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By Olli Aulio, Outokumpu Oy

"GENERALThe Outokumpu Company is today an important European producer of metals from its own mines: copper nickel cobalt, ferro chrome and zinc being the main products. In 1972 about 4 million tons of ore was hoisted from eleven mines.Outokumpu Oy has gained experiences on the various aspects of on line computer control since 1968. This knowledge has been combined to develop a standard computer control package for concentrator control. Before the development of computer control package was started Outokumpu Oy had three large computer control systems. The first system was at the Pyhasalmi Concentrator, thee second at the LokkolaPlant, and the installation of the third system at the Vuonos Concentrator was just started.The characteristics of general computer software packages - both control and executive ones - were thus well-known as well as the practical usage of control theory. Furthermore Outokumpu had developed the Courier analyzer which included a so-called minicomputer. This project had given experience both 1n totally self made real tire executives and in computer hardware and peripheral d=vices. The instrumentation of the Outokumpu concentrators was designed and installed traditionally by the engineers of Outokumpu themselves."

Jan 1, 1973

By Robert Louis Adams

A general discussion of the structure of the junk automobile recycling system shows that the generation of stripped automobile hulks and scrapped automobiles is price inelastic. As a result, it is extremely difficult for the price mechanism to automatically achieve an equilibrium that will prevent the accumulation of excessive automobile wrecker inventories and vehicle abandonment by the last owners of scrapped cars. The new shredder processing technology and the new portable flattener technology have altered the structure of the junk automobile recycling system. The shredder technology has increased the demand for processed automobile scrap. This increased demand is reflected in higher prices paid for hulks by scrap processors. The portable flattener has reduced the transportation cost of shipping hulks to processors. The two new technologies have eliminated, at least potentially, the net cost of shipping stripped hulks so frequently incurred by wreckers in the past. The elimination of this cost eliminates the economic incentive for excessive wrecker inventories. Unfortunately, the incentive for last owners to abandon their cars does not appear to have been eliminated by the new technologies. The last owner of an automobile with no spare parts value is still likely to incur a cost by delivering his automobile to the recycling system. Although a subsidy payment is probably unnecessary to reduce excessive wrecker inventories, such a payment might be one solution to the problem of automobile abandonment. However, there are a wide variety of subsidy programs that could be introduced. Before any Federal subsidy program is introduced to reduce automobile abandonment, it is recommended that the program be tested on a limited basis in many different parts of the country.

Jan 1, 1973

By Robert Stefanko

The following tables contain the average, maximum and minimum power parameter levels for several mining machines. Power factor is listed only for defined transducer output regions. The reasons for the undefined areas are provided in the Instrumentation Chapter. Several maximum voltage drops are included, and are computed from the no load line-to-line voltage: Again, the drops are from measurements at the low side of the load center. The machines are: Continuous Miners; F6A Alpine 76AM Jeffrey (d-c) 8CM Joy 8CM (10CM) Joy 9CM-2AH Joy loam Joy CU-43-2H Joy 2 each CM26H Lee-Norse CM28E Lee-Norse Shuttle Cars; 18SC Joy 48S Torkar (a-c) 2 - 10SC Joys input to rectifier 2 - 16SC Joys input to rectifier

Jan 1, 1973

By T. G. Donnelly

This final report summarizes the prototype development and testing of an air curtain respirotory protective device under Bureau of Mines Contract HO122087. The air curtain respiratory protective device, as part of a miner?s hat, provides protection for the underground mining machine operator against inhalation of dangerous amounts of respirable coal dust. Major components of the air curtain respiratory protective device are: 1) a modified miner hat incorporating an air curtain jet manifold from which the protective air curtain emanates, 2) a motor blower which supplies the air for the air curtain, 3) a filter element to remove the particulate material from the air used for the air curtain, and 4) the hoses and coupling used to duct the filtered air from the motor blower to the modified miner's hat.

Jan 1, 1973

By H. B. Carroll

This Bureau of Mines report evaluates the performance of commercially available portable instrumentation for the detection of carbon monoxide, carbon dioxide, oxygen, and methane at conditions simulating an industrial work atmosphere. Portable instrumentation included in the study was gas-detection tubes (length-of-stain and color intensity), catalytic detector, liquid absorption detectors, paramagnetic oxygen detector, galvanic detector, and pelement or hot-wire methane detectors. Evaluation of the instruments was in atmospheres with 50 and 80 percent relative humidities at 75° F and containing test gas concentrations of 0.1, 0.25, 0.50, 1.0, 1.5, and 2.0 times the thresh-old limit value. Correlation of the results from the portable gao analyzer with measurement from the standard instruments was made by calculating and plotting an estimated line of regression, prediction, and confidence limits and the correlation coefficient for each detector system. Relative humidity in the 50-to 80-percent range did not appear to contribute to instrumental uncertainties in either performance or operation. Considerable deviation in detection precision between the portable gas-detection systems and the standard systems was established, especially at the lower gas concentration levels. The main difference or inconsistency in toxic gas concentrations determined with length-of-stain tubes resulted from the observer's interpretation of the results rather than difference in the tubes themselves.

Jan 1, 1973

By Llewellyn A. Rubin

Under Bureau of Mines Contract H0122007, Telcom, Inc., with the assistance of Fenix & Scisson, Inc., conducted a 17-month research and development project aimed at provid¬ing a field-test model of a guidance system for use with the Bureau of Mines Probe Drill. The Probe Drill is a part of the Bureau's Mine Rescue System developed under Contract H0101262. Volume I of this report is subdivided into seven sections. Volume II consists of a number of supporting appendices. In addition, there were delivered under the Contract, a number of other documents which are referenced in the text. Section 1 deals with essential contract information, Program Background, and a general system description. Section 2 covers the project chronology in brief. Section 3 is a digest of design considerations and implementation related to the requirements of the Contract. Section 4 is a description of the System, including illustrations of the hardware, and software. Section 5 is devoted to Operation and Maintenance. Para. 5.1 describes step-by-step field assembly and disassembly of the downhole unit. Para. 5.2 covers Operation. Para. 5.3 covers various aspects of maintenance from the lowest field echelon possible. Higher level maintenance must be accomplished in the laboratory, for the present field-test model. Para. 5.4 covers system calibration. Para. 5.5 covers detailed step-by-step operational sequences. Section 6 covers the results of the field testing, post-test evaluation, and recommendations. Essentially, we conclude that the present hardware (field-test model) has proven every aspect of system performance, but failed to provide reliable assurance of an operationally ready system. Telcom, therefore, recommends a three-phase continuing effort devised to provide the operationally-ready model of the system.

Jan 1, 1973

By Robert C. Johnson

Domestic byproduct fluorine (in fluosilicic acid) availability at various price levels of aluminum fluoride were determined and a contingency availability curve developed. The supply of byproduct fluosilicic acid is restricted in amount to certain geographic regions, where plants processing phosphate rock are located, and the byproduct can be collected. The maximum possible U.S. annual supply, based on potential plant capacities, is 373,400 tons of fluosilicic acid containing 295,400 tons of fluorine. Based on inputs of 5, la, 25, 50, and 100 thousand tons per year, five levels of producing aluminum fluoride from fluosilicic acid (100 percent) were costed. Based on a 12-percent discounted cash flow rate, including the cost of salvaging the fluosilicic acid, the calculated selling price of aluminum fluoride ranged from $233 per ton to $448 per ton. At the higher price, 98 percent of the potential supply of byproduct fluosilicic acid could be used profitably; at the lower price only 46 percent could be used profitably.

Jan 1, 1973

By Dale R. Ralston

This investigation was divided into two major phases. Phase I of the study was an examination of the occurrence and production of acid water within the Bunker Hill Mine in northern Idaho. The second phase of the project involved the study of water movement through an abandoned tailings pile. Mineralogy and hydrogeology were determined to be the two most important factors in the acid mine drainage problem. Low pH water was formed in the mine in areas of lead-zinc ore rich in pyrite. Water movement in the mine was important in the production of acid and the transportation of heavy metals. Areas of recharge to the mine were identified. A data collection network was installed to monitor water quality and quantity changes. The quantity of acid drainage from the mine was found to vary directly with surface runoff events. The study of the abandoned tailings pile was performed to determine the characteristics of water movement through the tailings material and the resultant impact on the hydrologic environment. The Page Tailings Pile, abandoned in 1969, was utilized as a study area. An extensive network of piezometers and meteorological data collection sites were installed in and near the pile. Data collected to date indicate the presence of a ground-water mound under the east half of the pile. Some transfer of ions from the tailings pile to the ground-water system has been detected.

Jan 1, 1973

This report describes the work performed by Mine Research Company in developing a prototype mobile roof shield during 1971-1972 for the U. S. Bureau of Mines, along with background information leading to the design decisions adopted for the project. In addition, the report evaluates the choice of design and analysis and the results of the project in terms of future possibilities of mobile roof support systems. The report begins with the discussion of the problems of designing, building, and using mechanical and hydraulic roof support in coal mines. It then gives a historical summary of past work with discussions of the design choices made for previous roof support systems.

Jan 1, 1973

By M. D. Aldridge

The results of a two-year research effort aimed at improving communication systems in coal mines is reported. A review of communication methods presently used in coal mines is presented. Theoretical and-experimental results of a four pronged effort in the areas of (1) through-the-earth propagation, (2) paging system design, (3) improvement of wired telephone systems, and (4) carrier current systems are described. Auxiliary systems not included in the above are considered briefly. Various conclusions are drawn in light of practical constraints and the needs of the mining industry. The study clearly demonstrated the need for nine communications to be designed on system basis. The viability of new technology for providing reliable mine communication for improving mine safety and operating efficiency is shown.

Jan 1, 1973

By J. A. Herbst

Until the past decade, the energy-size reduction relationship was the dominant form of mathematical model used in the description of tumbling mill grinding processes (1,2). Typically, in these models some single measure of product fineness (e.g. the 80% passing size, the size modules, the specific surface area) is chosen as the dependent variable and the energy input per unit mass of material being ground acts as the independent variable. In some instances these models have been useful for the correlation of experimental data, but, invariably, they have been found to be inadequate for meaningful process simulation. During the last decade considerable advances have been made in the development of phenomenological grinding models derived from population balance considerations (3-7). In these models a set of dependent variables is employed, corresponding to the set of mass fractions which constitute the product size distribution, and energy input is abandoned in favor of "time in the mill" as the independent variable. The phenomenological models have been shown to provide accurate simulations of the entire size distribution of ground products produced in batch (8-10), locked cycle(11)and steady and unsteady state, open and closed circuit continuous grinding(12,13).

Jan 1, 1973

By Harold J. Bennett

This study was performed by the Bureau of Mines to evaluate the potential supply of primary copper from domestic resources. A tonnage-price relationship was developed indicating the quantity of copper that could be produced economically from known deposits at various copper prices and at various rates of return on the required capital investment. Costs of production are based on estimated capital and operating costs for mining, concentrating, smelting, and refining the copper. Total known recoverable copper resources are 189 million short tons of which 83 million tons could be economically recovered assuming a price of $0.50 per pound of copper, credit for the recovery of byproducts, and a 12-percent rate of return on capital investment. The quantities of recoverable byproducts associated with the 83 million tons of recoverable copper are molybdenum, 1.8 million tons, gold, 43 million troy ounces, and silver, 740 million troy ounces.

Jan 1, 1973

By R. J. Leary

The technologies of contemporary iron and steel production and of direct reduction processes have been studied to identify and estimate the potential effects of direct reduction on mineral consumption and the problems raised thereby for the Nation's mineral supply to the iron and steel industry. Contemporary patterns of mineral raw material and energy consumption were determined from a study of the 1964-70 period. Major changes were observed in requirements for 14 of 20 principal commodities. Average practice in 1970 was compared to best practice to estimate the potential effects of implementing existing technology without recourse to direct reduction. Potential effects of direct reduction were estimated by comparing the mineral requirements for 95 percent reduced pellets with 1970 best practice technology for two cases of use: (I) complete substitution for hematite pellets in blast furnace burdens, and (11) partial substitution (40 percent) for scrap in electric furnace steel charges. Effects upon mineral supplies are described; important collateral factors are analyzed, and the principal metallurgical, industrial, and environmental consequences of implementing direct reduction are discussed. Major effects of direct reduction on the domestic steel industry and its mineral supply system are foreseeable. Direct reduction will (1) create a large demand for low-gangue iron ore; (2) relieve the dependence of the steel industry on coking coal, and (3) permit great increases in furnace productivity, both in blast furnace ironmaking and electric arc furnace steelmaking.

Jan 1, 1973

This manual provides instructions for installing, operating, and maintaining a protective canopy on the Galis Mfg. Co. roof drill. The instructions are based upon two actual installations: one made in a mine on roof drill, model 300, and one in the factory. The parts list and engineering drawings for the protective canopy are included at the end of the manual. And a discussion of some alternative design concepts is also included. The manual can also be used for retrofitting other roof drills with similar protective canopies. Skilled mechanics can determine if the instructions herein would be applicable to the other roof drills and can determine any necessary modifications if they are not.

Jan 1, 1973

By Arnold P. Szaj

There is no startling revelation to the fact that the mining industry as a whole is generally moving toward the use of larger equipment to process ores in quantities far greater than what was even considered a decade ago. Trucks and shovels have led the way in extra large machines and many other manufacturers have followed suit in the development of so-called "supers" in their line of equipment. In order to keep pace with the industry, crusher manufacturers have also enlarged the size of their equipment. There is now on the market, a Gyratory crusher capable of accepting a 72" diameter piece of ore. Primary jaw crushers have also increased in size. It is inevitable, therefore, that larger secondary cone crushers would also be required to complement the other equipment used to process these large quantities of ore. This super-size secondary cone crusher is the SYMONS 10 Ft. Cone Crusher. Until 1973, the largest cone crusher built was the 7 Ft. Extra Heavy Duty crusher, which is currently used in the majority of the mining operations throughout the world. The 10 Ft. crusher, when compared to the 7 Ft. Extra Heavy Duty Crusher, is approximately 1-1/2 times larger in physical dimensions; three times heavier; will accept a maximum feed size which is approximately twice as large; and will crush at approximately 2-1/4 times the rate of the 7 Ft. machine at identical closed side settings. It will be the largest cone crusher built in the world. At the present time, Rexnord's Nordberg Machinery Group has accepted an order for two 10 Ft. Standard cone crushers to be delivered to an iron ore mine in South Africa in early 1975.

Jan 1, 1973

By K. R. Nichol

The author points out that corrosion works 24 hours a day, every day. It is an economic reality that the cost of corrosion is inevitable and that its cost should be incurred in the least expensive way. An economic evaluation technique to properly assess its relative impact is the Discounted Cash Flow Method. Various remedial and corrosion control measures are available and these, when coupled with a planned corrosion control program, help reduce the cost of corrosion.

Jan 1, 1973

By Kenneth L. Whitehead

After many years of research, the occurrence of pneumoconiosis, black lung disease, among miners has been related to the mass of respirable coal dust to which mining personnel have been exposed. Congress passed Public Law No. 91-173 in 1969, which limited the dust concentration of respirable dust allowed in the mine working areas to 2.0 mg /M3 as of December 31, 1972. As a result of these restrictions, much work has been done in determining methods of either eliminating or suppressing respirable dust. The purpose of this project is to determine the state-of-the-art in continuous mining machine bit technology, particularly with regard to dust production.

Jan 1, 1973

By R. D. Saltsman

This report is in fulfillment of Contract No. H023001.5 awarded to Bituminous Coal Research, Inc., on November 15, 1972. The scope of the work under this contract was to perform a two-phase survey for the purpose of determining the status of work in the following specific areas of industry needs under the Technology Transfer Program and to increase industry's awareness of research efforts under the Federal Coal Mine Health and Safety Act of 1969 6f (P.L. 91-173): 1. Research and development of respirable dust sampling instruments which will more accurately collect the respirable Cuss as defined by the Federal Coal Mine Health and Safety Act of 1969. 2. Development of a better means of control of respirable dust and float dust.

Jan 1, 1973

By D. S. Burgess

This report summarizes the incidents that preceded the December 9, 1970, propane-air explosion in Port Hudson, Mo., and then attempts to establish the nature of the explosion from the ensuing events. Special emphasis is given to possible ignition sources, the distribution of flammable vapors, and the analysis of blast damage. Both near-and far-field damage indicated that this explosion may be attributed to the detonation of propane in air with an energy release equivalent to that from about 50 tons of detonating TNT.

Jan 1, 1973

By R. H. Hiltz

One of the major hazards in underground coal mining is fire. The inherent hazard of fire is exaggerated by the nature of coal mining restricted areas, the highly combustible nature of coal itself, and a potential for explosive concentrations or dust and gas in the air it becomes imperative therefore to make every effort to eliminate the causes of fires, while providing the most effective means possible to control and extinguish those fires which may occur it has been demonstrated by prior work that the problem of control increases in proportion to the time necessary to institute control procedures. There are several areas of underground coal mining with obvious fire potential. Some of these, like belt heads, have reliantly undergone improvements in standby fire control devices Others, although having fire suppression systems available to them, have not received as complete a systematic study of their problems. Face machinery, particularly those without a water supply, falls in this latter category.

Jan 1, 1973