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By K. B. Bengtson

This task report provides the process technology, preliminary design, capital and operating costs for a 25 TPD pilot plant to produce cell-grade alumina using a clay/hydrochloric acid extraction - HCI gas induced crystallization process. The report consists of six volumes: I - Process Technology and Costs; II and III - Equipment Lists, Specifications and Quotations; IV and V - General Specifications; VI - Drawings. The process was selected by the Bureau of Mines as the more promising method to produce cell-grade alumina from clay based on the results of the two previous task reports under this contract: Task I - Comparison of Six Processes (alunite, anorthosite-lime sinter, clay/sulfurous acid, clay/nitric acid, clay/hydrochloric acid evaporative and gas-induced crystallization) and Task 2 - Comparison of Two Processes (clay/nitric acid and clay/hydrochloric acid - gas induced (crystallization). The pilot plant process utilizes a unique dual crystallization process to produce aluminum-chloride-hexahydrate crystals having sufficient purity when decomposed to meet stringent alumina product specifications. The size of the 25 TPD pilot plant has been selected to permit scale-up to commercial size plants of equipment, technical and economic parameters. The capital cost estimate for the pilot plant, exclusive of fee and escalation, for a southeastern U.S. location is $52,311,000 expressed in 1979 dollars. The total time required to construct the pilot plant including engineering and procurement is 32 months. The operating cost to produce the estimated 9,000 tons of alumina required for testing in Hall cells is $40,91[0],190 expressed in 1979 dollars.

Jan 1, 1979

By K. T. Menzies

Over 1500 literature citations related to diesel exhaust sampling and analysis were obtained as a result of both computer and manual searches of nine data bases. Abstracts and hard copies of relevant citations were reviewed and those considered appropriate for evaluation were included in a bibliography. Based on the literature collected, available sampling and analysis methods for the following diesel exhaust contaminants were evaluated: CO, CO2, NO, NO2, Hydrocarbons, Particulates, PNA, S04, Oxygenates Emphasis was given to both laboratory and field methods for these species. Methods were evaluated on the basis of sensitivity, selectivity, accuracy and reliability and a selected list of preferred methods was developed for each compound/ class. The selected methods were additionally evaluated through communication with current investigators. Sampling and analysis methods for all compounds except CO and CO2 were observed to have some unreliability. Recommendations were made for future research to develop, improve, and validate methods.

Jan 1, 1979

By Robert F. Kehrman

As with many new technologies, the rapid growth in solution mining for uranium has created uncertainties regarding the environmental impact of mining operations. In solution mining, the largest area of concern is the impact of the process on the quality of ground water supplies. As a result, a rapid and reliable technique of detecting lixiviant excursions is desirable. Such a method would replace the periodic sampling technique and should provide a more or less continuous monitoring method. To this end, resistivity techniques were evaluated as an alternate means of tracking lixiviant movement. A program was devised which had five specific tasks. These were: (1) evaluation of the techniques, (2) development of the most promising technique or techniques, (3) field testing of the techniques, (4) testing of the BuMines probe, and (5) reporting. The result of the analytical and field work is that various resistivity/ resistance techniques do provide a means of detecting lixiviant movement in Northern Wyoming. Surface and downhole galvanic surveys and controlled source audio magnetotellurics (AMT) were evaluated. All three techniques showed some degree of success.

Jan 1, 1979

By Felix du Breuil

Contract H0177044 included three objectives; (1) consolidate, maintain, and distribute information on STE approved lighting systems; (2) develop and present one-day seminars on underground mine lighting; (3) determine direct labor and hardware costs associated with the installation of mine illumination systems. All objectives were completed with results as follows: Task I - A file containing 1350 Statements of Test and Evaluation (STE) for all types of underground equipment was developed and publicized throughout the coal fields, A total of 40 requests for STE information was received and processed. Task II and III - A series of 50 seminars was scheduled and presented to 942 attendees throughout the coal fields. The seminars were well received and attendees indicated the information presented would be helpful in bringing their equipment into compliance. Holding a series of seminars in the coal fields, instead of a few in population centers, was favored by attendees. Task IV - Installation cost data obtained on 415 lighting systems indicate that the factors which most affect installation costs are higher hardware cost for DC powered systems and slightly higher manpower requirements for systems installed underground. Based on these data, the total cost to industry of retrofitting existing underground equipment could range up to $50 million.

Jan 1, 1979

By Gary R. Gavan

This report presents the documentation and User's Manual for a data retrieval and report generation computer program. The program operates on a data base containing over 19,000 pieces of coal mine equipment in use in 1976.

Jan 1, 1979

By John D. Foulkes

A study to categorize and characterize underground metal/non-metal mining operations from the viewpoint of telecommunication requirements and practices. The objectives were to: ? Gather and analyze data; ? Identify communication requirements; and ? Recommend systems for operational emergency and post-disaster telecommunications.

Jan 1, 1979

By Clark P. Mangelsdorf

The report consists of two parts. In Part I is a state-of the-act study of roof truss technology as of January 1979. Included are a history of the truss concept, a review of analysis techniques, a record of hardware available and equipment used in its installation and numerous examples of user experience. Part II is concerned with a study of the role of friction in the behavior of a roof truss. The appendices include laboratory tests by the author.

Jan 1, 1979

By F. S. Kendorski

This report presents the results of a search for viable-self-drilling roof bolt concepts, detailed development, design, and manufacture of such bolts that drill their own holes, and testing in the laboratory and in the field in two different coal mines of three self-drilling roof bolts. Three new types of bolts were designed and tested, which drill their own holes and then anchor in continuous operation. These were a spring-actuated mechanical expansion shell, a slot and wedge, and a self-contained resin anchor bolt. Such bolts when fully developed for mine use would allow safer and remote installation of ground support and increase productivity. Recommendations are given for further work to improve drilling and anchorage performance.

Jan 1, 1979

By Herbert H. Einstein

The innate variability of natural materials and processes causes uncertainty in the models representing the natural phenomena and uncertainty in estimating the parameters that are used in these models. Reliability analyses, in contrast to the traditional factor of safety approach, are well suited to a rational incorporation of uncertainty in design and exploration decisions. Probabilistic kinetic and kinematic analyses were developed and combined to form reliability analysis methods. With one method the reliability, i.e.) the probability of failure, of an individual 2-plane wedge in a slope can be determined. The other method is aimed at slopes with a single slope parallel set of joints. In each case two approaches were developed, an encompassing one relying on computer codes and a simplified or summary approach relying on charts or pocket calculator computation. A major contribution of these approaches is the treatment of joint persistance. Instead of having to assume a certain persistence, it is now possible to use exploration data on joint geometry and to include the persistence effect rigorously.

Jan 1, 1979

By John H. Johnson

This report covers the third and final year of work conducted under U. S. Bureau of Mines Grant G0166027, "Monitoring of Mine Air Pollutants". The report discusses work performed in three areas. These are the White Pine Mine (WPM) Experimental Unit, diesel mine-vehicle tailpipe emissions monitoring, and mine ambient air concentration data analysis. The WPM experimental unit was used to study diesel exhaust stratification in an 80 foot long dead-end heading while loading ore with a Wagner ST-5D scoop train LHD. The MTU Mine Air Monitoring Laboratory (MAML) was used to gather temperature and CO2 concentration data at 10 locations. Three different ventilation conditions were compared. The data substantiate the presence of strong buoyant forces of the hot exhaust gases which result in temperature stratification in dead-end headings. The diesel mine-vehicle tailpipe emissions monitoring study involved laboratory measurements of diesel undiluted exhaust pollutant concentrations by the portable tailpipe emissions measurement apparatus (EMA) assembled for in-mine use. The results were compared with simultaneous measurements by standard laboratory exhaust monitoring instruments. These results indicate that accurate field source quality control measurements can be obtained for CO2, CO and NO but NO2 results were low for all engine conditions. The mine ambient air concentration data analysis study included analysis of diesel pollutant concentration data in the Orchard Valley Mine air and comparison of the results with data collected earlier in the White Pine and Brushy Creek mines. The analysis included preparation of lognormal frequency distributions and calculations of C02-based concentration ratios and correlations. In the three mines compared, pollutant concentrations are distributed quite similarly, and the concentrations appear to be controlled to present standards.

Jan 1, 1979

This appendix contains the list of equipment, their corresponding number and their specifications with the quotations from the vendors/ manufacturers who can supply this equipment. The listings are arranged by process plant areas.

Jan 1, 1979

By F. S. Kendorski

This report covers the work on developing criteria for determining when a hazard exists when mining stratified mineral deposits beneath bodies of surface water. The nature of water bodies is considered, the disturbance to the strata induced by mining is described, inundation case histories reviewed, reasonable water inflows derived, and methods of mining to prevent or minimize the hazard are presented. Criteria are given whereby effected industries and agencies can recognize a potential hazard and plan a mine accordingly, releasing considerable mineral reserves otherwise considered unminable.

Jan 1, 1979

By Robert L. Lagace

A prototype adaptive volume control for the loudspeaker output of mine trolley carrier phones was designed, built, and tested in the laboratory and in a mine. This volume control senses, and adapts to, the ambient acoustic noise environment in such a way as to produce a loud sound output under noisy conditions, and a quieter output under quiet conditions, thereby producing an understandable and unstartling volume level under all noise conditions. The design approach, prototype hardware, and test results are described, and the device is shown to be feasible for in-mine operations. The circuit design principles are easily applicable to currently available mina trolley carrier phones. Recommendations for practical improvements are included. An in-mine experiment to assess the practical feasibility and utility of the dedicated wire technique for overcoming poor trolley carrier phone system performance was designed, performed, and evaluated. The technique involves the use of a single, low-loss, properly terminated auxiliary wire, placed in the rail haulageway, which allows signals to naturally couple to and from the trolley wire/rail transmission line, and thereby significantly decrease the overall signal attenuation rate on the trolley wire/rail line. The in-mine dedicated wire experiment, results, and conclusions are described, and the technique is shown to be a valid and practical one for significantly Improving carrier phone system performance in mines. Guidelines for the installation and use of the dedicated wire are provided. Recommendations are made for obtaining further practical information on its performance and utility. A second in-mine experiment to assess the feasibility and utility of the low-impedance (low-Z) line technique for overcoming poor carrier phone signal transmission in mines was designed, performed and evaluated. The low-Z line technique involves the periodic connection of shunt capacitors between the trolley wire and the rail to artificially lower the line characteristic impedance. This causes the low impedance shunt loads encountered across the trolley wire/rail line to be less mismatched to the line, thereby reducing the overall attenuation of carrier phone signals. The results of in-mine experiments performed along unenergized and fully operational sections of trolley wire/rail line are described. The experiments were designed to measure line parameter such as inductance and capacitance per unit length, characteristic impedance, and propagation phase velocity, in addition to signal strength versus distance behavior under normal and low-Z line conditions. The low-Z line technique is shown to be valid, but not as practical as the dedicated wire technique which is recommended as the most favorable for most coal mine applications.

Jan 1, 1979

By John E. Carr

A bewildering variety of continuous thickeners and clarifiers are used in mineral industries and other heavy industries. General topes arc: ? Conventional thickeners ? Thickeners with flocculating feedwells ? Solids contactors ? Tray thickeners ? Lamellas ? Conventional thickeners with Lamellas ? High flow, fluid bed thickeners These units must be adapted to varied applications. They must provide operating flexibility to meet process needs. Such factors multiply the decisions which must be made prior to the selection of a thickener. The seven types of thickeners listed above, with their variations, share design concepts which limit their application and which can be used to evaluate their performance. Some of these arc: ? Feed velocities must be limited and/or controlled. ? Natural or reagent flocculation is necessary. ? Horizontal settling area is the basis for capacity. ? Overflow velocities must be limited and. or controlled. ? A controlled underflow is necessary. Thickener selection is the application of these needs to the basic process concepts. The basic function of a thickener, in the minerals industry, is the separation of a thickener sludge containing fine solids from water. In addition to this primary separation function, others include: ? Separation of solids from water ? Separation of flocculated solids from slimes ? Storage of solids ? Control of percent solids ? Storage of water ? Process control by absorbing fluctuations in feed ? Process control by increase in head clue to the depth and percent solids of the thickened sludge. Most thickener designs, suitable to minerals applications, are based on the separation of minus 65-mesh, 2.7 specific gravity solids containing slimes. These designs are routinely adapted to coarse and or denser materials. Materials of lower specific gravity such as coal, wood, char, some chemical precipitates and organics act Hike slimes if a thickener is used. Perhaps the most conservative approach to sizing and application is the use of comparative data from similar plants or similar industries. Thickeners are-routinely used in a great number of industries from which there is good historical information available. In the minerals industry, thickeners are used in: clay sizing, coal refuse, heavy media, copper concentrates, copper tailings, gold flotation concentrates, and countercurrent decantation for cyanidization in gold and CCD in uranium. Concentrate and tailings thickeners are used in iron ore plants, and concentrate and tailings units in lead-zinc plants. In addition, there arc thickeners designed to handle lime mud; limestone concentrates and tailings; phosphoric acid; potash; and rutile concentrates. Thickeners are, in addition, widely used in gravel plants for water reclamation. This gives excellent data on clay settling in some cases. Thickeners are used extensively for slurries generated by flue dust from wet scrubbers. Thickeners in flue dust applications are operating with considerable variations, treating blast furnace dust. BOF flue dust, and wood char. Similar applications are met in the power industry with fly ash and SO2 scrubber systems. Even though field data is preferred, such data has limitations as listed: ? Flowsheets are seldom identical. ? Data is often incomplete or limited. ? Ores vary significantly. ? Operating needs are changing. For these reasons, mathematical and theoretical methods are needed for application of field data to a specific project. In addition, laboratory data for similar projects and, if possible, laboratory data on a representative sample should be used to specify the thickener. There is a great volume of thickener literature. The references for this paper, along with their references, and past AIME papers provide excellent background. Older literature can be reviewed in light of current methods. It is interesting to note that the requirements for higher flow rate designs, more extreme flocculation systems, etc., can be logically introduced by reading Gaudin's Sections on Flocculation and Thickening, which was written before field installations could illustrate all of his ideas. The problem, then, is to select hardware which will take into consideration the functions of flocculation, separation of the solids, water clarity, control of the underflow, and control of the overflow. Reliable operation and simple control are customary.

Jan 1, 1979

The Full Scale Model Roof Bolt Test System described herein was designed, fabricated, erected, and installed by MSA Advanced Systems Division for the U. S. Department of Interior, Bureau of Mines, Spokane Research Center. It was furnished under USBM Contract No. 50271014 and Modifications. The test system is intended for use by the Bureau of Mines to run comparison tests on roof bolt systems. The mine entry cross section is made from special concrete pillars and roof slabs. They are constructed within a steel beam frame with hydraulic operated cylinders to apply loads that simulate the action of mining overburden. The frame is designed so it can be disassembled for replacing the concrete in subsequent tests. A computer and data acquisition system is furnished to control the load application and measure and gather data.

Jan 1, 1979

By Terry S. Cory

This report describes a complete system design methodology for medium frequency (MF) wireless radio systems for use in coal mines. The emphasis Is on AC mines where no trolley wire exists and, for which, conventional trolley phone communications can not be used. The report constitutes an MF system design handbook and includes a compendium of all previous MF technology elements as well as a reference Index with abstracts of all pertinent literature. A particular strawman system design analysis is Included for the Helvetia Coal Co. Lucerne #8 mine In the Upper Freeport seam.

Jan 1, 1979

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Jan 1, 1979

By O. B. Bucklen, J. P. Matoney, P. G. Meikle, R. L. Terry

INTRODUCTION The trend in the coal industry for many years has been to make every- thing "bigger and faster." This also holds true for loading and storage facilities. Where once a 1 million st per yr (910,000 mt/yr) mine was rare, 3-5 million st per yr (2,730,000-4,550,000 mt/yr) mines are not uncommon today in the bituminous industry. This great increase in production, made possible through mechanization, requires greatly improved loading facilities just to get the coal away from the mine. Also, there is a trend to- ward combining production from more than one mine and cleaning it in a single preparation plant. In addition to increased loading capacity, this frequently necessitates raw-coal storage and blending facilities. The development of the unit train with its attendant economics has contributed more than any other factor to the widespread construction of storage and high-speed loading facilities. In the export market, the construction of ever larger coal colliers has added to the need for faster and larger loading facilities. In this climate of rapidly changing technology, any written ac-

Jan 1, 1979

The Canadian Institute of Mining and Metallurgy. Milling practice in Canada. CIM Special Volume 16. 1978. The purpose of this volume is to up-date The Milling of Canadian Ores, which describes Canadian mineral. processing plants and gives other metallurgical information, and was published by the Sixth Commonwealth Mining and Metallurgical Congress in 1957. NIM reports Report no. 1874 Activation analysis and classification to soune of samples from the Kimberley Reef conglomerates. (10th Mar., 1977; released Jun. 1978). Report no. 1926 The analysis of anode sludges by X-ray-fluorescence spectrometry. (5th Jun., 1978). Report no. 1936 The analysis of mineralogical and metallurgical materials. A guide to the analytical techniques and instrumentation available at the National Institute for Metallurgy. Report no. 1959 The slag-metal equilibrium, and the activities of slag and metal components in the production of high-carbon ferromanganese. (15th May, 1978). Report no. 1965 Analyses, by several laboratories, of three ferromanganese slags. (22nd May, 1978). Report no. 1968 The influence of carbonaceous reducing agents on the rate of reduction of representative manganese and chromium ores. (28th May, 1978). Company Affiliates Guide To The Preparation Of Papers for Publication In The Journal Of The South African Institute Of Mining And Metallurgy The following notes have been compiled to assist authors in the preparation of papers for presentation to the Institute and for publication in the Journal.

Jan 1, 1979

By Kenneth K. Humphreys, Joseph W. Leonard, Robert L. Llewellyn, William F. Lawrence

INTRODUCTION Cleaning fine coal sizes utilizing air currents in machines as the primary separating medium is called dry concentration or pneumatic cleaning. In 1947 approximately 18 million tons (16.38 million mt) of bituminous coal were cleaned by air machines; in 1965, 25.4 million tons (23.1 14 million mt); but in 1975, only 7 million tons (6.37 million mt). Table 11-1 shows the tonnages cleaned of bituminous coal and lignite in the United States by various types of equipment from 1938-1963. Table 11-2 shows only tonnages cleaned by pneumatic methods from 1964-1975. The decrease in tonnage to approximately 7 million tons (6.3 million mt) is due to a higher moisture content in the mined coal and the greater difficulty in cleaning the coal by air. There also was a definite trend to load raw coal at the mines, especially the slack which is the most expensive to clean due to the dewatering and drying requirements. While there have not been any applications of pneumatic cleaning in the anthracite field, its use has not been fully explored. The same is true for lignite and subbituminous coals.

Jan 1, 1979