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By E. R. Hoskins

The Gulf Coast States ranging from South Texas to Alabama contain vast resources of lignite ranging in energy content from about 4000 to 7000 Btu/lb (as-received) with sulfur content ranging from about 0.5 to 2 percent. Currently, the strip mining rate is about 35 million tons per year in Texas and essentially zero in the other Gulf Coast states. Estimates of future mining rates are as high as 310 million tons per year by the year 2000 with 240 being in Texas. In this paper, we examine the life cycle of the surface mineable lignice based on the most recent estimates of surface mine recoverable resources with two scenarios. The first indicates that a 310 million tpy rate could be sustained for only 15 years while the second scenario suggests that the 310 million tpy could be sustained for 25 to 30 years. If lignite resources are required beyond those that are surface mineable, the deep basin lignite will be developed. Five strategies for developing deep basin lignite are discussed.

Jan 1, 1983

By T. M. Gurr

In recent years the need for reducing energy costs has led many in search of alternative fuels, examples are gasohol, "cow power", oil shale, biomass, peat and many others. We have been involved with several peat resource evaluations and would like to share with you some of our observations and experiences. We hope our experiences may help you in your evaluation of existing or future projects where peat is considered as an energy resource. The items that we will cover are listed as follows: ? Peat Uses, Occurrences, and Characteristics ? Identifying Exploration Targets ? Peat Exploration ? Peat Prospecting and Reserves Analysis ? Peat Harvesting and Reclamation Assessments ? Summary and Conclusions

Jan 1, 1983

By J. G. Eacott

This paper reviews the role of oxygen potential and the advances that have been made in the application of tonnage oxygen in copper smelting. Brief reference is made to reaction kinetics before attention is turned to the thermodynamic considerations in copper melting to illustrate the importance of oxygen and. oxygen potential in the component parts of the overall smelting process. The chemical potential diagram for the Cu-Fe-S-O-Si02 system is used to elucidate the difference b etween the conventional matte smelting process and the modern continuous processes. A progressive oxidation scale' is constructed to show the common elements which exist, and the matte grades produced, during the smelting of concentrates to blister copper in commercially available copper smelting processes and those under development. The common route in producing blister copper from molten mattes, regardless of process, is illustrated on the Cu-Fe-S equilibrium phase diagram. The essential features of oxygen enrichment, in terms of its effect on combustion conditions (i.e. oxidation of fuel and sulphide minerals) and the heat balance are outlined. The benefits of oxygen enrichment are listed. The influence of tonnage oxygen and its effect on productivity, fuel savings, gas volume and strength in various copper melting processes are examined as a state-of-the-art review. Reference is made to the economics of tonnage oxygen utilization.

Jan 1, 1983

By Brij M. Moudgil

Separation of dolomite from apatite, because of nonselective adsorption, cannot be achieved by conventional froth flotation technique. Results obtained in the present study also indicate, that this can be attributed to the depletion of the collector molecules due to complexation with the calcium and magnesium ions, dissolved from the two minerals. However, it has been established in this investigation that conditioning the material at pH 10, followed by reconditioning, without any additional collector, at pH 4, results in selective flotation of dolomite from the mixture. The recovery of apatite, in the proposed reconditioning process, is much higher than with the conventional conditioning under similar pH conditions. The mechanisms involved in the conventional conditioning, and the reconditioning process are presented.

Jan 1, 1983

By Hal McVey

"Philosophy" addresses the definition and assigning of importance to the marketing of by-products. Two examples, one in metals and the other in industrial minerals, explore prime product to by-product relationships. Relative revenues from all products illustrate the importance of by-products to economic feasibility. "Mechanics" takes a broad view of the types of marketing organizations that are applicable to individual circumstances in the marketplace. In-house marketing as well as agents, merchants and trading companies are outlined and discussed. Philosophy Definition Of Terms Philosophy Definition Of Terms The definition of terns for a paper such as this is generally a necessary but not-very-interesting exercise. However, in simply trying to clearly define the term "by-product" some interesting relationships between products arise and the line of demarcation between "product" and "by-product" often becomes obscure. The search for that distinction represents the philosophy portion of the title. A couple of definitions of philosophy can even help to set the tone for what follows. According to Webster, philosophy is : 1 Pursuit of wisdom. 2. A search for a general understanding of values and reality.

Jan 1, 1983

By Dale K. Nash

The authors have developed a com¬puter-assisted critical path planning and scheduling model to help reduce time required to move longwall mining units. The model includes time constraints and limited resource constraints, such as manpower, machinery, supplies, work space, and transportation routes. Outstanding results were achieved on the first move to which the computer-model pas applied; e.g., downtime due to the move was cut by 50%. The model and the schedules developed using it provide an excellent blueprint for future moves and have led to significant savings in time and costs for Emery Mining Corporation, Huntington, Utah.

Jan 1, 1983

By Ernest M. Spokes

Starting in 1980, a committee of the National Research Council studied the question of why some underground coal mines are safer than others and what could be done to improve the ones with poorer performance. The results indicated that safety is improved by management commitment to safety, by cooperation between labor and management on safety matters, and by quality training of employees and managers. Younger mines have higher accident frequencies, but are less likely to be killed or permanently disabled by a lost-time accident. Methods for improving safety performance are proposed.

Jan 1, 1983

By Richard S. Allen

"The casual visitor is not apt to think of the Adirondacks as a one-time hive of mining and manufacturing activity. However, where there are mountains there are usually minerals and northern New York State is no exception.The Adirondacks are a rocky shield, a great stone cap pulled down over what is now northern New York. The bedrock consists of layered metamorphic rocks which were once sandstones or limestones on the bottom of a shallow sea that covered the region 1000 million years ago. The highlands are composed for the most part of the igneous rock anorthosite. Ancient earth upheavals at temperatures of at least 750°C mixed molten masses of anorthosite and the minerals it contained with the older metamorphic rock, resulting in deposits of iron-titanium oxide s, red garnet and other valuable minerals. Of these, the most readily recognizable was iron.The first hint of the existence of iron ore in the Adirondack Lake Champlain region of upper New York State seems to have come from a Swedish naturalist, Peter Kalm (1716-1769), who travelled through French Canada and visited the military outpost of Fort St. Frederic in 1749. In July of that year, Kalm wrote:""Among the kinds of sand which are found on the shores of Lake Champlain; one is black and the other garnet-colored... and they sparkle when the sun shines. All the grains of this sand without exception are attracted to the magnet, the uppermost or black sand being about a quarter inch deep...""Concerned primarily with the fur trade, the officers and men who occupied this remote bastion of La Belle France were apparently unaware of the industrial and commercial possibilities beneath their feet. No deposit of iron was then known to exist any closer than the Three River s area in Lower Canada."

Jan 1, 1983

By W. L. Falke

The Bureau of Mines has developed a system that permits the "soft" soldering of aluminum and aluminum alloys with standard tin-lead solders. The method employs application of a thin nickel-copper-alloy coating to the substrate, which enables the tin-lead solders to wet readily and spread over the areas to be joined. With conventional technology, aluminum and aluminum alloys are extremely difficult to solder because tenacious surface oxide films prevent wetting. With the Bureau-developed method, the aluminum substrate is mechanically or chemically cleaned to facilitate bonding to a minute layer of zinc that is subsequently applied with an electroless zincate solution. The nickel-copper-alloy (30 to 70 pct Ni) coating is then applied electrolytically over the zinc, using immersion cell or brush-coating techniques. Development of acetate electrolytes has permitted deposition of the proper alloy coatings. The coated areas can then be readily joined with conventional tin-lead solders and fluxes. The joints so formed are ductile, strong, and relatively corrosion resistant, and exhibit strengths equivalent to those formed on copper and brass when the same solders and fluxes are used. The method has also been employed to soft-solder magnesium alloys.

Jan 1, 1983

By J. W. Jefferies

"Plant availability up 13%, production output up 40%, tons per employee up 15% and labor turnover down 52%. One mine manager states these were direct spin offs from the work being done to qualify for a safety award in the program known as the ""IMSRS 11 over a three-year period of time. ""Of Course"", stated this manager, ""these were in addition to an 87% reduction in our disabling injusry frequency rate.”Officially known as the International Mine Safety Rating System or the Five Star Mine Safety Rating, a new approach to mine safety is being used with enthusiasm by a significant number of mines in Canada, the U.S., Australia, Chile, Indonesia, the Philippines and South Africa. Significant results are coming into the International Loos Control Institute from over 125 mines from these countries.The program is built around a mine safety audit system that gives positive recognition to a mine at 5-step intervals along the way, (a star with each step attained). The Institute has licensed auditors in locations in Canada and the U.S. available to audit.It is believed the success of this program is the result of the premise upon which the program is based. The results being achieved are due to the concept that a modern, well-managed mine safety program maintains the basic foundation of a complete management system. When properly implemented, it reinforces those factors common to production, quality and safety. (Attitude - skill - knowledge - fitness - structure - machine - equipment - materials and processes). The IMSRS contains elements that reinforce all these factors. It uniquely treats safety as part of the ""right way"" to do the job and not just the ""safe way"" as a distinctly separate entity. Mines using this program now recognize that many of the older safety techniques were not necessarily the right way or the most efficient way to do things. It appears that this new approach to mine safety is a new avenue for the attainment of management's real goals for being in business, and at the same time achieves optimum support for the important target of safety and health for the mine worker."

Jan 1, 1983

By W. J. Nosek

Reserve Mining Company completed construction on a major process modification project in June of 1980. These modifications enabled Reserve to reduce and control its final iron ore pellet silica content from 9.0 20.77 percent to 5.0 50.26 percent. The paper outlines the implementation of neutron activation on-line analysis and associated computer control loops for measuring and closely controlling the silica content of the iron ore concentrate at Reserve Mining Company. It contains a general overview of Reserve's taconite processing facilities and a presentation of the theory and operation of the neutron activation analysis equipment coupled with the computer silica control loops.

Jan 1, 1983

By Michel Gauthier

Several zinc showings, exhibiting many similarities to the well-known Balmat-Edwards zinc deposits of New York State, occur within the Grenville Supergroup strata of the Mont-Laurier Basin, Quebec. Metallogenic mapping programs have revealed much of the stratigraphic control of this mineralization. This control is observed on both regional and local scales. At the regional scale, these showings are confined to the perimeter of the Mt.-Laurier Basin, while at the local scale, a definite association between the zinc mineralization and dolomitic marble horizons is clearly exhibited from detailed mapping. These new exploration guidelines have proven to be useful for base-metal exploration in the Mt.-Laurier Basin and should be applicable to the entire Grenville Province.

Jan 1, 1983

By Peter Van deVelde

Many companies in North America because of economic or environmental reasons are considering reprocessing material from their waste ponds. The Japanese have developed highly specialized machines and techniques to reprocess industrial/mining wastes from settling ponds. This paper discusses the techniques and results of applying this technology to North American applications.

Jan 1, 1983

By Max B. Holfeltz

[Many factors impact the selection of one mining method over another for deep seated, thick seam coat deposits. Generally if an operating mine is recovering coal at high volumes from thick seams then a truck/shovel fleet is required for coal loading. The next consideration is how to remove the associated burden. If an operation has relatively small amounts of burden associated with the coal then a truck/shovel fleet may be employed for burden removal simply to standardized the entire mine equipment concept. On the other hand large amounts of burden associated with the coal can justify employment of draglines for burden removal. Specific economic, productive, and physical factors contribute to the final decision.]

Jan 1, 1983

By S. A. Matthes

This Bureau of Mines report describes a system for the dissolution of metal and mineral samples using a microwave heat source. Samples and an acid mixture are placed in sealed polycarbonate vessels. The vessel contents are heated using microwaves, digested for 2 min, and quickly cooled. After the solution is brought to a final volume, the vessel contents are heated an additional 2 min in the microwave oven. Using this method, a slag, a feldspar, and a Ni-Cu alloy were dissolved and analyzed by atomic absorption spectroscopy. Values obtained for Na, K, Cu, Ni, Si, Mg, Mn, Ca, Al, and Fe agreed with certified values and had an average relative standard deviation of 1 pct. This system results in a significant savings in time and expense over traditional methods of sample dissolution, and is ideal for preparing solutions for analysis by atomic absorption, plasma optical emission, or X-ray spectroscopy.

Jan 1, 1983

By George F. Swindle

This paper discusses a composite of two coal reserve studies, each of which made use of a computer-based modeling system to assist in an evaluation of multi-seam deposits. The model permitted simultaneous consideration of seam thickness, seam structure, overburden thickness, over-burden ratio, and quality parameters for sulphur content, ash content, BTU values and the EPA Compliance index. The model is designed for use by a non-programmer, geologist or mining engineer. It enables the user, from a computer terminal in his office, to specify constraints (for example maximum um sulphur and maximum- ash content, minimum seam thickness and minimum BTU rating), and produces a report showing the volume, quality and location of that part of the total in place deposit satisfying all the constraints.

Jan 1, 1983

By Gordon Cook

American Electric Power Company (AEP operates 31 coal mines in three states, and some 26 electric generating stations (19 coal-fired) located in the Ohio River Basin. Normally the system burns over 36,071,600 tonnes (40,000,000 tons) of coal and generates in excess of 3.6 X 1018 J (100 billion kwh) of electricity per year. In 1975, AEP, in response to the progressively more stringent air quality requirements of the clean air act, acquired large low-sulfur reserves in Carbon County, Utah (Figure 1. Location Map). Price River Coal Company (PRCC) is the operator OF this multi-seam complex, which is part of the Book Cliffs coalfield at an elevation exceeding 1,829 m (6,000 ft.). The topography is mountainous and divided by numerous canyons. Flat areas are at a premium (Figure 2. Castle Gate Area). Modern high production longwall mining takes in some top and bottom waste, and in this particular operation, it amounts to about 14% of the ROM tonnage.

Jan 1, 1983

By Michael Gauna

A high seam geologic condition exists at Jim Walter Resources No.4 mine which requires immediate rib support after a continuous miner cuts a place, High seam mining heights are typically 2.4 to 2.6 m (8 to 9 it) and a thick rock layer is present in the upper portion of the coal rib side. The 610 m (2000 ft) mining depth at No. 4 mine induces horizontal rib line movement after excavating an entry. Horizontal rib movement greater than 30.5 cm (12 in) have been noted. When lateral movement occurs in the high seam areas, the thick rock layer, and the coal above the rock layer, become fractured and tend to roll into the entry. If not adequately supported, large rib rolls develop in the place being bolted as well as in previously mined areas which endanger men and equipment. To control this situation rib support must be installed in the roof bolting operation as the bolting crew works towards the face. A rib control system has been developed for this high seam mining condition utilizing a mechanical anchor bolt placed at an angle in the rib and installed with a modified Fletcher DDFI- 15 bolting machine. Over 120 km (75 mi) of entry have been supported with angle rib bolts. These angle bolts constitute 43 to 60% of the total roof and rib bolt footage in the high seam port- ions of No.4 mine. The angle rib bolting system has proven safer, more effective, and more efficient than the earlier support method employing bolts installed horizontally into the rib. No rib roll accidents have occurred since the angle drill bolting machines were placed in service in 1981. By securing the broken rib material with an angle bolt anchored above the coal pillar, a more effective means of rib control is achieved. Angle rib bolting does not interfere with continuous miner productivity. In addition, bolting crews are now reduced from three to two people and the total drilling supply costs are approximately 60% the previous cost, when compared to the previous support method using horizontal rib bolts.

Jan 1, 1983

By B. W. Madsen

The Bureau of Mines conducted a large-scale (6.4 t), long-term (2,165 days) test to gain a better understanding of the leaching characteristics of chalcopyritic ores. An ore sample containing 0.77 pct Cu was leached in a fiberglass column by downward percolation of acidified ferric sulfate solutions. Three sets of leaching conditions were investigated: (1) ambient temperature leaching, (2) elevated temperature (50° to 60° C) leaching, and (3) elevated temperature leaching after inoculation with thermophilic bacteria. Leaching at ambient temperature resulted in a copper extraction rate of 0.44 pct per 100 days. Increasing the temperature to 50° to 60° C resulted in decreased activity of natural mesophilic bacteria, and the leaching rate decreased to 0.22 pct per 100 days. The pH was lowered from 2.0 to 1.6, and nutrient solutions that contained thermophilic bacteria were added. This procedure resulted in an increase in the ferric-to-ferrous iron ratio and an increase in the copper leaching rate. However, the increased leaching rate was not sustained, and 120 days after inoculation the bacterial activity declined, the ferrous iron content increased, and the copper leaching rate decreased.

Jan 1, 1983

By J. A. Herbst

It is widely recognized that Semiautogenous Grinding (SAG) circuits require the use of effective process control techniques to achieve their full processing potential and to protect them from the harmful effects of overloads and grind-outs. This requirement is even more essential as the variability of the ore being processed increases. The new Chino Mines Company concentrator located near Santa Rita, New Mexico started operation in June of 1982. At least eight major rock types are mined and milled. Ore hardness, feed size, and specific gravity are quite variable. Typical feed rates per grinding line are 850-900 tph but extremes of 260-1200 tph have been encountered. Normal feed rate variations of between 400 and 1100 tph are encountered on a weekly and sometimes daily basis. Feed size varies with rock type from a maximum of eight inches for the harder ores to two inches for the softer ores. One somewhat unique characteristic of the Santa Rita ore body among major copper mines is the wide variation in ore specific gravity. Specific gravities of the major rock types range between 2.7 and 3.6. The specific gravity variations are due to large changes in magnetite concentration throughout the pit. The result of this is large variations in SAG mill throughput which can have a harmful effect on downstream ball milling and flotation performance. Due to these wide fluctuations in ore characteristics, it was recognized soon after startup that successful operation of the grinding circuit and the plant at large was dependent upon the development of an effective automatic grinding control strategy. Research at the University of Utah has suggested that control based upon critical but difficult or costly to measure variables would improve automatic control performance. A project team made up of the Chino process control staff, Kennecott's Process Control department and the University of Utah Metallurgy Department was established to assess these concepts at Chino. This paper describes the development and on-line plant implementation of an Extended Kalman Filter that uses simple models of the SAG milling process, to predict the volumetric loading, the rock mass, the water mass, and the ball mass within the SAG mills at Chino. The on-line estimation of these parameters is the first step in the development of an integrated SAG mill/ball mill control strategy which is hoped to L eventually maintain the grinding circuit at its maximum capacity, while balancing the grinding load between the SAG and ball mills. Examples of long term estimation with the models and filter are shown for typical operating conditions as well as a SAG mill overload and grind-out.

Jan 1, 1983