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By Ta M. Li

Recent economic and environmental setbacks have not slowed Occidental Oil Shale, Inc.'s program aimed at the commercialization of oil shale. In fact, the firm expects to have a 795 MI (500C) bbl) per day production unit working by the end of 1976. The key to Occidental's ambitious program is an in situ method that extracts the valuable oil by retorting the shale in place. The process will require practically no water and will leave the spent shale in place underground. Additionally, all plant operations are to be located within the mine. These factors thus serve to make the operation attractive from an environmental viewpoint, in contrast to proposed conventional schemes which call for extensive underground mining, crushing and grinding at the surface, and construction of a massive surface retorting facility.

Jan 12, 1976

By Russell A. Carter

Alaska is a land of immense proportions and resources. Its very name, derived from an Aleut term, means "The Great Land." Yet, in a state slightly larger than Texas, California, and Montana combined, there are presently only two-large scale mines in production, excluding dredge operations. Once referred to by its territorial governor as "a storehouse of minerals," Alaska is, in the opinion of many industry observers, at least 20 years away from a healthy, productive mining industry. The mineral potential of the state is tremendous: coal deposits on the North Slope alone have been hypothetically pegged at 1.5 trillion tons. Copper-zinc deposits on the south flank of the Brooks Range are conservatively estimated to be worth $4 billion to $6 billion. However, the problems facing mineral development are of equal magnitude, and include:

Jan 11, 1976

By F. G. Miller, E. B. Wilson

In 1972, coal mine productivity was in steady decline and labor and maintenance costs were spiralling upward. Yet, despite this sad state of affairs, nowhere in the US at that time was there a comprehensive and coordinated coal research and development plan in the offing. The Bureau of Mines had not yet been charged with such a responsibility, and industry was content to rely on machinery manufacturers for innovations. It was during this period that Bethlehem Steel Corp. determined that a new approach to coal mining research was needed for the industry as well as for the company itself. After studying Bethlehem's own mining practices, the state-of-the-art of mining research elsewhere, and development work by manufacturers, a comprehensive research package was presented to company management in late 1972. The ideas and experience of many operating and management personnel in the company contributed to the formulation of the final plan as approved.

Jan 10, 1976

Coal - Surface Mining Coal Preparation Coal Utilization Research and Development Health and Safety

Jan 3, 1976

By W. J. Langford

"Conventional design criteria assume that the fracture strength of a structural material exceeds its yield strength. Fracture below the design load is not expected, y et many structures have failed in this way. The causes of the fractures are almost always discontinuities such as cracks and welding defects. Linear Elastic Fracture Mechanics (LEFM or simply 'fracture mechanics') provides an analytical framework for assessing the influence of sharp defects on the load-bearing capability of a structure. Fracture mechanics techniques have reached the point of acceptance by ASME Design Codes for nuclear components, and ASTM Standards now include well-defined rules for measuring fracture toughness. Starting with a simple equation which relates applied stress and crack size, the influence of the material's thickness and yield strength can be calculated. Thus, the size of defect which will cause failure under the applied stress may be determined. Armed with this information, the metallurgist can assess the safety of a structure from the viewpoints of non-destructive testing standards, construction standards and conditions of operation throughout its service life."

Jan 1, 1976

By J. F. Cornelsen

Wheel loaders are currently being used in many mining applications for a variety of reasons. While they sometimes provide the lowest loading cost, a primary advantage of the wheel loader versus other loading systems is the increased versatility and mobility inherent in a wheeled vehicle. The advent of large wheel loaders with much greater digging capability enhanced wheel loader usage in severe loading applications. To match these severe conditions, machines offered today were designed to work in these rocky conditions. Soon after the introduction of large wheel loaders into rocky conditions, however, it became apparent to many users that tire costs could at times account for up to 50% of total hourly operating costs on large wheel loaders. In some applications, tire costs alone pushed wheel loader economics beyond the economic feasibility for these jobs, prohibiting their use. In an effort to combat high tire costs, several attempts have been made to put fast moving steel around the tires to provide a strong interface between vehicle and ground. Some earlier attempts involved wrapping tracks around tires. Mechanical difficulties with these systems limited their customer acceptance. Subsequently, the development of protective tire chains came into favor. While tire chains offered added protection to the tires, the cost and maintenance of the chains remains a problem in 1972, the Dystred arrangement was announced for usage on a 6 cu yd wheel loader from Caterpillar Tractor Co. (See Figure 1). The Dystred offered the advantages of greatly increased tread life over conventional tires, as well as resistance to tread puncture in most situations. The arrangement basically employed a track system similar to that used on track type loaders. Pin and bushing wear often caused high hourly operating costs and excessive machine downtime. In addition, the connection of shoes through the use of links, pins, and bushings forced a limitation on too speed of the vehicle.

Jan 1, 1976

Direct electrowinning is an electrochemical process which has been developed for the extractive recovery of copper from dilute, acidic leach solutions. In passing through a thin particulate coke cathode. copper is reduced and electrodeposited in a thin layer forming a solid copper-coke sheet. The product is melted in a furnace to separate the coke, then the molten copper is fire refined to produce a salable product. A description is given of a prototype unit which is designed to treat 20 gpm leach liquor and recover over 100 pounds of copper per day. Economic analyses show that in a commercial facility producing about 25.000 TPY copper.*the direct electrowinning process has lower overall cost than either conventional iron-cementation or the newer liquid ion exchange-electrowinning when the leach liquors contain less than 2 grams per liter of copper.

Jan 1, 1976

By Frank E. Dalton, Bart T. Lynam, Forrest C. Neil

The Tunnel and Reservoir Plan (TARP) is the largest tunneling program in the history of the metropolitan Chicago area (Figure 1). Between September 1976 and September 1977, rock tunnel contracts having an estimated cost of approximately $420 million will be advertised. During the past six months, the Metropolitan Sanitary District of Greater Chicago (MSDGC) has awarded contracts for 16.5 miles of rock tunnels in diam of from 9 ft to 30 ft having a total bid price of $120,261,750. RECENT CONTRACT AWARDS Addison-Wilmette Tunnel $63,140,480 Upper Des Plaines #20 Tunnel 35,749,664 Upper Des Plaines #21 Tunnel 21,371,607 Addison-Wilmette Tunnel The first contract was advertised in September 1975. This contract, described as the Addison-Wilmette Tunnel, runs from Wilmette Harbor at Lake Michigan under the North Shore Channel to Addison Street in the City of Chicago, a distance of 10 miles. The contract calls for constructing approximately 27,750 linear ft of 30 ft ID and 24,020 linear ft of 22 ft ID unlined rock tunnels, excavation of two construction shafts, and the excavation of 32 drop shafts of various diam. Two hundred ninety-three companies were notified of this contract being advertised, 70 companies took out contract specifications and 3 companies ultimately submitted bids. The contract was awarded to a joint venture of:

Jan 1, 1976

In attempting to vegetate pnob!em sites some basic pn.i,ne%ptes, namely the phys.ica.e and chemi.ca2 pnope/ti;es og the problem mateni.al and the selection oU hu.itab.2e p!antts {cor pnopagati.on, have to be considered. Pnobtem sites such as tai ing dams, mined-out atteas, and areas which have been genehaUy advehse2y a46eeted by mining activities, are not only o~ten located in a divehs.ity o4 climatic regions, but they also usuaUy dL64en substantially in theAjt .int' Lns c phys.ica2 and chem.i cat pnopen t i.es . To estabP.ish vegetation on such sites 6requent2y requites: .%) The ame Lonaton oU adverse {yaetors in onde t to exeate a hoot env.utonment suitable Uon "satis1actony" plant growth. .%i) These.2eationo4 plant species suited to the improved Hoot env.utonment, and eompat%b&e with the e2imate o{y the site, and the ultimate Land use o4 the site. iii) The estabL shment o{y a Laboratory and p-LLot scale testing programme to aeeomptizh the above.

Jan 1, 1976

By B. S. Ignasiak, Dennis Carson

"Laboratory study of the behaviour• of binary coal blends shows that coke strength is more closely dependent on the distribution of ""reactive"" oxygen in the parent coals than on their proximate, elemental or petrographic compositions, and it also appears possible to qualitatively predict coke strength from information about reactive oxygen. Proceeding from this recognition, experiments were carried out to test the possibility of preparing metallurgical cokes from binary blends in which non-caking hvb coal was substantially freed of reactive oxygen by prior heat t1•eatment under controlled conditions. The results indicate that such blends can yield surprisingly strong cokes and that coke strength may be amenable to further improvements by modifying the size distribution of the pre-heated component and the rate at which it is charred."

Jan 1, 1976

By Ellis J. Brien, O&apos

This afternoon I would like to talk to you about coal, its defi- nition, its constituents, its associated minerals and present and future coal preparation techniques. This discussion will be an attempt at presenting sufficient coal preparation and associated fundamentals to enable you to understand "deep cleaning", a more advanced beneficiation process which will be commercially practiced in the near future.

Jan 1, 1976

By Gary M. Larwood

A study was conducted to determine the amount of transportation equipment required to move 1.2 billion tons of coal in 1985. The Federal Bureau of Mines has investigated a majority of the various practices associated with coal transportation and has gathered information on the regional origin-destination patterns, methods of movement, equipment stocks, rate structures, and operational capacities of the most important modes of coal haulage currently in use. Models employing this information were developed to establish the origin-destination pattern for 1985 coal shipments, estimate practical tonnage capacities for selected coal hauling rivers, develop modal shares for both unconstrained (by river capacity) and constrained cases, and present a range of coal transportation equipment requirements for given sets of constraints. Projected transportation shares for rail ranged from 63.7 to 72.3 percent, and for river, from 8.8 to 16.4 percent. Other coal transportation modes (truck, conveyor, Great Lakes, and tidewater) are expected to retain their historic shares of coal traffic. Equipment estimates were made for 1985 rail and water transportation based on 1973 average and best practice. Average practice estimates ranged from 675,000 to 710,000 hopper cars (100-ton) and 3,100 to 5,940 barges (1,400-ton equivalent). Best practice estimates ranged from 126,000 to 142,000 hopper cars and 1,750 to 3,450 barges. Full implementation of 1973 best practice by 1985 is unlikely.

Jan 1, 1976

By Andres M. Liebenthal, Jan M. Mutmansky

This paper is concerned with the layout of a conveyor and beneficiation plant system involving several mines and a single point of delivery. The objective of the procedure is to locate the conveyor lines and beneficiation plants in an optimal manner considering the economics of scale inherent in both the transportation and beneficiation processes. Upon completion of the mining plan, the layout of the conveyor network is achieved through the principle of Steiner minimal trees. The optimal number and location of beneficiation plants for this layout are then determined using a sequential economic analysis based upon the flow of material from the individual sources to the ultimate destination. The practical aspects of the method and the advantages and disadvantages of its use are discussed to link the model to a practical problem.

Jan 1, 1976

By Gordon R. Sima

This contract is concerned with feasibility studies, design and fabrication of a prototype hand-held test instrument and a machine-mounted test Instrument for measurement of electrical shock hazards of mining machines. This report presents the proposed and detailed design of the hand-held test instrument and the machine-mounted test instrument. Theory of operation of each instrument is discussed and includes the operating parameters.

Jan 1, 1976

By N. W. Bliss

"Bauxite has been the almost universal ore of aluminum for about 100 years, with most of the world's reserves oc¬curring in the developing countries. As a result of fiscal and political activities prompted in part by the energy crisis, the formation of the IBA combined with increasing freight and labour costs, these reserves are no longer as competitive or as secure as they once were. This has given fresh impetus to the development of processes for alumina production that utilize raw material other than bauxite. Canada has no bauxite and it is prudent to look for alter¬native raw materials within our own boundaries suitable for one of these processes.Of the three igneous rocks that have been used as a source of alumina, only anorthosite is considered as a potential source in Canada. The Al content would be extracted by a sinter process, which currently requires a raw material with a. minimum of 28% Al2O2. Thus, about 4 tons of anorthosite and 10 to 12 tons of limestone are needed to produce one ton of alumina. There are two petrologically distinct types of anorthosite, one containing the plagioclase andesine-labradorite and around 26% Al2O3, and the other containing upwards of 30% Al2O3, in by¬townite-anorthite; for our purposes they may be con¬sidered as low- and high-alumina anorthosite respectively. The high-alumina anorthosites are somewhat rare; the low-alumina anorthosites are much more common, partic¬ularly in Eastern Canada. Geologically speaking, there is no shortage of anorthosite in Canada. The reserves are im¬mense, although their low Al2O3 content coupled with con¬siderations of location, access and proximity to limestone could be constraints to their development. Fly ash from coal-fired thermal power stations and nepheline syenite can also be used in a sinter process, but neither is likely to be utilized in Canada in the immediate future.The H+ process utilizes an acid attack to leach Al from a raw material with at least 20% Al2O3. One of the best raw materials is kaolinite-bearing clay; not only is it high in Al, but most of it can be extracted. With the possible exception of the Whitemud clay in Saskatchewan, Canada is apparently deficient in clays with sufficient reserves to support an alumina plant utilizing the H+ process. Low-alumina clays with illite and montmorillonite may also prove to be a suitable raw material if advantageously sited with respect to industrial centers. The average shale con¬tains only 15% Al2O33, much of which may be contained in minerals, such as feldspar, not amenable to acid leaching. If shale is used as a source of alumina, it will be because it contains some other valuable commodity, such as oil or uranium, the extraction of which leaves the spent shale upgraded in extractable Al2O3 and lowers the over-all costs to a point where it is economic, Thus, rejects from coal washing plants are most commonly considered as a source of alumina; they are already mined, are available in large and ever increasing amounts, and may contain significant amounts of combustible material which upgrades the Al2O3, content of the resulting ash. Coal rejects from existing and developing coalfields in Alberta and British Columbia are a possible source of raw material, but present data indicate they may contain insufficient Al2O3."

Jan 1, 1976

By David. C. Hoffman

As you are all well aware, the minerals processing industry and process industries in general are now heavily involved in reassessing their process flowsheets. The topic of concern is the little arrow in one corner of the drawing at the end of the process flow that usually says "to waste." A really startling statement might have said "to waste disposal area," which implied that there was some concern, thought, or measures taken to deal with the waste. Since 1965, the year of the Water Quality Act, many laws have been passed and agencies formed dealing with the multi-faceted area of pollution. One of these laws, the Air Quality Control Act of 1967, was the initiating force in the development of Calcilox additive to help solve the problem of sludge disposal resulting from the scrubbing of SO2 bearing gases. The intent of this paper is to focus in with a wide-angle view on a particular type of waste stream, generally an aqueous, inorganic slurry, and present the reader with an alternate approach to their disposal via Calcilox additive stabilization. Each waste stream is unique and will require different techniques to meet the design objectives. Calcilox additive is not intended to be a panacea for every slurry disposal problem, but, rather a viable alternative that should be investigated before a final waste disposal approach is chosen. This paper will summarize the development of Calcilox additive; briefly discuss stabilization; and most importantly, discuss some applications to develop a feeling for Calcilox additive stabilization. Actual dollar costs will not be presented, for each waste stream differs and the ultimate disposal mode chosen greatly influences the costs.

Jan 1, 1976

By Barrie A. Wigmore

There are two aspects of financing western coal development -- whether there is going to be enough money to finance the prospective large development of the industry, and the specific techniques of raising money for that development. To take the first question of whether there is going to be enough money around to finance your industry, I think it is quite clear that the restrictions on the development of western coal are going to be non- financial. Environmental impact problems are creating the greatest delay in coal mine development, at the moment; but getting enough personnel, mining equipment, railroad equipment, and failure of the Department of Interior to act on leasing federal coal lands all appear likely to create significant bottle- necks in the development of western coal -- larger bottlenecks than financing. Financing appears straightforward for the industry. There are many projections of the financing required to meet Project Independence goals. The National Academy of Engineers estimated that development of 500 million tons per annum of western coal would be necessary by 1985 to meet the Project Independence goals which might require $20 billion of capital spending. It is generally agreed that 500 million tons a year is not a realistic possibility. Carl Bagge?s estimate of production of 250 million tons a year by 1983 appears a more reasonable projection. Development

Jan 1, 1976

By Richard J. Gonzalez

The petroleum industry includes varied and extensive operations required to supply increasing quantities of refined petroleum products and natural gas that are essential for the economic progress of an expanding population Petroleum has provided the power for the transformation from the "horse and buggy days" to the age of jets and space exploration, and for the remarkable improvement in productivity per worker in agriculture and manufacturing. Without increasing quantities of oil and gas, the world would face painful readjustments to more expensive forms of energy and lower standards of living Petroleum operations start with exploration, development, and production activities that supply the basic crude oil and natural gas Pipelines, ships, barges, and trucks first transport the raw materials to processing centers and then move the finished products to the ultimate consumers. Processing plants extract liquids from natural gas and refineries convert crude oil into a wide range of products These products include transportation fuels, feedstocks for conversion into numerous products (such as fabrics, rubber, and plastics), light fuels for heating, lubricants, and heavy residual materials (industrial fuel oil, asphalt, and coke) The final activity of wholesale distribution and retail marketing moves products into millions of homes, farms, industrial plants, and motor vehicles The use of coal exceeded that of oil and gas until 1946 in the United States and until 1968 in the rest of the world. However, oil and gas have proved to be such convenient and attractively priced fuels that they now supply three-fourths of the total commercial energy (including coal, hydroelectric, and nuclear power) used in North America and more than one-half in the rest of the world. LARGE SCALE OF OPERATIONS By the beginning of 1970, world crude oil production exceeded 43 million bbl daily, -equivalent to more than 2200 million tpy In addition, natural gas and the liquids recovered from processing natural gas supply about 40% as much energy as crude oil Production of oil and gas provide by far the highest value of all mining operations. In the United States, the value of oil and gas production in 1969 of $13 8 billion exceeded the $13 0 billion value for all other minerals The rate of expansion in use of petroleum has been extremely rapid since World War II World crude oil production doubled from 7,500,000 bbl daily in 1946 to more than 15,000,000 bbl daily by 1955 It doubled again to 30,000,000 by 1965, and will double again by 1975 The use of natural gas has increased greatly in the United States and also in Europe, as important discoveries in the Netherlands and the North Sea and technology for moving liquefied natural gas from Africa provided attractively priced supplies

Jan 1, 1976

By Joseph D. Martinez

"The benefits of modern technology can readily be identified with energy availability. A clear correlation has been established between per-capita energy consumption and the GNP for various nations. The United States is an outstanding example of a nation which has benefited from vast energy reserves. The nation is now challenged, how¬ever, by dwindling reserves and the need to develop new sources consistent with the preservation of environmental quality. The development of new, virtually inexhaustible and environmentally acceptable sources cannot be expected for several decades. Meanwhile, we will have to depend on coal, nuclear energy and/or rigorous conservation measures.The net effect of environmental considerations has been to delay and perhaps ultimately eliminate the nuclear energy option as a national energy alternative. This forces a more positive move toward coal as the next major source of electrical power. Our coal resources are large, but the use and production of coal is also a threat to the environment. Thus, we seem to be moving from one major accessible source to another due to environmental concern only to face the probability that the alternative is also environ¬mentally unacceptable.Controversies revolving about energy choices must be resolved by an analysis of the relative benefits and impacts of these two sources and others. The pattern of changing energy sources is not new. We have moved from wood to coal to oil and gas in the past and must learn to adapt in the future. Rational decisions must be made relative to the utilization of intermediate energy sources pending development of promising future approaches. A collapse of current levels of energy supply could threaten our technological society and the means to develop a new energy base."

Jan 1, 1976

By Roméo Roussin

"The yearly production from the Asbestos Hill pit is 1,550,000 tons of asbestos ore, with a yield varying between 18 and 20 % . The orebody was exposed at the top of a hill, and initial production started without having to remove any overburden. The projected ratio of barren rock to ore, based on the present orebody, was 2 to 1. However, as it was necessary to push back the upper benches, this ratio has changed to 3 to 1. The final pit will be 2,300 feet long by 1,000 feet at the longest and widest points. The final depth will be 680 ft. A pit slope stability study was carried out and an average wall angle of 60-70 degrees must be maintained. Preshearing of final pit limits will produce good wall stability. Permanent access ramps will be 60 ft wide, with an 8 % maximum grade. Geological conditions and the low rock temperature are the major causes of the operation's drilling and blasting problems."

Jan 1, 1976