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By J. Steenkamp, A. L. Hannaford, A. N. Jones

O’Okiep Copper Co. Ltd.’s 45-kt/month (49,600-stpm) concentrator at the Spektakel mine in South Africa is comprised largely of reconditioned equipment from the old O’Okiep mill, which operated from 1940-1975. When combined with modern approaches to layout, crushing, classification, and flotation, a simple-to-operate plant was constructed at a cost of only $3.2 million.

Jan 11, 1982

By E. L. Fidler, T. E. Finch

Wayne Anderson Regarding the technical paper by Thomas E. Finch and Edward L. Fidler, "Recovery of Stray (Thin) Seams in Western Coal Mining." I would like to comment on this subject. In western Canada, most strip mines encounter thin seam coal or rider seams. Although the paper addresses the problems and costs associated with the recovery of this coal, it does not take into account what the savings are. Without looking at the savings, the "Total Objective" is of course not clear. I feel that in a stripping operation the mine can spend per ton (of the thin seam) up to their dragline stripping costs per ton to recover a rider seam or thin seam. The reasoning behind this is simply that this is the price the mine will have to pay to expose an equivalent amount of coal without the recovery of these thin seams. If the mine can recover a rider seam or thin seam for less than the dragline operating costs per ton, a savings will be realized. By recovering a thin seam or rider seam, the life of an ore body is extended by that amount of coal not thrown away. In addition, the cost of land acquisition, associated permits, capital, and reclamation will be reduced as more coal is delivered for a given area. When the above points are considered, the recovery of these thin seams can be very profitable and indeed worth recovering.

Jan 11, 1982

By James M. Link

The first rule of mineral deposits always seems to be: the deposit is never close to the market. With gems and precious metals, this is not much of a problem. But with most of the mineral commodities used in today's world, transportation becomes a major part of the cost to the consumer. In Japan, for example, more than 60% of the cost of coal to the consumer may be attributed to transportation. The purpose of this article is to examine pipeline transportation, particularly mineral slurry pipelines, as a means of getting the mineral to market. Pipelines Today Regulated pipelines in the US totaled nearly 724 Mm (450,000 miles) in 1980 according to the Federal Energy Regulatory Commission (FERC). Worldwide, more than 210 Mm (125,000 miles) of new pipelines will start construction in 1982 at an estimated cost of more than $150 billion. According to the Bechtel Corp., the period between 1982 and 2000 will see major growth in pipelines of all kinds. In North America, major movements of crude oil from Alaska and synfuels from the Rocky Mountains will require the construction of nearly 16 Mm (10,000 miles) of new pipelines. Nearly 42 Mm (26,000 miles) of new gas transmission pipelines will be needed to tap both US and Canadian arctic gas fields and move the gas to major markets on both coasts. Other pipelines will be required to move additional quantities of natural gas from the Rocky Mountains to more populous regions. Bechtel says more than 24 Mm (15,000 miles) of slurry pipelines will be needed to transport coal from both eastern and western coal provinces to the Mississippi valley and coastal areas. In 1980, 125 companies delivered more than 1 km3 (6.5 billion bbl) of crude oil and 652 hm3 (4.1 billion bl) of products in the US. At the same time natural gas pipelines transported 498 km3 (17.6 trillion cu ft). The reported investment by these companies was nearly $20 billion at the end of 1980. Advantages of Pipeline Transportation The obvious success and vitality of the oil and gas pipeline industry is based, at least in part, on the fact that pipelines are a very efficient and low-cost method of transportation. This fact, coupled with the need for lower cost trans¬portation, has led to the marriage of oil and gas transmission technology and the bulk mineral solids transportation industry. The off-spring of this marriage is the mineral slurry pipeline. Slurry pipelines have a number of advantages over other transportation methods. One of these is the fact that they are buried-out-of-sight, out-of-mind. Second, they are relatively small users of labor because they lend themselves to automation and remote, or even computer control. Third, they offer an attractive economic alternative to other transportation systems. For example, for a 1000 km (621 miles) distance, rail costs of 1?/ km (1.7?/ton-mile) are about equivalent to slurry pipeline costs. But, as the distance increases, pipeline cost per t-km continues to drop while equivalent rail charges remain essentially insensitive to distance. Where existing rail, barge, or ocean ships are available, the cost of new construction associated with a slurry pipeline probably will render it noncompetitive. However, where new rail or other construction is needed, the cost of a slurry pipeline is very competitive. About three-fourths of the cost of a pipeline is in pipe, fittings, and construction. Nearly a fifth of the investment is in pump stations and the remainder is in right-of-way, surface facilities, utility acquisition, communication facilities, and other support areas. The fact that pipelines are capital intensive is, at the present time, a mixed blessing. For example, the delivered cost of coal in a hypothetical project doubles when the cost of money rises from 9% to 17.5% per year. The largest cost element for delivered coal in this example is in depreciation and finance charges. The next largest cost element is electricity to power the pumps, with labor making up the smallest increment of the delivered cost of coal. World Slurry Pipelines The idea of a slurry pipeline was probably first investigated in the latter 19th century, but the first ones were successfully built and operated in the US in the early 1900s. Today, they are fairly common worldwide. Table 1 shows a number of the world's slurry pipelines. An examination of these will further emphasize the fact that pipelines provide a cost competitive alternative where new construction of a transportation system is required. In each of the examples, the desired mineral commodity is located in a remote corner of the world, markets are at a great distance, value of the commodity is not great, and no other transport system is available.

Jan 10, 1982

By Ernest E. Thurlow

Introduction Today, more than 50% of rail-carried commodities are mineral industry related, with coal being the most important single commodity moved by rail. In 1980, coal accounted for more than 5.7 million of the total 22.6 million carloads moved by rail. Metallic ores were third behind grain, with more than 1.4 million carloads. Crushed stone, gravel, sand, and other non-metallic minerals totaled almost 2.3 million carloads. Chemicals and allied products, including fertilizer and coke, added another 1.7 million cars, with petroleum and petroleum products totaling 300,000 carloads. Coal Several things happened in the 1970s that gave rise to increased consumption of coal-particularly western coal-and to its dominant position among rail-carried commodities. First, the Clean Air Act of 1970 required generating plants to make significant reductions in sulfur dioxide emissions. To comply, utilities could either invest in scrubbers or switch to low-sulfur western coal. Many opted for the latter. By 1972, increasing demands by the utility companies halted what had been a 25-year decline in national coal consumption. Second, the Arab Oil Embargo of 1973 put an end to cheap oil and gas, limiting their future as fuels for electric generating purposes and increasing the potential for coal. Third, in 1977, President Carter announced an energy program with coal as its cornerstone, calling for an annual two-thirds increase in national coal production by 1985. He also called for conversion to coal by utilities and large industrial users. Finally, he proposed a 10-year, $10 billion program to encourage domestic coal production and stimulate development of export markets. Coal bounded into world prominence. Foreign demand for steam and metallurgical coal increased tremendously, while US demand for western coal also shot up. This meant greater demands on the transportation sectors that traditionally carried coal to market. Many railroads began programs to serve the coal industry. One example is Burlington Northern's commitment to handle increased western coal tonnages. The company spent more than $1 billion in recent years to develop a system capable of moving more than 91 Mt (100 million st) of coal each year. Other leaders in this renewal were Norfolk and Western, Union Pacific, Santa Fe, and Southern Pacific railways. The importance of the rapid growth of coal traffic to the railroads is shown in the accompanying table, which gives percentages of total tonnages hauled and revenues attributed to coal. With coal providing the railroad industry with a substantial share of its revenues, there is keen competition among the rail companies themselves and among railroads and other transportation sectors for coal haulage. But there is also cooperation when more than one railroad is involved in delivering the coal from mine to market or when a combination of transportation modes is more economical. The latter is represented by Conrail's interest in working with the port authorities of New York and New Jersey to establish a new coal port that would serve not only export markets, but also utilities and industries in the northeast. Iron Ore Next to coal, iron ore (taconite) is the most important single mineral commodity handled by railroads. In Minnesota, where most iron ore is produced, rail transportation is primarily by Burlington Northern and the Duluth, Missabe, & Iron Range Railway Co. (DM&IR). The DM&IR, owned by US Steel, serves several producers on the Mesabi Iron Range. Two of the larger producers, Erie Mining Co. and Reserve Mining Co., also own railroads that operate between the mines and the ports of Silver Bay and Taconite Harbor on Lake Superior. Several iron mines and taconite plants in Michigan are served by the Chicago and Northwestern, and the Soo Line. Total 1981 shipments of taconite and iron ore are estimated at 55.9 Mt (55 million It), compared with about 61 Mt (60 million It) in 1979 the most ever shipped in one year. Still, with annual production capacity of the eight Mesabi Range

Jan 10, 1982

By A. T. Yu

Two major events highlight recent developments in US ore and coal ports: completion of the last series of modern taconite pellet transshipment facilities on the Great Lakes; and modernization and construction of coal ports, particularly on the East and Gulf Coasts. The New Taconite Transportation System To reduce raw material transportation costs, a fleet of new generation high-capacity 304-m (1,000-ft) self-unloading vessels were built to carry iron ore pellets from the Minnesota-Michigan iron ranges to the steel plants on the lower Great Lakes. Existing port facilities had to be modernized, revised, or completely rebuilt to accommodate these large vessels. Some of these were Burlington Northern's Allouez, WI, loading dock; Duluth, Missabe & Iron Range Railway Co.'s Two Harbors, MN, facility; Republic Steel's Lorain, OH, facility; and Chessie's Toledo, OH, dock. Allouez and Two Harbors receive taconite pellets from unit trains and load them onto large vessels either after dumping or via a large stockpile and reclaim system. The Lorain facility receives iron ore pellets from self-unloading vessels' discharge boom conveyor and reloads the pellets into rail cars or small vessels destined to inland steel mills. The Toledo facility receives Armco pellets from vessels, stockpiles them through the winter, and reloads into unit trains destined for Armco's mills along Chessie's rail tracks. Burlington Northern's $75-million Allouez pellet dock, completed in June 1977, was built to receive pellets produced by Hibbing Taconite Co. and National Pellet Plant in Minnesota, stockpile them through the winter when the lakes are frozen, and load them into 304-m (1,000-ft) vessels in the shipping season. As much as 10 Mt (11 million st) of pellets may be stockpiled within the loop track. A 6-km (4-mile) long conveyor system connects the stockpile area and the dock. Thirty-six new concrete silos were built on the dock to house 2 kt (2,000 st) each of pellets before shiploading. The $35.5-million expansion of the Two Harbors transshipment facilities began shiploading in July 1978 after ground breaking in Aug. 1974. Particularly noteworthy is the first application of the Orboom system-a breakthrough in technology for the modernization of the century-old pocket docks on the Great Lakes to accommodate the new generation of super vessels. The pocket-type loading dock has been a standard on the lakes for nearly a hundred years. Bottom-dump rail cars fill the ore pockets on top of a finger pier. Gravity chutes matching standardized ore ship hatch spacings are lowered to fill the holds of a 20.3-kt (20,000-dwt) ship. The construction is simple and the loading swift. In spite of advances in technology elsewhere, most of these docks continue to serve the iron ore and coal trade in the same manner they did in the 19th century. Although performance of the pocket docks on small vessels remains outstanding, the new 304-m (1,000-ft) vessels are beyond the reach of the old docks. After extensive development, the Orboom system (Patent No. 4,065,002) for pocket docks was successfully developed. The heart of the Orboom system is the retractable shuttle loading arm which loads the wide beam vessels. The Orboom shuttles are fed by existing pockets of the dock that, in turn, are charged by a tripper conveyor along the length of the dock. The Two Harbors shiploading system is supported by a 0.9 Mt (1 million st) storage-reclaim network. Unit trains are bottom dumped. Taconite pellets are stacked and reclaimed by bucket wheel reclaiming systems. Lower Lakes New Ore Ports At the lower Great Lakes receiv-

Jan 10, 1982

By Sharon Thomson

Since 1977, Amax Coal Co.'s Belle Ayr mine near Gillette, WY, has been the largest producing coal mine in the US. In its 10 years of operation more than 90 Mt (100 million st) of coal have been shipped from the mine's facilities to electric generating plants across the country. It is thought to be the largest amount ever produced in US history from a single coal mine. The railroad is Belle Ayr's lifeline for moving this massive volume from a relatively isolated corner of northeastern Wyoming. There are no waterways for barge traffic, and highway truck hauling would be impractical considering the quantity and distance of coal to be moved. Transportation in the Powder River Basin-at least for the present-is strictly unit trains. An average of four unit trains daily load at Belle Ayr. These trains average 108 cars long, with a capacity of 91 t (100 st) per car. Burlington Northern Railroad serves the Powder River Basin, but locomotives supplied by Union Pacific, Milwaukee Road, and Kansas City Southern are a common site as well, since coal will often travel these lines too on its way to utility plants in Colorado, Kansas, Iowa, Texas, Arkansas, Louisiana, Wisconsin, and Oregon. When Belle Ayr opened transportation in the Powder River Basin was in an early development stage. As the first large-scale coal shipper in the area, Belle Ayr was the only user of a 27-km (17-mile) railroad spur south of Gillette. Other mines, however, were to open soon on the abundant, low-sulfur reserves. Today, less than a decade after Belle Ayr's debut, 13 large-capacity mines operate near Gillette. The 27-km (17-mile) spur that once served only Belle Ayr has been extended 177 km (110 miles) south to service other mines as well, and to tie into a major rail line in central Wyoming. The Powder River Basin is now served by a wishbone-shaped track configuration that allows train movement north into Montana, south into Colorado, and east into Nebraska for connections across the country. Operations at Belle Ayr are closely tied to train arrivals and departures, with coordination essential between mine operations and rail personnel. "Train movement in the Powder River Basin has evolved to the point where we are fine-tuning mining operations to coordinate them with a more dependable transportation system," according to Joe Jefferson, transportation supervisor with Amax Coal's western division. That, however, hasn't always

Jan 10, 1982

By Fritz Kleiner, Walter Meintrup

On Nov. 4, 1981 A/S Sydvaranger's 1-kt/h (1,100-stph) wet-process, iron ore ball mill completed its first four months of uninterrupted, full-load operation in Kirkenes, Norway. This 6.5-m-diam (21-ft-diam) mill is driven by a gearless ring or wraparound 8.1-MW (10,860-hp) motor at 13.1 rpm-a first of a kind in this segment of industry. This article examines reasons for selecting this type of drive over more conventional schemes, lists specific advantages of such large mills, and describes the installation in Norway. History For almost a decade, good operating experiences have been gained with 28 gearless ring motor drives in the cement industry, driving 2.5 to 4-m-diam (8.2 to 13-ft-diam) tube mills with drive powers ranging from about 3-4 MW (4,000 - 8,000 hp). Why then did the mineral ore processing industry hesitate until 1980 to adopt this successful concept for similar applications on ball, semiautogenous, and autogenous mills? There are a number of good reasons in the eyes of conservative mill builders and operators, the most commonly cited ones are: • No operating experience in this segment of specialized industry. • More severe environmental conditions in the wet ore grinding process. • An indifferent attitude of mill builders and electric motor manufacturers towards new drive technologies. • Limited confidence in solid-state power supply systems, such as frequency converters of the required size. There have been and still are numerous problems associated with low-speed geared mill drives of any kind, especially with individual motor/gear sizes approaching or exceeding about 4 MW (5,360 hp). Every mill builder knows about them, but operators learn to accept them as inevitable. The Decision to Change Three things combined to break this technological stalemate: the courage and progressive spirit of one major iron ore processor in Scandinavia, the cooperation of three experienced manufacturers, and an unusual application problem that could not be solved by any conventional approach. The last factor was surely the decisive one, but the first one does not come as a surprise either. The Swedes near Kiruna and the Norwegians around Kirkenes are experienced ore miners and processors, and much credit goes to them for technological breakthroughs in the industry. At A/S Sydvaranger in Kirkenes, above the Polar circle at about the latitude of Alaska's northern tip, the existing grinding facilities, with a total of 14 100 to 240-t/h (110 to 264-stph) ball mills, can not be expanded. Nevertheless, to increase mill throughput, only installing a larger mill in place of an existing smaller one was a practical alternative. For this replacement, the owners set requirements that seemed impossible to meet: • The old 100-t/h (110-stph) ball mill should be replaced with a new ball mill with 10 times the rated throughput, without significantly impairing the operation of the remaining mills, and without significantly changing the mill building. • The new mill should have a variable-speed drive to ultimately optimize the grinding process by means of a closed-loop process¬computer-controlled grinding cycle, and to minimize the specific energy consumption. • Availability, efficiency, and life expectancy of all new components must be higher than those being replaced. • Inrush-current and harmonic loads on the rather weak electric supply line must be minimized to ensure safe plant operation. All old ball mills at A/S Sydvaranger are the geared type, using single synchronous and wound-rotor, slow-speed motors with ring-and-pinion gears. Operators are familiar with the limitations and problems associated with such drives, and they are aware that the following items become major concerns when drive powers are drastically increased: • Gears are subject to wear and tear, require frequent maintenance, and eventual replacement of major parts. • Gears are sensitive to misalignment, overload, and thermal distortion, limiting their useful life. • On dual or quadruple drives, load-sharing and torque oscillations between motors can be a major reason for concern. • At these speeds, ring-and-pinion gears reach their torque transmission capabilities altogether at around 4 MW (5,360 hp) per motor/pinion. To obtain the desired variable-speed performance of the new drive, the only practical and economical conventional solution would have been a frequency-controlled, low- or medium-speed dual motor drive with about 8 MW (10,720 hp) of power. This, however, was not feasible because of limited floor space. Therefore, bids were solicited for the alternative drive method, the gearless ring motor. General Considerations Why are such large mills considered? After all, one could avoid all the problems by simply staying with smaller mill unit sizes. Under competitive pressures of free markets, however, grinding efficiencies and specific energy consumption become key factors in selecting new equipment. Specific energy consumption of ball mills decreases with increas-

Jan 9, 1982

By Randolph E. Scheffel, David C. Fitch, David K. Hogan, Mark R. Welsh

In Oct. 1981, Ranchers Exploration and Development Corp. began producing silver bullion from the Escalante mine and mill complex, located in southwestern Utah. Current in-place reserves are estimated at 2.42 Mt (2.67 million st) of ore, containing about 936 t (33 million oz) of silver at an average grade of 428.5 g/t (12.5 oz/st). The vein-type deposit is being mined underground through a decline that is currently 864 m (2,835 ft) in length, but will ultimately be at least 1.5 km (5,100 ft) long. The mine is completely mechanized with rubber-tired equipment, and is producing 680 t/d (750 stpd) of ore, five days a week, or 177 kt/a (195,000 stpy). Additional capacity is available. The cyanide leach mill and associated refinery are presently producing 4.35 t/month (140,000 oz/month) of silver bullion-an an¬nual rate of about 52.25 t (1.68 million oz). With minor modifications, the mill can produce up to about 70 t/a (2.25 million oz/year), and expansion is currently underway. History The Escalante property is located 68 km (42 miles) west of Cedar City, UT, on the west side of the Escalante Valley, where the vein forms a gentle ridge in an area of low, rolling hills. For years, the vein has been the object of considerable exploration, but never became more than a sporadic producer, primarily due to low silver prices. Heber Holt of Enterprise, UT, staked the original four claims in 1896; they were patented in 1910. During the next 48 years, limited exploration and mining activity was conducted on the property. Systematic evaluation and development did not, however, begin until March 1958, when Samuel S. Arentz, a prominent mining engineer and consultant, formed several joint ventures with mining and oil companies that conducted drilling, drifting, mining, and water drawdown tests on the property. However, it remained uneconomic, principally because of low silver prices and costs for pumping large flows of underground water. In 1975, Ranchers obtained an option on the property and in 1979 began a drilling program. As of May 1982, the company had drilled 70 core holes, bringing the number of exploratory holes drilled on the property to 138. Test mining began in 1979 as silver prices increased, and full mine development began in 1980. Mill construction began in Sept. 1980, and on Aug 29, 1981, the first ore was fed to the mill.

Jan 9, 1982

International Minerals & Chemical Corp.'s New Wales operation near Mulberry, FL, is reportedly the world's largest concentrated phosphate chemical fertilizer and phosphate-based animal feed ingredients complex. Its latest expansion represents a $191-million investment. Two Northwest draglines were put to work at the operation early last year and, according to a company spokesman, total production from the units have more than doubled that from older rigs. This article describes how the draglines are used and provides details on the New Wales operation. The principle product at New Wales is phosphoric acid, produced by reacting ground phosphate rock with sulfuric acid in large concrete attack tanks. For each ton of phosphoric acid produced, New Wales must dispose of about 4.5 t (5 st) of waste gypsum. New Wales stores the gypsum on-site, and uses durable Northwest draglines to help handle the material. Two Units Maintain the Gypsum Stack After the gypsum is separated from the phosphoric acid through 23-m-diam (75-ft-diam) vacuum filters, it is mixed with water from a 121-hm2 (300-acre) recirculating cooling pond and, in slurry form, is pumped to the top of a 121-hm2 (300-acre) gypsum stack located adjacent to the cooling pond. The slurry contains mostly gypsum (CaSO4), with small traces of silica and other elements. The water at this point is corrosive, containing from 1-2% phosphoric acid. Its pH usually ranges from 1.5-2.0. Water drains from the gypsum stack into the cooling pond. Only about 15% of the pond's water, however, comes from the gypsum stack; the balance is from various sources throughout the complex and is held in the pond to cool before being returned for reuse in the plant. About 97% of New Wales' water needs come from this recycling program. The gypsum remains on the stack, inert, ready for future processing if it becomes economically feasible. Throughout the handling process, Northwest draglines work around the stacks' rim, continually directing the waste flow and digging out dried solids to heighten the perimeter dike to provide more storage volume. When wet, gypsum is extremely soft. When dry, it compacts well and provides footing with enough bearing capacity to support the machines. Processing at New Wales started in 1975 and the gypsum storage area has already been built up 12 m (40 ft) above grade. A total of 14.8 km3 (12,000 acre-ft) of solids are now stored. The draglines dredge material from near the perimeter dikes and place it to build parallel berms. This

Jan 8, 1982

By M. Churchill, V. R. Degner

Over the past two decades, declining ore body grades and increased operating and construction costs have provided an incentive for the development of progressively larger flotation machines. As a result, the 1.7-2.8 m3 (60-100 cu ft) flotation machine of the 1950's and 1960's is being rapidly replaced by large volume machines. The result has been improved flotation machine specific capacity (tph processed per sq ft of floor space); specific power (hp per tph processed); and process control simplicity. The recent development and satisfactory plant evaluation of the 28 m3 (1000 cu ft) flotation machine allows economic and operating advantages in high tonnage mill applications. Some principles of mechanically induced air flotation and the development of the large 28.3 m3 (1000 cu ft) flotation machine are reviewed here. Performance evaluation in beneficiating metalliferous ores-copper, zinc, and iron-is also given and recently completed plant results provided. Mining lower grade ore bodies results in the need to process increased tonnage in the concentrator. This greater tonnage requires more individual flotation machines, unless individual machine capacity, or cell volume, is increased. As the ore processing rate of the concentrator increases, the benefits of progressively larger individual cells in the flotation section become more significant. The accompanying figure illustrates the advantages of a larger flotation machine. In the figure, the number of machines in the rougher-scavenger section is related to the plant tonnage for three sizes of flotation machine: 8.5 m3 (300 cu ft), 14.2 m3 (500 cu ft), 28.3 m3 (1000 cu ft). The 28.3 m3 (1000 cu ft) flotation machine results in 95 fewer machines, compared to the 8.5 m3 (300 cu ft) machine at 45.4 kt/d (50,000 stpd) feed. The flotation cell reduction is, of course, doubled at a plant production rate of 90.7 kt/d (100,000 stpd). Using fewer flotation machines saves floor space. The 14.2 m3 (500 cu ft) and the 28.3 m3 (1000 cu ft) machines result in a floor area reduction, relative to the 8.5 (300 cu ft) machine requirements, of 134.7 and 418.1 m2 (1450 and 4500 sq ft), respectively, for the 45.4 kt/d (50,000 stpd) rate and 269.4 and 836.1 m2 (2900 and 9000 sq ft), respectively, for the 90.7 kt/d (100,000 stpd) rate. In addition, flotation practice has shown that the "specific power intensity"-power per unit cell volume-is less for increased cell size. This results in a power draw reduction, for the rougher-scavenger circuit, of between 552 and 686 kW (740 and 920 hp) for the 14.2 and 28.3 m3 (500 and 1000 cu ft) machines, respectively, when processing 90.7 kt/d (100,000 stpd). Fewer cells improve machine control and simplify maintenance needs while reducing floor space and power requirements. These are tangible incentives for the development of large flotation machines for high tonnage applications. Flotation Principles The accompanying figure shows how key hydrodynamic regions influence the performance of a mechanically induced air flotation machine. Air is induced into the fluid from the top of the cell, due to the mechanical action of a rotating impeller. The impeller circulates the liquid, or pulp, from the bottom of the cell. The result of these dual flow paths is the mixing of the two fluids and one solid phase in the highly agitated region where physical contact between the air bubbles, and the solid particles to be floated, is accomplished. The particle to be floated is assumed to have a properly prepared hydrophobic surface prior to flotation. Upon leaving the three-phase mixing region, the "floatable particle-air bubble matrix" and

Jan 7, 1982

By Carl Eschman

Productivity from large walking draglines is primarily dependent on operator skills. This machine may be in operation three shifts a day, 364 days a year, and its output is directly related to coal uncovered and mine profitability. Dragline operators must have highly developed manual skills and be knowledgeable in mine planning and working strategies. When using equipment costing more than $25 million, some formal training is usually required before an operator is allowed to assume complete con¬trol; however, dragline operators rarely receive any structured training before operating these giant excavators. A form of apprenticeship is usually followed where an operator candidate progresses from a groundsman to an oiler position. As an oiler, he is permitted to operate the dragline for short periods under supervision. After apprenticeship, the operator is considered sufficiently prepared to operate the largest, most powerful machine at the mine. The apprenticeship training method has obviously provided the surface mining industry with skilled dragline operators; however, conditions are arising that require a realistic and effective training tool that can be accessed by mining companies. New mines -either planned, under construction, or recently opened in the West-do not have access to a pool of experienced operators and oilers as do Midwest mines. As coal mining activities increase in both the West and Midwest, demand for trained dragline operators could be required in a short amount of time. Also, the more productive techniques along with sound basics of strip mining are sometimes lost in the informal "OJT" training method. Modern draglines are the pacemakers of the strip mine, and are simply too expensive to be used as a training device where lost productivity and susceptibility to damage can directly affect mine output. The Dragline Training System is a logical first step in formally educating or retraining operators. The program, started by the US Bureau of Mines and continued by McDonnell Douglas Electronics Co. under contract with the US Department of Energy, was installed and evaluated at DOE's Carbondale Mining Technology Center in Carterville, IL, last year. It is now being operated by Southern Illinois University at Carbondale. System Description The Dragline Training System addresses specific environments and work practices encountered during an actual mining operation at a midwestern US surface mine. This area was chosen because of its high number of strip mines using large walking draglines. Most draglines in the region are Bucyrus-Erie 1370, 1450, and 2570 models, so the dragline trainer was patterned after the company's 1370 machine. Operating and emergency controls are sufficiently standardized for most large walking draglines, and peculiar dynamics and responses from any specific dragline can be programmed into the computer system. The computer simply prompts the user to select the manufacturer and any peculiar response or rate changes needed. A 46-m3 (60-cu yd) bucket is simulated, but for closer simulation, various bucket configurations can be provided. Dragline Trainer The dragline trainer uses the TV-model simulation technique. A scaled model of the dragline is positioned in a model mine. A television camera is positioned at the operator's theoretical eyepoint, and the view captured is projected into a large screen in full scale. The screen is positioned in front of the operator seated in a full-size cab at Bucyrus-Erie controls. By manipulating the controls, the trainee can operate the model dragline and observe its reaction in the television display. In addition to housing dragline controls and consoles, the wooden, oversized cab contains the digital computer, terminal, video recorder and monitor, power switch box, air conditioner, and has enough room for the instructor and five student observers. The 50:1 scaled dragline model contains servo-controlled functions for hoist, drag, swing, delta swing, and longitudinal and lateral position. The delta swing provides bucket lag during swing and a realistic pendulum action when the swing is terminated. The over-responsive second order servo system is designed to provide hoist, drag, and swing rates exceeding present draglines. In all cases, position servos are used for better control and sta¬bility. The normal rate operation of an actual dragline is computed for the specific machine and presented to the servo amplifiers as iterative position commands increasing or decreasing

Jan 6, 1982

By John H. Bassarear

How best to grind? This article compares conventional crushing and grinding circuits to semiautogenous circuits, reviews recent installations of each circuit, and describes seven methods of using autogenous or semiautogenous techniques. In addition, steel and power consumption data are reported and benefits of a dedicated digital computer are discussed. Size reduction is the most expensive operation in most mills. Crushing and grinding are usually the greatest part of capital costs. They often make up 60-70% of total mill operating costs. Picking the proper crushing and grinding method must, therefore, be done with great care, so the best circuit is chosen. In the past 10 years, there has been a strong trend toward using autogenous or semiautogenous grinding in mills throughout the world. Autogenous grinding is favored when the ore is quite competent and a fine grind is needed. Semiautogenous grinding is applied when fine crushing could cause severe problems or when ore varies in hardness or competency. The taconite iron ores of northern Minnesota fit the description for an autogenously ground ore and many are successfully ground that way. Most im¬pressive are the nine lines of 11 x 4.9 m (36 x 16 ft) mills powered by 9 MW (12,000 hp) motors at Hibbing Taconite. Porphyry copper and molybdenum ores fit the description for semiautogenous grinding. Recent installations include Highmont in British Columbia, Canada, and Quintana in New Mexico. Sampling Many mills have been built based on inadequate sampling data or insufficient tests. With the cost of many mills exceeding several hundred million dollars, it is mandatory that geologists, mining engineers, and metallurgists work together to prepare representative testing samples. Simple, repeatable work index tests are usually sufficient for rod and ball mill tests. However, pilot plant tests on 50-100 t (55-110 tons) of ore are frequently necessary for autogenous or semiautogenous mills. Preparation and selection of the test sample is of utmost importance. Procedures for autogenous and semiautogenous mill pilot plant tests are relatively simple for those experienced in running them. Reliable and repeatable results can be obtained if simple, fundamental procedures are followed. The accompanying figure shows a typical conventional crushing-grinding circuit with three stages of crushing followed by ball mills or a rod mill-ball mill combination. This flowsheet is typical of many mills that have been built throughout the world. Also shown is a typical semiautogenous (SAG) circuit with feed coming directly from a primary crusher, and the semiautogenous mill product going to the separation process. Many similar semiautogenous circuits are built today because they are simple and flexible, lend themselves readily to high tonnages, and usually cost less to build and operate. With some ores, it is possible to send mine-run ore directly to the semiautogenous mill, eliminating the need for a primary crusher, as at Benquet's Dizon mill in the Philippines. An autogenous or semiautogenous circuit, as the name implies, uses the ore itself to assist in the grinding process. Generally, for this type of circuit, the ore must be competent so large ore chunks can be used to grind smaller ones. If ore alone is used, then the circuit is autogenous; but if balls are added to supplement the charge, then the circuit is termed semiautogenous. Ore competency is not always a criterion, to break up large pieces and wash away cementing material. Autogenous and semiautogenous mills have been very successful on relatively soft uranium ores where the values are frequently found in the material that cements together the sandstone grains. Autogenous Circuits When an ore is hard and competent, it is always possible it might make good "pebbles" that could be used for fine grinding media. Seven methods have been tried using combinations of autoge-

Jan 6, 1982

By William L. Young

There is an old saying in Canada: "Mines are made as much as discovered." What follows is Young's perception of his experience developing and financing the Cochrane Hill gold mine project. In 1974, I came back from rutile and zircon exploration and mining in Australia. I became interested in a copper, lead, and zinc project in the Bathurst District, New Brunswick. Much field work had already been done but I was convinced that a reinterpretation of the geophysical work left room to enlarge on the known mineralization. So, with my own money I put a property deal together, found an underwriter willing to raise $100,000, and had a lawyer produce a prospectus. The prospectus was ultimately accepted for filing by the Ontario Securities Commission and I acquired funding and began work. It did not take many drill holes to determine that the interpretation was not geologically valid. However, while drilling was going on, geophysical and geochemical explorations indicated interesting anomalous zones elsewhere on the property. But by now the base metal market climate had soured and the $50,000 I had left was not enough to evaluate the new results. So I decided to farm out the property. A data folio was produced and the property was optioned to a major mining company, with Northumberland Mines Ltd. retaining a 20% free, carried interest. By 1976, the market for junior issues was so bad no under¬writer would even talk to a geologist and I still had the $50,000 in the bank and was looking for something to initiate. A Project That Went Nowhere Market research indicated that the Toronto area imported fine calcium carbonate fillers from Georgia, Alabama, and Vermont. I was aware of the specs and the fact that there is a large marble belt in Eastern Ontario. After some prospecting, I found an interesting deposit. The product was slightly high in silica and low on brightness. Research work eliminated the silica and corrected the brightness. So, with insufficient money we launched a feasibility study. This included diamond drilling, bulk sampling, special fine grinding and air classification tests, and an in-depth market survey. Our product was as good or better than those on the market. Our advantage was that delivery could be made by a two-hour truck haul to the customer. The present system of rail delivery had many problems, especially in winter. Despite everything looking rosy, we ran into a stone wall. The underwriters were singularly unimpressed because the public saw little glamour in a substance most people had never heard of. The issue would have been difficult-if not impossible-to sell. Banks and government agencies took the position that if we could get long term take-or-pay contracts then they would lend the required capital. None of the suppliers, however, would even consider a contract until production had begun and they could evaluate the production material. It was a classic "catch 22" situation. I have gone into this in some detail to show how tough the industrial mineral market can be. We eventually optioned this calcium carbonate property to a major corporation. The option agreement would give us a free, carried 15% and the right to buy up to 40% for contributing 25% of the production costs. But the experience left my company in poor financial shape. To survive, I think the entrepreneur-geologist must always have at least one project in reserve, an emergency plan. I had been searching out a new project to work on, after the calcium carbonate option was wrapped up. It was gold. Gold intrigued me and I knew quite a bit about Nova Scotian gold. I felt that with any rise in price, many of the former high-grade gold mines would have interesting potential for the larger, low grade portions of the deposits. That is how I happened on Cochrane Hill, where much work had been done in the early 1970s when gold as $4.82/g ($150/ oz). This time my timing was good. No sooner had Northumberland signed an option agreement than gold prices started to rise. In six months, they went to $27.331g ($850/oz). Even so, financing gold prospects in early 1980 was still not easy. It had been years since gold financing had been undertaken. A whole new generation of investors, with no knowledge of gold mining, had grown up. So, with accounting and legal council, we decided on a semiprivate "seed money" offering. Under the new Ontario Securities Act, this was a new-and partly tax sheltered-concept. At the time, it was very innovative.

Jan 6, 1982

Hoses provide a variety of critical functions in nearly every mining operation. Care must be taken when selecting, installing, and maintaining hoses to insure maximum hose life. This article provides some tips on selecting, installing, and maintaining hoses, and gives some background on hose construction and safety. In the mining industry, hoses are used for everything from hydraulic systems that power drills and hammers, to suction systems that carry away dust and debris. Hoses are used on such a large scale that a detailed discussion of specific applications would require many volumes. Dayco Corp. has, however, provided these basic and brief guidelines on how to select and maintain hoses for mining applications. Hose Construction Industrial hoses are classified as much by construction as they are by application. So, it is a good idea to start any discussion of hoses with a description of their basic construction. There are four basic components to hoses: the tube, reinforcement, cover, and couplings. The tube is the inner core or lining, and is usually made of smooth rubber or plastic. Rubber or plastic composition is scientifically determined to be compatible with the materials passing through it, such as fluids, chemicals, gases, or substances. Other considerations in compounding rubber or plastic for the tube are temperature ranges and stresses. In practice, the required compound can be precisely chosen from various charts listing them according to application. There are, however, applications where the compounding of tube rubber or plastic must be customized. The reinforcement hose layer immediately surrounds the tube. As its name implies, this layer gives the hose strength and provides protection for the tube component. Reinforcement must be able to contain the inner forces-pressure and shock-transmitted through the tube, and such external forces as twisting, bending, and crushing. So it is usually made of high tensile strength cord, fabric, or wire that is wrapped, wound, or braided around the tube. The cover is the outermost layer, so it may encounter oils, acids, water, dust, abrasion, and other potentially damaging influences depending, of course, on the application. An appropriate cover material must be selected, usually a rubber compound. Couplings, even though they are a hose attachment, are as vital as any other component and should be considered part of the hose. Couplings are usually made of carbon steel or malleable iron; however, bronze or stainless steel might be used if corrosive chemicals are involved and brass or aluminum might be used for flammable fluids. A coupling is usually in two parts: an insert that fits into the hose bore and contains the threaded male, female, or other type of connection, and the ferrule or collar that fits over the hose and secures the coupling in place. There are, however, some one-part couplings that fit securely into the hose without a ferrule. These are usually limited to low pressure applications and are secured to the hose by clamps or metal bands. Some fittings can also be permanently "built-in" as the hose is made. Couplings can be classified as reusable or permanent. The reusables can be removed when the old hose expires and used again on a new hose. The permanent types are crimped or swaged on at the factory or in the field (using special equipment) and must be discarded with the hose. Although couplings are most commonly thought of as having threaded fittings, there is another type called "quick connect." These either have a crow-foot or jaw-type design that permits a fast, "snap" connection. This can

Jan 6, 1982

By Thomas F. Stinson

Energy-producing states see severance taxes as attractive sources of increased revenues for otherwise tight budgets. Consumers in energy-poor states, however, protest that current rates are excessive and have moved to obtain a reduction. The US Supreme Court heard two cases questioning such taxes during its 1981 term, and Congress, in each of its last two sessions, has seriously considered measures placing a ceiling on severance tax rates. Although discussions usually focus on coal severance taxes levied by Montana and Wyoming, ramifications of changes in national policy are much larger, potentially affecting mineral taxes in all states. Severance taxes yield substantial revenues in some states, as illustrated in the accompanying table. In fiscal 1980, Texas collected more than $1.5 billion from such taxes, while Louisiana, Alaska, and Oklahoma collected $525 million, $507 million, and $436 million, respectively. Oil and natural gas production were the major items taxed. While the table shows only the 10 states with the largest severance tax collections, a total of 17 states had severance tax receipts exceeding $10 million in 1980. The enormous increases in severance tax revenue between 1970 and 1980 can be seen from the table by comparing columns A and B. For the 10 states shown, revenues increased from $650 million to $3.8 billion during that period, due to a combination of higher prices, increased production, and new or increased taxes. In most states, increases in prices and production were more evident than higher tax rates. Although the revenue increase is impressive, it understates the extent of changes occurring during the past decade. Since tax collections are shown for fiscal 1980, the full impact of the decontrol of domestic oil prices is not evident. Also, taxes on natural gas reflect controlled prices. When full de-control of natural gas occurs, significantly higher revenues can be expected in gas-producing states, even if tax rates, production, and world prices remain constant. These increases in severance tax revenues, coupled with further increases expected to accompany natural gas decontrol, have produced fears that a substantial transfer of income is taking place from residents of energy-poor states to those living in energy-rich areas. Others worry that increased severance tax revenues will be used to substitute for a substantial portion of state taxes that would have otherwise been collected from firms and individuals. The resulting improvements in tax climate, it is thought, may encourage firms and workers to migrate to energy-producing states. While these issues are often portrayed as pitting energy have-nots against the haves, such is not entirely the case. Much of the original impetus for limits on coal taxes came from Texas residents, the state collecting the most severance tax revenue. One way of gaining perspective on these concerns is by examining severance taxes per capita and as a percent of state tax collections (see columns C and D in the table). When this is done, Alaska, where 1980 taxes on oil and gas production totaled more than $1300 per capita (and 35% of all state tax collections), stands out as a special case. There, the state was able to eliminate some individual taxes, place revenues in a permanent trust fund, and consider offering a rebate of some previous income

Jan 4, 1982

Traditional loading systems have relied for many years on wheel and track loaders, power shovels, conveyor belts, and more recently, hydraulic front shovels. Each has certain advantages and disadvantages, depending largely on job conditions. Hydraulic backhoes were introduced several years ago as still another truck loading option. At first, buckets were small and backhoe use was limited to small earthmoving projects. Now, as backhoes are equipped with shorter sticks and bigger buckets to move larger quantities of earth. The "mass excavation" concept offers an excellent truck loading option in many situations. System Development and Advantages Mass excavation was first used successfully by contractors in site development and highway construction, loading both on-highway and off-highway trucks. Operators were able to take advantage of the excavator's ability to work in poor underfoot conditions and dig in tough materials. The technique was first applied to mining in the kaolin mines of central Georgia. Kaolin, one of the world's most abundant minerals, is used to make paper, paint, ceramics, rubber, plastics, and many other products. Since kaolin clay is slippery when wet, load-out with wheel loaders is very inefficient. Also, kaolin is found in very spotty deposits due to the weathering process involved in its formation. Consequently, draglines are also impractical for kaolin mining since they don't have the mobility to move between clay deposits. In response to these mining conditions and kaolin characteristics, mines began using excavators in mass excavation as early as 1976. They have developed a system that takes advantage of the excavator's •high penetration and breakout force in tight materials; •fast-cycling hydraulics; •ability to work in poor underfoot conditions; and •mobility in comparison to draglines. This loading method has been successful in Georgia's kaolin mines and now can be applied to other mining operations as well. The excavator's ability to carefully dig spotty ore deposits is an asset at uranium mining operations. Any mine can take ad-

Jan 3, 1982

By Pedro Lilienfeld

The objective of this program was the development, design, and fabrication of six personal-sized completely self-contained dust monitors capable of real-time as well as time-averaged monitoring of the concentration of respirable particles in coal mines, in the range of 0.1 to 100 mg/m3. The operation of these monitors is based on light scattering and passive air sampling. The design stressed overall miniaturization, ruggedness, simplicity and versatility. These instruments incorporate a single-chip CMOS microprocessor to perform all signal processing, data display and storage, and timing functions. The overall dimensions of these devices are, approximately, 10 by 10 by 5 cm.

Jan 1, 1982

By Jorge Lema Patino

"The purpose of this paper is to determine the best techno-economic alternative for the treatment of tin ores, when comparing the various mining and metallurgical methods of preconcentration, concentration, volatilization (fuming) and up to the final stage of selling to the smelter. The study of the influence of the different parameters of cost, recovery and quoted prices has motivated the paper, which aims at determining the best process of ore treatment in terms of its techno-economic feasibility.Method of WorkOn the basis of head grades of 0.5, 0.75 and 1.0% tin, the following alternative methods of treatment are possible:1. Mining-Concentration-Smelting.2. Mining-Preconcentration-Fuming-Smelting.3. Mining-Concentration-Separation, with direct smelting and fuming/smelting of the two fractions produced.The calculations were carried out on the basis of existing information and publications concerning the various experimental recoveries in the operating mills of COMIBOL. In the case of concentrates containing less than 10% or more than 40% tin, extrapolation was required.The final grade of the tin concentrates and the gross weight of the concentrate were calculated on the basis of the estimated recovery curves. The costs of the preconcentration and the concentration stage s were determined per gross metric ton of material treated.The calculation of the cost of the smelting stage is similar for all the alternatives, the royalties and smelting charge varying with the grade of the final concentrate. In the fuming stage, a uniform recovery of 90% was taken in all cases so as to obtain a final concentrate grade of 65% tin, regardless of the head grade of the feed material.For the separation stage, the following considerations apply:a) Separation can be carried out by gravity separation or flotation methods.b) The cost of separation varies depending on the system used.c) The distribution of tin in the two fractions is 100% at this stage. In other words, there is no loss of tin during separation."

Jan 1, 1982

DR. BANOWSKY: Thank you very much. That was the shortest introduction that I have had lately, and I didn't have time to get my coat on. But I appreciated it, and I'm delighted to be here with an industry with which 1 feel strong affinity. At the University of Oklahoma we have an energy history. We are a little more currently involved in oil and gas, and those of you who know the history of our state would be aware we have an early coal development back really before the turn of the century in the southeast part of our state what we call Little Dixie. How many of you have spent anytime in Oklahoma or are from the state of Oklahoma? I'm not going to ask how many are from OSU or the University of Colorado. We did send you a football coach here from Oklahoma, and 1 see you have exchanged him. Several of you were only interested in the lobby in asking about our football team this year. 1 would like to go somewhere where we can talk about something besides football. I'm just trying to build a University that our football team can be proud of. We're going to be strong again. 1 can assure you. We've got the best football team money can buy. It's not quite as bad as the college president who called the coach in and said, "Coach we're in trouble, you're losing games and the alumni is very unhappy." "What can we do?" the president asked. The coach said, "Well the football team is flunking the admissions test. We can't get them in with the standard achievement and SAT tests." The president said, "What can we do?" The coach said, "Well the coaching staff has substituted for the American College Test the simple fill in the blank questionnaire." The president said, "Let's use it. We have got to get the team in." The first question was, Old MacDonald had a (-). And a couple of the big tackles were taking it and one of them said, "Hey, what did Old MacDonald have?" His friend said, "Stupid, Old MacDonald had a farm." "Well how do you spell farm?" He said, "Stupid, e i e i 0." Now the gentleman who met me at the registration line from Lakewood, Colorado, was asking me about one of our great big tackles; and he is doing well. We call him Doctor Death; he is also a wrestler and that gentleman said, "1 don't know how bright he is." 1 said, "He is bright enough for our academic tutoring that he is going to get through all right." So I'm delighted to see you and be here with my very dear friend, Carl Terzian. Carl and 1 were in Los Angeles together for 10 or 12 years when I was president of Pepperdine University. He and I are exactly the same age. Born in 1935 and 1 a month or two later in 1936. Fewer children were born in that period than in any other period of time in this century. For those of you who remember anything about that period, you will know why no one was having babies during that period. But Carl called and said, "Bill do you know where Vail, Colorado is?" Well when you live in Oklahoma, you learn where Colorado is in a hurry. 1 not only know this beautiful area, but have made too much of an investment here at a place called Beaver Creek. The real estate is cheap over there. 1 play regularly in the Gerald Ford Invitational Golf Tournament here. Hope you will visit Beaver Creek. It's just 10- 12 miles to the west. The sight of the 1976 winter olympics until the people of Colorado voted them out. And now Vail Associates and I are good Oklahoma families. Bass family, Harry Bass of course, many of you know this story, who is chairman of the Board of Vail Associates, is making quite an investment in that year-round resort area. Beautiful golf course now. You can come out and afford the green's fee and beautiful, beauti-

Jan 1, 1982

By Denis Yeung

In an effort to find better ways to dispose of potentially toxic material, the effect of longitudinal and lateral dispersion on the dilution of toxic fluids was investigated numerically and experimentally. Homogeneous and non- homogeneous tests were conducted to model this effect for surface mine backfills. These tests used a high-density zone [package] to bury undesirable material. The studies, utilizing inert tracers, showed that an increase in density in a soil will decrease the maximum level of tracer in the discharge. Within the range of experiments performed and using only natural materials, a 65 percent reduction in peak concentration was obtained.

Jan 1, 1982