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By E. D. Calvert

The Bureau of Mines, in its effort to promote greater utilization of domestically abundant materials, conducted reasearch on an alternate mold material that has commercial potential for titanium investment casting. Using variations of the conventional lost wax molding process, investment shell molds were formed entirely of fused, calcia-stabilized Zr02 and a Zr02-forming binder. Optimization of binder/slurry properties', stucco grain size and dis¬tribution, and curing practices resulted in a structurally sound investment shell that was distortion free and thermally stable. Small titanium castings, weighing up to 10 pounds, were prepared in unheated molds by both static and centrifugal casting techniques. Microstruc¬tural examination of the castings revealed that mold fill and surface quality were enhanced by centrifugal casting, although good results also were obtained from the statically poured molds. Microstructural and electron microprobe examinations showed that excessive, brittle case formation could be avoided by curing the dried shell molds in air for at least 2 hours at 1,400° C. Increasing curing temperature and time above these levels yielded added bene¬fits. Molds fired in vacuum at 1,500° C for 4 hours yielded castings essen¬tially free of case formation. The tensile properties of as-cast test specimens (no surface conditioning performed) id the chemical composition of representative metal samples showed that castings produced were comparable to Grades C-1 and C-2 unalloyed titanium This indicated that no sifnificant degradation of metal properties resulted from mold/metal interaction.

Jan 1, 1981

By Morris Loshinsky, George Ziegler

NEW ROUTES - 63rd STREET CROSSTOWN The New Route construction along East 63rd Street in Manhattan began in 1969 with the East River tunnel connecting Manhattan and Queens. The 63rd Street Line, once in Queens, is planned to connect to another new route called the Queens By Pass or Super Express (See Exhibit 1) which would connect to the Queens Boulevard Line at Forest Hills. The purpose of the Queens By Pass was to alleviate subway congestion to and from the Borough of Queens, whose population had rapidly expanded during and after World War II. The existing Queens Boulevard subway lines (the "E" and the "F" trains) are almost filled to capacity at their terminal stations with passengers from Long Island. Passengers boarding trains enroute from the local Queens stations have difficulty boarding crowded trains, and, at times, cannot board the trains. The New Routes, thus, were to give additional train capacity into Manhattan and thereby relieve the crowded conditions along the Queens Boulevard corridor. PROFILE - METHOD OF CONSTRUCTION The portion of the New Route passing east-west under East 63rd Street on Manhattan (See Exhibit 2) had to snake beneath intersecting structures running north and south, such as the Con Rail tracks below Park Avenue and the 80 ft deep Lexington Avenue Express track structure along Lexington Avenue. Further, the Lexington Avenue Local tracks are in a separate structure which has a high profile close to the street surface. Therefore the 63rd

Jan 1, 1981

By D. L. Mckay

"Texasgulf's 25-foot-diameter Kidd Creek No. 2 Shaft is situated next to the company's No .1 Shaft, so that both shafts can share common surface and underground facilities. Shaft construction, covering a span of five years from collaring to commissioning , started by freezing the 50 feet of grey varved clay covering the bedrock. After first completing the concrete headframe, sinking to the 5/00-foot horizon utilized two different shaft construction methods. The top 2800 feet was excavated by slashing a 6-foot-diameter borehole and hoisting the broken material up the 3OO0-foot-deep No.1 Shaft; the remaining 2300 feet was excavated by conventional benching methods. Prior to installing the 5100 tons of galvanized shaft steel on the completion of the sinking operation, the sinker was able to install all thirteen armoured electrical cables in one pass with his modified galloway stage. All loading and lip pockets were installed along with the steel guides and bun tons during the equipping operation.IntroductionOn November 21,1978, Texasgulf completed the No.2 Shaft at Kidd Creek Mine. This shaft is the largest shaft (volumewise) in North America and is unique in many respects . The purpose of this paper is to outline some of the unique features of this shaft as well as to record how this facility was constructed.Soon after sinking No.1 Shaft, Texasgulf started a program of exploratory diamond drilling from the 2800 level in No. 1 Mine. The drilling outlined sufficient ore below that level to justify a second mine. Feasibility studies demonstrated that production could be increased by one-third exclusively from this deep ore . The study called for a 25-foot-diameter shaft to the 5100-foot horizon to service a mine producing 5,000 tons of ore per working day.The site chosen for No.2 Shaft and head frame is 350 feet southwest of No.1 Shaft. This, along with No.1 Shaft, will be away from the influence of ground subsidence when mining at depth. The collar and head frame foundations are located on a flat rock ledge some 70 feet below surface. This flat ledge was found by test holing through the overburden by diamond drilling. It is fortunate that this location best satisfied the surface layout and logistics for both surface and underground ore and waste handling."

Jan 1, 1981

By Herbert H. Einstein

Swelling ground is one of the most feared problem in tunneling. Although usually not causing sudden failures during construction, the very large and long- lasting deformations give contractors and designers the impression of facing an inevitable phenomenon against which there is no technical defense. Examples are concrete liners of up to 1 m that have been cracked or crushed, tunnel inverts that are heaving at a rate of 0.1 m per week during construction and continue to heave during decades. This author (Einstein (1979). Einstein et al. (1972) (1975)) and others (Huller (19761, Grob (1972) (1976). Golta (1967), tienke (19761, Krause (1976). Lee et al. (1976)) have described many cases of swelling tunnels that illustrate the significance and magnitude of the problem. This paper intends to show that tunnels in swelling rock can be built to perform satisfactorily. . For this purpose the tunnel builder needs to know how to determine the existence and specific behavior of swelling ground, how to select appropriate structural characteristics of the tunnel and predict its performance under the specific ground conditions, and finally how to construct the tunnel such that the anticipated performance will be achieved. This concept of a design-construction procedure is the same as that for tunneling in general; it is mentioned here for NO reasons: 1. To point out that design and construction cannot and should not be separated. The way in which the tunnel will be built has to be an integral part of the design. 2. This paper will be structured corresponding to the procedural concept.

Jan 1, 1981

By D. S. Choi, D. L. McCain

A method of estimating the chain pillar size required to support the wide working faces of longwall or shortwall coal mining is presented. The pillar size is determined through the use of coal strength, entry geometry, panel width, and overburden pressure. Design analysis is focused on a three-entry development system in the Pittsburgh Seam but can be used for other development plans and other seams by substitution of the proper geometric and strength data.

Jan 1, 1981

By John R. Benham

The Blue Joint Mtn. RARE II area may contain barite resources. One claim, the Woods Creek Barite No. 1, contains two veins of barite of drilling mud quality. The quantity of barite present could not be determined due to limited surface exposures. Sections 1, 2, 11 and 12 of T. 2 S., R. 23 W. in the study area are classified by the U.S. Geological Survey as prospectively valuable for geothermal energy resources. These sections border Blue Joint Creek Hot Springs, which are outside the study area.

Jan 1, 1981

By Anil Mahyera

Under contract to the Bureau of Mines, a roofbolting machine has been developed which will: control torque on the bolthead to within 4 percent of a set point, control thrust to a low level (150 lbf), and implement a tightening method to minimize variability due to bolt tension decay of a group of bolts caused by differing anchor creep rates. This bolter was used to determine bolthead and thread friction factors, and to determine the effect of adding a hardened washer to the bolt assembly on the uniformity of bolt tension in the laboratory and field. Recommendations for torquing speed, bolt lubrication, use of hardened washers, and thrust level on the bolthead are made. The relationship of this system to Improved roof control is discussed, along with additional work that remains to be performed. Patent Notice Patents are pending which protect the hardware and methods of controlling tension decay as discussed in this paper.

Jan 1, 1981

To precondition a stope in advance of mining and thus reduce or prevent rock bursts. Approach Drill deep holes from a mine opening in a radial pattern in the vein and load and blast to fracture, the rock prior to production mining How It Works Preconditioning of a sphalerite galena vein in a hard gangue of quartz and quartzite creates a zone of softer rock that fails by displacement rather than violently as an elastic-battle mass. However, the entire area must he analyzed carefully so that the stress transfer does not cause problems in other workings of the mine A typical drill hole pattern and explosive loading is shown in the sketch. Hole diameter is about 4 inches and a down-the-hole, type drill is used. Drilling speed in hard quartzite is about 12 inches per minute High pressure compressed air (250 psi) is used to run the drill. An overhand cut-and-fill stoping area on the 7700 level of Hecla Mining Company's Star Mine in Burke, Idaho was preconditioned above and below the

Jan 1, 1981

By David A. Fawcett

An auxiliary cross-pit mining system, working in tandem with the prime excavator, is evaluated technically, operationally and economically for application in the selective removal and replacement of soils and unconsolidated ovezburden. Previous studies on cross-pit technology and applications of this technology are briefly reviewed. Stratigraphy plus pit, operating and economic parameters are assumed and applied in the evaluation and comparison of a base case dragline system with two alternatives - a dragline/scraper-dozer combination and a drag- line/cross-pit system combination. The economics of the proposed cross-pit system favour it as a viable alternative to conventional systems.

Jan 1, 1981

By B. H. Eccleston

Experimental data were obtained from two medium-duty diesel engines derated to qualify for use in underground mines. Gaseous and particulate emissions from these engines were measured and results provide information on the effect of exhaust treatment devices on the emissions. The devices in the study were a catalyst, a particulate trap, and an exhaust gas cooler of the water scrubber type. Emission levels of carbon monoxide and hydrocarbons were observed to be very low in comparison with emission levels of comparable engines in full-rated operation. Oxides of nitrogen and benzo(a)pyrene content of the exhaust also were found to be somewhat low in comparison with previous findings. For particulate reduction, the combination of a particulate trap and a scrubber was observed to be the most effective combination tried; in some cases, over 60 pct particulate reduction was effected by the trap-scrubber combination.

Jan 1, 1981

By D. E. Salman, R. R. Maclachlan, R. J. Barclay

"There is a considerable resource of data for spherical charge cratering, both as single charges and in row-of-charge geometr(1). The data are. however, based on cratering performance to a single free planar surface.In practice. the more common circumstance involves an angular surf ace geometry. such as occurs at the toe of a bench or the wall of a stope. It is for the purpose of investigating this circumstance that the described test work was conducted.The test objectives were: (1) to observe the change in single-charge cratering performance between planesurface and angle geometry; (2) to identify the optimum performance of single charges cratering to a plane surface. cratering from a bench sub-grade position and cratering from a condition of zero sub-grade or stope wall geometry; and (3) to observe the performance of row-of-charges cratering to an angular surface at various row burials and spacing. The row charge burial and spacing dimensions were to be expressed in simple numerical multiples of single-charge depth-of-burial data."

Jan 1, 1981

By Seth C. Schaefer

The Bureau of Mines has determined the standard Gibbs energies (AGf°) of CoS1.035 (cobalt sulfide) and Ni2.515S2 (nickel sulfide) with high-temperature galvanic cells using stabilized Zr02 (zirconia) as the electrolyte. Potential measurements were obtained for the cell Pt, CoS1.035, CoO, S02(g, 1 atm)//Zr02//02(g, 0.0114 atm), Pt, with the overall cell reaction C0S1.035(c) + 1.535 02(g, 0.0114 atm) = CoO(c) + 1.035 S02(g)¬ These results, combined with the best available data for ?Gf° of CoO and S02 from the literature, give the standard Gibbs energy of formation of CoS1.035 for the reaction Co(c) + 0 5175 S2(g) = CoS1.035(c) ?Gf° = -38.890 + 18.87 x 10-3T ± 0.185 kcal/mole (866.0 - 1,104.9 K), where temperature (T) is expressed in kelvins. Similar measurements were obtained for the cell Pt, N12.515S2, NiO, S02(g, 1 atm)//Zr02//02(g, 0.0122 atm), Pt, with the overall cell reaction Ni2.515S2(c) + 3.2575 02(g, 0.0122 atm) = 2.515 NiO(c) + 2 S02(g). Combination of these results with data for ?Gfo of NiO and S02 from the literature yields the standard Gibbs energy of formation of Ni2.515S2 for the reaction 2.515 Ni(c) + S2(g) = Ni2.S1SS2(c) ?Gf° -65.377 + 24.67 x 10-3T ± 0.541 kcal/mole (968.6 -1,053.7 K).

Jan 1, 1981

By Phillips H. R

The action of free rolling disc cutters is well understood, relationships between disc geometry and performance having been established both in the laboratory and under field conditions. However, under severe operational conditions a malfunction of the disc bearing assembly is likely to produce a definite change of cutting action. Collapsed or siezed bearings can even prevent the disc from rolling and thereby create what is equivalent to a drag pick. This paper describes a programme of laboratory experiments using deliberately stalled discs. Their performance under such conditions is contrasted with that for a free rolling disc and also with a drag pick having a ridged front developing into a negative radiused back clearance angle. In conclusion an assessment is made of the influence stalled discs can have on the torque and thrust requirements for a tunnel boring machine.

Jan 1, 1981

By J. Eric Belford

The Kidd Creek orebody is a massive base metal sulphide deposit with surface dimensions of 168 m by 670 m. The steeply dipping ore- body has been evaluated to a depth of 1 524 m. To date, the mining of the orebody has been divided into three stages. The first stage of mining was an open pit operation which supplied ore from 1966 until 1977 when a depth of 219 m was reached at the widest or north end of the orebody. The second stage of mining, called No.1 Mine, was the development of an underground mine to replace the pit and recover the ore from the floor of the pit to a depth of 792 m. Development of the underground mine started in 1969. Full production of 273 000 tonnes per month was attained in 1977. The third stage of mining called No.2 Mine, was initiated to accommodate a production expansion and included the development of a second underground mining operation to recover the ore from the bottom of No.1 Mine, i.e. the 2600 level; to a depth as yet undetermined but most likely the 4600 foot level. Development of the No.2 Mine began in 1974. Full production of 91 000 tonnes per month will be achieved in 1982. The choice of the 2800 level as the partition between the two underground mines was based on the following factors: The 2600 level is the lowest level which can conveniently be mined through the No.1 Mine crusher on the 2800 level. Development and trial stoping methods for mining at depth could be evaluated in the 2600 to 2800 block utilizing the existing hoisting facilities of No.1 Mine. Early development of the ore in the 2600 to 2800 block would provide additional mill feed sooner than could be achieved by developing from No.2 Shaft. The underground mining plan then is to mine from the pit floor down to the 2600 foot level and at the same time mine from the 2800 level down to at least the 4600 foot level. PLANNING The Kidd Creek operations are designed to follow a logical mining sequence. The grade of ore supplied to the concentrator is the result of following the mining plan. The philosophy of mining has been to mine downward in horizontal slices. In the case of No.1 Mine the slices are 122 m thick while in No.2 Mine the slices will be 183 m thick. The point of this approach is to mine the pillars immediately after creating them rather than allowing them to stand, deteriorate and generate uncontrollable situations. Two types of ore are handled separately to optimize recoverable values in concentrates. The 'A' type ore is a copper zinc ore with some silver and little lead. The 'C' type ore is a zinc silver ore with some lead and copper

Jan 1, 1981

By Hiromu Kusakawa, Tetsuo Kanematsu

INTRODUCTION In urbanized area with heavy street traffic and with environmental requirements to lessen construction noise and vibration, the cut-and-cover is not always a feasible method to build a small diameter tunnel for sewage, water or other utilities. That is where the use of the shield machine to bore such a small diameter tunnel should be considered as a more acceptable alternative. Although the shield machine of this type should be small enough to meet specific requirements for a given tunnel, it should be big enough to provide some working space inside of the tunnel. Recently, we have successfully developed the fully mechanized small diameter tunneling method which enables us to bore a tunnel as small as 600mm in finished diameter. This paper discusses the concept of this newly developed method, including a case history where sewage tunnels of 800mm finished diameter were constructed by using this method. OUTLINE OF METHOD Developed from the original slurry shield pipe-jacking tunneling method, this method is highly automated so that all operations inside of the tunnel can be remotely controlled. Various data including the advance rate, position and inclination of the shield are transmitted to the central control room outside of the tunnel and monitored by the CCTV and the instrument panel at all times to

Jan 1, 1981

Dragline performance drops considerably when chop-down and double handling of material is needed due to increasing overburden thick- ness or total pit depth. Beyond a certain pit depth the dragline needs support by a pre- stripping system in the upper portion of the overburden. In soft to medium hard ground the bucket wheel excavator can be used for pre- stripping, whereby several methods of material transport are investigated. Conveyor transport around the pit and dumping by stackers is the best solution from the technical point of view. Cross pit transport and dumping by means of a conveying bridge is the method with the lowest costs per volume moved. Cross pit transport by use of a beltwagon with overlong discharge boom is both, poor from the technical point of view and high in overall costs.

Jan 1, 1981

By Clinton A. Hollingsworth

The Flotaire Flotation Cell is a simple, efficient hydraulic/pneumatic Flotation Cell that has no moving parts. It is normally used in conjunction with a surfactant (frother) in which case the combination is known as "The Flotaire System". On many ores, metallurgical efficiencies are substantially increased and operating costs reduce. For example, in floating phosphate rock, it is not unusual for BPL recovery to be increased more than 10%, the major increase being due to floating coarse phosphate, up to 14 mesh, and the difficult to float phosphate. Substantial improvements have also been made on coal, mica, vermiculite, kaolin, barite, copper, etc.

Jan 1, 1981

By M. D. Flavel

Testing methods are described to help in decisions of selecting the most viable comminution circuits. The authors present a comparison evaluation based on numerous studies to help make initial choices for feasibility evaluations. An update summary of completed Bond grindability and Abrasion Index testwork at Allis-Chalmers Process Research Test Center for all materials is included. "What is the best circuit to comminute primary crusher product to make beneficiation feed?" This frequently asked question has the implication that there is one circuit which is universally the right circuit. The answer has been sought ever since it has been necessary to break rock to liberate entrapped mineral values. With every new contribution to the art and the science of comminution, the scope of the discussions broaden. It is not even possible to define what the abstract term best means.

Jan 1, 1981

On December 16, the General Services Administration (GSA) suspended weekly sales of surplus silver from the national defense stockpile because Congress approved the Defense Appropriation Act, which contained an amendment to halt silver sales. The amendment, introduced by Senator James A. McClure (R., Idaho), prohibits sales for 6 months while the impact of the sales and alternative methods of disposal are evaluated. The GSA sold 2 million troy ounces since sales started October 14. 46.5 million troy ounces were authorized to be sold during this fiscal year and an additional 58.6 million troy ounces were authorized to be sold over the following two fiscal years. The stockpile held 139.5 million troy ounces of silver when sales began in October. Brush Wellman, Inc., a vertically integrated producer of beryllium products announced plans to modify its Delta, Utah beryllium concentrate processing facility to utilize beryllium concentrates containing as little as 7% beryllium oxide. The company plans to invest $2.5 million for this modification with completion expected in mid-1983. Implementation of this plan to consume lower grade beryllium minerals will significantly increase world reserves of beryllium concentrates.

Jan 1, 1981

Smoky Valley Mining Company, Round Mountain, Nevada, was the pioneer operation designed for large scale heap leaching of crushed gold ores. It is located in the Big Smoky Valley which stretches 160 km (100 miles) through central Nevada west of the Toiyabe Mountain Range. Gold was first-discovered at Round Mountain, 88 km (55 miles) north of Tonopah, in 1905; and mining in the area included placer operations, which ran from 1946 to about 1960. Smoky Valley Mining Company is a partnership of Felmont Oil Co., Case-Pomeroy & Co., and Copper Range Co., with the latter being wholly owned by Louisiana Land and Exploration Co. In 1969, an option on the Round Mountain property was acquired by Copper Range, and during 1974 a decision was reached to proceed with mine development and plant construction. Ore reserves were reported at 10,537,000 mt (1 1,617,000 st) of 2.09 g per mt (0. 061 oz per ton) gold using a cut- off grade of 0.69 g (0.02 oz). Silver content was approximately 2.4 g per mt (0.07 oz per ton) and the waste to ore ratio was about 1: 1. By the end of 1976 heap leaching was in operation. The ore is a rhyolite tuff, sometimes described as a gold porphyry with highly abrasive qualities but which does not break down into slimes upon contact .with cyanide solutions. Gold is unevenly distributed through the ore but as a whole it is in a very finely divided state. Climatic conditions are extreme in central Nevada. Summers are hot and dry while winters are windy and cold with subfreezing temperatures. Elevation of the property is about 1,920 m (6,300 ft). Precipitation averages 203 mm (8 in.) per year. Until February of 1980, leaching was continued until the temperature reached minus 2ºC (28º F), and about 10 months leaching was the average. Water for the operation is drawn from the Toiyabe Mountains through a 13. 7 km (8. 5 mile) pipeline, originally installed in 1915, or from wells in the valley bottom. The plant requires make-up water at the rate of about 1,500 liters per min (400 gpm). On a schedule of three shifts, seven days per week, the daily output at Round Mountain amounts ,to 12, 700 mt (14, 000 st) consisting of 6,350 mt (7,000 st) each of ore and waste. Ore is hauled with a fleet of 45 mt (50 st) trucks and dumped into the 1,0.70 by 1,650 mm (42 by 65 in. ) gyratory primary crusher located near the pit. The primary

Jan 1, 1981