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By Neal P. Cochran

The Office of Coal Research Program has been outlined in our Annual Report for a number of years and reported on by various members of the OCR staff as well as by our contractors. The program is national in scope and is intended to develop new and improved uses for our Nation's coal resources and to maintain coal in a favorable economic position, vis-a-vis, the other energy forms. A program has been developed that includes conversion of coal to gas, gasoline and other petroleum-type products, and to electricity. These projects are only one facet of the OCR program albeit an important one. In many of the conversion projects we have underway, original development work has been done with bituminous and sub-bituminous coal. It is the intention of this paper to present a general outline as to how lignite might fit into one or more of these projects as a raw material. Our national lignite reserves are vast in scope and this has been recognized in the OCR program by development of a project specifically for lignite and by including lignite as a test raw material in many other projects. Project Lignite is intended to develop the Cop Acceptor Process for conversion of lignite to a high B.t.u. gas. In this effort we have included the design, construction, and operation of a lignite gasification plant at Rapid City, South Dakota. The work is being conducted by the Consolidation Coal Company and is an outgrowth of their laboratory development of this process. The first portion of our effort included a detailed economic study of a somewhat arbitrary grouping of States designated Market Area A that could be expected to use gas manufactured in a lignite gasification plant. The area included the Dakotas, Minnesota, Nebraska, and Iowa. This geographical area could readily be served if a process could be developed for converting North Dakota's lignite reserves, estimated at 351 billion tons, to high B.t.u. gas. Our study showed that Market Area A had a potential commercial- industrial market of one trillion cubic feet of gas a year. To meet this demand, we believe that part of the load can be obtained from commercial lignite-to-gas plants. At the time of our original study, we concluded that gas could be delivered to the city gate in Market Area A at about 45¢. As a result of price escalation in the interim, our estimate today might be slightly higher, but not significantly so, since some parts of the process appear better today than they did at the time of the original projection.

Jan 1, 1968

By J. David Lowell

This paper describes the geology of the Kalamazoo copper orebody discovered in the course of an exploration project carried out by Quintana Minerals Corporation under the author's direction in an area immediately southwest of the San Manuel mine, Pinal County, Arizona. In the period 1943-1947, exploration projects were carried out in the San Manuel area by the U.S. Bureau of Mines and Magma Copper Company which resulted in the development of the San Manuel underground block-cave mine which is now in production at a rate of 41, 000 tons per day. Mining claims covering the area immediately west of the San Manuel orebody were staked in 1946 by Frank F. Salas, R. A. Buzan, H. G. Buzan, and W. C. Buzan of Mammoth, Arizona. These claims were optioned to Martha Purcell in 1946, and in the period of 1947-1958 seven churn drill holes ranging in depth from 1,400 to 2,950 feet were drilled by Mrs. Purcell. These holes did not intersect ore and no further deep exploration was attempted prior to the Quintana Minerals project which began in August, 1965, and which is described in this report. The Kalamazoo deposit is in Sections 3, 4, 9, and 10, T 9 S, R 16 E, Pinal County, Arizona, and it is reached by driving seven miles east from Oracle, Arizona (Figure 1) . The writer is indebted to Corbin J. Robertson and Ronald B. Thompson who participated in the exploration planning of this project and to a number of other individuals who contributed to its execution and management. Petrographic work by J. M. Guilbert was used as a basis for rock and alteration classifications.

Jan 1, 1968

By M. Adnan Goksel

The hydrothermal agglomerating process described (U.S. Pat. 3,235,371, (1966)) is different from the conventional high temperature processes. Green pellets or briquettes made with mixtures of moist iron ore concentrates and burned or hydrated lime fines are hardened in an autoclave at 198°C and under steam pressure for 1/2 to 5 hours, with or without previous drying. Under the neutral conditions, oxidation of magnetite does not occur as in the conventional processes. The resulting agglomerates are hard and resistant to abrasion and weathering, and they do not disintegrate in the Linder test. The equipment required for the process is not complicated, and favorable operating costs are projected because of the low temperature and efficient heat recuperation. A low capital investment makes the process attractive even when the annual pellet production is below a million tons.

Jan 1, 1968

By Robert W. Holliday

Natural resources are the reservoir from which society draws its material sustenance. Although there is a growing awareness of the need for aesthetic resources such as space for recreation and natural beauty, the basic resources are soil, air, water, and minerals including fuel. Minera's and all sources of energy gain in relative importance with advancing technology and expanding industrilization. In the highly industrialized economy of the United States, almost every aspect of man's life is touched in some way by a product of, the mineral; industries. Agriculture owes much of its productivity to mineral-based fertilizers, insecticides, and mechanical equipment. Modern construction, manufacturing, communications, and transportation are all dependent on nonmetallic minerals, metals, and fuels. Throughout history, those nations with access to minerals, and the technology for using them, have gained ascendency. Before World War II the leading powers also were, leading coal producers. In order of declining rank the five leading' coal producers were the United States, the United Kingdom, Germany, the USSR, and Japan. That the military victory went to the side with the greater' capacity to convert iron and coal into tools of industry, and weapons, is' more than coincidence. It is a fundamental' fact of existence. It is axiomatic that the United States must have a continually increasing supply of minerals if we are to meet the needs of our burgeoning population for a comfortable standard of living and for national security.

Jan 1, 1968

By Charles H. Grant

Communications in whatever we do, is one of the major problems we encounter. In an effort to provide a better understanding of the use of explosives, I am going to take a little different view of what explosives are, and how you might look at them as tools to fragment rock, and some of the problems encountered in doing so. First, let's take the explosive, and although there are many factors involved, I want you to consider these as being reduced to only two--shock strain imparted to the rock by the high early development of energy; and the other, the gas effect which is a combination of heat, moles of gas formed, rate of formation of these gases which develop pressures, etc..

Jan 1, 1968

By David W. Wisecarver

Kennecott Copper Corporation and the U. S. Bureau of Mines cooperated in a full-scale slope stability research project at the Kimbley Pit near Ely, Nevada. The west wall of the Kimbley Pit was mined from an over-all slope angle of 45° to an over-all slope angle of 57° and the pit was deepened nearly 50 feet. Mining was begun February 10, 1966, and completed October 30, 1966. Approximately 2.55 million tons of ore and waste were mined. The project was designed and carried out to learn more about the behavior of a pit wall as its slope angle is steepened and to obtain a possible insight into engineering parameters for use in design of future slopes. Data from this project are presented as obtained from (1) instruments installed in two adits for deformation and displacement measurements, (2) a subsidence network installed on the surface above the steepened wall, (3) pre- and post-mining observations of stress in rock, (4) sonic-velocity measurements, and (5) seismic and microseismic investigations. Changes occurred in measured quantities as the slope was steepened but stopped when mining was completed. Agreement was noted between the measured changes and predicted changes obtained from calculations using the finite element technique. Subsidence surveys and microseismic studies show the steepened pit wall to be stable.

Jan 1, 1968

By R. W. Ballmer

Bingham Canyon lies in the heart of the Oquirrh Mountains, 25 miles southwest of Salt Lake City, Utah. In it is located the world's largest open-pit copper mine, owned and operated by the Utah Copper Division of Kennecott Copper Corporation. From the beginning of open pit mining operations in 1906 until 1963, the pit haulage, or materials transportation, was primarily by rail. In 1963, phase-in of a truck haulage system in the upper two-thirds of the pit was begun. The details of that conversion, its associated problems and the resulting pit operation have been covered in an earlier paper.1 The purpose of this paper is to discuss various factors for consideration in transportation system selection, and to discuss some of the alternatives considered prior to making the change from rail haulage to truck haulage for a portion of Bingham Canyon.

Jan 1, 1968

By George E. Summers

A salt dome appears to provide the basic medium requirements for the excavation of the 315 foot diameter, unsupported spherical cavity at a depth of 2700 feet required by the AEC in a proposed "decoupling" experiment. Tatum Salt Dome was a natural choice for a site because more geological and hydrological information has been accumulated on Tatum than any other salt dome on the Gulf Coast. The Tatum Dome is a mile in diameter, roughly flat topped, nearly cylindrical in shape and has some overhang at the top. The salt stock has nearly vertical layering of alternating bands of salt and anhydrite. In the vicinity of the dome, adequate fresh water for solution mining is available in surface streams and in subsurface aquifers. A saline aquifer is available for brine disposal. A tentative cavity location was selected near the center of the dome which meets the design criteria established by the AEC.

Jan 1, 1968

By William E. Mead

The process of selecting a building site for a major structure is a complex procedure involving the consideration of a multitude of factors. The approximate geographic location for a structure is usually fixed by its intended function, though often there may be several site alternatives. Socio-economic, logistic, marketing and political factors are the primary site determinants. Also critical in site planning, however, are the environmental factors, both natural and man-made. These factors will influence the precise siting location within the limits allowed by the primary determinants and will dictate some of the basic design criteria. This paper discusses environmental factors, principally those which are natural conditions, that must be analyzed for five different groups of structures. The importance of thorough site environmental analysis based upon the principles of applied earth science is described. Significant elements to be considered in an appraisal of the geology, hydrology, seismology and meteorology are outlined.

Jan 1, 1968

By P. A. Meyer

The Tenmile Range is a north trending zone of high relief within the central Colorado porphyry-mineral belt, located between Leadville and Breckenridge. (Figure 1, the Index Map of the area surveyed.) The Climax mineralized zone is located at the southern end of the range on the northwest side of the Continental Divide. This portion of the total area surveyed will be discussed in detail today. A fixed wing aeromagnetic survey was flown over this range and mineralized zone in the fall of 1957. The survey was run as an experiment to see if a useful geophysical tool could be applied in the exploration for similar type deposits. The purpose of this paper is to describe the results of this survey and the approaches used to aid in the interpretation of the total intensity data.

Jan 1, 1968

By J. W. Cooksley

Seismic methods provide an efficient and comprehensive approach to overburden studies pertinent to mining exploration and development, and to other mining and civil engineering problems such as rock mechanics, slope stability, and foundation engineering. For the purpose of defining geologic units and structural features, these methods are generally regarded as the most accurate, but most expensive, of the commonly-used geophysical exploration methods. Although the accuracy and cost of seismic work are generally affected adversely by rugged topography and complicated geologic conditions, it is in rough terrain and complex geology that seismic methods offer important advantages in overburden investigations. For example, to find the surface of rock underlying unconsolidated overburden at depths of approximately 200 feet, a 50-foot spacing of drill holes along the profile line would be required to yield a degree of resolution and accuracy similar to that obtained from a 50-foot spacing between seismic detectors along the same line. See Figure 1. In cases similar to that shown in Figure 1, a twelve-channel recording seismic system would be used. The main components of such a system would be: 1. detectors (commonly referred to as geophones) which convert the ground movement resulting from seismic waves into an electrical signal. 2. a multi-conductor cable which connects the seismic detectors to the amplifiers. 3. ampliiiers, amplify and filter the electrical signals . 4. oscillograph, records the amplified signal. 5. the blaster and firing line. A typical layout of the seismic spread and the components of the system Is shown in Figure 2.

Jan 1, 1968

By Mehmet Guney

During the last decade various modifications of room and pillar and sub-level methods have been tried in an effort to eliminate gob-fires, dangers from roof falls, surface subsidence and to increase efficiency of extraction in the Armutcuk Mine, Turkey. It was eventually decided that the most likely system to give maximum benefits in view of existing geological conditions and coal seam characteristics was a system of cut-and-fill stoping employing hydraulic stowing. This paper has attempted to examine the trends of working techniques of hydraulic stowing. In addition, the results achieved and technical problems involved are discussed.

Jan 1, 1968

By E. Alan Haley

Accurate and economic control of line and grade on long tunnels, large structures, excavations and waterways, has been a problem to surveyors and engineers for decades. The conventional method of surveying, incorporating a level, transit, and a number of surveying technicians, has proven, in the past, to be a very expensive and time-consuming operation. Alignment with a laser has solved most of the problem. Figure 1. With the advent of the Perkin-Elmer Model 5620 Construction Laser, use of laser light is now both dependable and economically feasible for unlimited applications in modern construction and surveying. The laser projects a continuous, narrow red beam of brilliant light, providing a constant alignment reference, and will not interfere with operations.

Jan 1, 1968

By D. W. McGlashan

[Comideha;tion o 4 chyakd- chem and aLtuctund phopetttiu o auRdide nm&, The in~o/uncction gained h ;to be uned ;to iM;tmph& ( I! dnukey bho hen mind-aundacu , ( 2 ) modidicakio~n 06 ;the minmd n~tdacu, and (3) eac;tiom at ;the mind adac fnom ;thu e baic din oipfina, concep;tc, wLth hegattd ;to .the changen kha;t awtgacu undehgu, heac;tiom kha;t might take place, ,the geom&y 04 ;the inkmduce, ;the nkde 04 diddmenk &om and iom in ;the intmdace, and okhm phyaicd and chemicd pttopemXu od an intmdace mun;t be developed, weighed and appfied. The au/tho~ ded wah thue concep;tud connidmatiom @om which hypokhuu me n& ko denchibe khe envhomenkd-ivttadaciae hela;tiomhipa doh nevmd nddide minettah, The ch&enge and moltivation in khe hu eattch h in a henhe a deattch doh baic dad and helcctiomkipa needed doh accompfi he&.] INTRODUCTION Qualitative and quantitative explanation of particulate solid separations are unknown entities because of the lack of adequate models and mathematical relationships to explain the activity occur- ring between the solid and liquid phases. It is a transitional region in which it is difficult to ascertain the mechanisms of adsorption of ions, molecules, etc. on mineral surfaces, as well as other secondary reactions which occur in interfacial regions. Thus, in this paper the authors deal with conceptual considerations from which hypotheses are set forth to describe the environmental- interfacial relationships for sulfide minerals.

Jan 1, 1968

By Arthur W. Ruff

The iron-ore beneficiation and shiploading facilities of the Marcona Mining Company are at San Nicolas Bay which is on the Peruvian coastal desert about two hundred and seventy miles south of Lima. The mines are at elevation of 2,500 ft. Crude ore is transported from the Mine primary crushers to the beneficiation plants by ten miles of overland belt conveyors. After the predominantly magnetic ore is reduced to minus 3/4 in. in the secondary crushing plant, the ore is ground by rod and ball mills and concentrated with magnetic separators. The concentrate slurry is pumped to a thickening and filtering installation for desliming and dewatering. Pelletizing is accomplished with a Lurgi and also a Dravo-Lurgi machine. Deep-water shiploading facilities are available close to the beneficiation plants. Figure 1 shows a flowsheet of the general operation. Pelletizing operations are scheduled 24 hours a day and 365 days per year. A maximum tonnage rate with a high percentage of operating time is necessary to produce the three and one half million tons per year required from the two pellet lines. Process control is a major responsibility and of primary concern to all Operating personnel. The particle size, moisture, and chemical composition of the filter cake must be closely controlled to get uniform high-grade pellets. Key points are sampled routinely and analyzed on a two-hour basis to provide the necessary structure and chemical data to maintain a superior final product. The iron content of the pellets is held between 65.3 and 65.8 percent with 4.0 percent Si02. Sulfur is below 0.04 percent and copper is below 0.02 percent in the finished pellet.

Jan 1, 1968

By R. S. Shoemaker

Expanded markets for copper in the past few years and a consequent search for new ore bodies have revitalized the widely known but seldom applied method of producing copper called heap leaching. This term should be differentiated from dump leaching in that the latter is applied to dumps of mixed oxide and sulfide ores (although either may predominate) that have been too low grade to beneficiate and have, therefore, been stripped off the higher grade underlying sulfide ores. Heap leaching is defined here as the process applied to oxide ores which have been mined solely for the purpose of leaching. In this case, all costs of mining the ore become a part (and a substantial one, as will be shown) of the cost of the copper produced, whereas in dump leaching the mining cost has already been accounted for as a stripping cost for the sulfide ore. Of course, with newly opened ore bodies, stripping costs may be divided through accounting procedures, between the copper produced by the mill and that obtained by leaching, but in general this type of operation must be economic on the basis of the sulfide ore alone. Heap leaching, as a beneficiation method, is unique in that it is the only process used for the recovery of a metal in which the time involved from mining the ore to metal production is measured in months instead of hours or at the most, days, Then too, after the ore body has been depleted and mining has ceased, metal production will continue for some substantial period of time. Heap leaching is also unique because unlike any other method of beneficiation, metal recovery cannot be accurately forecast ahead of time and recovery will never approach that of a conventionally milled sulfide ore or even that of a vat leached oxide ore. Counter-balancing this drawback, however, is the relatively low capital expenditure necessary to put a heap leaching operation into production and the consequence that smaller ore bodies which would not support the higher capital cost involved in a vat leaching plant can be made into producers. Stated more simply, in heap leaching the operator accepts low recovery in exchange for low capital costs and the break even point, that is, where the operator should go to vat leaching with its higher recovery and higher capital costs, is a matter of economics and also, to a great extent, a matter for the nature of the ore to decide. For instance, an ore that will vat leach in 7 to 10 days using 7 pounds of sulfuric acid per pound of copper produced might use double or triple that amount of acid during the months that are required for heap leaching.

Jan 1, 1968

By George I. Staber

As stated by the Congress in the preamble of the act establishing the Office of Coal Research, its purpose is, "To encourage and stimulate the production and conservation of coal in the United States through research and development by authorizing the Secretary of the Interior to contract for coal research, and for other: purposes." Thus, while the overall responsibility for air pollution control from all sources rests primarily with the Department of Health, Education and Welfare, it is obvious that OCR could not perform its mandate of, increasing the utilization of our Nation's greatest energy resource if it ignored one of the greatest practical obstacles to achieving that objective. Therefore, air pollution abatement and prevention is one of the practical considerations taken into account in the selection of the OCR program. And as the severity of the air pollution problem imposes new restrictions on the use of coal, the importance of this criteria in the selection of OCR projects increases. The work done by OCR in air pollution abatement does not conflict with nor does it duplicate the program developed by HEW's National Center for Air Pollution Control. Technical members of the OCR staff maintain close formal and informal liaison with their counterparts in NCAPC. One formal agreement has been executed whereby the HEW agency has transferred funds to OCR for a practical study of the potential effectiveness of air pollution control when coal is burned in a fluidized bed comprised of inert alkaline earth material. It is hoped that this initial cooperative effort will be

Jan 1, 1968

By J. R. Johanson

In recent years the procedures for functionally designing bulk storage bins and hoppers have evolved from qualitative guess and try methods to a quantative method based on theory and tests of the bulk solid to be stored. This quantative method, developed and implemented by Dr.'s A. W. Jenike and J. R. Johanson as with any new design, must prove its effectiveness and validity in the actual operation of the finished equipment. How accurate are the theoretical predictions? Is it possible to extrapolate from bench size tests on a small ample of the bulk solid to the full scale bin design? Can the theoretical designs be economically translated into working hardware? In this paper the answers to these questions are discussed in light of actual bin operations.

Jan 1, 1968

By M. M. Fine

One of the most persistent topics at technical gatherings and in the recent scientific press has been the reduction of iron ore. To cite some of them, in May 1960, a symposium on the subject was sponsored by the Electrochemical Society. The proceedings, comprising two dozen papers, were later published.3/ More recently, November 1966, a similar gathering took place at Michigan Technological University, Houghton, Mich. The latest meeting was the International Congress on Production and Utilization of Reduced Materials, Evian, France, May 1967. If the volume of literature, symposia and conferences is a measure of industry concern, then current interest must be at a high level. To the casual observer of the metallurgical scene, the abiding and recurring attention to iron ore reduction outside the blast furnace must be somewhat puzzling in that so much research endeavor has resulted in so little commercial activity.

Jan 1, 1968

By Frank K. Mattson

The Minerals Processing Section of Surface Combustion is currently engineering and erecting a plant designed to produce 400,000 LTPY of 95% metalized pellets from raw magnetite concentrate, This venture is the first domestic commercial facility that will manufacture pre-reduced pellets as an integral part of a process to produce steel. Surface Combustion has developed the methods that will be used. Midrex, a division of Surface Combustion's parent company, Midland-Ross, will own and operate this plant. The site is adjacent to the City of Portland, Oregon on a 15 acre hydraulically-filled area on the east bank of the Willamette River. Either filter cake or concentrates in slurry form will be purchased from Marcona in Peru, delivered to the dock facility by ocean vessels and distributed to a pond for wet storage. Reclamation from the pond will be with a conventional dredge delivering concentrate to a thickener.

Jan 1, 1968