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By Andrew S. Prokopovitsh

The Bureau of Mines is concerned with all the approximately 60 industrial minerals, although its research program currently is focused on 10 of them--bauxite, chromite, clay, manganese, phosphate, potash, refractories, sulfur, titanium, and zirconium. To alleviate reliance on imported materials, particular attention is directed to those minerals having a potential for production from domestic resources. Another important consideration is environmental problems associated with the production of industrial minerals, principally in mining and mineral processing operations, The Bureau also is looking at the opportunities to substitute more abundant minerals for scarce raw materials such as rutile, fluorspar, and bauxite. In its overall minerals surveillance, the Bureau's mining and metallurgical research and development are coordinated with its minerals information activities from which reviews, projections, and forecasts identify the potential for critical disruptions and short supply situations.

Jan 1, 1975

By M. L. Sharrah

Communication about the energy problem has come at us in great profusion during the last couple of years--reports, speeches, editorials, advertisements--and events. Events such as the Arab embargo on oil exports which vividly demonstrated the world's dependence on oil, a finite and nonrenewable resource. And the three-fold increase in the price of oil which provides a constant reminder of the political and economic implications of dependence on foreign oil. A distinction among countries exists today which was almost inconsequential two years ago--the oil exporting nations and the oil consuming nations. The only rational way for the consuming countries to lessen the political and economic clout of the OPEC group is to reduce their dependence on oil. The United States is capable of playing a significant part in such a move for several reasons.

Jan 1, 1975

By Wayne D. Gould

The Cities Service Company's Pinto Valley mine and concentrator lie about 6 miles west of the town of Miami, Arizona at an elevation of approximately 4,000 feet above sea level. The concentrator started its first ballmill in July 74 and all six were available by November. Every effort was made to reduce capital costs, consequently, each unit process was studied critically to eliminate excess capital costs without loss of efficiency. Equipment selection was made on the basis of proven dependability and operating costs rather than on low bids. The result is a very workable plant with some important innovations. The concentrator is nominally 40,000 tons per day. The flowsheet is typical with 3 stage crushing, single stage closed circuit grinding, flotation, regrinding of rougher concentrate and cleaning of the rougher concentrate. The major equipment list is: 1 60 x 89 Traylor Primary Crusher 1 84" x 20' Stevens-Adamson Apron Feeder 3 7' x 16' Double Deck Tyler Screen 3 7' Nordberg Standard Crushers 6 8' x 20' Tyler Screens

Jan 1, 1975

By Paul Kents

The Canadian Javelin Limited Cerro Colorado copper-porphyry deposit in Panama, possibly the largest known copper-porphyry, contains between 1350 and 450 meter elevations, drill proven and probable ore in excess of 3.0 billion tons averaging 0.65% of copper equivalent. The deposit is located in the Central Cordillera Range, straddling the Continental Divide at 1500 meter elevation. Local topography is very steep. Accessibility is difficult, all logistics made by helicopter, and only recently a 52 km. road from the Pan-American highway was completed into the area. The deposit was discovered in 1969, and since then 75 shallow exploratory holes and 98 deep holes, the deepest 1340 meters, totalling 45,000 meters have been drilled. Deep holes were drilled at the corners of a regular rectangular 150 meter grid.

Jan 1, 1975

By J. D. Miller

The processing of residues derived from various operations in the mining and metallurgical industry for by-product recovery is becoming more prevalent. A principal target for by-product recovery is flue dust produced by conventional smelting operations. Flue dust from zinc smelters has been processed for many years for the recovery of cadmium (1,2). The cadmium recovery technique which consists of a selective sulfation roast, followed by a water leach and zinc dust cementation, produces a lead cake residue (see chemical analysis in Table I), which consists primarily of lead sulfate.

Jan 1, 1975

By Allen M. Newcome

The Ohio valley division of consolidation coal company has incorporated two new aspects within its coal mining concern. A new communication system, thru the cooperation of the c. & p. Telephone company, has been established in each of our mines with its central control in the general office building. In conjunction with this system, a Texas instruments 960 a computer has been incorporated into the system. The purpose for our computer is to provide modernization and improvement to our safety, production and maintenance programs. Thru proper use, the computer will help eliminate inaccuracies and inefficiences that have previously caused inaccurate analysis of problems. Due to federal requirements for more reliable communications in underground mines, Ohio valley division is making a concentrated effort to improve its communication systems. Systems such as the magneto phone and trolley phone have been looked at more critically. It was found that these systems are being used well beyond their limits. With these facts in mind, division personnel started looking for a system that would have these built in advantages: ease of maintenance and installation, increased reliability, low cost, and an inherent ability as a multiple use system.

Jan 1, 1975

By Wayne D. Gould

Planning for a project does not start with the announcement of the approval for a project. Planning actually begins when the project is only a prospect and it involves the years of experience of many people because their expertise influences the final decisions. In partial anticipation of the Pinto Valley project, as well as a search for improvement in the Copper Cities operation, two projects were undertaken. The first project was to substitute one 26" cyclone for three 20? cyclones in the single stage grinding circuit. The second project was to replace the Hunt air flotation cells with 300 cubic foot mechanical cells. The 300 cubic foot cells were just being introduced, consequently two types of cells were selected for testing. The results from both projects influenced the decisions on equipment for the Pinto Valley project.

Jan 1, 1975

By E. C. Winegartner

In producing and selling coal, the coal company is faced with many different parameters by which the quality of its product is evaluated. One type, which we choose to call the economic parameters, includes moisture, ash, sulfur, and Btu's. These are reasonably well understood by both the coal supplier and the customer, and the dollar values can be placed on them. This is the group of parameters of primary interest to most purchasing agents buying coal. A second group of parameters governs how the coal will behave in the boiler itself and is of primary concern to the engineers designing the boiler and to the men who must operate and maintain it. Since we have not yet learned to put dollar values on these parameters, they generally show up in coal contracts simply as cutoff points, the purchaser simply saying that he will not accept coal outside of certain limits.

Jan 1, 1975

By Robert B. Crookston

Oil from shale has been produced in foreign countries for more than a hundred years; however, except for short-lived, small operations, no commercial quantity of oil shale has yet been produced in the United States. Efforts to develop a viable oil shale process have been underway domestically for many years. At the present time, with the need for energy so urgently upon us, almost a dozen development ventures are underway or planned in Colorado and Utah. Of these several ventures, only Colony Development Operation has completed the development, testing and design of a ready-to-go 50,000 barrel per day com¬mercial project. Colony is a joint venture of the Atlantic Richfield Company, Ashland Oil Company, Shell Oil Company and The Oil Shale Corporation, more commonly known as TOSCO. TOSCO is the exclusive licensor of the TOSCO II retorting process and other oil shale technology, which includes mining, crushing and spent shale disposal techniques. This paper will deal, however, with only the materials handling aspects of the commercial oil shale operation. Oil shale handling for this infant industry is unique in that an understanding of the physical characteristics of the ore and the demands on material handling to the plant must he understood. Colony Development has completed ten years in the research and development of techniques and processes for mining, crushing and retorting raw oil shale and the disposal of spent or processed shale. A great deal has been learned about oil shale, in many cases confirming our intuitive analyses and the work of others, but more specifically we have brought it all together to a point where equipment performance and the specifications have been established and a design for the first commercial plant is now mature.

Jan 1, 1975

By John P. Cummings

Glass is the most unique substance which man has made. It is understood that Phoenician sailors playing on the beach in Mesopotanmia around 12000 BC, produced glass by the fusion of sand and soda in their campfire. Glass is unique for many reasons. However, let us consider the following. It is made of materials which are opaque and yet glass can be translucent, transparent, or opaque. It can be as soft as cotton or stronger than steel. It transmits light readily and yet is totally impervious to gases and liquids. It is chemically an inert, creates very little pollution in its manufacture. It is made of the most abundant raw materials on earth. It is readily recyclable and has little pollution in its disposal. Glass containers are made principally from sand (that is, silica), soda, which is sodium carbonate, and lime, which is calcium carbonate, plus decolorizers or colorants and cullet. The proportion of cullet, broken glass, in most glass tanks today is roughly 10 to 20% of the glass product. In most cases, the cullet used in the plant is glass from off-ware, or broken ware, which is a waste product within the plant. Cullet has the following advantages. It contains all of the raw materials normally used in a batch. It tends to melt at a lower temperature than batch, thus saving some fuel, and, finally, by forming a crust above the normal melting system, there is a tendency to cut down air pollution.

Jan 1, 1975

Rendering a solid hydrophobic and solid-fluid particle* attachment in flotation are recognized as not necessarily related (1,2). The attachment is governed by forces of attraction and repulsion which need to be considered. The induction time required for attachment after solid and fluid particle are brought into proximity (3-8) illustrates the point. Laskowski(8) showed that a reduced induction time favoured flotation but detected no change in contact angle, a standard indication of solid surface hydrophobicity. Induction .time is observed in fluid-fluid particle coalescence, there being called a rest time (9-11) The induction time phenomenon is related to the presence of a metastable liquid film (disjoining film (2)) of the continuous phase (water in flotation) which must thin and rupture to permit attachment. The lifetime of this film, which is governed by the rate of thinning and the probability of rupture with thicknesss, depends on a complex interaction of forces. Investigating these forces should help clarify the attachment process. Practical benefits would be improved understanding of slimes flotation (12,13) This paper is concerned with the role of the mobile fluid particle-water interface on the film lifetime, in particular, the role of time-dependent or dynamic interfacial properties resulting from deformation of this interface.

Jan 1, 1975

By C. M. Sliepcevich

This paper is a brief status summary of investigations by the authors over the past decade to develop a continuous process for recovering' high purity metal powder from pregnant solutions by gaseous reduction at elevated temperatures and pressures. Although these studies included extraction of other metals such as nickel, silver, and gold, this presentation will be confined to the hydrogen reduction of acidic and ammoniacal solutions of copper. The continuous hydrogen reduction process (CHR) described herein enjoys the environmental advantages of other hydrometallurgical processes but, in addition, provides a substantial benefit in fuel economy over competing processes. As was recognized by Schaufelberger in 1956, for a given amount of fuel a continuous hydrogen reduction process has the potential for producing four to six times as much metal as an electrolysis process (1). Although hydrogen reduction of metal salt solutions has been known for more than a century, extensive development work leading to commercialization was not initiated until the 1950's. Since then, commercial applications relative to other extractive techniques have been minor and have been confined to batch or to continuous, completely-mixed autoclaves. By contrast, the process described herein utilizes a continuous, tubular reactor which is operated in modified plug flow so that only limited and localized backmixing occurs. Thus, gradients in concentration, temperature, and pressure exist over the length of the reactor, the presence of which can be utilized to advantage for achieving high conversions and product quality (2, 3).

Jan 1, 1975

By C. D. Kuchera

Ore crushing facilities at the Phelps Dodge Morenci Reduction Works became operational in January of 1942. This plant, with a capacity of 25,000 tons per day, was part of a project started some five years earlier with development of the Morenci Open Pit Copper Mine. In the following year, World War II's heavy copper demands prompted an 80% expansion in concentrating capacity to 45,000 tons per day resulting in a doubling of the secondary crushing plant. In the late 1950s and early 1960s, grinding capacity was again expanded to the present 60,000 TPD. This time the then 20 year old crushing plant was obliged to meet a 20% increase in production demand with no additional equipment. The ore, principally a medium hard monzonite porphyry, is dumped from 40 yard rail cars into an ore pocket over the primary crusher at a rate of approximately one car per minute. The primary crushing flowsheet, Figure 1, has remained essentially unchanged over the years. Equipment consists of a 40 by 16 foot grizzly set on a 40° incline and having 6" openings, a 60" gyratory crusher nomin¬ally set at 62" + 1" on the closed side and two 72" by 38' panfeeders which load crushed ore and grizzly undersize at a rate of 4,000 tons per hour onto a twin 54" belt conveyor system for delivery to the coarse ore bin. Ore is distributed across the bin by two single side discharge tripper cars. Bin capacity is extremely limited at 23,000 tons of which only 12,000 is available or "live".

Jan 1, 1975

By Nick Barton

The ability to estimate that support is unnecessary for various dimensions of opening in certain rock mass environments is of particular relevance in the mining industry, where most excavations are not expected to remain open indefinitely. As Hoek1 observes: "the basic aim of any underground excavation design should be to utilize the rock itself as the principal structural material, creating as little disturbance as possible during the excavation process and adding as little as possible in the way of concrete or steel support". Approximately two hundred case records have been analysed for the purpose of determining the amount of permanent support normally used when a given span is excavated in known rock mass conditions Some thirty cases concerned unsupported openings. Excavations that can stand unsupported appear to have certain common characteristics as regards rock mass quality. However, the mechanical properties of the rock mass are not the only factors controlling the choice of design. The dimension of the opening (span or height) and the type of excavation are two important variables.

Jan 1, 1975

By Ed Ramsay

The Hill is a cyanidation plant with flotation and roasting. The grinding and treatment have at the present time a capacity of 1400 tons of ore per day and the precipitation has a capacity of 6000 tons per day. The ore is delivered by a 36" conveyor belt and tripper to 8 mill bins having a capacity of 6000 tons. The ore from these bins is discharged onto 20" gathering conveyor belts which are regulated with p.i.v. speed changers to control the belt weight. A weightometer determines the tonnage milled. The feed enters the 8' x 12' rod mill through a rubber lined chute and the product is discharged through a launder to a 7' rake classifier in closed circuit with 10' by 6' hardinge ball mill. Lime slurry is added at the rake classifier to give a strength of .30#/ton. The classifier sand is fed into the ball mill with a scoop feeder and the mill discharge flows in a launder back to the classifier. The classifier overflow is pumped to a 24' by 12' bowl classifier in closed circuit with a 8' by 15' regrind mill. The bowl classifier sands are fed to this mill and the mill discharge is pumped back to the bowl. The bowl overflow at 8% - 200 mesh is the final product from the grinding circuit.

Jan 1, 1975

By Laszlo Valentyik

The wide scale acceptance of the heavy media separation is due to its simplicity and efficiency. The two most important variables of the process are specific gravity and consistency of the medium. The latter is a function of the settling rate of the media solids. The almost always present clay in the feed and conse¬quently in the medium acts as a stabilizing agent, and its optimum concentration varied between 3-4%.(1,2) Since polymers essentially perform the same function in oil well drilling muds - i.e. to suspend cuttings during drilling - as the fine clay in heavy media separation, this led to the investigation of whether polymers could be used in heavy media separation as supporting agents. During the first phase of the work, it was found that by the controlled addition of polymers, the stability of the heavy media increased without unduly increasing viscosity of the suspensions, thus yielding conditions for more effective and efficient separation. The results of the experiments were reported in a paper at the AIME Centennial Annual Meeting, March 1971.(3) This paper presents the results of the experiment carried out during the second phase of the work.

Jan 1, 1975

By Clifford W. Schultz

Four native copper ores, two conglomerate and two amygdaloidal, were tested to determine their amenability to sorting. One of them, a conglomerate ore from the Kingston mine, showed a high sortability as evidenced by an 80 pct recovery of copper in the minus 6-, plus 1/2-inch size range. Using the Kingston as a case example, the cost of mining and concentrating was estimated for a standard case and five optional cases involving varying degrees of sorting. This analysis indi¬cates that the production cost per pound of copper can be reduced on the order of 1 to 1-1/2 cents per pound along with a significant decrease in capital investment.

Jan 1, 1975

By Marcel Michaud

Over the past five years, the two-fold growth in Canada's coal industry "Figure, 1" results primarily from the coking coal market to Japan and, to a lesser degree, by the increasing use of sub-bituminous and lignite coal for power generation in the Prairie Provinces. This expansion will continue, but production of coal for domestic thermal generation of electricity will grow at a faster rate than coking coal exports "Figure, 2". Half of the 20 million tons of thermal coal used for electrical power generation in Canada during 1974 were imported by Ontario Hydro from U.S. coal companies in West Virginia and Pennsylvania. Ontario Hydro's Nanticoke station on Lake Erie which will consume 7.5 million tons of coal in 1977 when fully operative, as well as other future planned projects, could cause Ontario Hydro's coal consumption to rise from 10 million tons today to 20 to 25 million tons by 1985

Jan 1, 1975

[The development of economically effective and safe methods of mining thick coal seams enables to involve considerable coal reserves into the energy resources in different countries all over the world.]

Jan 1, 1975

By Jerrold J. Marcus

United states reserves of oil and gas have been steadily declining while consumption of petroleum products has continued to increase. The nut result has been an ever increasing shortfall between supply and demand. This imbalance has been made up by imports of both oil and gas causing a strain on the United States Balance of Payments. To complicate the situation further, exporting nations have recently formed a cartel and dramatically increased the selling price of petroleum products. To meet U.S. energy demand, increased attention has been drawn to the production of synthetic oil and gas from coal. To date, considerable research has been conducted and is continuing on various processes for liquefaction and gasification of coal. Some of these processes are now in the pilot plant stage and at least one demonstration plant has been proposed. The coal conversion complexes envisioned will be very large, requiring substantial capital investments and abundant reserves of coal. Coal production to feed these proposed complexes has been estimated on the order of 75,000 tons per day. With the viability of these projects becoming economically attractive, the Office of Coal Research initiated a contract with Fluor Utah to determine and define the problems of surface mining coal at very high mining rates, under varied physical, geographic, and climatic conditions. The flow of recent events in the Middle East has created a greater sense of urgency for this study.

Jan 1, 1975