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By R L. Mayville

The author explains why the strategic location and important limestone reserves at Chattanooga Quarry led to a decision to extend operating life by continued benching down to lower levels. He discusses the steps taken to accomplish this objective. These include relocation of the primary crusher from the second level to the fourth level, pre-testing of explosives designs and powder factors, control of a substantial water problem, and computer monitoring of stone production costs.

Jan 1, 1984

By James K. Gowans

Polaris Mine, a Cominco Ltd. property located on Little Cornwallis Island, Northwest Territories, Canada, (Lat. 75°30'), is the world's most northerly base metal mine. Polaris Mine, which commenced operations in late 1981, is characterized by its unique process barge. The lead/zinc concentrator, powerhouse, shops, offices, dry and warehouse have all been incorporated on a 400 ft. long by 100 ft wide by 65 ft high barge. This process barge was constructed in Southern Canada, at Trois Rivieres, Quebec, then towed 3500 miles into its final resting place on the high arctic. This paper describes the unique design of the barge concentrator and deals with the start-up and continuing operation of the Polaris Concentrator.

Jan 1, 1984

By R. E. Chaney

This report summarizes the research on the Strategic and Critical Materials Program tasks conducted at the Idaho National Engineering Laboratory (INEL) between Mdy 1983 and April 1984. The work is divided into two areas: 1. Production Technologies - Tasks directed at developing advanced extraction technologies ? Biologically-Assisted Minerals Processing ? Metal/Gas Reactions and Thermal Plasmas ? Dehydration of Aluminum Chloride Hexahydrate. 2. Conservation/Substitution Technologies - Tasks directed toward establishing the technical processing base which will permit the use of advanced materials ? Joining of Rapidly Solidified Alloys (RSA) ? Joining of Silicon Nitride-Based Ceramics ? Nondestructive Evaluation of Ceramic and RSA Joints and Materials.

Jan 1, 1984

By Larry G. Stolarczyk

This report deals with information regarding a new Medium Frequency (MF) Wireless Communication System for underground mines. This new telecommunication system works on low loss electromagnetic wave propagation modes which allow it to provide quality radio communications almost anywhere in a mine. Tests show the MF system can provide improved safety and managerial control, increased productivity, better organizational team-work and reduced maintenance cost; furthermore, MF's unique design allows for easy installation at a minimum cost. This paper covers the following: 1) MF design plan, 2) Overview of mine radio communications systems, 3) Preparations needed for designing an MF system, 4) MF equipment, 5) MF installation, 6) MF design considerations, 7) MF design specifications, and 8) Recommendations dealing with MF system. Experiments in four mines are illustrated to demonstrate the success and viability of the MF system. The mines range from small (500 tons/day) to large (67,000 tons/day) capacity and represent several different mining methods. The MF Wireless Communication System represents an advancement in mining communication and the groundwork for other advanced mine systems.

Jan 1, 1984

The dust exposure of the longwall shearer operator is usually determined by his position relative to the cutting drums. The dust generated during cutting may travel up-wind, against the primary airflow, and be carried out into the walkway where it can contaminate the intake air for as much as 10 feet outby the shearer operator's controls. Thus, both head and tail drum operators are exposed to un-acceptably high levels of air-borne respirable dust. One Solution The latest generation of long-wall shearers has features that make the use of radio remote or umbilical (hard wire) remote control relatively easy to implement. Remote control can enable shearer operators to control machines from positions that are less dusty than normal control stations. With either type, the head-drum operator can now control the shearer from a position up to 20 feet on the intake-air side of the shearer, while the tail-drum operator's station is now located across from the head drum.

Jan 1, 1984

By G. H. K. Pearse

Sulphur is derived from both 'voluntary' and 'involuntary' production. The former category includes sulphur obtained from elemental sulphur deposits and from pyrite and gypsumanhydrite deposits. Sulphur in the latter category is produced by pollution abatement at fossil Juel plants and from treatment of metallic sulphides. Canada is the world's largest sulphur exporter and third largest producer. Main resources of Canadian sulphur are sulphurous fossil fuels, metallic sulphides and native sulphur. Only the first two sources have produced sulphur in Canada 10 date; the first source accounts for over 85% of total Canadian production. Future sulphur sources will be derived increasingly through pollution abatement and decreasingly through voluntary production.

Jan 1, 1984

By BARRY BANNATYNE

Ombrotrophic Sphagnum peat bogs have a characteristic signature on both colour injrared film (750 nm to 3,000 nm response) and Daedalus injrared line-scanner images (thermal infrared 3 to 5 microns and 8 to 14 microns response). This remote sensing method was used to survey bogs in southeast Manitoba to delineate targets for surface exploration. Target bogs all have a surface growth of Sphagnum; underlying dead Sphagnum ranges from 1 to 6 m thick. Large Sphagnum reserves exist in the Caribou cluster of bogs, and in /979 a bog first identified by infrared sensing was brought into production.

Jan 1, 1984

By JOHN DUNFIELD

Good quality sphagnum peat bogs occur across Canada in areas of ample rainfall and cool, temperate climates. Early peat production techniques were restricted primarily to hand digging blocks of peat and piling them up to be dried by sun and wind. Suburban de velopment in the 1950s and the concomitant spread of home gardening triggered a dramatic growth in peat demand; labour costs rose in the same period. Peat production techniques had to alter accordingly. The three mechanical inno vations attempted were hydraulic mining, mechanical block digging and vacuum harvesting. Of these, the last method pro ved the most successful in Canada and is used to harvest 80% of Canadian peat production. Escalating transportation costs are the most important feature affecting future development of the Canadian peat industry.

Jan 1, 1984

By J. J. . BRUMMER

Kimber/ires are intrusive rocks whose main constituenr, olivine, has been altered entirely or almosr enrirely ro serpentine. Texture usually is porphyritic, superimposed upon a brecciared one. Diamonds are found only in kimberlites, and are present in economic quantities only in about I% of all kimberlites known. Two glacial drift diamonds, one near Peterborough and one near Timmins, both in Ontario, have been found in Canada and are believed to have been eroded and rransporred from their original source by glaciers. Many more glacial drift diamonds have been found sourh of rhe Great Lakes in the United States, parricularly in Indiana, Illinois and Wisconsin . There are nine known kimberlire occurrences in Canada. Diamonds have been located in rwo of rhem: on lie Bizard near Monrreal and on Somerset Island in the Northwesr Terrirories. The lie Bizard occurrence comprises three kimberlire diarremes; samples of rhe largest one revealed JO riny diamonds totalling 0.0537 carars. The Somerset Island kimberlites are rhe mosr significant yet discovered in Canada. Ar leasr 19 separare kimberlite occurrences are known on rhe island. Testing by Diapros Canada Lim ired, however, revealed only "a few small diamonds". fr is likely rhar, wirh enough time and funds, additional kimberlires, possibly bearing economic quanriries of diamonds, will be found in Canada.

Jan 1, 1984

By D. Racicot, T. Hanel, E. H. Chown

Over thirty plutons in the Chibougamau-Desmaraisville belt were examined briefly in the field and sampled, in addition to the few masses that have been studied in detail. The survey indicates that the intrusions may be conveniently grouped in four main categories, based on their time of intrusion. These are; remobilized basement domes, pre-kinematic intrusions, syn-kinematic intrusions and postkinematic intrusions. Basement domes, as exemplified by the Lappa rent Massif, are composed of migmatized tonalite-diorite gneiss that has undergone at least two periods of mafic dyke intrusion and at least three major deformational periods. The rise of the basement domes was accompanied by extensive mylonitization and the intrusion of syn-tectonic plutons. Pre-kinematic plutons, such the Chibougamau pluton, are diori te-tonalite in composition, and were intruded into the supracrustal pile and partly eroded before the main deformation of the belt. Syn-kinematic plutons occur principally as marginal intrusions bordering the belt (Barlow), or as discrete intrusions along structural highs (La Dauversiere), and are either hornblende monzodiorite or tonalite in composition. Post-kinematic plutons, such as Muscocho, are principally granodiorite and often porphyritic intrusions locally deforming the enclosing rocks. The close relationship between mineralization and high-level intrusions such as the pre-kinematic and some of the post-kinematic plutons is discussed.

Jan 1, 1984

By E. H. Chown

Scattered outliers of the Chibougamau Formation and the more continuous Mistassini and Otish Groups lie unconformably on an Archean basement abutting the Grenville Front. All the Aphebian rocks are deformed and offset by faulting related to the Front. The older Chibougamau Formation is exclusively elastic in origin, whereas the two later, time-equivalent groups include carbonatedominated (Mistassini) and elastic (Otish) sequences. Known syngenetic mineralization within these formations is limited to various radioactive showings in the Mistassini and Otish elastics, and the iron formations of the upper Mistassini Group. Three distinct types of epigenetic mineralization occur within the sedimentary rocks; pitchblende fracture fillings in all types of rocks in the Otish Group, widespread Mississippi-Valley type galenasphalerite showings at certain levels in the Mistassini Group, and chalcopyrite-pyrite bearing veins in or near argillaceous horizons of the Mistassini Group and Chibougamau Formation. The Otish elastic basin is part of a large area of the central Ungava peninsula which contains a variety of radioactive showings, the most promising being of the unconformity type, The final control for many individual showings appears to be local physico-chemical changes within faults and fracture zones. The overall structural control is in part supplied by the faulting episode related to the Grenville Front, which in turn limits the mineralization to the depth zone appropriate for open fracturing. The lead-zinc showings exhibit a strong stratigraphic control as well as close ties to secondary porosity developed by f aulting. The ore solutions were probably derived during the low grade metamorphism of the formations. Chalcopyrite- pyrite veins have provi ded the only mine production (Icon Mine) to date. They appear later than the low-grade metamorphic fluid circulation, and deposition is related to favourable structures and stratigraphy. The veins are clearly related to major faults. Thus, whereas stratigraphic settings appropriate to individual types of deposits are important, an overall structural setting may be demonstrated for a wide range of mineralizations. Detailed structural interpretations of individual showings may be the most fruitful pursuit in developing a concrete prospecting model.

Jan 1, 1984

By William G. Doepken

With most of the mining industry emerging from the deepest business recession in 50 years, primary attention must be given to surviving in a business climate where dominant foreign competition, depressed prices, and potential overcapacity hang heavy over much of the industry. While already shackled with regulatory constraints, restrictive work rules, and high labor costs, mine operators are faced with the difficult task of reducing costs and improving productivity while operating at less than full capacity. To counter these nearly over-whelming factors, the mining industry must continue at the national level to seek regulatory relief and a rational policy toward foreign competition from government-controlled mines. In addition, dialogue with labor organizations must continue to minimize the impact of labor costs, cost escalators, and antiquated work practices. Although national and international actions have a tremendous impact on the future of domestic mining operations, local actions by mine operators to dramatically improve mining productivity will strengthen the industry's competitive stance. Before any substantial progress can be made, however, mine operators must recognize and define areas that depress productivity and establish goals and measures for improvement. Once problem areas are defined, a combination of technological and motivational concepts can be applied to improve productivity. Timing of Improvements While there is an immediate need for productivity improvements, only certain concepts offer near-term improvement potential while others must, of necessity, fit into a mid-range or long-range time frame. Near-term solutions (immediate to one year) likely will involve motivational concepts - work incentives and training - coupled with available technological concepts that require little capitalized development or site testing. Mid-range solutions (one to three years), by contrast, will include technological improvements in mining equipment, techniques, and systems automation. These concepts require a longer period of capitalized development and site testing before use. Long-range solutions (three years or more), which include adoption of new mining methods and computerized control systems, will appear only after prolonged research and capitalized development programs. Motivational Improvements Developing motivational con-

Jan 11, 1983

By Wallace W. Roepke, James C. Church

Introduction The history of mining machine development has been and is one of "bigger is better." While this may not always be true, it is currently the only approach open to machine designers without specific in situ cutting force information. The US Bureau of Mines has tried to modify this approach by supporting research, both in the laboratory and in field tests, that demonstrates that bigger is only better if the equipment is used correctly. In-house research has shown conclusively that deeper cutting reduces both dust and energy (Roepke, Lindroth, and Myren, 1976). This approach has been applied to a large Lee-Norse (LN456) continuous mining machine, which confirmed that slow deep cutting is beneficial and does not have a negative effect on production (Black and Rounds, 1977; Black et al., 1978). Specific in situ engineering data needed on coal cutting forces have not, however, been obtained by field tests with the LN456. Although the machine was instrumented to obtain data on one seam, it would be impractical to move the machine from mine to mine. It became apparent that a portable, easy to use device was needed for obtaining coal cutting forces in situ. Such a device could provide the engineering data needed by manufacturers, the site-specific cutting information needed by operators, and a field research tool to establish correlation with laboratory cutting tests. Design and Development According to a set of design guidelines established by the Bureau, the proposed device should be able to measure cutting forces directly with standard coal cutting bits, be transportable by two miners, and be self-contained. These guidelines were given to Ingersoll-Rand Research Inc. (IRRI). The contractor performed a rigorous review of 16 existing in situ portable tester designs, none of which could use a standard coal cutting bit to measure cutting force directly. These included a wide range of devices, all of which are discussed in the final report (Banerjee and Wisner, 1982). A series of design tradeoffs were established to satisfy initial design guidelines. The final deci¬sion was heavily weighted by an industry survey to determine the preferred concept from four man¬ufacturers and four operators. To assure ease of use with maximum information, all respondents wanted a linear cutting device that could work in seams down to 1 m (40 in.). The final design choice was between a linear and a rotary tester. The rotary tester would cut on an arc in the same manner as a rotary drum machine. It had several faults, however, that could not be resolved within the scope of this contract. The worst was related to arc cutting (Roepke, Lindroth, and Myren, 1976). Since any bit cutting on arc enters the coal at zero depth, goes to maximum depth only at the horizontal centerline, and exits at zero, maximum cutting force is obtained only at the instant the bit crosses the horizontal centerline. This centerline peak response would require that many replications be made with an arc-type cutter to get reliable force information. The arc-type tester would require extensive face preparation to establish the cutting path and extensive wasted clearing cuts to advance the device for additional layers of cuts. The linear tester could be mounted directly on any face or rib with only minor preparation. By its nature, a linear cut at a constant depth provides multiple peak force data over the length of the cut, thus reducing the required number of replications. The final review of these two major design concepts plus indus-

Jan 9, 1983

By Calvert D. Iles

Open-pit mines in the US and throughout the world are typically characterized by increasing operating costs and decreasing ore grades. Thus, companies must continue to improve their use of human and technological resources to remain competitive in the marketplace. Duval Corp. has historically been very sensitive to mining costs, in part because of relatively low grade copper-molybdenum ore bodies. These concerns have resulted in three haulage system generations at the 218 kt/d (240,000 stpd) Sierrita-Esperanza open-pit mine south of Tucson, AZ. Each generation has exceeded the performance of the one replaced. The latest system of portable crushers and conveyors reduces hauling costs by combining both hardware and technique. Savings are achieved not only bysubstituting conveyors for haul trucks, but also by permitting the crusher-convey or system to closely follow mining as the pit deepens and/or mining areas change location. The Duval system is capable of easy and inexpensive relocation in varying site configurations in relatively short time periods. Its implementation in active mining areas results in minimum disruption to both the mine operation and mine design. This haulage concept allows the mining engineer maximum freedom to design an open pit for profit rather than for equipment. Maximum savings with a portable system are achieved by minimizing truck haulage costs. At Sierrita, for example, the yearly estimated operating cost savings for each thousand feet of +10% truck ramp replaced by conveyors is about $1 million per portable crusher. A savings of $30 million could be achieved fora three-portable system overa 10 year period simply by reducing the average truck Iiftto the crusher by 30 m (100 ft), There is also the added capital expense of buying trucks to cover the additional 30 m (100 ft) of lift. Relocation costs are an important consideration in a portable system. Direct costs can become a significant operating expense if frequent relocations are necessary to take full advantage of potential haulage cost savings. A site preparation cost of $375,000, for example, would add an additional operating cost of 2.8¢/t(2.5¢/st) for a system handling 13.6 Mt/a (15 million stpy), assuming one move a year, In addition to the direct cost of site preparation, such as installation of retaining walls, apron feeder slots, and equipment pads, there is the cost of site renovation after abandonment. Indirect relocation costs, while less tangible and more dependent on specific mine design and scheduling, can be of significance. A slowdown in the mining rate or a less efficient mining plan can result from a site not being immediately available for mining after abandonment. Conversely, mining in narrow areas can be adversely affected if two or three month lead times are required for site preparation.

Jan 4, 1983

By Kerry M. Masson

Perhaps the hottest item on the agendas of most state legislators this year is the state budget. The main question: Where will all the dollars come from to finance health care programs, state jobs, unemployment compensation programs, and on and on? This is especially so since people are out of work, business bankruptcies are up, sales are down, and incoming revenues from some sources have decreased or dried up. A sure bet is that state taxes will be increased in some form or another. The mining industry could face increased income taxes, property taxes, severance taxes, or even a host of new taxes (if the state does not already have them) like a gross receipts tax, investment tax, or tax on revenues made outside state borders. That's bad news for an already depressed industry, even though increased taxes may be the least of the industry's worries in the current economic climate. While reopening existing mines and developing most new mineral projects depends primarily on higher commodity prices, new taxes still could pose long term concerns for mine project development. Just how mineral tax law impacts a project is not easy to figure. It involves a complex set of calculations based on interpretations of numerous federal, state, and local tax laws that change almost annually. At best, projections of tax effects for the life of a mine are educated guesses. At the same time, projections are necessary to evaluate the economic feasibility of a mineral project. At a recent Technology Transfer Seminar, the US Bureau of Mines introduced a computer software program designed to evaluate the feasibility of a mineral project and to determine the tax effects on the project's discounted cash flow rate of return (DCFROR). The program, called MINSIM, began in 1967 as a 200-statement FORTRAN II program for evaluating a hypothetical large-scale open-pit gold mine. This single-commodity oriented program employed discrete simulation techniques and a continuous DCFROR was used to measure the effect of changes in revenues and costs. Over the past 15 years, MINSIM has developed into a program 70 to 100 times larger than the original. Basically, it will analyze costs and parameters specific to an identified deposit, then determine the DCFROR. Or by using a specified DCFROR, it will determine the primary commodity price required to attain that specified rate of return. MINSIM, which is explained in detail in this article, is available from the Division of Minerals Availability, USBM free of charge. Written in FORTRAN IV, it comes on punch cards or magnetic tape and is compatible with most major computer systems. The MINSIM Program The main objective of any freeenterprise mining venture is to make a profit. To determine profitability of a given project, alternate methods of operating and financing must be evaluated. That is the purpose of MINSIM. While there are a number of methods of evaluating the economic profitability of a mining project, MINSIM uses the Discounted Cash Flow Rate of Return (DCFROR) method as its major criterion because DCFROR considers the time value of money and gives the truest measure of profitability. One disadvantage is that the calculations are deposit oriented. In other words, MINSIM analyzes only those costs and parameters specific to the deposit. It cannot be used to evaluate the overall corporate picture. The program is designed to simultaneously handle five different commodities and a leach operation for any type of mining project. For example, analysis of a coal project would include only one commodity-coal at the mine mouth. Analysis of a copper operation might include numerous commodities-from the raw material to the refined product. Input MINSIM considers capital investment-recoverable exploration, acquisition, and development costs; depreciable capital investments such as mine plant and equipment, mill plant and equipment, and infrastructure costs; all general and commodity specific operating costs; and the cost of alternate financing methods. The program has the capacity to incorporate different types of depletion allowances, numerous commodity-dependent severance taxes, variations of property taxes, and many methods for calculating state or provincial taxes. There are even many different ways to calculate federal and national taxes. The capacity to handle tax variations is generated from an internal subroutine in the program called the "open file." The user can reconstruct, customize, or evaluate any kind of tax desired. Outputs Given this kind of capacity for numerous input parameters, MINSIM is capable of the follow¬ing major outputs:

Jan 3, 1983

By Alex G. Sciulli

According to recent estimates, nearly 30 percent of the material from underground coal mining in the United States is rejected on the surface as waste. This accumulation of almost three billion tons of coarse and fine coal refuse is primarily from coal cleaning operations. The marketable coal is intermixed with sandstone, clays, shales, and carbonaceous rocks, which must be removed and disposed of in an acceptable manner. The disposal of mineral wastes is a major environmental concern. The most common types of environmental problems associated with coal refuse disposal are acid formation, erosion, and sediment control. Other areas of concern include air and water quality, combustion control, mine sealing, and reclamation. This paper focuses on these topics and attempts to outline special environmental features which can be incorporated into the design and construction of a coal refuse facility. Often these measures can minimize and possibly eliminate the potential environ- mental hazards. It is imperative, however, that these measures be adopted prior to and during construction, because of the relative ease and cost savings compared to post-construction implementation.

Jan 1, 1983

By Joseph A. Hrabik

The Bureau of Mines compared the feasibility of mining deep phosphate deposits by a borehole mining system with mining by proven conventional techniques. An economic comparison of the borehole mining system with conventional dragline and bucket wheel excavator mining systems was completed at various mining depths and production rates. Hypothetical phosphate deposits, with various overburden thicknesses and reserve tonnages, were defined. Geologic conditions necessary for the application of the borehole system were identified. Discounted cash flow analyses based on derived capital and operating costs were used to generate rates of return and product prices. Borehole mining was found to be more economical where overburden thickness was 150 ft or greater; however, at 50- and 100-ft thicknesses, conventional surface mining was more economical. Overburden thickness has a great effect on the economic feasiblity of the conventional mining systems but less effect on the economics of borehole mining. Economies of scale are only realized in conventional mining, since larger equipment is employed to achieve greater production, whereas increased production from borehole mining is achieved using additional equipment units. A comparison of the environmental effects of borehole and conventional surface mining systems showed that borehole mining is environmentally more desirable.

Jan 1, 1983

By G. R. Moulder

A device was developed that measures dynamic stress (ultrasonic energy) transfer through installed rock bolts, a measure that is directly proportional to the degree of grout bonding of the bolt to the mine roof structure and thus the ability of the bolt to bear static stress. The rock bolt bond tester (RBBT) is a hand-held portable device that shows three ranges of bolt bond condition; i.e., one-third (Bad bond), two-thirds (marginal), or fully bonded. These are shown respectively by a red, yellow, or green light that displays for 4 s. RBBT performance was verified with 2 1/2-to 8-ft bolts installed in various types 0f mine roof structures (sands tone, shale, and boney coal-mud), and 15 now being tested by the Bureau of Mines in mines across the United States. The unit is about the size of a five-battery flashlight and contains the transducer electronics, and battery pack. The RBBT is designed for extreme ease of operation, requiring only manual contact with the bolt and signal read-out. The batteries are rechargeable and the package is designed for durability in a mine environment.

Jan 1, 1983

By Donald E. Ranta

An ore zoning technique developed by Climax geologists during the past forty years has been used to contour drill-hole assay values on cross-sections for fourteen porphyry molybdenum deposits in western North America, including the Climax and Henderson orebodies. Detailed geological studies of these large, complex deposits are essential in determining ore controls, which are the factors most critical to the zoning of MoS2 assays and to conceptualizing geologic models. The technique provides a detailed representation of the size, shape, grade distribution, and geologic continuity of the individual deposits. It demands a disciplined approach and adheres to rigorous rules while maintaining flexibility for adaptation to widely varying geologic conditions. By defining the limits that guide and control manual, computer-assisted conventional, and geostatistical reserve estimates, it exerts a strong geologic influence on the estimation process. A combination of ore zoning and geostatistical analysis of molybdenum deposits produces a significantly more accurate, precise, and defendable geologic reserve estimate than other methods.

Jan 1, 1983

By P J. Minehan

The investigation of the potential of the Webb/Baynes block of the Buller coalfield for anode carbon manufacture has generated much information on the physical beneficiation characteristics of the Buller coals in general. A further 36 drill holes of the block in question and several other samples have been analysed by sink/float analysis, either at a single density or over a range of densities. In addition, many samples have been beneficiated on a laboratory shaking table or by flotation. The ash content can be reduced by a variable factor. The reduction factor of between two and four by sink/float analysts is understandably less for tabling where separation is not perfect. All Buller coals behave similarly, there being greater ash reduction factors for higher ash coals.

Jan 1, 1983