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By Felicia F. Peng

One of the serious environmental problems related with the extraction of coal for carbon and energy resources is that upon preparation of coal a large quantity of fine coal has been discarded and/or lost to tailing impoundments. These problems present hazardous conditions to the local community. Also, the precious heating value of energy resources has been wasted and Left unrecovered in the tailing impoundments. Both RCR and SMRC ACTs recognize and mandate an investigation into slurry impoundment problems, including consideration of potential use of those coal fines in the tailing ponds. Bituminous coal producing district 46 encompasses the northern panhandle of West Virginia. The major producing seam in this district is the Pittsburgh coal, 1-7 meters thick. 75 percent of the coal producted in this district is deep mine. This district produces approximately 3 million tons of coal waste materials annually. One of the coal preparation plants in the district which we have visited has been processing Pittsburgh too. 8 seam coal for the past ten years. The characteristic data of the Pittsburgh raw coal is shown in Table 1. The raw coal produced in this district is characterized by its high heating value, high ash and high sulfur contents. The coal preparation plant flowsheet designed and used to process this Pittsburgh raw coal prior to 1979 is shown in Figure 1. It was a partial coal cleaning plant' with 1 092 mt/hr designed capacity, which consisted mainly of a coarse coal cleaning circuit. The rejected fine particles in the size range of -600µm which consisted of vorsiv underflow and cyclone underflow from clean coal streams and spiral classifier overflow from refuse stream were settled down in a thickener with the aid of anionic flocculant prior to being pumped to the tailing ponds for disposal. Figure 2 shows that the same coal preparation plant in Figure 1 was modified to a semi-complete coal cleaning plant and expanded its designed capacity to 1 820 mt/hr, when market of coal fines becomes feasible in 1979. Tabling in the clean coal circuit and thermal dryer in the dewatering circuit were added to the flow sheet. The purpose is to recover more coal fines, reduce more pyritic sulfur and ash contents in coal and also to reduce solid waste material to be stored into the slurry impoundment, giving them a Longer Life. The rejected fine particles fed to the thickener are clean coal fines from two cyclone overflows and the fine refuse from the rufuse cyclone overflow. The clean coal fines presently lost to the tailing impoundments are in the size range of -150 µm and constitute about 5 percent of the overall plant feed. Total amount of tailing waste material accumulated in a tailing impoundment is estimated at 1.3 million metricton for the past ten years.

Jan 1, 1982

By J. Hupka

The limited effectiveness of the original hot water process for recovery of bitumen from certain Utah tar sands containing bitumen of higher viscosity (e.g. Sunnyside, Tar Sand Triangle)1,2 indicated that bitumen viscosity strongly' influences the separation efficiency. In this regard, there should exist a critical value of bitumen viscosity above which the effectiveness of the hot water process decreases significantly. Apparently certain tar sands contain bitumen of such high viscosity that even a digestion temperature of nearly 100°C is insufficient to lower the viscosity below the critical value. In addition it seems that differences in physico-chemical forces which act between sand and bitumen are negligible in comparison to the difference in visco-mechanical forces. Predominantly mechanical forces hold viscous bitumen on the rough surface and in the pores of sand particles, resulting in strong adhesion. This phenomenon is a critical feature in the phase disengagment of oil-wetted domestic tar sands with viscosity control by temperature. Besides increasing the temperature for viscosity control the effectiveness of the original hot water process could be enhanced by control of bitumen viscosity with diluent additions. Strictly speaking this appraoch is the only possibility for heavy bitumen for which the high temperature of digestion does not lower the viscosity sufficiently. As a result of viscosity control by diluent addition the digestion temperature can be lowered which is important from an industrial standpoint. Another important consideration is that effective phase disengagement occurs only when the entire bitumen phase has the same viscosity. This means that some time (penetration time) is necessary for complete and uniform dilution of the bitumen. If the viscosity of bitumen, which is a function of temperature, diluent addition and penetration time, controls the separation efficiency, hot water processing of many different kinds of tar sands should be possible, assuming that the sand phase consists primarily of quartz-type minerals.

Jan 1, 1982

By J. H. Russell

As part of its efforts to maximize resource recovery, the Bureau of Mines conducted studies to recover valuable byproducts from Western phosphate beneficiation tailings. Potential byproducts include phosphorus, vanadium, and uranium. The objective was to determine roasting and leaching conditions for maximum dissolution of vanadium from tailings containing approximately 13 pct P205 and 0.23 pct V. Sulfuric acid leaching tests were conducted with the tailings either as a dilute suspension dried, or in a roasted condition with or without NaCl added during roasting. More than 90 pct of the vanadium was dissolved by roasting at 850° C for 120 min with 8-pct NaCl and leaching at 75°C for 120 min with an excess of 2N H2S04, By roasting without NaCl and avoiding the difficulties of the chloride impurity, nearly 80-pct vanadium dissolution was achieved with an 800° C roast for 180 min. Quadratic regression equations were derived to relate vanadium dissolution to roasting and leaching conditions.

Jan 1, 1982

By J. I. Paige

As part of a continuing effort to develop technology that maximizes mineral and metal recovery from domestic resources, the Bureau of Mines investigated a method to totally utilize copper converter slags without recycling them back through the matte smelting furnace. The research was directed toward (1) recovering the contained copper in converting slags by producing a recyclable copper-iron matte, (2) carbothermically reducing the slags to recover the iron, and (3) producing slag wool from the depleted slags. This report deals with the reduction of three industrial converting slags, containing 2.0 to 7.3 wt-pct Cu, in an 800-kVA electric arc furnace to produce a recyclable copper-iron matte. The addition of sufficient iron pyrite to provide 29 to 113 pct of the stoichiometric sulfur (based on producing 40-pct-Cu matte) produced a recyclable matte (36 to 61 pct Cu) at an energy consumption of 520 to 700 kWh per ton of solid material charged. The expected energy saving for treating molten slag in an electric furnace (5-to 9-MVA range) is about 400 kWh per ton of molten slag treated.

Jan 1, 1982

By Richard L. Werner

The petrographic microscope as a tool in determining impurities and grain size of limestones, clays, sand and coal ash for possible use as raw materials is discussed. Its use in the determination of the mineral composition of various size fractions of the raw mix, after fine grinding in ball mills, and of the waste dust from the rotary kiln. A description is given of the typical clinker crystals; alite, belite, tricalcium aluminate and ferrite. The process problems indicated by various changes in the crystal characteristics are listed with possible solutions. Finally the microscope as used in relation to field problems with concrete such as air void volume, percent hydration of the cement, cement aggregate bonding and the determination of solid additives, is presented.

Jan 1, 1982

By Bob de Raadt

After a review of the general principles for blasting stacks, the stagnations of two stack demolitions are investigated. The author concludes and demonstrates that MS-delay blasting can be risky under certain circumstances. How this initiation device can still be applied safely to the demolition of stacks is shown in an account of a blasting operation, in which two 106-m (350 ft) -high concrete stacks were involved. The recent discovery of a possible hazard of MS initiation in this field of blasting is an essential contribution to increased safety in blasting tall structures.

Jan 1, 1982

By L. M. Litz

In reply to Mr. DeVries comments on my paper, I would like to say that it is true, as pointed out by Mr. DeVries, that under some special conditions, the use of high concentrations of hydrogen peroxide might provide higher short term in-situ …

Jan 1, 1982

By Robert D. Brown

The purpose of this paper is to tell a story - and it is a story with a moral. My topic is Present Trends in the Tax Environment Affecting Mineral Development in Canada, and the first thing to recognize is that, with depressed metal prices and weakening western economies, taxes, in and of themselves, are not really the cause of the Canadian mining industry's present doldrums. But the character and level of mining taxes in Canada has had a profound influence on the development of the industry over the past decade, and the expectations of what taxes the industry will face in future years will influence the industry's further growth. My theme today is that, in Canada, our tax system has, in the past, served as a negative and destabilizing influence in the mining industry: it has contributed to a major short-fall in investment commitments and hence in the contribution which the mining industry can make to the Canadian economy, and the adverse effect on the industry of previous high tax rates was made far worse by the confusing, contradictory and perverse nature of the tax system itself. This is a story with some happy parts in it, and, in fact, governments in Canada did learn, haltingly and grudgingly, that there are limits on the amounts that governments could safely extract from the industry, and that some assurances of long term fiscal stability were necessary if investors were to be induced to make massive commitments which could only be recovered over very lengthy periods.

Jan 1, 1982

By Richard B. Berg

Chlorite veins in the Silver Star district (40 km southeast of Butte) were of little interest to those who were mining gold and silver in the late 19th century. It wasn't until 1975 that unusually pure magnesian chlorite of the variety clinochlore was identified from a ?talc? claim in this district. In 1977 tests by Cyprus Industrial Minerals showed that this chlorite was suitable for use in ceramics. Mining begun in that year continues. These replacement veins of chlorite in Precambrian quartzofeldspathic gneiss differ from the metalliferous veins to the northwest in both attitude and mineralogy.

Jan 1, 1982

By R. E. J. Putman

Introduction Self-tuning regulators are a class of controllers built around the concepts of sampled data theory, and are especially suitable for implementation in a digital microprocessor or minicomputer control system. The algorithms used are distinctly different from those based upon analog control techniques and include automatic adjustment features which permit them to adapt to unmeasured changes (in, for example, ore grindability) or process nonlinearities (as exhibited by cyclone classifiers). They are also designed to handle transport lags in a simple manner, for example, anticipating the effects of a variable recycle rate on particle size distribution. The advent of distributed control systems will encourage the exploration of these techniques in the minerals processing industries, and particularly for improving the control of comminution circuits, which are especially energy intensive. This paper outlines some current work in progress on this topic. Background Those engaged in the practice of process control have long had two philosophical problems for which solutions have been actively sought - what is optimal control and how can we attain it in some heuristic fashion automatically. The basic analog controller can be represented by the differential equation: [V = Ko + K1 f y • dt + K2 dt(1)] where: v and y are the instantaneous values of output and error respectively and K0, K1, and K2 are tuning constants. The empirical rules for establishing the values of K0, K1, and K2, which provide stability, have evolved from the initial suggestions of Ziegler and Nichols(9) in 1942 and have served their purpose well. However, later analyses demonstrated that there are in fact many combinations of the values of K0, K1, and K2 which, besides being stable, behave better or worse in relation to other process control criteria; some examples are duration of error, amplitude of a damped response, magnitude or rate of movement of control valve or adjustment of speed regulator, etc. The definition of optimality had broadened. In 1964, Kalman(4) published his classic paper which tried to resolve these problems. He defined a

Jan 1, 1982

By D. Krzyszton, P. Czaja

Mining explosions in rocks originate stress waves of great intensity, which crush the surrounding rocks and are then propagated as a seismic wave. Seismic waves are the cause of dynamic loading of pillars and their subsequent destruction. In calculating safe dimensions for inter-room pillars, not only the stresses conditioned by overburden pressures should be taken into consideration, but also the dynamic stresses caused by explosion. This is of particular importance for pillars with great specific acoustic impedance which have been destroyed mainly by the reflected seismic wave. It is possible to take dynamic loading into consideration in the calculation of pillars when the parameters of the propagation wave, the dynamic elastic constants of rocks, the strength properties of rocks, the strength properties of rocks subjected to dynamic loads and the parameters of the blasting charge are known. An example of the calculation for the safe width of an inter-room pillar subjected to the seismic effect of an explosion is given and the possibilities of reducing the dynamic loading of pillars are discussed.

Jan 1, 1982

By John H. Perry

The Bureau of Mines has developed several techniques for draining methane from coalbeds in advance of mining. Drilling long horizontal holes from an underground location is one such technique, which was successfully demonstrated in the Pittsburgh and Sunnyside Coalbeds. The same technique has now been applied in the Mary Lee Coal bed at Jim Walter Resources, Inc.'s No. 4 Mine, Brookwood, Ala., where two holes were drilled horizontally--one to a depth of 1,010 feet (308 m) and the other to 540 feet (165 m). The 1,010-foot (308-m) hole proved successful in degasifying a portion of the Mary Lee Coalbed. The hole drained methane for 1 year, during which time the initial gas flow of 200,000 ft3/d (5,663 m3/d) declined to 65,000 ft3/d (1,840 m3/d). Total gas production was 40 x 106 ft3 (1.1 x 106 m3). The gas was of commercial quality, with 98 pct methane and a heat rating of 990 Btu/ft3 (36.89 Mj/m3). The methane emissions from the faces of the mine section advancing into the degasified zone were reduced by 60 pet. The 540-foot (165-m) hole was terminated prematurely when it became impossible to maintain an open hole. Because of caving, very little gas was drained through this hole.

Jan 1, 1982

By Brian P. Atkin

The NISOMI-81 opaque mineral searcil and identification system uses quantitative color values (Pe, dA, y) and VHN as its determinative para-meters. The system is designed to operate on a Radio-Shack TRS-80 micro-computer which is interfaced to a motorised diffraction grating mono-chromator (WILSCAN). Using an interfaced monochromator/photometer combination a typical identification including the measurement of the photometer data on both specimen and standard, calculation of color values and a computer search takes about 6 minutes. The data file contains 240 minerals at present but can easily be expanded as reliable new data become available.

Jan 1, 1982

By Richard H. Bares

One criterion central to most definitions of reclamation is the restoration of mined lands to their original productive potential. This is often difficult to achieve on mined lands in the Northern Great Plains because of the rigorous climate (Bares 19;2) and various soil related problems including sodicity, salinity, soil permeability, low organic matter and plant nutrient deficiencies (Malakondaiah and Safaya 1982). Field study sites were established on recontotured mined areas during the early 1970's (prior to the topsoil mandate) in which several amendments were tested for their ability to improve spoil/topsoil conditions and, hence, increase plant production. Physical and chemical properties of these control (untreated) and amended spoils and topsoils have been summarized (Safaya et al. 1982). A number of grass and legume species combinations were studied. The general effects of one time (prior to seeding), single rate (approximately 100 mT ha-1) application of leonardite and/or slack coal to spoils and topsoils was the reduction of grass dry matter yields (NB 1 test site: dry matter yield (DMY) without slack was 110 g m 2 yr I ; DMY with slack was 80 g m -2 yr 1 I and the promotion of legume establishment and yield (SB test site: DMY without leonardite was 13 g m 2 yr -1; DMY with leonardite was 93 g m 2 yr 1). On South Beulah topsoil, treated with leonardite, production of weedy species was remarkably lower than that without leonardite (SB test site: DMY without leonardite was 252 g m - yr -1; DMY with leonardite was 177 g m 2 yr 1). The general effect of commercial fertilizer applied one time prior to seeding (rates ranging from 9-13-0 to 44-1 12-28 kg ha-1 of N-P-K) was to increase plant production during the first two to three years after which the effect disappeared. This effect was much more pronounced on spoils (NB I test site: DMY on spoils without fertilizer was 53 g m -2 yr -1; DMY on spoils with fertiliser was 132 gm -2 yr -1). Weedy species accounted for most of the biomas, production during the first growing season. Three of the test sites were designed to study plant production on topsoils and spoils. Establishment and production of grass species were comparatively better on topsoils (30 cm in depth) than on spoils while legumes were most successful on the soils (Center test site, 1979; DMY of grasses on topsoil was 170 g m 2 yr -1 DMY of grasses on spoils was 52 g m -2 yr -1; DMY of legumes on topsoil was 20 g m -2 yr -1; DMY of legumes on spoil was 191 g m 2 yr -1). Total plant production on topsoiled (302 m thickness) plots at the South Beulah site (DMY in 1979 of 269 g m 2 yr 1) was comparable to that of native western wheatgrass prairie (DMY of 262 g m -2 yr -1). An experiment was conducted to find out if time of planting would have any effect on establishment of grasses on spoils. It was fund that late fall seeding was superior to spring planting for establishment of wheatgrasses at NB 3 test site (Control Plot, 1975: DMY on spring-seeded was 1 g m -2 yr - 1; DMY on fall-seeded was 55 g m -2 yr -1). In general, wheatgrasses (slender, streambank, thickspike and western) yielded the most aboveground biomass of all the grass species tested; yellow sweetclover was the most successful legume. Yellow sweetclover established and was productive on both spoils and topsoils but only where competition with grasses was apparently minimal. Durar hard fescue established and thrived on topsoil but dry matter production was low compared to that of wheatgrasses. Emerald crown-vetch demonstrated a potential for growth on spoils where water conditions were adequate, whereas side-oats grama, prairie sand-reed, alkali sacaton, and bird's -foot trefoil demonstrated only sporadic success. Little bluestem did not become established at any of the test sites. Peak production of the planted species, especially grasses, was generally reached by the second week of July. Legume and weed production continued to increase into late August.

Jan 1, 1982

By Robert E. Moore

Renewed interest in olivine refractories has led to efforts to characterize them employing modern techniques of experimentation and data analysis. Initial studies have focused on determination of physical and thermophysical properties. Special equipment for the determination of thermal shock resistance and creep behavior have been constructed. Optimal compositions for maximizing various properties are being identified using appropriate statistical techniques. The overall goal is to develop response surfaces for each of a selected group of engineering design and use properties. Development of ?olivine Refractories? in the United States The term "olivine refractories" is used here because it does appear that domestic deposits of this rock will be the focus of renewed interest and "olivinell is the preferred term in this country. There are extensive deposits of high quality olivines extending through parts of Georgia. North Carolina and in the state of Washington. The eastern olivines are much more localized and extensively altered compared to the western materials. The Washington olivines exist as massive rock deposits in the Twin Sisters mountain area northeast of Seattle and their inaccessi-bility has slowed efforts to develop them. The North Carolina olivines have been used in steel plant applications since the 1930's. Geologists use the term "olivine" to describe assemblages of ortho-silicates. 2RO.SiO2, wherein the RO may be MgO. FeO. MnO. etc. When the RO consists essentlally of MgO and FeO. the material is called dunite and. as such, is synonymous with "refractory olivine." Refractory olivines utilizing North Carolina materials were developed for brick products by Birch and Harvey in this country around the mid-1930's. (I) Their work was completely independent of that of V. M. Goldschmidt and co-workers who used massive dunites located in Denmark. (2) These deposits are currently being mined by A/S Olivine of Denmark for the manufacture of a rather complete line of brick shapes for use in steel-plant. glassplant. and cement kiln applications. Birch and Goldschmidt

Jan 1, 1982

By Richard H. Bares

This report describes the purpose and application of seventeen statistical and mathematical procedures used in a series of studies made in the project ?A Systems Approach to the Reclamation of Strip-Mined Areas in North Dakota". The objective is to help readers better understand the utility of these procedures.

Jan 1, 1982

By T. R. Strombotne

The purpose of this report k to document a contract undertaken by TSA Systems, Incorporated for the United States Bureau of Mines to develop a commercially available source of a continuous, working,, level detector for the measurement of radon daughter products in various working environments. The basic radon measuring technique was devised by Robert Droullard and Robert Holub and has been applied here. For further details or purchasing information contact: TSA Systems, Incorporated 4919 North Broadway Boulder, Colorado 80302

Jan 1, 1982

Activated carbon is ideally suited to treating low grade ores and tailings by the carbon-in-pulp process and is rapidly replacing the use of zinc for recovering gold from cyanide leach solutions. Coarse carbon particles derived from coconut shell adsorb up to 30,000 ppm Au as a gold cyanide complex and can leave barren solutions containing

Jan 1, 1982

By Norman M. P. Low

"IntroductionIndustrial applications of mica utilize two commercially important varieties of mica: muscovite and phlogopite. Muscovite mica is a potassium mica with a general chemical formula, H2KA1(Si04)3 h, and is sometimes referred to as a potas hsilicate. Phlogopite is a magnesium mica having a general chemical formula, H2KMgSi(Si04)3, and is distinguished from the muscovite mica by its decomposition in sulphuric acid.Canada is one of the major natural mica producers in the world. A large tonnage of the mica powders is at present mined and processed in the Eastern Townships of Quebec. This Canadian mica is of the phlogopite type. A closely related mineral of the mica family which is widely used in the construction industry is vermiculite. It is a dehydrated magnesium-aluminum-iron silicate characterized by a foliated structure. Expanded vermiculite, which is often referred to as exfoliated mica, is used as many types of thermal and acoustic insulation, as loose fill in buildings, as an aggregate in concrete, as an ingredient in plaster and insulating concrete , and in fire-proofing compositions. Natural phlogopite and muscovite mica powders are used extensively as reinforcing agents in organic polymers. They also have a wide range of applications in commerical products. For example, dry-ground mica powders are used in large tonnage as a surface finish in roofing materials and as a bonding agent in wallboard joint cement. Common products such as paint, rubber, plastics and welding rods contain mica. Recent studies have also shown that mica powders can be added to portland cement in the preparation of concrete products, as they could improve the tensile strength of the concrete products. The potential and possible"

Jan 1, 1982

By Brian McIntrye, Bo Trygg

"The need for grinding mills of ever increasing capacity and greater feed openings has tended toward mill trunnion diameters being beyond the size limits for roller bearings.Hydrodynamic plain bearings need to be wide enough to achieve the necessary bearing pressure in order to obtain an oil film with sufficient carrying capacity at low rotational speeds. This greater width increases edge loading resulting from the deflection of the mill under load.Because of the high surf ace pressure involved, the life of support rollers and girth rings is often inadequate-fatigue leads to flaking on the contact surfaces. Heat treatment of the girth rings also has its problems.The hydrostatic shoe bearing permits unlimited trunnion diameter and a high carrying capacity. The self-aligning shoes compensate automatically for radial deviations and large deformations can be tolerated at the girth ring.The sliding surfaces are completely separated by oil under pressure, enabling negligible starting torque and good damping capacity to be achieved together with low rotational speeds.IntroductionHydrostatic bearings have been known within machine technology since 1865, when the Frenchman Girard received a patent for such a bearing. During the following 75 years, these types of bearings were used sporadically for thrust bearings, primarily in water turbines. The first usable radial bearing was not designed until 1938. Since the 1950s, when hydrostatic bearings started to come into use within the field of machine tools, extensive research and development work has been carried out at various institutions and research centres throughout the world. Many support problems are now solved by means of hydrostatic plain bearings and the primary factor in deciding to use them is their unique characteristics:• ability to carry high loadings• no starting torque• large damping capacity• no wear• large running accuracyThe hydrostatic shoe bearing has been developed specially for use in the heavy machine industry, with the requirements for high loadings and large support diameters which this market demands."

Jan 1, 1982