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By H. J. R. Way

Dr H. J. R. Way: In his reply to my queries Mr Bath still adheres to his statement that it may be possible to replace the estimated R200 million reduction in gold revenue in 1980 by exports of ferro-chromium, and apparently based his conclusion on a growth rate in demand for corrosion resistant steels of 10 per cent per annum in the next few years. As I pointed out at the previous discussion at Middelburg this would entail a production of about one million tons of ferro-chromium in 1980. Exact statistics of South African ferro-chromium production are not available, a fact which is very much to be regretted. But statistics of exports of ferro-chromium are available from "Foreign Trade Statistics" of the Customs and Excise. These show that South Africa exported 99,580 short tons in 1967. The quantity of ferro-chromium consumed in South Africa in 1967 was fairly small and we can therefore assume that the production was 99,580 tons. For this amount to grow to 1,000,000 tons in 1980 would require a growth rate of 19.4 per cent per annum. At 10 per cent this would grow to 344,000 tons and at 7 per cent 240,000 tons. The following growth rates in the form of average trends are pertinent: STEEL - Per annum World steel ingot production - 1957-67 – 6.8 per cent Free-world ingot production - 1957-67 – 6.0 per cent Consumptions of crude steel by four major Free-world Consumers - 1957-67 - 5.6 per cent CHROMITE World production - 1952-67 - 2.5 per cent South African total sales - 1948-67 – 5.4 per cent South African exports - 1948-67 – 3.9 per cent United States consumption, very irregular, but - 1962-67 – 6.5 per cent FERRO-CHROMIUM - Per annum United States consumption - 1952-67 - 6.5 per cent South African exports - 1957-62 - 25.2 per cent South African exports - 1962-66 - 41.9 per cent South African exports - 1966-68 - 21.2 per cent These figures show that exports of ferro-chromium have been growing at a very high rate varying from 21.2 per cent to 41.9 per cent since 1957, but in view of the market situation it seems somewhat doubtful if that high rate can be maintained up to 1980. Of our 1966 exports U.S.A. took 63 per cent which was 53 per cent of their total imports. Their average consumption is trending at a growth rate of 6.5 per cent per annum from 1952-67, but the growth from 1964-66 was 5- 2 per cent and 1966-67, -12 per cent!

Mar 1, 1968

By R. S. Shoemaker, R. M. Darrah

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. 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 Requires Low Capitalization 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 low break even point. Whether the operator chooses vat leaching with its higher recovery and higher capital costs, is a mater of economics which depends in part on 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 12, 1968

By C. A. Rowland, R. C. Nealey

Wet grinding rod mills have been used for 50 years to grind ores and to make specification sand. The application of wet grinding rod mills is well understood. Until recently, there have been very few installations of dry grinding rod mills. The selection of dry grinding rod mills follows the basic principles established for the selection of wet grinding rod mills. The basic Bond Formulae1 [ ] is used to select mills when using grindability test results as the basis for selection. W is multi- plied by the 1.3 wet to dry grinding factor established from wet and dry ball milling experience, and then by any other applicable inefficiency factors.1 Dry grinding rod mills have also been selected by scaling up bench scale continuous rod mill tests and pilot plant tests.

Jan 12, 1968

By L. L. Peterson, W. C. Morgan

This paper discusses some of the problems involved in predicting the productivity of a shovel and truck fleet in a new set of operating conditions. More specifically, it concentrates on the problems of predicting the travel times on the haul and return portions of the truck cycle under new profile conditions and the prediction of the interaction effect between the shovel and truck at the loading point. The ability to calculate the travel times for a new road profile is not new. Additional corrections of these calculated times for expected actual operation can be made. In considering the interaction between the loader and the hauler, there are two approaches that can be taken. Probably the most accurate method of predicting the shovel-truck interaction is a simulation of the step-by-step operation considering the variation in cycle times of the shovel and trucks. This is usually called a stochastic simulation and requires input describing how these cycle times vary. However, by understanding the causes of this shovel-truck interaction it is possible to make sufficiently accurate predictions with much simpler methods. Haulage Cycle Established from Existing Operations For the purpose of this discussion let us assume that the problem involves trying to predict the productivity of a single shovel-truck fleet at some future time in an existing operation. Let us also assume for simplification that the new operation to be simulated has the same loading and pit conditions and the same dumping conditions as did the existing operation. Therefore, the only difference would be the difference in the hauling profile for the new operation. The problem then becomes one of predicting the change in the travel times on the haul and return portions of the cycle, and in determining the change in interaction between and the shovel and trucks with the new truck cycle times.

Jan 12, 1968

By P. R. Jochens, D. D. Howat, C. W. Wolhuter

Prof D. D. Howat (Member): I am a man with a grievance this afternoon. The other authors of the paper entered into a conspiracy to ensure that I presented the paper, and finally even had the audacity to say that this was the least that could be expected from me as I had done so little of the other work. Looking at the distinguished audience here that includes some figures who have forgotten more about cement that some of us have ever learned, I realise how right the other authors were. I feel very much cast in the role of the fool who was pushed in where angels fear to tread. I hesitate to say, Sir, that I would not use the word angels in any definition of the authors of this paper. In presenting the paper, may I try to put forward a few simple points about cement that are probably as little known to the majority of the audience as they were to me-at least until very recently. Concrete, made by mixing Portland cement, sand, crushed rock and water is the most widely used constructional material in the world. Generally the production of actual Portland Cement is about two-thirds that of steel and by the time this is formed into concrete the total is about five times the world tonnage of steel produced. A very rough approximation suggests that world consumption of concrete is about one ton per person per annum. Apart from fresh water mankind consumes no other material in such quantities. What mankind originally required was a mortar to be used for joining blocks of stone or bricks. Such mortar was originally made from limestone burned in a kiln and then mixed with water. Production of mortar of this type began over 5,000 years ago. Some samples from pyramids in Egypt have shown this mortar to be in good condition although over 4,500 years old. The progress of technological development was very slow until 1824 when an English bricklayer, Joseph Aspidin, patented a new mortar material which he made by burning limestone and clay together in his kitchen stove. Aspdin called his product 'Portland Cement' because, in colour, it resembled a well-known building stone quarried in the Isle of Portland on the south coast of England. Aspid's same types of raw materials are used today in modern cement production and the product is still referred to as Portland cement. A lime-containing material such as chalk or shell and a clay-type material such as shale, slate or clay itself, are mixed in the required proportions, ground and fed to a kiln where the minimum burning temperature is about 1,500°C. The raw materials react to form hard chunks of a material known as 'clinker'. About 5 per cent of gypsum is added to the clinker and the mixture is then ground to a very fine powder, the function of the gypsum being to control the rate of setting of the concrete. The key oxides in cement production are lime, silica, alumina and iron oxide. The possible reactions occurring during and the products of the burning process are shown in Table I.

Jan 12, 1968

By B. E. Hoffacker, R. E. Lund, J. Ferrighetto, G. E. Welch

Since October 1965 the Josephtown Smelter of St. Joseph Lead Co. has commercially applied the Heavy Media Separation process to reclaim zinc and reject gangue from electrothermic zinc furnace residues. In addition, heavy medium is produced from the ferrosilicon which is present in the furnace residues. By way of background, the Josephtown Smelter produces zinc metal and zinc oxide by the electro- thermic process. The principal feed to the vertical shaft electric furnaces is sized sinter and coke. Temperature of the charge in the furnaces varies from roughly 900°C near the wall to 1300-1400°C in the central regions. Zinc smelting is rapid and nearly complete in the main body of the charge, but little zinc is smelted near the wall. In addition to fusing high gangue content particles, the high temperatures promote side reactions, the most important of which is reduction of iron oxide and silica to form a low grade ferrosilicon containing about 82 % Fe and 13% Si.

Jan 12, 1968

By E. C. Wilson

The knowledge concerning the lubrication of open gearing for mining machinery has contained many unknowns and at its best has relied to a great degree on a "Rule of Thumb" procedure. It will be within the scope of this paper to explain what we have learned to date and what must be learned in the future. Action of Two Gears in Mesh Let us review some of the basic fundamentals concerning the action of two gears during mesh. Most of the gears we use are involute and may be spur, helical, or herringbone. The gear contact is a combination of rolling and sliding action.

Jan 12, 1968

By B. Mienie, J. F. Morrison, C. H. Wyndham, M. J. Martinson, N. B. Strydom

Contribution to discussion M. J. Martinson (Associate Member)*: Application of the simple selection test mentioned in the penultimate paragraph of the paper (reference to a more detailed description of the test would not have been inappropriate) should assist South African mining engineers to make more efficient and possibly more humane use of available labour. The authors mention that the test 'is in use in the gold mining industry', and it would be interesting to know the extent of this usage in terms either of number of mines or as a percentage of the total number of labourers employed on 'heavy' tasks. The paper would have been of greater interest had the authors attempted to relate their findings to the statistics of labour usage in gold mines, members of the Chamber, and to the 'heavy' tasks in particular. On this the authors confine themselves in their Introduction to the somewhat ambiguous statement that 'A relatively high proportion of the 360,000 Bantu mine labourers are employed underground on manual tasks'. To appreciate the practical significance of the authors' work one needs a detailed breakdown of the underground labour force by occupations, together with estimates of quantities such as: (a) total stope and development tonnages moved manually per shift: by shovelling by shovel/tram by tramming together with distances and any other relevant data; (b) theoretical energy expenditures required to accomplish (a); (c) actual energy expenditures required to a accomplish (a); (d) energy theoretically available to accomplish (a) based on 50 per cent of the total maximum oxygen intakes of the labour force allocated to these tasks. Analyses of this sort on an industry basis might demarcate the more promising areas for detailed investigation. Stress is often laid on the need for increased mechanisation to increase stope productivity, but it may be questioned if enough is known about the characteristics, performance and potential of our underground labour force to warrant blind acceptance of stope mechanization as the industry's panacea. Provided that health and safety are not compromised, the ultimate yardstick for assessing any form of stoping is profitability; obviously the industry must investigate very thoroughly any form of mechanization which might reasonably be expected to increase profitability, but it should also be remembered that a radical overhaul of existing systems-which have after all evolved by trial and error over the past 75

Jan 11, 1968

By James H. Allen

The development of large diameter rotary drilling techniques and equipment in the last nine years has been the main factor for the rapid advancement made by this method of shaft construction. In 1959, less than 5000 ft of large diameter hole was drilled in the United States for the mining and construction industries. By 1967, large diameter hole footage had increased to 117,000 ft. Part of the increase in footage for holes drilled represents AEC requirements due to the discontinuance of atmospheric testing of nuclear devices. The increase in footage for holes drilled for the mining industry can be attributed to cost savings of shaft construction by rotary methods as compared to conventional blasting methods. Until the late 1950's most large diameter holes were drilled with positive displacement rig pumps or air compressors, direct mud or air circulation, conventional sized oil well drilling strings, and multipass reaming techniques. In some very soft formations it was possible to run a pilot bit with one or more hole openers in tandem to drill the hole in a single pass. The main problem with single pass drilling using tandem hole openers was in providing sufficient circulation fluid for proper hole cleaning through conventional sized drill pipe.

Jan 11, 1968

In an earlier day, a moderate-sized 600 tpd mine could easily require 60 working faces and might use five supervisors. The miner had a tonnage rate as an incentive and was largely his own boss. With the advent of conventional mining machine crews, the typical pattern of resource used changed radically. The number of work places could be cut by a factor of ten, but supervision only by a factor of somewhere around three, or at most, five. Obviously, supervision was increased. Capital use rose at the same time by a factor of approximately eight. Materials used, such as powder and bits, probably in- creased in both quality and unit cost, too. It certainly required a better-trained man to run the machines, but fewer miners were needed. It is clear that each input factor such as land, labor, capital and management, has changed significantly and it would be foolish to attribute all the gain to improved machines. However, concentration of work was a vital consideration in the change, sketched above, and such focusing of work in fewer areas could not have occurred without high capacity mining machines.

Jan 11, 1968

By A. A. Dor

Out of nine new major iron ore concentrators put in operation during the last three years, or expected to be commissioned in 1968, seven incorporate primary grinding mills and have a total design capacity of 13,150,000 ltpy of pellets, while only two include conventional rod and ball mill grinding circuits for a total design capacity of about 6,100,000 ltpy (Table I). This evolution in the application of primary grinding to hard, fine grained magnetite ores represents an important development in the technology of mineral processing. It has been the outcome of comprehensive testwork in the laboratory and in pilot plants.

Jan 11, 1968

By S. D. Michaelson

Open pits and quarries are the major sources of all "hard rock" tonnage mined today. Normally, ore is fractured from the pit face by blasting and then truck-hauled to a primary crusher where pro- cessing begins; overburden (or waste) is generally truck-hauled from the pit to dump areas. Truck haulage of blasted ore and overburden accounts for some 25 to 50% of total mining costs in a typical open pit and commonly is the largest single cost factor. Obviously then, cost reduction efforts should properly focus on improving existing haulage systems and developing new breakthrough techniques for material transport. Continuous flow systems for large tonnages ordinarily will result in a lower cost than batch systems such as truck or rail haulage. Continuous flow with pipelines for liquids and slurries, or conveyors for medium to coarse dry materials (in the -8-in. range) are the economic answers for bulk materials handling over reasonable distances.

Jan 11, 1968

By A. T. Yu

As the first loads of Noamundi iron ore rumbled into the new 54-in. Gyratory Crusher on March 30, 1968, one of India's largest and most modern iron ore processing complexes began operations. The completion of the $13 million mining and processing complex brought to a successful conclusion the second chapter of a phased expansion program initiated in 1958 by India's gigantic Tata Iron and Steel Co. The completed complex will yield annually 2.5 million tons of washed, sized ore and sinter fines destined for Tata's furnaces at Jamshedpur. Hewitt-Robins Div. of Litton Industries was awarded the turnkey project on the basis of world- wide competitive bids. Eighty miles southwest of the city of Jamshedpur, Noamundi lies on an approximate geographic grid of 22º-5' latitude north and 85º-30' longitude east. The mine is approximately 600 ft above sea level.

Jan 11, 1968

By Roscoe W. Stensrud

Marcona Mining Company operations are located 500 kilometers south of Lima, Peru, on the Pacific Coast, at approximately 15º-22' latitude south and 75º-11' longitude west. The terrain is sandy rolling hills ranging from sea level at the coast and rising sharply (escarpment) to an elevation of 800 meters at the mine area. The climate is arid and windy with a moderate year-round temperature, ideal for a year-round mining operation. San Juan, a new and modern community of 14,000 inhabitants and developed by Marcona, houses the working forces and their families.

Jan 11, 1968

By Y. J. F. Haven, G. H. J. Kitson, D. G. Beadle

I have read this paper with considerable interest. By using an automatic instrument to assess the dust samples taken in South African collieries, the authors are ahead of the gold mining industry, which still uses the laborious method of microscopic assessment, with its limited accuracy, of the half-a-million dust samples taken each year. As the authors state, the result obtained from the photoelectric assessment of the samples is approximately proportional to the surface area of the respirable dust. However, modern theory is that, in assessing coal dust, it is the respirable mass which is important in determining the danger to health. Thus Table II of their paper is of considerable value in showing the relationship between the P.E.R. value and the mass concentration measurement. Unfortunately this table only gives the mean relationship. The important point is to know the scatter around this mean. If the scatter is small, then this mean value (for different operations) would have considerable value in converting from respirable surface area to respirable mass, but if the scatter is large, then such a conversion, using a fixed factor, will have little value. In the text the authors mention the range of values as being between 3 to 24, but without a statement on the number of samples used to determine this range and their distribution, this is a rather nebulous statement. I hope, in their reply, that the authors will give, in statistical terms, some statement on the overall correlation between these two parameters. I might add that at present a member of my staff is working on similar relationships for dust samples taken in gold mines. Another factor which may well be most important in determining the danger of dust levels in coal mines is the composition of the dust, specifically its quartz content. I understand that the authors have some information on this point, and to make their results of greater value in International comparisons of dust levels and the concomitant development of pneumoconiosis, it will be extremely useful if they could place this information on record. Even though, as I have said above, modern theory postulates that respirable mass is a better parameter to use than respirable surface area, the problem remains of how to measure this parameter with short time sampling, which, as the authors point out, is their preferred strategy for dust sampling and dust control. I know of no easily portable instrument, independent of external power supplies, which can, in 5 to 10 minutes, collect sufficient dust to enable it to be weighed accurately. Thus the authors' implied intention of continuing to sample by their present techniques and using their present parameter to report the results is, in my opinion, an entirely valid decision.

Jan 10, 1968

Falconbridge Nickel, the one-time subsidiary that grew up to swallow its own parent, Ventures Limited, in 1962, is not about to be left behind by rising nickel consumption. At a cost of several hundred million dollars, this Canadian firm has undertaken a series of new projects that will not only ensure its present share of the market, but also lead it into new areas of the nickel business. Although Falconbridge Nickel Mines Ltd. was not formed until 1928, it actually had its start in 1917- 18 with the discovery of a large, good grade nickel- copper deposit in Falconbridge, near Sudbury, Ontario. However, due to several factors, financing could not be obtained and the orebody lay fallow. It was not until 1928, when the Thayer Lindsley interests bought the property from the original owner, that it was developed.

Jan 10, 1968

For a nation whose mining industry has generally been floating through history in the shadows of major mining developments elsewhere in the world, Australia has in the decade of the Sixties made a convincing bid to be one of the world's great "store- houses" of minerals. In fact, at the rate things are developing Down Under and Out Back, what with professional prospecting teams crisscrossing the continent under the direction of professional exploration management, Australia may one day find itself as the world's greatest storehouse. Whereas Necessity may be the Mother of Invention, Consumption is surely the Mother of Exploration. At least this is true in Australia of today. First, the forecasted shortage of iron ore in the world led to the fabulous discoveries in the Pilbara district of Western Australia. Now, the demand for nickel has generated even more interest among mining companies in the vast, untapped potential of Australia.

Jan 10, 1968

Long range expansion plans begun in 1966 by The International Nickel Co. of Canada, producer of over 50% of the free world supply of the white metal, are so mammoth as to give rise to the speculation that something might have to burst at the seams. From an annual level of capital expenditure of $35 to $70 million, the company jumped in 1967 to $145 million in new capital investment and will come close to $200 million in 1968. Inco expects to spend $700 million in the next five years, beginning in 1968, for new mines and surface facilities in Canada. The program involves the opening of nine new mines within the next 3 1/2 years, expansion of producing mines, and construction of new plants and modernization and expansion of established ones to process the increased ore production. Beyond this, the company is committed deeply in developing new sources of nickel abroad. Any one of these new projects, if proven economic, would necessitate expenditures of about $100 million or more. For Inco, the economic strain was relieved without a rupture this spring when Henry S. Wingate, company chairman, reported' at the stockholders annual meeting that $150 million had been raised by the sale of bonds. This marked the first time in 32 years that the company had gone into debt.

Jan 10, 1968

By Paul Queneau

Some years from now, perusal of the unfolding saga of the nickel family will show that the year 1968 was the herald of change-both in the geography of its endeavors and in its technology. No one should doubt any longer that oxide ores of nickel have come of lusty age-their heavyweight stature in the Caribbean area and in the Western Pacific can be shrunk only by immersion in the politics of unhappiness. The sulfide branch of the family has been augmented afar off by substantial ore deposits in western Australia-right across the globe from Sudbury-and in southern Africa, 9000 miles from the nickel hub. The Foreword of the 1961 AIME volume, dealing with the extractive metallurgy of copper and nickel, noted that "the dead hands of nitrogen" had been lifted from oxidation reactions utilizing air and that the industry was on the threshold of under- standing this fact. Here, at least, nonferrous industry had led its ferrous counterpart in the commercial use of tonnage oxygen in liquid phase pyrometallurgy-the reference is to oxygen flash smelting. Today large oxygen-producing plants are blossoming everywhere and the fruits which will follow are many and varied. Among them is Inco's forthcoming use of the top-blown oxygen converter for sulfide melts. The bell tolls for those "pyro- metallurgical dinosaurs" which still stalk smelter aisles the world around. Silicate oxide nickel ores will rejoice in the glow of modern elevated temperature chemical metallurgy in its various manifestations, vindicating the bulldog spirit of that ancient of clans, the hot metal men-including the renovator of Le Nickel's Doniambo Works.

Jan 10, 1968

The nickel suppliers are hard at work across the entire spectrum of the industry-from exploration and mining on the one hand to the development of new applications of this unique metal on the other. The reason-a surging demand for nickel by the free world. Evidence of interest and activity in nickel abounds. Companies such as Anaconda, American Metal Climax, Kaiser Aluminum & Chemical, Patino, Newmont-firms that have not been in the nickel industry before-are now involved in various exploration and development ventures around the world. International Nickel, Falconbridge, Le Nickel and Sherritt Gordon-the big names in the industry -have committed vast sums of money and talent in a variety of new developments designed to ensure their status as leading producers of this commodity. As a result, the world is now seeing a rapid build- up in nickel capacity, and in this issue of [ ], the editors have prepared a summary of these fast- moving major developments.

Jan 10, 1968