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By A. Aly Selim, Bruce D. Hanson

A computer model capable of simulating the basic production system in a variety of underground mining methods has been developed at the U.S. Bureau of Mines Twin Cities Mining Research Center. The simulation of the basic production system at the working face, which includes drilling, blasting, mucking, and roof bolting, is described in this paper. The model is event-oriented; that is, the status of the system is updated at the occurrence of an event. All event or activity times, including failure and repair of equipment, are treated as stochastic variables. A location dimension, in addition to the time dimension, is used, allowing the simulation of systems with a number of stopes or faces. To aid the user in determining the efficiency of his system, the model provides several reports. An event or activity report gives the frequency of occurrence, total active time, and cumulative delay statistics for each event. An equipment report delineates the availability and utilization of all equipment. A production report provides information on various performance measures such as tons produced and holes drilled. The cost report gives the cost of various elements in the system. Operating data from an actual mining situation were used in validating the model. In addition to the description of the model, examples of simulation experiments which were performed on a room-and-pillar mine system are given. Use of the model to determine methods for improving the efficiency of the system is discussed.

Jan 1, 1976

By Ben H. Daud

The systems optimization approach to mine planning has led to the adoption of a number of mathematical and computer models for short, medium and long range planning of mining operations. In the realm of open pit mine planning, the most common uses of such an approach have been in the areas of optimal pit design and planning of materials handling operations. Since a truck-shovel combination is the most widely used method of materials handling in open pit mines, a number of models have been presented in the past to analyze and optimize such systems. Broadly, these models can be divided into two categories. The simulation model, which is primarily used as an aid in analyzing the performance of either an operating or a proposed haulage system under the influence of externally alterable parameters, and the linear or integer model which is used as a tool for short or medium term optimization of the system under the operating constraints. In the first part of this paper, a brief discussion is presented of the linear/integer optimization models presented in the past, and in the second part a new model is described which is actually a combination of the simulation and the integer programming models. In its bare essentials, the model consists of an integer optimization algorithm, but the constraints are regularly and dynamically updated by incorporating the conclusions drawn from a stochastic simulation model of the mine haulage system. Since the successive optimization is performed by the mine operator who manipulates the constraints to guide the model towards the optimum, the mystical black box approach is minimized and should help in adoption of the model by the mine personnel. Also, by combining the stochastic simulation model and the deterministic integer model, some of the advantages of each are acquired.

Jan 1, 1976

By R. F. Winkle

Shortly after World War II, considerable impetus was given to use of truck haulage in open pit mines by the manufacture of large off-highway trucks. Mine management was quick to utilize this more flexible approach to open pit operation and in the ensuing years much time and energy has been spent to improve the basic concept. Dramatic progress has been made in drilling, blasting, loading and hauling with much emphasis placed on equipment improvement. In general, haul roads in open pit mines and quarries have received rather perfunctory treatment in studies of surface mining operations. Their importance to the successful pit operation requires more than a brief sentence saying, "Good haul roads must be maintained." Haulage costs account for approximately one-third of total mining costs including general costs and about 90 percent of the total loading-haulage cycle time is consumed in travel, hence, good haul road planning, construction and maintenance are mandatory for a viable operation.

Jan 1, 1976

By D. A. Wilson

A laboratory method for processing lead battery scrap has been developed that eliminates virtually all of the S02 emission that normally is produced when a reverberatory or blast furnace is used. The method employs a hydrometallurgical step to convert the PbS04 to PbO and CaS04 by mixing the battery scrap with a slurry of Ca(OH)2. The reaction is exothermic and goes to completion in 2 to 5 minutes at room temperature. The dried product is mixed with a KC1-NaC1 flux and carbon and reduced at 6500 C. A minimum charge ratio of 3 parts of carbon to 100 parts of battery scrap is required for reduction. The process produces lead reductions and recoveries as high as 97.0 and 94.9 percent, respectively. The KCI-NaCl flux is recovered using a standard counter-current water leach followed by evaporation.

Jan 1, 1976

By B. M. Fisher

A process for making electrolytic copper of high quality from copper flotation concentrates is described. The concentrates are first slurried and then subjected to a high-temperature, high-pressure, oxidation-leaching operation under controlled conditions. The resulting slurry from the oxidation-leaching operation is cooled or flashed to atmospheric pressure and then subjected to a solids-liquid separation. The separated liquor, containing the recovered copper values, is cooled and then fed to an electrolytic deposition operation where metallic copper cathodes of high purity are produced. The spent electrolyte is then subjected to a sulfide treatment to precipitate the residual amounts of copper not deposited in the electrolytic cells. The precipitated copper sulfide is recovered and recycled in the form of a slurry to the initial stages of the process.

Jan 1, 1976

By Robert M. Abrams

The passage of an ore pulp through the froth flotation process results in the production, after dewatering, of a finely divided concentrate. This intermediate product Trust be handled to the subsequent process facilities via belt or other types of conveyors, hoppers, bins, chutes and feeders, and the like, Flotation concentrate has some difficult handling properties such as abrasiveness, sluggishness when moist, or fluidity when dry, These characteristics require the judicious selection or design of handling, equipment and the careful engineering of transfer chutes. It is to the special problems which are encountered in this in-plant handling procedure that this paper is addressed. The methods which will be discussed have beer. developed primarily for the handling of the froth flotation concentrates of copper, leap, and taconite iron ores, but may be generalized, with appropriate modifications, to apply to other similar metallic concentrate&. The controlled feeding of concentrates frog: bins and hoppers is covered alone with some of the techniques used to transfer concentrates from ore belt conveyor to another. Methods are described for unloading belt conveyors into bins or storage tiles, The reclamation from storage piles is also treated.

Jan 1, 1976

This Bureau of Mines report comprises tables listing the name, location, and other pertinent data concerning certain future fuel-related projects. The tables include information on projects involving the proposed or planned development of fuel resources, as well as the development of storage, transportation, and conversion facilities; the report covers the 26 States east of the Mississippi River. Of the total 594 projects for which information is provided, 492 concern coal mines and electric generating plants.

Jan 1, 1976

In attempting the predict coal cleat orientation in the subsurface for effective methane degasification of the coal beds in the Warrior coal field of Alabama, approximately 150 rock joint orientations and 45 coal cleat orientations were measured in each of 37 7 ½ minute quadrangles in Tuscaloosa, Walker, Jefferson, Fayette, Winston, Blount, and Bibb Counties. Data from these surface locations, and coal cleat data from eight underground mines was corrected for magnetic declination and titled beds rotated to the horizontal where necessary and plotted on rose diagrams for comparative analysis. Data collected on each joint and cleat consisted of attitude, quality, type, spacing, persistence, lithology, bedding thickness, surface texture, and filling. File data and published and unpublished reports from the State Survey and the State Mine Inspector's Office were re-viewed. Twenty-seven mining companies, most of which supplied information pertinant to the project were also contacted. The information obtained consisted of crop line information structure, and underground mine outlines, all of which were put on 7 ½ -minute topographic quadrangles. LANDSAT-1 imagery and Skylab photography were compared to dominant joint and cleat trends in the study area. Detailed results can be found in an open-file report entitled "Fracture Analyses in a Selected Area of the Warrior Coal Field, Alabama." A master's thesis entitled "The Relationship Between Surface Joints and Subsurface Structure in a Selected Area of the Warrior Coal Field" is being prepared to illustrate the relation-ship of the fracture system to the structure in the Warrior coal field. A proposal has been submitted for research on a project entitled "Rock Fracture Systems and Their Affects on the Extraction of Fossil Fuels in the Warrior Basin, Alabama"

Jan 1, 1976

By Prosser A. P

The conditions under which vanadium is rendered insoluble by silica in the alkali-roast process have been investigated starting with both slag and reagent-grade materials. The inert phase is a glass formed slowlyfrom soluble NaV03 produced at lower temperatures. It contains approximately 30 per cent V in a partly reduced state; iron is not a principal component. Some of the vanadium in the inert phase is slowly returned to a soluble form by heating in an oxidizing atmosphere below the temperature at which the glass is formed (750°C). As the reaction leading to the required, soluble form of vanadium is also slow between 600 and 750° optimization and control of the temperature profile and atmosphere in the furnace, and the residence time of the solids, are necessary to ensure high vanadium extraction during subsequent leaching.

Jan 1, 1976

By Barrie A. Wigmore

There are two aspects of financing western coal development -- whether there is going to be enough money to finance the prospective large development of the industry, and the specific techniques of raising money for that development. To take the first question of whether there is going to be enough money around to finance your industry, I think it is quite clear that the restrictions on the development of western coal are going to be non- financial. Environmental impact problems are creating the greatest delay in coal mine development, at the moment; but getting enough personnel, mining equipment, railroad equipment, and failure of the Department of Interior to act on leasing federal coal lands all appear likely to create significant bottle- necks in the development of western coal -- larger bottlenecks than financing. Financing appears straightforward for the industry. There are many projections of the financing required to meet Project Independence goals. The National Academy of Engineers estimated that development of 500 million tons per annum of western coal would be necessary by 1985 to meet the Project Independence goals which might require $20 billion of capital spending. It is generally agreed that 500 million tons a year is not a realistic possibility. Carl Bagge?s estimate of production of 250 million tons a year by 1983 appears a more reasonable projection. Development

Jan 1, 1976

By A. F. Banks

"Potash processing has much in common in terms of unit operations and plant operating strategy with other mineral processing plants. As it is a rather large topic the processes will be broad brushed to give you some background and then I will go into a little detail on the things we do in the Cominco plant that may be of interest to the group as a whole. In particular the centrallized computer control system and associated instrumentation and the operator training programs will be covered as well as the mill fire, something that could happen in any plant. THE ORE AND PRODUCTSThere are differences in potash ores as you would expect. It is my intention to deal with the ores processed in the Saskatoon area. These are mined from the beds in the Patience Lake Member and have a mineralogical description as follows:Sylvite (Potassium Chloride) 40%Halite (Sodium Chloride) 55%Insolubles (Slimes) 5%A number of products are made from this ore. It is characteristic of a potash plant that you put as much effort into grading and converting the sylvite to meet market requirements as you do in recovering it."

Jan 1, 1976

By S. Ramachandran, L. A. Vazquez, N. L. Grauerholz

A novel process is described for the selective flotation of scheelite from low-grade (- 0.5% W03) tungsten ores having appreciable quantities of calcareous and siliceous gangue minerals. Specifically developed for the Tempiute, Nevada facility of Union Carbide, the process yields tungsten concentrates exceeding 15 percent W03 with at least 85 percent recovery. This condition was not achieved through conventional processes. This process consists of conditioning the ore pulp with judicious amounts of lime, followed by soda ash and sodium silicate as modifiers. The scheelite is then floated using a mixture of oleic and naphthenic acids as collector. Contrary to the common observation as to the deleterious effects of calcium in fatty acid flotation systems, lime addition is found to be beneficial in achieving satisfactory results. The process has also shown excellent results on a Brazilian scheelite ore.

Jan 1, 1976

By Carl G. Schwenk

Rusk County is located in the northwestern portion of the state of Wisconsin, roughly 130 miles east of Minneapolis (Figure 1). The topography is generally flat with dairy farming the principal activity. Forest and swamp lands are common, as well as pasture and cultivated ground. Rusk County falls near the southern terminus of the Precambrian Shield and is covered by a thick layer of glacial drift. Outcrops are quite rare, but the few available exposures indicate that the subsurface is comprised of steeply dipping metamorphosed volcanics and sediments of Early Proterozoic age. A thin section of flatlying Cambrian sandstone is sometimes found directly under the glacial till. The depth to Precambrian basement has been recorded to be as great as 150 feet beneath the surface.

Jan 1, 1976

By Jagdish C. Agarwal

Although copper ranks very low in the order of abundance of elements in the crust of the earth, it has been one of the first metals utilized by mar, at his emergence from the Stone Age, about 10,000 years ago. Use of copper for weapons, tools, utensils and ornaments dates back to the twilight of history, 6,000-5,000 B.C. Native copper outcrops and the malleability of the metal explain its very early use by the cave-dwellers. The working, melting and extraction of copper from its minerals are among the oldest metallurgical achievements of the human race. The oldest complete smelting installations for the extraction of copper from its minerals, dated about the fourth millenium B.C., were recently discovered in the Timna Valley, Wadi Arabah, Israel. (1) The history of the developments of the extractive metallurgy of copper has been adequately reviewed recently. (2,3) The center of copper production migrated from the Eastern Mediterranean to Northern Europe (Mansfeld, Germany, Swansea, Wales) towards the end of the Middle Ages (1500 A.D.). The production of the metal was boosted tremendously in North America since the end of the nineteenth century (Fig. 1).

Jan 1, 1976

By Richard J. Gonzalez

The petroleum industry includes varied and extensive operations required to supply increasing quantities of refined petroleum products and natural gas that are essential for the economic progress of an expanding population Petroleum has provided the power for the transformation from the "horse and buggy days" to the age of jets and space exploration, and for the remarkable improvement in productivity per worker in agriculture and manufacturing. Without increasing quantities of oil and gas, the world would face painful readjustments to more expensive forms of energy and lower standards of living Petroleum operations start with exploration, development, and production activities that supply the basic crude oil and natural gas Pipelines, ships, barges, and trucks first transport the raw materials to processing centers and then move the finished products to the ultimate consumers. Processing plants extract liquids from natural gas and refineries convert crude oil into a wide range of products These products include transportation fuels, feedstocks for conversion into numerous products (such as fabrics, rubber, and plastics), light fuels for heating, lubricants, and heavy residual materials (industrial fuel oil, asphalt, and coke) The final activity of wholesale distribution and retail marketing moves products into millions of homes, farms, industrial plants, and motor vehicles The use of coal exceeded that of oil and gas until 1946 in the United States and until 1968 in the rest of the world. However, oil and gas have proved to be such convenient and attractively priced fuels that they now supply three-fourths of the total commercial energy (including coal, hydroelectric, and nuclear power) used in North America and more than one-half in the rest of the world. LARGE SCALE OF OPERATIONS By the beginning of 1970, world crude oil production exceeded 43 million bbl daily, -equivalent to more than 2200 million tpy In addition, natural gas and the liquids recovered from processing natural gas supply about 40% as much energy as crude oil Production of oil and gas provide by far the highest value of all mining operations. In the United States, the value of oil and gas production in 1969 of $13 8 billion exceeded the $13 0 billion value for all other minerals The rate of expansion in use of petroleum has been extremely rapid since World War II World crude oil production doubled from 7,500,000 bbl daily in 1946 to more than 15,000,000 bbl daily by 1955 It doubled again to 30,000,000 by 1965, and will double again by 1975 The use of natural gas has increased greatly in the United States and also in Europe, as important discoveries in the Netherlands and the North Sea and technology for moving liquefied natural gas from Africa provided attractively priced supplies

Jan 1, 1976

By Peter N. Yanker

The two types of dryers used in the drying of copper concentrates are the rotary dryer and the spray dryer. The rotary dryer has until recent history been the traditional drying method used, Although spray dryers have been used in the chemical field for many years it is only recently that they have been accepted for drying of copper concentrates. The comparison made here will apply in a narrower sense to the drying of copper concentrates as fed into the reverbatory furnaces of the Smelter. To compare a rotary dryer and a spray dryer, which are two totally different methods and pieces of equipment, it is best to view them as systems each made up of certain elements

Jan 1, 1976

By Yoshinori Iwasaki, Shosei Serata, Yutaka Mochida

A new comprehensive insitu instrumentation technique named this RCC Method has been developed for rapid assessment and improvement of the structural stability of underground openings. When applied to tunnel construction, the degree of present and prospective safety of underground openings can be determined in quantitative terms within 10 to 20 minutes of microcreep observation. When applied to mining, roofs and floors can be stabilized by controlling the stress conditions. This stress control method has eliminated the need for intensive roof bolting and extensive floor renewal in all cases where it was applied. Use of this technique is illustrated by field examples from the Seikan Undersea Tunnel of Japan and deep potash mining in Canada. NEW INSTRUMENTATION TECHNIQUE: THE RCC METHOD Failure problems in underground excavation usually arise in weak non-elastic grounds where conventional rock mechanics theories of elasticity are not only useless but also misleading. Presently, discontinuity planes in the ground are being considered a factor in assessing these failure problems, and while this development is interesting academically, it is not of much use in actual excavation work, where it is nearly impossible to identify and quantize all existing planes of discontinuity. Even if such an extraordinary task could be accomplished at an underground excavation site, effective use of the data would be difficult and impractical for rapid excavation work, with the possible exception of rare cases of ideally elastic ground.

Jan 1, 1976

By Robert Lundquist

REAM is a unique method of rock breaking using high energy projectile impact. This report-describes the most recent in a series of tests demonstrating mining applications for the REAM method. In an underground limestone mine at Greer, West Virginia, REAM was used to drive a short tunnel and drill a large diameter borehole. Along with breakage data from these tests the goal of the program was to examine environmental problems which might result from the use of cannons under-ground. A total of 103 shots was used to advance a 14-l/2-feet high by 10-feet-wide face a distance of 5-1/2 feet. It is estimated that the 9.3-pound-concrete projectiles launched at 5000 feet per second will break an average of 0.78 tons of limestone or 67 percent of the 1.125 tons of granodiorite broken in previous tests. The 9-inch-diameter borehole was drilled horizontally by repeated axial impact for 7 feet, 2-1/2 inches by 21 shots giving an average of 4.12 inches per shot. Scaling this result to compressible impact energy yields an estimated 5.8 inches per shot for a 12.8-inch-diameter hole compared to 8 inches per ~hot for a 16-inch-diameter hole in granodiorite. Noise measurements indicate that a silenced cannon can be used within a few hundred feet of mine personnel in a room and pillar mine within the legal limit of 140 dB impulse without additional protection. Some fume measurements were made with satisfactory results, even though the military propellants used produce much greater quantities of toxic fumes than the liquid propellant proposed for the future.

Jan 1, 1976

By E. I. Robinsky

"This paper describes a new, proven approach for tailing disposal. Not only is the disclosed system less damaging to the environment, it is also less costly to operate, to close down and maintain in perpetuity. The basic concept is to discharge thickened tailing from one permanent location.This creates a conical or hill-like deposit which:(1) requires lower perimeter dykes for equivalent storage capacity;(2) eliminates decant towers and decant lines;(3) requires no steep dams built of tailing;(4) is stable:(5) requires only a small pond outside the deposit;(6) decreases pollution of the surrounding environment by water seepage and deflation; and(7) simplifies abandonment and ""closing-down"" operations.The approach is made possible by the fact that, at a sufficiently high ratio of solids to water, tailing material can be made to accumulate at slopes of 5 or 6 per cent -- considerably steeper than possible by traditional methods using low solids-to-water ratios. To achieve the necessary solids-water ratio (35 to 60 per cent), it may be necessary to install a thickener. It is expected, however, that at many concentrators it may be possible to discharqe relatively clear plant water through a line separate from the tailing line, thus reducing the load on the thickener."

Jan 1, 1976

By Moto Goto

Onahama Smelter of Onahama Smelting & Refining Co., Ltd. has two green- charge reverberatory furnaces; the old furnace was constructed in 1965 and the new one in 1973. This paper discusses the use of oxygen-oil burners in a green-charge reverberatory furnace and also compares the copper loss in slag between the two furnaces at Onahama Smelter. During the past ten years of operation, no shutdowns of the old furnace were necessary and the smelting capacity was increased by 25% by the use of two oxygen-oil burners. These burners are suitable for a green-charge reverberatory furnace to in- crease the smelting capacity without causing an increase of the exhaust gas volume and refractory erosion. After two years of operation of the old furnace, a bottom build-up in the charging zone of approximately 50 centimeters was experienced, and this build-up has stayed at this level since then. In 1973, a new additional reverberatory furnace was put into operation. Copper content in slag of the new furnace was lower by approximately 0.15% than that of the old one during the first several months after the start-up. Investigations were then made on the effect of the bottom conditions in the charging zone on the copper content in slag.

Jan 1, 1976