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By G. Archer

ASARCO, a large and diverse producer of nonferrous metals, is involved primarily in the smelting and refining of lead and copper. Lead-antimony alloys, antimony trioxide, bismuth, cadmium oxide, selenium, tellurium, silver and gold are among products which result from processing by-products of smelting and refining. The complex mixture of concentrates at some smelters and the high impurity loads at some refineries result in various drosses, sludges, dusts and slags. In this paper, the complex interplant and intraplant transfer of by-products is addressed. These by-products result in an exchange of metals between the lead circuit and the copper circuit. Examples of the transfer of by-products and the prospects for the recycle of valuable products from wastes generated by customers and unrelated processors are also discussed.

Jan 1, 1992

By L. K. Walker, G. A. Kosick, P. D. Young

"MillEX is an information management system designed by mineral processors for mineral processors. The system utilizes ""cutting edge"" software technology to gather and store all automatically and manually recorded data from the plant operation and laboratories. This data is delivered to the desk of superintendents, metallurgists, technicians and managers, and permits the user to query, correlate, graph, report and present this data in minutes. In the past this task would have taken days and even weeks of tedious work to complete.MillEX allows the engineer/analyst to quickly develop a very thorough understanding of the complex relationships of process variables and equipment that exist in the plant, and their effect on product quality and quantity. The time and resources that are currently wasted on duplicating data entry will be an effort of the past.This paper describes the structure of MillEX and how it conforms to the needs of mineral processing personnel.INTRODUCTIONPicture a personal computer on your desk which will carry out the following commands:1. Plot a graph over the last six months, using weekly averages, of percent minus 200 mesh material in the primary cyclone overflow.2. Overlay this graph with a graph of concentrate grade versus recovery over the same time period.3. Retrieve a prior month end report, update all operating supplies tables and metallurgical performance with this months data, and embed the graphs created above.4. Edit text and print the current month end report. This is only one example of the type of power MillEX isbringing to the mineral processing industry."

Jan 1, 1992

By T. J. A. Smith

This paper provides an overview of some of the key issues in design of smelter gas handling systems, with particular reference to sulphide smelting plants. In both primary smelting and converting. gas handling and treatment systems often represent the major capital cost component. There is also ample evidence that poor system design can be a major cause of smelter down time, lost production and unforeseen high maintenance costs. The paper discusses these issues and offers guidance for improved design.

Jan 1, 1992

By L. S. Jen

Canadian copper, nickel, zinc, lead and molybdenum mines are characterized by the mining of ores from which more than one metal is recovered. During the 1980s, approximately 15% of the gold, 25% of the zinc, 30% of the copper, 55% of the molybdenum, 80% of the silver and 90% of the lead produced from Canadian mines were produced as co-products and by-products of base metal mining operations. This trend is not expected to change significantly in the near future. The presence of co-products and by-products affects the level of production and the level of revenue from base metal mines in several ways: (I) in general, production of one base metal cannot be expanded or cut back without affecting the amount of production of another metal;(2) the commercial success of certain base metal mining operations depends on the substantial bonus revenues from co-products and by-products; (3) the quality and economic viability of many ore deposits are significantly improved by the presence of co-products and by-products; and (4) while coproduction is critical to the survival of some mines, bonus revenue from by-products can also be life saving to others during economic downturns. For these reasons, deposits with significant co-product or by-product values are likely to continue to be significant targets for exploration and for acquisition.

Jan 1, 1992

By Hendon G. W, Carr F, Jiang Y

A vast majority of the operating longwall sections use shield-type face supports to provide ground control in the United States. As a co-operative research program between the University of Alabama (UA) and Jim Walter Resources, Inc.(JWR), a joint research program is underway to study interaction of shields with surrounding rock masses. A series of analyses on the response of shields are performed using monitored data at a longwall face in a deep coal mine. In this paper, various effects of parameters, such as leg pressure, setting load, developing load, maximum loading rate, pressure in capsule, and convergence between canopy and base, are discussed and recommended as stability indices. A microcomputer program is being developed for instantaneous interpretation of the shield monitored data, and for giving warnings of potential problems. The preliminary results define the effects of the setting load, developing load, and rate of developing load or leg closure rate. The objective of the study is to understand the shield characteristics and their interaction with surrounding strata in real time, then develop a reliable program for maintaining longwall stability.

Jan 1, 1992

By Kenneth L. Driggs

The Environmental Protection Agency's Clean Air Act of .1970 provided the driving force for the current Magma Smelter configuration. The historical and technical perspectives of those process developments are reviewed. Innovations in procedures and equipment have allowed compliance with the requirements of the regulating authorities. The wet scrubbing of converter gasses and the monitoring of converter operations by a controlling foreman are two of the major contributors to these successes. The Clean Air Act Amendments of 1990 have posed many new concerns for all U.S. industry, including the few (seven) primary copper smelters remaining. Future concerns include tightening the sulfur dioxide ambient standard from the current three-hour averaging period to one hour"

Jan 1, 1992

By S. L. Bessinger

Introduction Extensive testing in the past ten years has shown that where a uniform natural gamma background is present in the strata bordering a seam, the thickness of the boundary coal left in place after mining can be determined by measuring the attenuation of that radiation (Nelson and Bessinger, 1989). Measurements made by the authors in underground mines in Pennsylvania, West Virginia, Ohio, Illinois and Kentucky and by others in Wyoming and New Mexico have shown the presence of such a gamma background (Nelson. 1989). Natural gamma coal-thickness sensors of several configurations have been tested in mines owned and operated by the Consolidation Coal Company (Consol) in Pennsylvania and West Virginia (Nelson and Bessinger, 1988). This paper describes the installation of a natural gamma coal-thickness sensor on an operating continuous miner. Previous tests had shown that the NGB-1000 coal-thickness sensor manufactured by American Mining Electronics, Inc., of Huntsville. AL, is an accurate, mine-worthy instrument. This large gamma detector consists of a sensing head and a control panel. The sensing head contains thallium-doped, sodium iodide scintillating crystal, which is coupled to a photomultiplier tube. The control panel contains the electronic components required for calibration, count conversion and display to the operator. Methods Conditions at a Consol mine in northern West Virginia require that 10 to 15 cm (4 to 6 in.) of coal be left at the roof boundary of continuous miner development sections. This roof coal is required because the shale of the immediate roof is friable and unstable. In the past, operators have used a dirt band that is usually visible near the top of the seam as a guide in maintaining the proper cutting horizon. However, this is not always reliable. Earlier observation showed that the actual thickness of the coal left on the roof varied widely; further, it was noted that occasional, accidental excursions into the immediate roof required supplementary roof control measures, such as installation of planks or center bolts. Thus, it was concluded that operators needed a better source of guidance for control of the cutting horizon, and a roof-coal thickness sensor was scheduled for installation. The NGB-1000 sensor was installed on a Joy 12CM10 continuous miner in June 1988. The sensing head was mounted on the cutter boom of the miner, and the control panel was mounted in the operator's cab. Power for the sensor was initially derived from an intrinsically safe battery power supply. Initial measurements with the sensor showed that the calibration was the same as that used in earlier tests at two other mines, indicating the uniformity of the natural gamma background above the Pittsburgh seam. Operating personnel were initially skeptical of the instrument's accuracy, and were hesitant to use its readings as a guide in maintaining a proper cutting horizon. Because gamma attenuation, the instrument's operating principle, is somewhat abstract, attempts to demonstrate the instrument's accuracy by explaining that principle were generally ineffective. It was found, however, that an operator could usually be convinced of the usefulness of the instrument by placing a large piece of coal of fairly uniform thickness over the instrument's sensing head and allowing the operator to see that the instrument reading increased by an amount very near his estimate of the thickness of the piece. The mine was provided with seven battery power supplies and a charging station. The charging station was kept in the lampman's office, and the mechanic on each shift was instructed that he was responsible for two battery power supplies each day: a freshly charged one to be taken in at the beginning of his shift and a depleted one to be brought out at the end. This system worked well for a few weeks, but eventually some battery power supplies were left in use so long that their batteries were discharged too deeply to allow recharging. In addition, transport and recharging of the batteries represented an additional task for the mechanics, who were already very busy. Consequently, a request was filed with MSHA to allow the sensor to be powered through intrinsic safety barriers by an electronic power supply connected to machine power. The permit was granted, and the sensor was connected to machine power. After the sensor was connected to machine power, the only operating problem experienced was occasional failure of cables. A supply of the required cables was made and delivered to the mine so damaged cables could be quickly replaced. Much of the cable damage could be eliminated by slight modifications to the miner during a rebuild, so that cables could be installed in more protected locations. After the sensor had been in operation for about two months, a survey was made to determine its effect on continuous miner operations. In previous research, coal thickness measurements made in 88 locations by the natural gamma method were compared to measurements made in the same locations by observing drill cuttings and by inspections of drill holes with a borescope. That research showed that the gamma method is at least as accurate as the other two methods (Nelson and Bessinger, 1989) and is also much easier to use. The object of the survey described here was not to assess the accuracy of the natural gamma measurements. but rather to determine the effectiveness of the sensor output as a guide for the operator in maintaining control of the cutting horizon. Thus a smaller, hand-held gamma detector

Jan 1, 1992

By K. S. Narasimhan, T. C. Rao, R. Bhima Rao

Investigations have been carried out to evolve a grinding aid useful in grinding a 40% iron-bearing magnetite containing quartz as the major gangue, based on studies conducted with pure magnetite, pure quartz and its synthetic mixture. These investigations established that an addition of 200 g of CaO per metric ton of ore was the most effective in grinding quartz preferentially over magnetite at 75% solids concentration by weight. The limited rheological studies conducted suggest that the effect could either be due to dispersion or the structural modification of quartz. More importantly, a new concept, that of Critical Solids Concentration, where two different minerals behave like one with respect to response to communication in a tumbling mill, has been introduced for the, first time. Above this concentration, one of the minerals is ground at a faster rate than the other, whereas the reverse is the case below this concentration.

Jan 1, 1992

By Larry B. Fiske

Elimination of dust and processing of fines for both thermal and metallurgical coals is addressed. The efficiency of treatment with lignosulfonates compares favorably to oil in thermal coal. Effect of treatment with various lignosulfonates upon cokability of metallurgical coal was determined by Free Swelling Index, Gieseler Plasticity and Arnu Dilatation.

Jan 1, 1992

By B. Bringhurst, J. J. McClelland

A filter consisting of a synthetic fibrous material has been determined to be a viable alternative to the wire mesh panels currently used in irrigated filter dust collection systems. An extensive laboratory investigation of the material showed that it removed a higher percentage of both respirable coal and quartz dust from the air entering a collector than did the flat and pleated wire mesh panel designs. This improvement in dust collection efficiency reduced the amount of coal and quartz dust discharged from the collector exhaust by approximately 44%. Since continued exposure to excessive levels (>5%) of respirable quartz dust presents a severe health hazard, this alternative filter medium could be of use to those mines required to comply with more stringent dust standards due to quartz.

Jan 1, 1992

By E. Arioglu

Y. Luo and S.S. Peng are to be congratulated for their outstanding paper providing new results from surface subsidence monitoring over longwall panels under different conditions. This writer found the authors' paper very interesting. In reference to this paper, the following contributions are offered: • In the paper, the maximum possible subsidence (?Smax) induced by chain pillar convergence has been related to a parameter (h/I -p) by linear regression. (Notations are expressed in this discussion's Fig. I (b).) It is a well-known fact that in a goaf the roof lowers onto broken material that gradually compacts. Then the physical behavior of goaf may closely follow the compaction characteristics of broken materials. In light of this assumption, a mathematical means (Fig. 1(a)) of defining the expected compaction (i.e. surface subsidence) represents an exponential expression between ?Smax/m vs. h/1-p. This is based on Luo and Peng's field observations from the Appalachian, Illinois and Alabama coal fields. (The coefficient of regression "r" under consideration was computed to be 0.883). • According to Wardell's (1969) findings for board and pillar mining, the maximum possible subsidence can be expressed in terms of maximum pillar loading (depth, ratio of extraction) and the height-to-width ratio of the pillars left. Using Luo and Peng's 1991 results, this writer discovered a regression equation between the above-mentioned factors. As displayed in Fig. 1(b), the functional expression approximates as closely as possible the observed subsidence data.

Jan 1, 1992

By Musa Karakus

Reflected light microscopic (RLM) examination of dust particles from lead and copper smelters can effectively characterize their mineralogy, texture, and origin. Scanning electron microscopic-energy dispersive spectroscopic (SEM-EDS) analysis provides confirmation of the optical identifications and chemical data on the phases. Studied lead smelter dust samples were from the: I) blast furnace, 2) sinter plant scrubber, 3) sinter plant crusher, 4) dross furnace, and 5) refinery. Phases identified included galena fragments, melted PbS, metallic Pb and Cu, Cu-Ni, Cu-Zn, Zn-Ag, Zn-Cu-Ag, Ni-Cu-Sb, and Ni-Cu-Zn-Ag metal alloys, Ni-sulfide, Cu-sulfide, and Cu-Pb-sulfide dross .phases; slag and sinter particles, coke fragments, unreacted original feed phases: pyrite, chalcopyrite, sphalerite, siegenite, bravoite; and oxidized particles: iss, bornite, chalcocite, covellite, magnetite, hematite, and goethite. Dust from a secondary copper refinery were found by RLM and SEM to consist of tenorite, cuprite, cassiterite, two silicate phases. Magnetite, hematite, Fe-Al-Cr-Mg spinel, periclase, forsterite, and wollastonite were derived from the furnace linings during initial cleaning.

Jan 1, 1992

Pictured on these pages are the eight RMCMI Scholarship Award Winners for the 1991-92 year followed by a brief profile. All winners were present as guests of the Institute at the June convention in Durango, Colorado to receive recognition at the Institute Awards Luncheon Monday, June 29, 1992. Each state vice president served as the host for the collegiate winner. In addition to receiving a plaque from the Scholarship Chairman, Dr. Matthew Hrebar, each winner receives $750 tuition credit for the coming academic year. As this is a continuing award, the winners from the previous year will receive another $750 for tuition credit in their senior year if they have maintained good academic standing and are recommended by their university. A mident from each of the eight RMCMI member states is selected from among Board approved institutions. Criteria for these awards to be made in the spring annually is (1) That the award be made to a sophomore student and used as tuition during the junior year. (2) That the recipient be both a U.S. citizen and a resident of the member state. (3) That the recipient have good academic standing, be pursuing a degree in a mining related field and have an expressed interest in Western coal as a possible career path. The scholarship program includes curricula other than those in the mining departments, but in the engineering disciplines, such as geology, mineral processing and metallurgy. Contributions to this worthy project are tax deductible to each individual RMCMI member or his firm. Through annual donations of $100 or more, the Patrons of the Institute fund the scholar- ship program and the various vice presidents con- tribute the travel expenses to convention for these outstanding young collegiates. Donations to this worthwhile program may be made payable to RMCMI Scholarship and mailed to the RMCMI Office, 3000 Youngfield Street, Suite 324, Lakewood, CO 80215. Profiles of the 1992 Scholarship Winners: [ ] ARIZONA WINNER BRIAN C. TRAWEEK University of Arizona - Tucson, AZ The winner from Arizona, Brian Traweek, attending the University of Arizona, is a mining engineering major from Tucson, Arizona. Brian is the treasurer of the Society of Mining Engineers Student Chapter and spends many of his weekends working at the school's San Xavier underground mine. He has had summer work experience at ASARCO's Ray Unit. [ ] COLORADO WINNER MARK ANDREW NORRIS Colorado School of Mines Golden, CO The winner from Colorado, Mark Norris, attending the Colorado School of Mines, is a mining engineering major from Eaton, Colorado. Mark is active in varsity swimming, intramural sports, and Army ROTC Pathfinders and Pershing Rifles. Mark is a co-designer of the Clear Creek County, Colorado, abandoned mine hazard rescue team plan though an introductory engineering course at Mines. [ ] MONTANA WINNER MARK J. BREN Montana College of Mineral Science & Technology, Butte, MT The winner from Montana, Mark Bren, attending Montana Tech, is a mining engineering major from Butte, Montana. Mark is an excellent student and active in the student chapter of the Society of Mining Engineers. He has worked at a gold mine in Montana, in the Earthquake Studies Office at Montana Tech, and a volunteer on the Neversweat and Washoe Railroad.

Jan 1, 1992

By W. E. Heinrichs, R. W. Davis

Introduction Cross borehole seismic tomography (CBST) is a geophysical technique that allows definition of the distribution of some physical rock property between two boreholes. The method is similar to the computer-assisted tomography (CAT) scans used by the medical industry. This paper describes the method, its applications and the developing trends in its use that interest the mining industry. The idea of using tomography in connection with geophysical methods for measuring rock properties between boreholes has been around for three or four decades. Until the advent of high-speed, large-capacity computers, the necessary calculations were too formidable for production use. Another factor in the development of the technique has been the refinement of a mathematical base to meet the needs of the medical industry. The geophysical applications have benefited from this refinement. An extensive discussion of the basic theory is given in Kak and Slaney (1988). CBST, although widely researched and written about, is still not extensively put to use in mining and engineering projects. Most real world examples in the literature have come from research carried out by government laboratories or by large companies. An exception is the regular use by Prospection Geophysique Francaise (Cottin et al., 1986) in damsite investigations. The Japanese appear to be doing extensive research and testing of CBST's uses in civil engineering projects (Saito et al., 1988). Canada is researching the use of the method in connection with nuclear waste site investigations (Wong et al., 1987). Finland has tested the method in connection with a foundation investigation for a nuclear power plant (Cosma et al., 1984). In the US, the US Bureau of Mines has taken an interest in using CBST as a means to enhance in situ mining operations (Tweeton, 1988). Major oil companies are examining the method as a tool in oil field development (Justice et al., 1989). Description of the method CBST involves placing a series of receivers down one borehole and recording transmissions from an energy source placed successively at a series of positions in another hole. The objective is to generate a dense network of seismic raypaths between the holes. The denser the network of raypaths, the better the features between the boreholes are resolved. Either seismic travel times or sine wave amplitudes are measured by the receivers. Analysis of travel times between boreholes develops a picture of rock velocities between the holes. Analysis of seismic wave amplitudes develops a picture of the distribution of energy transmission characteristics between the holes. These seismic properties can be used to define occurrences of fracture zones, lenticular sequences or other important geologic data not apparent from examination of the borehole logs. When longitudinal (compressional) and transverse (shear) waves are analyzed, the physical properties, such as elastic moduli, can also be mapped. When wave amplitudes are measured, rather extensive corrections to the data are necessary. There is some disagreement among researchers as to the feasibility of making some of the corrections. For this reason, this paper will concentrate primarily on travel time analysis. Wave amplitude analysis will be mentioned occasionally only in passing. This does not mean that amplitude analysis does not provide important data on rock parameters, only that for the present there are limitations on its uses. Vertical seismic profiling (VSP), extensively used in recent years in oil exploration, is similar to CBST. Instead of using two boreholes, however, the VSP method uses an array of seismic sources or detectors down one hole and an array of detectors or sources along the surface radiating outward from the hole. While adequate for determining vertical velocity distributions, the VSP method is not, by itself, suitable for most engineering or mining projects. Computer programs used to analyze the field data make use of the fact that the total travel time or change in signal amplitude between boreholes is described by Dines and Lytle (1979) as: [9k = f Rk f( x,Y) ds (1)] where gk = the total time or attenuation along the kth ray path,

Jan 1, 1992

By W. Curlook

"A review is presented of a growing number of imperatives, some self-imposed, some imposed by society, which the mining and metals industry faces in carrying out its business. These imperatives bear on all activities from the exploration phase, through engineering, design, plant construction and operation, to decommissioning.IntroductionThe mining and metals industry must learn to cope with, i.e. manage, a growing number of imperatives. Some of these, such as the need for responsible stewardship of natural resources, the requirement to respect laws and regulations, the need to provide for safe and healthy workplaces, and the need to provide appropriate returns to investors of capital , have been with the industry for a long time (fable I). But the industry now faces additional imperatives that are growing in number and in importance (fable 2):• There is the growing concern about the impact of operations, not only on the workplace environment and the external environment, but also on the need to monitor not only the chemical concentrations in various effluents but to also monitor the effects of such emissions on the environment; i.e. there is a growing concern about the ""net"" consequences of operations.• There is the need for on-going improvement in productivity and safety to compete and survive in a global economy. The global business environment has become paramount.• There is the imperative to failsafe all designs, equipment and operational procedures, and having done that to provide for containment of unavoidable spills, and to have ready and in place systems for emergency response.• There is the need, indeed the imperative, to involve all employees in various quality improvement programs.• There is the imperative to face up to ""virtual elimination/zero emissions""; and• One must have waste management plans in place to cope with the need to reduce, reuse, and recycle; and• There is the need for decommissioning plans for all operations, for the restoration of business habitats to their original states (or better). Indeed, one must engage in the decommissioning exercise from day one, i.e. right from the time of design and commissioning."

Jan 1, 1992

By J. P. Evans

The modem 'copper smelter today utilizes tonnage oxygen for smelting concentrates. ,generating a high strength S02 off-gas leaving the smelter vessel. This gas stream. which also contains any unreacted oxygen, plus CO2; N2 and H20. also carries with it the volatilized portion of heavy metals in the feed, plus partly oxidized sulfide concentrates, The time/temperature history and subsequent treatment of this off-gas stream emerging from the smelting furnace exit up to the acid plant can influence the partitioning and segregation of heavy metals, in the off-gas circuit. Depending on this history. the type and characteristics of the chemical and physical reactions which occur in the gas handling system 'can be influenced. This fact can also be used as a tool to adjust the separation of copper from heavy metals. In this paper, the impact of different time/temperature histories of the gas, due to different furnace geometries and design. on the subsequent formation and characteristics of the smelter dust is examined. Based on the available data. several case histories drawn from examples using both bath and flash smelting technologies are analyzed from this perspective.

Jan 1, 1992

By R. P. Stahura

Conveyors are the lifeline of mining and processing operations. They continuously supply materials to and carry finished products and waste away from operations. When conveyors are running at less than maximum efficiency, the operation's productivity is in trouble. Inefficient conveyors suffer carryback, leading to the buildup of materials on idlers and other expensive components. They spill and leak material at loading zones and conveyor transfer points. This causes accumulations that can damage the belt, wear moving components and increase both clean-up labor and maintenance expenses. They wander or mistrack, spilling material and endangering personnel and conveyor components. And through these inefficiencies, they multiply the operation's hidden costs. These added expenses occur in lost production, increased downtime for service and maintenance and replacement costs for prematurely worn equip¬ment. In addition, the attitude that inefficiency is "good enough" is recognized elsewhere in the organization. As a result, other departments relax or operate at less than peak performance. Quality goes down along with employee morale. Costs of inefficient conveyors A key to efficiency is handling a product as few times as is necessary. That means conveyors should be loaded, track true to the unloading point and then be unloaded, all without material escape or waste motion. An inefficient conveyor is often signaled by accumulations of DURT - material that has escaped from the system and is now at large in the plant. This DURT adds costs to an operation that are uncounted and, perhaps, uncountable.

Jan 1, 1992

By Tucker A. J

An overburden blast utilising horizontal blast holes was successfully attempted at the Ulan Coal Mines during December 1991. The blast reduced operational problems and costs and improved dragline productivity in an area of that contains poorly consolidated sands and clays overlying very hard Permian strata.The fan shaped shot consisted of seven 250 mm diameter holes between 80 and 95 metres long drilled into the highwall face. The holes were loaded with ICI Powergel Gold 25606 bulk Emulsion explosive. The design powder factor was 0.15 kg/bcm for the total shot of 180 000 bcros and 0.44 kg/bcm for the competent Permian strata into which the holes were drilled. Fragmentation from the horizontal blast was comparable to areas conventual blasted. Following the success of this shot further shots are planned for this area.

Jan 1, 1992

By Wright G. N

Curragh Queensland Mining Limited, a co-venture of Australian and overseas interests, operates an open cut coal mine 13 km north of the township of Blackwater in Central Queensland, refer attached location map.

Jan 1, 1992

By Deni Lessard, Roger Demers, Noël R. Billette

"The Quebec Mining Association has for many years been supportive of the activities of the Centre de recherches minérales which were initiated to ensure regular production hoist and cable inspections to maintain safety and productivity standards in underground mines in Quebec. CRM and CANMET have agreed to fund a Quebec Mineral Development Agreement contract to capture this accumulated knowledge. Using VP-EXPERT to process the information and subdirectories to store regulations, the prototype access D-BASE III records on hoist information and LOTUS 123for simulating working conditions that meet local regulations and expert rules of thumb criteria. Objectives are to improve safety in emergency operating procedures, maximize hoist productivity and safety, and promote knowledge transfer to operators."

Jan 1, 1992