Search Documents

By James J. Olson

Most of the projects summarized in this paper are funded under the Bureau's Advancing Metal-Nonmetal Mining Technology program and are part of the in situ mining subprogram coordinated at the Twin Cities Mining Research Center. The borehole mining equipment development, are funded under the Bureau's Advancing Coal Mining Technology program, is essential to accelerated progress in the in situ mining subprogram, and some background information on this concept is included. The initial in situ research projects started in 1971-72 evaluated some of the critical blast design parameters for in situ copper leaching. The present program totals about $1 million per year and includes in-house research projects, cooperative (cost-sharing) projects with the mining industry, and research and development contracts. Two different extraction schemes are under investigation: inplace leaching and borehole (or slurry) mining. The principal commodity targets for the Bureau's improved in situ mining technologies include copper, uranium, coal, and potash. The principal purpose of this paper is to inform the mining industry of the in situ mining research recently completed or being conducted by the Bureau of Mines. In addition the Bureau encourages companies to comment on the program accomplishments as well as offer suggestions on top priority research needs for improving the in situ mining methods described in this paper.

Jan 1, 1977

By William F. Riggs

Inspiration Consolidated Copper Company, located in a semi-arid climate in Arizona, continually struggles with a water problem. This applies to quality as well as quantity. When the EPA considered installing a new centralized sewage plant to handle the combined waste from the municipalities of Globe and Miami, Arizona, they automatically assumed that He could use the sewage effluent for process water in flotation. The treatment plant was to be a tertiary system producing 1600 gpm of sewage effluent. Inspiration decided that this could possibly be a source of additional process water. It was decided to test sewage effluent from Miami Treatment Plant at the rate of 400 gpm since it was only a primary treatment plant. The 400 gpm was combined with the 5000 gpm of process water going to the Concentrator. After one week the results were disastrous. The recovery and final grade had each dropped approximately 5%. With the results from this brief run, it was concluded that sewage effluent from a primary treatment plant could not be used. Research was then brought into the problem to begin an evaluation of sewage effluent in flotation.

Jan 1, 1977

By R. A. Matuszak

Throughout the history of power excavating machines, engineers have continuously tried to shape the main drive speed-torque characteristics to provide an optimum performance from each main motion. Selection of prime mover for the various motions has been the subject of many engineering studies and most forms of energy conversion have been tried. A new form of electrical power conversion looms on the horizon' as the most optimum yet. Controlled frequency operation of a squirrel cage induction motor increases the reliability of the most reliable form of energy conversion (electrical) found thus far and at the same time improves the performance characteristics.

Jan 1, 1977

By Robert L. Gamble

The world's largest fluidized bed steam generator located at Rivesville, West Virginia is currently undergoing initial operation. This unit is designed to generate 3708 kg/s (300,000 Ib/hr) equivalent to 30 MWe of superheated steam while firing coal in a fluidized bed of limestone. Coal was first fired in this unit in December, 1976 and start up operation is progressing.

Jan 1, 1977

By Norman K. Olson

A geologic investigation of mineral resources in South Carolina first began in 1825 when the General Assembly authorized Lardner Vanuxen to conduct a "Geological and Mineralogical Survey of South Carolina." Vanuxen, South Carolina's first State Geologist, reported in 1826 on the limestones (marble) of the Piedmont which during those early years, were burned in many shall, scattered kilns in the region wherever suitable raw material was available. He also mentioned the possibility of using marl from the Atlantic Coastal Plain province for direct application and enrichment to the soil. Since before the year 1844 industrial minerals in South Carolina have been commercially produced literally from A to Z, asbestos to zircon. The first pub¬lished reports of actual commercial production, not just an occurrence, are referenced in Table 1 for 33 known industrial minerals and rocks in South Carolina. Known or suspected occurrences of undeveloped non-metallic mineral resources in South Carolina await future verification by geologic mapping, sampling (including coring), possible beneficiation, and market analysis. These industrial minerals and rocks include, but are not limited to, special, clay minerals (e.g. bentonitic clays, zeolites and others), sillimanite, argillite (lightweight aggregate), kaolin (alumina) and marl (underground storage and tunneling medium). In addition other non-metallic minerals, once mined but still worthy of reconsideration, include topaz (industrial), heavy minerals, barite, feldspar, and monazite. Finally, possibilities for new reserves, as an expansion of existing mine output, might develop for fuller's earth, limestone (lime), sericite (finely divided mica), vermiculite, kaolin (paper coating and filling, other filler), and metallurgical gravel. Official South Carolina data from the U. S. Bureau of Mines for 1974 indicated a total value of mineral production of $105.2 million. During 1974 production consisted of cam-on clays, (brick and tile), fuller's earth, kaolin and vermiculite

Jan 1, 1977

By R. T. Langland

The U.S. Bureau of Mines has conducted underground tests and computer analyses to study coal mine roof behavior. Southern Ohio Coal Company provided test sites it) their Heigs mines located near Athens, Ohio. Testing apparatus was adapted for monitoring roof behavior at the face of mining from a remote surface location. Finite element analyses were applied to study the structural conditions present. Test sites were located at three different intersections of entries and crosscuts of the room-and-pillar mine. Electrical read-out instruments were used to record roof bolt loads, roof sag, and roof-floor convergence. They were installed during the roof bolting cycle of a conventional mining section and data was recorded for several months. Normal mining operations continued throughout the test period with minimal interruptions due to the installation and monitoring of the instruments. A computerized data acquisition system, partly underground, partly on surface, permitted continuous monitoring of data and its retrieval, display, manipulation, and storage. The finite element code used to model the test sites accounted for three-dimensional geometry, nonlinear material behavior, and the mining excavation and bolt installation sequences. Results of the test are highly variable. Comparable values between test and analysis results were obtained by applying statistical averaging of. roof test data. Results of the analyses indicate that bolts have a lesser effect on the gross behavior of mine roofs than has been indicated and that bolt load changes are strongly influenced by mining excavation sequence, bolt-placement sequence, and face distance

Jan 1, 1977

By Jr. Goller

You and I can visit cement plants, inspect the various rotary kiln systems and find some equipment or some burning techniques that waste energy--fuel and power. After we have made such a visit and studied a few ideas, we could recommend ways to eliminate much of this waste. Probably every idea would cost money to bring into action. For our discussion, let us arbitrarily set an upper limit of $1,000,000 on the recommendations that we are allowed to make. Call these "low-cost" or "short-term" measures. They are improvements that do not require more than say, three months to complete; they do not require a major revision to the process. Other recommendations are "high-cost" or "long-term"; they are outside the scope of this discussion. Some of our "low-cost" recommendations would offer a satisfactory return on the money that they cost; the remainder would not. Now, is there some way that we can rather quickly pick out the "low-cost" measures that will show a satisfactory return and spend our time making these improvements first? Can we separate these items from those where the return is less likely to be good? I feel that we can pick some of these items quickly if we have a kiln system that has consistently non-uniform day-to-day operation. If the operation is uniform we probably cannot pick them quickly.

Jan 1, 1977

By Conrad W. Steller

What is the definition of a successful construction or development project? It could be described in many ways: a project that performs as designed; a project completed on time, a project completed within budget. The title of our talk today is, "The Advantages of Applying Design/Build -Construction Management to the Mining Industry." As our talk develops, you will see that rather than tell you how to apply this concept, we will discuss the advantages and details of Design/Build so that you can independently apply the concept. Design/Build is not new, and it cannot be universally applied. It has, however, within the past ten years, carved a specific and substantial place in the overall construction -development market. The reasons for its rather recent rise to considerable prominence as a concept is due, in part, to the increasing urgency of gaining productive access of a production facility and, in part, to the inherent advantages of the concept's economics--and they are considerable. If the Design/Build concept of contracting were fully understood, it would, without exception, be the favored way for private industry to contract for its new construction and development as well as renovation work. The basic advantages are: earliest possible access and completion at the lowest cost. Design/Build is often equated and compared to "fast track" or "turnkey" methods of construction. The Design/Build concept can, in fact, be both of these or neither. "Fast track", in and 6f itself, implies that the project will be phased construction, that is to say, it will be built quickly; whereas I "turnkey" is a measure of the completeness of the project, usually meaning essentially that the

Jan 1, 1977

By Immo H. Redeker

The Kings Mountain area of North Carolina is the lithium pegmatite center of the U.S., if not of the whole world. We have two spodumene and by-product mineral producing companies, Lithium Corp. of America, and Foote Mineral Company. We also have Kings Mountain Mica and Kings Mountain Silica Companies producing mica. feldspar, quartz and clay from weathered pegmatites in that area. Figure 1 gives the location of the spodumene pegmatite area in North Carolina. The two spodumene producers mine typical pegmatite ore in open pits after removing amphibolite or mica schist overburden which is sold to aggregate producers. The ore reserves are discussed elsewhere in this session. They are in the order of plus 50 million tons but not unlimited. 1.2 The major minerals found and concentrated from the North Carolina spodumene pegmatite ores are tabulated on Table 1.

Jan 1, 1977

By John T. McDonough

The Climax Mine of AMAX's Climax Molybdenum Division is currently producing approximately 34,000 tons of molybdenum ore per day from two underground levels (see Figure I), and initial design is underway for the next deeper (1200) level. The aim of this report is to present the methods of site evaluation used at Climax for cavability determinations and underground support design. Climax succeeds with its panel caving system of mining (Julin, 1973) (Figure 2) largely because of the presence of pervasive geologic structural discontinuities. The stockwork ore body at Climax was formed by the multiple intrusion of mid-Tertiary rhyolitic magmas into Precambrian granite, schist and gneiss, and the hydrothermal emplacement of molybdenite into the network of fractures that were generated during the forceful upward intrusion of magma. Subsequently, intrusive events that were more deeply seated refractured the overlying, ore- bearing stock and propagated a complex system of axial and radial fractures. Post-ore movement along the Mosquito Fault (Wallace, 1968) and its associated stranded shear zones further fractured the ore body and disordered the existent geologic structure. The result of these structural events is a brittle, crystalline ore body that is transected by a complex pattern of faults, shear zones, and joints that augment cave initiation and enhance comminution of the ore blocks. Generalizations can be made about the structural trends within the ore deposit (King, 1946; Kendorski, 1973), however, the intensity and orientation of geologic structure is by no means uniform throughout the ore body. The relative intensities of silicic and argillic alteration are also highly variable (Vanderwilt and King, 1955). As a consequence, no single rock-mass model suffices as a standard for mine design, and site characterization for cavability and support design is a continuous process.

Jan 1, 1977

By Stephen R. Holsinger

During the year of 1972 ASARCO's Silver Bell embarked upon a project that would test a modified grinding circuit using direct digital compute against the performance of its other five grinding lines, implementation and subsequent outcome of that project has been previously reported in a paper by Pitts, et al. The main purpose of the present paper will be to describe major problems incurred during the implementation of this control strategy on the remaining five primary grinding lines and their solutions. Also included will be a discussion of changes made in operating philosophy and methods used since that report was written. Description The Silver Bell concentrator is a 10,436 tonne/day copper sulfide plant supplied by ore from two separate open pits approximately 4 km. apart. As well as receiving ore from these two main pits, ore is received from several exten¬sions of both pits. The ore bodies are variable in rock type and the extensions have increased this variability. Grinding is carried out by six primary, single-stage, 3.20M x 3.66M Allis Chalmers grate discharge ball mills in closed circuit with four Krebs D20B cyclones (Fig. 1). Each of these grinding circuits is controlled by four independent but interactive control elements. These control elements are the fresh ore feed, the water added to the feed end of the mill, the water added to the ball mill discharge sump, and the cyclone feed pump speed. At the present time, instrumentation for measuring primary process variables consists of Merrick weightometers for fresh ore feed, orifice plates coupled with differential pressure transmitters (dp's) for incoming water measurements, back-pressure diaphragm coupled with a dp for estimating ball mill discharge sump level, a magnetic flowmeter for determining cyclone feed velocity and a nuclear density gauge for measuring cyclone feed density. All measuring instruments develop electrical signals that are measured as 2-10 V DC "inputs o the computer interface.

Jan 1, 1977

By Brij M. Moudgil

Flotation was introduced in phosphate rock processing in the late twenties and since then it has been an important part of the concentration process. More than two thirds of the rock produced in Florida is upgraded by the flotation process. Since no crushing or milling steps are involved in the material preparation, the flotation plant feed is coarser than in most other mineral flotation systems. During hydraulic processing of the rock, particles in the size range of -14, +150 mesh constitute the flotation feed. This size fraction is further classified by hydraulic sizers, stationary screens and vibrating screens into a coarse (-14, +35 mesh) and a fine (-35, +150 mesh) flotation feed. The flotation techniques for concentrating the fine feed as practiced by the Florida Phosphate producers have been standardized over the years, however, methods for upgrading the coarse feed differ from plant to plant. In this paper an effort has been made to present relative merits of the techniques employed for concentrating the coarse phosphate rock..

Jan 1, 1977

By Boghani. A. B.

A computer program has been developed to simulate evacuation of a mine in various configurations. The simulation input variables include characteristics of the mine, expressed, in the form of a network of passages, properties of hoists and hoisting strategies, initial miner positions, ventilation and compressed air velocities, stench warning system and self rescuer capabilities. The simulation can be carried out for cases in which there is no fire, i. e. , fire drill simulation, or for cases in which there is a fire at any arbitrary location. The fire is assumed to generate gases which impede movement of miners in the gaseous region. However, the thermal effects of the fire are not considered. The simulation output include the evacuation time for each miner, movement of the hoists, propagation of smoke through the mine passages and smoke exposure of the miners. Several illustrative simulations have been carried out to verify validity of the program and to demonstrate its capabilities. The computer program has been able to predict evacuation time, within 5 percent, for an actual fire drill. It is believed that this program can be used to evaluate evacuation performance of a mine, identify problem areas and demonstrate improvements due to the recommended corrective actions.

Jan 1, 1977

By F. Milton Lewis

In this paper an attempt has been made to review the cost trends in producing copper by conventional milling. smelting and hydro-metallurgical means during the last five years. The primary objectives of this cost analysis are to provide a base for future projections as well as to indicate which cost items are more volatile in their influence on overall cost of producing copper.

Jan 1, 1977

By John L. Shafer

Often an in situ leach is the only practical economic method for copper recovery from small low grade oxide deposits. The decision to develop a copper property by an in-situ blast and leach is strongly dependent on ore grade, tonnage, hydrology, and the copper extraction and acid consumption rates. The inherent "leachability" of the ore will in part determine the desired amount of fracturing of the ore deposit by the blast in order to obtain a copper extraction rate that is economical. For the last several years Occidental Research Corporation (ORC), the corporate R&D for Occidental Petroleum has under-taken a modest effort to address the question of "how to best identify and determine the information necessary to predict and control the operation of an in-situ leach for the economic recovery of copper."

Jan 1, 1977

By V. Rajaram

The Parachute Creek Member of the Green River Formation in the Piceance Basin, Colorado, contains vast reserves of oil shale, nahcolite, dawsonite, and other accessory minerals. The dry alkali process of sulfur dioxide removal using nahcolite (naturally occurring sodium bicarbonate) has great potential. A room and pillar mining scheme has been designed to extract a nahcolite zone occurring at a depth of 472 m, from the lease application area of the Yankee Gulch Joint Venture. Geotechnical parameters affecting mine design will be discussed. A preliminary development plan for mining at the rate of 1000 t/d will be described in detail.

Jan 1, 1977

By P. Geoffrey Feiss

The Piedmont province of the southern Appalachians is becoming the focus of interest for many exploration geologists. In the past, only those deposits with significant surface exposure have been exploited. Thus, few deposits have been found and relatively little exploration has been conducted in recent years. Modern geochemical and geophysical techniques can alleviate this problem of concentrating on exposed ore bodies by allowing us to "look through" the soil and saprolite to detect the presence of significant mineralization at depth. This paper will attempt to evaluate the feasibility and effectiveness of several geo¬chemical exploration techniques in the Piedmont, of Cabarrus and Stanly Counties, North Carolina. The area chosen for the study is shown in Figure 1, lying almost wholly within the Mt. Pleasant quadrangle, North Carolina. The area is on the eastern boundary between the Charlotte belt, a zone of plutonic and intermediate grade metamorphic rocks, and the Carolina Slate belt, a series of complexly interbedded volcanic and sedimentary rocks of predominantly low grade metamorphism. The area is now considered to be a 500 million year old active, continental margin.1 As is typical of most of the piedmont, outcrop is sparse. Figure 2 is a sketch map of the general geology of the area under study, showing the Charlotte belt rocks in the northwestern quadrant and slate belt rocks, to the east. Within the area are a number of old mines and prospects, the most famous of which are the Furniss and the Phoenix mines in Cabarrus County. All are reported to have contained Au and Cu. Ag and Pb were reported from some. A summary of the deposits is given in Table 1. Data used in this study are from three Master's theses conducted at the University of North Carolina at Chapel Hill. 3,3,6 In separate studies, well waters5, B-zone soils3, and vein and float quartz6 from the area described were sampled and analyzed. Each study concluded separately that geochemical anomalies in the vicinity of the ores justify use of that specific sample type in a geo-chemical exploration program. However, no comparative study of the methods has

Jan 1, 1977

By W. C. Patrick

Introduction The availability of a thorough, simple-to-use roof fall classification system is desirable for several reasons. First, such a system would expedite the reporting of falls for the purposes of estimating material removal costs, analyzing damage levels, and complying with federal regulations to report falls in certain areas of the mine. Second, the classification system would allow the mining engineer to record falls routinely with little time and effort expended. This would encourage him to make observations concerning what type of roof support would work best in a given situation. Third, and probably most important, an adequate roof fall classification system is the first step toward developing a means of predicting the occurrence and extent of future falls. It was with these three reasons in mind that the following classification system was developed. The type of classification chosen reflects the background of the developer and the intended purposes of the system. Hylbert has proposed a geologic-based classification which groups falls as to structural and compositional origin. The need for similar systems is noted by Cox and by Ferm and Melton. Each of these researchers is confronted with a situation requiring a relationship between local geology and roof fall occurrence. Such a relationship would allow the prediction of the relative frequency of falls from a knowledge of local geologic features. The current research is aimed at fulfilling somewhat different requirements, as noted above. Fall geometry has been chosen as the basis of the classification system so fall type can be reported independent of local geological, environmental, and tectonic conditions. This approach parallels that used in the common slope failure classification with groups failures relatively independent of

Jan 1, 1977

By Karl J. Benecke

Though the first patent on a bucket wheel excavator was granted in 1881 in the U.S. this technology was developed in Germany to the high standards of today. However, this development was only possible in parallel with the development of shiftable belt conveyors and boom stackers. The combination of these three types of equipment in the open pits of the Federal Republic of Germany has made lignite the cheapest energy source for power generating, despite the low heating value of German lignite in the order of 8500 kJ/kg (3600 BTU/lb) only. Comparing the costs for fuels used in power generating on the basis of their heating value, the relation between lignite, high quality black coal, and imported crude oil is in the order of 1 to 1.5 to 2.5, hence highly in favour of lignite. These cost advantages for lignite in Germany are due mainly to the concentration of lignite mining in a few high-output open pit mines. The largest one, Fortuna Mine in the Cologne district, produced a, total of 45 000 000 t lignite in 1976. That equals the annual fuel need of a 5750 MW power plant running 7000 hours per year at full capacity. Altogether 95 200 000 bank m3 equal to 200 000 000 t overburden had to be removed to accomplish this lignite output. The largest BWE (Fig. 1) ever built is working in the Fortuna Mine, too. At a digging height of 51 m above crawler level, the total vertical reach in relation to the face conveyor level is 98 m by means of its conveying bridge and loading unit. The hourly output is 10 400 bank m3. Its weight in operation is 13 000 t, its wheel diameter 21.6 m, as high as a 7-storey building.

Jan 1, 1977

By James J. Scott

In the fall of 1976 the author started test work with Friction Rock Stabilizers in uranium mines of the West, principally in the Ambrosia Lake and Churchrock districts of New Mexico. Tests were also conducted in other uranium mines in the Rocky Mountains area. These mines are plagues with problems in ground control due to the weak formations in which mineralization occurs, mudstones, siltstones, weak sand, etc. For this reason, it is extremely difficult to obtain good anchorage for long periods of time with conventional mechanical roof bolts. Resin bolts give good anchorage but are expensive and, because of hole erosion and difficulties in installation due to inadequate equipment for mixing the resin and placing the rebar, they are not widely used. Field testing was also carried out in trona, limestones and hard and soft shale formations. The mechanism of the Friction Rock Stabi1izer support is discussed and pull test data presented for various rock types.

Jan 1, 1977