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By Nickelsen J, Theisen KG, Hansen PH

The use of stationary calciners in the processing of aluminium hydroxide has emphas- ized the importance of Bayer hydrate properties with respect to particle breakdown during calcination and subsequent treatment. Test results from calcination of several Bayer hydrates to sandy alumina in the FLS Gas Suspension Calciner (GSC) were obtained in a 250 kg/h pilot plant unit. Particle breakdown during calcination was influenced by content of solid sodium oxalate, trapped in the hydrate particles and operating gas velocities. Owing to the design and operational principles of the GSC it is possible to reduce particle breakdown to at least the same as what is found in long rotary kilns. Other major advantages reviewed are obtained through simplifications in plant design and operation, pointing to low specific power and heat consumption, and generally low production costs, thereby providing an attractive alternative to fluid-bed calciners.

Jan 1, 1981

By F. Weinberg

"The recent development of the continuous casting process for steel has required basic understanding in a number of areas in the metallurgcal sciences. In some areas, information is still lacking. The success of the application of basic knowledge and research to the process is evidenced by the fact that a large percentage of the steel now produced in the world is produced by continuous casting.A number of areas in which metallurgical science has contributed and is currently contributing to better design and control of the continuous casting process and leading to a better quality product will be considered. These include:(a) heat transfer studies of the entire casting process;(b) fluid flow in the tundish, strand and liquid metal stream;(c) solidification structure and segregation;(d) strength and ductility of steel at high temperatures related to bulging and cracking; and(e) problems related to horizontal casting developments.IntroductionThe continuous casting of steel is a relatively new technology in steelmaking. It is now used extensively throughout the industry. In Japan, for example, continuous casting accounts for approximately 40010 of steel production, and this value is expected to increase to over 50% in the near future . New steel plants are now designed to use continuous casting exclusively. This means the process must work well and be completely reliable, because all the steel produced must go through the caster.The development of the continuous casting process in a short period of time has required concerted research and development in many areas . I shall cite a number of examples of these developments and refer to work done in Canada when applicable. No attempt will be made to review all of the research in continuous casting, nor refer to all of the workers in the field.The developments in continuous casting are based in many cases on metallurgical science, as described below. The use of metallurgical science in these developments is qualitative, in that concepts and idea s are used, as opposed to quantitative values calculated from fundamental equations. In general, most metallurgical problems are too complicated to enable fundamental equations to be used without the introduction of uncertain approximations and boundary conditions in the calculations.Starting at the beginning of the steelmaking process, very extensive research and development has been carried out to produce liquid steel of the required composition and temperature. The replacement of open hearth furnaces with BOF furnaces reduced refining time from many hours to roughly 30 minutes for 250 tons of steel. Two BOF furnaces effectively enable a continuous flow of steel to be available in a plant, essential for the introduction of the continuous casting process. This area of research will not be considered here."

Jan 1, 1981

By A. C. Lyons

The presentation describes the history, preliminary report, site investigation, including examination of old records, design of tunnel including choice of levels, alternative linings and working sites, the preliminary contract involving shaft sinking on the site of the Tower Block; design modifications, the main contract, including shaft sinking, ground treatment, compressed air installation, machine tunnelling, tunnelling enlargements for chambers, waterproofing and equipment.

Jan 1, 1981

By W. L. Chen

The Batac jig was first introduced in the US for fine coal cleaning in 1973 (Tackett, 1977; Hake, 1976). Since then, a total of six such jigs of various sizes have been installed in five US plants for a total capacity of 2346 t/h. The raw coal size ranges from 19 mm x 0 to 9.5 mm x 0-fraction sizes previously fed to heavy medium cyclones, Deister tables, or water only cyclones. Growing interest in the Batac jig as a replacement for the above equipment is due to the following reasons: • Unlike heavy medium cyclones, no magnetite is required. As a result, the operating cost of the plant is reduced. • The compactness of equipment is unique on a unit ton per hour basis as compared to other equipment. • Solid state electronic control of jig stroke length, frequency, and jig bed depth makes the equipment highly efficient. Installations of Batac jigs in the US as of June 1980 are shown in [Table 1]. Use of the Batac jig is even greater outside the US (Anonymous, 1980; Chen, 1980). Its use is not limited to fine coal but is applied to coarse coal as well, with 102 mm size in the feed (Zimmerman, 1975). In countries where consumption of magnetite associated with the heavy medium system of coal cleaning is considered a waste of iron ore resource, the Batac jig is regarded as the primary choice in the selection of cleaning equipment (Chen, 1980).

Jan 1, 1981

By Peter G. Dunn

Geologic studies during development at Copper Flat were directed at acquiring the information necessary in evaluating a low-grade porphyry copper deposit. In addition to the geologic mapping and core-logging of a typical exploration project, these studies included the following : (1) careful checks on the sampling and assaying (2) selection of representative samples used to establish the recoverable amounts of precious metals in the ore (3) examination of underground workings driven to provide samples both for metallurgical testing and for assay comparisons (4) evaluation of plant site and waste dump areas as non-mineral, including a placer examination of the taillngs disposal area (5) location of an adequate water supply. All these investigations were carefully documented to provide the necessary data both for the engineering design and, more importantly, for the feasibility studies required for successfully financing the project.

Jan 1, 1981

By H. Dr. Boldt, J. Dr. Henneke

PREFACE In German coal mines the application of tunnel boring machines has become a very effective and economic technique for major development works. After initial trials around 1970 the breakthrough was reached by driving 13 km of road ways on Rheinland and Friedrich Heinrich collieries, using a DEMAG tunnel boring machine of 6 m diameter. INTRODUCTION The coal mines of Rheinland and Friedrich Heinrich are to be found in the West of the Ruhr Area, the largest coal mining area in the Federal Republic of Germany (Table 1). They form part of the Ruhrkohle company. Rheinland coal mines produces 41000 to 43000 t of run-of-mine coal every day, of which 20500 t are usable coal. Friedrich Heinrich has a daily production of 17000 t of run-of-mine coal, 9000 t of which are usable. The coal is worked at depths of 600 to 1100 m in seams 0.6 to 3.0 m thick. The method of mining is longwall, and the machines used are ploughs and shearer loaders. From 1973 to 1980 a programme was put into operation in these two mines to develop and open up the coal field on the 885 m level. A total tunnel length of 20 km was to be driven. After thorough investigations it was decided to employ a full-face tunnel boring machine for

Jan 1, 1981

By Massy-Greene RB

Limited recourse financing techniques reduce the financial exposure of equity holders to major mining projects by transfering some of the risks to the banks which provide loan funds for project development. This can only be achieved by a clear understanding of the principles involved. Engineering and management decisions on how the resource is to be developed and extracted must be made in the light of lender's requirements. The structure of sales contracts, joint venture agreements and many other documents can be important in limited recourse financing. If projections show that the debt can be repaid from project cash flow, loan agreements and other arrangements can restrict lenders ability to look to the equity holders for repayment of project loans.

Jan 1, 1981

By John W. Tieman

Coal is a term applied to vegetable matter (trees, grasses, etc.) which was subjected to heat and pressure through geologic ages. This resulted in a change in both the physical and chemical properties. Because its chemical composition is variable, geologists classify coal as a heterogeneous mineral rather than a homogeneous mineral. Peat represents the initial, unconsolidated stage in the development of coal. This coalification continues with time and the application of temperature and pressure to lignite, subbituminous, bituminous, and anthracite toward the theoretical graphite end member. PHYSICAL PROPERTIES OF COAL The physical properties are concerned with the characteristics of coal in its natural state, or prior to its end use as a fuel. For example, the hardness and grindability of coal determine the maintenance cost for coal mining, handling, and pulverizing equipment; the specific gravity of coal and its associated minerals determines the coal preparation technique used in a cleaning plant as well as the capacity of coal bins, boats and size of cargo, and other coal storage facilities. The physical properties are, of course, dependent on the chemical constituents of coal, and all properties are interrelated. Specific Gravity The specific gravity (sp gr) of a solid is the ratio of the weight of a cubic foot of the solid to the weight of a cubic foot of water. The specific gravity of pure coal has been reported to range between 1.23 to 1.72 and increases with the change in rank from lignite to anthracite. This means that it is 1.23 to 1.72 times heavier than water.

Jan 1, 1981

By John C. Draper

The principal object of an underground coal mine transportation system is to move coal from the face where it is produced to the outside of the mine where it is prepared for market. In addition to the movement of coal, a transportation system must also move supply materials to the inside; it must move men in and out of the mine; and it must move rock and other debris out of the mine for disposal. Usually, mine haulage is divided into three categories named for the various areas of the mine served : 1) Face Haulage. This is used at face from the mining machine to the intermediate transport system. 2) Intermediate or Secondary Haulage. Generally this is used between face haulage and main haulage. Sometimes this is merely an extension of the main haulage. 3) Main Haulage. This extends from the secondary haulage to the outside and is usually either a track or conveyor system, sometimes a combination of both. Transportation modes of coal in the various areas pose different problems, but the whole system must be synchronized. For instance, at the face the coal should be removed quickly from the various places to facilitate the movement of machines, whereas the intermediate system just passes the same coal on to the main transportation system. Selection of the transportation system must be based on the seam height, mining methods used to extract the coal, capacity required, ease of coal handling, and haulage efficiency. When driving rooms, mine cars can be used. They often simplify supply haulage and rock handling because they can also handle these items. Conveyors could be used and would have a greater haulage capacity but they cannot handle supplies easily or segregate the rock. When using a different mining method, such as longwall, mine cars cannot be used because there is not sufficient space to move the cars at the face nor can the cars haul the coal without delays which would cause excessive losses in production. As for ease of handling

Jan 1, 1981

By William R. Beloff, Franklin M. Grynkewicz, Puza

Construction of the MBTA Red Line Extension through Somerville, MA, called for driving twin tube tunnels through a zone of approximately 83m (273 ft) with mixed face conditions. While the majority of the tunnels were driven through competent hard rock using drill and blast techniques, the mixed face zone was advanced using floating crown bars for primary support. The overburden consisted of medium clay, underlain by water bearing glacial till, over a sloping bedrock surface. Due to the unusual nature of the construction techniques, a program was undertaken by the Contractor to monitor ground movement and stresses in the temporary steel supports. This paper presents a description of the instrumentation employed, as well as the measured ground movements and support stresses. Additionally, the tunneling techniques are briefly presented and commented upon. PROJECT DESCRIPTION The Davis Square to Porter Square Tunnel Contract is part of the Massachusetts Bay Transportation Authorities (MBTA) Red Line Extension from Harvard Square in Cambridge to the Alewife Brook Parkway via Somerville. The 5.1km (17,000 ft) Red Line Extension consists of four major new stations, three of which will be interlinked via tunnel construction, and the remaining station will be the last link of an open cut portion, and a terminal point for this phase of the extension. This 866m (2,790 ft) portion began at Porter Square in Cambridge and rose at a 4% slope through Somerville, terminating at the new Davis Square Station. Twin tube tunnels were constructed through 763m (2,517 ft) of rock and 83m (273 ft) of mixed face conditions at the Davis Square end. Figure 1 presents a plan view of the entire contract.

Jan 1, 1981

By A. H. Rhoades

The modern polarizing microscope with such accessories as cameras, infrared devices, reflectance and/or transmission photometers, indention hardness, and heating stage is used to characterize coal, coke, and other carbon forms. It allows characterization of coke by-products, such as tars and pitches and their insoluble residues. A useful product of the microscopic approach is the coal petrographic analysis which permits the prediction of coke strength carbonization pressure and volume change. Carbonization tests are expensive, time-consuming and require large amounts of coal. Tests on the coke show it to be strong or weak but give no indication of why. Petrographic analysis requires grams of coal and yields data that indicates why the coal produces coke of a given quality. Small samples from drill cores are sufficient for petrographic analysis. These data are also used to optimize blends for coke production. When coke-plant problems occur, ~he microscope can be used to check the coal blend proportions, as well as for weathered coal. Microscopy is useful in spore correlation work which may be a prerequisite to sound coal reserve estimates. Dispersed vitrinoid reflectance studies are used to determine the degree of organic metamorphism which serves to establish oil and gas deadlines. Tars and pitches are examined microscopically for the amount of normal solids as well as the size of undesirable carry-over solids resulting from pollution abatement practices in coke works. The microscope is also used to study coals for gasification and liquefaction.

Jan 1, 1981

Traditionally, surface coal mines in the Western United States have been limited by economics to depths between 150 to 200 feet. Utah International Inc., however, is now planning to strip coal its San Juan Mine in Northwestern New Mexico to depths ranging up to 400 feet while uncovering 20 feet of steam coal. This method is cost-competitive with nearby shallower coal deposits and underground mining of the same property. How trucks and shovels can pre-strip for a dragline, along with results of the planning process, comparison with alternate systems, capital requirements, operating costs and comparisons with other coal sources are all detailed. Also discussed are the major problems anticipated, how they might be corrected, and potential improvements to the concept. Introduction The San Juan Deep Stripping Project will be situated at Utah International's San Jean Mine. The mine is in the Four Corners region, so-called because four states enjoy a common border point about 30 miles to the northwest.(see Figure 1). The area is a semi-arid plateau region with an average elevation of 5,200 feet, receiving an average of 6 inches of precipitation annually

Jan 1, 1981

By P. J. D. Lloyd

The Witwatersrand reefs contain gold, uranium, and pyrite in the following average concentrations: 0,001 per cent, 0,02 per cent, and 1,7 per cent respectively. The paper discusses the flotation of pyrite to produce a s,ulphide concentrate, reviews work done on the production of gold concentrates, discusses attempts to produce maximum concentrates, and closes with a review of processes for the simultaneous flotation of these three species. It is concluded that high recoveries of all three species can be achieved only if a rougher concentrate of perhaps 20 per cent of the feed (by mass) IS produced, and it is suggested that reverse leaching (leaching before cyanidation) of this concentrate, followed by a cleaning flotation step for the recovery of the pyrite, would be more efficient than the routes employed at present.

Jan 1, 1981

By David B. Plumeau

The Cayuga Mine, a deep rock salt mining, operation, changed from a standard room and pillar mine design to a yielding pillar/pressure arch design five years ago. In general the roof conditions improved. However, entries adjacent to the abutment pillars continued to fail. It was noticed that where abutment pillars were accidentally "notched" (by driving cross- cuts one cut into the pillars), the abutment entries had better roof conditions than where there were no "notches". Experiments with intentionally notched abutment pillars showed that notching did improve abutment entry conditions. During the past four years notch configuration has been varied to suit local ground conditions. Recently, "pre-cutting" of notches has proven itself as a means of protecting abutment entries under severe ground conditions. As an added bonus, the notches improve productivity by providing more places to work and reduce costs because it is not necessary to bolt the notches.

Jan 1, 1981

By G. A. Wells

The consumption of barytes in certain paints, polyurethane foams, seamless flooring, glass, brake linings, plastisol gaskets for food containers, and in fluids used for gastrointestinal X-ray examinations relies on the unique properties of barium sulfate. There are no readily available mineral substitutes. Barytes are also the essential raw material for the manufacture of industrially important barium chemicals. High quality barite ore has become scarce throughout the world. Processing ore into quality end products is both capital and energy intensive. These factors have tended to limit availability and increase Prices which have encouraged the use of alternative or competitive materials and restricted market growth.

Jan 1, 1981

By Khamis Y. Haramy

This Bureau of Mines paper describes the use of the borehole shear tester (BST) In mines. Assembly and procedure sections explain how the equipment is assembled and used properly. Schematics of the BST, limitations, test hole specifications, data recording and calculations are all explained briefly, and an example of the data collecting and calculations is given to assist understanding.

Jan 1, 1981

By deur R. Dippenaar

'n Kort kursus oar die teorie en praktyk van hittebehandeling is vanaf 29 Junie 1981 tot 3 Julie 1981 in die departement Materiaalkunde en Metallurgiese Ingenieurswese aan die Universiteit van Pretoria aangebied. Die kursus is dour dosente van die departement opgestel en in samewerking met 'n aantal gassprekers aDder beskerming van die Suid-Afrikaanse Instituut vir Mynbou en Metallurgie aangebied. Tunnelling The Third International Symposium on Tunnelling is to be held in Brighton from 7th to 11th June, 1982. Professional development seminars The Department of Mining and Metallurgical Engineering of McGill University is to hold the following seminars during 1981-1982.

Jan 1, 1981

By P. R. Jochens

It is interesting to note that, when the Technical Programme Committee-Mining first decided on this particular topic for a colloquium, the proposed title was different in that it used the words 'rising price of gold'. The very fact that the title was reworded to use the words 'fluctuating gold price' highlights the problem that faces the South African gold-mining industry.

Jan 1, 1981

By Toshio Fujiwara, Sumikichi Ito, Masao Kitamura

The Tennohji-Benten Giant Trunk Sewer Project has been under construction since 1974 in the eastern part of Osaka, the second largest city in Japan. The entire project is divided into 7 blocks, some of which have already been completed. This 8.8-km sewer tunnel, being driven through a densely populated area, was planned to be constructed by the shield tunneling method. This paper described shield tunneling performances and ground behaviors during the construction of Blocks 2 and 3. An earth pressure shield (dia., 6,750 mm) was employed in Block 3 tunneling. The ground was generally soft and the cover over the tunnel varied from 13 m to only 4.5 m, so that a considerable amount of chemicals was injected to stabilize the ground. A hand-digging type shield (dia., 7,250 mm) was used in Block 2 tunneling under compressed air. For 85 m of the total length of 1.6 km, the soil at the face was extremely soft, and therefore, the ground freezing method was additionally employed.

Jan 1, 1981

By David R. Jessey

An ore microscopic and geochemical study of the nickel-cobalt occurrence in the Southeast Missouri Mining District has revealed several significant relationships. Siegenite [(Ni,Co)3S4] is the dominant nickel-cobalt sulfide in the ores, however, several other members of the thiospi¬nel group (AB2S4) occur: carrollite (CuCo2S4), nickelean carrollite [(Co,Ni,Cu)3S4], fletcherite [Cu(Ni,Co)2S4] and polydymite (Ni 3S4). In addition, bravoite [(Ni,Fe)S2], vaesite (NiS2), millerite (NiS) and gersdorffite (NiAsS) are present. Thiospinel composition varies dramatically within the district. Paragenetic studies have shown that the stratigraphically lowest thiospinels are the most cobalt-copper-rich. A detailed ore microscopic study of the AMAX Lead Company Buick mine has also shown significant changes in mineralogical association, texture and grain size of the siegenite along the north-south strike of the major ore bodies. Siegenite commonly replaces and veins chalcopyrite and is subsequently replaced by sphalerite. Less commonly, siegenite and chalcopyrite are observed to form linear replacements along sphalerite grain boundaries. The grain size of the siegenite varies markedly, but in a predictable north-south pattern that is consistent with a genetic model formulated from geo-chemical data. The compositional as well as textural trends displayed by the thiospinel mineralization could be exploited to optimize recovery of any or all thiospinels of economic interest.

Jan 1, 1981