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By John P. Norton

Microcystaline silica has been mined in Illinois from the Clear Creek formation since the turn of the century, especially in the area around Tamms in Alexander County, in the southernmost part of the state. Production of this silica, consumed mainly by the abrasives and coatings industries but also sought after for many filler/extender uses, has grown with the economy with several new applications overshadowing traditional markets in recent years. Such an important commodity was given the early attention of the Illinois State Geological Survey and a very complete report was issued in 1953 (Report of Investigations No. 166), authored by J. E. Lamar. The mining and processing of the silica ore has changed very little since the first reported production in 1906, although emphasis has been placed on the production of the finer sized grades to meet newer market requirements. Industrial Mineral Notes 40, published by the Illinois State Geological Survey in June 1970, describes a method by which a less than 1-micron fraction could be commercially produced from the readily available finest commercial grade presently being marketed (99% minus 10 microns). The finer grades exhibit to a lesser degree the reinforcement, high flatting efficiency, thickening and dry brightness properties associated with the synthetically produced silicas. It is expected that the extremely fine grades of microcrystaline silica will become accepted in the markets that now use a combination of precipitated silica and less expensive extender/filler minerals such as kaolin or calcium carbonate.

Jan 1, 1976

By James M. Barker

The borate deposits of Death Valley, first exploited in 1882, were a major world source of boron-bearing products until shortly after very large deposits near Boron, California (Kramer) came on stream in 1926. Borate mining in Death Valley then became moribund, with most extant deposits held as reserves backing Kramer. Tenneco began borate operations following acquisition of claims in 1967 and is the only active borate producer inside Death Valley National Mon¬ument. Borate ores, confined to the lower Furnace Creek Formation (early to middle Pliocene), initially precipitated in a shallow lake fed by boron-rich volcanic hot springs associated with the Basin and Range province. Later diagenesis and remobilization plus regional folding, faulting, and erosion altered and complicated originally simple borate mineralogy and distribution. Dominant ore minerals are ulexite (NaCaB509.8H20), probertite (NaCaB509.5H20), and colemanite (Ca2B6011.5H20). Tenneco currently operates two open pits near Ryan, California. Mining is by bulldozer-pushed scrapers hauling waste and front-end loader/off-highway truck combinations for ore and waste haulage. Archeological, environmental, and aesthetic considerations influence both mine plans. Boraxo Pit, opened in 1970, has deep ore (stripping ratio 10 to 13:1) which occurs along a fault and as beds in shale on the hanging wall. Problems include pit wall instability (adverse bedding), non¬ripable calcareous shale (11,000 fps), and mixed ore separation. Sigma Pit, opened in 1975, has shallow (stripping ratio 1 to 1). low dipping, bedded ore in shale. Massive ulexite and "granular" un- cohesive colemanite present problems in mining and milling. Colemanite is crushed to -6 inches, washed, dried at 350°F, then calcined at 800°F with 100 tpd capacity. Crushed (-6 inch) ulexite or probertite is Raymond milled to customer specifications with a capacity of 1000 tpd.

Jan 1, 1976

By David Hoadley, Kenneth R. Maser, Ashok B. Boghani, James E. Billar, D. Randolph Berry, Mackenzie Burnett, Robert H. Trent

3. Application of Proposed Revised Standards 57.11-50 to Mines Surveyed 3.1 Subparagraph (a) 1 "Each mine shall have at least two separate and properly maintained escapeways from each working place to the surface which are so positioned that physical or environmental damage to one will not lessen the effective¬ness of the other, and which meet the requirements of travelways and man hoisting standards These escape¬ways shall reach to within 1000 feet horizontally or 300 feet vertically of each working place " 3. 1. 1 Discussion This section will deal with the 1000 and 300 feet distance requirements, Section 3. 5 will deal with the "environmental damage" provisions. During the course of the mine surveys, it became obvious that one mine's 1000 foot distance was nowhere near equal to another' s --not in the actual distance but in the time required to traverse that distance. This -Ls true for the 300-foot requirement as well. The most obvious example is that one could traverse down a 300-foot raise much faster than climbing up the same distance. The temptation is strong to recommend that the distance requirement be changed to travel times instead. However, this approach would unfortunately lead to a lot of subjective evaluations. Having a time requirement for an entire mine evacuation (Subparagraph 6) is one thing, time requirements and the requisite inspection proce¬dures for each working place are quite another.

Jan 1, 1976

By H. M. Harris

The Bureau of Mines investigated chlorination of domestic ilmenites in a fluidized coke bed at temperatures of 950° to 1,150° C. Objectives were to develop an effective process for producing TiC14 suitable for TiO2 pigment and to reduce pollution by collecting and treating waste byproduct chlorides. The reactor for these tests was a 10.2-cm-diam quartz tube heated externally by electrical resistance heaters. It contained coke beds of from 35.6 to 82.5 cm in depth that were fluidized by 13 to 25 l/min of chlorine. Ilmenite concentrate powders were introduced at the bottom of the fluid-bed reactor, using the chlorine gas stream as a carrier. Test results showed that greater than 90 pct of the ilmenite reacted at optimum conditions and recovery of TiC14 ranged from 95 to 99 pct of stoichiometric. A temperature-controlled cyclone was used to remove high-boiling-point chlorides such as MnCl2, MgCl2, and FeCl2, and also collected fine unreacted ilmenite and coke dust. Impure TiC14 and FeC13 were separated by collecting the, iron chloride in a condenser con-trolled at 200° C. Titanium tetrachloride vapor was cleaned by passage-through a salt-column filter followed by condensation in water-cooled and refrigerated condensers. Liquid TiC14 was purified further by well-known industrial methods to meet specifications for pigment-grade chloride. Integrated tests were conducted in which chlorine, produced by dechlorination of FeC13 with oxygen, was recycled and used directly in a fluidized-bed chlorinator.

Jan 1, 1976

By S. Maemura

Miike Colliery of Mitsui Coal Mining Company, the biggest and oldest coal mine in Japan, is producing a quarter of the national coal production, about 5.2 million tons of clean coal annually and almost a half of which is now being mined under the "slicing Mining System". The slicing system is a mining method to mine a thick coal seam dividing it into two faces, upper and lower. Its history started nearly 20 years ago. However, the all-around modernization of this system has made little progress up to recent years, while mining methods for single longwall faces has made a remarkable progress together with the improvements in mining machineries, self advancing supports and so on. The reason was that the tremendous difference in adaptabilities of mechanized face equipments existing between the upper and lower faces has made it very difficult to increase the total production capacity of slicing system. After our persistent study for seventeen years, we have recently realized successfully the quite satisfactory slicing system, applying the combination of shield type self advancing supports and double ranging drum cutter at both faces. We are now fully convinced of that the high efficient, quite safe and improved slicing system has been basically established for the present. This paper intends to brief the transition on the combination of self advancing supports and mining machines, its results and further to detail the development of shield type self advancing support for upper face and artificial roof material which shall be the key point to be successful in full mechanization of slicing faces.

Jan 1, 1976

A preliminary research and development program dated April 25, 1974, was prepared for Development Engineering, Inc. (DEI) for laboratory, field and other engineering studies on the disposal of retorted oil shale. This program was revised and published as a final document dated December 17, 1974. The document included discussions on the peculiarities of retorted shale materials to be investigated and discussions of the various laboratory and field tests which would need to be conducted to define their physical and chemical properties. The proposed research and development program was divided into eight work phases as follows: I Program Development. II Exploratory Laboratory Tests on Old U.S.B.M. Retorted Shale. III Laboratory Tests on Pilot Plant Retorted Shales. IV Laboratory Tests on Retorted Shales from the Semi-Works Plant.

Jan 1, 1976

By Clement K. Chase, F. Milton Lewis, Roshan B. Bhappu

In situ extraction for copper, gold and uranium, generally involves several common alternative processes and techniques. These include dump leaching, heap leaching, leaching of fractured ore in-place or bore hole mining and unit operations such as cementation, solvent extraction, ion-exchange or carbon-in-pulp. Since the metallurgical effectiveness and economics of such processes and unit operations are well established, it would be possible to select the optimum alternative for extracting either copper, gold or uranium from their ores using in situ extraction technology. In this paper, efforts have been made to provide metallurgical evaluation as well as capital and operating costs for the various processes and unit operations. Attempts have also been made to utilize the above costs in preparing feasibility studies for in situ extraction of these metals.

Jan 1, 1976

At Hilton Mine, 18 kilometres north of Mount Isa, the silver-lead-zinc sulphide bodies have undergone strong deformation in the form of folding and later faulting and brecciation in the hangingwall region of the mine. Variation in grades and widths over compara- tively short distances causes problems regarding accurate sampling of orebody exposures in underground development, and in defining confidence limits for the extrapolation of ore intersections in ore reserve calculations. The paper gives a preliminary insight into the problem of obtaining representative samples for exposed orebodies and discusses the sampling techniques employed. Results gained from these sampling methods could not be verified due to lack of individual bulk samples for comparison but strong evidence for precision was provided. INTRODUCTION In a developing mine like Hilton, accurate grade information is of extreme importance. Original grade information for a potentially viable ore deposit is gained from surface drilling, and initial ore estimates are calculated from the resultant ore widths and grades. After underground development has proceeded, the opportunity arises for detailed examination of orebody exposures, and the resultant assay grades and widths from sampling of these exposures may, in the long term,

Jan 1, 1976

By J. D. Pitts

The worldwide production of iron ores was approximately 880 million metric tons in 1975. This level is the result of an annual growth rate of nearly four percent during the period 1967 to the present. The high growth rate was particularly significant in that two relatively severe worldwide recessions occurred in 1971 and 1975. The current upturn in world economic growth will probably allow future annual iron ore production growth rates in excess of the four percent figure, and, in fact, the International Iron and Steel Institute (IISI) has predicted that a five percent rate should be realized through 1985. The IISI figures would indicate a 1.4 billion metric tons per year output by 1985 or an increase in current production levels of around 500 million metric tons per year (MMTA)1. Even the more conservative four percent growth rate prediction from historical data would provide an 2 increase over current figures of nearly 350 MA by 1985. A large portion of world iron ore production is being provided by large resource-rich countries with relatively new industrial bases. These countries are typified by heavy export of raw materials such as iron ore and ore products and a large capital investment in the facilities to recover these raw materials. Brazil and Australia are typical of such countries and, indeed, their production of iron ore in the period 1967 to 1973 increased at annual rates of 17 to 30 percent, respectively, The continual reassessment of resources in these and other major iron ore exporting countries such as Venezuela and Liberia would indicate chat these high growth rates may continue for some years to come to meet anticipated world demand for raw steel production.

Jan 1, 1976

By R. B. Haagensen, E. Martinez, V. Kudryk

The sample under investigation contained approximately 16% BaSO, and was 80% -325 mesh. Established methods for floating barite did not produce concentrates of satisfactory grade or barite recovery because of low barite content and the presence of 6% calcite in the feed. By using a new long-chain sulfosuccinamate collector in combination with relatively high concentrations of sodium silicate, a barite concentrate was produced that would be acceptable as an oil-drilling mud using a simple rougher-cleaner circuit. No desliming of the fine-ground feed was necessary. Barite recovery was over 80% and the concentrate produced had a specific gravity higher than 4.3. During the course of the investigation, a procedure was developed to obtain semiquantitative determinations of barite, calcite, quartz, and feldspar in test samples using an infrared spectrophotometer. Samples were also analyzed in a thermobalance for determination of the calcite content. The use of these instruments made it possible to obtain quick mineralogical assays and proved to be of invaluable assistance in guiding the flotation testing.

Jan 1, 1976

By G. W. Elger

This report describes pilot-plant studies and an economic evaluation of a process developed by the Federal Bureau of Mines, Albany Metallurgy Research Center, to produce synthetic rutile from a rock-type ilmenite concentrate. In this process, ilmenite blended with coke and lime is smelted in an electric arc furnace to separate most of the iron as salable pig iron and to form a titania-enriched slag of low iron content, which is treated with oxygen and titanium pyrophosphate. The titanium oxides are converted to crystalline rutile; the phosphate glass contains most of the associated impurities. The treated slag is ground and leached with sulfuric acid to liberate rutile crystals, which are concentrated by physical methods. In pilot testing conducted to obtain data for a cost estimation, a synthesized product containing about 88 wt-pct TiO2 and less than 2 pct FeO was extracted from a rock-type ilmenite concentrate containing about 45 wt-pct TiO2. The estimated fixed capital cost (on a mid-1975 basis) of a plant producing 500 tpd of synthetic rutile is $28,290,100. Based on 330 operating days per year, the estimated operating cost for this process is $351 per ton of synthetic rutile. The estimated selling price of synthetic rutile made from rock-type ilmenite is $344 per ton, based on a credit of $160 per ton of pig iron and a 20 pct interest rate of return on investment after taxes.

Jan 1, 1976

By Samuel M. Brock

In recent years society has become increasingly concerned with maintaining and improving the quality of environment. Thus, public interest and concern with pollution problems is now high. This is reflected in recent federal and state efforts to formulate new legislation to prevent pollution and strengthen existing pollution laws. In reviewing literature pertaining to pollution problems, it is possible to distinguish many common elements. The most outstanding of these is the failure of the market to guarantee that private firms responding to price signals generated in the marketplace will make decisions leading to optimal resource use. Cases of market failure in allocating natural resources according to the wants of society frequently are due to the presence of technical externalities, or side-use effects.59 These roughly and generally can be defined as interdependencies among production and consumption units, the impacts of which are exerted other than through the market. They are, in other words, extra-market relationships. The economic unit generating external effects does not take them into account in decision-making. Thus, the tendency is for the unit to produce either more than society desires or not enough. In such cases society often has intervened in the decision-making process. This intervention frequently has taken the form of legislation to regulate production and consumption activities. Thus, a body of institutions, which acts as a constraint in decision-making processes, has materialized. These institutions are often far more influential in their effect upon resource use than are the forces of supply and demand acting in the marketplace. The problem of environmental pollution is essentially the problem of handling residuals which are the byproduct of all production and consumption activities which take place in the economy.2 These residuals are emitted into the air and water and disposed of on the land. They are interrelated, in that efforts to control emissions into the air or water can result in the production of solid wastes, which then present disposal problems. It is convenient to separate residuals by the type of pollution they cause-air, water, and land while remembering that these problems are related and that solutions may require coordinated effort.1 Residuals may be produced in both production processes and consumption. Residuals produced in production by the mineral industry, or firms utilizing its products, range from emission of sulfur dioxide by steam generating plants to radioactive mill tailings produced in the course of mining uranium.. Residuals associated with consumption are generated mainly through transportation of members of the household, space heating, and in the disposal of solid wastes, including refuse and junk autos. Residuals associated with both production and consumption receive attention in ensuing sections of this chapter.

Jan 1, 1976

By Rodney D. Rosenkranz

Energy consumption in domes tic copper production has increased nearly 60 percent in the last 10 years, reaching approximately 175 trillion Btu in 1973. Energy required to produce 1 pound of copper rose from nearly 41,000 Btu in 1963 to nearly 50,000 Btu in 1973. Production from lower grade ores and strict pollution control regulations have contributed to this increase. Each stage of copper production has been analyzed to determine total energy consumed, energy mix required, cost of the energy, and recent or proposed changes in operations which may affect the consumption of energy by the copper industry. Data have been gathered from a recent Bureau of Mines canvass of the industry, from visits to copper operations, and from conversations with copper industry officials.

Jan 1, 1976

By David Hoadley, Kenneth R. Maser, Ashok B. Boghani, James E. Billar, D. Randolph Berry, Mackenzie Burnett, Robert H. Trent

C. 4 Hoist Assemblies (not man-rated) A large number of manufacturers supply materials handling winches. These units are predominately electric powered while a limited number of vendors supply air powered equipment. Air powered units are currently used extensively for underground materials handling purposes. Suppliers of materials handling equipment normally include a disclaimer statement in their published literature which clearly states that the equipment "is not designed or suitable for lifting or lowering persons " This category of commercially available equipment can be adequate for emergency man hoisting provided that its' capacity is suitably derated and provided also that the necessary safety features are incorporated. Section C. 5 details the equipment which could be added to a commercial materials hoist to meet these needs. Four commercially available hoist assemblies, two electric and two pneumatic are discussed in the following paragraphs. This equipment is typical of what is commercially available and three of the units are currently used extensively in mining applications. Each hoist description includes a remarks paragraph which identifies the additional equipment each hoist would require for emergency hoist use.

Jan 1, 1976

Vibration resulting from blasting has been a source of concern from the inception of the use of explosives. As a result many investigations have been made concerning the seismic effects of blasting and at present there is available an adequate set of standards with which to judge seismically the damage capability of a blasting operation.

Jan 1, 1976

After the war that was nearing an end In early 1945, regular consulting work for Bralorne, the Bradleys, Pennsalt Chemical Co., and a directorship and occasional consulting for Homestake Mining Co. made it almost certain that in spite of my 61 years I would have enough work to feed my family. But this routine work would not provide enough income to lay up funds for the inevitable future when I could no longer do arduous work. And it would not give me the adventure that had first lured me into mining. Therefore I was greatly relieved as well as pleased when, in the 18 months from April 1945 to November 1946, I was asked to make three of the most adventurous as well as profitable examinations that ever came my way. Pati[n]o Mines, Bolivia The first of the exciting jobs was an examination of the Pati[n]o tin mines in Bolivia. After I had unsuccessfully tried to induce Anaconda to purchase these mines In 1915, the World War I crisis that had forced the half-Indian accountant to try to sell the mines had come to an end. The European market for tin improved dramatically, and "Don Simon" was able to borrow money for expenses while the concentrates were still In Bolivia. He took advantage of the favorable conditions by buying adjacent properties and increasing development work until his Bolivian tin mines were the greatest in the world. And his daughter had marled the French Count de Boisrouvain and was cutting a swath In high International society. Pati[n]o wanted to get rid of the drudgery of running a complicated mining Industry in a remote area In Bolivia when the fleshpots of Paris were much more seductive. An added incentive was the fact that his miners had become unruly and had even threatened his 11fe.

Jan 1, 1976

By Henry E. Perlee

In a Bureau of Mines study two-dimensional mathematical equations were solved that describe the transient thermal response of a rock dust particle in a cloud of similar particles in a gas flame's preheat zone subject to a radiant field from the approaching flame. The description includes both radiant energy absorbed and emitted by the particle and thermal conduction inside the particle and into the surrounding gas environment moving relative to the particle. Two situations were studied; in one the radiant energy incident on the particle is converted to thermal energy at the particle surface, and in the other the radiant energy is converted to thermal energy uniformly over the volume of the particle. The result of the study showed that for a 10-µm-radius particle, a 200-mg 1-1 loading density, and a flame approach velocity of 30 m sec-1, the particle temperature rise was twice that previously calculated by Singer and Cook based on the model of Essenhigh and Csaba. It was further established that under the conditions examined a rock dust particle temperature never increases more than about 200 K before crossing the flame front.

Jan 1, 1976

By J. Irwin

Con el fin de aumentar la productividad y la rentabilidad en el desarrollo de los recursos mineros, es necesario mejorar el sistema de productividad minera. En ese sentido, el presente texto señala las mejoras de métodos y costos a tráves de las perforados de chimeneas y el barrenado de voladura grande y las Trituradoras "Goblin" como parte del equipo de mayor potencia. Así como se ha mejorado las condiciones ambientales del operador (casetas a pruebas de sonido) y del tiempo de perforación.

Jan 1, 1976

By M. Saidman, R. Pizzuti, R. Hirschfeld, A. J. Desai, J. Rand

Two bedrock tunnels, 170 to 250 feet deep and with a length of about 17,000 feet each, will be used to convey cooling water from the Atlantic Ocean to the Seabrook, N.H., Nuclear Power Plant. Seismic reflection and refraction surveys were used to obtain preliminary information about overburden and bedrock conditions. A major boring program, including core orientation and water-pressure testing, was undertaken to provide detailed geologic data. The results of the geotechnical investigation were summarized in terms of rock type, frequency and character of joints, degree of weathering, modified core recovery (RQD), pressure-test results and strength and hardness. These parameters were used as a basis for evaluating the feasibility of using a tunnel-boring machine, for designing and estimating the initial support systems, and for evaluating the grouting and tunnel lining requirements.

Jan 1, 1976

By Alfred C. Maevis

On October 27, 1972, ground was broken for the first section of the Second Avenue Subway, a two track underground rail system that was to extend from the south end of Manhattan at Broad Street, north to the Harlem River at 126th Street, a distance of eight miles. This ground breaking was the culmination of 67 years of planning for an east side subway in Manhattan. Following the successful opening of New York City's first subway on October 1904 there was a mass planning for additional subways throughout the City. In 1905 approval was requested of the Board of Estimate for a First Avenue route and Third Avenue route. The Third Avenue route was approved but when action was not taken to start construction, the approval in accordance with the conditions under which it was given was withdrawn. Further reports and plans for an east side subway, usually to be constructed on Third Avenue, were issued in 1920, in 1922, in 1924, etc. Those of us who had worked on the Sixth and Eighth Avenue subways in the thirites and early forties left to join the armed services of World War II in the expectation that we would return and start work on designing and constructing that east side subway. The reason that much of the thrust in those years was to construct on Third Avenue was that there was a Third Avenue "EL" and business interests of the City were in favor of its demolition. This demolition was accomplished in 1955 so one of the incentives to construct on Third Avenue was removed; but an east side subway was always part of the master plan of the City.

Jan 1, 1976