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By David G. Kidd

The principles of Ore Sorting in general and photometric sorting in particular are discussed with detailed reference to the Model 16 machine. The operating principles and design of the Model 16 are discussed and a case study presented to demonstrate the use of sorters to process an industrial mineral. In addition, an economic study is presented, to highlight the benefits of ore sorting, by evaluating the increased revenue that can be achieved using an ore sorter to process a particular ore body.

Jan 1, 1983

By Mark E. Gershon

The development of long term plans and schedules for strip mines now faces many companies, especially those developing large properties in the West. The rule of mining the lowest strip ratios first, while delaying equipment acquisitions and recouping investment the fastest, creates the situation where stripping ratios are too high in the latter years of mining operations. A program concept taking life of mine return on investment into account is developed in this paper to optimize mine scheduling and equipment acquisition. In addition, quality considerations (heat content, ash, sulfur, washability) can be considered by including the appropriate blending constraints to meet contract requirements.

Jan 1, 1983

By Thomas E. Garnar

Zirconium and hafnium are curious elements because they are almost always found together in nature. Zirconium was discovered by Klaproth in 1789 and isolated 35 years later by Berzelius. Because hafnium's chemical properties are so close to those of zirconium, it was not discovered until 1923 when Coster and Von-Heresey detected it using x-ray spectrographic analysis. These elements occur most commonly in nature as the mineral zircon (ZrSiO4) and less commonly as the oxide baddeleyite (ZrO2). They also are found as a variety of other silicates. Zircon was identified as a component in alluvial and beach sands in 1895, but it was not produced in any quantity until 20 years later. Zircon is always a coproduct from TiO2 mining and processing. During World War I it was produced as a coproduct of beach sand mining for titanium minerals just south of Jacksonville Beach, FL, and was patented as a refractory. It was not until the 1930s when Zircon Rutile, Ltd. began mining at Byron Bay on the east coast of Australia that zircon was first used as a foundry sand. Later in the 1940s, NL Industries, Humphreys Gold Corp., and E. I. du Pont de Nemours & Co., Inc. began production of zircon sands from fossil beaches in northeast and northcentral Florida. Baddeleyite first became available as a commercial product in 1916, but never in the quantity of zircon. Zircon holds a unique position as an industrial mineral because it is used for both its physical and chemical properties as well as an ore of zirconium and hafnium metals. Australia is the major zircon producer followed by South Africa and the US. Zircon is also produced in India, Sierra Leone, Sri Lanka, Malaysia, China, Thailand, and Brazil. Undeveloped heavy mineral beach sand reserves containing zircon are known to occur in Egypt, Malawi, Senegal, and Tanzania. Locations are shown in Fig. 1. Mineralogy Zirconium and hafnium are always present together in naturally occurring compounds. Most commonly they form as the silicate sometimes containing iron, calcium, sodium, manganese, and other elements. Less commonly they are found as oxides in combination with titanium, thorium, calcium, and iron. Zircon is the most common form. It is extremely resistant to weathering, therefore, often it is present in ancient beach sands and placer deposits. Although resistant to alteration from external sources, it is vulnerable to internal alteration as the result of thorium and uranium substituting for zirconium either in the zircon lattice or in solid solution. Alteration to the metamict state takes place as radioactive emanations from these elements disorder the crystal lattice, accompanied by hydration, reduction in specific gravity, and changes in color. The mineralogy of zircon and baddeleyite and variation of physical and chemical properties are shown in Table 1. The effects of zircon's internal alteration and darkened color can be corrected by heating to 1000°C for 30 min or so. A certain time-temperature relationship makes it possible for decolorization and reordering of the crystal lattice to take place when heating at higher temperatures for shorter periods or at lower temperatures for longer periods. After heating, x-ray diffraction patterns are sharper, the grains may be harder, and except for particles of malacon, the grains will be white or colorless in the absence of grain surface coatings. The color change is only temporary and the particles slowly darken with time. Zircon fluoresces light yellow in shortwave ultraviolet light. If exposed to ultraviolet light for extended periods of time, white (calcined) zircon turns purple. With time the induced color begins to fade and eventually disappears (e.g., calcined Florida zircon exposed to ultraviolet light for 24 hr still retains faint, but discernible, purple color after six months).

Jan 1, 1983

By Daniel F. Meyer

INTRODUCTION The Metropolitan Boston Transit Authority (MIA) Red Line has served greater Boston commuter needs from its Harvard Square terminus since its opening in 1912. Since then, the population of Boston's northwest area has increased substantially, and with this growth have come dramatic changes in the type and distribution of urban land uses, including the number of households, jobs, shopping and recreational opportunities; these changes have created a need for improved transportation. Extension of the Red Line to better serve these communities has been a topic of discussion for nearly 40 years. In November of 1977, the Urban Mass Transportation Administration (UMTA) granted the MBTA approval and funding for the Red Line Extension Project. With funding in place, the MBTA proceeded with final engineering and construction of the section from Harvard Square to Alewife. When completed, the Red Line Extension will add 3.2 miles of new track to the MBTA system. Estimated final cost is about $400 million. On October 3, 1978, the MBTA received bids for the construction of Project 091-105, Harvard Square to Porter Square Tunnels and Shafts, which is part of the overall Red Line Extension. The Joint Venture of Morrison-Knudsen, White, Mergentime was the low bidder at $47,478,600. Official award of the contract came on October 25, 1978, with Notice to Proceed given October 31, 1978. The contract called for construction of two independent parallel concrete-lined tunnels in rock, soft-ground and mixed-face

Jan 1, 1983

By C. H. Perbix

[On Pier D in the Port of Long Beach, California, the Port of Long Beach has built a new bulk cement distribution terminal. The facility is operated by Pacific Coast Cement Corporation, who designed the complex and leased it from the Port of Long Beach on a 40-year lease. At one bulk cement is unloaded from vessels carrying from 12,000 to 30,000 t. The unloading is performed with pig speed mechanical unloading equipment and delivered into a concrete silo complex with, a capacity of 50,000 t. From the silos, bulls cement is loaded into trucks for delivery. The facility was completed in September 1981.]

Jan 1, 1983

By R. D. Hammett

This paper describes an investigation that MS carried out using the three-dimensional, stress analysis computer program "NFOLD" to assess pillar stability in relation to existing mining conditions and the proposed layout of future stopes. The stress analyses were designed to assess the present stability of the mine (particularly the pillars adjacent to the shaft), the change in pillar stresses as mining proceeds, and the optimum stope geometry to minimize ground control problems. The existing conditions were modelled first, and rock mass strengths were adjusted until a good agreement between the predicted and observed conditions was obtained. Analyses of alternative mining layouts, based on the calibrated rock mass strengths, were then compared. The paper describes the results and the conclusions of the study.

Jan 1, 1983

By Wen L. Chen

The steam coal quality is less stringent than metallurgical coal quality. The steam coal is prepared either by cleaning full size range of raw coal or cleaning coarse coal only, leaving the fine coal raw. The latter scheme is more cost competitive. It is particularly applicable to U.S. eastern soft coal where low ash coal is concentrated in fine sizes. For raw coal size separation, a recently developed Rotating Probability Screen, developed by the British Coal Board, may be advantageously used for easy change of raw coal separating size and to avoid screen deck plugging when handling wet and clayey raw coals.

Jan 1, 1983

By J. A. Herbst

In spite of potential theoretical and economic advantages of large-diameter ball mills, many manufacturers elect not to build these mills owing to what is perceived as an excessively large design risk. This risk results from the fact that traditional predictions for mill-scale-up to large diameters are not always accurate. It is apparent that alternative methods of analysis and scale-up are required. Recent studies have shown that detailed population balance models which account for important grinding subprocesses, i.e., grinding kinetics, material transport, and classification, are capable of predicting the performance of small- and intermediate diameter mills (up to 4.3 m (14 ft)) from small-scale batch tests. These same models are used in the current study to predict the performance of a "borderline" large ball mill (4.7x5.5 m) at Asarco's Sacaton operation, a ball mill (5.0x5.8 m) at Kennecott's Chino operation, and one of the world's largest ball mills (5.5x6.1 m), at Cities Service Pinto Valley operation. Model parameters required for scale-up have been estimated in a 380-mm diameter batch mill. Predictions are compared with the results of detailed plant sampling in the three plants. For the Sacaton and Chino operations, the error of the predictions was found to be less than 2.5%, while the corresponding error for the Pinto Valley operation was less than 2.7%. It is concluded that proper representation of the major subprocesses of grinding in the model equation is the key to achieving accurate scale-up. Of special importance is the need to account for the size distribution of the grinding media and the influence of the size distribution environment in the mill on grinding kinetics.

Jan 1, 1983

By R. J. McClincy

The potential techniques for the direct smelting of copper sulfide concentrates to blister copper were evaluated from the standpoint of commercial application. Many existing smelters are adaptable to direct smelting practice but only with improved control of metallurgical performance. Modified and innovative procedures for slag cleaning and metal refining, prerequisites to direct smelting, are presented and discussed. The ability to smelt directly to blister copper using existing equipment and eliminating the need to convert matte offers ,significant advantages to traditional smelting practice from the viewpoint of cost, 'S02 control, and process simplicity.

Jan 1, 1983

By William P. Shell

An important part of process control engineering is the implementation of the basic control system design through commissioning to routine operation. This is a period when basic concepts can be reviewed and improvements either implemented or recorded for application in future systems. The experience of commissioning the process control systems in the Homer City coal cleaning plant are described and discussed. The current level of operating control performance in individual sections and the overall system are also reported and discussed.

Jan 1, 1983

By Richard L. Rains

The U.S. Bureau of Mines conducted a field study of mines and prospects of the Black Canyon RARE II area (No. 5061), Inyo County, California, from June to October 1981. Geological) geochemical, and geophysical studies were conducted by the U.S. Geological Survey. The Black Canyon RARE II area is east of Owens Valley and 6 mi east of Bishop, California. The principal mineral commodities are gold, silver, lead, zinc, and tungsten. Properties with resources in and adjacent to the area are listed in table 1; the locations are shown on figure 1.

Jan 1, 1983

By D. A. Dahlstrom

With today's high energy costs per million BTU's, far greater emphasis is placed on increasing thermodynamic efficiency in the use of energy. America has long since discarded its previous golden age of "low cost energy" in the past ten years. Energy costs are now a very significant percentage of operating expense in industrial operations. Public utilities have felt the same influences of increasing costs in energy for the generation of electricity. Not only has the input energy expense increased seriously, but as pointed out by Blackmore in a paper, fuel costs were 53.4% of the total operating costs for American Electric Power Company.

Jan 1, 1983

By Robert S. Nichols

Fording Coal Limited's mine in the Rocky Mountains near Elkford, B.C. has produced 21.8 million clean tonnes of metallurgical coal from 1971 to 1980, inclusive. This production has come from several pit areas and required the removal of 149.1 million bank cubic meters of waste rock and overburden by truck-shovel and dragline operations. Waste dumps from 30m to 200m in height have been successfully constructed on natural slopes, generally between 10° and 26°. Design considerations for the dumps include foundation and soil conditions, natural slope angles and containment of weak overburden or rehandle materials. Dump control is maintained by monitoring the crest and the face of an active dump area. Crest movement is measured by extensometers locally termed "Spoil Monitors". When crest movement rates progressively increase above normal, dumping operations are temporarily relocated. Some unstable conditions and mass failures have occurred as the result of natural foundation slopes being in excess of 26°, failure of weak water saturated foundation soils or weak material being placed on the dump.

Jan 1, 1983

By Jaime V. Ongpin

"The author will give a capsule history of Benguet Corporation and attempt to identify its operating environment and underlying ""strategy"" until 1974, when the company's management assumed office. The company's operating environment and ""interim strategy"" from 1975 to 1980 will be described. The discussion will cover an environmental forecast and define the company's"" strategy for survival"" for the balance of this century.IntroductionIn December last year, I was asked to deliver a pa per for the management lecture series a t the Asian Institute of Management in Manila. The paper was entitled "" The 1970's: A Decade of Disaster For New Mining Projects"" . In that paper, it was my task to review the results of new mining projects in the Philippines during the previous decade. The task was not a happy one, for the results themselves were not only unhappy, but disastrous on a scale unprecedented in Philippine history. Out of a total of 17 major mining project s involving an aggregate capital investment in excess o f US $2 billion during the 1970s, only three project s have been profitable, and all the rest have either gone "" belly up"" or are teetering on the very edge of financial disaster.It is in the context of this shocking record of widespread financial dislocation in the Philippine mining industry, (which in varying degrees appears to have been paralleled in virtually every other country in the world where mining is an important sector of the economy) that I address myself tonight to the theme of this symposium. My paper is entitled ""Risk Management Strategy in Mining"" and it is sub titled ""Can Benguet Corporation Survive to Celebrate its Centennial in 2003?"". I have inserted the word ""Strategy"" and added the subtitle, because I wish to make it clear first, that my presentation to you tonight will be focused exclusively on the strategic aspect s of risk management, and second that I will limit myself to Benguet's own ""in-house"" experience and perspectives on this subject. I would caution you therefore, to consider my views within this restricted framework, and in light of the particular and sometimes peculiar circumstances within which Benguet Corporation operates."

Jan 1, 1983

By R. J. Sweigard

Three case studies were undertaken to investigate the role of land use potential evaluation in reclamation planning and to determine the impact of regional differences on the evaluation process. The three surface mines studied were representative of operations in the Appalachian, Interior, and Northern Great Plains provinces. The scope of the investigations included a survey of regional characteristics, a detailed investigation of the mining operations and site conditions, and an assessment of local land use planning activities in the area of the mine. Special attention was given to key factors that presently determine the use of reclaimed land. Also, for each case study, the postmining land use potential was evaluated using site planning principles. Specifically, the environmental, economic, and social impacts of several potential postmining land use plans were considered.

Jan 1, 1983

By H. Shafick Hanna

The beneficiation characteristics of low grade Birmingham red iron ores of the Big Seam and Ferruginous Sandstone seams were investigated using flotation and magnetic separation after reduction roasting. Samples of Bib Seam Ore responded more readily to concentration than the Ferruginous Sandstone ores. The impurities inherent with the iron oxide minerals limit the grade of concentrates recoverable from these ores to a maximum of about 61% Fe if reasonable iron recoveries are sought. Flotation concentrates assaying 60-61% Fe and about 0.1% P with attendant iron recoveries of about 63% were achieved from Big Seam ore charges while those obtained from the low phosphorus Ferruginous Sandstone samples analyzed 54-56% Fe. Reductive roasting and magnetic separation of ground charges of the two ore samples yielded concentrates assaying 60-61% Fe. Iron recoveries were better than those achieved by flotation, but the magnetic products of Big Seam ore were high in phosphorus (0.2-0.3% P).

Jan 1, 1983

By Allan M. Johnson

Dewatering is a major operational cost at sane mines. Under certain conditions, costs associated with water disposal may continue beyond the productive life of the mine. For mines with mineralized waters, this is of special concern. Since 1974 experience has been gained from the examination of a number of closed underground metal mines that exhibited drainage problems. It was observed in certain cases, that had appropriate steps been taken prior to closure, that the resulting drainage problems could have been largely avoided. The pre-closure steps would have involved alteration to the "plumbing system" of the mines: i.e., the drifts and crosscuts interconnecting the workings of the mine. This could have best been accomplished by the placement of bulkheads and/or selective drifting. In addition to reconfirming that hindsight is 20-20, a lesson learned from these case studies shows that a relatively simple hydrologic evaluation prior to mine closure may avoid a troublesome and costly drainage problem.

Jan 1, 1983

By Eduardo M. Sacris

The performance of the grinding circuit, from the initial stages of operation to the present, is discussed. The mill efficiency as measured by the Bond grindability data and the operating work index is presented. The objective has been to produce a sand cyclone overflow containing not more than 6% +65 mesh. However, this has never been attained even at low milling rates. On the other hand, significant improvements in throughput were achieved by instituting some equipment changes and process modifications within the grinding circuit. The latest approach to solving the coarse grind problem is also discussed.

Jan 1, 1983

By J. A. Eisele

The Bureau of Mines is investigating the recovery of alumina from domestic nonbauxitic resources, including anorthosite. The United States has large reserves of anorthosite, but its aluminum content is less than 50 pct soluble in acid, unless a source of fluoride is added to the acid. A flowsheet that includes leaching with HCl and fluoride followed by crystallization of AlC13.6H20 from the pregnant liquor by HCl gas injection was designed. Approximately 90 pct of the aluminum values were recovered from the anorthosite when a ratio of 0.14 mole of fluorine per mole of aluminum was used. Sodium chloride is cocrystallized with the A1C13.6H20 but is removed by water washing of the Al203 product. A material balance is given based on results of laboratory studies of the unit operations.

Jan 1, 1983

By J. Wesley Atkins

In considering the importance of lease management and administration, I have decided to approach the topic, Lease Default and Eviction: Action or Reaction, as a three phase presentation dealing with mineral lease administration and management, past, present and future. Though the title may border on the dramatic, it illustrates the real consequences of alternative approaches to property management viewed from my experience in the evaluation, development and implementation of a number of such systems and services in my current position as president of Talco Group Corporation. First, though, let's take a moment and set the stage by giving a few actual examples of why a pragmatic approach is needed in this particular area.

Jan 1, 1983