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By Frederick V. Lawrence

Broadly speaking, fluxes are substances which promote wetting and spreading or enhance the fluidity and manipulative properties of materials in joining, fusion, and smelting operations. The term most strictly applies to substances used to facilitate soldering and brazing; but in the discussion which follows, the definition will be broadened to include materials used to promote fusion in arc welding and which aid in the smelting of metals. In each of the mentioned applications, the role of flux and its composition differs considerably; consequently in the discussion which follows, fluxes for soldering, brazing, arc welding, and smelting applications will be considered separately. Soldering and Brazing Fluxes Soldering and brazing are metallurgical joining processes in which a joint is formed using a filler metal of composition dissimilar to that of the joined pieces (base metal). The filler metal, solder or braze, is always of lower melting point than the base metal. Consequently with these processes there is no melting of the base metal. The successful creation of the joint depends upon the wetting and spreading of the solder or braze around or throughout the joint. The obstacles to successful soldering and brazing are contaminants and tenacious oxide films on the metal surfaces. In soldering and brazing applications, fluxes act to remove and exclude oxides and other impurities from the joint. There is no fundamental difference between soldering and brazing. The distinction between them is made on the basis of temperature. Join¬ing operations carried out at temperatures above 500° C are termed brazing. The higher temperatures used in brazing enable higher melting point filler metals to be used which generally provide stronger joints. The higher temperatures of brazing processes also require fluxes which are substantially different from those used in soldering and which will remain effective at high temperatures. Consequently the distinction between soldering and brazing can also be made on the basis of the fluxes used. Soldering Fluxes Even thoroughly cleaned and degreased, metal surfaces still possess tenacious oxide films which inhibit the soldering of the joint. The reactions which form these films increase with increasing temperature. The rate of oxide formation and the tenacity of the film varies with each base metal. Aluminum, magnesium, stainless and high alloy steels, aluminum and silicon bronzes when exposed to air form hard, adherent oxide films. These metals require highly active and corrosive fluxes to remove and prevent the reformation of oxide films during soldering. Metals such as copper and silver, on the contrary, form less tenacious films at a lower rate, so that mild fluxes are sufficient. Soldering fluxes must dissolve or remove oxides and promote rapid wetting and spreading of the solder. The flux removes the oxide film by loosening and floating it off into the main body of the flux. The oxide removal is often aided by the alloying of the solder with the base metal, undermining small areas of the oxide and detaching them (Anon., 1959). The flux coagulates and suspends the oxide particles which have been loosened. The flux forms a protective cover preventing the reformation of the oxides, permitting the spreading of the solder and the formation of a metallic bond between the solder and the base metal. Constituents of Soldering Fluxes: Soldering fluxes are commonly grouped into three categories: highly corrosive, intermediate, and noncorrosive. One normally would choose to use the least corrosive flux which will give satisfactory performance.

Jan 1, 1983

By L. F. Mashburn, T. J. Ferree

A Reichert cone concentrator was installed in an aggregate plant circuit to recover the extremely fine "flour gold" known to exist in the deposit. The gold content of the bank- run gravels averages about 0.1 g/t-about $1.29/t, based upon $12.86/g ($400 per oz) gold. The fineness of the gold averages between 950 and 960. The Reichert cone, in conjunction with a conventional shaking table, recovers in excess of 85% of the gold. A screen analysis of the gold particles shows 44.1 % is - 74pm (-200 mesh) in size. The plant operates with a two-man crew.

Jan 1, 1983

By Wendell E. Dunn

INTRODUCTION The early history of the chloride process has been recorded in a chapter of a Bureau of Mines bulletin (9 by one of the inventors of a chloride process, Stewart Croasdale, who is famous for the Pohle- Croasdale Process. The earliest use of chlorine in metallurgy was in 1557 by Bartholome Medina. But apparently even earlier there was knowledge that salt could be used in gold and silver extraction because a treatise, de la Pyrotechnica, published in 1540 in Venice, asserted that silver could be obtained from its ores by a wet salt process. In 1609 a priest, Alonzo Barba, invented a process using a copper vessel and boiling a solution of salt to extract silver chloride ores. The copper vessel was, of course, one of the reactants. This led to the Kronke process introduced in Chile in 1860 which substituted cuprous chloride for the kettle. A major step was taken in Europe in the late 1700's to chloridize roasted silver ores in combination with amalgamation using iron to reduce the silver chloride. By 1843 the Augustan process was introduced. Ores were roasted with salt and leached with a saturated salt solution. The silver chlorides passed into solution from which silver was precipitated by copper. In 1848 sodium or calcium thiosulfate solution of silver chloride was suggested by Dr. John Percy, and the idea was applied in 1856 by Von Patera in Bohemia.

Jan 1, 1983

By S. S. Hedge, J. C. Ferm, J. T. Berger

The coal procedures described in this paper address the problems building a body of coal data that is accurate, precise, readily available, and easy to manipulate. The system is a set of interactive computer procedures consisting of a) data gathering (core hole and geophysical logs, their location, elevation, etc.) and standardized computer printouts, b) the graphic outputs of coded logs (log strips-scale variable) wing on-line electrostatic plotter, c) determination of seam continuity via relative movements of the log strips on an interactive graphic display terminal, d) calculation of the seam parameters (minable seam thickness, volume of non-coal material in the seam, ash and sulfur content of the raw or prepared product, roof and floor characteristics and other attributes relevant to mining), e) posting of seam parameters wing on-line drum plotter controlled by a microprocessor on-line to the minicomputer (PDP- 11).

Jan 1, 1983

By Walter E. Dean

Deep-sea manganese nodules are considered to be potential ores of manganese, nickel, cobalt, and copper. Considerable time, effort, and funds have been applied to the study of the distribution of nodules on the seafloor and the location of economically important areas, but less effort has been spent in understanding the origin of nodules. Most theories that have been proposed to explain the origin of manganese nodules have been based on inorganic processes. It is not by coincidence, however, that the area considered to be most economically feasible is, in the zone of high biological productivity in the eastern equatorial Pacific Ocean and underlain by siliceous biogenic sediment. The genesis of manganese nodules and the concentration of many trace elements are related indirectly, and possibly directly, to the activities of organisms.

Jan 1, 1983

By G. Herget, O. Garg

Trends will continue towards more automated, and sometimes larger mining and haulage equipment to reduce pit development and haulage costs. To save labour costs, larger capitalization of open pits is required and pit design and stripping ratios have to be firmed up at a very early stage of mine planning. Bench failures will assume a greater importance with larger equipment and at present we have only a limited capability of predicting stable slopes in complex structural geological settings. Deep open pits will pose particular problems in regard to high toe and floor stresses. This will require the development of more efficient systems for rock mass exploration and an improvement of our predictive capability in regard to pit slope stability and appropriate management of ground- water and materials. To meet the challenge, we have to improve: a) Analytical tools to assess slope stability in structurally complex settings as found in large open pits; b) Core orientation methods during diamond drilling operations; c) Geophysical logging methods to obtain geotechnical and structural geological information for large volumes of rock; and d) Geotechnical data handling systems to define mechanical properties

Jan 1, 1983

By J. W. Parkinson

A coal-cleaning plant's environment can be hazardous to a computer system. The computer must be more reliable than the coal-cleaning plant mechanical processes if it is to help improve clean-coal quality and yield by performing data gathering and process control tasks. This paper discusses coal-cleaning plant environmental hazards and installation philosophies that can protect the computer. Specific reference is made to a computer system installed at the Electric Power Research Institute's Coal-Cleaning Test Facility.

Jan 1, 1983

By John B. Goddard, David R. Brosnahan

Leaching of uranium in situ from sandstone deposits with ammonium carbonate solution containing dissolved oxygen occurs rapidly compared with the leaching of the bulk of the sulfur present as FeS2. However, because of their high reducing capacity and their relative abundance, the FeS2 minerals consume the bulk of the oxidant. A pressure leach apparatus was constructed that permitted measuring oxygen consumption by FeS2, best described by a first-order reaction. The experimental rate constants for various cores are roughly proportional to their FeS2 contents.

Jan 1, 1983

By E. Topuz, G. Faulkner, M. Karmis, C. Haycocks

The Appalachian coal region of Virginia, southern West Virginia and Kentucky and the extreme eastern portion of Tennessee constitutes a unique area of surface coal mining activities. The area contains a number of contiguously placed coal seams, up to a total of fourteen in some places, which vary in thickness from a few centimeters to 2,5 meters. Much of this coal is of high quality, some being the highest grade metallurgical coal found anywhere in the world. The region may be broadly characterized physiologically as a dissected plateau with a relief above the valley floors of up to 500 meters and a dendritic drainage pattern. Up to six seams may outcrop in the hillsides above drainage, many of which have been subjected to contour stripping operations. Prior to the passage of the surface mining reclamation act, little effort was made to reclaim stripped areas. The passage of the strip mining act, including the controversial requirement for returning the land to its approximate original contour, has forced intensive recla¬mation efforts from the mining industry. The wisdom of this original contour requirement has been the subject of considerable debate and litigation, mainly because of its cost, inconvenience, and value of the land after it has been reclaimed. Regardless of whether recla¬mation is carried out, under current practices slope failures do occur. This in effect circumvents the intent of the law and can expose large unvegetated spoil areas, and contribute to hillside erosion and stream silting. Such failures must be eliminated if further costly reclamation efforts are to be avoided.

Jan 1, 1983

By David H. Y. Tang, Syd S. Peng

In general, the strata sequence of the immediate roof in the under- ground coal mine openings can be divided into three types. They are: (A) each stratum deflects independently, (B) some stratum (or strata) loads on the underlying stratum, and (C) each stratum loads on its underlying stratum. The flexural behavior of the immediate roof which is made up of multiple strata not only depends on the material property, geometry, and external loading of rock strata, but also on the strata sequence. A computer program based on the beam-column theory is written for determining the bending stress and deflection for the generalized immediate roof. The flexural behavior of the immediate roof in various strata sequences are investigated for the following effects: roof span, horizontal stress, thickness and Young's modulus of the lowest stratum. In addition, some of the results are compared with the results of the finite element method.

Jan 1, 1983

By L. L. Oriard

In order to predict the influence of blasting on slopes, one must first understand the action of explosives, the manner in which rock is broken or displaced, and how seismic waves are transmitted, and the nature of these seismic waves. In this paper, the author describes the action of high explosives on rock masses, beginning at the source of the explosion, extending through the zone of rupture to a distance where only elastic waves of low energy persist. The paper describes the relationships between explosives charge quantities and distances, including the character and intensity of the seismic waves in various types of terrain. In looking at the analysis of slopes subjected to seismic waves, it has been common practice to assume a simplified model in which the anticipated acceleration is applied horizontally to the slope as an equivalent static force, or a model in which there is a rigid base subjected to mechanical shaking. Such models do not accurately portray blasting activity taking place within or near the slope in question. In dealing with blasting effects, it is important to under- stand seismic wave types, wave lengths, attenuation and transmission paths, as well as vibration intensity. In most cases, those slopes that are the least stable under static loading will also be the least stable under dynamic loading, although there may be rare exceptions. Thus, the more that is known about a slope statically, the better will be the assessment of it dynamically.

Jan 1, 1983

By Andrew Button

INTRODUCTION This review deals with the controls exerted by unconformities on the stratigraphic and areal distribution of gold (and uranium) in Precambrian conglomerates. The relations described are drawn mainly from Precambrian basins in southern Africa, particularly the Witwatersrand Basin. The mining industry of South Africa started in earnest with the discovery of diamonds in 1866. Gold was first discovered in 1870, and in March of 1886, two out-of-luck prospectors stumbled across what was to become the world's greatest goldfield, in the vicinity of Johannesburg. George Harrison and George Walker sold their claims for a pittance and were heard of no more. The Witwatersrand goldfield has been in continuous operation since that time, some 150 mines having operated at one time or another. Deep mining technology developed here has allowed operations to proceed to depths approaching 13,000 feet. The Witwatersrand has produced some 55% of all the gold ever mined, and currently produces 60% of the world's supply, some 650,000 kg Au per year. To 1971, the Witwatersrand had produced some $32 billion of gold and $2 billion of uranium (when average prices were less than $35/oz. for Au and $10/lb. for U308). At present prices, the annual Witwatersrand production of close to 700,000 kg would be worth about $10 billion. Uranium was discovered in the Witwatersrand in 1923. In the $15-30/lb. bracket, the basin contains a reasonably assured plus

Jan 1, 1983

By Richard W. Markley

The predominant methods for mining coal in the USA are room and pillar and longwall. Approximately 95 percent of the coal is mined by room and pillar and 5 percent by longwall. The U.S. Department of Energy (DOE) has an ongoing program to improve the rate, quality, and cost effectiveness of stabilizing the roof for both of these mining systems. In room and pillar mining, the installation of permanent roof support is often the task which paces the system operation, and it thus controls the level of production achieved during any mining shift. Two automatic roof bolt insertion equipment developments are discussed, as well as a flexible drill for operation in thinner seams. Progress will be reported on under- ground trials of a particular flexible drill which has been combined with a bolt inserter to form a compact, reliable module for retrofitting to continuous mining machines. In longwall mining, the use of hydraulic supports on the working face provides roof stability. The DOE has several trials ongoing with shield- type supports in difficult strata conditions which are described, as well as a co-funded project with the Bureau of Mines on a resin injection remedial method for consolidating a shear zone at one site. A project to improve the match of strata conditions to shield design is also described, which involves the use of a 1360 tonne vertical load mine roof simulator.

Jan 1, 1983

By J. E. Dreier

The Pachuca - Real del Monte district has produced about 46.6 kt (51,300 ton) Ag from subvolcanic vein deposits. Three types of wall rock alteration are spatially related to the veins: K-feldspar, propylitic, and phyllic. K-feldspar alteration occurs within veins; propylitic alteration occurs in fractured rocks between veins; and phyllic alteration occurs above veins. Concentrations of some trace elements in altered rocks relative to unaltered rocks are summarized below. [ ]

Jan 1, 1983

By Jamie Deuel

The a ad on Connection" For the purpose of this paper, we will concentrate on the ubquitous radon gas as the principle, low-level radiation effect from uranium tailings piles. Standards are also proposed for gamma radiations but, by most accounts, this is much less of a low level problem than is radon. I am also aware of some just completed research at Oak Ridge National Laboratories that suggest polonium may be a major concern in tailings, but those data are preliminary at this time. What is radon gas? In the first place it is not a gas in the accepted sense in that it has no driving pressure head. It might prove a more convenient description to call it radon vapor. Radon vapor, then, is 7-1/2 times heavier than air. Radiologically, it is an alpha emitter which means it spontaneously gives off high ionizing potential but low penetrating power particles. In fact, the alpha particle has such low penetrating power that this sheet of paper will completely shield a person. The problem, though, is breathing the radon decay products, called radon daughters. If radon daughter products are ingested into the lungs, their alpha emissions may cause cancer. The principle carcinoma associated with breathing radon, or more basically, associated with radiological effects is oat cell car- cinoma of the undifferentiated mall cell type. Radon has a 3.8 day half life which means in less than four days half of its initial radioactivity has decayed away. In less than a month it essentially becomes inert or non-radioactive. The Tailings Situation The NRC, in its April 1979 Generic Environmental Impact Statement

Jan 1, 1983

By Richard H. Olson

"Rarely in our technological society does the discovery of a new class of inorganic materials result in such a wide scientific interest and kaleidoscopic development of applications as has happened with the zeolite molecular sieves." That opening sentence in a landmark volume on zeolite molecular sieves by D. W. Breck (1974), is, if anything, an understatement. Zeolites were recognized as a new group of minerals in the 1750s, but it was not until 1930 that the first analysis of the crystal structure of a zeolite mineral was made. In the late 1940s research workers at Union Carbide Corp. began a program of zeolite synthesis and study which has resulted in one of the major research achievements of all time. Naturally, with the vast research and development efforts devoted to the synthetic molecular sieves, Union Carbide became concerned in the mid-1950s about its position should minable deposits of natural analogues be discovered. Zeolite minerals have diverse origins, and even a brief discussion of these is beyond the scope of this paper. The early work on zeolites was confined to igneous rock occurrences (e.g., amygdules and veins) which were formed by "space-filling;" these crystals tend to be euhedral, thereby rendering them appealing to both mineralogists and collectors. During the first year or so of Union Carbide's exploration (which began in mid-1957) attention was devoted solely to such igneous, occurrences. A landmark paper by Bramlette and Posnjak (1933) heralded the potential significance of the occurrence of zeolite minerals as alteration products of vitric ash and similar materials. In the summer of 1958, full attention was directed by Union Carbide to the search for deposits of this type in the western United States. Since then, such exploration has been continuous by both commercial firms and private parties. The future economic potential for natural zeolite deposits seems to be restricted to those of the "open-and-closed system" types as described by Sheppard (this chapter). Therefore, this and the following discussions will concentrate upon these types; the other types of zeolites in sedimentary rocks (e.g., deep-sea sediments, burial metamorphic, and hydrothermal) will be, for the most part, ignored. Despite the relative cheapness of natural zeolite deposits as compared with the cost of synthetic molecular sieves, there has been minimal development of zeolite mining in the US over the past 25 years or so. Mumpton (this chapter) discusses the present commercial utilization of natural zeolites and their future potential in detail, but perhaps the following will serve as useful background. In the early days of synthetic molecular sieve research and production, the efforts were concentrated largely upon such high-value applications as physical separation of components in a stream (based upon molecular size and geometry) and in catalysis. Due to a number of reasons (some of which are difficult for an outsider to understand), natural zeolite ores (beneficiated or not) have not made substantial inroads upon the use of the higher-priced synthetic molecular sieves for the foregoing applications, but this is not to say that such a condition will exist forever. Furthermore, in view of the many other uses which are now known, or which loom in the future, the competitive position of the natural zeolites vs. the more expensive

Jan 1, 1983

By Allan M. Hale

The paper discusses past trends in phosphate reclamation, indicating advantages and disadvantages of land and lakes, sand tailings capped with overburden, phosphate slimes capped with overburden, and overburden fill reclamation. In addition, new techniques of reclamation such a clay settling-pond disposal and wetland restoration are discussed.

Jan 1, 1983

By W. Fletcher, R. C. Schenk

This paper outlines a well proven and highly successful approach for eliminating many of the problem and frustrations often experienced in plant startup. The approach was developed over a period of 25 years during which some 90 plants were commissioned. This paper discusses startup from the contractor’s perspective and highlights the requirement for detailed startup planning, careful coordination during the project final construction phase, and thorough checkout of equipment prior to introduction of feed. Performance of these services has demonstrated a valuable opportunity exists for the contractor to assist in the training of the plant operating personnel.

Jan 1, 1983

By C. W. Mallett

The distribution and properties of interseam and overburden rocks in coal mines is largely controlled by conditions at the time of their original deposition. Within the developed areas of the Bowen Basin, depositional environments range from fluvial through upper and lower detaic, to marginal marine and intertidal facies. Each environment has a characteristic association of lithologies with specific range of properties, and each lithology has a characteristic geometry. Fragmentation problems are associated with ancient sand channel systems, where the difficulties encountered depend on the dimension and shape of channels, their continuity, orientation to mining face and associated sediment bodies formed as levees or interdistributary muds. Stability problems in spoil, pit floor and highwalls are usually associated with mudstones which contain swelling clays derived from the original Permian volcanic source. This clay problem is aggravated by deep Tertiary weathering. Case studies are presented of detailed analyses and prediction of geomechanical properties on a mine site scale. These are used in investigating or forecasting fragmentation and stability hazards. The studies incorporate detailed field mapping, bore log data and computer data processing. They allow the development of detailed depositional models for specific interseam intervals within mines. As areas of depositional environment are identified they allow the construction of maps of similar mining conditions and the determination of the most suitable mining techniques.

Jan 1, 1983

By Roy R. Weil, John A. Dziubek

This paper discusses the use of computer modeling, data manipulation, and mapping of three multi-seam coal properties in the Appalachian coal basin. Each case history represents a slightly different application of computer usage for estimation of reserves and planning surface mine sequencing. This practical use of computers demonstrates the suitability of data processing for normal evaluation of coal properties.

Jan 1, 1983