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By J. Keith Haddock

"Introduction The Boundary Dam Mine is located 5 km south of the City of Estevan, Saskatchewan and is operated by Manitoba and Saskatchewan Coal Company Ltd., one of the Luscar companies. The entire production of 1.7 million tonnes per year is delivered to the Boundary Dam Generating Station of Saskatchewan Power Corporation. Geology There are basically two seams mined on the property, the main Estevan seam ranging in thickness from 3.0 m to 4.5 m with partings and the upper Roche Percee seam (roughly 15 m to 23 m above the Estevan) which ranges from 0.6 m to 2.0 m in thickness. Most of the reserves are concentrated in the Estevan seam, the Roche Percee only being mined whenever its thickness makes it economic to recover. The coal measures belong to the Ravenscrag Formation of Tertiary (Paleocene) Age. This formation is widespread in North Dakota and Montana and contains the lignite fields of North Dakota and subbituminous coals of Montana. The formation is gently tilted to the southeast at Boundary (0.5 degrees) and consists of weak sandstones, siltstones and silty mudstones. Reserves and Coal Quality The present minesite encompasses a coal reserve of approximately 50 million tonnes calculated to a maximum stripping depth of 37 metres or 20:1 mining ratio. The reserves form only a part of the total reserves in the Estevan area which are owned by the Saskatchewan Power Corporation. The coal being mined is classed as Lignite ""A"" and has the following specifications:"

Jan 1, 1985

By Charles A. Seitz

This Bureau of Mines report describes a chromatographic method for analyzing impurities in helium that utilizes a helium carrier gas contain-ing 25 to 30 ppm Ne. An example of the effect of trace amounts of nitrogen, methane, and moisture on the detector's response is shown. The added neon in the carrier does away with irregularities of the analysis which were experienced when the carrier contained up to 3 ppm Ne. The addition of 25 to 30 ppm Ne causes a loss of sensitivity, but the re-maining sensitivity is adequate for routine analyses. The high-neon carrier allows positive and more linear responses for eight impurities: neon, hydrogen, argon, oxygen, nitrogen, methane, carbon dioxide, and ethane. Neon concentration levels of 0.02 to 125 ppm in helium carrier gases were studied. The high-neon carrier has been in successful rou-tine use in Bureau of Mines helium facilities since October 1981.

Jan 1, 1985

Many of the large refrigeration plants used in, the cooling systems on deep South African gold mines are situated on surface where they are exposed to seasonally and diurnally varying climatic conditions, and to a diurnally varying demand for cooling made by the mine. It has been traditional to accommodate the seasonal variation in climate by manual control applied to the plants at appropriate times of the year, and the plants have normally been specified to conform passively to the diurnal variations. This paper introduces new strategies for the active automatic control of the plants on a diurnal cycle, and shows that attractive benefits in energy and chilled water resource management can be accrued through the use of these strategies. The results have been derived through the modelling and simulation of a representative refrigeration plant.

Jan 1, 1985

By G. L. Dollinger, J. P. Kindsvater, J. A. Gibson

DESIGN AND DEVELOPMENT OF A MOBILE MINING MACHINE INTRODUCTION Until recently, developing tunnels in hard rock has been accomplished either by the drill and blast method or by using large tunnel boring machines. Combining the flexibility of drill and blast with the safety, efficiency and productivity of a TBM has been the objective of mining machinery producers for many years. In 1979 The Robbins Company began developing a new type of tunnel boring machine called the Mobile Miner to meet these objectives. The development and testing of the Mobile Miner is the subject of this paper. CURRENT MINE DEVELOPMENT METHODS Both the drill and blast method and the use of a TBM have notable advantages and disadvantages. The drill and blast method, for example, allows much more flexibility, requires less setup time and has a lower initial cost than a TBM; however it requires the use of high explosives and blasting has a disrupting effect on the rock surrounding the development. A TBM, on the other hand, is safer to operate, more efficient, more productive and produces smooth tunnel walls without disturbing the surrounding rock. In longer straight drifts it will easily out distance the drill and blast method. The TBM, however, is limited to boring a circular cross section tunnel which must then be modified if a flat floor is required. It also has a higher initial cost and an extended setup period.

Jan 1, 1985

By Edward M. Jacobs

In some ore grinding circuits it is desirable to make separations purely on size. The normal choice for this is vibrating screen equipment. Developments in screening process technology have led to improvements in the capacity and efficiency of vibrating screens, through the adoption "Thin Layer Wet Screening". This process can reduce recirculating loads and equipment requirements in the ore grinding circuit.

Jan 1, 1985

Provide respiratory protection and a clean work environment for stationary or semimobile workers at minerals processing plants. Approach An Overhead Air Supply Island (OASIS) was developed which filters, conditions, and evenly disperses an envelope of clean air over a worker's head, thereby insuring reduced dust levels and a clean work environment. How It Works The concept for the OASIS derives from an earlier Bureau development of a canopy air curtain for continuous mining machines (see Technology News #21). In this application, the benefits of a reliable, self-contained, self-cleaning industrial-duty air filtration and distribution system are extended to the minerals processing field. The OASIS draws dust-laden room air into a filtration system, removing the dust and delivering clean air to a specific 16-square-foot area. It consists of: ? a self-cleaning primary filter ? a heater (cooling coil optional) ? an airflow distributor and secondary filter (combined)

Jan 1, 1985

By K. Adam

Grinding in steel mills adversely affects the flotation of pyrrhotite. The electrochemical nature of inter action between pyrrhotite and active metals was investigated by contacting pyrrhotite with platinum at different applied potentials. Flotation tests, scanning electron microscopy, Auger electron spectroscopy, and X-ray photoelectron spectroscopy were wed to examine the surface properties of pyrrhotite. The formation of hydroxide or oxide and sulfate species of iron through the oxygen reduction reaction at the cathodically polarized surface of pyrrhotite was shown to be the mechanism responsible for the reduced floatability of pyrrhotite.

Jan 1, 1985

By John D. Campbell

"IS YOUR MANAGEMENT CONTROLLOOP FUNCTIONINGMineral processors make use of hundreds of control circuits in their mills, process plants, smelters and refineries, to optimize throughput and recovery and minimize cost. This afternoon, I would like to discuss what is probably the weakest circuit in any mineral processing operation - the management control loop.In their recent book ""The Winning Streak"", Goldsmith and Clutter describe extensive research on unsuccessful companies. They conclude that ineffective control, which does not immediately identify the problems, is one of the main failings of unsuccessful companies.We will look at the three key components of control which, from the manager's point of view, ensure that the loop is complete. These three are:• measuring what's happening,• assessing its significance, Rnd• altering performance.If we compare management control to process control as shown in this first figure, ""We see that parameter sensing by the analyzer in a process circuit is analogous to performance monitoring by management in a responsibility centre. The analyzer senses temperature, pressure, flow, weight or some surrogate indicator such as colour to indicate ion concentration. For manage1nent, the performance to rnonitor is dependent upon the objectives of the responsibility centre, and the key factors which affect these objectives."

Jan 1, 1985

Contents

Jan 1, 1985

By Tomek Ulatowski

INTRODUCTION In 1974, Industrial Miners Mexico, S.A. (IMMSA), agent for the borrowers, was the largest privately-held mining, smelting, and refining company in Mexico (accounting for 32% of Mexico's nonferrous metal and coal production in 1974), the fourth largest company in terms of sales, and the second most profitable company in Mexico, excluding government wholly-owned and operated industries. The company was engaged in the mining, smelting and refining of coal, copper, fluorite, gold, lead, silver, zinc and related by-products for domestic consumption and export. A combination of favorable factors led IMMSA to propose an investment plan amounting to US$286 million for 1974 through 1978, of which US$150 million was to be financed. These factors included: Substantial profits in 1973 and 1974 Positive near-term outlook for metal prices Success of the reinvestment program in increasing productivity Substantial additions to proved reserves during 1973-1974 and Fiscal incentives provided by the Mexican government to stimulate investment in the mining industry. The primary purpose of the investment program was to construct a new electrolytic zinc refinery and to expand and modernize many of the company's existing mining and refining facilities. THE BORROWER Company History Compania Miners Mexico, S.A. was incorporated in the city of Monterrey in 1918 as a wholly-owned subsidery of ASARCO Inc. (formerly American Smelting and Refining Company, New York) for the purpose of mining and processing non-ferrous metals and related products. In compliance with the Government's Mexicanization program, ASARCO Inc. divested itself of 51% of its equity in Compania Miners Asarco, S.A. on June 30, 1965. Subsequently, ownership in the divested share was apportioned as follows: 15% ownership in Compania Miners Asarco, S.A. to a group of private investors, and 36% in trust for subsequent public sale. The company's name was changed to Asarco Mexicana, S.A. in 1965. Mexican ownership in Asarco Mexicans, S.A. was increased to 51% in 1967, following the purchase of the 36% share ownership held in trust, and then to 66% in 1974 when ASARCO Inc. divested itself of an additional 15% of its holdings in Asarco Mexicans, S.A. Following its 1974 divestiture of 15% of Asarco Mexicans, S.A., ASARCO Inc's ownership in Asarco Mexicana, S.A. was reduced to 34%. In 1974, the company changed its name for the second time to Industrial Miners Mexico, S.A. (IMMSA). Fiscal Agreement IMMSA entered into a fiscal agreement with the Mexican government in 1969. The agreement, which was renewed in 1974, provided for 100% of the production and export tax corresponding to the federal government with a minimum of 50% of the amount refunded to be reinvested in fixed assets. Further, the agreement permitted the company to

Jan 1, 1985

By J. B. Hiskey

The hydrometallurgical application of thiourea in processing precious metal ores and concentrates has reached the development stage. This paper reviews recent technical literature covering the process development of thiourea leaching. In addition, recent fundamental contributions are discussed. Most of the interest in thiourea leaching has involved treating high grade concentrates that have sufficient value to just the use of thiourea as a reagent. An important development in thiourea technology is the addition of SO2 to the leaching solution. This procedure effectively reduces the decomposition of thiourea and eliminates the problems of passive surface layers that limit the leaching efficiency. Results for the thiourea leaching of a bulk sulfide concentrate and a residue from the autoclave leaching of a smelter flue dust are also reported. As determined by a standard bottle roll cyanidation test, the bulk concentrate was extremely resistive to cyanide leaching yielding only 16% gold and 2% silver extraction in 24 hours. Leaching with a relatively concentrated thiourea solution (1MCS (NH2)2) resulted in 83% gold and 75% silver extraction in four hours. With the treated flue dust residue, gold extraction was about 60%. Gold and silver extraction with cyanide was sensitive to both cyanide concentration and oxidizing conditions. Cyanidation resulted in 59% gold extraction and 77% silver extraction in 24 hours.

Jan 1, 1985

The cleaning of copper containing fayalite slag using a CuFe alloy was studied under an oxygen pressure ranging from 10-7 to 5 X 10-11 atm at 1200º c. The reduction of copper from fayalite slags by Cu-Fe alloys was found to be very effective. For example, at a P 02 of 10-7 atm, the copper content in the slag was reduced from 4.1 to 0.402 wt. percent after 90 min. of reaction time using a Cu- 5.27 wt. percent Fe alloy. The copper reduction rates were found to be independent of P02 in the gas phase when using Cu-Fe alloys which exhibit an iron activity of greater than 0.4. A mechanism for slag c1eaning is proposed based on the concept that the Cu-Fe alloy lowers the oxygen potential of the slag according to Eq.1 1, fol1owed by the reduction of cuprous oxide by wustite as shown in Eq.2. Here X represents element X in the alloy phase while (X) represents the element in the slag phase. The copper and iron transfer behaviour obtained in this study are explained by a ?Stepwise equilibrium model.

Jan 1, 1985

By N. J. Duncan

"Coal mining, whether surface or underground, has hazards that make it unique in the field of industrial safety and health. The often soft, faulted and folded sedimentary strata make wall or roof movement a risk to the safe and economic removal of the coal, while the extraction and handling of coal may create an explosion hazard even in surface operations, In Canada, these problems are compounded by the situation of the coal fields which range from deep undersea deposits in Nova Scotia to steeply pitching thick coal seams high in the Rocky Mountains. Climate too can create its own problems, particularly the effect of metals of minus 40°C temperatures, as crumpled dragline booms at prairie strip mines witness. Because of the difficult and sometimes hazardous conditions, Canada's underground colliery managers, in common with those of other Commonwealth coal-producing countries, must have a government ""certificate of competency"" before being appointed as mine managers. Certification of assistant managers (""under-managers"") and foremen (""fire-bosses"") is also a legal requirement for all of Canada's underground collieries, while the province of Alberta requires certification of surface management personnel. Electricians and mechanics who install and maintain the specially designed equipment underground and in hazardous areas of surface mines and processing plants, and mine surveyors who ensure accuracy of the location of underground workings, must also hold government certificates of competency. The requisites for all certification include a minimum work experience and knowledge of coal mining technology and mine safety and health legislation. Despite recognition of the hazards and increasing knowledge of methods of preventing explosions of flammable gas and coal dust in Canada's underground mines, there have been several disastrous explosions such as those at Springhill Colliery in Nova Scotia in 1891 with the loss of 125 lives, at Hillcrest Colliery in Alberta in 1914 with 189 dead, and more recently · explosions and fires in No. 20 and No. 26 Collieries in Cape Breton. Preventing explosions has required developing optimal ventilation techniques, reducing ignition potential, suppressing ignition at source, draining flammable gas before it can enter the air courses, and preventing, or sealing off, autogenous heatings with their associated carbon monoxide or explosion dangers."

Jan 1, 1985

By D. L. Sawyer

The Bureau of Mines studied alumina extraction from uncalcined, kao-linitic clay at temperatures from 1000 to 2500 C using 20-or 27-wt-pct-HCI concentrations and with an acid-to-clay ratio of from 0.8 to 1.4 times stoichiometric. Autogenous digestion pressures ranged from atmospheric pressure to about 900 psia. Extraction of 96 pct of the alumina was obtained by HCI leaching at temperatures and leaching times that varied from 1000 C for 120 h to 2000 C for 15 min. Hydrochloric acid stoichiometry of the reaction A1203'2Si02'2H20 + 6HCI + 2AICl3 + 2Si02 + 5H20 was studied at different temperatures and leaching times in a 750-mL tetrafluoroethylene-polymer-lined autoclave. A combination of high temperature and 20 wt pct excess HCI promoted rapid and almost quantitative extraction of alumina (99 pct in some tests). Additional Bureau data obtained with 35-mL tantalum bombs and leach-ing tests with added fluoride are also provided. At high temperatures, the addition of fluoride did not result in a significant improvement over HCI alone and was deleterious to the filtering properties of the digest residue.

Jan 1, 1985

By Jon C. Volkwein

The Bureau of Mines and many member companies of the Industrial Sand Association have been working in several areas to reduce personal exposure to respirable dust. Areas investigated include ventilation, modification of hardware, moisture addition to the product, and improved housekeeping practices. Ventilation systems have been devised and shown to contain 100 pct of a tracer gas released within the hood. An industrial clean air island has been developed and shown to reduce dust levels 90 pct at the opera- tor's position, Modification of hardware on a bag filling machine has been demonstrated to reduce dust 83 pct at the machine operator's lapel. This particular development has been termed a significant advancement in the state-of-the-art of bag filling by industry representatives. Addition of moisture to dried product materials has been tested with results showing dust reductions of 90 pct are possible!, Control of the moisture addition method still needs refinement and costs may be prohibitive. Dust sampling results clearly show the benefits of housekeeping practices such as building cleaning and vacuum sweeping. Rotation of work schedules is also effective for reducing personal exposure.

Jan 1, 1985

By Terry J. Close

From 1981-84, Bureau of Mines personnel examined and evaluated mines and prospects in the highly mineralized 62,400 acre Inyo Mountains U. S. Bureau of Land Management (BLM) Wilderness Study Area (WSA), located east of Lone Pine, CA. The 62,400 acres studied is the part of the 87,145 acre WSA designated as suitable prior to February 28, 1983. The WSA is underlain principally by quartz monzonite and quartz diorite that have intruded sedimentary and volcanic rocks. Three types of mineral deposits are present: 1) gold in fissure veins, 2) silver in fissure and replacement veins, and 3) talc in metasomatic lenses. Of the 84 nines, mills, and prospects examined, 54 are significant: 1) 5 in the intrusive rocks total about 4.4 million tons of inferred marginal gold reserves averaging 0.24 oz gold and 0.74 oz silver/ton; 2) three associated with intrusive-sedimentary rock contact zones total about 280,000 tons of inferred subeconomic silver resources averaging 7 oz silver/ton; 3) 27 gold and silver occurrences in the intrusive and sedimentary rocks total about 1.2 million tons of material in poorly defined bodies too small or low grade to be resources; 4) 15 gold and silver occurrences in the intrusive and sedimentary rocks are too poorly exposed to estimate tonnage and grade; and 5) four talc deposits along intrusive-sedimentary contact zones have inferred marginal reserves totaling about 640,000 tons. The marginal gold reserves at $450/oz might be profitably mined (reserve) at a gold price of about $600/oz and the subeconomic silver resources at a silver price in excess of about $27/oz. The marginal talc reserves might become minable at prices of about $50/ton and $80/ton for unprocessed and processed talc, respectively, after present supply sources are depleted. At most of the 54 significant mines and prospects, additional reserves or resources would likely be disclosed by trenching or drilling. Present in the WSA are 13 gold mills, numerous small pits and cuts, 270 underground workings totaling about 36,000 ft, and 80 mining benches totaling about 11,000 ft. Gold, silver, or talc were produced from most of the workings. A total of 1,561 lode and 18 placer samples were taken.

Jan 1, 1985

By R. O. Y. Breese

Perlite is a hydrated acid volcanic glass that has been derived from the alteration of obsidians through incorporation of water into the silica structure. It is distinguished from other members of the water-bearing natural glass family by total water content, characteristic fracture and luster. The distribution of major occurrences worldwide is associated with silicic Tertiary through early-mid Quaternary volcanics related to plate movement. The No Agua dome and flow complex is one of the most highly studied perlite occurrences in the world. It clearly exhibits lithologic and textural zonations that reflect simple cooling history. Similar features are commonly observed within other perlitized, extrusive glass selvages. This paper briefly discusses current thought regarding geologic occurrence, the hydration process and the modes of origin with special emphasis on No Agua.

Jan 1, 1985

By Jeffrey Y. Foley

Chromite deposits along the Border Ranges Fault in southern Alaska were investigated by the Bureau of Mines. This report, part 1 of a two- part series, describes the deposits. Part 2 describes the mineralogy and the results of metallurgical tests. Fieldwork began in 1981 and continued through 1983. Ninety-four subeconomic podifom chromite deposits in eight mafic-ultramafic complexes were investigated. Previously unreported chromite deposits at Red Mountain on Kenai Peninsula, on Kodiak Island, and near Tonsina are described. Deposits range in size from less than a thousand tons to over 1.25 million tons of contained chromic oxide (Cr203). Grades range from about 5 to 10 pct chromite. Excluding all deposits more than 10 miles from tidewater or existing roads and all deposits containing only chemical- or refractory-grade chromite, about 2,200,000 tons of Cr203 are contained in 41 hard-rock deposits. A placer deposit contains an additional 556,000 tons. These 42 deposits constitute a subeconomic indicated and inferred reserve sufficient to meet the Nation's chromite demands for about 4 yr, or the metallurgical industry's demands for over 5 yr, at 1981 consumption rates.

Jan 1, 1985

By Ken Musgrave

"What Most Effective Management Does?It must satisfy the demands, of three groups of people: owners, employees and the public.OwnersOwners want profitable operations that will pay them a return on their investment, plus operations managed for long life. Many owners are also concerned with employee's well being and their company's public image.EmployeesJob security and a good income are probably still the most important demands, however, as time goes by, employees are also demanding more involvement in safety issues, working conditions, and even how work is done.The PublicThe public requires acceptable environmental standards, as well as enjoying the prosperity supplied by a successful operation.How are Mines Managed?Most mines are managed very traditionally. The basic credo is that the managers make the decisions, and the hourly, and junior salaried employees do what they are told. Clearly this is the extreme case, epitomized by the long service shift boss who might say ""It took twenty-years to become a shift boss, and no miner is going to tell me what to do"" .There are some exceptions, two notable ones being Campbell-Chibougamau, and T.G.S. (now Kidd Creek Mines) which, in very different circumstances, decided on a more participative style.Campbell-Chibougamau, having closed down due to unprofitable operations, reopened, using a team structure with working leaders, and a system for sharing gains against cost targets with employees. Although the system has some problems, and development miners are bonused conventionally, this has been a basically successful program.Texasgulf Sulphur, a company with a history of non-union operations, and a participative management style, made a corporate decision to operate their Kidd Creek Mine in the same way. The orebody was rich enough to allow them the luxury to do this, but they have never had a strike, so perhaps they have more than saved the cost of the benefits and salaries they needed to pay. They also reward employees with a stock distribution scheme based on service and earnings."

Jan 1, 1985

By Borsaru M

The production of high-grade calcined bauxite is very dependent on the moisture content of the final product. Existing procedures rely on the ignition of small samples to monitor the effectiveness of the calcination process. The results obtained by this gravimetric technique are several hours behind production and do not permit regular adjustment of the furnace to optimize the control of the chemically bound water content (LOI).To provide rapid and hence more relevant results, a neutron moderation technique has been developed for measuring the LOI of bulk samples of calcined bauxite while they are still hot. The method uses fast neutrons from an 241 Am-Be neutron source to irradiate the samples, and the backscattered thermal neutrons detected are a measure of bound moisture content.The rms deviation between neutron and conventional determinations of LOI, in 15 calcined bauxite samples, was 0.08 per cent LOI over the range 0.1 to 0.9 per cent LOI. When allowance is made for the rms error in the ignition method, the error in the neutron method is found to be 0.07 per cent LOI.

Jan 1, 1985