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By R. Blickensderfer

The sparking and gas-igniting tendency of steels and alloys were evaluated my measuring the radiance of spark showers produced by grinding a sample on an abrasive wheel in air, the time required for a spark shower generated on an abrasive wheel to produce an ignition in an explosive gas mixture, and the energy and speed required for impacts between various materials to ignite an explosive gas mixture. Mixtures of air-methane were found quite resistant to ignition by showers of sparks. A mixture of air-9.S pct hydrogen was used to increase the sensitivity of the tests and to thereby extend the range of materials that could be evaluated. The results of the spark-shower tests indicate that carbon steels and the alloy steels found in coal-cutter tools are among the most sparking and most incendive of any materials tested. Stainless steels, nickel alloys, and tungsten carbide are among the least sparking and least incendive. The brightness of the spark showers depended upon the degree of oxidation of the abraded particles. Impact tests against hard rocks such as solid quartz and sandstone, showed that high-carbon steel was more inc endive in the hydrogen mixture than were the softer steels or the alloy steels found in coal cutters. Ignitions were found much less likely to occur at speeds somewhat lower than the speeds currently in use in continuous mining machines.

Jan 1, 1972

By E. R. Cole

Laboratory heats of an 80 percent copper high-leaded tin-bronze alloy, similar to Brass and Bronze Ingot Institute (BBII) alloy 3A, were made with reduced tin content to determine whether an alloy comparable to BBII alloy 3A could be produced using less tin to aid in conserving this strategic metal. The tin content was lowered from 10 percent to 8 percent and 5 percent (nominal values), respectively, and the reduction in tin was offset by either increasing the lead content or adding zinc. Mechanical properties, machinability, and corrosion characteristics of the resultant alloys were investigated, and the mechanical properties were compared with BBII typical values and American Society for Testing Materials (ASTM) minimums for high-leaded tin-bronze alloy. Results indicate that the tin content of this alloy could be reduced approximately 1 percent (difference between the 8.4 percent actual tin composition obtained and the 9.3 percent BBII minimum) without seriously affecting the desired properties. Results also show the tin content could be reduced without significantly increasing the chances of rejects for mechanical property failures, which might result from normal variations in the casting process.

Jan 1, 1972

By E. L. Singleton

The Bureau of Mines investigated extraction of aluminum from aluminum-silicon alloys as a means of utilizing domestic aluminum silicate ores for aluminum production. Aluminum was extracted from aluminum-silicon alloys by electrolysis in molten electrolytes of NaCl-KCI-AIC13 and NaCl-KCI-AIF3 in a laboratory-scale cell. Six alloys with aluminum contents ranging from 20 to 87 percent aluminum were tested, and aluminum products of primary grade or better were obtained. More than 80 percent of the aluminum was recovered with current efficiencies as high as 91 percent. Recovery of a metallurgical-grade silicon product from the anode residue by an acid leaching procedure was possible with the 50-50 and 65-35 Al-Si alloys.

Jan 1, 1972

The Wednesday morning session was opened by President Joe Ward at 9:30 a.m. He complimented Walter Mueller, Program Chairman, for the excellent job he did as head of that very important committee. He also thanked all those on the various committees, speakers, and all who participated in making the 1972 meeting a success. He called on William S. Landers, Chairman of the Auditing Committee, to give his report. He read the report and asked for a motion of approval. Motion was made, seconded and approved. (See Treasurer's report on page 5.) A. E. Pagnotta of the Resolutions Committee read their report as follows: RESOLVED: Whereas, since the 67th Regular Meeting of the Rocky Mountain Coal Mining Institute. held at Park City, Utah, the Institute and the coal mining .industry has suffered the loss through death of service and fellowship of the following members: W. H. Carson James Dalrymple Edward H. Denny A. B. Foulger Thomas E. Graham G. R. Harris Frank Markosek Anthony C. Moschetti Harry Swihart Franklin B. Thomas

Jan 1, 1972

By R. B. Schluter

Drying and preheating (partial induration) the green, unfired iron ore pellets is a means of reducing the energy required to produce metallized pellets. The Bureau of Mines processed three magnetite and two hematite concentrates through the unit operations of pelletizing, preheating in air, and reduction to metal to determine the effects of preheating upon the properties of the metallized pellets. The pellets were prepared in a 16-inch-diameter laboratory balling drum. Preheating and metallization were carried out in an externally heated 4-inch-ID by 4-inch-long stainless steel drum using air for the preheating atmosphere and lignite char as a reductant. The results 'varied considerably: two of the magnetites spalled when preheated in air at temperatures of 900° C and above, and the third magnetite and the hematite flotation concentrate required complete induration at 1,300° C to produce satisfactory pellets. The earthy hematite ore yielded excellent pellets at all preheat temperatures.

Jan 1, 1972

By Robert M. Jimeson, James M. Grout

The competitive market potential for solvent-refined coal is estimated and the market advantages are enumerated. Markets are possible in combustion, railroad locomotion, and carbon electrodes. The combustion characteristics are consistent with expected air pollution restrictions on the emission of sulfur and particulate matter. A market potential of sufficient size exists to support the initiation of solvent refining in the United States. The market analysis should help fuel producers determine the advisability of their undertaking solvent refining of coal.

Jan 1, 1972

By G. Barbery

Since the original paper, two methods have been introduced to compute the parameters of the three parameter size distribution equation: [ ] Both of them are based on graphical means, which are time-consuming and of little statistical significance. A program has been developed, using the Gauss-Newton method to compute by nonlinear regression analysis the parameters of the equation. Although the method is quite general in curve-fitting applications, it does not appear to be used in the field of size analysis, and a brief description is given. As applied here, the Gauss-Newton method involves the minimization of the least squares: [ ] where n is the number of sieves used. The second member of Eq. 2 can be approximated by a multiple Taylor's series expansion of first order about a starting value [ ] The minimization of Q (r,s,Xo) means: [ ] Putting Eq. 3 into Eq. 2 and differentiating, we obtain a system of equations which can be represented in matrix symbolism (box) The system can be solved for: [ ] and the operations repeated with new values: [ ] The starting values for r and s are taken as 1, for Xo, a value higher than the maximum sieve opening value. Applied to the data given by Herbst 5,6 for batch grinding of 7 X 9 mesh dolomite, the parameters given in Table 1 were obtained. The discussion of the significance of the residual sum of squares is a difficult subject in multiple nonlinear

Jan 1, 1972

By A. L. Mular

A great deal of effort is being expended by mineral processing engineers to acquire a basic knowledge of modelling and optimization techniques. Stimuli such as immediate process improvement, expanded process understanding, optimal flowsheet design and re-design, and the development of new and better control systems are goals which excite the imagination in terms of increased profits. To reach these goals, process models and efficient optimization strategies, regardless of their purpose, assume an important role. Consequently, few of us can argue that such efforts are of no value. The purpose of this paper is to review empirical modelling methods and optimization strategies which appear to be of value to mineral engineers.

Jan 1, 1972

By Charles A. Kelliher

In November of 1957, the Aliquippa Works started operation of the third basic oxygen furnace shop in North America. This high speed basic steelmaking method provided a very economical increase in capacity at the Works. The success of these two (2) 81-ton furnaces led to the construction of a second B.O.F. shop, producing heats of 230 tons at J&L's Cleveland Works in 1962. The experience gained operating both shops provided the background for the design of the new steelmaking complex at the Aliquippa Works. This new complex consists of a three (3) furnace shop with two (2) furnaces blowing alternately producing heats ranging from 120 to 207 tons. This variation in heat size is predicated on the requirement that approximately 20% of the shop production will be used to supply steel to a six (6) strand casting machine, producing 4' through 7" billets. The new B.O.F. shop has replaced all other steelmaking units including the #1 Shop, where operations were discontinued in September of 1968. With the advent of the strand casting facilities in September of 1969, many of the standard shop practices had to be changed to compensate for higher tap temperatures, longer handling times, and reduced ladle availability. The subsequent changes in these areas led to the evolution of the strand cast ladle practice which is described in this paper.

Jan 1, 1972

By J. M. Kuchta

Ignition and flammability test methods were developed by the Bureau of Mines for use in the classification of flammable solids by the Department of Transportation. A rotating disk ignition apparatus and a flame-spread-rate apparatus are proposed for determining the ignitability and flammability, respectively, of most flammable solids. Extremely flammable solids, such as pyrophoric materials, are evaluated by determining their ease of spontaneous ignition in an environmental chamber at high-humidity conditions. Data are presented for various representative solids to show the reliability of the test methods for classifying the materials. A classification system is also proposed for use in government transportation regulations.

Jan 1, 1972

By P. D. Bergman

The high price of pollucite ore, its limited availability, and the need to provide stack removal of S02 present formidable obstacles to the use of pure cesium as a seeding material in MHD power generation. Cost estimates indicate that mixed potassium-cesium seeding is preferable to the use of either pure cesium or pure potassium. Cheaper electricity and higher open-cycle MHD operating efficiencies result from the use of mixed seed. Savings of $3,000,000 per year in power costs for a 1,000-MWE open-cycle MHD power-plant are envisioned if the mixed seeding technique is adopted.

Jan 1, 1972

By D. G. F. Hedley, F. Grant

"In 1958, the Ontario Department of Mines appointed a committee to study the accident situation and mining methods used in the uranium mines in the E1liot Lake district. This committee reviewed the existing knowledge on mine design, pillar support and roof spans and came to the conclusion that scientific knowledge had not yet reached the stage of producing rational design procedures which would reduce the dependence on trial-and-error methods. Since that time, the Mining Research Centre has made numerous stress measurements in two mines to define the pre-mining and pillar stresses. A comprehensive series of tests has been done in the laboratory to measure the compressive strength of the rock; a geological survey of the region has been made to evaluate tectonic stresses; and a survey was done on mining conditions with regard to stable and unstable pillar configurations. This information has been used to evaluate pillar design as effected by pillar width and height, depth below surface, extraction and pre-mining stress fields. The resultant design of pillar widths and corresponding extraction as the depth increased is in line with past and present experience in these mines. The information available on roof stability is still insufficient to design stable stope spans with the same degree of confidence; experience and trial-and-error methods are still required."

Jan 1, 1972

By Sheldon P. Wimpfen

Sand and gravel has been, and will continue to be, our principal construction material. Most of us are familiar with the patterns of past growth. Today we will examine the present status of this vital industry. We shall also attempt to look into the future to see where it is going and to evaluate the constraints that are being imposed. Natural aggregates are among the lowest in value of all bulk industrial minerals. From the processing point of view, sand and gravel production is relatively simple since the products are sized materials obtained from a deposit of satisfactory physical soundness. They can be used either loose or bound to provide bulk, strength, or protection. One of the main uses of coarse aggregate is in concrete as a filling material. As a general rule, the coarse aggregate constitutes about three-quarters of the volume of concrete. The other main use for aggregate is as a roadstone or roadbase to provide protective and stabilizing bulk beneath the road surface. Also it is used in a mixture with petroleum products as the wearing course on top. The sand and gravel industry is geographically widespread. In general, the output of operations is directly proportional to the amount of construction in any area. A wide variety of other aggregates compete with sand and gravel, including crushed stone, blast-furnace slag, clinker, and artificial and natural lightweight materials.

Jan 1, 1972

By D. R. Lowe

Silicic volcanic ash and its alteration product, bentonite (montmorillonite and cristobalite), occur widely within sedimentary phosphate deposits. The genetic link, if any, between volcanism and phosphate deposition has yet to be satisfactorily established The phosphatic member of the Santa Margarita Formation (upper Miocene) in northwestern Ventura County, California, consists of approximately 15 per cent volcanic ash and bentonite. Ash and bentonite units greater than one foot thick can be subdivided into a lower zone of airfall origin and an upper zone of mixed ash and terrigenous detritus washed in from surrounding land areas. This upper zone also contains up to 20 percent phosphate pellets. These thick volcaniclastic units are typically overlain sharply by thin beds (less than 6 inches thick) of relatively pure, silica-cemented pelletal phosphorite. The shelf basin in which the phosphatic sediments accumulated was characterized by quiet, reducing but not euxenic bottom waters; Abundant decaying organic debris, mainly diatoms, served as a reservoir of readily available phosphate. The sudden influx of a large volume of silicic volcanic ash into this basin and its subsequent alteration to montmorillonite had two profound effects on thechemistry of the interstitial and bottom waters: (1) during alteration magnesium was removed from these waters and incorporated into the montmorillonite lattice, and (2) the pH of these waters increased as alteration progressed Both of these effects led to the crystallization in the bottom waters of carbonate fluorapatite. This accumulated as thin phosphorite beds immediately above the volcaniclastic units.

Jan 1, 1972

By M. Friedman

Applications of rock mechanics to the design of engineering structures in rock involve the assumption that the stresses are due entirely to the present applied loads. For instance, it is assumed that the vertical normal stress in undisturbed rock free of topographic effects is equal to the weight per unit area of the overburden. In fact, vertical dilatational strains associated with stresses of more than 100 times the present overburden pressure have been measured by strain-relief methods on outcrops. 1,2 The notion of residual strain (stress) or latent stress3 seems unassailable; and indeed this has long been recognized by metallurgists. It is difficult, however, to assess the residual component of the in-situ state of elastic strain with conventional strain relief methods employed in mines or down boreholes. That is, in principle, the in-situ state results from the superposition of present applied loads (natural or man- induced) and potentially recoverable elastic strains (stresses) that exist in a given volume of material even though there are no external forces across the boundaries of the body (Voight,4 and Fig, 1). Accordingly, only in unloaded blocks can the true residual strains be measured by strain relief methods. Using X-rays, the elastic strains locked within the quartz grains or crystals of a rock can be measured. These strains are known to persist even when the rock is reduced to small chips but to vanish when the rock is disaggregated and the grains are powdered. Although we have just begun to investigate the mechanisms by which the strains are stored (see Preliminary Results), we believe that "pressure solution'' at grain boundaries, secondary cementation under load, permanent ("plastic") deformation, and temperature changes are possible processes. In any event, in our study of naturally deformed rocks, it is significant that we are work-

Jan 1, 1972

Since roof falls in the vicinity of the working face in underground coal mines are a major source of fatalities and injuries in this country's coal mines, it is evident that the present systems of temporary support for use in this working area are ineffective. This seems to be chiefly due to the inconvenience of setting up heavy and awkward devices such as jacks, posts and the like, which also interfere with the movement of men and machines in this critical working area. This program was concerned with defining and testing commercially available materials that could be used as support elements in a more convenient flexible personnel shield. The objectives of this program were to: 1. survey the materials that might provide the support elements of a flexible-material personnel shield for use in underground coal mines and prepare a list of those materials which appear most suitable for use in coal mines. 2. prepare a proposed testing plan for the materials to be selected from the aforementioned list by the Bureau of Mines for further evaluation. The test plan was designed to provide the following information: a. Tensile strength. b. Proportional limit. c. Creep characteristics at room temperature. d. Elastic properties depicted by stress-strain curves. Properties were tested in two directions for woven fabrics. e. Density. f. Resistance to abrasion. g. Resistance to attack by mine atomsphere. h. Resistance to humidity. i. Impact characteristics.

Jan 1, 1972

By G. R. McMeekin

"THE TOPIC suggested for my contribution to this Symposium was ""Lead-Zinc Smelting - 40 Years of Pollution Control"". The history of the development of smelting industry at Trail and the control of sulphur dioxide could make quite an interesting historical study. However, in the field of environmental control, the public is not particularly interested in what you did yesterday, but rather what you are doing today and what you are planning to do tomorrow. I can't fault this approach, but because there are some subject lessons that history can demonstrate, I would like to tell enough of the story (under three headings) to bring a focus on matters of contemporary concern in regard to public relations and ecology. The three general headings suggested are: (1) time before the capture of by-product sulphur; (2) the capture of sulphur; and (3) the ecological and public relations conclusions from these."

Jan 1, 1972

By Praterm J. D.

The process parameters for effective utilization of nitric acid as an oxidant for copper-iron sulfides have been developed. Leaching variables found to be important were acid concentration, temperature, time, atmosphere, pressure, mineral type, particle size, and percent solids. Particular attention was devoted to analysis and control of fumes evolved during the oxidation. Responses recorded were metal extraction, elemental sulfur formation and oxidation, product gas composition and evolution rate, reagent consumption, and residue flotation response. The paper concludes by laboratory testing a flow sheet based on the above observations. Ninety-eight percent of the copper contained in a chalcopyrite-bornite concentrate was recovered, requiring 1. 6 pounds of nitric acid to be regenerated externally per pound of copper extracted. Iron remained in the leach residue as hydrogen jarosite and was ultimately rejected from the system by froth flotation. Sixty percent of the sulfur contained, in the heading concentrate reported in the elemental form; the remainder was oxidized to sulfate and eliminated with the hydrogen jarosite in the flotation tails or by neutralization of the solvent extraction raffinate with lime. Nitrogen was evolved primarily as NO and NO2; up to 3 percent N2O was also present. Gases containing sulfur were absent except when pyrrhotite was solubilized in the absence of soluble copper. In this case, H2S was evolved.

Jan 1, 1972

By John Ward Smith

Detailed oil yield, lithologic, and mineral distribution data are presented for core and drill-cutting samples from the Western Oil Shale Corp. Project Utah EX-1 Corehole (WOSCO EX-I), drilled to sample a deeply buried oil-shale sequence in the Green River Formation of Utah's Uinta Basin. Drilling of this corehole was part of the evaluation of this site for possible oil-shale development by nuclear explosion. Sections sufficiently thick for nuclear development average 15 gallons per ton or less and consist predominantly of low-grade shales. Some properties of low-grade shales may be advantageous to a nuclear experiment by facilitating breakage, fracture development, and in situ retorting. The formation correlates precisely with the well-studied oil shales 25 miles east near the Colorado border. A 235-foot mineralized section containing nahcolite, shortite, and searlesite whose bottom lies 300 feet above the Mahogany zone is described.

Jan 1, 1972

By Michael E. Charles, Jaroslav J. Vocadlo

"The hydraulic transport of solids through pipelines can have many advantages over other modes of transport. Numerous successful applications both within plants and over longer distances have demonstrated the technical and economic feasibility of slurry pipelining. Solids successfully transported include kaolin, coal, iron ore, gilsonite and limestone, and others, such as sulphur and potash, are likely to be transported in Canada in the near future. However, though the technology of solids pipelining is quite advanced the underlying principles have not yet been formulated past the semi-empirical stage. The main objective of this paper is to present a discussion of the important technical and economic considerations in the design of so lids pipeline systems by reference to typical data. The Worthington slurry pumps and pilot facilities are briefly described."

Jan 1, 1972