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By J. W. Walkiewicz

The U.S. Bureau of Mines has conducted studies using microwave energy to stress-crack iron ores. In a microwave chamber which simulates a continuous throughput operation, the Bond grindability of a taconite sample was improved by 13 pct at a bulk temperature of 197? C. To further improve the economics of microwave fracturing, higher powers up to 16 kW were used to rapidly heat samples to relatively low temperatures in a continuous belt-fed applicator. A significant enhancement of grindability was obtained with a minus 1.9-cm taconite rod mill feed. At a sample temperature of 130? C, the grindability was improved a maximum of 26.1 pct over the non-microwaved sample.

Jan 1, 1993

By D. K. Sengupta

Increased recycling of waste paper has been emphasized in recent years in both the USA and Canada for environmental and economic reasons. Removal of ink particles from the waste paper pulp is therefore necessary. One of the most promising methods for ink removal is froth flotation. Our study investigated the feasibility of a simplified flotation scheme which showed that about 90-92% ink removal can be achieved while 95-97% ink removal is achievable if a hydrophobic polymer is used ahead of flotation. The clean paper pulp recovery was over 90%. The effects of pulping pH, flotation pH, and concentrations of flotation and polymeric reagents are discussed in the paper.

Jan 1, 1993

By E. J. Donovan, O&apos

The use of Dynamic Analysis techniques in the design of conveyor systems is extremely limited. The most frequent use of the technique is in large and expensive systems where the emphasis is on insurance against failure caused by catastrophic tension waves. This paper sets out to illustrate a much wider range of applications where dynamic analysis has been successfully employed. The examples chosen deal with identification and correction of dynamic low tension problems, the variability in take-up movement as other system parameters change, the requirement for proper tuning of starting controls and finally the absolute necessity for a complete understanding of the entire system when specifying brakes for critical applications. The intent of the paper is to get designers to view a conveyor as a system of interacting flexible components rather than as a single rigid body.

Jan 1, 1993

By J. F. Childs

Montana consists of an Archean crystalline basement overlain by Proterozoic through Cenozoic sedimentary rocks. Igneous rocks range in age from Archean to Pleistocene; the most voluminous magmatism and volcanism occurred during the Late Cretaceous and early Tertiary. The state can be divided into three tectonic provinces whose deformational styles are a function of different bedrock responses to Late Cretaceous-early Eocene compressional tectonism. Several long-lived structural zones have been periodically reactivated since the Precambrian, and were the sites of recurrent magmatism. Regional gold distributions are strongly influenced by the tectonic provinces and structural zones. Lode gold systems in Montana occur in diverse geologic settings resulting from a complex interaction between structure, magmatism, and sedimentary depositional processes. Reserves or resources are known for 19 significant lode gold systems, and additional unannounced discoveries have been made recently. Mineralization ranges in age from Archean to Tertiary. The influence of long-lived structures is apparent at both the regional and deposit scale, and in some cases multiple mineralizing events have been superimposed upon one another. Most Montana gold systems have a direct spatial and genetic association with Late Cretaceous through Oligocene igneous rocks. However, the importance of sedimentary rocks and associated depositional processes should not be underestimated.

Jan 1, 1993

By A. G. Fonseca

The effects of coal cleaning, coal combustion and flue gas particulate removal systems on the partitioning of 12 trace elements were investigated. This study was prepared to help document the fate of trace elements in modern coal preparation plants and coal-fired utility boilers. The coal cleaning data were obtained from several coal preparation plant operations. The CONSOL 1. 5 MM Btu/hr pilot combustion and electrostatic precipitator (particulate removal system) test facility was used to develop the combustion systems data. A comparison with the very limited amount of published data from utility boilers is presented.

Jan 1, 1993

By M. D. Attfield

During 1992 a number of papers were published on aspects of respiratory disease in US underground coal miners. These included reports on trends in prevalence of coal workers' pneumoconiosis, the risks of developing coal workers' pneumoconiosis in relation to dust exposure, and the relationship between lung disease other than pneumoconiosis and dust exposure. The intent of this paper is to provide a summary of the essential findings from these investigations. PREVALENCE AND INCIDENCE OF COAL WORKERS' PNEUMOCONIOSIS Coal workers' pneumoconiosis (CWP) is usually detected in living miners through use of the chest x-ray. Deposits of dust in the lung, and the fibrotic tissue reactions to the dust, are manifested on the x-ray as small and large opacities. These abnormalities are quantified into degrees of severity using a standardized classification scheme (the International Classification of Radiographs of the Pneumoconioses of the International Labour Office). For small opacities, the scheme provides for a four-point scale of abnormality (0, 1, 2, 3), reflecting increasing profusion of the opacities on the x-ray. In this report, category 1 or greater small rounded opacities (CWP 1+) represents the earlier radiographic stages of pneumoconiosis. Large opacities, indicate the later and often disabling stage of pneumoconiosis, usually referred to as progressive massive fibrosis (PMF). Information collected in a national surveillance program for underground coal miners (the Coalworkers' X-ray Surveillance Program (CWXSP)) and a large epidemiologic study (National Study of Coalworkers' Pneumoconiosis (NSCWP)) provide a means to assess trends in CWP prevalence over the years following the reduction in dust levels mandated by the 1969 Federal Coal Mine Health and Safety Act (FCMHSA). These programs are operated by the National Institute for Occupational Safety and Health (NIOSH), and are described in detail in Attfield and Althouse (1992) and Attfield and Castellan (1992). Both studies were divided administratively into distinct time periods, and the results shown here reflect that division. Figure 1 shows the prevalence of CWP 1+ as determined from data from the CWXSP, plotted by time period and years in mining. There is evidence of a temporal reduction in prevalence. (The lack of an obvious decline in the early 1970s may be an artifact arising from use of different versions of the standard classification.) Figure 2 provides information in the same format for PMF, and shows a similar trend [ ]

Jan 1, 1993

By N. D. Jagger

In order to maximize the benefits obtained from flocculating agents when used as settling aids in high rate and conventional thickeners, it is often necessary to dilute the thickener feed prior to flocculant addition. In some cases, no flocculation at all is possible unless dilution water is used. The most common method of diluting thickener feed has been to recirculate some of the thickener overflow by means of a centrifugal pumping system. This represents a significant capital and operating cost. Supaflo Technologies of Australia has developed and patented an internal recirculation method known as Auto Dilution (or "Autodil") which is based on the principle that an hydraulic head differential exists between the inside and outside of the feedwell because of the higher S. G. of the pulp inside the feedwell, By installing non-return ports in the feedwell wall at the appropriate level, supernatant solution flows into the feedwell at a calculated rate and dilutes the feed without any need for external recirculation of overflow.

Jan 1, 1993

By R. W. Waytulonis

This paper is an update of the activities of the U.S. Bureau of Mines, other government agencies, and the automotive and truck industry concerning diesel emission control. Enacted and proposed regulations from the U.S. Mine Safety and Health Administration (MSHA) and developments in diesel emission control are presented in terms of their impact on underground coal, metal, and nonmetal mines. Mine air quality regulations proposed by MSHA may require the underground mining industry to comply with new standards. Some mines may be required to take additional actions to meet new diesel particulate and lower nitrogen dioxide exposure standards; however, the mining industry is in a position to benefit from emission controls developed for the on-highway diesel engine market. The U.S. Environmental Protection Agency (EPA) has enacted regulations to reduce emissions from on-highway diesel trucks and buses. Engine manufacturers have responded by developing cleaner burning engines. Fuel producers have responded by providing cleaner burning reformulated diesel fuel, and exhaust aftertreatment devices have been developed to provide additional emissions reductions. Bureau research and development projects seek to determine the advantages of using modern engines and fuels, and to evaluate the efficacy of new exhaust control devices on mining machines. It appears that the diesel engine will continue to be a practical power source for use in confined environments because no other available power source is as mobile and efficient.

Jan 1, 1993

The Bureau of Mines has studied 260 underground coal mine fires which occurred from 1970 through 1989. Every fire had the capacity to be hazardous to life and property, however upon closer examination some were found to be inherently more dangerous than others. Our research involved reviewing and recording specific information contained in published Mine Safety and Health Administration fire accident reports. The objective was to determine if degrees of hazard relative to fire source or location could be construed from information contained in the reports. We specifically looked at the propensity for fires to cause injuries and fatalities as well as the need to seal the area in order to extinguish the fire. Relative to all underground locations, this review found that fires occurring in main haulage-ways were most likely to cause injuries and fatalities as well as require sealing of at least the immediate area to extinguish.

Jan 1, 1993

By T. M. Yegulalp

A short review of the current practice and recent developments is followed by a description of a newly developed approach for the solution of the optimum ultimate pit limit problem. The new approach utilizes the network modeling of the problem for solution by maximum flow algorithm. The latest developments in the implementation of maximum flow algorithm present significant time and memory savings as compared to initial development due to Ford and Fulkerson. Results of a series of computational tests are presented to demonstrate how this approach performs as compared to the well-known Lerchs Grossman algorithm. It is also shown that the solution by the new method will automatically include several optimal solutions based on predetermined number of benches to be included in the analysis.

Jan 1, 1993

By Tevfik Güyagüler

Airborne dust is one of the important environmental problems in mines. Besides conventional dust control methods, recently, extensive studies have been carried out on the elimination of dust before it has actually been formed. Determining to what extend rock characteristics influence the amount of dust produced during different mining activities are considered as a guide for this purpose. The factors analyzed in this study were main mechanical, physical properties and petrographical constituents, namely free and combined silica. In the study regression analysis techniques were applied to investigate the effectiveness of aforementioned factors. INTRODUCTION Nearly every aspect of mining activity contributes to the air pollution caused by dust. Therefore the harmfull effect of airborne dust has been investigated many years and limit dust concentration levels were determined for various types of mine dust. To keep the dust level below limit value different dust control techniques have been applied in mines. So far, the well known techniques regarding dust control focuses on reducing the amount of airborne dust. However, recently various studies have been carried out to avoid the dust before it has actually been formed (Bhaskar and Gong, 1991). In this respect, influence of rock characteristics on dust formation is regarded as a guide for this purpose. The present contribution describes such a study in which the drilling operation is considered as the source of the dust. In this study drilling and dust sampling process were undertaken in a model gallery that simulates an underground working. The mechanical and physical properties of the rock samples were measured in rock mechanics and ore dressing laboratories. Quartz and combined silica contents of the rock samples, on the other hand, were determined in the laboratories of geological engineenring department. Rock samples used in the research were different types of coal measure rocks, namely, sandstone, shale and conglomerate. The rock characteristics studied in this work are brittleness, toughness, rock strength, hardness and hardgrove index as inherent properties; free silica, and total silica contents of rock samples as petrographical constituents. Although there have been various studies to determine the effect of rock characteristics on the dust formation, still the type and extend of effectiveness have not been understood clearly. LITERATURE REVIEW Most of the studies investigating the effect of rock properties on dust formation concluded that they are effective. In such an investigation, it has been found that inherent rock properties influence dust formation (Das, 1973). In the another study, dustiness of the air was considered as a function of the composition, hardness and moisture content (Panov, 1967). It was also accepted that in a drilling operation more fine dust is produced if the rock to be drilled is hard (Skochinsky and Kamarov, 1969). In some other investigations dust production were considered as a function of hardgrove index (Moore and Bise, 1984) or formulated in terms of brittleness, toughness and hardness (Güyagüler, 1991). The effect of the petrographical properties of coal or rock on dust formation characteristics have also been studied (Baafi, 1979) (Panov, 1967). Because of its importance, various researches were conducted the study to find out the effect of free and combined silica content of dust on dust formation. In one of the study, the relationship between quartz in the coal seam and quartz in the airborne coal dust was investigated (Ramani et al, 1988).

Jan 1, 1993

By M. S. Klima

A 25-mm diameter dense-medium cyclone was tested to investigate the effects of geometry and operating conditions on cyclone performance when processing -150 I'm coal. The emphasis was on examining those variables (e.g., flow rate and inlet velocity) which impact the separation kinetics (specifically the number of g's and the mean retention time) and the occurrence of apparent bypass. Apparent bypass, indicated by partition curve "tails", results from the short circuiting of the feed coal to one or both of the product streams and represents a loss and/or contamination of the clean coal. This paper presents the results for this series of tests.

Jan 1, 1993

By Byron Belew, Juris R. Harlamovs, D. B. Dreisinger, John L. Watson, G. A. Kordosky, Thomas O. O’Keefe

Unwanted impurities, present in raw materials, are often coextracted along with desired constituents during leaching. Due to its abundance and ease of extraction, the presence of ferric iron in leach solutions, solvent extraction circuits, and subsequently in electrowinning circuits, has always been a problem. In the case of zinc hydrometallurgical processing, iron is frequently an impurity in leach solutions. Purification of such solutions by solvent extraction, using di (2-ethylhexyl) phosphoric acid (D2EHPA) in a kerosene diluent, results in ferric ions being readily extracted along with zinc into the organic phase. Ferric iron has proven difficult to strip from the organic phase, but it is known that ferrous iron may be easily stripped from D2EHPA, and hence a process to effect reduction of iron present in the organic would have great potential. This research investigated a process to directly reduce ferric to ferrous iron in the organic phase, and to strip the ferrous iron using a dilute acid solution. The process utilized metallic zinc as the reductant and a low concentration sulfuric acid stripping solution. The results of the laboratory tests illustrated that iron could be readily removed from the organic phase by simultaneous direct reduction and acid stripping. The reductive stripping process was subsequently utilized in industry at the laboratory and pilot plant levels. The results of the industrial tests were encouraging and demonstrated the potential of this novel concept.

Jan 1, 1993

By Lee W. Saperstein

The Research Council of SME, at its Annual Meeting in Reno, NR, in February 1993, held a Research Forum on Technology for the Future. The Forum's purpose was to find out from the members, particularly those from industry, their opinions on research needed in the mineral industries. Panelists were selected for their breadth of knowledge and connections. Many panelists, in turn, solicited opinions from additional contacts. A similar effort is underway with mineral-oriented schools. A parallel mission has been undertaken by the American Mining Congress (AMC) through its Committee on Technology. In particular, AMC is concerned that the needs of industry be transmitted in a timely way to federal agencies, especially the US Bureau of Mines. This article reports to the SME membership the principal findings of the Research Forum. The article is derived from a full report that is available from SME. Many of the calls for research made during the Forum can be clustered into five broad categories. These categories are discussed in the following sections of this article. However, since the time of the Forum, many reviewers of the full report have noticed that fundamental research was not given much emphasis. The Research Council points out that the Forum was organized around industrial needs. There is a call to the academic and research community to organize a similar Forum. The Council emphasizes that this is not the last word on research needs and that the membership is urged to continue to give ideas and opinions to the SME Research Council. There will be an opportunity at its next meeting during the SME Annual Meeting in Albuquerque, NM, Feb. 22, 1994, for open discussion of this report. Because the opinions were intentionally confined to representatives from industry, the problems portrayed and the solutions sought are from the vantage of an operator. It comes as no surprise that many of the espoused research desiderata seek more efficient or cost-effective outcomes for the various mining activities discussed. The order of the Forum was a straightforward set of mining activities: exploration, evaluation, mining and processing.

Jan 1, 1993

By R. Gong, R. Bhaskar

A coal mine study was conducted to evaluate the effectiveness of a compressed-air, foam spray system installed under a continuous miner boom and directed to cover the pan and the gathering arm. The study's objectives were to evaluate the foam, underboom sprays' effect on: • the respirable dust concentration in the ambient air, and • the quartz concentration in the airborne, respirable dust. The foam generation and delivery system's engineering design is described in the paper, followed by descriptions of the mine and the dust sampling strategy. The data were analyzed to study the foam's effects on respirable dust and quartz concentrations at the continuous miner cab, the face return and the intake. The data indicate reductions in the dust's quartz content, ranging from 19.7% to 64.6%, in eight of 11 comparisons of the foam vs. no foam cuts. In addition, airborne intake dust reductions were observed in eight of 11 comparisons.

Jan 1, 1993

By Lynn E. Bowman

Efficient filtration of fine kaolin particles plays a crucial role in the processing of raw kaolin to a marketable product. Filtration can often be the rate-controlling step of the whole process. Consequently, plant production depends on the rates being achieved in filtration. To alleviate the bottleneck in production, Nalco Chemical Co. initiated a reagent development program to chemically enhance the performance of the filtration units. Filter aids of different classes were assembled and evaluated in bench simulations. These included reagents whose primary mode of functionality were coagulation, flocculation, thickening and combinations of each. This article discusses the development and application of a new reagent that improves the filter production rate with minimal impact on filter cake percent solids. Plant data indicate that this reagent can increase production rates by as much as 35% on clays of varying particle size, as well as clays that are calcined. The reagent's impact on solids content, re-slurrying characteristics, Brookfield and Hercules viscosity and drying is within the standards set by plants that evaluated and now use this product.

Jan 1, 1993

By Charles T. Staniek

Following a dragline relocation at Agrico's Fort Green phosphate mine in 1986, the recovery plant experienced a significant decrease in flotation performance. Through weeks of trial and error testing, we discovered we could restore recoveries by conditioning feed at pH's higher than we had used historically. The higher pH's essentially increased flotation cell kinetics, although we still do not understand the exact mechanism at work. Armed with new-found appreciation of pH modification, we initiated a program to determine the optimum modifier for us, from both a performance and environmental perspective. Environmental considerations were important because ammonia, the standard industry modifier, is a plant nutrient and higher usage rates could affect the quality, of our recycle process water. This paper describes the research and development work spanning a 3 year period that culminated in making a major change in our reagent suite when we replaced ammonia with soda ash on a permanent full-time basis.

Jan 1, 1993

By S. N. McIntosh

Column bioleaching was evaluated by the U.S. Bureau of Mines as a means of recovering manganese from a low-grade ore from the Three Kids deposit in Southern Nevada. Manganese was solubilized from the ore using indigenous heterotrophic microorganisms. Diluted molasses medium was provided as nutrient for the microorganisms. The medium was recirculated through the ore bed until the sugars were spent. Two methods were evaluated to recover manganese from the sugar depleted bioleaching solution: (1) adsorption with a weak cation exchange resin followed by stripping and precipitation techniques, and (2) direct precipitation of the manganese using ammonium carbonate. Both methods removed up to 95 pct of the solubilized manganese from the medium as a carbonate salt. After manganese removal, the medium was replenished with fresh molasses and recycled back through the column. More manganese was effectively leached. This process of manganese solubilization and recovery followed by replenishment and recycling of the medium was repeated until 98 pct manganese was extracted from the ore.

Jan 1, 1993

By R. G. Johnston

Minerals have many uses in paint systems. These roles include use as primary and extender pigments, sheen control, film durability enhancement, and rheology control. These and other uses of minerals in paints, and the effects of mineral quality variations on coatings performance are discussed. As coatings performance requirements become more demanding, tighter consistency of important mineral properties, such as particle size distribution and purity, is becoming increasingly vital. Future directions of mineral use to meet projected environmental restrictions and performance demands on coatings, including the use of advanced minerals technologies, are examined.

Jan 1, 1993

By H. E. Wyslouzil

The highly competitive nature of the international iron ore market has forced producers to improve the quality of their pellets. The demand for low acid pellets suitable for direct reduction has resulted in an increase in the number of plants utilizing reverse froth flotation for silica reduction. Column flotation is being favoured for this service due to the low capital and operating cost of the equipment, as well as improved metallurgical performance when compared to conventional flotation cells. This paper describes the benefits of column flotation and discusses some important aspects of circuit design.

Jan 1, 1993