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By D. Muraoka

Introduction Soda ash, anhydrous sodium carbonate, is produced from underground trona deposits occurring in the Green River Basin of southwestern Wyoming. Stauffer Chemical Co. of Wyoming, a jointly owned subsidiary of Stauffer Chemical Co. and Rocky Mountain Energy Co., mines the trona and processes it into high-purity soda ash. Stauffer Wyoming has been in operation since 1962 with a current production capacity of about 1.8 Mt (2 million st) per year of soda ash. The refinery has five parallel operating trains using the monohydrate process which is a series of chemical processing unit operations described below. Screening and Crushing The mined trona is brought to the surface in two counterbalancing ore skips. The ore is initially screened with refinery feed (less than peagravel size material) entering the process. Oversize is conveyed to an outdoor stockpile. Ore is recycled from under the stockpile via cone feeders as the refinery needs require. The ore is conveyed to hammer type crushers and screened. The refinery feed enters the process and the oversize is recycled to the crushers. Calcining The first step in refining trona to soda ash is calcining the trona ore. This is accomplished in concurrent flow, rotary kilns that are direct fired with natural gas. [2 (Na CO NaHCO 2H O) Heat 3Na CO + 5H20 + CO 2 3~3~ 2 ~~2 32] The trona ore is fed to the kiln at the burner end and is intimately mixed with the hot exhaust gases from the burner. Direct contact with the flame is avoided. The ore moves down the kiln by gravity and rotation aided by the kiln's internal lifters. The exhaust gases are cleaned to 99 + % particulate removal and discharged to the atmosphere. Dissolving the Calcined Trona The calcined trona is conveyed from the kiln discharge to a rotary drum dissolver where it is mixed with water and weak solution (unsaturated solution of calcined trona in water). The calcined trona is soluble whereas the impurities, primarily shale, are insoluble. The discharge from the dissolver is a slurry containing saturated solution (about 30% dissolved calcined trona in water), some undissolved calcined trona, insoluble impurities, and organic impurities. The dissolver discharge enters a rake classifier that makes the first solid/liquid separation in the process by removing the heavy undissolved material from the saturated solution. This undissolved material is conveyed to a second rotary drum dissolver and mixed with water to dissolve any remaining calcined trona. The secondary dissolver discharges to a second rake classifier that separates the solids from the liquid. The solids are now primarily insoluble impurities with very little unrecovered calcined trona. These wastes are conveyed to evaporation ponds for disposal. The liquid from the secondary rake is recycled to the primary dissolvers' weak solution system. Returning to the primary rake classifier, the saturated solution which contains suspended insoluble muds is pumped to a thickener. Flocculant is added to aid settling of the suspended muds. The flocculated muds are collected at the bottom of the thickener and pumped to vacuum cloth filters. The adhering saturated solution is separated from the muds that remain on the filter cloth. The recovered solution is returned to the dissolvers' weak solution system. The muds are reslurried and pumped to the evaporation ponds for disposal. Saturated solution, containing some suspended insoluble muds along with the organic impurities, overflows the thickener. Filtering the Saturated Solution The saturated solution overflowing the thickener enters a holding tank where it is pumped to a bank of pressure leaf filters. The suspended muds are captured on the filter leaves while the cleaned saturated solution is pumped to polishing filters. The polishing filters are also leaf pressure type, intended to remove any suspended solids that may pass the primary filters. Organic impurities are removed with activated carbon. The purified solution is now free of insoluble muds and has most of the organic impurities removed. Crystallizing and Drying the Monohydrate The purified saturated solution is pumped to evaporative crystallizers. The solution is circulated from the crystallizer vessel through a heat exchanger. Indirect contact with steam in the heat exchanger causes the saturated solution to boil, thus crystallizing the soda ash in its monohydrate form. Slurry crystal density is maintained in the crystallizer by simulta¬neous feed of fresh saturated solution and drawoff of the slurry.

Jan 1, 1986

By K. P. Chong

Introduction One of the requirements of processing oil shale or other energy bearing rocks is to optimize particle sizes and permeability distributions in fragmentations as indicated by Hommert (1984). Basic to the understanding and planning of in situ fragmentation and ex situ mining of oil shale are the mechanical properties. During the past six years, an innovative and unique program was established by Chong et al. (1979, 1980a, 1980b, 1982a, 1982b) that developed an efficient methodology for standardized and simplified mechanical testing of the western oil shale. The experiments include precise, representative, and duplicable sample preparation; uniaxial static compression testing; "modified" split cylinder testing; uniaxial creep and relaxation testing under extended periods of time; dynamic testing with varying strain rates; and 3-D constitutive relationships. However, as far as the fracture mechanics is concerned, as Edl (1980) pointed out, there is still a lack of understanding "of the fundamental explosive rock breakage mechanisms," which "has necessitated extensive reliance on very costly empirical approaches." Fracture mechanics of rocks and oil shale (Costin, 1981; Schmidt, 1977; Abou-Sayed, 1977; and Barker, 1977) has been based on conventional fracture mechanics using regular notched samples with limited variations of oil yields and assuming the material to be isotropic and elastic (Kobayashi, 1975; Caddell, 1980). A cylindrical double cantilever beam (DCB) specimen with a "V" slot, known as a short rod specimen, has been used by Barker (1977) to determine fracture toughness of rock materials. The inherent geometric stability of the reinforced DCB specimen makes it suitable to be used with all brittle materials. Due to its remarkable stability for the initial crack growth, the DCB specimen can be used for dynamic fracture toughness testing as well. This specimen is more suitable for the evaluation of fracture toughness at high strain rates than most other fracture specimens. However, Barker's DCB specimen is not very well adaptable for short cores or layered rocks since the specimen contains numerous layers (say in a 100-mm (4-in.) long specimen), and the rock properties change from layer to layer. Schmidt (1977) studied the fracture mechanics of oil shale with two oil yields, using notched beams. Using several independent established testing methods, Costin (1981) pioneered the investigation of the static

Jan 1, 1986

By L. S. Kolbert, C. H. Baab

Introduction In June 1981, the Electric Power Research Institute (EPRI) issued a report titled "Control Systems in Coal Preparation Plants" to determine the status of instrumentation and automation systems in the coal preparation industry. EPRI concluded that the control systems presently being employed in the US coal preparation plants "are relatively primitive compared with those in other mineral processing industries; and analytical instrumentation is virtually non-existent." With tighter specifications on the quality of steam coal, interest is increasing in more sophisticated control systems. One type of device that is currently assisting the preparation plant operator optimize and control the coal cleaning process is nuclear based instrumentation. Nuclear instrumentation includes methods for measuring weight, level, and density as well as for performing elemental analysis on coal. Major Features and Benefits of Nuclear Measurement and Analysis Systems There are many features and benefits of nuclear instrumentation. The major benefit is that nuclear instrumentation is non-contacting. The measuring heads do not contact the process materials. This enables measurements of corrosive, abrasive, or high temperature materials with no loss of performance, reliability, or useful life. Also, there are no moving parts to wear or be fouled by dust or corrosion. Installation is simple and inexpensive. For instance, density gauges are simply clamped onto existing pipe runs. Weigh scales and level switches usually require nothing more than welding brackets to customers' equipment. Once installed, routine maintenance can be performed without interrupting the process. Thus, nuclear instrumentation is highly reliable and easily installed and maintained. The operating life of the instrumentation is virtually unlimited. Principle of Operation Nuclear belt weigh scales, point level switches and density gauges all operate on the gamma-ray transmission principle. A beam of gamma radiation from a radioisotopic source is projected through the process material either on a belt, in a vessel, or in a pipe. Opposite the source is a radiation detector whose electrical output is proportional to the intensity of the radiation it absorbs. Gamma radiation is part of the same electromagnetic spectrum that encompasses light, infrared, and x-rays. In many respects, gamma radiation behaves much like light. However, it is far more penetrating and can be transmitted through considerable thickness of materials that are opaque to visible light, e.g., several inches of steel. Types of Nuclear Instrumentation in Coal Preparation Plants There are four types of nuclear instrumentation presently being employed in coal preparation plants. They are: •Belt Weigh Scales •Point Level Switches •Density Gauges •Coal Analysis Equipment. Each type of instrumentation has a number of potential applications within the plant. What follows is a discussion of three different types of devices and their applications. Weigh Scales In coal preparation plants, weighing instruments are used for measuring material throughput, totalized weight, and batch weight on conveyor belts and other transport equipment. They are also used on drag chain conveyors, vibrating conveyors, and screw conveyors. Weighing is important for receiving the run-of-mine coal, controlling mass flow, scheduling production, and loading and shipping the washed coal to market. There are two basic types of weighing instruments: gravimetric and nongravimetric devices. Gravimetric devices are units which measure the pull of gravity on the material being weighed. Nongravimetric devices are not dependent on the force of gravity on the sample. Nuclear weigh scales are the most prevalent nongravimetric devices used. The nuclear weigh scale works on the same basic principle as other nuclear gauges. The greater the quantity of material placed in the path of a radiation beam, the more radiation will be absorbed by the material. In weigh scales, Cesium 137 source is generally placed above the moving stream of material so that the radiation is directed through the material. An ion chamber radiation detector is on the opposite side of the material. The radiation passing to the detector generates a signal which is inversely proportional to the weight of the material present. This signal is amplified and integrated with the speed of the process flow yielding the weight. The weight is indicated and can be totalized for throughput, batch control, etc. In conclusion, radiation weighing methods have become well established in the coal preparation industry throughout the world. As mentioned before, this device finds its most

Jan 1, 1985

By N. H. MacMillan, W. M. Mularie, R. E. Jackson, A. R. C. Westwood

The initial results of a study of the environment-sensitive microhardness and diamond rotary drilling behavior of granite and its constituent minerals quartz and feldspar (microcline)1 have established that many similarities exist between the environment-sensitive mechanical (chemomechanical) behavior of these materials and that of the simpler solids such as periclase, soda-lime glass, and alumina4 studied previously, at least as far as n-alcohol (straight-chain alcohol) environments are concerned. The results of this study (hereafter designated study I) also suggested that the rate of drilling of granite in these environments is controlled by the chemomechanical behavior of its quartz constituent, and is greatest in those environments which impart a zero l-potential to this phase, thereby maximizing its hardness. Now, cationic surface-active species strongly influence the l-potentials of silicate minerals. For this reason they are widely used in mineral separation operations. In particular, dodecyl trimethyl ammonium bromide (DTAB) was found in study I to produce f 0 for quartz at a concentration in water of 107 to 10-4 moles per 1. Accordingly, the influence of dilute aqueous solutions of this surfactant on the drilling behavior of granite also was examined in study I. This revealed that granite could be drilled three to four times faster in 10-° molar aqueous DTAB than in water, and confirmed by experiment the suggestion that granite is most effectively drilled with a diamond core bit in environments which impart a zero l-potential to quartz. According to O'Connor and Buchanan' however, the isoelectric point for quartz in aqueous DTAB solutions occurs at a concentration of .•.•2 x 10-° moles per 1, rather than [101 to 10-1] moles per 1. To confirm the results of study I, therefore, a more comprehensive investigation of the [ ]-potentials of quartz, microcline, and Westerly granite in aqueous DTAB environments has now been undertaken. At the same time an examination has been made of one of the basic assumptions of the current conceptual understanding of chemomechanical effects. In this view, although hardness changes occur essentially instantaneously following wetting of the solid, they are confined to a surface layer at most a few micrometers (µm) deep. Hence, to maximize the influence of chemomechanical effects on bit penetration rate only shallow cuts should be taken. Practical penetration rates are then obtained by increasing bit rotation speed. Experimental l-potentials were determined by the streaming potential technique using an automated rapid-cycling apparatus recently developed by Martin Marietta Laboratory from a design by Somasundaran and Kulkarni. The drilling studies employed 3.2-mm-OD 120-grit diamond-loaded core bits with a wall thickness of ~0.7 mm, and bit rotation speeds of 2200 and 25,000 rpm. The load applied to the bit was independent of the depth drilled in both cases. The 2200 rpm measurements employed the same drill press and puddle drilling technique as used in study I. The higher rotation speed was obtained using a water-driven dental turbine drill. In the case, the surface active fluid was pumped down the axis of the bit to ensure efficient wetting and flushing of the drilling debris from the hole. In both cases drilling rate was measured by the parameter D(200), defined as the average rate of bit penetration during the interval from 150 to 250 sec after drilling commenced.

Jan 1, 1976

By R. E. Hucko

Introduction The principal thrust of the US Department of Energy (DOE) coal preparation R&D program is to develop technology to reduce ash and sulfur content of US coals to levels where the resultant product can be formulated into a high quality solid or slurry fuel that could replace oil or natural gas in both new and retrofit applications. The coal preparation program is implemented by the Pittsburgh Energy Technology Center (PETC) and is conducted both in house and by a cross section of industrial organizations, universities, and national laboratories. Research is subdivided into three areas - coal characterization, beneficiation, and ancillary unit operations.

Jan 1, 1985

Reports on process control computer projects at the Kamioka Plant are summarized from the Japanese technical literature (see references). Fluidized Bed Roaster and Sulfuric Acid plant1 A small process control computer (Yokogawa CCS-200 with an OKITAC 5090P 8K central processor) was installed in the Kamioka smelter in the summer of 1964. A year-and-one-half installation project followed, which successfully brought the roaster and acid converters under computer control. The process plant consisted of two 130 RPD fluosolids roasters and two Monsan to acid units. The roasters are charged with lead-zinc concentrates with SO2 from the roaster processed to sulfuric acid. The computer system provides the following functions: 1) log data from the plant--the input is taken from 50 analog signals, 130 high-low digital alarm points, and 50 analog high- low alarm points; 2) set-point control on 18 control loops; 3) direct digital control (DDC) on eight control loops for which conventional controllers were difficult to adapt due to abnormal loop characteristics or delay times; 4) execution of a safe shut-down procedure

Jan 1, 1969

By S. Shapiro, R. G. Ames

Background Research on the respiratory health of coal miners has focused predominately on the relationship between coal mine dust exposure and ventilatory function impairment (Lapp et al., 1972; Jacobsen, 1976), on the prevalence of coal workers' pneumoconiosis (Lainhart et al., 1969; Morgan et al., 1973), and on coal miner mortality (Ortmeyer et al., 1974; Rockette, 1977). Lesser attention has been paid to the effects of other mining exposures. For example, underground exposure to diesel exhaust emissions (Reger et al., 1980; Ames et al., 1982,1984). An omission in US coal mining research, however, has been identified by the US Office of Technology Assessment (OTA) as the failure to study the effects of inhaled polyvinyl chloride (PVC) thermal decomposition and combustion products (Seltzer, 1979). These products may be released in the mine environment by cable fires, cable explosions, smoldering cables, and conveyor belt fires. In addition to the OTA concern, recent findings of chronic respiratory conditions and other health complications resulting from exposure to PVC decomposition and combustion products in firefighters (Peters et al., 1974; NBS, 1980; NIOSH, 1982; Wallace, 1982), and in survivors of several large scale PVC-fueled fires (Dyer and Esch, 1976; Wallace, 1981, 1982), add immediacy to the concerns. PVC decomposition and combustion PVC decomposition is initiated at temperatures far below ignition (Hartstein and Forshey, 1974; Wallace, 1981). Hence, exposures to decomposition products from smoldering cables may be important health hazards in addition to cable insulation combustion products. Hydrochloric acid (HCL) appears to be the principle toxic substance from the thermal decomposition of PVC since up to 60% by weight is released as HCL (Barrow et al., 1979). HCL is released both as a gas and as an adsorbant on soot particles (Stone et al., 1973), thus allowing penetration of respiratory defenses. In addition, laboratory results indicate that phosgene (carbonyl chloride), a potentially lethal gas, may be produced in significant quantities from electrical arcing of wires covered with PVC insulation (Woolley, 1971; Brown and Birky, 1980). Health concerns related to PVC Toxic effects resulting from high level exposures to PVC pyrolysis and combustion products in animals (Cornish and Abar, 1969) and in humans (Wallace, 1981) is beyond question. Analyses have reported acute, or short-term, health effects resulting from exposure to PVC decomposition and combustion products (Peters et al., 1974; Polakoff et al., 1975). Recently, however, several studies have found that acute effects are often followed first by apparent healing, and then by delayed chronic effects. This pattern of consequential respiratory involvement among persons involved in major PVC-fueled fires has been noted in firefighters, specifically the 1975 New York Telephone Exchange fire (Dyer and Esch, 1976; Wallace, 1982), and the survivors of the 1977 Beverly Hills Supper Club fire (Wallace, 1981). An obstructive syndrome (low FVC and FEV1) was seen in 15% of workers three months following fighting a PVC-fueled fire (Colardyn et al., 1976). Long-term respiratory symptoms seen in studies of survivors of PVC-fueled fires include the bronchitis symptoms of cough and phlegm, and lung dysfunction (Wallace, 1981). Additional support for the thesis of longer-term respiratory effects resulting from PVC-fueled fires is derived from the finding that four persons who initially survived the Beverly Hills Supper Club fire died within nine months of the fire of severe respiratory impairment (Wallace, 1981).

Jan 1, 1986

By G. T. Lineberry, L. Adler

Due to safety-imposed constraints on clearances for mobile bulk handling equipment, it is necessary to optimally select a unit based on speed and size. The unit cannot be both large and fast. Since output is proportional to both size (or capacity) and speed, the combination must be carefully examined to maximize output. A simple graphical procedure and a calculus-based solution are presented to accomplish this. While the procedure applies to all mobile bulk handlers, as an example of the solution technique, attention is focused on shuttle cars. Background Major variables To fully define a bulk handling problem, the conditions, equipment, and activities must be characterized. The conditions and activities, when lumped together, are termed "encumbered space," since they "act to impede motion, as with a burden" (Lineberry, 1979). The insertion of mobile bulk handling equipment into what is already a difficult set of conditions and activities compounds the state of encumbrance, as limited space is competed for by many normal and life support systems. Long (1972) recognized the effects of design criteria, including road width, on haulage vehicle speed and, therefore, on production. Velocity-clearance curves Velocity-clearance curves are either available or can be constructed in the field. A preliminary set of curves for average conditions and activities is shown in Fig. 1, where clearances are only for the side of the vehicle (Lineberry and Adler, 1984). These curves set the safe speed limits for a vehicle operating at given clearances, under given conditions and activities. When feasible, velocity-clearance curves should be constructed through field measurement and observation. Curve construction should also consider haulway roughness, distances, and operator skill, as well as loading and dumping characteristics. It should be noted that haulage capacity determination is a total systems problem, not one just dependent on velocity and clearances. Production requirements and company capabilities also influence capacity determination.

Jan 1, 1986

By John J. Dran

The elaborate analytical techniques for risk analysis used by the large mining companies in conjunction with the valuation of mineral reserve sites are totally inappropriate for the small miner. The small miner does not possess the financial and technical resources which are available to the large companies for such risk analysis. Even if these resources were available to him, the relatively small size of his investment would not justify a huge expenditure for risk analysis. What is required by the small miner is an improvement over the single point estimates provided by the valuation techniques that he currently uses. Such improvement should provide an indication of the extent to which the true value (known only after the fact) might differ from his estimated value of the mineral reserve site. In addition, a rough indication of the chance of occurrence of various differences between the true and estimated values would be helpful to him. These improvements must be obtained at low cost to be useful to the small miner. Such improvements would have to be based on a simple system requiring very few additional estimates by the miner. The small miner is not accustomed to dealing with sophisticated risk analysis techniques. Hence, any complex, time-consuming approach would be doomed to disuse or possible misuse. A simple, uncomplicated approach requiring a minimum of additional estimates by the miner can be based on a system devised by Frederick S. Hillier Although Hillier's method can be applied to various mineral reserve valuation methods used by the small miner, this note is specifically oriented to the discounted cash flow model. The basic discounted cash flow (DCF) approach provides a single point estimate of value and introduces the concept of risk (i.e. the possibility that the annual cash flows may differ from their estimated values and thus lead to an incorrect investment value) through the use of a risk-adjusted discount rate. This approach simply lowers the present value estimate with increases in the discount rate (i.e. increases in the risk assessment). The single point estimate still remains. Although the lower value estimate makes it less likely that the risky investment will be deemed profitable and undertaken, it provides no indication of risk that is suitable for examination and analysis. In addition to the "best guess" estimate of annual net cash flows required in the DCF model, application of the Hillier risk analysis model requires that the miner

Jan 1, 1976

By Victor Formanek, Paul Chataignon, Maurice Rey

IT is found when floating oxidized lead ores by sulphidization, that the presence of calcium salts in the water, is usually detrimental and lowers the recovery. This effect is particularly marked in dry countries such as North Africa, where the waters often carry large amounts of calcium sulphate and where the ore may even contain gypsum. The effect of calcium salts is readily visible. Whereas in their absence cerussite is quickly stained brown and then black by sodium sulphide, in their presence the mineral remains very light in color. A similar effect is produced when barium sulphide is used as a sulphidizing agent instead of sodium sulphide. Magnesium salts have little or no effect and even tend to reduce the detrimental effect of calcium salts. A study of this phenomenon indicates that it is due to the precipitation of calcium or barium carbonate in contact with the mineral simultaneously with the formation of lead sulphide. The chemical reactions can be interpreted as: PbCO3 + Na2S = PbS + Na2CO3 CaSO4 + Na2CO3 = CaCO3 + Na2 SO4 They might also be written: PbCO3 + S = + Ca++ = PbS + CaCO3 The precipitation of calcium carbonate can be followed by the lowering of the pH with which it is accompanied. Magnesium carbonate is more soluble than calcium carbonate and usually does not precipitate under the conditions prevailing. It is interesting to note that calcium salts have no effect on anglesite (lead sulphate) because calcium sulphate is soluble, but barium salts hinder the sulphidization of anglesite because of the precipitation of barium sulphate. Remedies When calcium sulphate is present in large amounts, the softening of the water with soda ash is usually too expensive to be considered, but the precipitation of the objectionable calcium carbonate can be prevented in two different ways. One is the use of sodium hydrosulphide instead of sodium sulphide. This salt gives a lower pH than sodium sulphide and does not bring about the immediate precipitation of the calcium which remains in solution as calcium bicarbonate. The other procedure is to add ammonium salts such as the sulphate or chloride which have the property of increasing markedly the solubility of calcium carbonate. Ammonium salts have other effects such as cutting down conditioning time and accelerating flotation. They should be added to the flotation cells rather than to the ball mills. Table I. Effect of Sodium Hydrosulphide and/or Ammonium Sulphate on the Flotation of Two Oxidized Lead Ores Mibladen Ore4 La Plagne Ored Con- Tall- Con- Tail-centrate ing centrate ing Reagents Pb, Pct Pb, Pct Pb, Pct Pb, Pot Without addition of CaSO, NaS 56.0 0.68 43.4 0.65 NaSH 56.2 0.60 40.4 0.50 Na2S + (NH4)2SO4d 54.6 0.56 NaSH + (NH4)2SO4d 43.0 0.66 With addition of 40 lb/ton CaSO4 Na2S 39.4 3.85 34.0 3.21 NaSH 49.1 0.70 49.6 0.88 Na2S + (NH4)2SO4d 53.9 0.85 NaSH + (NH4)2SO4d 51.0 0.45 41.1 0.78 In table I are given the results of representative tests on two different oxidized ores. They show that the strongly detrimental effects of calcium sulphate can be offset by the two procedures outlined above. Sodium hydrosulphide is now used regularly on a mill scale on certain ores. Tests are being carried out with ammonium salts. It should be noted that malachite is subject to influences similar to cerussite. One final word of caution—when the ore is rich in primary slime, which is flocculated by the calcium salts, it may be indispensable to remove these by washing or precipitation with sodium carbonate instead of keeping them in solution by the above methods. Acknowledgment We wish to thank Socibtk Miniere & Metallurgique de Penarroya and Minerais et Metaux, for permission to publish these results.

Jan 1, 1951

By Maurice Rey, Victor Formanek, Paul Chataignon

IT is found when floating oxidized lead ores by sulphidization, that the presence of calcium salts in the water, is usually detrimental and lowers the recovery. This effect is particularly marked in dry countries such as North Africa, where the waters often carry large amounts of calcium sulphate and where the ore may even contain gypsum. The effect of calcium salts is readily visible. Whereas in their absence cerussite is quickly stained brown and then black by sodium sulphide, in their presence the mineral remains very light in color. A similar effect is produced when barium sulphide is used as a sulphidizing agent instead of sodium sulphide. Magnesium salts have little or no effect and even tend to reduce the detrimental effect of calcium salts. A study of this phenomenon indicates that it is due to the precipitation of calcium or barium carbonate in contact with the mineral simultaneously with the formation of lead sulphide. The chemical reactions can be interpreted as: PbCO3 + Na2S = PbS + Na2CO3 CaSO4 + Na2CO3 = CaCO3 + Na2 SO4 They might also be written: PbCO3 + S = + Ca++ = PbS + CaCO3 The precipitation of calcium carbonate can be followed by the lowering of the pH with which it is accompanied. Magnesium carbonate is more soluble than calcium carbonate and usually does not precipitate under the conditions prevailing. It is interesting to note that calcium salts have no effect on anglesite (lead sulphate) because calcium sulphate is soluble, but barium salts hinder the sulphidization of anglesite because of the precipitation of barium sulphate. Remedies When calcium sulphate is present in large amounts, the softening of the water with soda ash is usually too expensive to be considered, but the precipitation of the objectionable calcium carbonate can be prevented in two different ways. One is the use of sodium hydrosulphide instead of sodium sulphide. This salt gives a lower pH than sodium sulphide and does not bring about the immediate precipitation of the calcium which remains in solution as calcium bicarbonate. The other procedure is to add ammonium salts such as the sulphate or chloride which have the property of increasing markedly the solubility of calcium carbonate. Ammonium salts have other effects such as cutting down conditioning time and accelerating flotation. They should be added to the flotation cells rather than to the ball mills. Table I. Effect of Sodium Hydrosulphide and/or Ammonium Sulphate on the Flotation of Two Oxidized Lead Ores Mibladen Ore4 La Plagne Ored Con- Tall- Con- Tail-centrate ing centrate ing Reagents Pb, Pct Pb, Pct Pb, Pct Pb, Pot Without addition of CaSO, NaS 56.0 0.68 43.4 0.65 NaSH 56.2 0.60 40.4 0.50 Na2S + (NH4)2SO4d 54.6 0.56 NaSH + (NH4)2SO4d 43.0 0.66 With addition of 40 lb/ton CaSO4 Na2S 39.4 3.85 34.0 3.21 NaSH 49.1 0.70 49.6 0.88 Na2S + (NH4)2SO4d 53.9 0.85 NaSH + (NH4)2SO4d 51.0 0.45 41.1 0.78 In table I are given the results of representative tests on two different oxidized ores. They show that the strongly detrimental effects of calcium sulphate can be offset by the two procedures outlined above. Sodium hydrosulphide is now used regularly on a mill scale on certain ores. Tests are being carried out with ammonium salts. It should be noted that malachite is subject to influences similar to cerussite. One final word of caution—when the ore is rich in primary slime, which is flocculated by the calcium salts, it may be indispensable to remove these by washing or precipitation with sodium carbonate instead of keeping them in solution by the above methods. Acknowledgment We wish to thank Socibtk Miniere & Metallurgique de Penarroya and Minerais et Metaux, for permission to publish these results.

Jan 1, 1951

By F. C. Wagner, E. P. Klier, D. E. Nulk

The presence or absence of plastic strain at a cleavarage surface is a question of much importance, and upon its answer depends future possible theoretical work. To investigate this question back-reflectinn X ray patterns were obained on the cleavage facets of ferrite grains. The test set-up consisting of FeK colli- mated radiation, single grain material and stationary cassette and specimen will not lead to a diffraction pattern, in general, but is an ideal arrangement for the exami-nation of surface effects. A pattern taken on hydrogen purified

Jan 1, 1949

By J. E. Flinn, J. M. Welch, R. L. Miller

Introduction Two samples of an iron-enriched basalt (IEB)-a silicate-based fused-cast ceramic waste form-containing components that simulate Three Mile Island Unit 2 core debris were tested for uranium recovery (Miller et al., 1984). This material is highly refractory towards leaching by ground water. The uranium content is high (15.1%) and the U-235 content (2.57%, only

Jan 1, 1986

By C. P. Mangelsdorf

Introduction The use of frequency of vibration measurements to determine tension has long been accepted by industries that use electrical or stranded cables of wire ropes in their operations. In contemplating how to determine the tension in chords of a roof truss, it seems almost inevitable that a similar approach should be investigated even though there are some important dissimilarities in physical behavior between a chord of a rod-type Birmingham truss and a stretched wire rope. While the dominant feature of both types of behavior is the existence of tension, the bending resistance of the vibrating truss chord cannot be ignored. And it is common to have attached to the chord, pieces of hardware (turnbuckles, extension sleeves, wedge boxes) that represent concentrations of mass not usually found in a vibrating wire rope. Analytical solutions to the problem of vibrating wires or beams can be found in the literature on vibrations (Timoshensko, 1955; Den Hartog, 1956). But in every case, at least one of the ingredients of the vibrating truss chord is missing. The presence of axial tension, or bending resistance, of concentrated masses and of end conditions peculiar to truss chords is a combination that appears not to have been dealt with before, although the techniques for dealing with it are commonly known. The purpose of this note is to report the results of a project to measure and calibrate such frequencies. The work was conducted by the University of Pittsburgh under the sponsorship of the US Bureau of Mines. Field observations Tests were conducted on 24 different truss installations. The first 18 trusses were installed in shale roofs above Kentucky No. 9 seam and Illinois No. 6 seam. The remaining six were placed against the competent sandstone over the Pocahontas No. 3 seam in West Virginia. Chord tension was determined by two electrical resistance strain gages, in series, applied diametrically opposite to one another on the rod before tensioning. Due to the combined effects of inexact gage placement, rod bending and residual torsion in the chord due to tightening, errors in tension as high as 1780 N (400 lb) were reasonably possible. Due to faulty soldering or damage, three of the first 18 trusses and one of the final six were rendered completely unreliable. In addition to strain, the first natural frequency of vibration was observed to the nearest 0.1 Hz. Dimensions recorded included the span between contact points at the bearing blocks (Fig. 1) and the locations and amount of excess rod and rod gap at the wedge box and turnbuckle, respectively.

Jan 1, 1986

By A. S. Malicsi, I. Iwasaki

The removal of hydrophobic coatings of flotation collectors from iron ores becomes of interest when a duplex flotation process is considered for upgrading, when a pelletizing process is considered for a concentrate floated with a fatty acid or a soap collector, or when a disposal of froth products from cationic silica flotation is of environmental concern. Ozone can oxidize organic compounds rapidly, thereby removing the hydrophobic coatings of flotation collectors. Ozone is widely used for treating and purifying drinking water, waste water treatment, and for chemicals processing (Murphy and Orr, 1975; Rice et al., 1980). Its uses in metallurgical operations, however, are very sparse (Allegrini et al., 1970; Chernobrov and Rozinoyer, 1975; Ishii et al., 1970; Iwasaki and Malicsi, 1985; Matsubara et al., 1978). Yet, its high reactivity and the absence of potentially hazardous byproducts become of interest in destroying flotation reagents adsorbed on mineral surfaces or remaining in mill water for recycle or for discharge. Duplex Flotation A duplex flotation process, as applied to oxidized iron ores, would involve a fatty acid flotation of iron minerals followed by an amine flotation of the siliceous gangue from the rougher iron concentrate. Such a process has been used in the Florida phosphate fields. Fatty acid coatings cannot be removed as readily with a simple acid or alkali treatment from iron oxide surfaces as from Florida phosphates. A combination of reagents, such as lime and quebracho, lime and alkali phosphate, or sulfuric acid and oxalic acid, has therefore been proposed. In a previous article (Iwasaki et al., 1967) , the use of activated carbon was found to be effective in removing fatty acid coatings both in the duplex flotation and the pelletizing processes. The use of ozone offers another approach to the removal of fatty acid coatings from iron oxide surfaces. To investigate the possible application of the duplex flotation process, a specularite ore from Michigan analyzing 36.5% iron was used. A 600-g (1.3-1b) sample was ground in a laboratory rod mill together with 250 g/t (0.5 lb per st) of sodium silicate to -150 µm (-100 mesh). This was transferred to a Fagergren laboratory flotation cell, and deslimed four times at 20 µm (quartz equivalent). The deslimed pulp was transferred to a laboratory conditioner, diluted to 40% solids, and conditioned with 250 g/t (0.5 lb per st) of soda ash and 250 g/t (0.5 lb per st) of oleic acid. The conditioned pulp was then transferred back to the Fagergren cell, floated until barren of froth, and the rougher froth product was returned to the cell and cleaned. The results are presented in Table 1. The cleaner concentrate at this point analyzed 45.3% Fe. The cleaner concentrate coated with fatty acid was transferred to a 2-L (0.53-gal) beaker. While the pulp was agitated with a glass T-stirrer, ozone was bubbled into the agitated pulp for 15 minutes at a rate of 10 mg/min (0.00035 oz per min) ozone (250 g/t or 0.5 lb per st 03 feed). It was observed that the pulp ceased to froth after about 10 minutes. The amine flotation of siliceous gangue from the ozonated pulp was carried out first by conditioning with a dextrin, a commonly used starch depressant for iron oxides. This was followed by flotation with a stage addition of an ether amine at increments of 100 g/t (0.2 lb per st). Three stages were required to float the siliceous gangue to near completion. The three froth products were combined and cleaned twice. When the cationic flotation Rougher, Cleaner 1 and Cleaner 2 cell products were combined, an iron concentrate analyzing 64.5% iron was obtained at an overall iron recovery of 72.8%. Pelletizing Fatty acid flotation concentrates have been pelletized successfully in northern Michigan mills. But at other locations, fatty acid coatings on iron flotation concentrates proved so undesirable in agglomeration that other methods of concentration had to be sought. For example, a sinter mix containing iron ore concentrates upgraded by fatty acid flotation resulted in decreased productivity. This occurred because the micropellets of particles with the hydrophobic coating are less tolerant of moisture. Thus, the bed permeability is lost (Beebe, 1965). The agglomeration of concentrates obtained by the fatty acid flotation alone, and the hydrophobic coatings destroyed by ozonation or by the duplex flotation process, is not expected to cause any difficulty since the surfaces of the concentrates would be hydrophilic. Removal of the fatty acid coating with activated carbon, indicated by the loss of floatability, was shown to restore the decrepitation temperature of wet balls during drying cycle (Iwasaki et al., 1967). Disposal of Cationic Silica Flotation Froths Recent demands of iron blast furnaces place the silica content of the magnetic taconite pellets at about 5%. Conventional process for magnetic taconite involving fine grinding and magnetic separation often produces magnetic concentrates analyzing in excess of 5% silica. This is due to the presence of the middling grains of siliceous gangue and magnetite. Cationic silica flotation of magnetic taconite concentrates (DeVaney, 1949) may be used to reduce the silica content. But the amine coating on siliceous gangue becomes of environmental concern when the flotation tailings are discarded in tailing ponds.

Jan 1, 1986

By G. J. Borbely, E. A. Devuyst, V. A. Ettel

Introduction Of the techniques reported for cyanide removal from effluents, alkaline chlorination is the most common (Fisher and Wasser, 1969; Reidt, 1969). Shortcomings with this technique are the high reagent costs, chlorine contamination, and potential formation of cyanogen chloride. Chemical oxidation methods are also not suitable to remove cyanide from effluents containing sulphides in suspension, such as flotation tailings. An inexpensive method for removing cyanide, combined cyanide and related species from waste waters has been developed in Inco laboratories. The method is based on the use of sulfur dioxide (or a sulfite), lime, and air as the reagents. The decomposition reactions of cyanide, combined cyanide, and related species are catalyzed by copper in solution. Complete removal of cyanide species, most of which are oxidized to cyanate, is obtained by treating copper containing cyanide effluents with sulfur dioxide-air mistures while maintaining the pH between 6 and 10 with addition of lime. The new approach can also be applied to selective destruction of cyanide and combined cyanide in effluents containing sulphides in suspension, such as pyrrhotite. Again, a sufficient amount of dissolved copper must be present or added. Metals and precious metals present in the effluents are recovered as hydroxides by adjusting the pH of the treated effluents to about 9-10. Using the new method, the anionic species are removed in the following order: Free CN- > Complex CN- > Thiocyanate The above removal sequence is unusual as oxidants such as chlorine and ozone oxidize thiocyanate preferentially over the combined cyanide.

Jan 1, 1985

By John Griffen

THE distinguishing principle of the Tromp process is the use of a medium in the bath which is not stable, i.e., the solids will settle and the density of the medium increases with depth. A medium of uniform density can most easily be effected by agitation or by means which increase the viscosity of the medium. Either of these works against the sharpness of separation of coal from its impurities. The Tromp process grinds the medium solids to relative coarseness, allows them to settle downward in the bath without hindrance, and introduces horizontal currents of medium at intermediate levels between top and bottom of the bath. This prevents any accumulation of particles denser than the upper layer of the medium from which the clean coal is conveyed away or an accumulation of particles lighter than the bottom layer or medium whence the refuse is removed. In a relatively shallow bath making a two-product separation, the intermediate horizontal currents sweep these intermediate gravity materials away to be discharged with the refuse removed by the conveyor. Such a system provides a number of advantages. The gravity of separation can be changed simply by changing the density of the medium without changing particle size of medium solids or other conditions, as would be necessary with a system requiring uniform or stable density throughout the bath. Some installations in Europe separate at 1.40 sp gr on one shift, producing a superclean coal, and on the next shift reclean refuse from dry cleaning units and effect a separation at 1.80 sp gr. Medium solids may be much coarser in size consist, which reduces the viscosity of the medium and promotes its fluidity and in turn the sharpness of separation. Coarser medium solids with a more rapid settling rate are much more easily recoverable from the dilute medium rinsed from the products. The Tromp process is not limited to the use of medium solids having magnetic properties. Instal-

Jan 1, 1953

By John Griffen

THE distinguishing principle of the Tromp process is the use of a medium in the bath which is not stable, i.e., the solids will settle and the density of the medium increases with depth. A medium of uniform density can most easily be effected by agitation or by means which increase the viscosity of the medium. Either of these works against the sharpness of separation of coal from its impurities. The Tromp process grinds the medium solids to relative coarseness, allows them to settle downward in the bath without hindrance, and introduces horizontal currents of medium at intermediate levels between top and bottom of the bath. This prevents any accumulation of particles denser than the upper layer of the medium from which the clean coal is conveyed away or an accumulation of particles lighter than the bottom layer or medium whence the refuse is removed. In a relatively shallow bath making a two-product separation, the intermediate horizontal currents sweep these intermediate gravity materials away to be discharged with the refuse removed by the conveyor. Such a system provides a number of advantages. The gravity of separation can be changed simply by changing the density of the medium without changing particle size of medium solids or other conditions, as would be necessary with a system requiring uniform or stable density throughout the bath. Some installations in Europe separate at 1.40 sp gr on one shift, producing a superclean coal, and on the next shift reclean refuse from dry cleaning units and effect a separation at 1.80 sp gr. Medium solids may be much coarser in size consist, which reduces the viscosity of the medium and promotes its fluidity and in turn the sharpness of separation. Coarser medium solids with a more rapid settling rate are much more easily recoverable from the dilute medium rinsed from the products. The Tromp process is not limited to the use of medium solids having magnetic properties. Instal-

Jan 1, 1953

By Rudolph G. Wuerker

The scarcity of values of tensile strength of rocks has been explained by the lack of successful testing procedures. In the case of mine rock a description is given' of the difficulties encountered in testing a cylindrical specimen, such as a core, by conventional methods. Over a period of years the following method has given definite and reproducible results with the weakest as well as with the strongest rocks. It does not completely supersede the use of cores with special fixtures but is a supplement in all cases where cores cannot be obtained, as from soft rocks, or in cases where it is less expensive to prepare test specimens by cutting them out of the rock instead of drilling cores.

Jan 2, 1955

By D. W. Fuerstenau

Measurement of zeta potentials is a useful tool to study the surface chemistry of minerals under flotation conditions. Because there is continued interest in this approach, the apparatus for obtaining zeta potentials of nonconducting solids by the streaming potential method is outlined here. Fig. 1 illustrates the streaming potential apparatus. The streaming potential cell or plug consists of two 24/40 standard ground joints (4) joined with a piece of pyrex tubing 60 mm long and 12 mm in diam (5). The electrodes are made of bright platinum disks 19 mm in diam and 1 mm thick through which 0.5-mm holes have been drilled (6). To the surface of each is welded a piece of 80-mesh platinum gauze. Each electrode is permanently mounted on the ends of the inner parts of the two standard joints by means of a platinum wire (7) which connects it to the tungsten seal at the end of the cell (8). For ease in cleaning and handling the apparatus, the streaming cell is fastened to the 500-ml reservoir flasks (1) by means of two 18/9 ball and socket joints (2). This particular arrangement permits passage of the solution in either direction through the plug of particles. Flow of solution can be stopped by a stopcock (3). One of the reservoir flasks has a large opening to permit insertion of either a thermometer or a pair of electrodes for measuring pH of solutions within the system. In making the experiments, the plug is filled with 48 to 65-mesh particles, but a layer of 28 to 35-mesh particles is placed at each electrode to prevent any of the finer particles from passing through holes in the electrodes.

Aug 1, 1956