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By J. J. Harrington

The pH control system at Kennecott Copper Corporation's Nevada Mines Division concentrator consists of two independent systems, lime dilution and lime addition. Lime dilution is accomplished in a mixing tank where slaked lime and water are introduced proportionately. The desired dilution of the milk of lime is determined by the electrical inputs provided by eight pH probes, one per grinding section. The inputs are averaged and applied to a time base generator. The summation output of the time base generator determines the proportion of lime and water that are to be mixed and applies this input to a voltage sensitive switching device. The switching device provides a signal to one of two relays which will add either slaked lime or water, dependent upon the summation output. The entire cycle is based on a two-minute repetition rate to allow for sufficient mix time. Responsivity is controlled by maintaining a limited maxi- mum solution level in the mix tank. Lime addition is controlled independently within each grinding section. The electrical input from the pH probe in a given section controls the solenoid valves which provide lime to each of the ball mills. The valves remain open within a time range capable of maintaining the pH of flotation feed at a given set point.

Jan 1, 1975

By A. J. MacKellar

The economic viability of any project is generally assessed on an evaluation of the total capital constructed costs along with operating costs, owner's costs and market conditions. This paper will be directed to the role that Cost Engineering plays in the development of the capital costs and the cost control techniques applied thereto.

Jan 1, 1975

By Thomas A. Simpson

Heretofore, underground coal mines in Alabama have operated under only 60 to 360 meters of cover: however, new mines (at least 5 in the early opening or development stages) will be operating under cover ranging from 600 to 660 meters. With increased rock confining pressures, roof stability problems will become more critical. Initial studies in two 7 ½ -minute quadrangle areas in the Warrior coal basin of Alabama indicate that the orientation of certain lineament and fracture-trace modes mapped from ERTS-1 (Earth Resources Technology Satellite) imagery correlate closely with the strike of joint and fault modes. High altitude (118,000 m) U-2 aircraft data were used to support these findings. In addition, over 50 percent of the normal faults mapped in the study area could be directly correlated with ERTS and U-2 lineaments and fracture traces. These correlations provide clues to the structural development of the Warrior coal basin and may, in turn, be used as a guide to the prediction of roof-stability conditions in advance of mining.

Jan 1, 1975

By R. E. Pennington

My subject this morning is coal liquefaction technology. Actually, coal liquefaction involves a number of technologies in a very complex system. The first slide shows the major components of such a system with arrows to indicate appropriate flows. The components are the facilities for coal feed preparation and handling; the coal hydrogenation or base liquefaction section; facilities for product separation and recovery, and in addition, facilities for the production of hydrogen from coal-based sources. A very rough break- out of the investments involved in these areas is given at the bottom of the slide. Investment is spread about equally among the three areas of operations Another way of looking at it is that the investments in what might be called support facilities are of the same magnitude as the base investment in the hydrogen facilities. Therefore, it is appropriate in a discussion of coal liquefaction technology to treat it as a system composed of a number of technologies. The next slide lists the various functions in the feed preparation section along with an indication of technology status. Storage, crushing, grinding, drying of coal all have been in commercial practice for a number of years. The slurrying and pumping of coal at least in water slurries, is practiced commercially also. The heating of coal slurries in oil to high temperatures under pressure is not in commercial practice and development and testing is going on by a number of people in this area. Some rather complex phenomena occur when coal oil slurries are heated to high temperatures.

Jan 1, 1975

By J. C. Fowler

[This i.untra t hds bmii III c'IIILt fur till- past 1':?:u yrlr;, Till-- wurir pnrfor rw:it '. ,JS hlui.rn dawn Ilttf lit Iu i eel i ih?IS( S. 1 hesrt aIII, Phase I Candor tlri I a lest It) donurnSlrale SeiSrrlir nurihudS to hu USi!d lot ttlr? rti?tei thin and Iu" ainnl ul trapped rrlinc:rs hitting (-)it the roof with a harnrner, Phase I' Design and cunStrur.t a permanent Seismic monitor System to rrlunrtur roof (ails arm r:xploslun', III ,r 'Vol king mine. Phase III - Ire dII an an i i irr for sVstl rtl Ii i`'Smltur air quality in till, niitii iiH II ? ir,iti tin; niln !III ;I I ,, i; Phase I V - Conduct 11(21 d tests of the seismic IT IUnit UT ieq system fur a period nl two 11IUIIIIIS. Phase, V - Condirct three test periods of the seismic system over a period of six mimilis. Detailed reports covering the wurk. done in Phases I, 11, and IV have been i : . r tr I - i t report will, therefore, cuni.entrate on the work perfurmed in Phases III anti V.]

Jan 1, 1975

By Peter D. Lohn

The Bureau of Mines conducted both laboratory and field investigations to study the effectiveness of medium-pressure (up to 30,000 psi) water jets in controlling the generation of airborne respirable dust during the hydraulic fragmentation of coal. Laboratory studies were conducted at the Farmington High Energy Test Site of the Twin Cities Mining Research Center, and field studies were carried out at the Humphrey No. 7 mine, Mount Morris, Pa., in the Pittsburgh coalbed. The water jets were produced by commercially available triplex pumps. The dust samples were collected by midget impinger samplers, and analyzed by electronic and optical counting techniques. Respirable dust concentration for a full-scale production model was projected at below 2 mg/m3, the maximum exposure allowed by the Federal Coal Mine Health and Safety Act of 1969.

Jan 1, 1975

By Roger G. Long

This final report reviews installation, maintenance and inspection of mine pager telephone installations. A Technical Handbook was developed and distributed. Certain commercial telephone test equipment was modified and a tone source and switching circuit were developed for use in the testing of mine pager phone systems. Descriptions are included of the modifications to a commercial test set and of a tone source/ switching unit.

Jan 1, 1975

By R. D. Lord

This paper deals with the search for the best practical means of storing sulphide bearing tailings, where there is no residual excess of carbonate material. It is the common experience that the sulphide content decomposes, with the aid of bacterial action, and the resulting sulphuric acid escapes, along with any heavy metal solutes, through embankments that are usually porous to some degree. The problem is typified in the tailings of the uranium operations of Elliot Lake, Ontario, where mining started some 20 years ago. The approach to tailings disposal paralleled the practice for other hydrometallurgical plants treating gold and base metal ores. Impoundment areas were designed to retain solids, and a clear and neutral overflow was considered satisfactory practice. Now experience has shown that these areas, some idle for over a dozen years, release acids, in seepage and overflows, to an unacceptable degree. To protect natural water courses neutralizing plants are operated wherever required. Lime slurry is fed continuously into the tailings outflows in a quantity sufficient to raise the pH to 8.5 and precipitate heavy metals that may be in solution. The objection to this procedure is that the plants will require servicing indefinitely, unless a better remedy is found.

Jan 1, 1975

By Franklin H. Persse

To meet escalating energy requirements, substantial increases in production from the strippable coal and lignite deposits in eastern Montana, western North Dakota, and northeastern Wyoming already have occurred, and further expansions are expected at least until the year 2000. Such production, attributable largely to rising demand for low-sulfur coal, must be accomplished with a minimum of adverse effects on the environment. Information on geology, climate, and current land use in the Upper Missouri River basin is presented in the Bureau of Mines review as a guideline to what operators may expect during and after mining. Proven methods of protecting the air and water from pollution and of restoring mined land for other uses are described, and untried methods of land reclamation, some with equipment yet to be manufactured, are discussed as possible means of maintaining aesthetic values in the basin. Costs incurred to protect the environment are part of the production cost and thus are borne by the ultimate consumer. Unit production costs are less for the thick coal and lignite deposits of the basin than for the thinner but higher Btu coal deposits of the Eastern and Midwestern United States. Precise comparisons of environmental protection costs between mines in such disparate areas cannot be made, because of differences in physical conditions, accounting procedures, and other variables.

Jan 1, 1975

A comparison is made between elementary block estimation techniques and the optimal methods of geostatistics using data from an Australian deposit. Considerable improvement in the estimates are obtained by using the optimal technique in this case.

Jan 1, 1975

By Iain Weir-Jones

The efficient operation of an open pit mine presupposes that the slopes are maintained at an angle which closely approaches that of the ultimate stability of the slope. In order to do this in a safe manner, it is essential that the data relating to the behavior of the slopes be monitored and made available, through an instrumentation system, to the appropriate personnel so that soundly-based engineering decisions may be reached with the minimum of wasted effort. In addition to simply detecting potential failures, the system should also define what type of failure is developing; i.e., rotational, wedge, or dilational failures. Providing this data is the prime function of a stability monitoring system. Therefore, in an operating open pit mine, the instrumentation system must provide information which will have a direct bearing upon both the safety and the economics of the operation, as well as provide data which is pertinent to initial design, or to the re-design of slopes where developing instability is found to be a problem.6 It is possible to excavate pit slopes which will remain stable under extremely adverse conditions; however, such slopes would usually be so flat that they would tend to render the operation of a pit uneconomical which might otherwise be mined at a profit. On this basis, all practical pit slopes must be considered to be, to some ex- tent, unstable; if they are not, the design is too conservative and the mine is not returning its maximum profit. To reduce the problem to its fundamentals, one can simply state that the ideal pit slope design produces a slope which stands with zero maintenance for the entire life of the pit and then collapses into the final excavation as soon as the personnel and equipment have been removed. Such a design is impossible to achieve, but the fact remains that an efficient slope would hover on the edge of failure for the life of I the pit. As one retreats from this position, the profitability of the mine decreases because of an unduly conservative design.

Jan 1, 1975

By Robert D. Saltsman

Two modes of seal application were identified, and promising state-of-the-art seals of both types -shaft and drum -were selected for initial rating by non-destructive testing. Only one shaft seal survived the initial test, and a search was made for other candidate seals including new seals. One new type of seal was found that gave promising enough operation, as both a shaft and drum seal, to be recommended for installation in prototype wet-head machines.

Jan 1, 1975

The patterns of occupational health pro- grammes in mining and metallurgy are discussed in relation to the impact of chemical and phy- sical hazards on the health of workers in these fields. Mining and metallurgy are quite unique in that their history and practice embrace virtually the total spectrum of occupational health problems and hazards as understood today. A panoramic concept of the possibilities would comprise the following fields: 1. The Pneumoconioses or Dust Diseases. 2. Physical stress due to exertion, and exposure to heat and humidity in deep mines. 3. The toxic effects of various metals in the mining of ore. The most obvious are lead, mercury, arsenic and manganese. 4. Diseases associated with mining. These include leptospirosis, ankylostomiasis and mycotic infections of the skin. 5. The Beat Diseases of coal miners working in narrow seams. 6. Illumination problems and miners nystagmus. 7. Geographical and climatic problems

Jan 1, 1975

By Thomas F. Torries, George H. K. Schenck

Crushed and broken stone is used directly in construction as an aggregate and accounts for about half the value and two-fifths of the quantity of natural aggregates consumed in the United States. Sand and gravel provide most of the balance of aggregates except for some lightweight materials such as pumice and expanded shale. Conditions necessary for production of crushed stone from a deposit are : 1) Quality-should pass rigid specifications for strength and durability. 2) Cost-low average total delivered cost. Construction aggregates are hard, essentially inert materials suitable for being formed into a stable mass either (1) by the addition of cementing or binding materials that produce a concrete or (2) by compaction or by natural weight to produce a road base or foundation. Aggregates usually provide about 80 to 100% of the material volume of the construction masses in which they are used. The construction industry utilizes as aggregates about 70% of all crushed stone produced in the United States according to statistics provided by the U.S. Bureau of Mines (USBM) , [Table 1], using definitions as shown below. Nonconstruction uses of crushed stone, [Table 2], are included elsewhere in Industrial Minerals and Rocks because such uses require the special physical or chemical characteristics which are discussed in those chapters.

Jan 1, 1975

By Henry P. Van Ormer

This paper discusses some basic fundamentals in compressed air system design and layouts that should always be considered in planning or evaluating a compressed air distribution system in Construction and Mining. Often times, mining operations use central air or "power house" type systems that more closely resemble a typical industrial or plant compressed air distribution system. This paper does not attempt to cover this type of system.

Jan 1, 1975

By James F. McConnell

Federal and State sulfur oxide emission and ambient air quality regulations have been implemented to fulfill the requirements of the Federal Clean Air Act Amendments of 1970. Primary and secondary air quality standards have been established at levels considered necessary to assure the protection of the health and welfare of the public. Standards of performance under this Act have been established to control the rate of sulfur oxide emissions from individual sources so as to protect and to improve the quality of the Nation's air. The new source standards of performance were made rigorous for large coal burning stationary sources. This has had a severe impact on the electric utilities that operate the coal fired steam electric plants which are the largest consumers of the Nation's coal production. States have taken different approaches in State Implementation Plans (SIPS) as approved by the Federal Environmental Protection Agency. Some states, such as Pennsylvania, have chosen to permit moderate SO2 emission rates from existing sources which are not in critical air basins. All are required to meet primary and secondary air quality standards and to limit sulfur oxide emissions from new large stationary sources to a minimum of 1.2 LBS of S02/MMBTU fired. This re- quires a fuel sulfur percentage of about 0.7 for a 12,000 BTU/lb coal. In an effort to develop strategies and technologies to conform to performance standards while continuing and hopefully expanding the utilization of the Nation's coal supply, the electric utilities, the Federal and State regulatory agencies, and other industries and government agencies are considering several alternatives. 1. Natural low sulfur coal 2. Flue gas desulfurization - (FGD) non-regenerative and regenerative 3. Coal gasification 4. Liquefaction and solvent refined coal 5. Fluidized bed combustion 6. Chemical coal cleaning 7. Physical coal cleaning Of these options, only the first and the last can be considered to be widely used in full commercial practice at this time. FGD has certainly demonstrated technical and operating feasibility and is close to being in full commercial practice but it remains to be seen if the large systems under construction are economically and environmentally optimum.

Jan 1, 1975

By Thomas V. Falkie

Of the various critics of federal energy and minerals policy we are hearing these days--and they are legion--few make their points more vividly than our fellow SME member and eloquent spokesman for the mineral industry. Mr. Eugene Guccione. In a moment of comparative mellowness. Mr. Guccione recently characterized Washington's time-honored legislative and bureaucratic machinery as a case of "...scientific illiterates asking the incompetents to do the unnecessary." I hope the prevailing industry view of government is not quite that harsh, and yet one cannot deny that government intervention is indeed pressing in on the mineral industry with increasing force. What is happening today in Washington and in state capitols will have enormous impact--both short and long term--on the future of coal and mineral production in the United States. Symptoms of this trend are everywhere. In the first place, there is a sentiment, widely held and still spreading, that the government must become involved-- that no matter what the problem, the solution lies in more government intervention. Free enterprise versus statist, reflex reaction organizations. When it cones to regulation in the resource field, there is too often a tendency to start out by assuming guilt on the part of the mineral industry. This can lead to laws governing mineral recovery that are more punitive than constructive...laws drawn up with little research into the scientific or economic considerations involved.

Jan 1, 1975

By R. V. Ramani, C. B. Manula, A. Owili-Eger

ANALYTICAL PRESSURE - VOLUME COMPUTATIONS FOR THE MINE PROTOTYPE A new coal mine is projected, with entrance by slope 1,500 feet long. Nine main entries will be standard for development, five as intake and four as return. One return shaft is planned near the slope bottom, and an intake shaft and portal are planned 5,000 feet north of the slope bottom. The slope will have an area of 150 square feet and a perimeter of 55 feet. A belt and supply track will be within the slope. The return shaft will be circular with a diameter of 18 feet and will be 500 feet deep with an escapeway. Two hundred feet of the shaft and 500 feet of the slope will be concrete lined. Select the fan to operate five units per shift and drive the 5,000 feet to a proposed new portal, using the slope for an intake. Two main splits are planned with the maximum of three units on any split. The amount of air desired at each unit is 25,000 c.f.m; a shop at the slope bottom will require 10,000 c.f.m. In the solution of this or any similar problem, the first step is to determine the resistance factors. CALCULATION OF R FACTORS Slope area = 150 sq. ft.; Perimeter = 55 feet; Length = 1,500 feet. The friction factor K must be established. Five hundred feet of the slope is smooth lined, moderately obstructed by belt; K = 35. The remaining 1000 feet is in sedimentary rock and moderately obstructed; K = 85.

Jan 1, 1975

By Ellis WK, Greenwood-Smith R

A nuclear technique for the analysis of copper in bulk materials has been developed and successfully field tested at Mount Isa Mines Limited. The technique utilises the gamma-ray resonance scattering process. A bulk analyser based on this technique gives a rapid and accurate measurement of the percentage by weight of copper or nickel aver- aged over a large mass of sample, typically 20 kg. The only sample preparation required for accurate analysis is crushing to -2.5 cm. At Mount Isa over 100 mineral samples covering a wide range of rock types and copper contents were analysed. Bulk analyser assays and chemical laboratory assays agreed closely for underground pillar-extraction and geolog- ical chip samples, conveyor belt samples, and finely ground samples from the ore concentrator. For the concentrator samples, the root mean square deviation between bulk analyser and chem- ical laboratory assays was 0.06 wt.% copper. The chemical assay errors for these samples were about 0.06 wt.%

Jan 1, 1975

By James W. Jensen, Aarne Visnapuu

Experimental modifications have been made by the Bureau of Mines on standard pneumatic rock drills to reduce the noise of the air exhaust, drill steel resonance noise, and noise radiated by the drill body. A close-fitting case and muffler around the drill body, consisting of a metallic honeycomb skeleton filled with viscoelastic absorber on the inside and a durable outer shell, provide both exhaust and drill body noise muff ling and absorption. Drill steel resonance noise is reduced by a constrained-layer treatment consisting of a tubular metal cover bonded to the ouside of the sod by a viscoelastic filler. Damping alloy components have been developed to reduce metallic resonance noise. Combined, these modifications have reduced the drilling noise level in granite from 115 dbA to 97 dbA. Data are presented on the individual and combined effects of these modifications on drilling noise and performance.

Jan 1, 1975