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By Richard P. Walters

This Bureau of Mines report reviews and assesses the technology for preparing electrodeposited coatings of the platinum-group metals from molten alkali metal cyanide baths. Methods are described for the preparation and purification of the cyanide electrolyte. Vacuum drying, fusion, and purity of the cyanide salts are discussed. Use of a sodium borosilicate test tube as a sodium-ion-conducting membrane for the addition of the desired platinum-group metal is described. The optimum plating parameters of potential and current density for Pt, Pd, Rh, Ru, and Ir coatings that result in the best deposits are given. A method for producing platinum-rhodium alloy coatings of predetermined composition is also described. The importance of careful substrate surface preparation is illustrated. While problems still remain with respect to coating porosity, careful application of the methods described permits the preparation of adherent, coherent electrodeposited coatings of the platinum-group metals.

Jan 1, 1984

By James L. McGregor

St. Joseph Lead Company has been paying incentive bonuses for well over 40 years. In 1958 almost half of St. Joe's 1,860 employees in Southeast Missouri received some form of incentive bonus in addition to their guaranteed wages. There are very few payroll jobs in St. Joe s Southeast Missouri organization that lend themselves to a reasonably good measurement of production or quality, or both, where an incentive bonus is not paid. The term "Incentive Bonus" is used to differentiate betwen bonuses that are based on quantity or quality of work, and those that are merely additional pay of a standard amount per hour or day because of an employee being temporarily assigned to some unusual task, An employee temporarily assigned to a job where the working conditions make the job performance unusually difficult or where a special skill is used is often given a bonus of some standard amount per hour or shift in addition to his usual rate. This is merely a convenient way of paying something extra without disturbing the normal rate structure. Actually, it is differential pay similar to that almost universally paid for evening and night shift work. Bonuses of that type are not being considered in this paper. The basic reason or theory for paying incentive bonuses 9s to get improved production at lower cost, Unfortunately, it is often difficult, if not impossible, to find a yardstick by which it can be definitely proved that a particular bonus plan is accomplishing its purpose, It becomes, then, a matter of judgment on the part of management personnel as to the value of the bonus plan. The fact that St. Joe Lead Company has continued to pay bonuses for over 40 yews and has increased the number of bonus schedules used attests to a definite belief that they are beneficial to the company's successful operations.

Jan 1, 1960

By M. B. Sizgoric

Quantitative mineralogy is used in a study done on an Inco Metals Company nickel sulfide occurrence from 'the Thompson area in Northern Manitoba. The study included: a) determination of the variations in chemical composition of the ore minerals; b) determination of the liberation of the ore minerals for the various types of ore and for different feed grinds; c) assessment of the preliminary mill test results by comparing the mineral distribution in the different tailings. Preliminary mill test results had outlined three main problem areas: 1) unacceptabiy low grade concentrate with, 2) very high weight recovery and, 3) low pyrrhotite rejection resulting in a high sulfur concentrate. The mineralogical study readily explained these results by showing that: 1) between 20 and 40% of the nickel in the feeds and 55 and 75% of the nickel lost in the tailings is associated with pyrrhotite. This accounts in part for the low grade of the concentrates obtained at high recoveries: 2) hexagonal nonmagnetic pyrrhotite constitutes over 90 percent of pyrrhotite. Since hexagonal pyrrhotite floats more readily than monoclinic pyrrhotite, this could be part of the reason for the undesirable high pyrrhotite recoveries into the concentrates. Further test work to establish both the optimal grind and the best conditions for pyrrhotite rejection is therefore mandatory.

Jan 1, 1981

By R Hargreaves, C Morley

The authors often see problems on mine sites that are due to insufficient feedback between technical discipline silos as the realities on the ground fail to inform the models and plans used to drive resource exploitation. Resource modelling, reserve definition, life-of-mine planning, short-term mine planning and scheduling, mine operations and beneficiation operations are all processes that inform each other, but in many instances feedback between these processes occurs in an ad hoc way and only after problems have come to light.Universal reconciliation uses a multidisciplinary approach across the entire mining value chain to identify both opportunity and loss of value and to maximise operational performance. This paper will look at the operational effectiveness of universal reconciliation and will outline the important elements that make it successful, including how to map out the detail underpinning modelling, planning and execution processes. We do this by documenting the physical processes, logical work practices, organisational roles and responsibilities, data origin and quality, working assumptions and information management practices at an operation. The results quickly show how misinformation and assumption causes suboptimal decisions to be taken, where inefficiencies exist and what the opportunity is to remedy these issues.A universal reconciliation study opens up an opportunity for stakeholders to reassess how the operation should be run and how operational effectiveness should be measured. Clear envelopes for reconciliation become obvious and questions about the practicality and data quality can be addressed.A reconciliation code of practice is a key element of a successful universal reconciliation project and the authors outline the important aspects that will provide an operating model, showing the effectiveness of the resource and reserve modelling, the practicality of the mine planning and scheduling practices, how well the mine operations team are executing these schedules and how effective the processing area is given what it is fed. Most importantly, a system that allows operations time to react before the losses become systemic and that is based on identifying early warnings from hard data when these processes start to wobble is outlined. Finally as a case study, the revenue and cost benefits resulting from universal reconciliation diagnostic projects for nine mine sites is documented.CITATION:Hargreaves, R and Morley, C, 2014. Universal reconciliation – a multidisciplinary approach across the entire mining value chain to identify loss of value and maximise operational performance, in Proceedings Ninth International Mining Geology Conference 2014 , pp 411–420 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 18, 2014

By J. E. Forciea, O. E. Palasvirta, L. G. Hendrickson

All pilot and commercial plants working with Mesabi Range taconite employ wet magnetic separation. Progress is being made with a dry magnetic process,9-11 but this has not yet been applied to taconite except in the laboratory and pilot plants. Flowsheets in all five plants are similar, including multiple stages of grinding, each followed by magnetic separation, which rejects a finished tailing. The flowsheet in Fig. 1 is used in the preliminary and commercial plants of the Erie and Reserve mining companies and in Unit C of Oliver's Pilotac plant. At Erie the desliming operation is omitted. In the Reserve plants two ball mills are used with each rod mill. Pilotac uses flowsheet 2 in Unit A-B and has also tested flowsheet 3. Principal differences in the three flowsheets are the number of grinding stages and the type of roughing. The terms open- circuit roughing and closed-circuit roughing are best defined by the diagrams.

Jan 12, 1958

By Daniel Harrington

On the night of June 8, 1917, the flame of a carbide lamp accidentally set fire to the uncovered and frayed insulation of an armored power cable near the 2,400-foot level of the North Butte Mining CO.'s Granite Mountain shaft. How this, insulation accidentally became exposed is explained on page 15. The highly flammable oiled fabric set fire to the shaft timbers, and as this is a downcast shaft the fire spread with great rapidity, soon filling the mine workings with smoke and gas. At the time 410 men were working underground, 247 of whom escaped by various means, but most of the 163 remaining were probably overcome soon after the fire started, and perished. Only two men were actually burned. The cause of the disaster was purely accidental. The immediate effect was the unexpected reversal of normal conditions; the ultimate effect was great loss of life and the destruction of the main hoisting shaft, putting it temporarily out of service. The work of rescue and fire fighting continued eight days. The following pages present an attempt to draw some practical conclusions and suggestions from this disaster. The property of the North Butte Mining Co. consists of about 220 acres in the northeastern part of the Butte district, Montana. Next to the Anaconda Copper Mining Co. it is the largest producer of the district. In 1916, the year before the disaster, there were 1,160 men employed. The output was 560,947 tons of ore, which yielded 24,498,181 pounds of copper, 1,047,063 ounces of silver, 1,712 ounces of gold, and 412,953 pounds of zinc. The profit was $2,479,595. The total development work for that year was 21,694 feet. During the first half of 1917, the year of the accident, the daily tonnage of ore averaged 2,000, an increase of 400 tons over that of the year 1916.

Jan 1, 1922

By J P. Sykes, T C. McCuaig, J E. Vann

Resources added to the global metal inventory through exploration over the past 15 years have been generally of poor quality (declining grades, recoveries and lack of acceptable financial return). Similarly, companies opting for an acquisitions-based strategy have had to pick from a group of poorer quality resources left from previous exploration booms, and will struggle to deliver this metal to market economically. Increasing difficulty in obtaining sufficient social and community acceptance of mining projects and potentially an energy-constrained future may exacerbate this problem, redefining what is considered ‘ore’. There will need to be more focus on deposit quality, defined as sustainable margin in the future business environment.Traditionally there has been a lack of translation of ‘mineralisation quality’ back to mineral project design and mineral exploration. This disconnect is due to two main factors: the first is technical – inherent deposit variability; and the second is organisational and socio-psychological –the mindset of explorers and project managers themselves.There are four elements to value realisation for a mineral deposit: (1) social licence to operate; (2) geological factors (depth, geometry, water and geotechnical, and geometallurgy – influenced by texture, mineralogy, chemistry and grades); (3) financial engineering (capex, opex, future commodity prices, future energy prices), and (4) operating factors (production rate, recovery, energy consumption). These elements are strongly interdependent, and geology underpins and drives linkages between them. A quality deposit addresses all of these elements and thus can be developed in a time frame that allows acceptable returns to the owners of the invested capital.Geological drivers of the above elements can be measured and mapped throughout a deposit. Moreover, when viewed in the context of mineral systems, a predictive understanding of the common causative processes of quality (despite deposit-scale variability) is emerging, and with it the ability to target quality of mineralisation, not just quantity of mineralisation.The second factor is a ‘heuristic software problem’. Current lines of education (and consequently organisational and professional structures) are discipline-based, producing ‘silos’ that do not speak each other’s language and work with different ‘mental models’. People who effectively recognise systemic links between these silos are called ‘boundary spanners’, of which we propose two distinct types: outside-insiders and inside-outsiders. Outside-insiders are people who are within a community, but recognise advances in outside fields and effectively integrate them into the community. Inside-outsiders start outside of a community, and successfully bring new ideas into it. Common traits in boundary spanners are: they seek exposure to (and embrace) key ideas that are outside of the framework of their own specialisation; they have high mental processing ability (MPA) – the ability to connect systems that are currently not perceived to be connected; and they introduce ideas from outside a field into a new context in a way that re-frames the field.The challenge is to identify and nurture potential boundary spanners that can build critical links, in particular between the (largely geoscientific) mineral exploration mindset and the (largely non-geoscientific) project development mindset. Critical linkages to be built are between mineral system science, targeting science, and whole of value chain modelling.CITATION:McCuaig, T C, Vann, J E and Sykes, J P, 2014. Mines versus mineralisation – deposit quality, mineral exploration strategy and the role of ‘boundary spanners’, in Proceedings Ninth International Mining Geology Conference 2014 , pp 33–42 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 18, 2014

By Douglas Milne

Most empirical and numerical approaches to design in rock mechanics incorporate rock mass classification. Numerical design methods generally use classification values to calculate input parameters for stress-based failure criteria. Empirical methods use classification to allow comparisons between similar rock mass conditions, generally based on a graphical design technique that differentiates stable and failed opening geometries. Classification systems are the best tool available for assessing rock mass properties; however, there are problems with classification systems that should be high-lighted. Rock mass performance can only be realistically estimated by coupling a unique description of the rock mass with known loading conditions. Current classification systems cannot provide a unique classification value. The weightings applied to quantify rock mass properties for classification can result in significantly different rock masses having the same classification values. These weightings have been proven effective for tunnel design and support, but classification systems are now used for many more applications. Rock classification systems evolved from a quick and easy field tool for estimating tunnel stability and support requirements. The need for a rapid field tool means that rock mass classification is relatively insensitive to improved methods of measuring rock mass properties. Problems with classification systems and their application are highlighted in this paper. These problems must be recognized and documented before improvements can be made. An understanding of the evolution of classification systems and their application for both numerical and empirical design approaches is invaluable in highlighting current shortcomings.

Jan 5, 2007

By M. M. Fine

The flotation work on samples from nine fluorspar properties in Crittenden and Livingston Counties, Ky., reported herewith was part of a wartime project that resulted in increasing the supply of metallurgical-grade fluorspar. The samples were tailings, dumps, and waste rock that had been rejected in previous milling operations. All were treated successfully by flotation to yield metallurgical-grade concentrates with recoveries ranging from 77.5 to 98.3 percent of the fluorite. After the laboratory testing, the results of which were available to the owners and operators of the properties, many of the tailing ponds and rock dumps were milled. The real value of this report, therefore, is to show the operators of gravity concentration plants the possibilities of re-treating waste products by flotation either at some future time or currently with the gravity

Jan 1, 1948

By T. Feroze, B. Genc

"The effect of some of the system variables in forcing and exhausting ducted fan systems on ventilation in an empty heading was investigated using computational fluid dynamics(CFD) and comparative analyses. The diameter of the duct, duct mouth to face distance, and the power of the fan (quantity delivered by the fan) were varied and their effect on ventilation determined through a comparative analysis of the flow rates calculated close to the face of the heading. Estimation models were developed, which can be used to calculate the flow rate close to the face of the empty heading for different settings of the system variables studied.The study showed that recirculation for a forcing ducted fan system can be reduced by increasing the duct diameter or increasing the duct mouth to face distance. For the exhausting ducted fan system, higher flow rates were achieved by reducing the duct mouth to face distance, andincreasing the fan design flow rate and duct diameter.The outcomes of this investigation will help ventilation engineers in deciding the optimum duct fan system required for sufficient ventilation.IntroductionThe ventilation of underground mines, irrespective of the type of mine and mining method, is divided into two broad branches, the primary ventilation and secondary or auxiliary ventilation. The primary ventilation is responsible for the total volumetric flow through the mine and the auxiliary ventilation is responsible for the ventilation of the development ends, production areas, and facilities disconnected from the main circuit with no through-ventilation connections. Auxiliary ventilation is the more difficult to achieve (Bise, 1996), and the disruption of this ventilation system is considered to be one of the primary factors contributing to methane and coal dust explosions (Creedy, 1996). A number of causalities have been recorded by many authors due to these explosions (Phillips and Brandt, 1995; Dubinski et al., 2011; Phillips, 2015). The ventilation of short headings, less than 10 m in depth, can be carried out without the use of any auxiliary equipment (Feroze and Phillips, 2015). However, for headings deeper than 10 m, auxiliary ventilation systems are required. These are generally classified into the three basic types, namely line brattice (LB) ventilation systems, ducted fan systems, and jet fans (Figures 1 through Figure 3 respectively)."

Jan 1, 2017

By Robert C. Dyni

This report details the investigation of multiple-seam longwall subsidence conducted by the U.S. Bureau of Mines from 1978 to 1989. A field investigation monitored ground surface movements over four upper-seam longwall panels and six lower-seam panels. The characteristics of the subsidence occurring as a result of mining these panels are examined; in particular, the angle of draw, subsidence development, total magnitude and areal extent, and critical width are evaluated and discussed. Comparisons are also made between the characteristics of multiple-seam longwall subsidence and single-seam longwall subsidence that occurred at the same site.

Jan 1, 1991

By William Ives

My presentation is from the viewpoint of the industrial mineral geologist, which is a relatively rare breed. Very few geologists become involved with industrial minerals for two reasons, I think: (1) Much of the industry utilizing non-metallic minerals has developed without the use of geologists in the begin¬ning and many of the management people, who generally derive from the processing plant supervision, tend to take raw materials for granted; and (2) non-metallic minerals are a very insignificant part of the curriculum of virtually all colleges granting a geology degree. One learns about the geology of industrial minerals by working with it. This "on-the-job-training" is probably best because it brings the geologist into close quarters with the production people and the production process. And the industrial minerals field has a distinctiveness when compared with the petroleum or metal mining field in that each deposit can yield a material differing in some aspect from that in any other or within the same deposit. The petroleum from a well in a given field will be similar to that from any other well, but a limestone on one side of a hill can differ signifi¬cantly in elemental composition, calcinability, soundness, specific gravity, or some other factor from the same ledge on the other side of the hill. This characteristic of almost certain variability creates problems sooner or later and provides for much of the employment of industrial mineral geologists. My job seen from the viewpoint of management is "Find us some rock we can extract and process at a profit." The industrial non-metallic geologist has much the same problems and approach as a detective. I do not mean the TV variety with the big mouths and the unfailing knack of spotting the wanted criminal immediately in a city of ten million people. Any real detective will tell you it takes leg-work, knowhow, and persistence to make a case. The same is true for the geologist who finds rock which can be quarried at a profit. I am responsible for finding raw materials for a company which manufactures portland cement and

Jan 1, 1977

By A. Z. Dimitroff

An improvised rock- dust disseminator, consisting of a 10-gallon galvanized metal milk can that dispenses rock dust in return air currents by the injection of compressed air has reduced the float dust explosion hazards at the Koehler coal mine, Koehler, N. Mex.

Jan 1, 1965

By Ken J. Brouwer

Stillwater Mining Company commenced construction and development of the East Boulder underground mine in 1998. This new PGM mine is situated adjacent to the East Boulder River approximately 35 miles south of Big Timber, Montana. Project planning and development incorporated detailed collaboration between the regulatory agencies, concerned citizens and mine personnel. A unique ?good neighbour agreement? was established with a local environmental group who have become actively involved in the review of ongoing site development and the implementation of environmental and compliance monitoring. Environmental management systems allow for integrated management of tailings, waste rock and water in order to minimize surface disturbances and to prevent adverse impacts to the East Boulder River. Long-term site development plans contemplate implementation of comingled waste rock and paste tailings. Water management capabilities allow biological treatment of all excess mine water in order to reduce nitrogen loadings prior to land application disposal by means of spray evaporation, snow making and land application. The comprehensive waste and water management plans have also been integrated with staged mine development and interim reclamation requirements.

May 1, 2002

By F. G. McCutcheon

UNTIL about 1930, the universal practice of horizontal-retort zinc smelters in the United States, as far as the writers are aware, was to operate the retort furnaces on a 24-hr cycle; that is, the retorts were charged in the early morning of one day, and in the early morning of the following day the residues were cleaned out, the retorts recharged, and a new cycle started. During the business depression of the early thirties, zinc production fell off to the extent that zinc smelters had idle retort capacity. Rather than continue to run some of the retort furnaces on a 24-hr cycle and shut down the remainder, a few companies decided to try out a longer cycle. Although the output of zinc per retort per day is lower, the longer cycle permits a larger charge per retort and improved zinc recovery. Advantages of the longer cycle were soon evident, and the practice spread rapidly. Various lengths of cycle were used, typical examples being 28-hr, 32-hr, 36-hr, and 48-hr. The 48-hr cycle fits in best with the standard routine of smelter practice that was built up on the basis of the 24-hr cycle; that is, the retort furnace "maneuver" always comes at the same time of day, and can be performed in the cool hours of the early morning. Under some conditions, particularly in some of the older plants, where the retorts are smaller than in newer plants, a 48-hr cycle is longer than necessary, and some intermediate length of cycle may theoretically be most economical. Use of an intermediate cycle, however, means that the maneuver comes at different times on consecutive days, and that sometimes it comes during the hottest part of the day. The work on the retort furnaces is extremely hot and arduous at best, and it is much worse, of course, if it is done during the heat of a summer day. When labor was plentiful and tractable, many plants were able to operate on cycles of intermediate length, but the workmen did not like the working hours. Under present labor conditions, it is hardly practicable to operate with a cycle of intermediate length, so the choice has narrowed down to the alternatives of 24-hr or 48-hr cycles. In any discussion of economics, too comprehensive generalization is not warranted, because local conditions affecting economics vary greatly. The best economic practice at one plant at any given time may be uneconomical at another plant, or even at the same plant at another time. To determine the length of cycle that is the better practice at a given plant at a given time requires a weighing of the advantages and disadvantages of each cycle, taking into consideration all the local conditions. Some of the factors that must be considered in making the comparison are discussed briefly in the following paragraphs.

Jan 1, 1947

By J. F. Burr, D. P. Snyder, G. W. Luxbacher

"The Mine Improvement and New Emergency Response Act (MINER Act) of 2006 (PL 109-236, 2006) established the Office of Mine Safety and Health, functioning as the Office of Mine Safety and Health Research (OMSHR) within the National Institute for Occupational Safety and Health (NIOSH) and provided authority for awarding contracts related to the development and implementation of new mine technology and equipment. The OMSHR external contracts program was formed in accordance with the MINER Act and has since issued more than 150 contracts focused on worker health and safety. Initial funding for this program was provided by the United States Congress through two emergency supplemental appropriations and was focused on emergency oxygen supply, communications and tracking, and refuge chambers (also referred to as refuge alternatives). Since the MINER Act, Congress has continued to fund the program through the annual NIOSH mining appropriation. The program was supplemented starting in 2009 with an academic capacity building program directed toward developing university tenure-track faculty and facilities and supporting graduate students in the area of mine ventilation. Ground control was added as an additional focus area in 2011. A short synopsis of each contract is published on the NIOSH Mining website (www.cdc.gov/niosh/ mining/researchprogram/contracts/index.html) and final reports are available in digital form on request. A summary of the progress OMSHR has made over the 10-year period since the Act was published previously (Snyder et al., 2016).External contracts are broadly classified by the following areas:• Communications and tracking.• Emergency response.o Self-escape and breathing air supply.o Refuge alternatives.o Escape and rescue.• Equipment safety.• Fires and explosions.• Ground control.• Mine environmental systems (mine ventilation and atmospheric monitoring).• Worker/workplace health and safety.Contracts are issued under a request for proposal (RFP), through a broad agency announcement (BAA) or under an interagency agreement (IAA). An RFP solicitation includes a specific problem description and a well-defined scope of work to guide the offeror in preparing a bid to conduct the research. Under the BAA several problem areas are described and the offeror develops the scope of work and deliverables for the proposed research. An IAA is very similar to an RFP except it is a contract between two federal government agencies."

Jan 10, 2018

By X. (Mike) Yao

Rock mechanics engineers must provide ground support designs that ensure a safe underground working environment. Unexpected falls of ground are unacceptable while ground support systems must be adequate. Ground support must be economic for the area supported and the time frame the opening is in use. While numerical modeling can be used for ground support design, empirical models are still the common useful design tools. Empirical models are best developed and improved from local experiences although some models, such as Stability Graph (Potvin et al, 1992), are in extensive use by the Canadian mining industry. To determine the adequacy of ground support practices at HBMS, a database of 50 fall of ground case histories between 1985 and 2001 was compiled. For each failure, the recorded data included: location, rock type, rock mass conditions, opening and failure geometry, installed ground support and failure mechanism. An analysis of the database was done to obtain an understanding of failure frequency association with rock types, stope geometry and installed ground support, and to assess what support design changes were necessary. The paper describes changes made to ground support and mining practices during the last five years, and the formation of new ground support standards and practices which have been successful in reducing ground falls while providing improved, efficient and economical ground support.

May 1, 2002

By Donald A. Bruce

Pregrouting is an extremely important part of many rock tunneling projects. However, poor and unsatisfactory performances have been frequently recorded often with very severe consequences, technically and financially. This paper, based on personal knowledge of several relevant case histories, provides recommendations with respect to specification drafting, drilling, water pressure testing, and grouting methodologies, and cementitious grout mix design principles. Even given that the logistical challenges facing tunnel pregrouting from underground will prevent all the sophistication and innovations of contemporary dam foundation grouting being practically implemented, there is still opportunity and need to change “traditional” approaches.

Jan 1, 2005

By Paul M. Price

The Mouat mine, Nye, Mont., was reopened in 1953 by the American Chrome Co. under a Defense Minerals Production Administration contract. Operations were terminated in 1961 after completion of the contract. Mining methods employed during this period are described in detail, and cost data are presented by years for 1953 through 1959. Ultramafic rocks of the Stillwater complex in Montana contain the largest domestic resource of chromite, and the Mouat mine has been the largest producer. Mine reserves were estimated in 1960 to be about 4.4 million tons containing 22.5 percent Cr2O3. The chromite deposits occur as a series of overlapping bands or lenses roughly paralleling the steeply dipping layers of the complex. Only two of the chromite layers have proven to be of economic importance. One layer is 2 to 16 feet wide; the other is 3 to 8 feet wide. Shrinkage stoping was generally used throughout the mine, but various methods of ore breaking, stope drawing, chute construction, etc., were tested to improve output and lower costs. Long-hole stoping proved to have limited use. Breasting down benches, developed outward from the center of the stope with air-leg drills, was satisfactory only in wider stopes. At the close of operations, the company had standardized the use of lightweight stopers to advance a flat back by breaking from a centrally located face. Mining costs were reduced 47 percent during 7 years of operation.

Jan 1, 1963

By B. M. Harra, F. G. McCutcheon, O&apos

Until about 1930, the universal practice of horizontal-retort zinc smelters in the United States, as far as the writers are aware, was to operate the retort furnaces on a 24-hr cycle; that is, the retorts were charged in the early morning of one day, and in the early morning of the following day the residues were cleaned out, the retorts recharged, and a new cycle started. During the business depression of the early thirties, zinc production fell off to the extent that zinc smelters had idle retort capacity. Rather than continue to run some of the retort furnaces on a 24-hr cycle and shut down the remainder, a few companies decided to try out a longer cycle. Although the output of zinc per retort per day is lower, the longer cycle permits a larger charge per retort and improved zinc recovery. Advantages of the longer cycle were soon evident, and the practice spread rapidly. Various lengths of cycle were used, typical examples being 28-hr, 32-hr, 36-hr, and 48-hr. The 48-hr cycle fits in best with the standard routine of smelter practice that was built up on the basis of the 24-hr cycle; that is, the retort furnace "maneuver" always comes at the same time of day, and can be performed in the cool hours of the early morning. Under some conditions, particularly in some of the older plants, where the retorts are smaller than in newer plants, a 48-hr cycle is longer than necessary, and some intermediate length of cycle may theoretically be most economical. Use of an intermediate cycle, however, means that the maneuver comes at different times on consecutive days, and that sometimes it comes during the hottest part of the day. The work on the retort furnaces is extremely hot and arduous at best, and it is much worse, of course, if it is done during the heat of a summer day. When labor was plentiful and tractable, many plants were able to operate on cycles of intermediate length, but the workmen did not like the working hours. Under present labor conditions, it is hardly practicable to operate with a cycle of intermediate length, so the choice has narrowed down to the alternatives of 24-hr or 48-hr cycles. In any discussion of economics, too comprehensive generalization is not warranted, because local conditions affecting economics vary greatly. The best economic practice at one plant at any given time may be uneconomical at another plant, or even at the same plant at another time. To determine the length of cycle that is the better practice at a given plant at a given time requires a weighing of the advantages and disadvantages of each cycle, taking into consideration all the local conditions. some of the factors that must be considered in making the comparison are discussed briefly in the following paragraphs.

Jan 1, 1949