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By Fred N. Kissell, Natesa I. Jayaraman

Introduction This paper describes a recent Bureau of Mines research project that resulted in a simple procedure for reducing the dust exposure of longwall shearer operators. This project involved the development and testing of a water spray and passive shield system to hold dust against the face and away from the shearer operators. This system is known as the Shearer- Clearer.

Jan 1, 1981

By James W. Baxter

Underground mining of limestone is becoming increasingly practicable in Illinois. Most quarries are near rivers on the western and southern borders where competition for land use is intensive. Increasing demands for stone can be met by expanded mining with access by adits in existing quarries and by inclines and shafts at downdip sites. Geologic, hydrologic, and engineering conditions indicate that deep mines in the Ste. Genevieve, Salem, Ullin, and basal Burlington limestones of Mississippian age and in the Moredock member of the Dunleith formation of Ordovician age are particularly feasible, but development will require prudent exploration and planning to ensure that the product will be of good quality.

Jan 1, 1981

By Lawrence Burkhart, S. B. Joo

Axially unsymmetric ordered circulation patterns on the surface of a hemispherical constant volume drop with forced Internal motion were considered as a manifestation of hydrodynamic instability, which was affected by internal flow as well as by the properties of the interface A simplified mathematical model was analyzed In order to study the mechanism of onset of interfacial circulation from a non-circulatory basic state. Values of the critical Reynolds numbers were obtained when the basic state became a fully developed rotational flow and the values changed for different interfacial properties. The work describes a heretofore unreported surface flow pattern on drop surfaces From a practical point of new, any motion in the interface of a droplet can have a significant effect of mass transfer rates in solvent extraction processes Although surface motion in droplets actual processing equipment is very complex, continued study of the fundamental nature of such phenomena should ultimately lead to more effective equipment design procedures.

Jan 1, 1981

The Gooseberry Mine is located 38 krn (24 miles) by road east of Reno, 13 km (8 miles) south of Interstate 80. The mine was originally discovered in 1906 and remained in the control of the Martin family of Fresno, who worked the-property with Mexican ranch hands for 68 years. Westcoast took over the property in 1976 from Apco Oil Corporation. During the time the Martins operated the mine, a 305 m (1,000 ft) inclined shaft was sunk with drifts developed on eight levels exceeding a total of 3,000 m (9,000 ft) in length. It is interesting to note that for over one -half century all development ore was stockpiled. West- coast, the United States mining subsidiary of Home Oil Company Ltd., Calgary, Alberta, completed sinking another vertical shaft to the 396 m (1,300 ft) level. Development work between 122 m and 305 m (400 ft and 1,000 ft) levels has proved the existence of a fine ore body over 300 m (1,000 ft) long. The silver-gold ore grade is fairly consistent in the vertical section, but copper, lead and zinc may show slight increases with depth. Average width of the ore bearing portion of the vein is 2.5 m (8.3 ft). Stoping is by cut-and-fill method. Average silver values within the ore zone have increased from the 152 m (500 ft) level to the 305 m (1,000 ft) level, although the gold values do show some decrease. It is not possible for the geological staff to predict the depth of the ore. However, several years of ore reserves have been proved in the existing mining areas. Important ore minerals are argentite, native gold, and electrum. Trace amounts of galena, chalcopyrite, and sphalerite are associated with the precious metal mineralization. The vein is mainly composed of calcite and quartz. Mine-run underground ore is dumped from the hoisting skip into a coarse ore bin followed by a jaw crusher, an impact crusher, and a 600 mt (650 st) fine ore bin. The mill has a capacity of 317 mt per day (350 st per day). Two-stage grinding is done by a rod mill followed by cyclones with the underflow sent to a ball mill in closed circuit with the cyclones. Cyclone overflow after conditioning receives a primary float in four 1.7 cu m (30 cu ft) cells and a second stage of conditioning ahead of 24 0.8 cu m (30 cu ft) secondary flotation cells. No cleaning stages are used. Flotation tailings are cycloned for a sand-slime separation with the sands used as underground stope fill and the slime portion to tailing dam storage.

Jan 1, 1981

By Z. F. Oszter, D. Vincent, W. K. Behrands

With the expansion of open pit operations, belt conveyors are going to be used in the 13 608 to 18 144 t/h (15,000 to 20,000 stph) capacity range, which calls for a review of some of the horsepower calculation methods. This paper presents methods (based on German research data, field tests and theoretical considerations) for the evaluation of the Ky factor in the CEMA formula for belt conveyors of large carrying capacity, which fall beyond the limits of the data given in tables in the CEMA book. (The CEMA limits are 407 N\\m (300 lb ft) and Tave = 7.3 Mg (16,000 lb). At these large loads, the impression resistance of the belting on the idlers plays a major role, which in turn influences the magnitude of the drive horse power required. An example will illustrate the order of magnitude difference of the horsepower values obtained by using a conventional calculation method and the suggested method, as well as the beneficcia1 influence of the 4-roll idler in comparison to the standard 3-roll unit for a large caving capacity belt conveyor. This paper concerns itself with the analysis of the resistance to motion of belt conveyors, emphasizing the evaluation of the frictional resistance to motion due to load and belt pressure on the idlers and the flexing resistance of the belt and material when passing over the idlers. In the case of long and heavily loaded belt conveyors, the aforementioned resistances reach extremely high values calling for close analysis of the phenomena, presently not calculable with normally used formulas. This paper establishes correlation between experimental and empirical data presenting practical formulas a tool for the designer of high-capacity belt conveyors. The application of the formula is illustrated in an example in the Appendix.

Jan 1, 1981

By Wilbur C. Helt, Joseph J. Yancik

Throughout the history of mankind, the principal use of coal has been to produce heat through combustion. The heat is used in many ways: to warm air space for our comfort; to provide heat or energy to power industrial processes, such as cement and steel production ; and to produce electricity. Because it is our nation's most abundant fossil energy fuel, coal in the late 20th century is on the threshold of becoming a significant source for synthetic liquids and gas energy fuels for this country. This is made possible by conversion processes which can change solid coal into various synthetic gases and liquids. These coal-derived fuels are nearly identical to the processed fuels and chemicals provided by natural gas and crude oils, which presently provide almost all the petrochemical feedstocks and energy fuels needed for the residential, light commercial, and transportation markets. A revolution is beginning to take place, not only in the United States, but in many other countries with a return to a coal-based energy economy. Also, new combustion and conversion technologies which are compatible with national health and environmental goals are rapidly emerging. These technologies will allow coal's use to be expanded not only in its traditional markets, but also to supply markets held by natural gas and crude oil. With the worldwide decline in natural gas and crude oil reserves, coal is being looked upon to meet the energy demand. Because of these new coal conversion technologies, coal will no longer be only a combustion fuel, but a valuable raw material for production of a variety of clean fuels and chemicals. MARKETS FOR COAL: PAST AND FUTURE A simplified diagram of the marketing network for coal is shown in Fig. 1. As shown in this figure, coal is transported to its traditional

Jan 1, 1981

By Randy M. Cole, Peter J. Phillips

A methodology is presented which quantifies six coal utilization cost components, each proportional to a coal's mineral content. These are: Ash disposal costs, coal transportation costs, plant maintenance costs, reduction in plant peaking capacity, reduction in plant rated capacity, and reduction in plant availability. Numerical examples illustrate that coal containing between. 12.5% and 25.0% ash-plus-sulfur can cause incremental utilization costs ranging from less than $1.00 to more than $8.00 per ton of coal, when combusted in a pulverized coal fired power plant. Estimated costs are then compared to historical data and the conclusion drawn that steam coal beneficiation may have broader economic justification than sometimes realized. It is noted that TVA, which first proposed the methodology and parameters used here, is continuing research on this aspect of coal utilization.

Jan 1, 1981

By E. R. Palowitch, P. H. Broussard

The United States aims to achieve some modicum of energy self-sufficiency through means such as conservation, increased domestic oil and gas production, substitution by the electric utilities of coal or coaloil mixtures for oil and gas, and development of a viable synthetic liquid fuels industry. Coal's role in attaining this goal will necessitate doubling coal production by the end of the 1980's. And if the United States does in fact become the World's Saudi Arabia of coal, the total annual production to meet these domestic needs and export markets could double again by the year 2,000. As only a small portion of our Nation's reserves are recoverable by state-of-the-art surface mining methods, most of the coal produced in the future will have to be mined underground (Averitt, 1975). But this projected increase in coal demand is occurring in the face of a decade of radically decreasing productivity. Specifically, average worker productivity in underground coal mines has decreased from 14.2 tonnes (metric tons) per workershift in 1969 to 7.2 tonnes per worker-shift in 1979; and 95 percent of coal produced underground during this period was produced by room-and-pillar methods (U.S. Dept. of Energy, 1980). Although there is no complete agreement on the impact of recent Federal legislation, there is strong correlation between the dramatic decrease in productivity in underground coal mining and the implementation of the recent Federal mine health and safety regulations (U.S. Congress, 1969). A review of the wide range of coal mining research, development, and demonstration projects currently being funded by the federal government and by industry gives little encouragement for increasing worker productivity on room-and-pillar sections underground in the immediate future (Palowitch, 1978). Conversely, the opportunities for increasing production/productivity underground with longwall methods appear somewhat more encouraging. Although at least one longwall face in the U.S. did produce more than one million tonnes of coal in a single year, the national two-shift average production from one hundred or so longwall faces is about 1,000 tonnes per day (Huwood-Irwin Co., 1978 and Consolidation Coal Company, 1976). Clearly, there exists some real opportunities for improvement. One of these opportunities is to automate the cutter-loader.

Jan 1, 1981

By J. D. Miller, M. Misra

The processing strategy for the effective separation of bitumen from low grade (<l0 weight percent bitumen) Utah tar sands by a hot water process differs significantly from that used for the processing of high grade (> 10 weight percent bitumen) Utah tar sands. Excellent separations (coefficient of separation = 0.9) can be achieved for high grade Utah tar sands by intense hot water digestion followed by a modified froth flotation step. Such a technique is ineffective for low grade tar sands. In order to change the characteristics of the low grade tar sand an attempt was made to enrich the bitumen content of the feed to greater than 10 weight percent by recycle of bitumen concentrate to the digestion stage. However, the quality of the separation was not improved under these circumstances. Similarly feed enrichment by heat treating the low grade feed with recycled concentrate prior to digestion did not improve the separation. More successful separations of low grade Utah tar sands were finally achieved by modification of the viscosity of the low grade bitumen with controlled addition of diluent. These results of the hot water separation tests and variations in the quality of separation are interpreted in terms of the physical properties of the bitumen and the surface bonding forces operative at the bitumen-sand interface.

Jan 1, 1981

By Kenneth P. Katen

INTRODUCTION Though the use of continuous mining machines consolidated the operations of cutting, drilling, blasting, and loading in one machine that would theoretically provide uninterrupted production, it was soon realized that the face haulage and roof support operations remained as major impediments to continuous production. The ability to provide not only continuous cutting and loading, but also continuous haulage and roof support (see Fig. I), was the basis for the introduction of mechanized longwall systems in this country from Europe in 1951. The early systems employed friction props for roof support, but were to become obsolete shortly after introduction of the first hydraulically powered, self-advancing supports in 1960. Since then, use of the longwall technique has grown to the point where it is currently providing more than 5% of the annual output of underground coal mines in the United States. The shortwall system had its origin in Australia, but was first introduced into this country in 1962 following the development of powered roof supports. It, too, provides for continuous cutting, loading, and roof support (see Fig. 2), but has not experienced the widespread popularity of longwall due to its inherent inability to easily provide for continuous haulage. While there are in the neighborhood of 100 longwall systems currently in operation in this country, there are only a handful of short- wall operations providing production of slightly more than 907 184.7 t/a (1,000,000 stpy) Both of these systems provide uninterrupted roof support for face operations by means of hydraulically powered steel roof supports. In each case, the coal removal consists of open-end cuts made from the narrow end of a large rectangular pillar (panel) which has been blocked out by continuous miners developing entries around its perimeter. However, this is the extent of the similarities between the two systems. It is hoped

Jan 1, 1981

By R. Hogg, F. F. Aplan, P. B. Bradley, M. F. Placha

Particle size distributions of the solids fraction in typical coal preparation plant black water have been evaluated. The carbonaceous and mineral fractions were found to have distinctly different size distributions: the mineral matter being significantly finer than the carbonaceous material in all cases. Based on analyses of 13 samples obtained from the Appalachian, mid-continent and western regions of the US, it was found that, on the average, 83% of the mineral particles but only 41 % of the coal particles were finer than 44 pm (325 mesh). Typically, the size distributions of the mineral matter fraction tend to be bimodal, probably due to the presence of relatively coarse quartz, calcite, pyrite, etc., together with much finer clay particles.

Jan 1, 1981

By E. Dow Whitney, Ravrinda M. Chhatre, George Y. Onoda

Phosphate deposits in Florida are a possible source of byproduct uranium. In this paper, the distribution of uranium in several recently mined areas is described. Flowsheets are established for several mines describing how the uranium becomes distributed during the beneficiation of the phosphate matrix.

Jan 1, 1981

By Ilmar Stöckel, Gösta Harlin, Agne Rustan

INTRODUCTION This chapter is a continuation of the studies by Rustan and Stockel (1979, 1980) on techniques for automating ventilation in Swedish mines and construction works. The studies have been financed by the Swedish Board of Technical Development. As a result of the studies it has been recommended that a good solution to diesel exhaust emission would be automatic, step by step control of the fans near the working place. Diesel vehicles are the major polluters underground in the mines. Therefore, we have suggested that diesel vehicles regulate the fans The goal of the continued study has been to find a way for active diesel vehicles to start and stop gallery fans at both intake and return air. In this paper different methods for activating fans are discussed. The best methods are chosen and tested in the mine. In this study we have found that change of temperature is an inexpensive and effective way to start and stop crosscut fans in sublevel caving and radio signals seem to be an attractive system for starting and stopping gallery fans . This work has been done in close collaboration between LKAB in Kiruna and the University of Luleå, Divisions of Electronics and of Mining and Rock Excavation. An advisory group for the project has been established with ventilation experts from the mines, representatives of the local mine workers&apos; unions, and authorities from the local offices of Governmental Inspection of the Workers Safety. VENTILATION SYSTEM STUDIED In the project the ventilation system at LKAB in Kiruna was studied. The mining method used is sublevel caving with 9-13 m slice height. The air above ground is heated in winter by hot water and the main fans push the air down to a main distribution level along the 4000 m long and about 100 m wide ore body. From the distribution level, air is taken through shafts down to the sublevels, where it is pushed through the levels by local gallery fans on both the intake and return sides, Fig. 1.

Jan 1, 1981

By V. R. Degner

The trend in both the metallic and nonmetallic mining industry is toward processing increasingly higher tonnages of lower grade ores, thereby resulting in a growing interest in progressively larger volume individual machines in the flotation circuit. Because of the relatively high cost of large flotation machine development and evaluation, it is important to establish a rational basis by which the existing smaller flotation machine experience can be extrapolated to establish the configuration of the next larger family of flotation machines with a minimum of development modification in the field. This Paper reviews the R&D approach used in translating smaller flotation machine experience to the configuration of a 28.3 m3 (1000 cu ft) induced air machine. Internal cell hydrodynamic principles, which governed this extrapolation, and cell (liquid) surface and froth management considerations will be reviewed, and prototype machine mill tests will be summarized.

Jan 1, 1981

By D. B. McWhorter, J. D. Nelson

Conventional analyses of seepage through saturated media do not apply when tailings impoundments are located above a partially saturated zone. Three stages of seepage are identified and methods for estimating the seepage rates and duration of each stage, based upon flow in partially saturated and saturated porous media, are demonstrated. The effectiveness of earthen liners is discussed and procedures for estimating the required properties of the porous media are provided.

Jan 1, 1981

By Ray Light, Everett M. White

Numerous articles have been written about the coal miner ; he has been compared with brave men who have gone out to conquer some unknown hazard throughout the ages. Now, however, modern mining is no longer something to be avoided, but a vocation that anyone can be proud of, with remuneration equal to or above that of almost any industry. A concerted effort is being made each day by both the operators of most mines as well as the state and federal inspectors to see that coal mines are as safe or safer than work places in any other industry. However, it is true that mine fires and explosions have occurred in the mining industry since its inception. One of the earliest accurate references to such an occurrence is found in the transactions of the Royal Society of London. In the Colliery Managers&apos; Handbook, 1898, Caleb Pamely writes of an explosion that occurred at Fatfield, England in August 1708, resulting in the deaths of 69 persons. He states: "Three of them, viz, two men and a woman, were blown quite up from the bottom of the shaft, fifty-seven fathoms deep, into the air, to a considerable distance from the mouth of the pit." It is interesting to note that women were employed as miners in England during that period. In the United States, the first record of coal mined was in 1702 by the Jamestown colonists. In 1786, about 20 years after Pittsburgh, PA was first settled, a charter was granted by William Penn to mine coal on the banks of the Monongahela River. Then in 1803, the first important coal company, the Lehigh Coal Co., was established. From this beginning, the mining industry continued to grow in importance and the first state mining law was formulated in 1870. The Pennsylvania state mining law was followed in 1873 by Ohio&apos;s, and in 1876 by Maryland&apos;s. A mine explosion at Avondale, PA in 1869 stimulated state legislatures to formulate these early laws. In 1907 near the town of Fairmont, WV, there were, within three days, two explosions resulting in a total of 597

Jan 1, 1981

By J. A. Herbst, R. Mackelprang, J. D. Miller

Droplet size distributions were determined by stabilizing in gelatin and measurement of the distributions by means of computerized image analysis Several variables that affect droplet sizes were studied and the resulting size distributions were modeled via a population balance equation Key parameters in the model were related to the physical properties and operating conditions of the systems examined using a multiple linear approach

Jan 1, 1981

By R. M. Schuller, J. J. Suloway, W. F. Childers, R. A. Griffin, S. J. Russell

Seven solid wastes from coal conversion processes were characterized chemically and mineralogically. The wastes included three Lurgi gasification ashes, two liquefaction residues (SRC and H-coal), a fly ash, and a water-quenched slag. Leachates generated from the solid wastes at various pH levels over the range 2.5 to 11.0 were analyzed for over 40 constituents. Results of the leachate analyses demonstrate the wide variation in constituent solubility for the solid wastes. To help assess the environmental impact of the disposal of these wastes, the leachates were also employed in soil attenuation studies and acute 96-hr static bioassays using young fathead minnows.

Jan 1, 1981

By Kjell Lidin, Christer Nordström

INTRODUCTION LKAB produces iron ore in several mines in northern Sweden, and has been doing so for nearly 100 years. Total production to date is 600 million tonnes of finished products of various kinds (pellets, lump ore, fines). Close to 400 million tonnes have been produced by sublevel caving. This method has been the company&apos;s standard method for more than 20 years. A review of the development of equipment over the past 15 years and an outlook up to about 1990 leads to the following general re- flections concerning probable trends. Trends for all equipment are increasing precision and stricter environmental requirements will necessitate cabs, remote control etc to an increasing extent. Conventional sublevel caving can be broken down into the following unit operations: 1. Planning incl prospecting drilling. 2. Horizontal drilling. 3. Fan drilling. 4. Charging and blasting. 5. Loading and haulage at sublevels. 6. Ore drawing in chutes. 7. Rock reinforcement. 8. Production service. This lecture will deal in brief with each of these unit operations and the trends we are experiencing for them. A number of slides illustrating equipment

Jan 1, 1981

By R. Crnojevich, J. L. Blanco, C. Nikolic, W. G. Sherwood

This paper describes the process used for cobalt purification and recovery at the AMAX Nickel Refining Co. plant In Port Nickel, Louisiana In the first stage, cobaltic precipitate produced in the Outokumpu electrolytic nickel cobalt separation process is dissolved using methanol and sulfuric acid liquor produced in this step is converted to an ammoniacal complex, and sufficient ammonium sulfate is added to facilitate cobalt oxidation to cobaltic pentammine Nickel is then selectively precipitated as nickel-ammonium sulfate double salt at pH 2 5 Final purification of the pentammine liquor is effected by pH adjustment with ammonia and removal of divalent nickel by ion exchange Purified liquor is then advanced to hydrogen reduction to produce cobalt metal Although similar to other cobalt refining processes used in the nickel industry, the Port Nickel process is unique because of a single point chemistry adjustment for a number of unit operations that occur in succession.

Jan 1, 1981