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By D. A. Fenton

The reliability of large diameter, high horsepower ball mill is paramount when large production and minimum downtime is required. The 17 ft. x 56 ft. double compartment ball mill at St. Lawrence Cement Company has the first gearless drive built in North America and has the world's largest hydrodynamic bearings currently built and running. The machine has seen three years operation and has met its specifications. The mill was designed by Aerofall Mills Limited and the gearless drive built and designed by the Canadian General Electric Company. This paper discusses the operation of the first North American installation of a gearless drive ball mill from the mechanical, electrical and process aspects.

Jan 1, 1977

By R. W. Lake

The decision to develop an ore body can lead to multi-million dollar profits, or equally substantial losses. Accordingly, the effort required to adapt a valuation model to the specific proposal at hand, or even the development of a new model from basic principles, is clearly warranted. In the formulation of a model of this nature, one is faced with some major questions. For example, with the long term obligations that it implies, on what basis should a decision to initiate mining operations be made? Furthermore, how can the vagaries of inflation and the uncertainties that shroud the future be accommodated? Beyond the general principles by which mineral deposits are evaluated, specific cost behaviour is a function of the geology of the deposit, and of the mine design. Moreover, mine design, during the life of the mine, must be a continuing process somewhat akin to dynamic programming. An initial, apparently optimal, design is selected and mining commences. With production, a continual process of information updating leads to revisions. Thus if the maximum value is to be obtained, the mine design must be adjusted to conform to the changed conditions.

Jan 1, 1977

By Stanley W. Ivosevic

The South-Central area of the Osa Peninsula, Puntarenas Province, on the Pacific coast of southern Costa Rica, may have produced on the order of 30,000 kg (100,000 troy oz) of gold since prehistoric times. The Peninsula lies along an 800- to 900-km-long belt of late Mesozoic eugeosynclinal rock deposition, hydrothermal activity, and deformation (Campanian). The oldest rocks exposed in the area are basalt and tuffaceous mudstone of the Late Jurassic or Cretaceous Nicoya ophiolite complex. The Nicoya Complex is overlain by weakly lithified Pleistocene Older Sediments, predominantly conglomeratic sandstone and derived from erosion of the Nicoya Complex. Erosion reduced the Complex to a surface of high relief, so that the detrital source was in the area originally; the source retreated with subsidence. Stratigraphically, the Older Sediments are followed by surficial deposits of intermediate age, consolidated Younger Sediments reworked from Older Sediments, and unconsolidated Holocene surficial deposits reworked from Younger Sediments. The most prominent structures are a northeast-trending anticline and northeast and northwest fault sets. Some deformation was Cretaceous, but folding and much faulting occurred after deposition of the Older Sediments. Remnants of plainlike features and destructional terraces on the Older Sediments attest to stepwise downcutting of the terrain during successive stages of uplift. Near the end of this process, the present valley floors and coastal headlands developed. During a probable epeirogenic rise in sea level, Younger Sediments filled the valley bottoms and an aggradational coastal plain developed. Sea level dropped by stages and with some reversals to its present position; this caused stepwise incision of the valley fill, stepwise beveling of the coastal plain, and development of the present wave-cut platform. Spilitization around the time of the Campanian orogeny caused some parts of the Nicoya complex to be calcitized and others to be silicified. Gold, pyrite, and probably additional silica were introduced during subsequent hydrothermal activity. Native gold was eroded from Nicoya Complex lodes and reconcentrated through three generations of placer gold deposits. First, the gold was deposited as a detrital.

Jan 1, 1977

The successful operation of diesel equipment underground does not entirely depend on selection of robust, reliable, easily maintained machines. Results are also heavily influenced by the following factors: Design and condition of the operating area. Skill of operators. Correct maintenance facilities. Experience, skill and initiative of maintenance personnel. If the mine layout does not allow access to a central workshop area, the effect of any shortcomings will be magnified. The best results will only be obtained by close co-operation between mining and maintenance departments right from the initial planning stages.

Jan 1, 1977

By John C. Nixon

In 1959, The Australasian Institute of Mining and Metallurgy (Aus. I.M.M.) was asked by the Federal Government of Australia and the State Government of South Australia to join in the formation and management of a new contract research organization which was subsequently named The Australian Mineral Development Laboratories (Arndel) ? This body was formerly the Research and Development Branch of the South Australian Department of Mines which had been set up to develop the Radium Hill uranium deposit. It had then gone into contract R&D and the State felt that it would be more appropriate for the Branch to become a separate national organization. The Aus. I.M.M. decided that a professional institute could not participate directly in Arndel and, as there was no other suitable industry group to do so, it formed the. Australian Mineral Industries Research Association Limited (AMIRA). AMIRA held its first Annual General Meeting in September 1959 when the first Council was elected and the Memorandum and Articles of Association were adopted. The initial task of AMIRA was to raise guarantees of work or cash from its members to underwrite Arndel for the first five years of operation. The Federal and State Governments also provided guarantees and Arndel commenced operations in January 1960.

Jan 1, 1977

By Geoffrey C. Huggins

Diagnostic: tests were performed on a production ST-5A Load-Haul-Dump machine manufactured by Wagner Mining Machinery Company to evaluate and rank order noise sources. The diagnostic evaluation indicated that the major noise sources were the transmission, the engine, and the cooling fan. This phase was followed by implementation of recommended noise control treatments, which included vibration isolation of the transmission, a transmission enclosure, an engine enclosure, and modifications of the inlet to the cooling fan. The final step in the program was an underground operational period which began on 31 August 1976 at the National Gypsum Mine in Shoals, Indiana. The noise control treatments successfully reduced the LHD operator noise exposure by 7 dB(A), thus increasing its allowable operation time by a factor of 2.7. Actual measurements made underground using noise dosimeters have indicated that, during, a typical shift, the noise control treatments have reduced the fractional exposure to an allowable level. The report discusses the mechanical aspects of the LHD, its noise sources, the treatments applied, the final levels achieved, and field experience with the noise-controlled machine.

Jan 1, 1977

By A. R. Rule

As part of the Federal effort to help maintain an adequate supply of fertilizer minerals, the Bureau of Mines is conducting research to characterize complex, low-grade western phosphate rock and to develop methods for economic recovery of phosphate. The rock varies from soft, friable, altered phosphatic shale to hard, tightly cemented, unaltered phosphate rock. To supplement current beneficiation by sizing, a flotation procedure was devised that included depression of phosphate minerals with H2SiF6 and anionic flotation of carbonate minerals, followed immediately by cationic flotation of silicate minerals. Application of the procedure to several different ores resulted in phosphate concentrates that ranged from 28 to 31 pct P20S in grade and from 60 to 70 pct in phosphate recovery.

Jan 1, 1977

By Lloyd A. Morley

This report abstracts project work performed under USBM Grant GO155003 during the period 4 November 1975 to 3 November 1976. The research was funded, as a continuance of previous support from USBM Grants GO133077 and G0155003, to gain further knowledge in mine electrical system safety. Five reports have been separately produced, all under the grant title, "Coal Mine Electrical System Evaluation," and are as follows: 1. Volume I - Continuous Monitoring, 2. Volume II - Transient Analysis, 3. Volume III - Shielded Cables, 4. Volume IV - Computer Modeling, and 5. Volume V - Battery and Battery-charging Safety. Abstracts of these comprise the balance of this document with one exception. The task ?d-c offsett currents," does not fall under the scope of the other report volumes and, further, the material to be presented does not justify a separate report. Hence, this subject concludes the Executive Summary.

Jan 1, 1977

By Jack E. Fraley

Because of their noncombustibility, silicate and magnesium oxycements are desirable for sealing shale in underground coal mines. In this Bureau of Mines investigation, cement samples were cured and tested (nonstandard tests) for submersion to note resistance to dissolution (breaking into parts), which is an important property for a coating. Nonappreciable dissolution during 1 week of submersion was set for passing the test. Over half of the coatings passed the test.

Jan 1, 1977

By W. D. Eddy

Topaz is a fluorine-bearing aluminosilicate mineral of the kyanite-sillimanite group. The formula has been given as Al2SiO4(F,OH)2, [Al(F, OH)]2SiO4, or 2Al2O3?2Al(F, OH)3SiO2. Topaz is generally considered a semiprecious-to-precious gem mineral, but it is a fairly common minor constituent of granites. In 1937 the U.s. Geological Survey reported an occurrence of massive topaz in the 3 Brewer gold mine, Chesterfield County, S.C. Over the next 8 years considerable research was done on topaz to establish its properties and to determine possible end uses The first reported shipment of ore was in 1939 Peak production was reached in 194412, and output then began declining until the mine closed in 194913? During World War II topaz was used in refractories, as a flux in steel mills, and in the manufacture of borosilicate glass 14. The main advantage of using topaz over kyanite and sillimanite in refractory use was that calcined topaz converted to over 95 percent mullite (3A1203 .2Si02) while calcined kyanite or sillimanite contained only 88 percent mullite15. However, a major draw-back to utilization of topaz is the evolution of fluorides during calcination. In 1973 the Geological Survey reported that topaz occurred in probable commercial quantities in at least two domestic locationsl6: the Brewer area of South Carolina and a location in Colorado. The literature also indicated that progress had been made in controlling fluorine-bearing fumes. This research has progressed to the state where valuable fluorine compounds are being recovered on a commercial scale 17. Thus, a major obstacle to utilization of topaz appears to have been resolved. The Bureau of Mines under its program of advancing minerals technology initiated a project to study techniques for the concentration of topaz from disseminated materials. The objective of the study was to determine those techniques that would be used to produce topaz concentrates that could be utilized as a source of fluorine and mullite.

Jan 1, 1977

By Ernest M. Spokes

Maximum fan efficiency can only be obtained when the fan has the correct combination of size, speed, and blade setting to provide the required flow of air against the mine resistance. As the mine grows older, resistance decreases unless old workings flow is restricted, and new combinations of speed and blade setting or different fan sizes may provide greater economy.

Jan 1, 1977

By Edmund H. Warner

Any city dweller who has walked alone along a remote mine passageway has to be impressed by the eerie silence - the total absence of noise except for ones own breathing and scuffing of boots on the bottom. An underground mine can have tremendous contrasts, from complete silence to the ear piercing clatter of percussion drills working on the mine roof. Noise in underground mining machines is both useful and detrimental. Without characteristic noises that are recognizable to miners, operators would have a more difficult job operating their machines. Noise serves as a warning of approaching machinery, and changes in noise give indication that breakdowns may occur. But excessive noise is a health hazard. In recognition of this fact, our Congress included noise exposure as a part of the "Coal Mine Health and Safety Act of 1969". As Fig. 1 indicates, allowable noise exposure is established by specifying a time duration permitted at different noise levels. This is the well known "Walsh-Healey" criteria which governs noise exposure in many industries.

Jan 1, 1977

By Dipak C. Talapatra

This report describes the development of guidelines for design, inspection and maintenance of automatic couplers. In order to devise the guidelines, performance requirements for automatic couplers were carefully established. This was clone through a comprehensive survey of coupler manufacturers and extensive observation of automatic couplers in service in a broad spectrum of mines. The capability of the couplers to withstand the demands of the mining environment in terms of strength characteristics, gathering range, curve negotiability, and other factors were all carefully evaluated. An analysis of coupler related accidents for the years 1972-1976 was carried out to provide information on the safety and reliability of existing automatic couplers. This formed an important input to the development of the guidelines. It is expected that these guidelines will he useful to coupler manufacturers for establishing designs for improved automatic couplers, and to mine operators for maintaining their couplers in a safe and good operating condition throughout their expected lifetimes. This report is in two volumes: Volume l - Technical Report Volume 2 - Design, Inspection, and Maintenance Manual

Jan 1, 1977

By W. Joseph Schlitt

The use of plate and frame filter presses for dewatering cement copper at Kennecott' s Bingham Canyon precipitation plant is described. The dewatering process begins by periodically flushing a dilute copper slurry from cone precipitators to a rake thickener. The thickener underflows intermittently to an agitated surge tank which feeds the filter presses with a relatively constant slurry containing 10 to 20% solids. The presses operate with a three-stage cycle; loading, air blowing and discharging. Exothermic reactions occur during the air blow which cause actual drying as well as promoting dewatering via simple filtration. At the completion of the air blow, the presses are discharged onto a conveyor belt which transfers material to the load-out building for shipment to the smelter. An extended investigation was undertaken to relate moisture content in the filter cake to maximum press temperature, acidification of press feed, percent solids in the feed, and percent insol in the copper. Of these, press tempera¬ture and feed pH (3. 5 to 1. 0) have the greatest impact on drying. Because the discharged filter cake is hot and continues to undergo exothermic oxidation, significant drying occurs during subsequent handling so that a product containing 8 to 14% moisture is delivered to the smelter.

Jan 1, 1977

By Kenneth J. Miller

The Federal Bureau of Mines coal-pyrite flotation process has been modi¬fied to produce a concentrated final clean coal slurry underflow that could be dewatered more effectively by filtration or centrifugation. This change was accomplished by redesigning the Bureau's two-stage flotation pilot plant facility and running the second-stage flotation step with undiluted or only partially diluted first stage coal froth concentrate. Results of the pilot plant flotation tests showed that substantial sulfur reduction could be achieved by flotation with undiluted pulp but some dilution is recommended for maximum selectivity. For example, coal-pyrite flotation in slurry of 25 percent solids yielded clean coal products analyzing as low as 0.7 percent pyritic sulfur and froth reject products containing slightly over 3.0 percent pyritic sulfur. In comparison, coal-pyrite flotation with pulp diluted to about 12.5 percent solids yielded clean coal containing as low as 0.4 percent pyritic sulfur and froth reject of 5.6 to 6.7 percent pyritic sulfur. Despite the need for some dilution, it was concluded that excellent coal-¬pyrite flotation selectivity could be achieved without diluting to 6 or 7 per¬cent solids as done in the earlier work. Thus the economics of coal-pyrite flotation would be improved by easing clean coal dewatering problems and by reducing second-stage flotation cell volume requirements.

Jan 1, 1977

By Ben L. Seegmiller

INTRODUCTION Site characterization using oriented borehole core is the subject of this paper. Borehole core is a standard source of data for rock mechanics investigations. Oriented borehole core provides data whereby the geometric orientation of various geologic discontinuities (faults, joints, bedding, etc.) may be determined. The orientation and strength characteristics of discontinuities are important in many engineering investigations and in particular, in slope stability analyses. In heavily vegetated or soil covered situations, oriented borehole core may provide the only means of assessing the subsurface planes of weakness which characterize the site. The purpose of this paper is to briefly describe various methods or orienting core, core characteristics which may be logged and the methods of processing and using the data for site characterization.

Jan 1, 1977

By Corale L. Brierley

The effect of hydrogen peroxide (H2O2) on growth and respiration of Thiobacillus, thiooxidans, and Thiobacillus ferrooxidans, organisms involved in acid leaching of copper sulfide minerals and uranium oxides, was examined. Oxygen uptake and growth by T. thiooxidans were inhibited after contact with 0.82 mM H2O2. Inhibition of oxygen uptake by T. ferrooxidans occurred at 8.24 mM H2O2, and growth was inhibited after 6 hours exposure to 2.06 mM H2O2. Higher concentrations of H2O2 can be used without detriment to thiobacilli if it is dissipated prior to reaching the oxidation pond or dump surface. INTRODUCTION In recent years, hydrometallurgical processes for recovery of metal values from low-grade ore minerals have played an increasingly important role. Dump leaching of low-grade copper waste materials in the western United States now yields 11.5% of the total U. S. copper production. Although scavenger operations in uranium leaching have been successful, the state-of-the-art of in-situ

Jan 1, 1977

By R. L. Brown

The burning sulphide ores in the Sullivan Mine generate sulphur dioxide gases. This paper is concerned with a description of the environmental impact of SO2 on air quality in the mine and on the surface in the vicinity of the mine. As a result of surface caving, SO2 has been able to vent to surface and winds have carried it into one residential area of Kimberley. Monitoring practices are described.

Jan 1, 1977

By J. A. Finch

Individual mineral cyclone performance curves were determined for the four major minerals at two lead-zinc concentrators. Sizing was by screen and cyclosizer down to approximately 10 um, with lead , zinc and iron as saying of each size fraction. The performance curves were similar in shape and located according to the mineral specific gravity, Pm. The curves displayed a discontinuity at the fine end and a magnitude of short-circuiting of fines to the underflow which increased with Pm. Mass fraction of water to the underflow was only a guide to this short-circuiting. Sharpness of separation seemed in dependent of Pm. An inflection in the over-all performance curve was shown to be a consequence of the individual component mineral performance. A general relationship was observed showing that the flow regime of classification changed from laminar/ intermediate to turbulent with increasing cyclone feed size. Individual mineral size reduction for the four major minerals at one of the concentrators was also determined. Size reduction of the silica was greater than that of the galena, in contradiction to their accepted relative grind-ability. The observation did correlate with silica being much coarser than the galena in the feed to the ball mill. It is suggested that the silica acted as a buffer to the galena.

Jan 1, 1977

By William P. Diamond

A 3-inch pilot hole was directionally drilled to intercept the Freeport coalbed horizon horizontally at Mather, Pa., as part of a Bureau of Mines degasification project. The original concept was to continue the horizontal drilling into the coalbed, after the initial intercept, with a total of three horizontal holes eventually being completed. However, the erratic thickness (0.0 to 4.3 feet) of the Freeport coalbed at Mather was not sufficient to support the horizontal drilling degasification technique, and the site was abandoned after six attempts to locate adequate continuous coal thicknesses. The drilling of coreholes in the immediate vicinity of proposed well paths to evaluate coal thickness is essential prior to future slant hole operations. Although mechanical failures of the new directional drilling equipment, mud pump and rig breakdowns, directional control problems, and exploratory horizontal drilling in the Freeport horizon more than doubled the anticipated cost of the pilot hole, continuing improvements in directional drilling equipment and techniques should significantly reduce the time and costs of future drilling operations.

Jan 1, 1977