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By Thomas M. Barczak

The Bureau of Mines is conducting research to optimize the capability of mine roof supports so that the selection and design of these supportsare compatible with the conditions in which they are to be employed. This report describes a study that investigates three parameters influencing the load-carrying capability of wood crib supports: height, configuration, and horizontal displacement. Four crib heights, four parallelogram configurations, and three ratlos of horizontal-to-vertical displacements were tested on full-scale wood crib supports in a mine roof simulator. Test results indicated a reduction in load-carrying capability for increases in crib height. Increasing the contact area by changing the intersecting angle between crib blocks to form parallelogram configurations provided a slight increase in load-carrying capability for the first 10 to 12 in of vertical convergence, after which the cribs became more unstable, resulting in significantly less load-carrying capability. Horizontal displacements did not appreciably affect the load-carrying capability of wood crib supports for the range of vertical displacements (less than 10 in) likely to be encountered underground. This report documents these tests and postulates some explanations of failure mechanics for the observed behavior.

Jan 1, 1988

By G. E. Slagel

On August 3, 1987, a hearing was held by the House Subcommittee on Energy and the Environment to commemorate the tenth anniversary of the Surface Mining Control and Reclamation Act (SMCRA). Four panels of environmental/citizen group representatives went before the Subcommittee to report on the state of affairs (from their perspective) of the coal industry and the Office of Surface Mining, Reclamation and Enforcement (OSMRE) As expected, these groups had little positive news to report and continued to focus on glaring deficiencies within the surface mining program. They indicated that gross abuse of SMCRA has continued over the past ten years and the states have performed poorly. Congressman Udall's opening comments perhaps best characterized the mood of the group with his statement that "The Act has not accomplished what I or the people of the coalfields had hoped." and " ? a segment of the coal industry has continued in its bitter and implacable opposition to the most basic of environmental controls."

Jan 1, 1988

Improvements in mechanisation should not be considered independently of safety and of environmental hazards. The need to keep gas contents within statutory limits may make the time needed to partially drain a gassy seam the effective control on face development times. Dust levels may provide an effective control on coal extraction rates on any one face. The combination of gas and dust on high output longwall faces may make it necessary for each one to be treated as a separate mine in terms of ventilation, and the faceworkers may need special protection. Mechanisation and safety can be mutually beneficial when mechanisation combined with systematic safety assessment reduces accidents, and when a thorough study of how to reduce accidents and health risks indicates the best method to improve mechanisation.

Jan 1, 1988

By Egil Aukrust

"An American Iron and Steel Institute Task Force evaluated developing direct steelmaking technology worldwide to seek a replacement for the coke-oven, blast-furnace, basic-oxygen process technology now in use. To remain internationally competitive it is essential to move away from the traditional series of batch processes towards continuous processing and the associated energy savings which are possible with high technology process control systems. The group identified in-bath smelting of iron ore pellets or fines with coal as the process most sui table for domestic raw materials (including abundant scrap) and called for research to study operation with varying degrees of preheat and prereduction of the ore by the gases generated from the coal and various degrees of combustion of these gases above the melt.A coordinated, 3-year, $27 million, direct steelmaking research program is proposed. Concurrent projects include design, construction, and experimental operation of an in-bath smelting pilot plant; modeling, simulations, and laboratory-scale experiments at universities on slag-phase and metallicphase reactions and interactions; and large-scale heat transfer and reaction rate trials. Also included are modeling studies and pilot plant trials of on-stream decarbonization and desulfurization; application of circulating fluid bed technology to fine ore reduction and hot gas cleanup; and specific heat transfer and fluid flow research projects.IntroductionThe American Iron and Steel Institute (AISI), based on the Task Force studying direct steelmaking, believes strongly that a coordinated program of research on the reduction of domestic raw materials to liquid steel should be undertaken as part of the Steel Initiative program. To specify the steelmaking process for development best suited to the American steel industry and domestic raw materials, it was important to determine the state-of-the-art of direct steelmaking worldwide, both as practiced and under development, and then, by expert analysis of the processes and their potentials, to choose the process most likely to provide a domestic competitive edge."

Jan 1, 1988

By N. P. Kripakov

The Bureau of Mines has developed a unique new mine design procedure to determine the changing static load distributions imposed on under-ground support structures during the mining cycle. The procedure reduces the complexities associated with analyzing a three-dimensional problem. A combination of the multiple-seam displacement-discontinuity model and a two-dimensional finite-element window model produces refined results for a specific area of interest by assuming displacement compat-ibility between models. Input to the procedure includes the geometry of mined-out areas in up to two adjacent seams, the rock mass characteris-tics of the surrounding geology, the in situ stress conditions, and the mining sequence. The displacement-discontinuity program calculates ex-pected loadings for mine structures affected by the mining cycle and/or by overlying or underlying seams. Pseudoelastic finite-element analysis using a yield-factor approach determines the stability of coal pillars by simulating the degree and extent of nrogressive rib failure and sub-sequent load transfer. Application of the procedure is demonstrated on a field problem. In-duced stress changes predicted from the numerical model analysis are in reasonably good agreement with stress measurements obtained from an instrumented chain pillar affected by remnant workings in an upper seam.

Jan 1, 1988

The equity market is now very much within a global village environ- ment, with various exchanges acting as agencies for the big casino. In this predicament, mining companies, who provide the most extensive, but relevant risk assessment information, will be best placed for favoured treatment by potential international investors: But what risk assessment information in summary form can be provided to support a resource/reserve statement? Even more importantly, does "objective" data exist, whose trends will support a resource/reserve state- ment? A prime need of the informed mining investor is to determine whether or not the resource/reserve statement is believable? But more importantly will it be realised? While the implications within the text of the majority of reports on resource/reserves suggests that the estimates are conservative, the record indicates that very few estimates are. In fact, to date, reports claiming to be conservative in respect of the overall grade estimate at a specfic cutoff have not reflected the realised grade at the stated cutoff; it has been more common for the realised grade to be lower than implied by the resource/reserve statement. Further, it is not uncommon for penalty elements to be understated and these components are rarely incorporated within resource/reserve statements.

Jan 1, 1988

By R. R. Klimpel

The process of froth flotation as a means of upgrading the quality of coal by removing ash/pyrite and of separating selected mineral(s) from undesired gangue materials is certainly one of the most common unit engineering operations in use today. Flotation has been successfully practiced at the industrial scale for well over 50 years, and if anything, its use is increasing due to the ever decreasing feed grades of the coals and minerals being processed. Flotation, as a process, has also shown itself to be an extremely flexible process that lends itself well to a wide variety of solid/solid separations. Thus separations can involve very different particle sizes, particle densities, relative weight ratios of materials to be separated, etc., with surprisingly little modification in equipment and operating philosophy required.

Jan 1, 1988

By J. Nakayama

For drilling large diameter holes for deep foundations, the common and distressing difficulty of long standing has been in coping with ground containing rocky formations and boulders. Where geological formation contains weathered rock or boulders, or deep rock socket is specified, drilling equipment occasionally is found to be unable to drill through and therefore will need supplementary equipment and procedures. Incentive of the MACH Drill Development has been to realize a capable drilling system for rocks of weathered to fresh rock without losing its applicability to usual overburden. Through seven decades' experience of manufacturing and operation of boring machines, the best features of all sorts of drillhead are known such as the drag bit, wing bit, auger bit, diamond bit, rock roller bit, down-the-hole hammer bit, etc.

Jan 1, 1988

This report presents a Bureau of Mines study comparing the construction costs, leakage measurements, and predicted performance of different types of large stoppings built and tested in a room-and-pillar oil-shale mine. The six full-sized structures (30 ft high by 55 ft wide) included both permanent and temporary stoppings and were fabricated using materials ranging from structural steel to coated brattice cloth. Leakage across each stopping was measured at differential pressures ranging up to 1.0 in w.g., using both the brattice window method and sulfur hexa-fluoride (SF6) tracer gas. Blast air pressures resulting from a full-scale face blast of approximately 1,800 lb of ammonium nitrate-fuel oil (ANFO) explosives were measured across two of the stoppings and the pre-and post-leakage rates were compared for all the stoppings. Overall performance of the stoppings for production applications was evaluated using an operational model of a two-panel oil-shale mine. Different combinations of temporary and permanent stoppings were evaluated based upon ventilation performance and construction and operating costs.

Jan 1, 1988

By T. W. West

INTRODUCTION This paper presents an assessment of conventional flotation technology. In addition it presents some ideas which can be used to change the perception of what may be done with conventional flotation equipment to maximize its efficiency. Perspective of Conventional Flotation Technology 1. Flotation in many coal preparation plants is defined as something between a necessary evil and a non-viable concept because: -Too much art is required on a continuous basis to achieve uniformly acceptable results. -It is expensive, the capital cost in dollars per ton of circuit feed for flotation and dewatering is high. -It is a difficult process to use when SO2 reduction governs system design and equipment selection. -It creates a product (fine coal froth) that is difficult to dewater in the presence of BTU/lb as-received pressures. -It is a difficult process to control from a management standpoint, there are no dependable set points to rely on. 2. Many froth cell circuits are 0.5m x 0 (nominal 28 M x 0) feed which is sourced from screen/cyclone underflows. The original intent was to obtain maximum yield at acceptable product quality and moisture using disc filters. (See Figure #1) 3. An alternate to conventional flotation and its perceived to be limits of efficiency, capital costs, etc. is to move towards such developing flotation technologies as column flotation, reverse flotation, and microbubbles. A lot of work is being done to move these concepts thru pilot stages into full scale, commercial plant operation. The majority of the coal producers and coal preparation plant designers view these concepts as being in the development/pilot plant stages. OBJECTIVES Based on the preceeding comments of the perspectives of the coal producers and plant designers, the options are limited. They can make do with what they have available to them in the way of industry standard equipment and practices or they can move forward with developing technology. I feel there is a third option: what can we really do today with what is available to us, without reinventing the wheel? APPROACH 1. When processing coal against ash and SO2 restrictions, the fine clean coal stream can be the best stream on the clean coal conveyor due to the release by size and the ability to create a high BTU/low sulfur (dry basis) product. 2. Targets: -Consistent raw coal size consist in the plant feed . -Do not put pyrites in the froth cells. -Adjust criteria defining good flotation away from yield towards maximum BTU recovery at minimum ash. -Limit the froth cell feed size consist to 0.15 mm x 0 (nominal 100M x 0). -Establish and maintain a correct, consistent percent solids in the froth cell feed. -Select flotation reagents with care. -Introduce reagents in the proper sequence.

Jan 1, 1988

By K. J. Murphy, A. R. Smith, A. P. Odorski

"The need for large quantities of oxygen for use in metallurgical processes was a major driving force in the commercialization of tonnage air separation plants. Oxygen, nitrogen and argon impact the quality, energy efficiency and environmental aspects of metals production. Cryogenic air separation processes have been used to supply most industrial requirements, however, newer technologies are available or under development to meet the needs of today's and tomorrow's metallurgical processes. This paper reviews the technical features and state of development of adsorption, chemical, cryogenic and membrane technologies. The technologies are compared in terms of plant size, oxygen purity and pressure, nitrogen and argon co-production, product use pattern and back-up requirements. Computer control systems are described that optimize operation over varying load patterns and ambient conditions; substantially lowering energy consumption. IntroductionOxygen production totalled 390 billion cubic feet in 1987. Although current production is lower than the peak of 455 billion cubic feet reached in 1979, oxygen remains the fifth leading chemical product manufactured in the u.s. (1) Metals manufacturing and fabrication accounts for sixty percent of the oxygen consumed in the u.s. Oxygen use in the steel industry consists of air enrichment for conversion of iron ore, purification of the iron in basic oxygen or other furnaces, and for cutting and welding the finished steel product. Nonferrous ores are smelted in oxygen enriched atmospheres to reduce energy consumption and increase capture of sulfur compounds to meet environmental requirements. In the future oxygen usage is expected to become even more important in metals production as energy costs increase, environmental standards become more stringent, and as new coal based processes become commercialized. Oxygen usage per ton of metal in the new direct reduction processes can be up to ten times higher than traditional steel making."

Jan 1, 1988

By B. D. Hanson

An interactive computer program has been developed by the Bureau of Mines which enables the user to identify the effect of cutting system changes on relative dust generation for longwall shearer drums. The program simultaneously evaluates machine and coal seam parameters, and those parameters which the user can control. The user can change one or more of these parameters at a time to determine their effect on relative dust generation, cutting forces, and/or cost. The program is written in the BASIC programming language. A complete program listing is included along with user instructions and sample outputs. This program is a more comprehensive version of the relative dustiness index (REDI) program described in Bureau Report of Investigations 8979.

Jan 1, 1988

By Stephen A. Swan

Certain types of mobile surface mining equipment are required to be equipped with rollover protective structures (ROPS) capable of protecting the operator in case of a rollover accident. The Bureau of Mines has developed ROPS performance criteria for wheeled front-end loaders. This report reviews the development of rollover test procedures and subsequent testing of ROPS for 52,000-, 286,000-, and 390,000-lb gross vehicle weight (GVW) loaders. The program consisted of both dynamic (roll) and static tests to assist in the development of the ROPS performance criteria. Each test included extensive instrumentation and photographic documentation to fully evaluate the performance of the ROPS. Data summarizing side, longitudinal, and vertical force and deflections are included. The data indicate that for loaders in excess of 240,000 lb, GVW, a side force-to-mass ratio of 1.0 and an energy-to-mass ratio of 6.0 appear to be adequate criteria to protect an operator in the event of a 5400 rollover. For smaller machines, Society of Automotive Engineers (SAE) 11040 performance criteria provide adequate protection. Longitudinal loading, though not ad-dressed in previous ROPS performance criteria, was shown to be a potentially significant factor in ROPS failure. Longitudinal loading and energy criteria equal to 80 pct of side loading criteria are recommended.

Jan 1, 1988

By R. Frenette, A. W. Mo, H. A. Hamza

Fine particles present major technical and economic problems to those who deal with solid/liquid separation processes. In the coal industry the problem is compounded by the large amounts of produced fines such as those present in Western Canadian coals. Flocculants in the form of high molecular weight water soluble polymers are commonly considered an effective solution for the enhancement of the separation process. These reagents are relatively expensive especially when considering a low-price commodity such as coal. Optimization of the use of these reagents is therefore an operational necessity. Six polymers were evaluated as to their effectiveness in flocculating a fine coal tailing. Results were compared with those for a reference flocculant, in-use at that time in the washery. It was shown that, in general, flocculants significantly improve the solid/liquid separation process. The ranking of the flocculants as to their effectiveness in settling and filtration indicated that the best flocculants for settling were not necessarily the most effective for filtration. Flocculants that showed the best filtration improvement were generally cationic and those best for settling were anionic.

Jan 1, 1988

By M. Fiset, D. Belley

"In a country with a cold climate like Canada, the cost of replacing worn parts of snowplow equipment such as blades, is enormous. A great number of these blades, with different mechanical properties, are available, but few studies have been made to facilitate their selection according to the optimum ratio of wear resistance to cost. To attain this objective, laboratory tests have been developed to correlate test results with those obtained from various road service conditions. The test materials, 1080steel in different states, 1090steel and D2 tool steel were chosen to cover a large range of hardness as well as different microstructures. Comparison of the wear resistance of the test materials relative to a standard revealed, in general, a good correlation between the results of laboratory cement wheel tests and those from the road tests. Scanning electron microscope wear scars of laboratory and road test specimens were compared to determine if similar removal material mechanisms were active. IntroductionThe correlation between wear tests in service and those performed with the aid of laboratory equipment is of considerable interest. As a matter of fact, when correlation exists, it allows one to evaluate the performance of a material more easily and at a lesser cost.Several authors have been interested in simulating various wear circumstances, especially abrasive wear. In particular, the simulation of wear on implements working the soil, has been tried by several researchers. The test using the rubber wheel seems to be the one giving the best correlation if the soil is rather sandy and its moisture content is low.However, little work has been done concerning wear on the plates, skids and blades attached to trucks used for levelling and snowplowing; such equipment being used to keep roads clear in northern countries. Now each year, companies introduce new steels by claiming that the y are superior in performance to their predecessor s and invariably they demand a higher cost. The study presented here was undertaken with the goal of making a more judicious choice of these steels by simulating their behaviour in the laboratory. Moreover, the examination of abraded surfaces in situ and in the laboratory have also allowed us to compare the respective wear mechanisms."

Jan 1, 1988

By C. L. Elmore

This paper describes a new development in the cyanidation of gold ores, which we expect will result in a major improvement in the way many gold ores are treated. The process has evolved through work at Hazen Research, Inc. for Kamyr, Inc. and in brief, the consists of utilizing oxygen rather than air in the carbon-in-1 each (CIL) process. We refer to this improved process for all ores amenable to cyanide leaching as carbon-in-1each with oxygen or CILO.

Jan 1, 1988

By Jong-Jip Kim, J. G. Byrne, W. Kim, In-Ok Shim, John E. Flinn

"Two rapid solidification processes for 304 stainless steel were studied: centrifugal atomization (CA) in a helium atmosphere and atomization by exposing argon-containing melt to vacuum (VGA). Positron annihilation and x-ray line broadening measurements of explosively consolidated monoliths were used to clarify microhardness measurements as a function of annealing temperature. Interesting differences in positron response between CA and VGA materials are ascribed to more carbide formation in the CA material than in the VGA material in the 600 0C range. In addition, hot isostatic pressing of the CA material was examined as to the relations between mechanical behavior, pore shape, and relative density. A variable stress concentration factor is introduced into the theory to allow for changing pore shape as relative density increases.IntroductionThere are many potential advantages of rapid solidification processing (RSP), such as a high degree of matrix supersaturation, finely dispersed microstructures, improved chemical homogeneity, and retention of metastable phases, which have been studied extensively. To consolidate rapidly solidified material which is in powder form into useful shapes often requires subjecting the material to elevated temperature for extended periods of time under mechanical forces, as in hot isostatic pressing or hot extrusion. In such cases, some of the characteristics of the rapid-cooling step can be strongly affected. An alternative is dynamic consolidation (1), for example by explosive forming, where the time frame at least is extremely short.In the present work, effects of the consolidation processes of hot isostatic pressing (HIP) and explosive forming in a die are examined. The particular material is 304 stainless steel. The characteristics of both RS and VGA 304 stainless-steel powders were described by Wright, Flinn, and Korth (2) earlier."

Jan 1, 1988

By Weatherstone N

Ironstone outcrops on the Savage River were discovered by State Government Surveyor C. P. Sprent in 1877. The limonitic outcrops were initially regarded as the surface expressions of pos- sible tin-bearing lodes, the tin deposits at Mt. Bischoff to the east having been found in 1871. By the turn of the century, shafts, adits and trenches had been developed on the deposits in the unsuccessful quest for gold, silver and base metals. The deposits were first reported as a possible source of iron ore by Tasmania Department of Mines (TDM) geologists in 1919. Modern exploration began in 1956 with the area registering the best magnetic response during an aeromagnetic survey of North- western Tasmania by the Bureau of Mineral Resources (BMR). The area had previously been reserved by TDM in anticipation of the lifting of the iron ore embargo. Reconnaissance Geologi- cal mapping (TDM) and grid-based magnetometer surveys (BMR) indicated that resources of iron-bearing material could approach hundreds of millions of tons. This provided the incentive for two diamond drill holes funded by TDM which demonstrated iron mineralisation in substantial tonnages, suitable grades and, fol

Jan 1, 1988

By P. Venkatasubramanian

"In recent years, computer based ""expert systems"" have been taking on large complex tasks for which no exact algorithmic solutions are feasible; tasks previously reserved for human experts requiring empirical knowledge, judgment, experience, developing a ""best solution "" by the use of plausible reasoning. Mining method selection is an appropriate area for the application of an expert system because extensive and detailed knowledge is required to make a ""best"" interpretaion of frequently ambiguous geological information. The expert system model presented here would enable users to apply expert knowledge to the evaluation of methods for coal deposits mineable by underground methods. IntroductionIn an increasingly complex and specialized world, human expertise spanning scientific, economic, social and political issues plays an increasingly important role in all branches of engineering. This is especially true of mining engineering. The number of scientific and professional disciplines involved in mine planning and evaluation, illustrates the problem. A conservative list includes geology, geophysics, geotechnics, hydrology, mining, environment, and economics.Engineers are almost obliged to be experts in at least one of the above disciplines if they are to handle the volume of information required in the planning process. Although computers have become indispensable tools in many endeavours, there is continued reliance on the human expert's ability to identify and synthesize these diverse factors, to form judgments, evaluate alternatives , and make decisions . This is especially true with regard to problems that are not easily amenable to precise formulations.The precious resource of human expert is also fragile and transient. The departure of a crucial expert from an organization ma y cause serious dislocations. Senior experienced people impart their knowledge of younger colleagues, but the demand for their talent may not leave sufficient time for such educational efforts. In recent years, computer based "" expert systems"" have been taking on large complex tasks for which no exact algorithmic solutions are feasible; tasks previously reserved for human experts, requiring empirical knowledge, judgment , experience, developing a ""best solution"" by the use of plausible reasoning."

Jan 1, 1988

By Aziz NI, Guo H

Most of the existing models of the mechanisms of drilling and cutting processes are oversimplified in both stress state and failure criterion. On the other hand numerical modelling techniques are a more versatile method with great potential for development. In reviewing drillability and predicting performance of excavation machines the empirical tests, which simulate the physical breakage action in excavating processes are seen to be the best in terms of penetration rate predictability. Future methods of determination of drillability should concern the breakage characteristics and rock abrasivity involved in the two basic types of attack, i.e., percussive and rotary drilling.

Jan 1, 1988