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By Richard L. Coleman

Metallurgical testwork to develop a flowsheet is described, beginning with background information required right through to a final process flowsheet. Both laboratory and pilot plant testing are reviewed with emphasis on the former.

Jan 1, 1978

By J. R. Hunter

Current trends in mining practices within the United Kingdom, with particular reference to longwall retreating systems in thick and steeply pitched coal seams at depth, are explained. Various successful mining layouts are considered with their associated machinery and operation, together with the future trends in mining practices to obtain higher outputs. Environmental difficulties are tabled and discussed, including strata control, methane emmision, and dust prevention, together with some modified systems and techniques to overcome them. The problems associated with developing and maintaining a continuance of longwall panels are outlined. The constraints on technical designs and output achievement imposed by noncommercial factors are also considered.

Jan 1, 1978

Asarco's Sacaton unit, located near Casa Grande 45 miles southeast of Phoenix, Arizona, was brought into production in February 1974. Ore reserves are estimated at about 48 million tons at 0. 95% copper. Mineralization of the orebody comprises both sulfides and oxides, with minor amounts of gold and silver. Preproduction stripping of 40 million tons of overburden was accomplished in less than two years. Mining is done at the rate of 9,000 stpd ore with a waste-to-ore ratio of 4.6 to 1. 0. The mine is developed on 40 ft benches, and by 1979 underground block caving methods will be phased into the operation at a depth of 1900 ft. Ore is mined in the pit two shifts per day, seven days per week, and is hauled with 85 ton trucks to the primary crushing plant. Trucks dump their loads into a 165 st capacity pocket equipped with a chain curtain which controls the ore flow to the 6 ft 6 in. wide by 24 ft long (2. 0 m by 7.3 m) vibrating feeder grizzly. Grizzly bars are inclined at a 5º slope on the first half of the 0 feeder and 10 on the last half. Grizzly bars have 6 in. (13 mm) spacings which pass 60 to 70% of the mine-run ore. Grizzly oversize drops into a 48 in. by 60 in. (1. 22 m by 1.52 m) primary jaw crusher. Both the grizzly undersize and crusher discharge are collected on a 42 in. (1.07 m) conveyor belt operating 398 fpm (121 mpm) for transport to the 4,750 live st intermediate storage area ahead of the fine crushing plant. Capacity of the Sacaton primary crushing plant is a nominal 1150 stph (1043 mtph). It operates fourteen shifts per week with an effective crushing time of four hours per shift. An economical open-air design was used, but an enclosed operator control room is located on the upper level where the dump truck, feeder, and crusher can be observed. Oversize rocks are removed from the feeder or crusher by the 10-ton bridge crane. Direct operating costs for this well-designed primary crushing plant, including labor, power, supplies, and maintenance, are only 3.5 cents per short ton. An interesting feature of the Sacaton orebody is that the non-sulfide copper minerals, which are less prevalent than the sulfides, occur intimately with the sulfide minerals; for this reason, all ores as mined are treated in a flotation circuit using sulfidizing methods for oxide recovery.

Jan 1, 1978

The Cuajone and Toquepala copper projects are located in the extreme southern area of Peru. Since 1960, Southern Peru Copper Company has operated the Toquepala open -pit mine, flotation mill, 110 smelter, townsites, power plants, and railroad. Toquepala and 10, the smelter and port location, are connected by a 110-mile-long (176 lun) railroad. Much of Toquepala's infrastructure has been used for the Cuajone project. Cuajone, at an elevation of 11,400 ft (3475 m), required five standard-guage railroad tunnels with a combined length of 17 miles (27.2 km) to connect with Toquepala so concentrates could be shipped to the no smelter. The total cost of Cuajone is estimated at $726 million for a designed annual capacity of 180,000 tons of copper, equivalent to about $4,000 per ton of installed production capacity. This relatively low cost per ton, by today's standards, has been made possible through the use of the 110-to Toquepala railroad, the ability to expand the 110 copper smelter, and other favorable factors. To mine the 468 million tons of copper sulfide or e at a grade of 1.0% copper, approximately 24 1 million tons of waste were stripped- before mining of ore to supply the new Botiflaca 45, 000 ton per day concentrator. The mining rate must exceed 300,000 tons of waste plus ore per day to maintain the 45, 0 00 tpd sulfide ore milling rate which was to be reached at the end of 1976. Waste stripping is done with 15 cu yd electric shovels and 120 -ton trucks. Ore mining is done with 8 and 9 yd shovels. A railroad connects the pit with the 60 in. by 89 in. Allis-Chalmers gyratory crusher. Side-dump railroad cars of 50.cu yd capacity dump onto a 0 16 ft 9 in. long (5. 1 m) grizzly inclined at 40º with 7 to 8 in. (178 to 203 rnrn) bar spacings. The grizzly is divided into two 22 ft 4 in. (6.8 m) wide sections and two side -dump railroad cars discharge simultaneously into the 150-ton capacity dump pocket. A Barco rock manipulator is used for breaking or removing oversize from the dump pocket. The bin receiving the grizzly undersize has a capacity of 5,000 tons, and the pocket beneath the crusher holds 900 tons. Each is equipped with an 84 in. apron feeder, which feeds a 60 in. (1.52 m) conveyor belt to the 150,000 ton coarse ore stockpile, where the ore is distributed by a 72 in. (1. 83 m) tripper conveyor. The 45, 000 live tons in the coarse ore stockpile are reclaimed by twelve 48 in. (1. 22 m) apron feeders. Maintenance on the crusher eccentric is made easy by an eccentric

Jan 1, 1978

By Harvey P. Knudsen

This paper illustrates the application of geostatistics to a roll front type uranium deposit located in Wyoming. The steps involved in calculation of experimental variograms, variogram modeling and verification of the resulting models are described in detail. The resulting spherical variogram models for grade thickness and thickness show strong geometrical anisotropies. The major axis of anisotropy for both variables is approximately parallel to the axis of the roll front and the minor axis perpendicular to the roll. This model confirms the technique of drilling "fences" across the roll front, where the drilling is much closer together than the fences along the roll.

Jan 1, 1978

The Molycorp operation at Mountain Pass, California, is unique in that it is the only place in the world where bastnasite is mined. The orebody is a metamorphic carbonatite; the mineral of importance is bastnasite, a fluocarbonate containing principally cerium, lanthanum, neodymium, and praseodymium, with small amounts of samarium, gadolinium, and europium. In addition, appreciable quantities of barite, calcite, and strontianite are present. Molycorp had mined and processed the bastnasite ore since the early 1950s at a rate of about 100 tpd by a unique hot flotation process in a plant originally used for cyanidation of gold ore. The concentrate was primarily used in high quality glass polishing, lighter flints, ceramics, and in specialty steel making. Then in the early 1960s, Molycorp and the Colorado School of Mines Research Foundation developed a solvent extraction process to recover europium from the bulk rare earth concentrates. In 1965 a new SX plant was constructed to produce this material for use as a red phosphor in color television tubes. Because of the demand for this material, a new 500 tpd concentrator was designed and constructed in 9 ½ months. Then, because of a sharply increased demand for europium, the plant was expanded to 1200 tpd only four months after completion of the original construction. The crushing section of the new plant was designed similarly to those portable units used in road construction and arrived on the site in ten major pieces. Foundations were concrete piers; and after their completion, the entire crushing plant composed of primary and secondary crushers, conveyors, and a screen was erected in fourteen days by a crew of ten men assisted by a mobile crane. Pit-run ore is loaded into 35-ton trucks by a 7 yd (5.4 cu m) loader, trans- ported to .the crushing plant, and dumped into the 65 -ton concrete pocket. A 42 in. by 20 ft (1.07 m by 6. 1 m) apron feeder feeds ore to the 30 in. by 42 in. (760 rnrn by 1070 mm) single toggle jaw crusher. Crushed ore is trans- ferred by a scissors conveyor to a 5 ft by 14 ft (1.52 m by 4. 27 m) double- deck screen which produces a final ¾ in. (19 rnrn) product with the oversize being treated in a 4 ¼ ft (1. 3 m) standard cone crusher. Cone crusher product is returned to the first scissors conveyor to join the primary crusher product. Dust collection is by a wet scrubber, and an operator's control room is located to overlook the primary. The entire crushing is in the open, and a 30-ton mobile crane is used for maintenance. Molycorp’s two-stage crushing plant is an excellent example of functional design for a small mining and milling operation.

Jan 1, 1978

By Paul G. Schmidt

The Crandon massive sulfide deposit Forest County, Wisconsin, was discovered by Exxon Minerals Company, U.S.A., in July 1975. Announced estimated in-place reserves are 62 M metric tons (70 million short tons), grading about 5% zinc and 1% copper. The reserves are evenly divided between massive sulfide are and stringer sulfide ore. The sulfide body is associated with Precambrian felsic pyroclastic rocks, and it is overlain by intermediate volcanic rocks and their derived sedimentary rocks. These rocks were subjected to greenschist facies metamorphism and were tilted to a near-vertical attitude. Geologic observations indicate a submarine-volcanic-exhalative origin for this deposit.

Jan 1, 1978

By G. Scott Zimmer

Mine planning at Cassiar consists of an annual cycle of projection, control, evaluation and revision following completion of annual diamond drilling during the summer months . The inherent difficulty in evaluating fibre grade and distribution, combined with a high-wall phase or push-back mining system, requires continuous modification to designs and schedules based on a cumulative evaluation of equipment performance and prediction versus production. To expedite the planning sequence, a mini-computer system has been introduced which allows emphasis to be placed on optimizing designs, exempting personnel from manual calculations and tabulations.

Jan 1, 1978

By Russell A. Carter

Although significant phosphate mining activity has occurred in four western states-Idaho, Montana, Utah, and Wyoming-southeastern Idaho contains the largest, most easily mineable reserves, and mining has focused there. More than half of the western phosphate field's economic reserves are within a 32 x 96-km (20 x 60-mile) rectangle bounded by Montpelier, Idaho, on the south, Soda Springs on the west, and Grays Lake on the east. A large amount of this land lies within the boundaries of the Caribou National Forest.

Jan 1, 1978

By S. J. Hussey

The Bureau of Mines investigated the applicability of carbon-in-pulp pro-cess for recovering silver from low-grade ores. The reasons for the research were (1) to illustrate a practical procedure for the process design of carbon-in-pulp adsorption circuits using leach slurries and simple equipment; and (2) to illustrate how equations of adsorption theory relating rate data and equilibrium adsorption curves can be helpful in process design. Carbon-in-pulp silver adsorption tests were made on Banner, Idaho; mine-run ore samples with silver contents ranging from 2.0 to 8.5 oz/ton and variations in cyanide leach extraction from 48 to 93 pet. The lower recoveries were attributed to the presence of complex silver sulfide minerals. Carbon-in-pulp batch adsorption tests provided rate data for the estimation of a silver equilibrium adsorption curve. Process design procedures in which the rate data were related to an equilibrium adsorption curvey by equations of adsorption theory were used to plan a four-stage pilot plant cascade. The pilot plant was successfully operated for 45 hr of countercurrent flow, producing a carbon product containing a mean silver loading of 571 oz/ton from a pregnant solution of 1.7 oz/ton of silver. Virtually all of the dissolved silver was recovered on the carbon.

Jan 1, 1978

By Donald J. Ninteman

This Bureau of Mines publication is a literature study of the problem of spontaneous oxidation and combustion of sulfides in underground mines. It summarizes the present-day hazards, process mechanisms, and prevention and control techniques of this growing problem in underground mines. The iron sulfides generally have the greatest tendency to oxidize, particularly pyrrhotite. The presence of moisture and oxygen is essential for the oxidation reaction. Highly fractured sulfides, when found with timber or combustible refuse in slowly circulating air, pose the most serious fire hazard. Quenching with water is effective in quickly dealing with local hot spots, but ventilation at high flaw rates is the most effective and economical means for long-term prevention and control.

Jan 1, 1978

By T. F. Muller

In recent years, a great deal has been written and spoken, both in our country and overseas, about the dangers posed to the environment and the ecology by mining operations. The object of this address is to put this problem, and it is a real problem, into reasonable perspective. I shall try to present the various facets that merit consideration as objectively as possible. In doing so, I shall examine the following factors: Book review National Coal Board. Gate belt conveyors. London, H.M.S.O. (Price 95p.) Although the preface of this handy little book states that it has been written for the guidance of miningoperation trainees, it will prove valuable to the practising engineer as well. NIM reports Report no. 1733 A mineralogical investigation of weathered carbonatite from Salpeterkop. (14th Apr., 1975; re-issued 28th Feb., 1978). Report no. 1823 The recovery of gold and pyrite from a residue dump at Crown Mines. (10th Jul., 1976; re-issued 28th Feb., 1976). Report no. 1829 An investigation of weathered carbonatite from Salpeterkop. (20th Jul., 1976; reissued 28th Feb., 1978). Report no. 1932 A BASIC computer programme for the evaluation of intensity data from the Telsec Lab-X-250 Analyser. (12th Jan., 1978). Report no. 1940 The extraction of the noble metals with n-octylaniline, and its application to the analysis of platinum-bearing materials. (30th Jan., 1978). Report no. 1945 Analyses of the NIMROC reference samples for minor and trace elements. (28th Feb., 1978). Report no. 1945 Analyses of the NIMROC reference samples for minor and trace elements. (28th Feb., 1978). International futures conference A conference entitled 'The Road Ahead' is being organized by the 1820 Settlers National Monument Foundation to be held in Grahamstown from 3rd to 7th July, 1978. Conference of metallurgists The technical programme has been established for the 17th Annual Conference of Metallurgists sponsored by the Metallurgical Society of the Canadian Institute of Mining and Metallurgy. This year the Conference will be held in Montreal, Quebec, on 27th to 31st August, 1978, together with the 8th Hydrometallurgy Meeting.

Jan 1, 1978

By D. W. Rogers

Several commercial polyacrylamide flocculants most widely used in Western Canadian mineral processing plants have been analyzed chemically and compared in standardized settling tests as aids to thickening and clarification. Data are included for both dry and liquid-type flocculants. Percentages of active ingredients in these commercial products varied Widely. Performances were compared on the basis of: equal additions of active ingredients, nearly equal molecular weights and nearly equal degrees of ionic character. Based on zone settling velocities and supernatant clarities of siliceous slurries coagulated by lime additions, dry flocculants proved more economical than liquid flocculants. Using these same two criteria, the most highly anionic were more effective than either weakly anionic or non ionic polyacrylamide- type flocculants.

Jan 1, 1978

By Ronald F. Ayers

The basic research for this study was conducted by Battelle's Columbus Laboratories in 1974. The high-sulfur content of coal threatens to erode its competitive position in the future. The impact of sulfur removal on final costs of eastern interior coal lies at the very heart of this market analysis. An extensive market survey was conducted that considered both traditional coal markets as well as anticipated future markets. Competition for coal from this province considers low-sulfur Western coal, nu- clear power, international oil and coal trade, as well as Appalachian coal producers. Based on projections of future energy consumption under several scenarios, a comprehensive market forecast for eastern interior coal was made to 2040. The study upon which this paper is based was completed by Battelle's Columbus Laboratories for the U.S. Army Corps of Engineers in 1974. It is but part of an overall effort by the Corps to evaluate the costs and benefits to the nation of waterway improvements. This study is primarily concerned with future coal markets for production from those counties near the Wabash River in the heart of the Eastern Interior Province. An objective here is to consider a most pessimistic energy (and hence, coal) demand for planning purposes.

Jan 1, 1978

In many practical situations, calculation of the point semivariogram is not necessary. Such a case is analysed in this chapter. The purpose of this analysis is to give a better understanding of the meaning of the mathematical formulae developed in the previous chapters. A similar problem will be studied in Chapter 11, using the point semivariogram.

Jan 1, 1978

By Jr. Lownie

Estimates of the cost of producing any commodity generally fall into several classes depending upon the motives and needs of the estimator. There are estimates intended to show how low costs might be with favorable conditions if everything goes well. At the other extreme, there are estimates which show how high costs might be if troubles develop. The estimates in this paper for the cost of producing direct reduced iron (DRI) are accompanied by discussion to point out how the final figures may be adjusted in either a promotional or a conservative direction. Because we do not have a specific process and a particular set of conditions in mind when discussing this subject today, this paper deals with the general situation, with considerable attention to how the estimates can be made more specific once one knows the particulars of a given situation.

Jan 1, 1978

By Guy A. Johnson

This Bureau of Mines report summarizes the results of efforts to develop reasonably priced, reliable mine shaft fire and smoke protection hardware for metal and nonmetal mines. The hardware was incorporated into a viable prototype system that would minimize fire and smoke hazards. The design of the system had to be sufficiently flexible to be utilized in a wide variety of metal and nonmetal mine shaft and shaft station configurations. As a result of long-term, rugged field tests, an improved (second generation) system was developed. The hardware is now commercially available.

Jan 1, 1978

By J. D. Jones

Unique aspects of tailing pond design aid reclamation facilities for three separate projects are described.

Jan 1, 1978

The environmental and social responsibilities of the mining industry have long been recognized by the industry itself, but during the past decade it became one of the main targets for the more radical members of the community. This came as something of a shock to an industry which had always considered that it had acted responsibly within the standards of the day. As far back as early 1968, the Australian Min- ing Industry Council (AMIC) was clipping from newspapers the odd letter written by environmen- talists and critics of mining activities. In those days every such letter was carefully studied to ensure that AMIC, if not having the answers, at least had an understanding of the types of argu- ments then starting to be used against mining activity and in favour of environmental preserva- tion. Within 18 months, the infrequent letter to the editor had become a flood of such letters and feature articles, and the environmentalists' attack on mining activities had been launched in all its Vehemence.

Jan 1, 1978

By H. M. Lewis

The current status of the international zinc market is summarized, and a supply /demand outlook is presented for the next five years. A number of technical problems facing the industry are outlined. Introduction ZINC has sometimes been called the unknown metal. Considering that on a world basis it ranks third among non-ferrous metals in production and consumption, zinc retains a certain modesty. It has no distinctive colour like copper, lacks the low density of aluminum or magnesium and is not always easy to identify as a product. The 'spangle' of galvanized steel is probably zinc's most distinguishing feature. The purpose of this article is to develop an over-all review of zinc. Starting with the current position of the metal, the major factors that will shape its future will be described so that an assessment of the outlook for zinc can be made.

Jan 1, 1978