearly 700 workers. The division produces some 6.3 Mt (7 million st) of phosphate rock annually. It is a good business. And Agrico has made it better by making it safer through a new approach to mine safety. In one year, Agrico - the second largest phosphate mining company in the US - recorded a stretch of one million manhours without an accident. That same year, the direct cost of accidents dropped to $9137 from a previous five-year average of about $50,000. Together with Don Roe, division manager of safety and security, Division General Manager Don Morrow made 1981 a watershed year for safety at Agrico. Morrow called on consultants from Safety Management Services of Du Pont's Specialty Services division to strengthen a safety program that was already better than average. From the late 1970s and into 1981, lost-workday cases (LWCs) were costing Agrico an estimated average of $22,000 each. And they were occurring with alarming frequency. In 1977, the company recorded six LWCs at an incidence rate of 0.64. This was followed by a jump to nine cases in 1978. In 1979, both occurrences and the rate increased - 10 LWCs at a 1.19 rate. The number of LWCs decreased to seven in 1980, with a rate of 0.71. Agrico instituted a far-reaching safety program in 1981, which began to take full effect in 1982. LWCs dropped from five in 1981, to three in 1982. And the direct cost plummeted from $110,346 to $28,828. In 1983, the mines recorded only one LWC. Its $9137 cost represented a reduction of $101,209 since the Safety Management Services of Du Pont had been called in. Through early 1984, the LWC incidence rate at the facility's three mines, phosphate drying plant, and transportation department was down to 0.26. This is 84% lower than the 1982 mining industry average, making it the safety leader among all Agrico companies, including its chemical plants. New Approach Agrico had the basics of a safety program in place when the Du Pont consultants arrived. But Du Pont suggested changes in responsibilities and company philosophy that formed the foundation of

Jan 1, 1985

By Marianne Snedeker

In September 1985 we published a questionnaire asking about the content of MINING ENGINEERING and about your interests. By Dec. 10, our cutoff date, we had 430 responses, representing about 1.5% of the 28,238 people who received the September issue of ME. In the data that follow the tabulation and percentages are based on the number of individuals who responded to the particular question. About ME Through responses to the questionnaire, we were hoping to learn more about you, your interests, and how the magazine could better serve you. Those of you who responded told us something positive - you look at or read the magazine. Of the 430 respondents, 428 or 99.5% indicated that they had read or looked through the July and/or August issues. Those of you who refer to the magazine once are 207 or 48.5%. Those of you who refer to the magazine two or three times are 193 or 45.2%. Those of you who refer to the magazine four or more times are 27 or 6.3%. How much time do you spend reading the magazine? Of those responding to this question: 64 spent up to 1/2 hr 15.0% 224 spent up to 1 hr 52.6% 115 spent up to 1-2 hr 27.0% 23 spent more than 2 hr 5.4% In an informal survey among our staff, we determined that most people spend 1/2 to 1 hr reading magazines to which they subscribe at home. Does that match your experience? Many of you, 335 or 79%, clip your magazine for further reference. Also, many of you, 313 or 73.6%, do not pass your copy on to another reader, indicating that you are clipping it or receiving the magazine at home. Those magazines that are passed on reach: 1 person 3 0.7% 2 people 64 15.1% 3-5 people 34 8.0% 5 or more 11 2.6% Answers to what portions of the magazine you find useful indicated that the top three were Industry Newswatch, feature articles and Technical Papers; see Table 1. The "other" category included advertising - display, classified, Employment, and Professional Services - Washington Survey, New Products, Free Literature, book reviews, technology news, and Coming Events and Short Courses. We asked your appraisal of the technical level of the magazine. Of those responding, 39 or 9.1% indicated that it is too technical, 55 or 12.8% indicated it is not technical enough, and 335 or 78.1% judged it to have the correct technical level. In response to the question about whether you like to read an occasional feature that is not technically oriented, 21 or 5.1% said no, but an overwhelming 94.9% (393) said yes. Of the specific

Jan 1, 1986

By Jorge Ferrero, Andreas Raedle, Uhland Konrad, Michael Dutton, Keivan Pak Iman, Walter Trisi

Strabag, in partnership with Arup, is constructing the Advance Tunnel for the Scarborough Subway Extension (ATSSE); a project by Metrolinx and Infrastructure Ontario (Sponsors). The 10.7 m internal diameter single bore tunnel represents a significant departure from the traditional arrangement of twin subway tunnels in North America. ATSSE is the first-time steel fibers are used to solely reinforce a tunnel of this size in Eastern Canada. This paper discusses the challenges with design and acceptance of SFRC segments and the state-of-the-art numerical models employed to check the joint performance. The advance procurement approach for TBM and PCTL’s procurement to accelerate the project schedule is also presented.

Jun 13, 2023

By John D. Smart, John W. Sager

The following paper is an evaluation of the instrumentation programs on recent Corps of Engineers tunneling projects. The authors have first-hand knowledge of the NORAD Cheyenne Mountain Complex (NCMC) Expansion Project. Information on the other projects comes from conversations with those directly involved in the instrumentation programs and from referenced reports. The specific objectives of this paper are: (1) to state the purposes of the instrumentation programs, (2) to discuss the benefits gained from the instrumentation, and (3) to present conclusions from this study that will provide guidance to those planning instrumentation on future projects. Presentation of detailed descriptions of the projects and instrumentation data is limited to that necessary to the accomplishment of the above objectives. NCMC EXPANSION PROJECT The NCMC is located at a depth of approximately 800 feet in Cheyenne Mountain near Colorado Springs, Colorado. For the current expansion project new chambers were mined to accommodate a new diesel power plant and associated cooling and air handling equipment. During 1971 some 55,000 yd3 of granite were mined through existing access tunnels for this expansion. A model of the new excavation is shown in Figure 1. The light shaded areas are new openings, and the dark areas are portions of the existing operating complex. The large chamber to the right is the power plant chamber and has a span of 67 ft, a height of 50 ft, and a length of 172 ft. The other large chamber on the lower level is the cooling tower chamber and has a span of 38 ft, a height of 45 ft and a length of 185 ft. The small chamber on the upper level has a span of 20 ft and is 27 ft high and 140 ft long. Other major excavations are the 18 ft diam air tunnel

Jan 1, 1997

By D. Kruse, M. Sanaei

"3D finite element models of the Segmentally Lined Shaft (SLS) structure are simulated as means of numerical analyses of the system’s structural behavior. Top-down constructed rings, comprised of precast concrete segments, create a large diameter, relatively shallow underground space that can be utilized for various applications. To further investigate the effects of soil conditions and different loadings on the shaft structure, the FE model was run under various boundary conditions. Simulations include a) effects of various soil layers on the SLS, including a circumferential boundary of modified ground, b) effects of various soil layers on the SLS without any ground modification, c) Seismic analysis of the SLS with ground modification and d) Seismic analysis of the SLS without any ground modification. Comparing the analyses outcomes emphasizes the significance of the inclusion of the ground modification boundary in the structural performance of the SLS. INTRODUCTION TO SLS Underground structures are classically built rectangular in shape, which normally requires a two-step construction process beginning with installation of temporary shoring to support earth loads during the excavation, followed by the construction of the permanent structure. Attractive and practical alternatives are circular shafts referred to as segmentally lined shafts (SLS). The structure consists of a stacked series of rings formed from an assemblage of precast concrete segments. Top-down constructed systems of large diameter, relatively shallow SLS structures provide both temporary earth support during excavation and permanent structural support for many civil and building applications. The circular shafts sustain the lateral earth pressure mainly through hoop-stress mechanism, resulting in improved stability and structural efficiency. Cylindrical shell structures with large diameter to wall thickness ratios are prone to buckling under external pressure. In typical designs of small diameter shafts and tunnel linings with small diameter to wall thickness ratios, nonlinear buckling analysis (i.e., nonlinear geometric analysis) is usually not considered, since the buckling capacities for those structures are much higher than typical pressures encountered at their design depths. With an economically viable wall thickness, buckling becomes a critical issue, which should be addressed, for circular shafts with very large diameters. In the design and construction of the SLS, the stability of the structure can be improved by modifying the soil surrounding the circumference of the shaft to a limited thickness and to about 10 ft below the finished shaft structure. This thick wall of soil mixed with cement creates a composite integrated structure while serving additional purposes such as ground control and ground water seepage cutoff."

Jan 1, 2016

By J. F. Archibald

It is often alleged by mine ventilation engineers that no reliable method exists to forecast the levels of radiation to be encountered in future uranium mines. It results that the design of uranium mine ventilation systems is based on factors other than radiological hazards, such as radon and radon daughter concentrations, for which permissible limits are set. Ventilation has been used to date as the main control mechanism for radon and radon daughters. Although it has become increasingly difficult to provide enough ventilating air to reduce the radon gas and its daughter products to safe levels in some mining arrangements, it is not the object of this paper to discuss alternatives to ventilation. This paper will describe a methodology followed by the authors over the years to estimate the levels of radiation to be encountered in underground and open pit uranium mines. Ventilating air is used to maintain working level concentrations within safe limits. The sources of radon and radon daughters and the quantities of each which will be produced, will be of great value in planning and designing a ventilation system to control them. This information can afterwards be integrated into the overall mine design. The methodology to be outlined can also be used to estimate, given a mine design format, the radiation levels to be encountered. If levels are not acceptable, modifications in the mine design can be made at an early stage. The emphasis is placed on an integrated effort where the ventilation engineers and the mine design engineers work in close collaboration from the very start of the mining project. Estimation of radon and radon daughter levels can be initiated as soon as core samples are obtained from the exploration programmes.

Jan 1, 1980

By R. R. Godard

The practice of dust abatement or control is not new to any operation of United States Steel Corporation. This report will review those activities, past and present, within the five operating districts of United States Steel-Coal Operations with specific reference to mechanical and continuous mining, and including both the health and safety aspects of the problem. Obviously, the first principle of dust control is to inhibit its formation If this is not practical, steps may be taken to prevent its becoming airborne. Airborne dust control can be realized by either collecting it at the point of generation, diluting it with large volumes of air to reduce concentration, settling it by various means, or with reference to ignition hazard only, render it incombustible by neutralization with an inert material. These basic principles have been verified by the work of many, including the Bureau of Mines, U. S. Department of Interior, Bituminous Coal Research, Inc., and the Mining Research Establishment of the National Coal Board of Great Britain. Their application to every day mining problems is best illustrated by the following examples.

Jan 1, 1967

By William T. Jr. Renfroe, Donald C. Gipe

INTRODUCTION Historically, pollution control in the metal-ore mining industry has been very limited. Unless mine water contained large quantities of solids, it was generally discharged without any treatment. If treatment was used to control solids, it was principally the provision of a settling basin in the form of a tailings impoundment used in conjunction with an associated metal ore dressing facility. Recently, however, a growing awareness of the adverse environmental impacts of mine drainage, coupled with strict environmental laws, has prompted the mining industry to look at new technologies and to refine the existing methods to further treat the wastes generated. This industry is unique in that waste loadings are extremely variable, and a "typical facility with typical waste loads" does not exist. Consequently, one waste- water treatment system cannot be utilized on an industry wide basis; rather, each treatment system must be designed specifically for the pollutants in each individual discharge. Public Law 92-500, the Federal Water Pollution Control Act (FWPCA) Amendments of 1972, became effective on Oct. 18, 1972. This law completely restructured Federal laws and philosophies underlying the Federal approach to water pollution control. Prior to the 1972 amendments, the principal Federal regulatory tool had been water-quality standards based on a designated use for a particular body of water. The concept was that waste disposal into water bodies is a desirable and acceptable use of the water body if it does not interfere with other beneficial uses. This had the effect of requiring various degrees of treatment and, consequently, various economic hardships on industries de- pendent upon their location. In many waterways. it is very difficult to quantitatively relate discharges to water quality. The 1972 amendments changed the basic philosophy, as stated in the Senate Committee report on the bill, to ". . . no one has the right to pollute . . . that pollution continues because of technological limits, not because of any inherent right to use the nation's waterways for the purpose of disposing of wastes." Pursuant to Sections 301, 304(b), and 306 of the FWPCA Amendments of 1972, the US Environmental Protection Agency (EPA) was required to establish effluent standards applicable to all industrial discharges. These standards must be based upon the application of the "best practicable control technology currently avail- able" (BPT) and the application of the "best available technology economically achievable" (BAT). The BPT and BAT levels must be achieved industry-wide by July 1, 1977, and July 1, 1983, respectively. WASTE SOURCES The waste-water situation in the mining segment of the ore mining and dressing industry is unlike that encountered in most other industries. Most industries (e.g., the milling segment of this industry) utilize water in the specific processes they employ. This water frequently becomes contaminated during the process and must be treated prior to discharge. However, in the mining segment, process water normally is not utilized in the actual mining of ores (exceptions are hydraulic mining operations and dust control), but it is a natural occurrence that interferes with mining activities and must be removed before mining can commence. Water enters mines by ground-water infiltration and surface runoff, and it comes into contact with materials in the host rock, ore, and overburden. The underground mine must pump large quantities of ground water to prevent flooding of the mine. Water from surface mining operations generally occurs as a result of surface runoff of rainwater. Generally, mining operations control surface runoff through the use of diversion ditching and grading to prevent, as much as possible, excess water from entering the working area. Nevertheless, some surface runoff does come into contact with the working area and may become contaminated. The quantity of water from an .ore mine is unrelated, or only indirectly related, to production quantities. De- pending upon its quality, the mine water may require treatment before it can be discharged into the surface drainage network. The variability of water quality from mines can best be demonstrated by looking at Table 1. This table shows the range of pollutant concentrations in untreated discharges from three different categories of mines (as categorized by EPA in the development of BPT and BAT effluent standards for the metal-mining industry). Data for this table were obtained during EPA's preparation of effluent standards for this industry. The parameters shown on the table are the pollutant parameters of primary interest in this industry; blanks in the table indicate that data were not available, and the parameter is not expected to be present in significant quantities. Other pollutant parameters are present in mining waste water, but they are either incidentally removed in the treatment process or are found only in trace amounts. The three categories comprise more than 90% of the metal production value in the United States and approximately 95% of the total mine discharges. It is important to note that not all parameters are found in significant concentrations at all locations. IMPACT ON WATER QUALITY One of the most troublesome mine-drainage problems is acidity. Although generally associated with coal mining, acid mine drainage frequently occurs from other types of mines. Although the exact mechanism of acid mine drainage is not fully understood, it generally is believed that pyrite (iron sulfide, FeS,) is oxidized by oxygen (Eq. 1) or ferric iron (Eq. 2) to produce ferrous sulfate (FeSO4) and sulfuric acid (H2SO4) . The mining of ores associated with pyritic material exposes the pyrites to water and oxygen and grossly accelerates the natural oxidation processes, resulting in the significant production of acid mine drainage.

Jan 1, 1982

By Roy Woodall

Successful mineral exploration is the lifeblood of the mining industry. Contrary to what the environmental lobby would have the world believe, the industry is replacing the metals it is extracting. The reserve base has not changed significantly in 20 years (Fig. 1.) Mineral exploration is a research activity. First there is the idea, the vision or the intuitive thought. The experiments follow. These involve repeated phases of data gathering, data interpretation and concept testing through drilling. For many companies, exploration is the main investment in scientific research. Each mineral exploration experiment may involve years of costly work. Despite the improving tools of science and technology, the investment remains high-risk. Only the promise of high rewards, or desire to survive as a mining company, will stimulate the necessary commitment and level of investment. Confidence that an economic return can be achieved, confidence in the science and technology being applied and confidence in the people involved are the foundations upon which successful mineral exploration is built (Woodall, 1984). The challenges facing the explorationist in the 1990s fall into two categories: - the challenge to make the activity economic; and - the challenge to make the activity socially and, therefore, politically acceptable.

Jan 1, 1992

By C. F. Meyer

The recirculation of mine air in an underground colliery, has always been regarded as a hazardous practice in South African collieries. The Mines and Works Act and Regulations states that fresh air, flowing Into an underground section, must flow out directly into the return airways after being utilized once in the section. One of the largest producing underground collieries in South Africa, Initiated a project on controlled recirculation with the permission of the South African Government Mining Engineer. The project involves the recirculation of 65 m3/s of air inside a ventilation district which serves a total of six production areas. The aim of the project was to increase the airflow to the sections without altering the existing ventilation system. Tracer gas studies were carried out to determine the actual distribution of the recirculated air to the individual areas. The results showed that an effective 54,18 m3/s of the recirculated 65 m3/s reaches the sections. This gives an air utilization figure of 83,4 per cent. Dust surveys were also carried out as part of the project to determine the effect of the recirculation of the return air on airborne dust levels. The results showed that the dust levels remained constant in the main intake and return airways and that no hazardous situation was being created. The project proved to be successful and showed that controlled recirculation can be executed and used as a solution for the supply of air to sections without endangering any lives.

Jan 1, 1993

By Peter V. Avotins

During last year's AIME meeting in New Orleans, Deepak Malhotra and I were discussing some of the topics that would be presented in this Symposium. It seemed appropriate that along with papers on specific reagent and flocculant types, we should address research management aspects of new product development. This development is a long, arduous task that requires a significant technical and fiscal commitment by the chemical company and potential users. A flow chart depicting the research process is shown in Figure 1. The sequence of events are plotted on an undefined time line. Our experience has shown that it takes 3-5 years to complete a typical reagent development project. A new project starts with an idea of how to do something better. The ideas range from relatively simple product modifications to opportunities created by technological change. An example of this is the use of flocculants in tailings operations to close the water recycle loop. The change was brought about by the need to conserve water and comply with environmental statutes. The result was the development and wide-spread use of synthetic polymers to help in solid-liquid separation. More recently the ups and downs of oil prices have led to development of coal water slurries as an alternative to fuel oil. The slurries contain high levels of chemicals (up to 3%) to insure proper stability and burn characteristics. There are technical changes under way right now that may lead to ideas for other new products. One exciting source of new technology is the ability to manipulate genetic material of microbes to select for specific capabilities. This has evolved by leaps and bounds over the past 5 years. Biologically assisted leaching and removal of wastewater impurities are two possible end uses. I'm sure that there are many others. The ideas can originate anywhere and are often half-baked at first, but to lead to new products they must be refined to provide project definition and eventually a research plan. A chemical ,development project cannot be started without approval to commit the company's resources. The internal selling job is often very difficult. The company must see clear financial benefits in order to launch efforts that may not pay off for many years. It is critical to project the total market, profitability, eventual market share, and timing of introduction of the new product. There is much uncertainty in this and the research manager is often skating on thin ice to retain his credibility. Once we obtain support from upper management, the research team is assembled to start the project. The teams generally consist of organic chemists, research metallurgists, and technicians. They have access to analytical scientists and technicians for surface and analytical chemistry. The projects are often augmented by help from university staff and consultants. This is particularly true where there is a need to develop fundamental understanding of the technology in addition to synthesis of chemicals. The project now proceeds along two lines. First, there is an emphasis on understanding the prior art. Extensive literature and patent searches are undertaken to provide research leads and to keep from "reinventing the wheel" and infringing on someone else's patent. The scientists and technologists are qualified to conduct computer-assisted library searches. This process usually uncovers 80-90% of the relevant information. The remainder is very much harder to get and requires the help of professional library search staff with scientific backgrounds. Along with literature searching, the team begins synthesis of new compounds. These are screened by use of techniques such as microflotation or filtration in a Buchner funnel. The scientists are looking for the direction of response as they modify structural features . Inevitably, a large number of candidates reach the next stage, a laboratory bench test. At this point it is possible to set up a research plan and use project management techniques to monitor progress. The bench tests are conducted in larger equipment, usually requiring 100-1000 grams of test substrate. Typical laboratory flotation tests are run in Denver or Wemco cells.

Jan 1, 1986

By J. C. Rhodes

The demand for good white minerals for many industries including paint and plastics have made it necessary to import high grade industrial minerals from various parts of the world. Some of the calcium carbonate, barite and talc minerals are from China, Mexico, Jamaica and Haiti. These materials can be processed by custom processors. The custom processor can provide a service to the Industrial Mineral owner. The imported materials can arrive in various feed sizes from lumps (3"-6") down to 325 mesh. The materials can also be in various size shipments or container loads. The economics for importing should be investigated thoroughly. The two factors just mentioned can influence the quantity of material to be processed. These two factors can also influence the total cost for each end product.

Jan 1, 1989