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By F. Milton Lewis, Roshan B. Bhappu

The methods for preparing operating cost estimates for a proposed mining venture are outlined. The procedures for estimating the direct and indirect operating cost for proposed mining and ore processing facilities are reviewed. Profits from the by-products are credits to the total operating cost, direct plus indirect, and are subtracted to obtain the total net operating cost. The non-operating costs which are a part of the total expenses are defined but are not considered in this manuscript. A method for developing the operating cost for a typical copper concentrator in the southwest is described in detail.

Jan 1, 1978

By F. J. Tuck

The Hayden mill of the Ray Mines Division, Kennecott Copper Corporation, is now equipped with two 9 by 12-ft. rod mills having a daily capacity of 6000 tons of coarse-crushing plant product from the mine. These two mills crush a ¾-in. product to approximately 19 per cent on 14 mesh, with only one pass through the mills. Each rod mill has taken the place of four sets of 42-in. Garfield rolls with their attendant screens, and is making a product for the fine-grinding department comparable to that formerly made by rolls in closed circuit with screens. The rod mills are lined with wave-type liners of white iron, varying in thickness from 2 to 3 in. The shell and end liners last approximately 600 to 700 days. Manganese-steel lifter bars, 3? in. thick, are used, spaced about 11 in. apart, and they give a life of 350 to 450 days. Fig. 1 shows the general design and thickness of the wave-type liners and lifter bars; 1½-in. liner bolts are used to fasten the lifter bars to the shell. The shell liners are held in place by the tapered lifter bars. A ¾-in. wood backing is used between the shell and the liners. The rod-mill scoop has removable manganese-steel lips, which last 250 to 300 days. The scoop proper has shown some wear in spots, and these spots have been protected by rubber bolted over them. Water and milk of lime are added to the elevator feeding the mill, but not enough water to cause a pounding of the rods against the shell. Roughly, the water added amounts to 25 to 33 per cent of the ore. Additional water is added to the mill discharge to facilitate distribution to the classifier bowls in the fine-grinding department. Rods are charged to the mill once every four days, the mill being down about 20 min. for this purpose. Other delays are negligible, and usually are due to a loose liner bolt or possibly power trouble. However, these occasions are extremely rare. In charging the mill, a crane is used

Jan 1, 1939

By F. J. Tuck

The Hayden mill of the Ray Mines Division, Kennecott Copper Corporation, is now equipped with two 9 by 12-ft. rod mills having a daily capacity of 6000 tons of coarse-crushing plant product from the mine. These two mills crush a ¾-in. product to approximately 19 per cent on 14 mesh, with only one pass through the mills. Each rod mill has taken the place of four sets of 42-in. Garfield rolls with their attendant screens, and is making a product for the fine-grinding department comparable to that formerly made by rolls in closed circuit with screens. The rod mills are lined with wave-type liners of white iron, varying in thickness from 2 to 3 in. The shell and end liners last approximately 600 to 700 days. Manganese-steel lifter bars, 3? in. thick, are used, spaced about 11 in. apart, and they give a life of 350 to 450 days. Fig. 1 shows the general design and thickness of the wave-type liners and lifter bars; 1½-in. liner bolts are used to fasten the lifter bars to the shell. The shell liners are held in place by the tapered lifter bars. A ¾-in. wood backing is used between the shell and the liners. The rod-mill scoop has removable manganese-steel lips, which last 250 to 300 days. The scoop proper has shown some wear in spots, and these spots have been protected by rubber bolted over them. Water and milk of lime are added to the elevator feeding the mill, but not enough water to cause a pounding of the rods against the shell. Roughly, the water added amounts to 25 to 33 per cent of the ore. Additional water is added to the mill discharge to facilitate distribution to the classifier bowls in the fine-grinding department. Rods are charged to the mill once every four days, the mill being down about 20 min. for this purpose. Other delays are negligible, and usually are due to a loose liner bolt or possibly power trouble. However, these occasions are extremely rare. In charging the mill, a crane is used

Jan 1, 1939

By Joseph Jensen, J. B. Stevens

The history of the normal oil field is supposed to show an oil graph starting high in flush production, descending more or less steeply into the curve of settled production and dropping gradually to the vanishing point of economical operation. Together with this, somewhere in the early history of the field, there appears from a vanishing point a graph showing the production of water. During the period of settled production this graph rises higher and, toward the close, unless extensive work is done in the line of correction, rises far above the oil graph to the point at which the cost of operation terminates profitable pumping. Fields that start out with a high relative content of water are generally very short-lived. Fields that never develop a water problem are exceedingly rare. The McKittrick oil field, Kern County, California, with 840 acres of proved ground, 300 wells and a present recovery per acre of 94,598 bbl. from 1898 to Aug. 1, 1930, presents a study which is an apparent reversal of the outlined normal history. Though the history of the field now covers over 30 years of operation, it is still too early and the conditions too unique to project the graph of production to completion. The present conditions and directions of change are most interesting, in that the curve of oil production is remarkably flat and the curve of water invasion, after reaching an appalling height, has shown a definite reversal and a continued decline for 10 years. Early drilling in the McKittrick field was in or prior to 1898. Development continued steadily to 1918 when the present limitations of the field were determined. Shut-offs, according to accepted practice of the time, were made by driving the shoe into a shale stratum or into a tamped-in bridge of sand, rosin and clay. Records of early days speak of three waters: (1) surface water which was fresh; (2) an intermediate sulfur water, encountered below the top oil or tar sand; (3) bottom salt water. In different portions of the field any one of these waters let into a well by faulty completion might require immediate correction to obtain satisfactory production. In many wells,

Jan 1, 1931

By F. J. Tuck

THE Hayden mill of the Ray Mines Division, Kennecott Copper Corporation, is now equipped with two 9 by 12-ft. rod mills having a daily capacity of 6000 tons of coarse-crushing plant product from the mine. These two mills crush a ¾ -in. product to approximately 19 per cent on 14 mesh, with only one pass through the mills. Each rod mill has taken the place of four sets of 42-in. Garfield rolls with their attendant screens, and is making a product for the fine-grinding department comparable to that formerly made by rolls in closed circuit with screens. The rod mills are lined with wave-type liners of white iron, varying in thickness from 2 to 3 in. The shell and end liners last approximately 600 to 700 days. Manganese-steel lifter bars, 3 5/8 in. thick, are used, spaced about 11 in. apart, and they give a life of 350 to 450 days. Fig. 1 shows the general design and thickness of the wave-type liners and lifter bars; 1 ½ -in. liner bolts are used to fasten the lifter bars to the shell. The shell liners are held in place by the tapered lifter bars. A 3/4-in. wood backing is used between the shell and the liners. The rod-mill scoop has removable manganese-steel lips, which last 250 to 300 days. The scoop proper has shown some wear in spots, and these spots have been protected by rubber bolted over them. Water and milk of lime are added to the elevator feeding the mill, but not enough water to cause a pounding of the rods against the shell. Roughly, the water added amounts to 25 to 33 per cent of the ore. Additional water is added to the mill discharge to facilitate distribution to the classifier bowls in the fine-grinding department. Rods are charged to the mill once every four days, the mill being down about 20 min. for this purpose. Other delays are negligible, and usually are due to a loose liner bolt or possibly power trouble. However, these occasions are extremely rare. In charging the mill, a crane is used

Jan 1, 1938

By Julian Glasser, Arthur Fleischer

THIS country was faced with the possible necessity of utilizing nonbauxitic ores for producing aluminum during World War 11. Construction of four experimental plants to treat such ores by four different processes was authorized1-4 including one at Salt Lake City, for the conversion of Marysvale alunite to metal-grade alumina and potassium sulphate by the Kalunite process.' An aluminum reduction plant in Tacoma, Wash., with a capacity of 50 tons of aluminum per day, was constructed to handle the Kalunite alumina produced at the Salt Lake City plant. The alumina and aluminum plants were Defense Plant Corp. projects operated by Kalunite, Inc. and Olin Industries, Inc., respectively. Kalunite alumina differs from Bayer alumina in several respects, particularly in that the former contains potash instead of soda. The presence of potassium in the alumina feed to the cryolite bath was stated by aluminum technologists to be undesirable under the usual operating conditions of aluminum furnaces. In 1940, about 20 tons of Kalunite alumina produced in the Kalunite pilot plant, were reduced electrolytically in a 10,000 amp furnace at Battelle Memorial Institute and at the aluminum reduction plant at Neuhausen, Switzerland. These relatively small scale tests indicated that satisfactory commercial aluminum could be produced in a practical manner. The Tacoma plant reduced about 2,500,000 lb of Kalunite alumina to produce more than 1,200,000 lb of aluminum, in accordance with the accepted gractice for reducing Bayer alumina. It was desired to determine whether commercial aluminum could be produced on a large scale and to establish the technological differences in commercial reduction practice between Kalunite and Bayer alumina. In the course of collecting data, the effects of the abnormal chemical composition and physical properties of Kalunite alumina were observed wherever possible. Tacoma Reduction Plant The reduction plant had two pot lines, each with 120 cells in series, operated at approximately 32,000 amp. Each cell was provided with a single rectangular Soederberg continuous anode, with side-pin electrical contacts. Each cell was hooded and ventilated through a stack connected to 14 other cells, with 25,000 cfm blower. When the plant started operation in 1942, all of the cathode linings were of block construction. Rebuilt cells were of rammed paste construction.

Jan 1, 1952

By Fred W. Shultz

The process engineer is familiar with the in any methods employed in the past for analyzing various materials. These include panning. eyeballing, and wet chemistry. Of those mentioned only wet chemistry has been and will continue to be a standard measure for the elemental content in a given material. However, wet chemistry, by the very nature of the method, can be excessively time-consuming and thus reducing obviously the number of samples that may be processed in a given period. The analysis by X-ray, in most cases, requires nothing more than assurance that the sample is in a suitable state for presentation to the X-ray spectrometer.

Jan 1, 1964

By Thomas M. Drown

IN a communication to this Institute at the Baltimore meeting, February, 1879,* on the "Determination of Silicon in Pig Iron and Steel," the method recommended was the treatment of the metal with nitric acid until action had ceased, and then evaporating with sulphuric acid until the nitric acid was nearly or quite driven off After filtration of the siliceous and carbonaceous residue, and washing with hot water and hydrochloric acid, a silica was obtained, on ignition, which was quite pure. Since this paper was read before the Institute, we have had large experience with the method, and * Transactions, vol. vii, p. 346.

Jan 1, 1880

By D. B. Barker, D. C. Holloway, J. F. Cardenas-Garcia

Tround International Inc. is currently developing a hard rock drill that uses a salvo of three frangible projectiles to prefracture the rock ahead of a conventional tri-cone bit. This paper reports on a series of experiments conducted for Tround to study the fragmentation enhancement possible through the use of an optimally timed and spaced salvo of projectiles. In this study the complex three-dimensional problem was simplified to a two dimensional salvo impact problem in a transparent brittle plate of glass. The use of high speed photography and dynamic photoelasticity was then used to study the development of the impact damage zone and the various interactions of the stress waves.

Jan 1, 1982

By Donald E. Freshcorn

The minimum sulphur level which can be attained during fluid bed roasting of zinc sulfide concentrates is largely determined by the residual sulfates of calcium, magnesium, and zinc. The fractional conversion of these elements to their respective sulfates is derived from semi- empirical relationships, and multiple regression analysis is used to fit the relationships to experimental data from a commercial fluidized bed roaster. The resulting equation shows that the calcine leaving the roaster contains almost no zinc sulfate, nearly all of the calcium is present as calcium sulfate, and the amount of magnesium sulfate formed is primarily dependent upon the roaster temperatures.

Jan 1, 1976

By Howard E. Kremers

Since the discovery of the first-known rare earth elements more than a century ago, these metals have always been of academic interest. It is not so well known, however, that a rather stable, respectably large industry based on rare earths and their related materials has been in operation for more than 60 years. Rare earths, of course, are the elements having atomic numbers 57 through 71--lanthanum through lutetium in the periodic table. The most important commercial members of this group are mixtures of the lower atomic-numbered rare earths, and cerium. Although yttrium is not a rare earth, it occurs with rare earths and its properties are so similar to them that. it must be included in a discussion of these elements. In addition, thorium is important to most producers of rare earths because their ores generally contain this element. Thorium extractive metallurgy and technology is closely related to rare earth chemistry due to the frequent similarity of properties.

Jan 4, 1962

By E. H. Crabtree, T. G. Chapman, V. W. Winters

This paper traces the experimental and pilot plant work completed by the authors since 1939 including the various methods which have been developed in applying coarse activated carbon to cyanidation. The methods and results developed by the authors in desorbing gold and silver from carbons are given and the possibilities for the re-use of the desorbed carbons are discussed.

Jan 2, 1950

By W. Z. Price

The coal lands that the Nemacolin mine is to develop embrace over 8400 acres; the tract is oblong and its eastern edge is along the Monon-gahela river. As shown in Fig. 1, the mine is divided into two parts (the North mine and the South mine) by a 150-ft. barrier, which however, is cut through at intervals by haulageways. Each part is fed from seven main entries—a loaded track, an empty, a manway, and four return air courses. The loaded tracks converge at the shaft bottom but the empty roads maintain their identity throughout their length. With three intakes and four returns on either side, there is ample room for expansion of air and every facility for ventilating is provided. The four south air courses converge into two, crossing the shaft bottom, and then into one at the south side of the air shaft. The four north air courses converge in a similar manner on the west side of the same shaft. This convergence is accomplished by concrete arched

Jan 1, 1927

By W. A. Hustrulid, N. A. Ross

An analysis of the design of medium to hard rock tunneling machines is presented. The developed equations are used to compare performances and machine requirements using kerf and fixed pick cutters to bore a given rock. With the use of pick cutters, required thrusts can be greatly reduced and still achieve the same boring rate as with present day tooth or kerf cutters. It appears that the cutting coefficient, which for most boring machines is of the order of 0.1, should be increased to one or larger to facilitate rock removal by cutting rather than grinding. The depth of cut and the indexing distance should be greatly increased to make use of inherent rock weakness.

Jan 1, 1971

By E. E. Bauer

Technical data describing the critical points for selection of the proper hammer and of the boom and power pack for mounting on mobile gyratory crusher installations are presented. Charts describing typical rocks with breakability indexes for hammer selection are included. Comparative data of representative available hammers along with criteria for evaluating hammer selection are also presented. Factors affecting the selection of the boom and the power pack, as well as optional features for ease of operation and improved safety are described.

Jan 1, 1986

By J. A. Herbst, J. L. Sepulveda, J. D. Miller

Abstract-Lead cake, a zinc smelter flue dust residue, consists primarily of lead sulfate. Characteristic properties of lead cake were determined in order to aid the understanding of reaction mechanisms involved in bismuth removal from lead cake by sulfuric acid digestion. Sp gr (specific gravity) measurements, surface area measurements, and photomicrographs revealed that the particles of lead cake are quite porous and seem to consist of an agglomeration of submicron grains (0.4 pm) fused together in a manner similar to cement clinker. Analysis of experimental rate data, which was independent of particle size, indicates that the dissolution reaction involves two distinct, rate limiting steps. The initial stage of reaction appears to be limited mainly by intergranular diffusion of the reactant, hydrogen ion, while the latter stage of reaction appears to be controlled by diffusion of soluble reaction products through the reaction product layer of the individual grains.

Jan 4, 1978

By Thomas J. O’Neil

Once again, the United States Congress is debating the minerals depletion allowance. If the past is any indication, the debate will quickly become politicized. Representatives of the densely populated but mineral-poor Northeast will no doubt claim that percentage depletion is sheer robbery of tax dollars perpetrated by corporations to line the pockets of wealthy investors. Many southern and western legislators, on the other hand, will portray the depletion allowance as our only savior from mineral deprivation, blackmail from foreign producers, and a stone-age nonmineral existence. Although this characterization of the usual minerals depletion debate may be overstated, the most unfortunate aspect is that the genuinely important role of the depletion allowance in domestic minerals production is often obscured in congressional hearings. This article will try to provide a basic understanding of the minerals depletion allowance, the underlying rationale, and the increasingly important role the allowance will play in the future. Although the discussions and conclusions can be extended to the metal mining industry in general, most of the examples are drawn from the copper industry.

Jan 10, 1974

MIXED emotions were produced by the announcement that the buildup of weapons will be stretched out till mid-1954 instead of the previous 1953 deadline. Reason: government assistance programs will be tougher to get but there will be easement in materials allocations. Earlier in February, DPA had announced that tightening up on regulations governing rapid tax -amortization would become effective March 1. In the future, DPA will have to certify amortization contracts for all construction and permanent installations costing more than $100,000. This action was necessary according to DPA's James F. King, so that new industrial expansions already approved could be assessed in the light of the changing critical mineral picture. When DMPA inherited the backlog of government assistance, requests from DMA, it moved in fast. The results of DMPA's work is described in the article on p. 351 by James K. Richardson; The speed with which these requests were approved and the lengthening of the military program have made a reappraisal of the critical mineral list necessary. It looks as though the consumer industries will be getting more metal soon and, led by steel, there is an industry push toward the abandonment of CMP. Relaxing of materials controls appears imminent but discontinuing CMP is in the "let's talk this thing over" stage.

Jan 1, 1952

THE man who forgot to mail the letters his wife gave him was for once justified at Tulsa, for envelopes, scratch paper and tablecloths were all in demand and through the two days of the meeting of the Petroleum Division, pencils were busy everywhere sketching out diagrams, drawing curves, figuring, or just taking notes. Those attending took the serious papers seriously, and discussion was wide-ranging but pointed. Despite the highly technical character of the papers presented, the chairmen had never to call for discussion; it was only necessary to say the paper was open for it. Both days the meetings lasted until after five in the afternoon, and it was enthusiastically voted to advance the meeting hour on Friday, in order to give more time. In all, ten papers, abstracts of which appeared in MINING AND METALLURGY for October, and copies of all but two of which were available in print, were presented in the two days, and no more could have been handled to advantage in that time. All but one of these dealt with problems of production engineering. That, the opening paper, was a general review of demand, supply and price in 1928, by Campbell Osborn, in which he argued for the price control of production and showed how the economic conditions determined development. J. Elmer Thomas presented a carefully prepared review of the same data, but came to somewhat different conclusions as to trend, and J. E. Pogue pointed out that in recent years it has been the manufacturing rather than the producing industries that have been notably profitable. These and other discussions were too long to be reported here, but will be printed in full later.

Jan 1, 1928

By Raymond Sanford

IT IS difficult to know just when a hoisting rope should be removed from service and a new one substituted. It is desirable to utilize the full life of a rope but, on .the other hand, the damage and possible loss of life, resulting from delay in replacing it may amount to many times the cost of a new rope. In the present methods of inspection the inspector must rely upon accumulated experience and a certain sixth sense or intuition in addition to any rules that may be laid down regarding the number and distribu-tion of broken wires. This condition does not neces-sarily arise from lack of interest among users or makers of rope, but is due rather to the lack of satisfactory or adequate methods for testing ropes to determine their exact condition. The main difficulty in devising a physical test lies in the fact that a number of causes, all operating in different ways, contribute to the deterioration of a rope in service, and affect not only the external conditions but also the inner structure of the material of which the rope is constructed. Wear and broken wires on the outer part of the rope are not difficult to detect, but a test is needed which will clearly indicate the presence of broken wires in the interior portions and the change in strength due to alterations in the structure and properties of the material itself.

Jan 7, 1923