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By Dale E. Wittmer

Nonoxide ceramic materials could substitute for high-temperature alloy steels containing imported critical and strategic materials such as cobalt, chromium, and nickel if their high-temperature properties can be improved. An important result of this substitution would be a reduction of the Nation&apos;s need for imports of critical and strategic materials. In this Bureau of Mines investigation, the primary objective was to produce high-purity u1trafine (particles <5 ~m equivalent spherical diameter (ESD)) alpha-silicon carbide (a-SiC) powders with improved high-temperature properties using the Bureau&apos;s patented turbo-milling process. A secondary objective was to determine the feasibility of using polymer mill construction materials as a means of eliminating metal contamination from the turbomill. U1trafine a-SiC powders with BET (Brunauer-Emmett-Te11er) surface areas from 30 to 35 m2/g (~0.06 ~m particle ESD) were produced in an all-polymer turbomi11. These high-purity powders (with I-pct Band I-pct C additions) hot-pressed to greater than 99 pct of their optimal density and exhibited properties commensurate with those of commercially available a-SiC. The most promising of the construction materials tested for the major wear surfaces of the turbomi11 was u1trahigh-mo1ecu1ar-weight (UHMW) polyethylene, a polymer thermoplastic.

Jan 1, 1984

By E. Wysocki

In the production of magnesium oxide, dolomitic lime and magnesium chloride are reacted to produce an intermediate product, magnesium hydroxide. Consistent product quality requires close monitoring of the soluble calcium hydroxide level during the reaction. Traditionally, this analysis has been done by manual titration; however, the product quality could improve with more frequent analysis and better control. A feedback control system was developed based on frequent automatic titrations, and reactor modelling was used to discern a control strategy. The system development and implementation are described.

Jan 1, 1984

By John L. Watson

A conceptual model (MAGSEP) is described to simulate the beneficiation characteristics of a drum magnetic separator in terms of the probability of an individual grain being recovered in the magnetic concentrate. This probability is determined as a function of particle magnetic composition and magnetic field strength and is modified by particle size and the separator operating conditions. The model predicts the size, magnetic grade and distributions of magnetic and gangue minerals in the concentrate and tailings produced by the drum separator. The configuration of the magnetic concentration circuit may be altered to permit single or double drum units in parallel or series operation. The characteristics of the feed material, in terms of a magnetic parameter, are essential in permitting the determination of individual grain recovery probabilities upon which the model is based. Thus the model requires input data relating to the distribution of composite grains in terms of magnetic grade and particle size. To illustrate the use of the conceptual model an example is given for the beneficiation of New Zealand iron sands.

Jan 1, 1984

By Jasinder S. Jaspal, Bradley J. Bourquin

Introduction Operation is underway at the Dutch Creek No. 1 mine of the first US longwall panel to be mined under the cooperative agreement between the US Bu¬reau of Mines and Mid-Continent Resources. The 244-m (800-ft) wide longwall face is part of a multilift longwall demonstration. A 3-m (10-ft) top slice is being extracted from the 8.5-m (28-ft) coal seam. This occurs in an area of the property where the Coal Basin A and Coal Basin B beds have come together to form one seam. This face, longest ever operated in the US, is being worked on an advancing longwall system. During the first months of its operation, this longwall face has been very productive and safe. Mid-Continent Resources operates two coal mines in the Coal Basin, located in the White River National Forest near Carbondale, CO. The Colorado Fuel and Iron Co. originally opened this property in 1895, and conducted a small mining operation for 10 years on the north rim of the basin and then abruptly shut down. Mid-Continent began operations in 1956, after the Coal Basin fields had lain idle for about 60 years. Operations commenced at the outcrop of the Coal Basin B bed situated at the 3-km (10,000-ft) elevation. At this time, coal was produced from Coal Basin A and Coal Basin B seams in the area. Since 1981, operations have been centralized at two mines, the Dutch Creek No. 1 and the Dutch Creek No. 2, both located in the center of the basin. Since 1981, Mid-Continent has shifted its emphasis to longwall mining as the primary method of production, and each of these mines is equipped with state-of-the-art longwalls using shields as the method of roof support. A 4-km (13,000-ft) long twin-bore rock tunnel is being driven at a lower elevation of 2.4 km (8,000 ft) to intersect the coal seams at depth, as they dip 12° in a westerly direction. This tunnel will enable the company to reduce costs by replacing trucks with conveyor belt haulage (Fig. 1). Mid-Continent began longwall operations in May 1976 with the US&apos;s first modern, mechanized advancing longwall face, using chocks. In August 1978, a second advancing longwall face was started. Results from two faces showed that the mining system could be used effectively to manage the difficult conditions encountered in both the Dutch Creek No. 1 and the L. S. Wood No. 3 mines. Unfortunately, low productivity and high costs plagued the company&apos;s advancing faces. The problems resulted principally from major equipment failures, poorly designed chocks and face conveyors, and the lack of an efficient, cost effective system for building packwalls. Flushing of rock between chocks and roof control were also major problems. In Sept. 1979, Mid-Continent and the US Bureau of Mines entered into a cooperative agreement to demonstrate the feasibility of mining thick coal seams using the multilift longwall mining method. Two lifts are to be used to mine the 8.5-m (28-ft) thick coal seam in Dutch Creek No. 1 mine. The Bureau provided mining equipment for 180 m (600 ft) of longwall face. This included the shields, face conveyor and drive units, shearing machines, panel belt, and stageloader. As a result of previous experience in advancing longwall mining, Mid-Continent purchased an additional 60 m (200 ft) of face, including roof supports and an additional face conveyor. Design The Dutch Creek No. 1 is a slope mine located on the flank of a plunging anticlinal structure that

Jan 1, 1984

By J. P. Bennett

The Bureau of Mines is investigating the acid resistance of ceramic materials to identify construction materials for emerging technology in chemical and metallurgical processes. Eight commercial ceramic materials, including two red shale, two fireclay, a silica, a silicon carbide, a carbon, and a high-alumina brick, were evaluated. Samples were exposed to 40 wt pct HN03 at 70° and 90° C and 60 wt pct HN03 at 50°, 70°, and 90° C for time periods of 110 days. Statistically significant changes in cold crushing strength were generally small or not detected, except for a strength drop in the high-alumina brick, which decreased in strength when exposed to the chosen acid concentrations at 90° C. Vol-ume and weight changes were also measured. The leach rates of Al, Ca, Fe, K, Mg, Na, Si, and Ti were monitored. Increasing temperature or a decrease in the acid concentration resulted in an increased ion leach rate. Of the conditions tested, the most severe corrosion occurred at 90° C for a 40-wt-pct-HN03 solution. The silica brick had the best overall acid-resistant properties, followed by a red shale and a fire-clay brick. The carbon and silicon carbide bricks are not recommended for service.

Jan 1, 1984

By Purvis A. H, Greenwood-Smith R, Sowerby B. D

A nuclear technique for the determination of copper and nickel in bulk samples and drill core has been developed at Lucas Heights andfield-tested at Mount Isa. The technique, which is highly specific to the element being measured, utilises the gamma-ray resonance scallering process.A bulk mineral analyser was installed in mid-1976 for the routine assay of copper in bulk samples and drill cores, and remained in operation until late 1981. The operation of the analyser over this five-year period is reviewed with particular emphasis on reliability, accuracy and principal usage.The main application of this analyser was in stope planning and design whereby several thousand drill-core and Wall-chip samples were analysed. It was also used as an aid to underground grade control of stopes where ore dilution by supporting barren backfill was a problem.

Jan 1, 1984

An examination has been made of the rate and extent of removal of carbon from scrap metal charges when the melt is exposed to atmospheres which are reducing or oxidising with respect to FeO at unit activity. The mechanisms of decarburisation of molten Fe-C-S- P-Mn-Si alloys with H2/CO/H20/C02 gas mixtures with controlled compositions at high or low concentrations of carbon in the melt in the presence and in the absence of sponge iron, in both slag free melts and in the presence of various slag forming additives are discussed. A significant quantity of carbon can be removed from the metal during the melting stage and under optimum conditions, a high percentage of metal recovery and low carbon can be obtained after exposure of melt to the above gas mixture with controlled compositions. The presence of ferrous oxide provided by poorly reduced ore in the charge and the use of controlled atmospheres facilitated the removal of carbon to very low level during the melting period.

Jan 1, 1984

By Z. Sartowski, M. J. Pearse

The authors present laboratory and plant results illustrating the benefits to be gained by using chemical additives, namely flocculants and surfactant dewatering aids, in the Bayer process. Advantages of synthetic flocculants over starch are illustrated in terms of more efficient solid/liquid separation in both the initial settling of blow-down slurries and in the CCD wash train. In addition, it is shown that the use of synthetic flocculants considerably reduce the levels of organic contaminants present in the process liquor. Secondly, very significant improvements in moisture removal were obtained by the application of dewatering aids to hydrate filtration/ washing operations.

Jan 1, 1984

By Richard L. Unger

The U.S. Bureau of Mines has designed, fabricated, and tested a prototype track maintenance vehicle for underground coal mines. The vehicle uses a stiff rotating brush to clean the track so that a visual inspection is possible. It is also equipped to measure track gauge and cross-level. The objective of this report was to describe the track maintenance vehicle and detail the results of investigations into present underground track inspection procedures and cleaning technologies, which led to the development of the prototype. Recommendations are made concerning the integration of components of this prototype vehicle into current track cleaning and inspection systems used in underground mines.

Jan 1, 1984

By S. P. Brown, J. E. Worthington

Increasingly, exploration geology seems to be growing into a practice overly separated from production geology, yet the eventual purpose of exploration is a producing mine. To help in the search for new deposits, exploration "lessons" will be drawn from the papers given at the Fall AIME Applied Geology Symposium. In addition, examples will be re-emphasized to show how early observation of matters now routine to mine work (for example, hydrology, rock mechanics, oxidation state) can help increase the effectiveness of exploration.

Jan 1, 1984

By Denni Nikols

"Planning for coal beneficiation in the electric utility industry is relatively complex, involving the coordination of experts and specialists in a broad range of fields, as well as compliance with a wide variety of government regulations.This paper examines the role of the planner, reviews possible benefits of coal beneficiation, identifies potential problems and illustrates a typical planning schedule.The steps involved in the planning process are:Step I-Bench- and pilot- washability studyStep 2- Wash plant designStep 3- Power plant and boiler designStep 4-Mine designStep 5-Major environmental and technical problems to address.IntroductionElectrical utilities and coal have a long and intimate relationship . Cleaned coal is becoming an increasingly popular fuel with the utilities for a variety of reasons. Generally, the greatest impetus to burn a cleaned or prepared coal fuel comes from the need to control airborne pollutants.Long-range planning is a standard practice for electric utilities, forecasts of demand must be made well into the future. Since the lead time required to provide new facilities is often as long as 10 years and the cost very high , planning becomes an important task.For a utility that owns and directs the operation of its coal mines, the mine planning or fuel acquisition planning takes on the magnitude of other corporate planning functions. It is from this perspective that a utility would view coal preparation. Except for the interaction of a coal-fi red plant on the actual mine design the planning considerations o f a beneficiating facility for a captive mine or a contract raw coal supply are about the same. Because TransAlta Utilities is currently supplied from captive mines, this discussion will tend to focus in that direction.It is the role of a planner to plan. This is easy to say but it is not always easy to do. Often we are working within a context that resembles the geological time scale. Frequently the objectives are not clearly defined when we begin and ultimately our plans are tested in the waters of government regulations and cost benefit analyses .Planning for beneficiation of Plains coal, or any coal, provides just such a test. The planner&apos;s role in this endeavour requires a wide vision. While parts of the process may be amenable to classical methods of project scheduling, the broad range of subjects and interaction of seemingly unrelated tasks is sure to obscure some of the considerations that must be made. Therefore, the planner&apos;s chief role is coordinating the work of many experts and specialists toward the final objective.Among the specialists are combustion , geo technical, mining, civil , and mineral processing engineers , geologists, hydrogeologists, soil, and reclamation experts to list a few.When one considers coal beneficiation, the planning part o f that consideration is probably more complex than any other single engineering function. Due to the company&apos;s location in the Alberta Plains and the proximity o f the mine to the thermal generating station, this paper will tend to emphasize that situation.Beneficiation may offer some advantages over run-of-mine coal to the power plant opeator. Some of these advantages are: removal of a contaminant, power plant efficiency gains , lower plant capital costs (for new plants), possible lower mining costs."

Jan 1, 1984

By Dan White

Stress measurements taken at Climax, El Teniente, Henderson, Lakeshore and Urad mines indicate that the deposits cited are generally subject to an inclined stress field that can be highly anisotropic. The horizontal stresses vary significantly between deposits and exceed the measured vertical stresses at Henderson and El Teniente mines. Experience at Henderson, Lakeshore and Urad mines is used to suggest a relationship between cavability and the premining stress. In poorly fractured, high strength rock masses, high stresses can assist the caving process. In well fractured, low strength rock masses, caving is ensured by breakage along fracture planes. The relationship between ground weight and the premining stress is also investigated. Ground weight problems appear to be most related to the competence of the ground rather than the magnitude of the premining stress as supported by experience at Climax and El Teniente mines. Recent developments in block caving favor the extraction of poorly fractured, high stressed rock. Accompanying the development of these deposits are new problems such as rock bursts. These pose particular problems to mine designers in that no experience currently exists in combatting rock burst problems at block caving mines.

Jan 1, 1984

By K. Kim

INTRODUCTION A thorough evaluation of the geologic material being considered must be conducted to determine the feasibility of constructing a large-scale underground facility in a deep geologic formation. The design and construction of a nuclear waste repository in basalt, due to the unprecedented nature of the project, adds significantly to the need for thoroughness of this evaluation and mandates that geoengineering data and analysis be of the highest quality. The investigations required to collect the data encompass in situ measurements and observations, as well as laboratory and field tests. Mathematical (numerical) models, which are required to predict the long-term performance of the repository structure, must be developed to evaluate rock mass behavior at canister, room, and repository scale and eventual 1 y must be validated through in situ tests and monitoring. The information generated from these geo- mechanics investigations is essential for assessing site suitability and will be utilized in the development of the repository design, the engineered barrier design, and the evaluation of repository performance. The Hanford Site near Richland, Washington is one of nine sites throughout the nation being investigated by the U .S. Department of Energy as a possible location for the first high-level nuclear waste repository in deep geologic formations. The process of site characterization is currently in progress. If the site is nominated by the U.S. Department of Energy, an extensive program will be undertaken, the culmination of which will be a decision on the suitability of the site for waste disposal. There are a mu1titude of elements to the proposed site characterization

Jan 1, 1984

By Lancelot E. Kun

The high-rate floc blanket clarification process developed by the Anglo American Corporation of South Africa is capable of continuously clarifying gold and uranium pregnant solutions containing 200-2500 mg/L suspended solids to below 25 mg/L solids at an average rising velocity of 8 m/h at the low process cost of R0,001-0,002 per ton of liquid treated. Overall process cost savings are mainly due to increased polishing filtration cycle times.

Jan 1, 1984

By Ernest Y. Baafi

The technique of linear kriging as a grade estimation method of mining blocks is reasonably established in the mining industry. Because of the nonbias condition imposed in kriging which requires that the kriging weights (?i) add up to one, negative weights are sometimes used in kriging. The use of negative weights is not justifiable from the practical standpoint. Also, negative block grades can be obtained in some extreme situations which makes no practical sense. To guarantee non-negative weights an additional constraint is required in the kriging system of equations. Unfortunately, the nonnegative weight constraint results in a set of non- linear system of equations. In this paper, a derivation of the resulting set of nonlinear equations is presented and a numerical algorithm is developed for the solution of the equations. Because the algorithm developed does not remove negative weights arbitrarily, optimal nonnegative weights are always guaranteed. Results obtained using the developed algorithm were compared with those using the standard linear kriging, in terms of computer time and the estimation results. Both the computer time and the kriging variance were found to be higher with nonnegative constraint, as expected. However, some systematic pattern was observed in the kriged values (i.e., over or under estimation) with or without the nonnegative constraint. The study also demonstrated when one should generally expect negative kriging weights in practice, and what practical impact the negative weights can have on the kriging estimates.

Jan 1, 1984

By Douglas W. Reeve, Hoc Nghia Tran, David Barham

"In kraft pulp mills, the spent pulping liquor is concentrated and used as fuel in the recovery boiler. Extensive deposits are formed in the upper section of the boiler due to the very high ash content of the fuel and the volatite nature of the ash. Deposits are composed of Na2S04, Na2C03 NaCI, some potassium salts and reduced sulphur compounds. Chloride and potassium salts are enriched in the deposits compared to the smelt due to their greater volatility.Severe corrosion of the superheater tubes in a recovery boiler has been traced to three factors: a non-uniform temperature profile in the flue gas, relatively high operating steam temperatures and high chIoride and potassium concentrations in the fireside deposits.The role of chIoride and potassium in superheater corrosion has been explained by increased Iiquid phase in deposits. Together with corrosion studies, this information has shown that kraft recovery boiler superheater corrosion due to the chloride and potassium enriched deposits can be avoided by proper boiler operation and by judicious superheater and furnace design.IntroductionThis investigation of recovery boiler superheater corrosion was initiated by the discovery of severe corrosion of the final stage superheater in a Canadian closed cycle kraft pulp mill(1,2). Metal wastage leading to tube failure was believed to be due to three major causes : the relatively high operating steam temperatures, the uneven distribution of flue gas temperature across the boiler which created a "" hot spot"" and the high chloride and potassium concentrations in the superheater fire side deposit. The mill responded to the problem by i) lowering the superheater steam temperature from 475°C to 380°C, ii) minimizing the chloride content in the spent pulping liquor, by controlling the NaCI input with recovered bleach plant effluent, and iii) changing metallurgy of a portion of the bottom section of the final stage superheater platens from ferritic steel T-22 (2.25% Cr, 1% Mo) to austenitic steel Incoloy 800H (21% Cr, 32% Ni, 46% Fe, 1.5% Mn, 1% Si, 0.6% Al) (Fig. 1). Details of the superheater corrosion experienced in the closed cycle mil! have been reported in previous papers(l ·2,) ."

Jan 1, 1984

By R. G. Burn

"A brief outline will be given of the concept of risk and its implications with regard to investment in exploration. The relationship between risk and decisions under uncertainty will be examined as a prelude to identifying those factors which contribute to exploration risks:consideration of the effects of corporate objectives (e.g. survival, expansion, diversification) on exploration strategy and ultimately on success or failure, exploration and mining as an investment (the relationship between risk and reward) and the desired return on investment; exploration odds, funding levels, staying power, financial exposure and the concept of gambler&apos;s ruin;origins of uncertainty in exploration decision-making-man-made risks and natural hazards; the nature of introduced constraints at each exploration decision stage and their effect on the rate of success;improving the chances of success and the invest reduction of risk through sound exploration strategy, effective project generation and efficient target detection capabilities."

Jan 1, 1984

By Bjorn N. P. Paulsson

A number of granitic rock specimens have been studied from the Stripa mine site in connection with a large-scale geomechanics research program. The purpose of the program was to evaluate and develop field and laboratory techniques for rock mass characterization and to determine design parameters for storage of nuclear waste. In this paper a minicomputer-based technique for studying dynamic rock properties in the laboratory is described, together with results from the tests. The specimens were tested under different uniaxial and saturation conditions. Specimens from a field-heated rock mass were also tested to determine if temperatures typical of those encountered with nuclear waste would introduce additional fracturing. Both Vp and Vs increased with stress for both saturated and dry specimens. Both Vp and Vs were higher for saturated specimens at all stress levels compared with the dry. The velocities increased linearly or near linearly with saturation. The test results on the previously heated samples indicate that attenuation is more sensitive to thermally-induced microfracturing than velocities. Analysis of the attenuation values with stress show that rock heated to 200°C is damaged, and that the damage is in form of low-aspect ratio fractures.

Jan 1, 1984

By Lee W. Abramson

INTRODUCTION The design of rock support for underground nuclear waste repositories requires consideration of special construction and operation requirements, and of the adverse environmental conditions in which some of the support is placed. While repository layouts resemble mines, design, construction and operation are subject to quality assurance and public scrutiny similar to what is experienced for nuclear power plants. Exploration, design, construction and operation go through phases of review and licensing by government agencies as repositories evolve. This paper discusses (1) the various stages of repository development; (2) the environment that supports must be de signed for; (3) the environmental effects on support materials; and (4) alternative types of repository rock support. Much of the information presented in this paper was derived from work conducted for Basalt Waste Isolation Project. Most of the information, however, would apply to other hard rock repositories. REPOSITORY DEVELOPMENT AND THE NEED FOR ROCK SUPPORT Repository development can be characterized by five general stages: exploration and design, excavation, waste emplacement, re trievability period, and backfilling. It is helpful to understand these phases of development to see where and when rock supports are required and how the design is verified. The description that follows is simplified. Details have been omitted, and future plans may not conform to this scenario.

Jan 1, 1984

By Roger B. Alke

INTRODUCTION Request to Mine Beneath Bridge The Jakes Run Bridge is a reinforced Portland concrete arch filled bridge located on WV Route 7 near Pentress, WV. The bridge has a span of 22.9 m (meters) and a height of 4 m above normal pool elevation to the underside of the center of the arch (See Fig 1). The bridge is a two lane structure with a width of 6.86 m. The structure is over 50 years old having been built in 1929 and is owned by the Department (WV Department of Highways). [ ]

Jan 1, 1984