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By Robert B. Fulton

The objective of this chapter is to discuss the interrelationship between industrial minerals and chemical manufacturing. It is intended to supplement rather than duplicate the commodity chapters. Particular emphasis is given to the pertinent chemical element and to market factors. Condensing this broad subject into a few pages of this handbook permits treating only the most important elements derived from industrial minerals. Hydrocarbons, which quantitatively dominate as raw materials for the chemical industry, are omitted, as are the metallic elements and the minerals covered in other "use" chapters such as phosphorous, potassium and nitrogen for fertilizers, and titanium dioxide for pigments. The remaining six elements of major importance are: boron, bromine, chlorine, fluorine, sodium, and sulfur. These elements are treated individually under separate headings. Table I (Jones, 1973) affords an overview of the main industrial minerals, the chemical products derived from them, and end uses of the products. Salt brines have particular importance as raw material sources for the chemical industry. Table 2 (Anon., 1967) is a chart of the chemical compounds derived from four types of brines: (1) Owens Lake-type brines, which are sources of boron and sodium compounds; (2) Midland-type brines, from which bromine, iodine, and chlorides of calcium, magnesium, potassium and sodium are derived; (3) Searles Lake-type brines, yielding boron, bromine, lithium, magnesium, potassium, and sodium compounds; and (4) Silver Peak-type brines, produced mainly for lithium. Market Attributes Some of the important market traits common to industrial minerals used by the chemical industry are listed below. 1. They are international commodities, such as fluorspar and sulfur, which largely move to foreign consumers. 2. Grade, and freedom from deleterious elements are important factors affecting their usability in chemical processes. An example is salt (NaCl) used in electrolysis where ultrapure evaporated salt is required to meet rigid specifications. 3. Purified products take on the characteristics of specialty items and command a distinctly higher price than the basic commodity from which they are derived. 4. In practically all cases, chemical users require some sort of cleaning or beneficiation of the naturally-occurring mineral to bring it to specification, and individual specifications may vary from user to user for essentially the same use. 5. In some instances it is necessary to strike a balance between what the vendor can supply and what the buyer requires, with the result that specifications have to be eased to afford the needed materials in marginal cases. 6. Because they tend to be bulk commodities, low cost for handling and transportation are important and such costs may limit the area from which a chemical user can draw his supply. For example, fluorspar from China and Thailand normally goes to Japan, while South African fluorspar can go either to Japan or to the US. 7. Shipments are usually in bulk and frequently in multiple-car, full-trainload or full-shipload lots to reduce transport costs, which in turn may require large terminal investment facilities.

Jan 1, 1983

By S. R. McCutcheon

"The regional stratigraphy of the Lower Carboniferous Windsor Group in the Moncton Subbasin indicates that evaporites could be present in the Marysville Subbasin, part of what was formerly called the Central New Brunswick Platform. The Windsor Group consists of basement-fringing, algal build-ups (Gays River Formation), in places with intercalated siliciclastics (Parleeville), which are laterally equivalent to deeper-water, very thin to thinly bedded, euxinic limestone (Macumber). The Macumber is overlain by stratiform, nodular to mosaic anhydrite (Upperton) that is hosted by carbonate or calcareous siliciclastics. The sulphate also is equivalent, in part, to the algal buildups. Deep-water salts (Cassidy Lake) which overlie and in places are laterally equivalent to Upperton rocks have a basincentre distribution. The Windsor Group is overlain by shallow water evaporites and mudstones (Clover Hill) or by greenish grey mudstone (""transitional beds""). The paleogeographic distribution of these rocks provide important clues that help predict where deposits of salt and potash can occur.IntroductionCurrently there are three known potash deposits in southern New Brunswick (2, 3 and 4, in Fig. I). All three deposits occur in the Windsor Group of the Moncton Subbasin, but until recently their exact stratigraphic position within the group was not known.The Windsor Group is a cyclic sequence of carbonates, evaporites and red beds that is up to 1.0 km in thickness (Schenk 1969, p. 1038). It is Late Mississippian (Visean) in age and the type area is near Windsor, Nova Scotia. The group was named by Dawson (1873) but the rocks were described earlier by Hartt (1867). Dawson (ibid.) was the first to assign rocks in southern New Brunswick to the Windsor Group."

Jan 1, 1983

By L. P. Kleinmann

To control the formation of acid drainage at its source, the Bureau of Mines has investigated the role of iron-oxidizing bacteria in the oxidation of pyrite. In laboratory tests, it was determined that Thio-bacillus ferrooxidans could be controlled in coal refuse using anionic surfactants, with an associated decrease in acid production of about 75 pet. Based on these results, large-scale tests were conducted at an 8-acre active coal refuse area in northern West Virginia and an 11-acre inactive refuse pile in southern West Virginia. Acid production was decreased 60 to 95 pet for 4 to 5 months after application of 55 gal/ acre of 30-pct sodium lauryl sulfate solution. To date, effluent surfactant concentrations have been extremely low. Either a hydroseeder or a road-watering truck can be used to apply the surfactant. Since the surfactant solution must reach the pyritic material to be effective, sites that have been reclaimed are generally not amenable to these procedures. A simple laboratory test is described that provides an estimate of adsorption potential; this can be used to calculate a safe application rate.

Jan 1, 1983

By D. L. Pentz

The use of "probability" methods in slope stability analysis has been practised by geotechnical engineers for some time. This paper questions whether the term probability has been properly used since in many cases the term is used in a classical statistical manner only to describe frequency distributions of data. This paper proposes a definition of the term probability which includes the engineers' subjective state of confidence for all critical parameters. Such parameters may include the slope stability model, undetected structural features, strength, groundwater pressure distribution, and geological framework. This process does not make a "better" analysis but it does force the geotechnical engineer to state his opinion in such a manner that others can understand and if necessary, criticize the assumptions. Further, this technique forces the question, "What impact would failure of a slope have on the production schedule or costs of a mine?" The level of risk taken in adopting a particular slope design strategy in a mine is not a question of what Factor of Safety should be selected but, rather, what trade-offs result from steeper slopes and the associated costs of failure. This paper also presents several simple probabilistic techniques which, though widely used in other fields have been all but ignored in geotechnical slope stability analyses. These include the use of stratified sampling to optimize Monte Carlo uncertainty approaches, and the use of simple functional approximations rather than complex stability models in probabilistic analysis. The author presents a case example of this technique and discusses the results in comparison with more traditional methods.

Jan 1, 1983

By James T. Finley

Profit, product quality, speed of operations, reliability, operator confidence, safety and environmental improvements have all been enhanced as a result of the recently completed maintenance, renovation and construction program at Crown Central Petroleum Corporation?s (Crown?s) coke calcining unit at its Pasadena, Texas refinery. (Figure 1) BACKGROUND The calcining unit was built in 1969 - 1970 and has been operated continuously. Approximately 400 to 500 TPD of high quality metallurgical grade coke is manufactured, stored, and shipped to consumers. About 1/2 of the feed stock to the calciner is manufactured in Crown's coking unit and the remainder is received, via barges, from various sources. The green coke is off loaded from the barges with a conventional grab crane that discharges into a small travelling hopper over a conveyor belt that feeds a radial stacker, which forms a stockpile on the ground. The green coke, from the coking unit at the refinery, is moved to the calcining unit with front end loaders. Reclaiming from the stockpiles is also done with front end loaders. The coke is primarily handled by covered conveyor belts. The finished product is stored in steel silos and can be shipped via railroad cars, but the majority of it is shipped out in ocean going bulk carriers. Maintenance work in the calcining unit is performed by Crown's refinery maintenance department on an as needed, on call basis.

Jan 1, 1983

By Randolph E. Scheffel

Mill design and project execution are very demanding and interactive processes requiring the dedication and cooperation of many parties. The development philosophy which lead to the successful completion of Ranchers Exploration and Development Corporation's Escalante silver mill is reviewed. The project spanned 25 months from initial feasibility studies to start-up with the major construction effort requiring only 4 months. Mill performance for the second and third months after start-up, as well as fiscal 1983, is compared against the design parameters. Capital and operating costs are also discussed.

Jan 1, 1983

By Hemendra N. Kalia

Several attempts have been made in the past sixty or so years to commerciliaze the vast oil shale deposits of the United States of America. However, the industry has yet to become viable and economic. To date, it has not been possible to produce oil from the oil shales at a competitive price when compared to the oil produced from oilfields by conventional methods. However, the development work has been quite fruitful in furthering the art of thick bed mining and technology of in situ retorting. The in situ method has the potential of recovering oil from thick beds and the resource recovery potential is much greater than that from underground mining and surface retorting. In situ methods require that the shales/ marlstones be fragmented ' in place to induce adequate porosity and permeability to allow in situ' heating of the fragmented shales. This can be accomplished by using explosives. However, it has been found that the existing blasting systems, though very efficient, are somewhat lacking. The explosive become insensitive when shot in multiple vertical decks. They can also become insensitive when spaced horizontally at close proximity to other charges. Also, since the blasting is done in a very limited free face, this limits the delay time that can be allowed between charges. Consequently it is not always possible to predict the performance of the blasting system on a routine basis. Furthermore, since it is not possible to undertake secodary blasting, it is imperative that the blast design function properly. Recent, successful retorting by Occidental Petroleum Company of retorts seven and eight suggests that some of these problems may have been overcome. This paper addresses some aspects of in situ retorting and problems those have impeded the development of a viable oil shale industry in the U.S.A.

Jan 1, 1983

By P. J. Clifford, A. B. Brown

The development of computerised mine planning has been hindered by the cost of processing the large data bases associated with mineral deposits and the inherent inconvenience of performing an interactive process on a time-shared computer. A dedicated computer is ideally suited for the purpose but reasonably priced micro/mini-computers have not had the capacity to store the volume of data or the processing capability required. Hardware development has cleared the way for the development of truly interactive mine planning software, covering the complete range of activities associated with mine planning, from geological assessment to short-term scheduling of operations, incorporating them into a single system using a common database. The integrated system, comprising software and dedicated hardware, adds previously unattainable speed, flexibility and clarity to the planning process because it has been tailored exclusively for that purpose.

Jan 1, 1983

By B. L. Bobo

To ensure the continued growth and economic viability of the Western coal industry, both in the domestic and inter- national markets, it is essential for the industry to become more creative and active in confronting the most serious obstacle in this objective; and that is, the inherently long distances which Western coal must be transported inland to reach its major markets. Figure 1 shows the 1982 coal consumption by state for those states where Western coal was consumed. (Except as noted in this paper, Western coal producing states are defined as Colorado, New Mexico, Arizona, Utah, Wyoming, Montana and North Dakota. Any exceptions used will have only an insignificant effect on the content of the paper). This figure illustrates the long distances that are required for Western coal to reach its markets. The total production for 1982 from the Western coal producing states was approximately 220 million tons, of which only 85 million tons was consumed within the boundaries of these states. The remainder was transported to markets outside the area. This map also shows, based strictly on the consumption of the states to which Western coal was shipped during 1982 and not considering other factors which are involved in the marketing of coal, the total market potential of Western coal would amount to a total of 445 million tons. This does not include export coal from the West Coast, which is now estimated to be less than 2 million tons for 1983. In 1980, it had been estimated that by 1985 the West Coast exports would have been at least 10 million tons per year, which will not be attained.

Jan 1, 1983

By J. E. Russell, Y. J. Wang

In this paper, we report the results of a study of the characteristics of Texas lignite based on a proximate analysis data base previously published by the Bureau of Economic Geology, University of Texas at Austin and the U.S. Bureau of Mines. The original impetus for this study was the desire to perform a parameter study in connection with the siting of potential underground gasification tests in Texas. A numerical model of the gasification process was available and required proximate analysis data, among other parameters, as input. If proximate data were available for a particular site, a prediction of the product gas quality could be made. However, in preliminary siting studies, it would be advantageous to know what the desirable characteristics of the lignite are, in order to target general areas for drilling. Consequently, a parameter study was in order. This paper presents the methodology required to systematically vary proximate analysis parameters and estimate the corresponding energy content for various group(or formation)-facies classifications of Texas lignite.

Jan 1, 1983

By Nicholas Kyriazi

The Bureau of Mines subjected three commercial compressed-oxygen self-contained self-rescuers to a series of laboratory treatments designed to simulate various environmental conditions in underground coal mines. The environmental treatments consisted of extremes of temperature and of shock and vibration. The tests were designed to predict the ability of the self-rescuers to withstand those environmental stresses without causing a decrease in wearer protection. A critical concern was internal damage to an apparatus that would cause it to malfunction or seriously degrade its performance without any obvious external signs. The Bureau has previously tested chemical oxygen self-contained self-rescuers in a similar research program. Although the three compressed-oxygen units are not as sturdy as the chemical oxygen self-rescuers tested previously, they performed reliably after treatments on treadmill tests with human subjects and on machine tests using a breathing and metabolic simulator. Serious damage was caused by both the heat treat-ment of 71° C (venting of the 02 bottle in most cases), and in the shock treatment (breaking open of the case and dislodging of the components). When physical damage is obvious, a complete refurbishing of the damaged self-rescuer is recommended.

Jan 1, 1983

By William X. Chavez

The Mantos Blancos copper-silver district, a major copper-producing area since 1961, is located on the Tropic of Capricorn about 45 kilometers northeast of the northern Chile port city of Antofagasta, as shown in Figure 1. Copper oxide minerals occurring as atacamite (Cu C1(OH)3) and chrysocolla (copper silicate-hydrate) were discovered in the district in the early 1900's (Knobler and Joseph, 1962). The mine is situated in the northern Atacama Desert, one of the most arid regions on earth, and presently receives less than 1 cm per year of precipitation. The extreme aridity of the Atacama Desert is thought to have prevailed since at least Middle Miocene time (Mortimer et al., 1978) when development of important supervene copper enrichment was slowed in many areas of northern Chile (e.g., Chuquicamata, Exotica). Despite the paucity of precipitation, landform development is mature, with large alluvial fans and alluvial-filled valleys covering much of the region. In addition, the aridity and presence of salts have led to the formation of a sub-surface cementing of alluvium and colluvium by halite-rich caliche ranging from a few centimeters to over 3 meters in thickness. These factors, resulting in poor outcrop exposure, make even reconnaissance mapping difficult.

Jan 1, 1983

By LeRoy D. Loy

The coal mining industry must be able to compete with alternate sources of fuel for the utility and industrial customers. If the industry is unable to control transportation costs, either due to government interference, or for other reasons, then mining costs must be kept down. Australia, South Africa, Canada, (and later Colombia) will take larger shares of the export market if mining costs are not kept competitive. The government's environmental regulations must be met without incremental increases in mining costs. Entrepreneurial instincts must be retained by the industry to provide for their investment in the future. What are the Problems with Existing Research? Government funding for coal mining research has been reduced or virtually eliminated. BCR (Bituminous Coal Research) is now a membership- supported organization, but its primary focus has been on health and safety-oriented research. BCR, however, is now attempting to widen its scope and conduct other types of research. There are almost no funds in EPRI's (Electric Power Research Institute) program for coal mining research. Large mining companies do some research for their own purposes and needs, but this is proprietary and therefore results are not shared with the remainder of the industry. The mining industry as a unit is not undertaking productivity (systems) oriented research in any common or cohesive manner.

Jan 1, 1983

By H. William Zeller

The Bureau of Mines is conducting research to determine whether the use of chemical surfactants improves respirable coal dust control and is evaluating laboratory test criteria for selecting effective surfactants. This publication presents the results from wetting effectiveness tests with emphasis on the capillary rise test. The test variables investigated included coal particle size, type of surfactant, surfactant concentration, test duration, and mineral con-tent of the water. In addition to the rise test, measurements of con-tact angle, zeta potential, and sink time for various coal and surfactant combinations were conducted. No significant correlations among the four wetting tests were observed, a surprising result which implies that each test type measures specific aspects of the wetting phenomenon and also that each test type should only be used to select surfactants for specific applications. For example, the rise test shows solution penetration into porous materials, and the sink test discriminates among surfactants for dispersing finely ground materials into suspension. Another important conclusion is that combinations of agents retain their individual wetting properties, allowing mixtures to be for-mulated to perform well in both rise and sink tests.

Jan 1, 1983

By Alfred Weiss

Over the past 25 years hard-rock mining companies have developed a number of profitable computer applications which appear applicable to operations in the coal industry. The evolution of these applications are described and the most profitable discussed. The basic nature of these systems is that they must cut across organizational boundaries. While technological advances contributed significantly to the successful implementation of computers within mining, the human aspects related to organization, management and control of systems projects remain as key to future success in coal as they were and still are in hard-rock mining.

Jan 1, 1983

By Harry E. Holzschuh

The two Agrico Chemical Company self unloading Phosphate Rock barges put into service in 1976 operate at over their design carrying capacity. Each barge now carries 26,000 short ton instead of the planned 25,000 short ton at 32 foot of draft. They are in service between Agrico's Tampa, Florida Terminal and the Donaldsonville, Louisiana Fertilizer Complex, moving a total of 2,500,000 short tons each year. This was the first use of the Parascrew design for a marine application. The barges, with their 3,000 STPH unloading and matching loading rate is the vital link in this total transportation and handling system. Rock is moved from the Pierce, Florida Mines through the Tampa Big Bend Terminal, across the Gulf of Mexico, and up the Mississippi to the Agrico Faustina Phosphoric Acid Plant 30 miles below Bacon Rouge, Louisiana. The trip from the terminal to the plant is 600 miles and the turnaround time is just about six days. Seven years operating experience has proved that the system works. Fittingly, the two barges are named the "Faustina" and the "Pierce". They have a beam of 85-feet and are 495 feet long. folded depth is 43 feet, with a ballasted light draft of 19 feet and a typical loaded draft of 32 feet. There are four separated holds with the machinery room located forward of 101 hold. Each hold is 51 feet wide at the coamings with an 18 foot straight section on the side, and a 24 foot long, 600 slope sheet for a 23 foot clear reclaim width at the bottom. The Parascrew in each of the holds is 37 feet long between the bearings and is supported on a 14 inch diameter hollow shaft. The screw pitch varies and the diameter of the flights step up from l'-9" diameter to 2'-6" diameter on the discharge end. By sloping the centerline, a minimum four inch bottom clearance is maintained across the hold. Some bending of the tube does take place.

Jan 1, 1983

By Robert B. Parsons

"Next month will mark the anniversary of the release of an important federal study on a mineral policy for Canada. The study, entitled ""Mineral Policy-A Discussion Paper"", provides well-researched coverage of a broad range of issues that are of interest to the mining industry. Unfortunately, there is a real possibility that the discussion paper will wither and die on the vine, unless the federal and provincial governments, and the private sector, collectively ensure that some of the key considerations which are raised by the paper are acted upon.IntroductionAlmost one year ago, on March 8, 1982, Federal Mines Minister July Erola released an important study entitled ""Mineral Policy-A Discussion Paper"". The discussion paper, which presents the government's assessment of the opportunities and constraints facing the Canadian mineral industry in the 1980s, was prepared within the context o f three principal objectives-strengthening the resource base on which the industry rests, ensuring the adequacy of research activities needed to support development of the resource, and furthering the development of markets for the resource It is clear that, in today's economic climate, not even the most generous incentives would turn the industry around: what is needed is a sound base for future development, when this is possible. In this regard, the discussion paper is an excellent stepping stone, in that it reviews a wide range o f fundamental policy issues which touch on all facets o f the mining industry."

Jan 1, 1983

By P. M. Prasad

The last two decades have witnessed the emergence of numerous hydrometallurgical and direct processing techniques for the extraction of some metals from pocketed/lean/complex sulfide ore deposits. A new approach with some inherent technological merits, investigated in recent years, is the lime-enhanced reduction of metal sulfides. Thermodynamic aspects relevant to the lime-enhanced reduction of metal sulfides by H2,C0 and C are discussed. A survey of the researches on the basic features of and factors influencing the lime-scavenged reduction of selected sulfides and sulfide concentrates reveals that lime tremendously enhances the sulfide reduction rates (up to 100 times) and drastically reduces the sulfur emission into off-gas to negligible levels. Further successful practice of lime-enhanced reduction requires only a moderate temperature of reduction (characteristic of each sul¬fide) and, in the case of gaseous reduction, relatively low gas flow rates. Relevant kinetic aspects of the concerned reactions that have a bearing on process development and its understanding are also briefly discussed. A conceptual scheme of general applicability for the processing of sulfide concentrates by the lime-enhanced reduction technique consists of three main steps: (0 lime-enhanced reduction by a suitable reagent (e,g., H,2, CO, gasified coal, water gas), (ii) separation of the product metal from the dry slag (CaS + unused CO) by mechanical separation, magnetic/gravity concentration or flotation and (iii) melting and refining by standard procedures. This novel approach, which is patently less complex, is expected to employ basically simpler flow sheets at comparatively lower operational temperatures and aid in pollution abatement. Potential for developing such a route for the small scale extraction of metals like copper, molybdenum and antimony is indicated. Possibility of utilizing this technique for the production of fibers/ filaments of some metals is also outlined.

Jan 1, 1983

By V. P. Keran

The lead and copper smelting processes employed by Mount Isa Mines Limited, Mount Isa, Australia, are used to illustrate an operating viewpoint of some problems and solutions encountered in existing commercial sulphide smelters. The smelting processes discussed; include updraught sintering, blast furnace and reverberatory smelting, and converting. Selected examples are given of methods implemented, and options available, to improve the productivity and efficiency of conventional smelting processes.

Jan 1, 1983

By Alice M. Chieruzzi

This Country Documentation Report presents the development of economic indices for Zambia for the period from 1970 through 1981. The work done through the Bureau of' Mines, Minerals Availability Program, under Contract number J0225001. This contract calls for the development of twelve index time series describing factor input costs in the mining sector of 95 countries. The twelve index time series describe the costs of: 1) mining wages, 2) construction wages, 3) equipment and repair parts, 4) bits and related steel, 5) timber and lumber, 6) fuel, 7) powder and blasting agents, 8) tires, 9) construction materials, 10) industrial materials, 11) transportation, and 12) electrical power. These indices combined with weight factors being developed by the personnel of the Minerals Availability Field Office (MAFO) of the Bureau of Mines in Denver, Colorado, will be used to perform instantaneous updates of all costs relating to the mining industry. The indices were developed primarily for use in the Bureau's Minerals Availability Program in assessing the worldwide availability of nonfuel minerals.

Jan 1, 1983