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By David P. Lindroth

The objective of this research by the Bureau of Mines was to determine the technical feasibility and associated pilot data for drying minus 1/4-in coal with microwave energy at a frequency of 2.45 GHz. The drying data were obtained experimentally on three coal types: bituminous, subbituminous, and lignite. The experiments were performed with a custom-designed conveyorized microwave oven having a continuous power capability of 12 kW. Drying efficiencies near the theoretical maximum of 1.54 kg of water per kilowatt hour of energy input were achieved for two coals and two sizes; overall drying efficiencies averaged 77 pct.

Jan 1, 1986

By Thomas H. Heine

"The Rabbit Lake uranium deposit is located at 58° 11’00”N.. 103°42'36""W., close to the west side of Wollaston Lake, and approximately 800 km north of Saskatoon. The orebody is hosted by Aphebian Wollaston Group rocks, initially deposited as a series of shallow-water marine sediments consisting, in part, of carbonates and possible saliferous petites. Metamorphism during the Hudsonian Orogeny, peaking at about 1850 Ma, recrystallized the sediments to upper amphibolite grade paragneisses. This was accompanied by partial anatexis. The waning stages of Hudsonian orogenesis appear to be marked by minor granitic intrusive activity.The post-Hudsonian period was marked by a long interval of physical and chemical erosion, resulting in the unroofing of the Wollaston metamorphic complex. The entire region underwent extensive lateritic weathering under tropical to subtropical conditions. Carbonates were especially vulnerable and, in the Rabbit Lake area, suffered extensive solutioning with accompanying formation of collapse breccias. Old zones of weakness also underwent periodic reactivation.It was during this period that uranium was leached from the surrounding meta-sediments by oxidizing meteoric waters, and transported into the karsted and fractured rocks of the Rabbit Lake doline.Athabasca Group sediments eventually covered the deposit, their diagenesis taking place at about 200 °C and 900 bars. This allowed the partial to complete recrystallization of the initial mineralization, resulting in a minimum age of 1281 ± 11 Major ""first""-generation pitchblende. Periodic fault/fracture reactivation modified the hydrologic regime within the deposit, resulting in episodic mobilization and recrystallization of pitchblende and other uraniferous species. This is clearly shown in the open pit at the present time: uranium is being mobilized and recrystallized on damp pit walls as bayleyite and liebigite due to the modification of the hydrologic system by mining activities.The uranium mineralization occurs mainly as fracture fillings, coatings, and impregnations within breccia zones and intensely altered metasediments. Lesser mineralization is intimately associated with phyllosilicates which form the matrix of a carbonate-col/apse mega-breccia. The primary ore mineral is pitchblende, consisting of five generations, and from which a large suite of secondary uraniferous minerals have formed. On a gross scale the metal content of this deposit appears to be simple, consisting almost exclusively of U, but minor Ni, As, Cu, Se, Fe and Co are also present. The eastern limit of the mineralization is defined by a vertically-dipping microgranite dyke - breccia complex, containing high-grade uranium values. The orebody is truncated to the west and at depth by the Rabbit Lake reverse fault. Minor mineralization occurs as fracture fillings in unaltered plagioclasite in the footwall of the ore body. Precipitation of uranium from solution could have taken place by a number of processes. A mobile reductant (methane, carbon dioxide, etc.) may have been generated from graphite present in some of the host rocks of the orebody. Sulphides are also a common accessory and may have aided in the formation of a reducing environment. Phyllosilicates may have acted as adsorbants for uranium, allowing for its fixation. This metal has also been incorporated into the phyllosilicates themselves."

Jan 1, 1986

By W. F. Moll

Absorbent clays are products, usually in the form of granules, that can absorb and hold approximately their own weight of liquids while essentially maintaining their size and integrity. They always contain in abundance at least one of three materials: montmorillonite, attapulgite and diatomite. The first two are complex silicates; the last is amorphous silica of biogenic origin. Not all montmorillonites provide the base for an absorbent clay, however. Nevertheless, the silicates in particular, and the diatomite to a lesser degree, have certain molecular properties that give rise to the useful physical properties. Uses Use of absorbent clays is as old as civilization. Numerous references to "fuller's earth" appear in ancient writings, including the Bible. Fuller's earth originally connated a clay that could absorb oil and grease from wool to facilitate cleaning. Robertson (1986) covers the fascinating history in interesting detail. In the modern sense, absorbent clays find application in three principal areas, and a host of minor ones. Industrial floor absorbents, cat litter and agricultural carriers comprise the major uses.

Jan 1, 1986

Several short color films describing new technology developed through Bureau of Mines research are available on a loan basis. The films review results of Bureau research programs aimed at aiding the minerals industry by increasing mine productivity, ensuring worker health and safety, and enhancing minerals recovery, processing and recycling. Most of the films are available in a choice of for mats: 16mm film, ½" VHS cassette tape, or ¾" U-matic tape. The films are loaned by the Bureau of Mines free of charge; borrowers are requested to pay only the return postage and for any damage to the films. All titles are also available for purchase in 16mm or videotape formats. Interested persons wishing to borrow or purchase a film should specify its title and the preferred and alternate showing dates. All requests should be addressed to: Motion Picture Library Bureau of Mines Cochrans Mill Road P.O. Box 18070 Pittsburgh, PA 15236 A short description of each film follows: Safer Coal Mining Equipment Traces the development of modified conventional and continuous mining equipment, beginning with an investigation of the problems encountered with mining equipment and continuing through long-term testing of the modified equipment in two mines. "Human engineered" coal mining machines are shown in operation. These machines include features such as adjustable cabs, easy access controls, improved illumination, and other safety improvements. (19 min)

Jan 1, 1986

By B. Farouk, D. Apelian

"A numerical model has been developed to predict the temperature history of particles injected in a low pressure d.c. plasma jet. The temperature and velocity fields of the plasma jet are predicted as a free jet by solving the parabolized compressible Navier-Stokes equations using a spatial marching scheme. Particle trojectories and heat transfer characteristics are calculated using the predicted plasma jet temperature and velocity fields. Correction factors have been introduced to take into account non-continuum effects encountered in the low pressure environment. The plasma jet profiles as well as the particle/plasma interactions under different jet pressure ratios (from underexpanded to overexpanded) have been investigated.I. IntroductionIn the plasma spraying process a d.c. plasma jet is used as a heat source to melt and accelerate powder particles which subsequently impinge and solidify on a given substrate. During low pressure plasma deposition (LPPD) prooess, the plasma jet is expanded into a low pressure environment (40-80 Corr) which results in high plasma jet velocities with Mach numbers ranging from 2 to 3. Previous efforts to predict heat transfer and fluid flow in plasmas have made use of incompressible flow formulation employing turbulence models [1-3] for atmospheric plasma spraying. However, these theoretical calculations have been limited to the subsonic flow regime; hence, the compressibility effects and viscous heat dissipation were neglected. In the LPPD process, the plasma jet is operated at the supersonic flow regime, therefore, the compressibility effects and viscous heat dissipation are no longer negligible. This is the main motivation of this work.In addition, production of high quality dense deposits requires that a large fraction of the injected particles be in a molten state when they impact the substrate. An additional motivation for this work is that it is important to understand the plasma/particle heat and momentum transfer since these phenomena dictate both the particle thermal history and particle trajectory.Early computational works in supersonic nozzle field flow [4,5,6] consisted of patching methods that divided the flow field into an invisoid free stream and a viscous boundary and. mixing layers. Each was analyzed independently and coupled through appropriate boundary conditions. Later schemes [7,8] involved solving time-dependent, compressible Navier-Stokes equations over the entire computational domain. These schemes show a great promise in predicting flows with complex structure, and where the viscous effects became prevalent."

Jan 1, 1986

By W. -S. Hwang, R. A. Stoehr, P. Ingerslev

"The flow of molten metal entering complex two-dimensional foundry molds has been modeled using the Simplified Marker and Cell (SMAC) and Solution Algorithm (SOLA) techniques. The molds were for a series of four and three-spoke wheel designs. The computer calculations were compared to physical experiments in which molten cast iron was poured into C02-bonded sand molds. The metal was photographed with a high speed motion picture camera focused through a Pyrex glass window on one face of the mold. To get good agreement between the calculations and the experiments, it was necessary to accurately represent the velocity through the ingate. This was calculated by application of the Bernoulli equation to flow through the feed system. Some difficulties were experienced with mathematical instability, expecially in the three-spoke design with a narrow ingate. This was overcome by using 100% upwind differencing, and over relaxation parameter near 1.0 (i.e. no over relaxation), and variable mesh spacing.IntroductionModeling the flow of molten metal entering molds has the potential for making significant contributions to the design of feed systems. It will supply information to the computer-aided-design systems of the future that will enable the designer to optimize the placement of gates, dimensioning of passages, and designation of casting speeds. Such design criteria have generally been based on application of energy balance (Bernoulli equation) principles to flow in the sprues, runners, and gates. Indeed, this is the easiest way to determine the proper dimensions to give a suitable filling time for a casting of a given size. A number of computer programs, including one by some of the present authors, have integrated such calculations into CAD systems. l Modeling the flow of metal inside the mold cavity requires other techniques that will handle free-surface transient flow. Stoehr and Hwang reported on the application of the Marker-and-Cell (MAC) technique to mold filling problems at the previous conference in this series at Hennicker, N.H. in 1983. 2 Although considerable progress has been made since that time in improving the accuracy, stability, and convenience of these techniques, the shapes to which they were applied remained limited. Also, physical verification of the results of the calculations was limited to water models.The work to be reported in this paper was undertaken with two objectives: (1) to apply these techniques to more complex and realistic shapes, and (2) to verify the results by comparison with flow patterns observed in molten metal poured into actual sand molds."

Jan 1, 1986

By Y. C. Kim

The strongly skewed grade distributions and the need to estimate the local recoverable reserves in a selective mining environment are the two problems that Ordinary Kriging (OK) cannot easily handle. With the recent introduction of the nonparametric, distribution-free technique of Indicator Kriging (IK), the above problems can be solved. This paper describes the results of performance evaluation of IK in an open-pit gold-silver deposit. For performance evaluation, the predictions of local recoverable reserves using IK were compared with the actual reserves based on blast hole information. The IK estimator, although a bit optimistic, performed very well in predicting the total recoverable ounces of gold from each panel on a test bench. The OK estimator was also used to try to predict local recoverable reserves, by treating each panel as either waste or ore, depending on the panel's average grade. Under this criterion. OK was found to be very biased and pessimistic.

Jan 1, 1986

This information circular describes research the Bureau of fines has conducted to improve technology for recovering precious metals from low-grade resources. Many of the reported findings are recent, and some of the work described is ongoing. Topics discussed include cyanidation of carbonaceous gold ores to enhance gold recovery, a new method for precipitating mercury during cyanide leaching of gold ores, a staged heap leaching process to generate suitable solutions for direct electrowinning of gold, the use of anion-exchange resins to recover gold from cyanide solutions, and precious metals recovery from electronic scrap.

Jan 1, 1986

By Z. Sun, H. A. Davies

"Current understanding of the mechanisms by which glassy and crystalline thin ribbons are formed in high speed continuous casting processes is considered. A computer model of the combined heat and momentum transfer during melt spinning has been developed. The influence of roll velocity and of heat transfer coefficient (between the melt and the roll) on the temperature and velocity distributions within the melt puddle is analysed and the thickness of the extracted ribbon computed. The relative importance of heat and momentum transfer under different conditions is assessed and differences between the casting of crystalline and amorphous strip highlighted.IntroductionHigh speed continuous casting of thin metallic ribbon and strip is currently of considerable interest both to metal processers and to those studying process mechanisms. The practical interest arises both from the potential economic benefits to be gained from a shorter and more energy-efficient production route and from the ability to obtain extended and uniform thin strip having a metastable microcrystalline or amorphous structure with enhanced or unique properties. The latter arise from the rapid solidification associated with the cooling of very thin sections of melt brought into intimate thermal contact with one or two rapidly moving heat sinks.The principal processes for casting thin strip include free jet, chill-block melt-spinning (GBMS) (1), melt drag (MD) (2), planar flow casting (PFG) (3) and twin-roll casting (TRG) (4). For the first three of these, all essentially variants of melt-spinning, melt flows through a nozzle onto the circumferential surface of a rapidly rotating roll, whereas for TRG the melt passes into the nip between two contra-rotating rolls. We shall be concerned in this paper with the single-roll melt spinning processes only. For these, a puddle is established where the melt contacts the roll surface and the length of this puddle l is a function of the process conditions, notably the circumferential velocity of the roll Us and the volumetric flow rate of the melt Q. The contact time between any point on the roll surface and this puddle, or residence time eR(= l /Us) determines the thickness of ribbon t extracted from the puddle. This thickness, in turn, partly governs the cooling rate T and the amount of undercooling in the melt and thus the microstructure of the solidified ribbon."

Jan 1, 1986

By M. J. U. T. Van Wijngaarden, R. J. Dippenaar

An electrochemical technique based on the solid oxide galvanic cel Mo / Mo + MoO2/ ZrO2-MgO / Fe + (FexO)slag + Ag / Fe was used in a determination of FexO activities in liquid slag systems. The emf measurements, scanning electron microscopy, and microprobe analysis of the cross-sections of the electrolyte tubes used in direct contact with the slag melts indicated that slag attack did not affect the open-circuit emf values during normal cell operation, The reliability of the cell was confirmed by the good agreement between the standard free energy of formation of liquid Fep obtained in the present study and those reported in the literature, The FexO activities were determined in FexO -CaO and FexO-SiO2 slags at 1673 K, and are in good agreement with those measured by the conventional gas-equilibrium technique. The experimental technique was successfully extended to the measurement of Fe2O activities in the complex slags that are used for the external desilliconization of the hot metal product of the blast furnace.

Jan 1, 1986

By R. D. Begley, A. W. Khair

Introduction The technique being investigated here uses a physical mine model which consists of a plexiglass room-and-pillar model 11.4 x 11.4 cm (4.5 x 4.5 in.). It is placed at the bottom of a larger plexiglass box 25.4 x 30.5cm (10 x 12 in.). The box is then filled with a model material representing geologic overburden. Sand has been selected because of its deformability under gravitational forces. The mine model is capable of creating a cavity and induces movement on the surface of the model material. This surface disturbance can be measured using a photographic technique called holographic interferometry. This paper discusses results of an investigation of the possibility of generating subsidence criteria using physical mine models and laser holographic interferometry. Problem Statement Subsidence appears to be widespread in two states - Pennsylvania and Illinois - although serious subsidence is found in localized areas of numerous other states (HRB Singer Inc., 1977). The US Bureau of Mines estimates that more than 1618 km2 (400,000 acres) of urban areas are threatened by subsidence. Pennsylvania and West Virginia contain 57% of these threatened areas, with the remainder being spread out over 16 states (Johnson and Miller, 1979). Events of subsidence have been reported in urban areas, including Pennsylvania (Gray et al., 1977) and Illinois (Mahar and Marino, 1981). One location has observed three episodes of subsidence beginning in 1950 (Bruhn et al., 1981). These subsidence events all occurred over abandoned room-and-pillar mines. Some mines have been abandoned more than 50 years (Bauer and Hunt,1981) . Available research does not offer much on the problem related to time dependent subsidence, especially those associated with the failure of remnant coal pillars. The physical modeling technique developed at West Virginia University is capable of measuring both instantaneous and time delayed subsidence. Laser Holographic Interferometry Laser holographic interferometry, or holometry, uses the interference properties of laser light to measure small movements of objects. The object requires only optical access and no surface instrumentation. This technique is closely related to photoelasticity. Both techniques rely on the uniqueness of the light reflected off or through an object in any given state of stress. The entire measurement process is done remotely without any surface instrumentation and without using a camera. The interferogram is constructed and visual observation will yield fringes on all areas that yielded or moved. The displacement represented by one fringe was determined by Wilson et al. (1977) and is given by the relationship: [d ='1(1) 2 cos 8 where d = displacement of one fringe 6 = incident angle of laser light A = wavelength of light (632.8 x 10-9 meters for Helium-Neon lasers)] In summary, holometry is capable of detecting very small movements of objects under study. It is a very sensitive process that requires laser light and vibration free experiments. Experimental Program Lab Facilities The primary components of the facilities were the laser and the optical table. The light source was 50 milli-watt, Helium-Neon laser. The optical table was a granite slab weighing nearly one ton. All experiments were performed on the optical table. It consists of a large table sitting on air cells similar to car innertubes. Six air cells were placed on top of two layers of wood and Styrofoam. Figure 1 is a schematic diagram of the vibration free table. Even with these precautions, the experiments still had to be performed at night to reduce potential traffic related vibrations. Room-and-pillar mine models consisting of three different pillar sizes were constructed out of plexiglass. The models were designed to represent three different extraction ratios. Figure 2 shows the models. The extraction ratios were determined by the tributary loading concept (Peng, 1978). These models were the primary component of a seam extraction simulator. A schematic of this simulation device is shown in Fig. 3.

Jan 1, 1986

This paper describes major technical developments in rod mill design and operating practice since its introduction into the North American minerals industry over fifty years ago. The basic operating characteristics of the wet, overflow rod mill are described, and significant operating variables are reviewed in terms of their effects on mill power draw, power efficiency, and practical aspects of circuit operation. Key factors for improving the economic performance of rod milling circuits are identified.

Jan 1, 1986

Between, 1980 and 1984, the demand for non- ferrous metals in the free world grew annually by 1.5 per cent for copper, 0.4 per cent for lead, 1.4 per cent for zinc, and 2.5 per cent for nickel. The growth rate decreased substantially compared to the rate experienced before 1980, and was far lower than the GNP growth during the corresponding period. The main reasons for this are considered to be 1. resource-saving efforts by industrialized countries resulting from the first and the second oil crises, 2. saturated demand for durable consumer goods, and 3. substitution of non-ferrous metals by new materials such as optical fibers.

Jan 1, 1986

By Y. Lizotte

The purpose of this paper is to describe a stochastic simulation program used to assess several dispatching rules applicable to small scale computerized systems for optimizing truck/shovel productivity. The system studied is semi-automated with a dispatcher communicating instructions by two-way radio. The simulation program is structured on an advance clock approach which enables the insertion of dispatching rules at various points in the haulage net- work. The rules tested include minimize shovel idle time, maximizing immediate truck use and assigning trucks to shovels to meet specific production objectives. A variation of the traditional "Match Factor" is implemented to maintain fleet balance throughout the shift. A mine case study demonstrates how the dispatching rules increase productivity of such semi-automated dispatching systems. Practical problems involved in the implementation of small computerized dispatching systems are also discussed.

Jan 1, 1986

By M. J. Waller

Surface resistivity techniques were used at four field sites to monitor changes in apparent resistivities with variations in soil moisture content in the vadose zone. Apparent resistivity values were correlated with gravimetric moisture contents from soil samples taken at each site. Tensiometer readings were taken at two sites and correlated with the results of gravimetric moisture contents and apparent resistivities. Moisture at two of the sites was added by extensive watering; rainfall events were monitored at the other two sites. A recharge event at a dewatering program was monitored at a fifth site. A Ghosh-Koefed multi-layer computing algorithm was used to derive true resistivities from bulk or apparent resistivities. An automated data acquisition system was developed to measure resistivity changes and to process the data in the field. These studies are the first to evaluate measurement of moisture migration in clay rich soils using surface resistivity techniques. Results indicate that surface resistivity techniques readily measure changes in moisture contents in the vadose zone in clay rich soils. Correlation of apparent and true resistivity values with gravimetric moisture contents is more complex and requires additional research.

Jan 1, 1986

By Albert W. Deurbrouck

The coal reserves in the United States are estimated to be in excess of 300 billion recoverable tons, and current projections of energy requirements indicate our increased dependence upon these reserves. The Department of Energy's Energy Outlook for 1984 projects that coal consumption in the United States will increase from 737 million tons in 1983 to 958 million tons in 1990, and then to 1,110 million tons in 1995 (Table 1). As shown in this table, the future utilization of coal in the United States is closely tied to the electric utility market, a market that consumes about 85% of the coal produced. Be- cause of this dependence on the utility market, the uncertainties of new environmental regulations, particularly those concerning sulfur emissions, could have a significant adverse impact on future coal demands in the United States. SULFUR IN U.S. COALS Most of the Nation's coal reserves contain too much sulfur to be fired directly and meet existing emission control standards. In Table 2, the sulfur contents of the coals of the eastern United States are summarized by sulfur levels according to regions. While the coals of some of the eastern regions are predominantly high in sulfur content, it is important to recognize that large tonnages of coal with relatively lower sulfur content are available in these regions. Furthermore, an often significant portion of the sulfur occurs in the form of iron sulfide (Fes2 or pyrite). Because pyrite occurs as discrete particles of high specific gravity, it can often be removed by simple, inexpensive physical coal beneficiation techniques after being liberated by stage crushing. The potential for physical removal of pyrite by conventional specific gravity processes combined with stage crushing is summarized in Table 3 on a regional basis.

Jan 1, 1986

By C. E. Jordan

The fundamental characteristics of ultrafine chalcopyrite flotation were investigated by the Bureau of Mines to establish techniques to improve recovery of ultrafine chalcopyrite. Intense agitation during conditioning was found to improve flotation recovery of the ultrafine chalcopyrite. A split-circuit flotation design, treating the plus 38-µm-size ore by the conventional method and treating the minus 38-µm-size ore with intense agitation conditioning followed by flotation, recovered 95.6 pct of the copper in a 28.3-pct-copper concentrate, This was a 5-pct increase in copper recovery over the conventional chalcopyrite flotation method.

Jan 1, 1986

By W. Nazarewicz

The introduction of continuous papermaking in the early 1800's was the beginning of the industry as we know it today. Since that time, the majority of the paper produced has employed an acid process. However, in the mid 1960?s, European producers began a transition to an alkaline papermaking process. Early European mill conversions to alkaline papermaking begun in the 601s, accelerated during the 1970's influenced by the dramatically higher cost for OPEC energy as well as the high cost of fiber and imported filler clay.

Jan 1, 1986

By W. G. Prast

Best known for its extensive bauxite and alumina exports, Jamaica also has a small but active industrial minerals sector. The island has for many years been a net exporter of small tonnages of gypsum, metallurgical-grade limestone and marble products. As bauxite and alumina earnings have declined the government of Jamaica has made extra efforts to promote growth of overseas sales of these nonmetallics. The nearby U.S. market is a natural first choice for new exports. Overview In 1984, Jamaica quarried an estimated 3.2 million cu m of marble and fill and an additional 3.5 million cu m of sand and gravel, for use in domestic construction. These amounts are in line with the production in earlier years of the 1980s but are not a factor in the export pattern and need not be considered further. Similarly, annual production of 15 million ton of silica sand for the manufacture of glass bottles is principally consumed by the domestic market.

Jan 1, 1986

By B. Das

Most coals are susceptible to spontaneous heating which in turn creates problem to mining, storage and transportation of coal. It is impossible in actual practice o eliminate spontaneous heating but spontaneous combustion can effecively be controlled through a clear understanding of its mechanism and the factors affecting it. There are altogether six stages in the process of spontaneous combustion. This includes the water adsorption stage and six oxidation stages: chemi-sorption (upto 70°C), decomposition of peroxygens (70°C-150°C), oxy-coal formation (150°C-230°C), combustion initiation (230°C) and active combustion (> 230°C). Heat is produced in all these stages. On the other hand heat is also dissipated so that some equilibrium temperature is reached. If this temperature exceeds a certain critical value (generally about 70°C), coal oxidation may advance to spontaneous combustion. The major factors influencing spontaneous combustion of coal are: coal rank, maceral composition,, water, mineral matter, joints and fissures, seam depth and thickness, mine Layout, method of ventilation, etc. Susceptibility is high for low rank coals and generally decreases with increase in rank. Of the macerals, the exinites are generally most susceptible, the inertinites least and the vitrinites somewhere in between. Water plays a major role on the spontaneous heating of coal, assisting in someways and inhibiting in other. Unrecovered coal in the gob (generally in thick seams) is a major source of fire hazards and this is specially important in shallow mine. Proper design of mine ventilation system can substantially reduce the risk of mine fire. Panel layout and load transfer can affect the development of induced cracks which in turn influence spontaneous heating. Finally, the difference between the spontaneous heating of coal in a seam and that in storage or transportation is mainly due to the change in moistured content, air circulation through the coal and coal fragmentation. These aspects have been analyzed in this paper with a view o reducing the risk of spontaneous combustion.

Jan 1, 1986