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The Aluminum Company of America announced a temporary reduction of the operating rate at its primary aluminum plant at Palestine, TX where it is developing a new process to produce aluminum metal by electrolysis of aluminum chloride, Output will be reduced by half to about 7,500 tons per year while some improvements are being made on the chemical segment of the plant. The modifications were expected to take 3 to 4 years to complete. Alcan Alumininum Ltd., a major U.S. supplier of aluminum, reported declaration of force majeure on aluminum ingot shipment commitments following the shutdown of its primary aluminum plants at Arvida, Isle Maligne, and Beauharnois, Que. The shutdowns, which began early in June, resulted from management and labor differences.

Jan 1, 1979

By Robin Adams

After nearly five years of economic hardship, the world copper industry is, in our opinion, about to enter a period of considerable strength. This opinion is based on three main propositions, namely: 1) there are a number of reasons, both general-economic and industry-specific why copper demand is likely to perform significantly, more strongly in the 1980's than in the 1970's; 2) the virtual cessation of investment in new facilities, especially at the mine level, over the past years makes it physically impossible for capacity to expand as fast as demand in the mid-1980's; and 3) there is much less "excess" inventory available than most analysts believe. If we are correct in these assumptions, then the implication is that copper prices will climb up to, and possibly beyond, the cost-justified price level. Combined with general inflation, this suggests a price in excess of $2/pound by 1985 or roughly treble the 1978 average.

Jan 1, 1979

By B. J. Moore

This publication contains analyses and related source data for 310 natural gas samples from wells and pipelines in 16 States. All of the samples were obtained and analyzed during calendar year 1978 as a part of Bureau of Mines investigations of the occurrences of helium in natural gases of countries with free market economies. This survey has been conducted in the United States by the Bureau of Mines since 1917. In late 1965, the survey was expanded to include foreign gasfields. The analyses published herein were made by mass spectrometer and a special helium analysis appara¬tus, which are described in Bureau of Mines Bulletins 4862/ and 576.3/ The results of the investigation of the occurrences of helium are published annually to make the information available as soon as possible to the gas industry and the public in general. Twenty previous publications have presented the results of 11,573 gas analyses made prior to 197R. The first three, Bulletins 486,4/ 576,5/ and 617,6/ contain analyses and related source data on 5,218 gas samples collected from 1917 through 1960. The other 17

Jan 1, 1979

By Bruce C. Trent

In order to effectively model subsidence caused by underground openings, a two-dimensional computer code has been developed which couples near- and far-field response. The near-field is simulated by a discrete element block code and a finite difference code represents the continuum region in the far-field. The explicit equations allow rapid and inexpensive solutions to geometries which may lead to subsidence. Two sample problems are presented which illustrate the important features of the code.

Jan 1, 1979

By Lee W. Saperstien

Section 709 of Public Law 95-87, "Surface Mining Control and Reclamation Act of 1977," requests the National Academy of Sciences to determine if the standards of the act are applicable to minerals other than coal. The Academy has established the Committee on Surface Mining and Reclamation to respond to this charge. The committee is, itself, organized to be responsive to the varieties of minerals, environments, mining systems, and locations that are representative of U.S. mining systems. It is not the charge of the committee to write trial legislation, but to indicate whether or not technology, extant or proposed, is available to meet the standards of the law, and at what cost. It is within this set of conditions that the committee will examine blasting.

Jan 1, 1979

By Jan Visman, S. J. Aresco

INTRODUCTION The accurate sampling of coal, as with most minerals, is a difficult task. Coal is a heterogeneous material made up of different types of coal and varying amounts of mineral matter. The product as mined may contain all the layers of coal and impurities found in the seam as well as portions of the stratas above and below the coal seam. The preparation plant is the device to size, crush, and/or remove impurities so the coal may be shipped as a salable product. Sampling may be needed at many stages in the preparation process. Although this chapter is primarily concerned with sampling in connection with preparation processes, the principles apply to all coal sampling. The main reasons for sampling in connection with coal preparation are: 1) To determine the washability characteristics of the raw coal by means of float and sink tests. These may be used for the design of a preparation plant, prediction of results to be obtained, or monitoring raw coal delivered to the plant. 2) To check the performance of various operating units in the plant, either by float. and sink tests or chemical analyses. 3) To determine the analytical characteristics of the products produced, such as moisture, ash, Btu, sulfur, etc. HISTORY The earliest accepted methods of sampling coal in the United States were given in US Bureau of Mines (USBM) publications by J. A. Holmes,l G. S. Pope,2 and A. C. Fieldner.3 The American Society for Testing and Materials (ASTM) more or less adopted the methods proposed by USBM in their Standard D-21-1916 and it remained a standard for many years. Briefly, this standard called for a 500 lb (227 kg) sample for coals less than 94 in. (19 mm) in size and a 1000 lb (454 kg) sample for all coals over 94 in. (19 mm) in size. No mention was made of increments, but there was an instruction that the sample should spread over the coal

Jan 1, 1979

By William R. Taylor

The information I have concerning the early in situ uranium mining activities in Texas is "sketchy." Apparently, the first test was conducted between 1967 and 1971 in Gonzales County, north of Yorktown, at the Dueterstat Site, by, City Service. Other tests were run in Webb County at the Bruni Site, and in Live Oak County at the Burns and Clay-West Sites in the early 1970's. During this period the Texas Water Quality Board maintained a general surveillance of these tests. In mid-1974, Mr. Glen Davis walked into our Austin offices and requested a permit for Atlantic Richfield's first in situ uranium mine. This permit, issued in January, 1975, was for 3 acres of production, and was the first such permit issued in the United States. It formalized the regulation of in-situ uranium mining in Texas. The 4 years since then have been characterized by growth and change. Today there are 20 permits approved for approximately 2,000 production acres. These permits are issued to 8 companies at 13 sites in 6 counties. There are 7 additional permits being processed, or on the verge of being applied for. These will involve possibly another 2,000 production acres, 3 more companies in one more county.

Jan 1, 1979

By R. W. Ballmer

Prior to initiating construction of a new mineral development project, sponsoring organizations must be convinced that the operation will be viable. Proof is typically provided by the feasibility study. Considerable man hours will be spent in assessing and evaluating data on the deposit, its environment, and the means of development. Impact studies must be made for various scales of operation, inclusion of by-products, new methods of treatment, deferent levels of integration, and infrastructure configuration. Examples of current materials handling cost estimates are provided from the ongoing investigation in which Amoco is a participant at Ok Tedi in Papua New Guinea and Gag Island in Indonesia.

Jan 1, 1979

Satisfactory means of managing growth in boom towns is a concern in mineral, energy and other large industrial developments. This session will include examinations of socioeconomic impacts, major issues such as social disruption, case studies, methods of managing growth, and concerns involving Indian lands. Innovative methods will be offered to assist the public, government, and industry in finding solutions to managing growth in rapidly growing communities.

Jan 1, 1979

By Gerald G. Johnson

The use of the Scanning Electron Microscope to characterize Coal Mine Dust has been possible because of two circumstances. First, the imaging process of the SEM allows multiple signals (secondary electrons, back scattered electrons, x-ray emission, etc.) to be viewed. Second, the use of a computer to analyze the signals and perform statistical tests on the results. The parameters described are size, shape, chemical composition, mass distributions, and particle thickness. Although the system is intended for particular systems, those of agglomerates (whether tile same or not) are handled by special aspects of the computer programs. The work on fibers is not completed at the time of this report. This work discusses the hardware (developed especially for this process) and software (both on an IBM 360/370 and a PDP 11/20). The latter system allows direct interaction between the operator of the SEM and computer for maximum information at the least time.

Jan 1, 1979

By Robert G. Woolery, S. Ramachandran, James A. Weber, Donald J. Hansen

Union Carbide began looking seriously at heap leaching in 1971. At that time some 1.6 million tons of mineral averaging 0.40 kg U3O8 /t) (0.80 lb U3O8) were stockpiled at various sites around the Gas Hills, Wyoming, uranium facility. Several alternatives for economically exploiting these reserves were considered and heap leaching seemed the most attractive. At the time, Western Nuclear Inc. was operating a heap leaching project nearby in which the low-grade ore was leached with sulfuric acid, the product liquor treated in an on site solvent extraction circuit, and the stripped product liquor re-acidified and recycled. The operators were most generous in allowing us to visit their site and in answering our questions. They were also helpful in discussing the problems associated with heap leaching. Their experience confirmed our belief that it was possible to operate a heap leach profitably on material too low grade for conventional milling. Based largely on what we had learned from Western Nuclear's experience, we undertook a program involving a laboratory study to determine the characteristics of the mineral stockpiles, as related to heap leaching, and to conduct a pilot heap leach adjoining our Gas Hill mill. Basically the pilot heap construction and leach procedure were similar to those described in the literature l, 2 with certain modifications to permit detailed monitoring of the operation. In May 1972, the decision was made to construct a test heap. The UCC plant at Gas Hills, Wyoming was selected as the most appropriate site for the following reasons: (1) The necessary equipment for heap construction was readily available. (2) Stockpiles of mineral from the various mining sites were on hand: (3) Construction of the heap could be made on an abandoned tailings pile minimizing problems associated with environmental approval. (4) Proximity of the mill would allow product streams to be absorbed into existing circuits. (5) Necessary utilities were available. (6) Tailings water from the existing circuit could be used for leaching. A program for the pilot heap leach was developed with the following primary objectives. (1) To confirm the data obtained in bench-scale tests particularly on uranium recovery, acid usage, and ore permeability. (2) To evaluate plastic liners used for base preparation. (3) To investigate heap configuration variables. (4) To determine heap leach amenability of the different mineral sources. (5) To establish the economics of heap leaching low-grade ores.

Jan 1, 1979

By G. W. Poling

This paper evaluates current environmental protection legislation, guidelines and criteria, focusing mainly on the land and water disposal of mill tailings. Effluent criteria and regulatory mechanisms are proposed, and submarine tailing disposal is discussed at length. The importance of basing regulations on the best available rationale is stressed.

Jan 1, 1979

"Status of the Mineral Industries" provides a written and graphic view of the Nation's mineral position and its mineral industries. The report, issued annually by the Bureau of Mines, U.S. Department of the Interior, describes recent activities in mineral production, consumption, imports, exports, and uses of significant minerals and mineral raw materials. Charts profile trends for the past 28 years in supplies and uses of iron, steel, major nonferrous metals, primary nonmetallic construction raw materials, fertilizers, and plastics. Also included are current and historical financial data on the mineral industries, such as debt-equity ratios, asset-to-liability ratios, and plant and equipment expenditures.

Jan 1, 1979

By Kenneth K. Humphreys

INTRODUCTION What is automation? Why automate? Webster's New Collegiate Dictionary defines automation as "the automatically controlled operation of an apparatus, process, or system by mechanical or electronic devices that take the place of human organs of observation, effort, and decision." This definition gives an implied answer to the second question, "Why automate?" Automation, automatic control devices, and process control equipment receive their justification in supplementing or replacing manpower, which results in decreased operating costs. In the past, processes were operated with the minimum amount of instruments needed merely to guide operators. Processes were manually con- trolled by the operator on the basis of simple temperature, pressure, flow, and level indications on a panel. Today the tendency is to design a new plant to operate in a fully automatic manner according to a preset pro- gram utilizing a minimum of manpower. In addition to this direct cost reduction in manual labor, increased equipment capacity results from uniformity of flow and uniform control of process variables. This control eliminates or minimizes surges and permits equipment to be operated at or near its ultimate capacity and, for a given material throughput, permits the use of smaller process equipment. Automatic control, therefore, be it in the field of coal processing or in any industrial field, is simply a problem of economics. Control equipment is justified in terms of its contribution toward increasing productivity, increasing profit margins, or producing a new and salable product at a profit. Instruments and control devices can be divided into two general groups: (1) units which measure and (2) units which both measure and control a process variable.

Jan 1, 1979

The concept of "profit" is implicit in the definition of an ore reserve. It is suggested that the flexible concept "economic" is more appropriate. This allows different economic considerations to be taken to account when determining what is ore at the feasibility study stage; during actual mining production; before mine closure; and from the viewpoint of the national economy. Economic factors which are highly variable, and largely beyond a mining enterprise's control, affect the economic exploitation of a mineral resource. Major economic factors include: metal prices; operating costs; the cost of original and replacement capital equipment; the cost of capital; taxation and royalties; inflation; exchange rates and the state of the world economy. The paper suggests why a careful quantification of the average value, trend, and variation from the trend of major economic factors should be made and how this will lead to a better definition of ore reserves. The paper also discusses the necessity of reappraising economic factors during the life of a mine in order to maximise the economic surplus and to minimise the wastage of natural, economic and human resources employed in mining.

Jan 1, 1979

By D. M. Doyle

A study of the various components contributing to energy costs and their relationships to generally trended operating data, such as tonnage, operating costs, etc., over progressively shorter time periods provides information for an energy audit. A study of annual data gives some insight into the importance of various energy components. As the time frame of the study progresses through monthly, daily and, finally, into quarter hourly data, the variations become more evident and, most important, strategies develop to minimize energy costs. The results of an audit conducted during the summer of 1978 at Wesfrob Mines Limited are reported to illustrate this important phase, prerequisite to a meaningful energy cost avoidance program. The balance of the paper deals with the energy conservation program at Falconbridge Nickel Mines Limited's Sudbury operations, the metering and control equipment, the commitment, the new energy accounting practices and, lastly, the policies. Examples of successful energy conservation endeavours include automatic peak electrical load control, waste heat recovery from mine air and compressor cooling water, energy reductions resulting from lower building temperatures and curtailment of idling loads. The use of pulse meters to measure the flow of gas, steam, compressed air and electrical energy, with their signals interfaced to process computers, allows monthly, daily and, if necessary, immediate reporting of energy and energy per unit of production information The program so reported at Falconbridge's Sudbury Operations is credited with an annual cost avoidance of .9 million dollars in a 14.0-million-dollar annual energy account

Jan 1, 1979

By Donald C. Myntti

INTRODUCTION A major segment in a successful heavy equipment maintenance and repair program is the provision of well-laid out and well-equipped shop and service facilities The facilities described here will be those required for a large, high tonnage hard rock open pit mine utilizing rotary drills, shovels, haulage trucks, support equipment, and service trucks. The term support equipment covers the equipment required to support the drill, shovel, and truck operations, these are crawler tractors, road graders, front-end loaders, water trucks, rollers, rubber-tired tractors, etc. Service trucks are the automotive type consisting of rubber-tired over-the- road equipment. The primary structures generally involved in the total maintenance effort are as follows. (1) the main shop with an attached warehouse (the structure could also house the tire and lube shops plus the equipment cleaning stalls), (2) a service station with bulk petroleum product storage tanks, (3) a heating plant, (4) a security station (lf this is a corporate requirement), (5) operating department and employee assembly buildings, and (6) an electrical substation. Under certain conditions, many of these facilities with the exception of the substation could be combined In one or several structures. This arrangement could have a great advantage especially in areas where the heating of the structures is extremely critical.

Jan 1, 1979

By Hans-Henrik Wallin

The stresses in the heads and shell of a grinding mill are largely dependent on the bending moment produced by the trunnion bearing. By using spherical roller bearings in a special narrow housing a short moment arm is obtained and the bending moment is reduced. For large mills a hydrostatic shoe bearing which also gives a short arm, can be used. Spherical roller bearings also require less maintenance and have a long service life. As the bearings are grease lubricated an automatic lubricator is used instead of an oil lube system. Service data from two Swedish mining companys confirm the fact that the above arrangements provide a long service life.

Jan 1, 1979

By Edward D. Thimons

As U.S. mines go to greater depths, the high temperatures and humidities characteristic of such depths make it difficult to maintain a comfortable environment in working areas. Better techniques for cooling these deep working areas are needed. At the Homestake gold mine in South Dakota the Bureau of Mines has tested a water spray cooler inserted into the fresh air vent tube entering a warm stope. The cooler supplied more than 6 tons of refrigeration to the stope air, which dropped from an inlet temperature of 83° F dry bulb and 75° F wet bulb to 73.5° F dry bulb and 71.5° F wet bulb. These preliminary results show the water spray cooler to be a feasible concept. However, there is a need for substantial refinement and further testing, and work on the concept will be continued under contract to the Bureau.

Jan 1, 1979

By Richard I. Miller

Science Applications, Inc. has developed for the U.S. Bureau of Mines a rapid response radon monitor capable of accurately responding within three minutes to changing radon levels of magnitude from 100 to 10,000 pCi/1, typical of the levels in working uranium mines. The instrument weighs 17 pounds, is sized 12" x 10" x 6", and is capable of 8 hours of continuous portable operation with a self-contained, rechargeable battery power source. Residual chamber contamination from a radon level allowed to remain in the chamber for 90 minutes is about 10 percent, decaying about a factor of two in one hour. The instrument sensitivity is a nominal 0.1 cpm/(pCi/1), with a background count rate of less than 1 cpm.

Jan 1, 1979