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By R. J. Balfour, T. L. Papucciyan

"INTRODUCTIONCapital Cost considerations are basic to feasibility in the achievement of success for Mineral Processing Projects as much as or more than in many other industries. Capital cost is an important factor ae it 1R the unit of measurement for process engineering economic decisions. As a result of ever increasing complexity, alternatives of process and remoteness of site, there is an ever increasing emphasis on accurate estimating and the attendant cost control systems in the international market of today for the Mineral Industry where initial plant costs are becoming a more important factor than operating costs. An undervaluation means trouble ahead. An over-cautious assessment may bring an unnecessary abandonment of a project. Consequently, the ultimate cost must be predicted early and accurately and must be controlled to this parameter during the design and construction phases. Cost Est!~ mating is one of a variety of project management tools used to assist in planning and achieving the optimum balance between Quality, Cost and Time, the eternal triangle of evaluation, namely obtaining a project of acceptable quality at minimum cost and on time. In order to attain these established objectives, proper planning, organizing, coordinating, monitoring, adjusting and controlling the design, procurement and construction elements of the project are essential.This project management approach based upon the principle of a Task Force under single management, comprising a complete service organization, requires a substantial number of qualified individuals specialized in their own field and capable of working together as a team to perform their various functions effectively. The Task Force is supported by their chiefs of discipline and performs in accordance with established procedures and standards under the leadership of a Project Manager.General Engineering Company Limited with the backing of the full resources of Surveyer, Nenniger & Chenevert and its total staff of approximately 1,0009 offers the complete project management service to the Mineral Processing Industry of North America and the rest of the world. As mine sites become more remote and difficult of access, the need for an experienced team of specialists who work under the Task Force principle, with well established standards and procedures becomes even more important. Our long history of successful pro1ecta in this field has been our training ground for the fulfillment of this need."

Jan 1, 1972

By G. E. Rennick

An oil well penetrating the Pittsburgh bituminous coalbed in northern West Virginia was plugged and safely mined through 3 months later. A sensitive chemical tracer, introduced into the oil reservoir before the test, was not detected in the mine air following the plugging and during mining of the pillar and penetration of the well. Effectiveness of the plugging in preventing reservoir gas from entering the mine through the well hole was verified by continuous monitoring of the mine air for indications of sulfur hexafluoride, an inert gas detectable in amounts as minute as 1/2 part per billion. Expandable cement and fly ash-gel-water slurry were utilized to seal the well above and below the coal seam. Three other wells were also plugged using various techniques.

Jan 1, 1972

By Ralph D. Gift

This report describes a program of research to evaluate methanometry in coal mines. The program commenced by conducting an extensive state-of-the-art survey. Details of the survey are presented which includes a rating of various types of instruments that can be used to detect and record methane gas. Laboratory test data, on mine instruments tested are presented together with results from a computerized statistical analysts.

Jan 1, 1972

By B. C. Scott

Every year more and more mining companies are entering joint ventures to look for minerals. Large companies join large companies, small companies join small companies, and large companies join small companies. Mining companies join oil companies, chemical companies, machinery companies, and companies with no other connection to the minerals business. And well they might, for here is a way for both minerals-oriented companies and those that have no background or knowledge of the minerals business to get actively involved in an outwardly-attractive but high-risk enterprise with the chance to participate in a lucrative minerals find. Thus, for reasons beyond those normally associated with joint ventures in many other fields, corporations, companies, groups, and even individuals are looking to joint exploration ventures as the answer to all problems of getting into or staying in mining.

Jan 1, 1972

By C. F. Johnson

Nearly all of the sulphur produced in the world today is converted to sulphuric acid and 49 % is used in the manufacture of fertilizers. In the last few years we have seen the beginning of another chapter in the volatile history of sulphur as the severe shortage of 1963:-67 has been transformed into present-day surplus. Prospects for further aggravation of this situation in the years ahead seem assured. In 1970, western world production showed a rate of increase of 4 -5%, which 1S somewhat less than that of 8% for the period 1963-1967. The rate of growth of consumption dropped considerably in 1968 when the demands of the fertilizer industry fell. During the same period of time, wide-spread demands have been set in motion for a clean environment which indicates that a fundamental change in sulphur supply, demand, and even sources, is likely to result from this upheaval. The sale of sulphur by Poland to the western world has increased and for 1970 was estimated at over one million metric tons. In the next few years, increase in Canadian sulphur supply will stern from two sources;

Jan 1, 1972

By G. L. Fitzpatrick

Preliminary results of an experiment in seismic holography indicate that the techniques of acoustical holography may be successfully used with seismic waves to determine the size and general shape of underground objects. This experiment was carried out under field conditions on a moderately large scale compared with the typical laboratory experiments in acoustical holography. The object to be mapped was a 100-foot-diameter, spherical, low-velocity zone of explosively fractured rock in oil shale at an average depth of 80 feet. The seismic wavelength of the Fourier component wave used in making the seismic holograms was 50 feet at a frequency of 140 cps. The hologram sampling aperture was 226 feet square and was sampled by 441 geophones in a 21 by 21 rectangular array. One novel aspect of the experiment was the use of a wide-band polychromatic explosive source of seismic waves rather than a narrow-band quasi-monochromatic vibrator source. A successful laser reconstruction of the object image from a lensless Fourier-transform hologram in the form of a 5/l6-inch-square photographic transparency is illustrated. The size of the underground object measured from the laser reconstruction of the object and the size inferred from a knowledge of the amount of explosives used to fracture the site and the tensile strength of the oil shale are found to agree.

Jan 1, 1972

By Charles C. Boley

High-volatile A bituminous coal from the Allen mine, Las Animas County, Colo., blended with char produced from the same coal yielded accept-able metallurgical coke in a 500-lb movable-wall test oven. Nineteen experimental runs were carried out using several concentration levels of two different chars, 5.6 and 19.6 percent volatile matter, produced by entrainment carbonization of the base coal. With the higher-volatile char, an acceptable coke was produced at a 22.5-percent concentration; the lower-volatile char did not produce an acceptable coke at the concentrations investigated.

Jan 1, 1972

By Joseph M. Pugliese

This work was done by the Bureau of Mines to provide quarry operators with an uncomplicated, first-approximation method for designing blast patterns, considering geologic structure, and to show the valid use of the technique by comparing drill and blast pattern dimensions used in the quarry with those determined by the presented method. The author visited 12 limestone and dolomite quarries in Ohio (Adam, Crawford, and Highland Counties), Wisconsin (Milwaukee, Racine, and Waukesha Counties), and Minnesota (Fillmore, Olmsted, and Wabasha Counties); observed the blasting practices; studied the major geologic features; and after discussion with the quarry managers, foremen, and blasters, compared the quarry blasting patterns with those as calculated by the empirical formulas (after R. L. Ash), with geologic structural considerations. When geologic structure such as bedding, jointing, folding, and caves, as well as explosive properties and field performance characteristics are accounted for in a manner suggested by the research, the presented empirical formulas may be used as a good first approximation. The included steps in planning a blast design and generalized blast patterns should be of help to the quarry operator. Design changes are recommended for those quarries where problems are occurring.

Jan 1, 1972

By Harold L. Lovell

The areas of application, the limitations imposed by water chemistry as well as the advantages and disadvantages in the use of limestone for the treatment of coal mine drainage have recently been described by the authors (1),(2), (3). The process has been demonstrated in continuous, full-scale operation to yield a treated water meeting specifications established by the Pennsylvania Sanitary Water Board and containing excess alkalinity. Their final pH levels are usually less than seven, a condition which avoids consumption of excess neutralization reagents, but which occurs with lime-based processes and results from unwanted side reactions. Operating experience has been cited by Calhoun (4) using ferric waters while others (5), (6), (7), (8), (11), have reported on related research efforts. Despite the advantages including ?the relative simplicity, and minimal costs of the process, there have been very limited industrial applications of mine drainage neutralization with limestone. Although any treatment of these waters may be considered as a temporary control measure (9), the lack of feasible, immediate alternatives, the extensive magnitude. of the waters and the high cost of treatment requires that optimum processes should be utilized and that operating experience in their use be developed as is feasible. This paper will review treatment experience with a ferrous water of moderate pollution loading .

Jan 1, 1972

By D. W. R. Haysom

"I AM CONSCIOUS of the honour you pay me by having invited me to address you on the subject of the Rehabilitation of the Sydney Steel Corporation. The true architect of the revival and rehabilitation is Robert Burns Cameron. Because of the numerous myths which have grown up around what seems to be the miracle of the revival of the Sydney Steelworks, I propose to go back to the time when they came under the full control of the Province, on the 1st of January, 1968. Late in 1967, the decision was taken by Premier G. I. Smith to keep the Steel Plant running for at least another year, in an endeavour to see whether the enormous losses being sustained by Dosco could be reduced to a level which would permit their continuing operation. When that decision was taken, Dosco was to continue management until the 30th of April, 1968, and in the intervening period, the Provincial Government would seek management of the right calibre to ensure that an objective view of the Steelworks operations could be secured. By a combination of circumstances which can only be described as most felicitous, the man selected for the task was R. B. Cameron. He very quickly determined that to permit Dosco to continue management of the Steelworks until April 30 could only result in heavy losses to the Province and a consequent deterioration in the already critical financial position and a declining morale of the worke"

Jan 1, 1972

A study was made of zircon powders bonded with phosphoric acid or aluminium orthophosphate. The influence of strength of solution of the phosphatic binders on the modulus of rupture over a temperature range was investigated. Physical properties of three grades of zircon powder bonded with phosphatic binders were studied at various temperatures. Examination of x-ray diffraction data indicated that phosphates ofzirconia are preferentially formed to phosphates of silica. However, zircon in the presence of excess phosphoric acid also forms phosphates of silica upon heating.Resistance to attack by slags from blast and open hearth furnaces was determined on phosphate-bonded zircon mortars in a cup test with industrially made ladle bricks. Zircon powders bonded with phosphates proved to have high P.C.E. values. The first satisfactory results of a plant trial with phosphate-bonded zircon mortar, used in a steel ladle, are now being assessed in larger scale industrial tests prior to accepting the mortar as a steel plant refractory.

Jan 1, 1972

The morning session opened at 9:00 a.m. and was presided over by Mr. George A. Nugent, Manager Mining Division, Peter Kiewit Sons' Company, Sheridan, Wyoming. The first speaker was Mr. Jack Huebler, Vice President Research, Institute of Gas Technology, Chicago, Illinois. Mr. Huebler joined IGT in 1961 as Director of IGT's contract research program, a major part of which is IGT's extensive coal gasification work. He is also an adjunct associate professor at Illinois Institute of Technology, teaching gas utilization. Before joining IGT, Mr. Huebler spent 20 years with Surface Combustion Corporation where he was chief research engineer. He developed, designed, and constructed a wide variety of heat processing equipment and the associated chemical processes and was involved in applied research in heat treating, gas chemistry, and gas-solids reactions. He has carried out extensive research on the heat treating of ferrous metals, oil gasification and gas combustion, and has made major contributions to the development, construction, and operation of large-scale industrial furnace equipment. He received B.S. degrees in 10th chemical engineering and mathematics from the University of Michigan in 1941. He has 60 publications including 15 patents. He is also a world traveler in the field of engineering. Mr. Huebler's subject "Gasification of Western Coals." (See Index for printed text of Mr. Huebler's paper.)

Jan 1, 1972

By Stephen Krickovic

A degasification experiment was conducted in a Pocahontas No. 3 coalbed mine in Virginia. It involved (1) drilling holes in the coalbed in the out-side headings of a set of five being developed in virgin area, and (2) con-ducting a methane emission rate study as mining progressed and additional holes were drilled. Degasification from all drill holes except the longest in each of the outside headings and the first three drilled (excluding the in-situ pressure hole), was erratic and inconsequential in methane emission rates. The two longest holes liberated 66 and 79 cfm of methane, which is significant for the coalbed, but such quantity lasted a relatively short time; the first three were uniform but low in methane emission.

Jan 1, 1972

By George A. Savanick

The objective of this research is to develop a method for measuring the tensile strength at the interface between minerals in rock. These measurements reflect the strength of the attractive forces operating at crystalline interfaces in rock. Since these forces act in opposition to the forces set up in various rock fragmentation processes, measuring their strength may help in designing more efficient methods of rock fragmentation. The method developed for measuring the strength of intergranular adhesion in rock involves separating a bicrystal from the rock and determining the tensile strength at its solid-solid interface. This technique has been successfully applied to the study of quartz-feldspar interfaces separated from massive pegmatites, graphic granite, and the Rockville granite, yielding average tensile strengths of 5.86, 8.62, and 10.65 meganewtons per meter squared (MN/m2) (850, 1,250, and 1,524 psi, respectively). The data this technique provides indicate that the members of these bicrystals are strongly adherent. Examirtation of bicrystals broken at the crystalline interfaces indicates that the bonds responsible for this adhesion operate over only a portion of the interfacial area. This work conclusively demonstrates that tensile strength tests can be conducted on small selected areas; for example, grain boundaries in rock. The small-scale zones of strength or weakness determined in this way can be related to the overall strength of the rock.

Jan 1, 1972

By I. D. Shah

Thermal decomposition of copper (II) sulfate (CUS04) and copper (II) oxy-sulfate (CuO?CUS04) are important steps in the overall oxidative roasting of covellite (CuS) and chalcocite (Cu2S). Nonisothermal thermogravimetric techniques were used to investigate the decomposition reactions in flowing Na and air. Thermal decomposition of CUS04 and CuO?CUS04 followed "linear" kinetics with an apparent activation energy of 55±2 and 66±3 kcal per mole decomposed, respectively. These apparent activation energies comply with those previously reported when isothermal kinetic techniques were used. The addition of oxygen decreased the rate of decomposition, while small amounts of iron which were admixed with CuO?CUS04 did not have a significant effect. Neither oxygen nor iron had any appreciable effect on the apparent activation energy of the decomposition reaction.

Jan 1, 1972

By B. C. Morrison

Because of U.S. Forest Service regulations and the consequent cost of leaving several diamond drill holes open at the same time, it was necessary to develop an electrical method that could be used in one hole at a time to extend known mineralization. This was achieved by balancing the surface current electrodes so that the two potential electrodes in the hole being surveyed were in the same equipotential surface. This condition eliminated stratigraphic response but enhanced any asymmetry due to ore between the hole and either current electrode. This method was successfully used in mineralized holes at West Fork, Reynolds County, Mo., to show the direction in which to extend the drilling into areas of better mineralization.

Jan 1, 1972

By John A. Teeter

"A SHORT WHILE AGO I enquired about The Mining Society of Nova Scotia. In all honesty I was apprehensive about addressing such a body if it was highly geared to the technical aspects of discovering and obtaining mineral resources. I was told that this would not be the case. Rather, there would likely be in attendance a broad cross section of people from business, industry and government and from across Canada and the U.S.A. Thus there would be an interest in a free-wheeling discussion of the prospects for industrial development in Cape Breton. Accordingly - being one who hates to miss an opportunity - I intend to exploit the invitation of your executive by being, over the next short while, frankly promotional. I would like to talk about what I consider to be some of the most important attributes of Cape Breton for industrial development and identify some of those prospects. Secondly, I will quickly review some of the things the Cape Breton Development Corporation is doing these days to stimulate some of that industrial development."

Jan 1, 1972

By M. A. Sochocky

Rod mills were developed, as a logical substitute for the rolls crusher when larger tonnages had to be handled, on a continuous basis. Today, with even larger tonnages to process, the trend is to install larger equipment, automate the plant and develop the highest availability possible, in order to cut costs. The rod mills, because of design limitations in size and speed 1'2, are not able to meet these new requirements. The autogenous mill was a timely development and serves as an excellent alternative for ores that are suitable to this type of grinding. When ores are not amenable to autogenous grinding, selection of a flowsheet is dictated by liberation characteristics and unit operations to be used for mineral recovery.. The following alternatives are available: (a) Multiple rod mills, capable of drawing no more than 2000 HP each, followed by ball mills. (b) Gyradisc crusher followed by two stages of ball mill grinding.3 (c) Tertiary crushing followed by closed circuit single stage ball mills grinding to approximately -100 mesh, as in the copper industry. (d) Tertiary' crushing followed by two-stage, ball milling. Each stage will operate in closed circuit with either screens or cyclones. It is this last alternative, particularly as it

Jan 1, 1972

By M. C. Irani, Maurice Deul, M. G. Zabetakis, T. G. Bobick

This survey was conducted to determine the magnitude of the methane emission and control problem in U.S. bituminous coal mines. The resultant data indicate that the emission rate for any given coalbed depends primarily on the coal production rate and on mine depth, as well as on the nature of the coalbed and the surrounding strata. An excellent correlation was found between (1) the methane emission rate and (2) the product of coal production rate and mine depth for the mines in the Pittsburgh, Pocahontas Nos. 3 and 4, and the Illinois Nos. 5 and 6 coalbeds. The highest total emission rates found in U.S. bituminous coal mines were as follows, in million cubic feet per day: Monongalia County, W. Va., 39; Marion County, W. Va., 30.4; McDowell County, W. Va., 13.1; Washington County, Pa., 11.9; Greene County, Pa., 11.4; Buchanan County, Va., 21.6; Jefferson County, Ala., 10.3; and Franklin County, Ill., 6.6.

Jan 1, 1972

By R. R. Faddick

A mineral slurry data hank has been compiled, containing slurry pipelining data on sixteen ores, concentrates, and tailings. The data bank it in the form of a computer print-out all they necessary system constants and headloss data for each mineral commodity. The purpose of the data bank was to assist in the development of a universal head loss correlation for mineral slurries, if such a thing exists. Present headloss correlations were tested and found to be inconsistent for the various mineral slurries. Consequently, a different approach was taken, that of compiling a library or Stanton diagrams relating friction factor and Reynolds numbers for a given slurry in a given pipe diameter. The advantages of the diagrams arc demonstrated and discussed. While this correlation shows excellent potential, it is necessary that additional work, both theoretical and experimental, be performed. In addition, two equations are given from which a design velocity may be obtained to minimize deposition or formation of bedload. The equations are based on data taken from the mineral slurry data bank.

Jan 1, 1972