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It is a sad commentary on human nature that for every successful, unscrupulous entrepreneur you need a multitude of incautious, greedy investors. One wonders whether is will be ever possible to completely protect investors from their reckless gambling instincts, which are so widely encouraged elsewhere in society.

Jan 1, 1989

By A. F. Roberts

The subject of mine fires is a very wide one. To give reasonable coherency, the paper concentrates on the behaviour of fires in the ventilated airways of mines; spontaneous combustions are not considered. The following topics are considered in some detail: 1) Material selection: Performance requirements for mining materials in terms of flammability and smoke/fume production; methods of test and need for relevance to mining conditions. 2) Fire growth: The influence of material properties and method of use on the rate of growth of fire in a mine roadway; the influence of ventilation, slope, material orientation, proximity of walls and roof on fire behaviour. 3) The fire in the ventilation network: The influence of fire on the ventilation distribution; the circulation of fire products in the network. The influences of these topics in determining fire control strategy are then considered but topics such as fire detection and fire extinction methods are not reviewed in detail. An extensive Bibliography on papers relating to mine fires is included.

Jan 1, 1989

It was Harold McMillan, Prime Minister of England 30 years ago, who used the phrase "The Wind of Change" to describe political events in Africa in his day. So well did this phrase capture the spirit of the time that it echoed around the world, and the echo has never stopped. Change is the constant factor in the society in which we live and everyone of us has had experience of the effect which it has had on our professional and personal lives.Change will not stop, it will continue at an increasing rate and the questions we must answer are how do we prepare ourselves to meet the challenge of future change and how do we take advantage of the opportunities which it will bring?It is these questions which I wish to discuss in this address.There is nothing new about change in the mineral industry, it has been happening for thousands of years and it will continue as long as civilisation exists on earth. One type of change is economic and we are all aware of the rises and falls which occur in the prices of metals and minerals (Figure 1). When these have happened in an orderly manner, and could be predicted and planned for, it has been possible to take advantage of the benefits and minimise ill-effects, but when they were sudden and precipitate, and could not be predicted, the consequences were serious. The extreme example, of course, was the oil price shock of the 1970s which had such disastrous effects on industry and society.Other types of change are social, cultural and political. They have all been important in recent years and will continue to be so in the future.But it is technological change which may well be the most important because its effects are profound and irreversible, and alter irrevocably the way in which we live. So in discussing the mineral industry in a changing world I will talk specifically about technological change.

Jan 1, 1989

By A J LYNCH

It was Harold McMillan, Prime Minister of England 30 years ago, who used the phrase "The Wind of Change" to describe political events in Africa in his day. So well did this phrase capture the spirit of the time that it echoed around the world, and the echo has never stopped. Change is the constant factor in the society in which we live and everyone of us has had experience of the effect which it has had on our professional and personal lives. Change will not stop, it will continue at an increasing rate and the questions we must answer are how do we prepare ourselves to meet the challenge of future change and how do we take advantage of the opportunities which it will bring? It is these questions which I wish to discuss in this address.

Jan 1, 1989

By Gordon T. Austin

The combined production value of natural abrasives, which consist of tripoli, special silica stone, garnet, staurolite, and emery, increased in 1987. The increase was, in certain cases, because the materials were used in nonabrasive applications, such as the increased use of tripoli as a filler and special silica stone material as a special-purpose crushed stone. The increased use of garnet as a blasting media accounts for most of its growth. Production and sales of garnet were at a record-high level in 1987. [ ]

Jan 1, 1989

By Iley J. D, Siviour N. g, Moffatt R. J

The process of desilverising by fractional crystallisation with reflux was investigated through laboratory batch tests and continuous laboratory bench scale tests at CSIRO Clayton, to a 300 kg/hr pilot plant at Port Pine. The pilot plant built at BHAS comprised a vertical cylindrical refining column with internal diameter 250 mm and height 3.2 m, attached at the top to an off-set cylindrical stirred crystalliser tank. Crystals were made in the crystalliser by intermittent immersion of steel cold fingers, which were water cooled between immersions. Gas heat was used for melting the crystals at the base of the column and for side compensation heating. A computerised in strumentation system was employed for data logging and for controlling some critical plant operations. A mechanical device was first employed to promote counter-current plug flow of crystals down the column against the rising stream of reflux liquid, but this was found to be unsatisfactory owing to excess noise, frequent mechanical failure, and excessive accumulation of dross. Plug flow was finally promoted by pulsing the column. Low silver levels, less than 1 gitonne, were achieved with both methods of crystal transport under total reflux conditions. The pulsed column gave results for silver and bismuth which agreed with the theoretical predictions of a computer model, but there was some selective drossing of antimony. In the mechanically agitated column, excessive drossing promoted selective removal of most of the antimony and some of the bismuth, and the results after extended operation were well removed from the theoretical predictions. Plant failures and operating problems prevented the achievement of satisfactory product quality with the necessary reliability under production conditions. Other priorities necessitated the termination of the project before the process could be optimised.

Jan 1, 1989

By J. Jerome MacDonald, Stephen B. Flewelling

"In the base metals industry of today, operations required to continuously improve productivity and reduce unit production costs. Consistent with these goals is the improvement of the muck haulage cycle from open stopes with the No. 12 Mine.Existing haulage from open stopes occurs with LHD units experience at Brunswick indicates that LHD units have a higher unit cost per tonne mucked than loader-truck combinations when the haulage exceeds approximately 150 m.The reintroduction of open stoping at Brunswick made existing loader-truck combinations unsuitable. It was recognized that application of recent continuous loading technology could potentially result in significant unit cost savings and productivity increases.A review of the technology resulted in the testing of the Voest Alpine AL60 loader in the open stopes located on the 1000m Le vel. Testing began in January 1988 and finished in late November 1988. The test will provide experience as well as quantified production and maintenenace parameters f or the purpose of quantifying production unit costs and system productivity, ultimately resulting in a decision to further utilize or not utilize the loader as a primarymucking unit at Brunswick .INTRODUCTIONBrunswick Mining and Smelting Corporation Ltd. produces approximately 10500 tonnes per day from the No. 12Mine located 35 km southwest of Bathurst, New Brunswick Mining is the largest (single mine) producer of zinc in the world having mined over 52 million tonnes since 1964. Many years of production still remain with proven and probable reserves in excess of 90 million tonnes. Reserves grade at an average of 3.65% Pb. 8.99070 Zn, 99g/mt Ag and 0.32% Cu . The operation employs 1446 people with approximately 800underground including operations and maintenance staff.In the No. 12 Mine two major mining methods are presently utilized . The primary method is Mechanized Cut and Fill (MCF) accounting for approximately 6500 tonnes per day from four major areas. The remaining 4000 tonnes per day is produced from open stopes with the majority of 2800 tonnes per day being produced by the 1000 level.The 1000Level contains 30 million tonnes segmented into open stope blocks 30 m high, 15m and 30 m on strike , with a transverse width of 10m to 50 m (Fig. I). Stopes are organized on a primary secondary stope arrangement along strike. Primary stopes are undercut and overcut full size with the back fully cablebolted. All stope and lateral development is driven 4.0 m high. All stopes to date are flat bottom (Fig. 2). Primary stopes are filled with cemented rock- fill , secondaries with conventional rockfill, Haulage from the stopes is primarily with 8-yard LHD units ; mucking is approximately 50% conventional and 50% remote. Haul distance to date has averaged approximately 150m with current stope haul distances of approximately 300m. Haulage is presently to a small jaw crusher situated on the 1000 Level. From August 1989on, haulage will be to a set of ore passes feeding to a large gyratory crusher situated on the 1200 Level. Start up of the gyratory crusher corresponds to an increase in tonnage from 1000 Level to 4100 tonnes per day."

Jan 1, 1989

By Linge HG, Klauber C

The key element in the carbon-in-pulp process for gold processing is the loading of dissolved Au(CN)2 from solution onto activated carbon. The mechanism and kinetics of this step have been examined by solution adsorption-desorption and X-ray photoelectron spectroscopy for both coconut derived activated carbon and peat-based activated carbon. The results show that these carbon types have the same mechanism and kinetics of adsorption. There is no contribution to the bonding from carbon-oxygen functionalities on the carbon surface, as has been invariably supposed in all previous theories for the mechanism of the reaction. It is shown that Au(CN)Z is reversibly adsorbed intact on and parallel to the graphitic planes of the carbon with the formation of a weak carbon-gold n-donor bond. The kinetic measurement of carbon gold loading reactivity is discussed and use of the Murdoch equation for this test is critically assessed.

Jan 1, 1989

By Peter McKenna

Different reefs being extracted from a mine will, in all likelihood, have significantly different semi-variogram models - and these will probably vary from geozone to geozone. As errors of estimation are dependent on the semi- variogram parameters, it follows, if a mine samples all reefs in all sections using the same sampling grid pattern, that estimation errors (or limits of confidence) will not be the same throughout the mine. This may be an undesirable situation! A geostatistical study of the relative merits of alternative sampling arrangements has been carried out by considering different reefs in different sections of a South African gold mine.

Jan 1, 1989

By T. D. Maki

FMC Gold's Paradise Peak Mine, located 13 km (8 miles) south of Gabbs, Nevada, became operational in April of 1986. Shortly thereafter heap leach testwork began on sub mill grade ore. Presently, testwork continues in combination with production size heaps that account for approximately 6% of total gold production at Paradise Peak.

Jan 1, 1989

By Larry L. Snyder

A compact 4.87 m (16 ft) diameter tunnel boring machine (TBM) is capable of boring a 12.2 m (40 ft) radius curve while gripping horizontally, or vertically, as may be required for the excavation of turnouts. The machine's 5.0 m (16.5 ft) length and a patented machine structure allows steering while boring without causing harmful eccentric loads. An extremely stiff thrust system, rigid front and rear grippers, and the torsional stiffness of a front end electric cutterhead drive combine to create superior machine stability and boring efficiency. A 2.2 m (7.2 ft) diameter prototype, complete with a soft ground shield attachment, was used successfully on a tunnel project in Scotland.

Jan 1, 1989

By Alizeibek Saleimen Nader

The intensive use of computers for mineral application at Serrana's phosphate mine in Jacupiranga, State of Sao Paulo, Brazil, began in the late seventies. The early hardware and software available are described in sufficient detail to allow comparisons between that solution and the new one, based on a personal computer and a new software package - PC MINE SYSTEM from GEMCOM SERVICES INC - that provides full color graphics capabilities plus mine design and planning tools. The process needed for adaptation to the new technology' and its impact on SERRANA S.A. DE MINERACAO are described. Finally, future enhancements to the System and mine control and planning are focused.

Jan 1, 1989

By Robert A. Jankowski

"Following passage of the Coal Mine Health and Safety Act of 1969 (Public Law 911173), the Bureau of Mines initiated a research program aimed at controlling respirable dust exposures of coal mine workers. Respirable dust is the dust that gets into, and interacts with, the lungs of those who inhale it. It has long been recognized as a severe health hazard to mine workers. This program has been implemented by a team effort consisting of the Bureau's in-house capabilities, the Generic Center for Respirable Dust, and contractors, as necessary. Over the years, Bureau research has addressed principally three areas:o Compliance with the Federal 2.0 mg/m3 dust standard (1970-76).o Dust control for longwall mining (1976-1983).o More stringent respirable dust standards due to quartz dust (1983-1987).In addition, fundamental studies have been conducted by the Generic Center for Respirable Dust, with emphasis on penetration of dust into the lung. Accomplishments have been significant, but problems remain, as noted later.The Coal Mine Health and Safety Act of 1969, established a 2.0 mg/m3 dust standard for all coal mining operations, underground as well as surface. At the time of enactment of this legislation, the industry was averaging approximately 4.0 mg/m3. The Bureau of Mines respirable dust research program played a significant role in identifying and developing effective technology to allow better compliance with this new standard, thanks to industry implementation and Federal enforcement."

Nov 1, 1988

By R. V. Ramani, R. Bhaskar

"The control of respirable dust in mines has been given paramount importance due to the health and safety implications associated with fine dust. The understanding of the temporal and spatial behavior of dust has been recognized as essential for increasing the efficiencies of the existing control techniques and for developing new control strategies. Mining-related studies in this area are, in general, limited. They are also mostly experimental. Some mathematical and computer analyses have been attempted. In this paper, first a review of the mathematical studies performed in the last three decades in this area is presented. Second, a mathematical model for analyzing dust flow in mines is proposed. The model takes into account a number of factors affecting dust transport. It incorporates varying dust generation source strengths and dispersion, deposition, and coagulation of dust in mine airways. Finally, application areas for the model are discussed. A computer program based on the mathematical model has been developed. The program will output the dust concentration in the mine atmosphere as a function of time and distance from the source. The amount of dust deposited on the sides, roof, and floor of the airway is also determined.IntroductionAn airborne dust cloud is a complex system containing particles of varied size, density, shape and state of aggregation. The behavior of the particles is dependent on a number of complex physical mechanisms, often opposing in nature. The net interaction results in the ambient concentration. This size dependent behavior of particles contrasts with that of gases, an area quite widely studied.The term aerosol is used to describe clouds of microscopic and submicroscopic particles in air such as chemical smoke or particulate matter released from smoke stacks. An aerosol system can be regarded as an arbitrary element of volume filled with gas and suspended particles of possible highly variable physiochemical nature. The parameters that are used to describe an aerosol system include concentration, mass average velocity and particle mass and radius. In characterizing such systems, several assumptions are made. Among these is the assumption that particles are smooth, inert and rigid spheres. Again, for example, when the particles are in transport, the possibility of collision exists. As a result of the collision, the particles may coalesce to form larger particles. The probability of sticking is considered a known quantity (lady, 1970). In this paper, the application of the principles used in aerosol systems is explored for the study of the transport and deposition of fine coal dust in underground mines."

Jun 1, 1988

By A. Wahab Khair, Richard D. Begley

"This paper presents results of destructive tests performed on rectangular coal specimen under the influence of two vertical and simultaneous wedge indentation forces. Several wedge designs and spacings were utilized in compression tests. The objective of these experiments was to qualitatively monitor the effect of different wedge designs and spacings on the stress distribution within the coal specimen.Coal samples from the Waynesburg coal seam were cut and trimmed to cubical dimensions of approximately 5 X 10 X 20 cm. These specimen were subjected to parallel compressive forces through two vertically applied wedge indentors. Loading was achieved with a hydraulic hand pump in order to facilitate interferogram construction. The load increments were limited due to the sensitivity of the holographic interferometric technique (holometry) in measuring small displacements; therefore, interferograms were taken only during similar increments in order to allow for a qualitative comparison between different wedge design and spacings. In some cases, interferograms were taken immediately before and after failure of the specimen.Introduction Failure Modes Three distinct modes of failure occur when geologic materials are subjected to wedge indentation forces. As shown in Figure 1, a crushed zone is located immediately adjacent to the indentor while chipping can occur if the fractures initiated in the crushed zone extend upwards to the free surface.. The third failure mode is a zone of intricate frac¬tures located between the crushed zone and the chipping zone. Several experiments have been conducted over the years to better understand crater formation and stress distribution within geologic materials under the influence of an indentor. Generally speaking, crack initiation and propogation observed in these experi¬ments correlate fairly well with wedge indentation theory; however, the nature of the .fractures is greatly influenced by different material properties such as grain size and cleavage planes. In other words, a wide range of behavior has been found in different rocks subjected to wedge penetration. For example, it has been observed that some rocks are merely crushed and indented while others are more prone to cracking and chip formation. Therefore, the development or nondevelopment of chips depends mostly on wedge geometry, rock type and depth of penetration. This work is part of the study associated with opti¬mization of cutting parameters, which is best modeled by using brittle materials and subjecting them to rigid wedge penetration tests."

Jun 1, 1988

By D. Hinton, M. McCawley, R. C. Lantz, F. Pisano, C. Stanley

"INTRODUCTION Aerosols (5 um have not been shown to be consistently generated and characterized in inhalation chambers. Particle deposition in the lungs however may occur with particles as large as 25 um(1). Therefore, in order to closely simulate the atmosphere of an underground coal mine where the distribution is bimodal, with modes at S and 15 um (2), particles much greater than <1 um must be characterized for uniform mixing and size distribution within these chambers. The Hazelton Animal Exposure Chamber has been chosen because it has been best characterized for smaller particles (<1 um) (3), and is the major type used by most inhalation toxicology institutes such as Lovelace Inhalation Toxicology Institute and Battelle Northwest Laboratory.BACKGROUNDPreviously published studies on the inhalation of solid aerosols have attempted to characterize the distrition of particles of <2 um in diameter. There are no published reports of extensive work characterizing either the size distribution of particles <1 um or the concentration throughout the exposure chamber (Table 1).Table 1 shows the variability and sizes of several aerosols <1 um in diameter used in five previous chamber studies.Discussion of Previous StudiesThe study done by Bauermash, Bryan, Dickinson, and Burke (4)stated two major concerns in the development of the 6.5 ft. diameter chamber. The first was that a quantity of animals could be exposed to the same concentration regardless of the location of the animal, and second was that the chamber could be easily cleaned and decontaminated. The solution to the first concern required a circular chamber with the contamination air entering the chamber somewhere along the central axis. The animals could then be changed during exposure time so that each animal was exposed throughout the total volume."

Jun 1, 1988

By Laxman M. Amaratunga

Laboratocy flarmnability tests were perfonned on dust samples from Fraser Mine in a 1.2 L Lindenburg horizontal tube furnace to detennine the percentage of sulphur oxidized during ignition. The explosion pot ential of sulphide dusts depends on their degree of spontaneous oxidat ion, which was measured by the quantitative analysis of so2 gas released during ignition. Test results indicated that dusts with low sulphur content could exhibit a higher degree of oxidation than a sample with high sulphur content. txlst characterisation using image analysis techniques suggests that the structure and the texture of dust are important factors influencing the explosibility of sulphide dust at ignition temperatures. Therefore for safe mine operations% sulphur content cannot be considered as a reliable single index that could be used to predict the potential of a sulphide dust explosion. Physical, chemical and mineralogical characterisation of dust plays an important role in the detennination of suitable indices for the prediction and prevention of sulphide ore dust explosions.

May 11, 1988

By M. Gershon

Four computerized approaches for coal blending are described and their strengths and weaknesses are explored. Spreadsheet analysis Other than word processing, spreadsheet software is the most commonly used software. Its wide availability and ease of use are two desirable features that have led many to try to adapt it to the purpose of coal blending. These are the two main advantages of this approach. To use a spreadsheet for coal blending, each row of data represents one source of coal. Each column represents a quality of the coal, with the last column specifying the tonnage of that coal in the blend. The calculated figures are the blended qualities, which can be programmed to appear in the bottom row. A trial-and-error approach is then used to develop the best blend. Inserting any blend in the last column provides the blend characteristics at the bottom of the page. If any specifications are not met, the blend can be changed, all calculations being immediately updated. This process is repeated until all specifications are satisfied. A third advantage of this method is that it is exactly the procedure that one would go through if doing this by hand. With a spreadsheet, many more blends can be evaluated in much less time, allowing the designer to try to improve over satisfactory blends to find the best of them. The resulting improved blends or cost savings are a fourth advantage of this approach. There is only one major disadvantage of using the spread-sheet. This is that most probably the best blend is not found. As an inexpensive introduction to computer-assisted blending, which can be easily understood and cost just a few hundred dollars, this is a recommended place to begin. Computerized search Computerized search approaches represent crude first attempts at letting the computer design the blend. Unfortunately, the blends found by these programs are very often less satisfactory than those developed manually. The way these techniques work is that they design, according to some predesigned pattern, a number of different blends and then quickly evaluate them. It is then straightforward to select the best from this sample set. The quality of the results depends on the number of blends designed, the way they differ from each other (the search procedure), the number of sources available, the number of quality specifications, and the severity of the specification limits. Good results are usually obtained for small, simple problems. At best, the results obtained are inconsistent from one blend to the next. Programs of this type are advertised in the mining literature. They usually mention how many different blends are evaluated, making it clear that this is more than can be tried manually. Expert systems Expert systems use a source of information known as a knowledge base. The knowledge base, usually a set of if-then rules, attempts to reconstruct the deductive reasoning process of an expert in some job capacity. For coal blending, the usual trial-and-error process has an easily recognized pattern of rules that are followed to try to find a better blend. By following these rules, it is possible to home in on the best blend without the exhaustive search required by the previous method and without the manual manipulation of the spreadsheet approach. The use of an expert system accomplishes this. One of the rules may say something like "if BTU is out of spec, then add more in the blend from a source having a high BTU and subtract some from a source having low BTU." In other words, it goes through the trial-and-error process. The process continues until all specifications are achieved and can continue further to try to optimize the cost. Of course, less simplistic rules are also needed. One set of rules would determine maximum changes in the tonnage added or deleted to the blend or from any one source. Other rules would be needed to determine which quality to improve if two or more are out of spec. At this level, the process of building the knowledge base provides the engineer with a deeper understanding of his or her own thought processes. The advantage of obtaining better blends is clear for this approach. Two more advantages should also be apparent. One is that it follows the same common sense logic that is used when doing the blends by hand or by spreadsheet, making it easy to understand. The other is that, like the search procedure, it designs the blend rather than just analyzing manually designed blends. Thus, it has all the good features of both approaches discussed thus far while providing improved results over each. A final advantage is the ease of use and ease of development. The expert system shells that are on the market are very easy to use and can be run on microcomputers. Linear programming Linear programming is an algebraic tool that solves a set of linear equations to yield an optimal solution to a problem. The optimal solution is based on the linear model so the results are only as good as the ability of the linear model to accurately portray the reality of the problem situation. It is fortunate for the coal blending problem that a linear model can be devel¬oped that reflects exactly the problem that is required. Unfortunately, the mining industry has been slow to use this tool. Coal blending applications available that use linear programming take one of three forms. The first, requiring exper-

Jan 12, 1988

By Richard R. Klimpel

Introduction Froth flotation is one of the most common unit engineering operations in use today. Its aim is to upgrade the quality of coal by removing ash/pyrite and separating selected minerals from undesired gangue materials. Flotation has been successfully practiced at the industrial scale for more than 50 years. Its use is increasing due to the ever decreasing feed grades of the coals and minerals being processed. Flotation has also shown itself to be a flexible process that lends itself well to many solid/solid separations. Thus, with surprisingly little equipment modification, separations can involve very different particle sizes and densities, and relative weight ratios of materials to be separated. In addition, the flotation process is economic, especially when compared to size reduction, its associated precursor process. Flotation also lends itself to continuous operations with a given equipment configuration. The operation must exhibit an ability to vary feed rate of solid to the process by as much as 50% without a total collapse of separating efficiency. In addition, the mechanical flotation cell is scaleable from 2.8 to 57 or 85 m3 (100 to 2000 or 3000 cu ft) with surprising ease relative to other unit engineering operations over the same relative size increase. The separating medium used is water. Most of the chemicals required - pH regulators, frothers, collectors, activators, and depressants - are all relatively inexpensive and common. They are not usually used in large quantities. Froth flotation is certainly one of the most versatile and forgiving unit operations in the chemical, mining, and agricultural industries. The problem with the industrial flotation process is that it is fairly easy to get reasonable results and relatively difficult to get excellent results. Why is it so difficult to fine tune the froth flotation process? There are some obvious reasons and a few not-so-obvious factors. The obvious category would certainly contain the tendency of natural feed materials (ores and raw coals) to have variable physical, metallurgical, and surface properties. This occurs even when special care is taken to minimize such differences with blending. There is another obvious reason for difficulty. An inherent broadness of the feed particle size range to flotation results from using any of the common industrial-scalefine grinding devices - ball-, rod-, or autogenous mills. Research has been done into the chemical reagent and equipment aspects of flotation. It has shown strong interactions (limitations) of chemical reagents and equipment on larger and smaller particles. The point is that current flotation practice works best on average- or medium-sized feed particles. The greater the amount of large or small particles, or of both large and small, the more difficult it is to achieve excellent flotation results. Other reasonably obvious factors include: • variations in mineral type and liberation sizes; • water chemistry variations such as those involving Ca", C03, or Fe", or various soluble metal cations; • the presence of stray organic materials such as returning soluble reagents or partially degraded reagents in reuse water; • the lack of reliable on-line instrumentation for monitoring and control; • frequent equipment malfunctions of all types; • excessive feed rates for installed plant capacity; • poor operator interaction with the process; and • poor reagent dosage control. There are less obvious, but real limitations to flotation. These are inherent in the design and operating characteristics of the most common cell design in use today - the mechanical flotation cell. Individual performance attributes of the chemical reagents used, along with their manner of use, also carry limitations. The bulk of this paper will deal with chemical reagents and their use. Chemical reagents In 1979, the author and his co-workers were asked to invent and implement, at the industrial scale, new flotation reagent chemistry. After reviewing some of the literature (Sutherland and Wark, 1955; Klassen and Mokrousov, 1959; M. Fuerstenau, 1962; D. Fuerstenau, 1976; and Leja, 1982), a series of carefully controlled plant scale tests were set up. These tests were designed to understand existing reagent scale-up from the laboratory to the plant. They were to quantify at the plant level the effect of some of the more important, controllable chemical reagent factors (frother and collector type, frother and collector dosage, pH effects). This is a learning experience that all researchers involved in flotation theory should experience. It quickly became apparent that: • because a factor is important

Jan 12, 1988

Power cable costs are only a small part of total mining costs. So many mine operators consider power cable failure and resultant downtime as part of the cost of doing business. But, viewed in terms of lost production, these costs can be quite significant. Now one company, Cablec, seeks to cut cable costs by upgrading the polymer compounding process used to make cable insulating and semiconducting materials. Cablec is the leading manufacturer of electrical power cables in North America. And with about a third of the market, Cablec is the largest supplier of power cable to the mining industry in the United States. To improve its products, Cable has entered the polymer compounding business. In July, it began producing insulator and semiconductor polymer compounds at its plant in Indianapolis, IN. "This new facility provides a quantum leap over conventional compounding methods," said Harry C. Schell, Cablec&apos;s president and chief executive officer. "The Cablec polymers plant is producing a dramatically higher standard of polymer compounds that provide significantly higher levels of performance and improved life cycle costs for power cable." Cablec faces tough foreign competition in the wire and cable business. Competing on price alone is difficult, particularly when foreign producers are state subsidized. So Cablec feels the best way to compete is to establish new quality production standards. The company&apos;s new polymers plant is one way to do this. By increasing purity control and uniformity in polymer compounding, Cablec says its power cables will last longer and fail less often. A typical medium voltage cable consists of a conductor, conductor shield, insulation, insulation shield, metal shield, and jacket. The conductor shield and the insulation shield are conducting polymers. Contaminants and imperfections can occur within the insulation, at the conductor shield/insulation interface, or at the insulation shield/ insulation interface. Over time, these contaminants and imperfections can decrease the electrical strength of the cable or cause premature cable failure. The effort to minimize the number and size of any possible contaminants begins with pure polymer compounds mixed in a clean facility. However, most power cable manufacturers manually handle raw materials, use ethylene/propylene (EP) in bulk bales, and mix polymercompounds in open Banbury mixers. The quality and uniformity of polymer compounds is also impacted by temperature variations in the mixing process. This results in wide gradations of product consistency from batch to batch and ultimately contributes to power cable failure. Cablec says the improved polymer compounds from its state-of-the-art plant will be the purest and most consistent insulating and semiconducting materials available. The plant itself RCA spent $18 million to build Cablec&apos;s Indianapolis plant. RCA used the facility to mix specialty polymer compounds used to make video disks. RCA had two considerations in mind for the plant, cleanliness and uniformity of the compounds. However, when the video disk market failed to materialize, RCA sold the 46.5 dam 2 (50,000 sq ft) plant to Cablec for $3.1 million. Cablec invested an additional $3 million for modifications and increased production capabilities. Today&apos;s replacement cost for such a facility is estimated at $30 million. Cablec says the plant will set a new standard for performance and be economically difficult to duplicate anywhere. One of the essential elements of the plant&apos;s clean process environment is the air intake system. It filters contaminants greater than 2 um, less than one-fiftieth the current industry standard. All material handling and conveying areas in the facility are air-locked. This keeps out contaminants such as smoke, dust, and pollen. Banks of pneumatic pumps move polymer components through the system and continually filter the air. The plant also has a backup air intake system. No process downtime due to pump failure here. From the time raw material enters the plant, it is stored, transported, and processed in filtered air by an airtight stainless steel system. The stainless steel resists rust and corrosion. This further eliminates the danger of contamination from paint or rust particles in the conveyance network. A computer system allows a single operator in a central control room to monitor every aspect of the compounding process from air quality to line speed. The computer

Jan 12, 1988