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By C. B. Manula

This report is volume 7 of an eleven-volume final report for a Grant completed by The Pennsylvania State University for the Bureau of Mines to develop a dynamic general purpose computer simulation model for underground coal mining. The simulator developed under the Grant has a wide range of possible applications in the design and evaluation of underground coal mining systems from the standpoints of health and safety, productivity, and mine environment. The Master Design Simulator consists of nine free-standing function-oriented subsystem models linked together into an integrated, comprehensive model of an entire mining system. The subsystems comprising the Master Design. Simulator include geology and reserves, methane generation, roof support, subsidence, production, rail haulage, cost, water generation," and ventilation. This volume of the final report describes the Rail Haulage subsystem of the Master Design Simulator. This subsystem can be used as a free standing model or can be linked to the Production subsystem to provide rail haulage capability. Complex rail haulage systems can be realistically simulated with this model. This report includes complete instructions for operating the subsystem as well as a program listing. In addition, a case study is included which illustrates the application of the subsystem when linked to the production subsystem.

Jan 1, 1974

The request for proposal from the U.S. Bureau of Mines outlined the purpose of this study in the following terms. "High grade near surface deposits are largely a matter of history. Most of the current mineral production in the united States is from large low grade ore deposits mined by large scale methods. It appears likely that exhaustion of near surface deposits and public resistance to open pit mining will tend to reverse the present trend toward open pit mining and lead to increased reliance on large scale underground mining. In view of the long lead time needed to improve basic technology, an in-depth study of the major underground mining methods is needed. "This study is intended to provide a systematic review and analysis of large scale non-coal underground mining technology with particular emphasis on current practices and problems, needed technological improvements, existing or potential environmental conflicts, and possible modifications or innovations that will assist in the satisfaction of projected national mineral supply requirements."

Jan 1, 1974

By Leon Y. Sadler

Three new transfer functions relating the time response of the amount of floatable mineral in the under flow to time-dependent changes in the amount of floatable mineral in the feed to the cell are presented. Using experimental stimulus-response data obtained from the flotation of -200+325-mesh glass spheres in a rotor-stator-type cell, the new transfer functions are compared to the only transfer function to be presently found in the literature by nonlinear least-squares fitting in the frequency domain. The new mathematical model based on the amount of available bubble surface area and its rate of introduction is quite promising. The transfer function which allows for a distributed first-order flotation rate constant also gives good results. Simultaneous sodium chloride tracer and glass bead stimulus-response tests show that the mixing conditions in the cell were nearly ideal. It is felt that the new transfer functions presented offer excellent alternatives for use in the design of automatic process control equipment for the continuous mechanical froth flotation cell.

Jan 1, 1974

By R. V. Ramani, A. S. C. Owili-eger

The rapid depletion of shallower coal reserves dictate that mining in the future will be deeper and more complex with more difficult natural conditions. Consequently, an increase in methane emission is expected. It is becoming evident that more accurate predictions and better planning are necessary to design efficient methane drainage systems. This objective can be achieved by the utilization of the knowledge of the physics of gas flow through coal seams and rock strata and by the application of digital computers in the solution of methane flow problems. Although the methane emission models described here have not been adequately applied to existing field operations, good agreement between actual field measurements reported in literature and the simulation results indicates the potential of these models for initial flow quantity approximations and ventilation planning. This report has, therefore, introduced to the mine operator yet another application of computers as a planning tool. AREAS FOR FURTHER RESEARCH The study reported here is by no means complete. Extensive research efforts should be directed to the following areas: (a) Better understanding of the physics of gas flow through porous media which exhibit fracture permeability. (b) Determination of field parameters which control gas migration. (c) Investigation of the effects of the rate of penetration on the emission rate and fracture propagation.

Jan 1, 1974

By I. R. Phimister

'Ancient' mining near Great Zimbabwe I. R. PHIMISTER. B.A. Hons. (Nottingham). B.A. Spec. Hons. (Rhodesia) (Visitor) In proposing reasons for the geographical location of Great Zimbabwe, the paper re-examines the popular assumption that Zimbabwe is comparatively remote from the known areas of 'ancient' goldmining. The lack of 'ancient' workings in the neighbourhood of Zimbabwe is pointed out, and it is suggested that the mining of placer deposits of gold may have played some part in the development of Zimbabwe on its particular site.

Jan 1, 1974

By Donald E. Crowell

In the fall of 1969, ASARCO and Newmont Mining Co. began the design of the 700tpd concentrator at their Black Cloud shaft located near Leadville, Colo. The concentractor would treat by flotation a Pb-Zn-Ag ore containing minor gold values. Flowsheet design was based on laboratory test work performed at the Minerals Research Testing Laboratory of ASARCO. Since the concentrator is located at an elevation of 11,000 ft, cold weather was a major factor in design considerations. The original capacity was designed as 700 tpd but for various reasons an ultimate capacity of 1,000 tpd was desired. This necessitated special consideration in the design of several areas, particularly the grinding circuit. The grinding circuit chosen was a single 9 X 12 ball mill operating in closed circuit with one 20-in. cyclone. The ball mill will operate at low speed and as an overflow type originally. The mill can be speeded up and converted to grate type for handling the larger tonnage when required. Thickeners and filters were oversized and space was left for additional flotation cells in order to handle the increased tonnage in these areas. Pumps were sized so that they could handle the increased tonnage by increasing their speed. Construction began in May 1970; the Black Cloud concentrator went on-stream in April 1791.

Jan 1, 1974

By George J. Thompson

The need for studying brittle fracture is defined; the main elements of this type of failure are explained; and the mechanism at crack initiation is outlined. Various design and maintenance practices which can preclude costly downtime caused by unexplained machine failures are proposed.

Jan 1, 1974

By A. Stumpf, Y. Berube

An experimental apparatus for studying the aqueous oxidation of sulfide minerals is presented. The oxidation kinetics for molybdenite in solutions of caustic soda and dissolved oxygen are discussed; results of leaching experiments on chalcopyrite concentrates are given. Preliminary results on the transfer of oxygen into water are also discussed.

Jan 1, 1974

By J. R. Maxwell

In 1970 expansion was completed increasing mill capacity from 2,000 to 3,000 T.P.D. Actual grinding capacity is 3,400 T,P,D. at a grind of 60% -200 mesh,The ore bodies are vein type, containing about 12% sulphides, with mill heads averaging 2.25% Cu, 0.015 oz.Au, and O.4O oz, Ag. per ton.Summary and Conclusions:During the period Jnnuar-1 1971 to December 1973 inclusive the use of large cells at Opeminka have shown that metallurgy is comparable to when using conventional cells, Operating and maintenance costs are lower, An on stream analyzer with reagents controlled by computer, are being assessed further.Opej1atljn Of Cells:!lo cell level adjustments are required when tonnage is adjusted 20 to 25%.Depending on mill heads and grade of concentrate reagents are adjusted to the first rougher for metallurgical control. Reagents to second rougher and scavengers are seldom adjusted as feed to this section has a maximum variation of about 0.2'~ Cu.Power – Maintenance and Space Requirement :Our total power consumption for 3,400 T.P,D. flotation circuit for operation and air supply is 280 H.P. Previous power drawn using conventional cells was 400 H.P. at 2,000 T.P.D.Total maintenance costs for flotation circuit has averaged $1,100.00 per year for the 3 years of operation, this cost should remain constant.Floor space required for cells and walkways is 2,000 sq.ft.

Jan 1, 1974

By Eugene L. Foster

The engineering profession has traditionally devoted its efforts to understanding and modifying the Earth's environment in order to adapt it to man's needs. In appraising our overall performance, I would have to say it has been a mixed bag. In many areas, notably communications taken in the broadest sense, and development of creature comforts, we have done a good job. In others, we have failed, particularly in our assessment of the effect of our work on the environment. Our failures have been due in part to a lack of understanding or foresight, and in part to a disproportionate emphasis on lowest first cost. Now, with an increasingly large number of people living in a finite environment, there is an urgent need for reassessment. It is no longer possible to pursue a single objective without regard to its side effects. Our projects are too large, and there are too many of them. Environmental impacts must be taken into account in all important engineering decisions of the future. There are forces at work which will help to bring this about. Thinking people everywhere have realized that adverse alteration of our environment eventually affects every one of us. The majority of our citizens, who now live in cities, are beginning to appreciate the advantages of a good natural environment in a way which others who have been closer to the soil have appreciated for years. Our people have flocked to the cities because they wanted to be "where the action is." At the same time, there is a strong desire for what we have come to call the quality of life. Today, we all want the standard creature comforts. We want to be able to move freely

Jan 1, 1974

By Jerry M. Riggsbee, John H. Weber

INTRODUCTION The Washington Metro is a 98 mile rapid transit system that will serve the District of Columbia, southern Maryland, and northern Virginia. The construction work herein described relates to Section B-1 of this system. The contract for this work was awarded by the Owner, The Washington Metropolitan Area Transit Authority, to a joint venture doing business under the name of Ball-Shea-Norair. The partners in this venture were Gordon H. Ball, Inc., Danville, California; J. F. Shea Company, Inc., Walnut Creek, California; and Norair Engineering Corporation, Washington, D. C. The bid price for the project was $33,741,524 with a contract duration of 910 calendar days. Notice to proceed was issued January 5, 1970. The present modified price for the work is $36,866,000 with completion anticipated in July 1974. (About 1,638 days elapsed time.) The work to be done consisted essentially of construction of 3,490 linear feet of cut-and-cover track with side platform, and 600 ft cut-and-cover arch shaped subway stations. Stations are located in Judiciary Square and Eighth & G Street, N. W., areas. Decking of excavation in street areas, maintenance of traffic and utilities, vent and fan shafts, underpinning of court buildings in Judiciary Square and the Smithsonian National Portrait Building, and an electrical substation were included in the contract. Stations were constructed of cast-in-place concrete.

Jan 1, 1974

By William J. Robinson

What is the cumulative rate of recovery of copper from a sulfide leach dump? The technical answers to this frequently asked question may vary from "I don't know" to "quite good" from people of the same company. Management also poses this question because it plays a vital role in planning future production. The answer is difficult because of the many variables between different operations such as physical construction of the dump, topography of the original site, characteristics of dump material, mineralization, and water application. Each of these factors and others have a bearing on the rate of recovery. Anaconda's method of water distribution at Butte is unique in that each dump is drilled to allow physical injection of water into the dump. The injection holes are drilled vertically on 25-ft centers from the surface of the dump [(Figs. 1 and 2)]. Normally, the holes are drilled 40 ft deep and cased with 4-in. PVC perforated pipe. The pipe is perforated at 1-ft intervals with four 1 -in.-diam holes at 90° spacing on the pipe circumference. Formerly, shallow holes (20-40 ft) were alternated with deep holes (80-180 ft) in an effort to cover the entire dump and hasten oxidation. The shallow hole depth varied according to the compaction thickness. The deep hole depth varied according to the height of the dump and the original ground profile. It is preferable to have the deep holes end 20-30 ft above the original ground level. This generally allows penetration of the coarse material at the bottom of the dump. Deep holes had to be discontinued in order to cover more

Jan 1, 1974

By C. E. St. Denis

"Training Program at Sherritt Gordon's Ruttar:. ConcentratorA formal training program for mill operators is being developed and employed at Sherritt Gordon's Ruttan Concentrator. The program was set up to fulfil the needs created by a shortage of skilled reliable labour, a 200% turnover of personnel within the first six months of operation and the rapid advances in mineral processing technology. All new employees are introduced into the Mill Department through an orientation program designed to familiarize them with the operation of the plant. All training and orientation of new employees is the responsibility of a. small training section consisting of two training foremen and one assistant. Using a combination of classroom and supervised on the job training, the training times have been cut by at least one half. High operating standards have been set and are maintained through the use of detailed manuals for each work area and competent instruction at all operating levels. The major portion of training costs arise from the salaries of the training staff but are negligible when compared to the improved recoveries, smaller turnover and less downtime. Government assistance is available to all industrial employers to offset the costs of training employees."

Jan 1, 1974

By R. D. Brown

"""A matter of serious concern to the mining industry in British Columbia""; this comment reflects the attitude of the Mining Association of British Columbia toward the proposed new B.C. Mineral Royalties Act. The proposed legislation, introduced by the provincial government in February and now being debated by the legislature, combines a basic 5% royalty on the selling price, less approved p1ocessing and transpo1•tation costs, of minerals produced in B.C. with an ""excess"" royalty of 50% of any price increases over a predetetmined base. Government estimates project annual revenues of $20 million from the new royalty structure. The accuracy of these figures has been contested by the mining industry. Based on current world prices for copper the industry estimates that the provincial revenues from this mineral alone may run as high as $140 million in 1974 and $150 million in 1975. The Mining Association has warned that the new royalties “threaten to become confiscatory""."

Jan 1, 1974

By G. M. Hughes

"400 cubic foot Agitair Flotation Cells are in use at Sherritt Gordon's Fox and Ruttan Mine Cu-Zn concentrators. The 4 impeller model No. 120, used at the Fox Mine Operation, appears to offer superior agitation and aeration qualities compared to the single impeller model 120A, in use at Ruttan. The advantages of the model 120 are most significant with ores of high specific gravity and coarse grind.IntroductionSherritt is using 400 cubic foot Agitair flotation machines at both the Fox and Ruttan Mine Concentrators.At the 3000 tpd, Cu-Zn Fox concentrator, 18 model 120 machines have been in operation since May, 1969.The 10000 tpd, Cu-Zn operation at Ruttan utilizes 49 model 120A machines. The plant started operation in May, 1973.The 4-impeller model 120 flotation cell has been marketed by Galigher since the early 1960's but the single impeller model 120A is relatively new.Model 120 Agitair -Cell DataThe Model 120 (Dwg. 1) has floor dimensions of 101 x 10' and a lip height of 2~ to 4 feet to provide up to 400 cubic feet of volume. This machine is shown with a froth crowder and stabilizer plates which are optional.Each motor drives two agitators. 20 HP is recommended by Galigher but 25 HP is more realistic with massive sulphides. The SG of ?ox ore is about 3. 6.The Model 120 can handle up to 600 cubic feet of air per cell at 2 psig which requires 5-6 HP at the blowers. Air volume to each impeller is controlled by a valve from a main header.During the first 3 years of operation at Fox there were few mechanical problems with the 120's."

Jan 1, 1974

The considerations which led to the decision to_ install discs at the Dampier Pellet Plant of Hamer ley Iron Pty. Ltd. are described. Initial testwork showed that the ore could be ground dry in open circuit to a Blaine index of 2500 cm2/g and that it pelletized readily. The various design criteria including diameter, slope, speed, motor size, depth of sidewall, feed point and water spray location were then determined. Plant performance after commissioning is described including the various problems encountered and the modifications since carried out to overcome them. The main problem was quickly identified as disc feed rate control. Various bin and bin feeder modifications were tried to overcome the effects of the fluidising characteristics of the dry ground ore. Other factors found to affect disc operation are ore size distribution, additives and operator competence.

Jan 1, 1974

By G. Merle, David L. McKay, Elmar Randveer

"THE ENGINEERING AND TECHNICAL SERVICES department is responsible for supplying the following services:1. Administration and co-ordination of the work required for capital projects.2. Engineering, design and drafting services for inplant changes or improvements as requested by the operating• and maintenance departments.3. Rock mechanics.4. Preparation of plans and layouts required for efficient extraction of the ore as mutually agreed with the mine operating departments.5. Mine planning and long-term schedules in co-operation with the mine operating departments.6. Grade control (long term and short term) and the preparation of ore and waste removal schedules to maintain a uniform grade of mill feed. This also includes the calculation of metal reserves and metal production forecasts.7. Surveying, underground and surface.8. Operations research at the mine site.9. Industrial engineering.10. Chemical analyses and assays.11. Instrumentation.12. Environmental control.A staff of approximately 35 supervisors, engineers and scientists, and 80 technicians, supply the foregoing services. Consulting engineering and drafting firms are used to supply specialized services and technical personnel in-house at Timmins to handle overloads on capital projects under the direction of Ecstall engineers.The operating and maintenance departments depend on the engineering department to supply engineering, design and drafting services for any new facilities or for any planned alteration to existing facilities. To do this efficiently requires a high level of communication and co-operation with these departments. This has been a major factor in developing the present organization of the department shown in Figure 63.The organization is predicated on a strong central technical and engineering resource from which personnel can be assigned responsibilities for different projects, and in different areas, as the work load demands. Job satisfaction is very high because of the variety and challenge in the tasks. Additionally, participation in projects with production and maintenance personnel broadens each technical employee's knowledge of operating and maintenance problems."

Jan 1, 1974

By William S. Alldredge

The Washington Metropolitan Area Transit Authority(WMATA) officially came into existence in February 1967 after the District of Columbia, Maryland, and Virginia joined in a com¬pact pursuant to Federal creative legislation signed the previous November to build a regional rapid rail transit system called METRO (1). The parent organization was the National Capital Transportation Agency (NCTA), a Federal agency, subject to Federal statutes and regulations. Soon after the completion of the transition from NCTA to the new "non-Federal" status of the Authority, the Board of Directors of the Authority formally adopted procurement policies and procedures (2). These are specific statements concerning competition by formal advertising for bids or by solicitation of proposals for negotiation, contracting authority, approval of awards, awards of contract modifications, and processing of claims and disputes. These policies and procedures are silent as to Federal procurement statutes and regulations. But because of the Authority's origin, the sensitive nature of the compact among the several sovereign jurisdictions, Federal financing of two-thirds of the costs, and the resultant surveillance by the General Accounting Office over staff operations, the Authority's procurement practices follow closely Federal regulations adapted to WMATA's needs. This is an important point and is the foundation of contractual relations between the Authority as the owner and its construction contractors. Various constraints and flexibilities of this arrangement with respect to excavation and tunneling contracts will be pointed out in the ensuing discussions.

Jan 1, 1974

By Yves Picot

Construction of new installations was recently completed in the Port of Tubarao, Brazil, With this expansion the port, operated by Companhia Vale do Rio Doce (CVRD), has become the largest iron ore port in the world, with an annual throughput capacity of 60 million long tons. GROWTH OR IRON ORE EXPORTS Since its formation CVRD has steadily increased the shipment of iron ore to overseas markets. Starting with less than 100,000 tons in 1942, the yearly export volume grew to 1,500,000 tons in 1951, 5,000,000 tons in 1961 and 25,000,000 tons in 1971. The number of different grades of ore also increased during this period. Production of high grade pellets, starting in 1970, further increased the number of ore products to be shipped. In the same period the size of ore carriers increased twenty-fold to over 250,000 DWT.

Jan 1, 1974

By T. J. Jr. Corwin

This paper will cover the problems confronting an owner when planning and estimating the cost of a proposed tunnel. Three factors are known: the length, size and the time allocated for the completion of the work. In general the difficulties encountered when driving a tunnel in California are the greatest at the lower elevations and in the Coast Range and are minimal in the Sierra Nevada mountains particularly in granitic formation. The writer will discuss the experience gained from observing the driving of about 120 miles of tunnel in California as well as the repairs of some tunnels. SIZE OF TUNNELS It is known that a small tunnel may be more costly to drive than one of somewhat larger dimensions. This fact was found to be true when a tunnel about 4,000 feet long was constructed to eliminate 7 miles of canal. The formation was lava so it was anticipated the ground would be self supporting because of the small bore. Actually the tunnel required support for most of its length and working conditions were poor. It became apparent that a larger size could have been driven at no additional cost and probably in less time. On another unlined tunnel, to be driven in granitic formation, the contractor was given the option of using

Jan 1, 1974