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By Ken Musgrave

"A program is described that helps managers and supervisors control maintenance more effectively. Work- order generation, preventive maintenance, repair parts inventory, planning and scheduling, reporting, analyzing costs, printing purchase orders and other functions are covered. Flexibility often permits integration with other programs such as payroll, cost accounting and materials management.The Role of MaintenanceMaintenance provides a service to allow the rest of the operation to do its job effectively. Its success should not be measured by maintenance cost alone, but also by its effectiveness in reducing downtime and maximizing production. It can make sense to spend more maintenance dollars if this results in an even greater contribution from increased production.The Cost of MaintenanceIn mining companies, maintenance costs can be as much as half of operating costs. Maintenance has generally not been given the management attention that an expenditure of this magnitude deserves."

Jan 1, 1986

By Paine G

Kidston Gold Mines commenced mining in 1984 and currently mine approximately 10 million tonnes per annum of ore and waste using a conventional truck and shovel open pit method. The overall mine grade is a low 1.82 grams per tonne.The mineralisation is generally uniform within the ore zones and mining boundaries are staked out from blasthole assays according to pre-determined cut-off grades. Buffer blasting is necessary to minimise post-blast lateral movement of in-situ grade for digging control.The characteristics of the rock currently mined vary widely from soft oxidised to hard unweathered rocks. Blasting problems have been experienced during the initial mining phase in these harder rocks.

Jan 1, 1986

By J. A. Herbst, O. A. Bascur

Fine coal cleaning by froth flotation has become common practice in the US with more than 73 kt/d (80,000 stpd) treated in this way. In spite of this large tonnage, developments in the automated control of coal flotation circuits have lagged significantly behind those for mineral systems. The primary reason is that instruments have not been available for the online measurement of carbon ash content or other critical variables in coal slurries. A second reason is that the influence operating variables have on coal flotation are not completely understood. During the last few years, some of the needed instrumentation has been developed, while an improved knowledge of the flotation process itself has occurred through mathematical modeling. As a result, certain control strategies for coal flotation are beginning to emerge. This paper attempts to evaluate several control strategies using a detailed flotation dynamic simulator, Dynafloat. After construction of a process matrix for the system of interest, promising alternatives for linking manipulated and controlled variables were analyzed. To develop combined grade and recovery control strategies, it was necessary to construct a grade/recovery map with the aid of the simulator to drive the system to known, final, feasible grade/recovery operating conditions. Finally, an advanced strategy that uses an on-line model to identify disturbances and take control actions is proposed.

Jan 1, 1986

By J. D. Patsey

A computer program has been developed for use by the mining engineer for analyzing drum-type hoists prior to the modification of an existing system or the designing of a new one. Its use permits the preliminary evaluation of a system before seeking the technical assistance of mine hoist designers and manufacturers. Compatible with an IBM-PC, the user-friendly program accepts a variety of data and can analyze hoisting systems for any balance state. The extensive program can be used to: (1) calculate skip capacity to yield a desired production rate; (2) solve for required drum face width; (3) select a permissible wire rope from a menu of 50 available rope types: (4) estimate total horsepower of the hoist plant; and (5) estimate power cost. An example of the model's use in evaluating a hoisting system will conclude the paper.

Jan 1, 1986

By W. C. Patrick

The Spent Fuel Test-Climax (SFT-C) was con- ducted to evaluate the feasibility of retrievable deep geologic storage of commercially generated spent nuclear-reactor fuel assemblies. One of the primary aspects of the test was to measure the thermomechanical response of the rock mass to the extensive heating of a large volume of rock. Instrumentation was emplaced to measure stress changes, relative motion of the rock mass, and tunnel closures during three year of heating from thermally decaying heat sources, followed by a six month cooldown period. The calculations reported here were performed using the best available input parameters, thermal and mechanical properties, and power levels which were directly measured or inferred from measurements made during the test. This report documents the results of these calculations and compares the results with selected measurements made during heating and cooling of the SFT-C.

Jan 1, 1986

By G. A. Kordosky

Solution mining followed by solvent extraction-electrowinning (SX-EW) is one possible way to economically extract copper from ore bodies which cannot otherwise be profitably exploited. Published costs for the unit processes of SX and EW are out of date especially in view of the newer reagents now available and the newer circuit configurations, This paper updates the costs for SX-EW in 1985 dollars and also discusses some of the trade-offs which must be made when designing an SX-W plant.

Jan 1, 1986

Increase the safety of underground mine workers by minimizing hazards associated with rerailing mine cars after derailment. Background and Approach A serious operational problem in underground mines is the task of rerailing mine cars. Current rerailing practices are not only hazardous but are inefficient as well. Most methods involve pulling the derailed car back onto the track with a locomotive. This causes damage to the road bed and is not effective on curves or in situations where the car's wheels are too far from the rails. Jacks, wooden props, and pry bars are also used to raise or lower cars back onto their tracks but methods involving these tools require much strenous manual effort by mine workers, thus posing possible serious injuries. The problem is further compounded by the cramped, narrow confines of the underground mine environment which allows no space to permit use of cranes or other surface railroad rerailing techniques. The Bureau of Mines, aware of these problems, investigated improvements in current underground rerailing methods. Through a cooperative effort with Hoesch MFD, a system was designed and modified that can be easily carried into the mine by workers and quickly assembled at the derailment site. The system is hydraulically and pneumatically powered rather than reliant upon manual operation.

Jan 1, 1986

By C. E. Larson

Man's use of 'glass predates recorded history. Although early man had no knowledge of how to form glass, artifacts have been found near naturally occurring glass formations where molten rock had been rapidly cooled. In areas where volcanic activity is evident, primitive people fortunate enough to have lived in that area used the naturally formed glass to make arrow heads, knife blades, tools and ornaments. These glass artifacts have been found all over the world. In fact in todays modern society there are recorded cases of aboriginal tribesmen in Australia fabricating arrowheads from glass bottles. 2. A Brief History of Glass The first evidence of man made glass were beads made around 2500 BC by the Egyptians. The Mesopotamians also made glass beads at about the same time.

Jan 1, 1986

By J. Menashi, D. A. Douglas, A. S. Rappas

Aqueous solutions of Na2Cr04 are reduced with CO to produce hydrous Cr2O3 and NaHCO3/Na2CO3. CH3OH, HCOO- and HCHO in the presence of CO2 also reduce Cr(VI) and yield similar products. It is shown that the rate of Cr(VI) reduction can be represented by the expression -d [Cr(VI) ]/dt = k[Cr(VI)]0.5[R], where [R] is the aqueous phase concentration of CH3OH, HCOO- or CO. With these three reductants, the activation energies for the reduction processes are comparable and are of the order of 100 kJ/mol (43,000 Btu per lb mol). Rapid reduction rates are attained at temperatures in excess of 220°C (428°F). With these three reductants, a green acid-insoluble readily filterable hydrous Cr203, is formed. With HCHO, significant reduction of Cr(VI) occurs at about 80° to 100° C (176° to 212° F). The product is an acid-soluble violet modification of hydrous Cr203. Solutions of Na2CrO4 contaminated with Mo(VI) and W(VI) can be reduced to yield a Cr2O3 product with significantly reduced contaminant levels.

Jan 1, 1986

By Wilson AC

Permian coal from Western Australia's only producing coalfield at Collie is the dominant fuel used in generating electricity for the State's interconnected grid. Collie coal is sub-bituminous, non-coking and has a low ash, medium volatiles and high moisture content. The seams were laid down in a fluvial basin which extended beyond the Collie Basin and included the Wilga and Boyup Brook Basins at least. Adjacent parts of the southwest Yilgarn Block are prospective for Collie-type basins. In the past few years significant deposits have been delineated within the Perth Basin, specifically on the Vasse Shelf and in the Hill River area. In the former area high quality steaming coals are correlated with the lowest coal bearing member at Collie. The seams are amenable to underground mining and because of their high quality, the coal may have export potential. Sub-bituminous coal deposits of Jurassic age are present in the Hill River area. Exploration has down-graded the prospectivity of the Carnarvon and Canning Basins for sub-bituminous near-surface coal deposits. Tertiary lignite deposits are present in palaeo-drainage systems in the southern part of the State and their potential for development is being evaluated.

Jan 1, 1986

Stability on surface mining projects is primarily controlled by five factors. These include structural geology, the most important of the factors, the existence of weak layers, primarily clayey gouge or clay infill, groundwater, blasting and weathering. Case examples of stability on many surface mines including some coal mines are presented. The experience and lessons learned are applicable in some way to stability of surface coal Mines.

Jan 1, 1986

By Raymond H. Green, Mitchell W. Green

The authors examined the application of precise millisecond delay electric blasting at a well-known Vermont quarry. The paper explains how the use of a new high-accuracy electric delay detonator has improved fragmentation, raised productivity 10%, simplified blast design, and increased the ability to predict results from blasting.

Jan 1, 1986

By P. K. Sims

One-day field trip via U.S. Highway 6 and Colorado Highways 119 and 279 from Golden, Colorado to Idaho Springs. This field trip provides an opportunity to observe aspects of the Laramide ore deposits in the Central City and Idaho Springs mining districts and the Proterozoic basement rocks, which host the ore deposits.

Jan 1, 1986

By H. M. Wells

The known high grade mineral re- sources in the United States are fast becoming exhausted; viable new deposits are more difficult to find and more expensive to develop; operating and capital costs have increased to meet more stringent regulatory standards. By contrast, international producers enjoy a cost advantage as a result of higher mining grades, improving technological competence, and more favorable government support. The domestic base minerals industry is finding it more and more difficult to compete in world markets. It has become essentially a marginal industry today. The current philosophy of taxation in the United States has evolved over the past century. The structure of the taxing system is based on the assumption that a firm must be able to pay its tax imposts out of profits. In principle, firms incapable of supporting the tax load should be replaced by others that can do so. This philosophy applies equally well to the mining industry, so long as it remains economically healthy. However, mineral resources are finite. The situation in the domestic base mineral industry has changed fundamentally in recent times. For the reasons given above, much of the industry now cannot continue to compete profitably in the open world market; and there are no known alternative domes- tic mineral resources more capable of doing so. Under these circumstances it is important to consider the effect of taxation not only on profitability, but also on survivability.

Jan 1, 1986

By John M. Wootten

The development of new coal markets is -t upon the ability to utilize coal in an environmentally acceptable and economically viable fashion. Foremost in the concerns about coal utilization is the impact its combustion has on air pollution. Concerns over environmental issues, such as acid rain, are currently one of the major impediments to the development of new coal markets. The Department of Energy and the Synthetic Fuels Corporation are addressing certain aspects of the development of new technologies for the utilization of coal. However, at the present time, there is a void in the new technology development process. That void is the step from proof- of-concept to commercial demonstration. Congress has established the Clean Coal Technology Fund at a level of $750 million to fill this void. The Department of Energy, in a solicitation of interest, received over 175 proposals for commercial demonstrations of clean coal technologies. A review of these solicitations indicates that $1.2 billion worth of research could be accomplished with a federal cost sharing of $425 million or 35 percent of the total. Industry has indicated, through this response, its willingness to invest its limited funds on projects it feels have the greatest potential for the clean use of coal. What must now occur is that Congress must appropriate the monies from the fund to initiate the commercialization of these clean coal techno1ogies.

Jan 1, 1986

Possible consequences of continuing internal political unrest and the imposition of foreign sanctions raise concerns about the traditional reliability of the Republic of South Africa as a major world supplier of important minerals. A recent Bureau of Mines' technical report (Open File Report 76-86) examined the impacts of temporary peacetime disruption scenarios for six key materials and mitigating options. Because of South Africa's dominant producer position for these minerals (except for cobalt), expansion of primary production capacity outside of South Africa is not a short term mitigative option. However, prospects of a longer term disruption would likely spur investment in capacity expansion in alternative Market Economy Country supply sources. This report identifies the resources, production costs, and burdens that would be placed on alternative MEC producers of chromium, cobalt, gold, manganese, and platinum-group minerals if South Africa's production were subject to a long term; disruption. When long term supplies from South African deposits are discounted, more than a few years reserves were found only for cobalt and manganese. Even for these two minerals, higher sustained prices would be required to increase manganese production capacity and to support means of cobalt transportation not through South Africa.

Jan 1, 1986

Surface geological observations are predominantly two-dimensional but can be expanded into three dimensions using geophysical techniques. These techniques have proved succ- essful in the past and will be utilised more frequently in future mineral exploration. Geophysical training establishments must recog- nize future requirements and teach geophysics as part of a broad earth science course as well as a specialised geophysical course. Central- isation of teaching skills, the use of high- technology in the classroom, and greater interaction between academic and industry staff are recommended as a means of ensuring a vibrant geophysical training base in Australia, for the geophysicist of the future.

Jan 1, 1986

By Marshall GA

Structural fatigue damage of haul truck frames is a costly problem associated with the operation of large mine haul trucks. A monitoring programme is described which has been instigated to measure stresses in the frames of haul trucks under actual mine operating conditions. The instrumentation used and methodology employed in the computer analysis of the results is briefly described. The results of the monitoring programmes are reviewed, and the effects of various factors affecting structural fatigue damage of three common types of rear dump truck are considered. Factors discussed include the effects of haul route features (for example shovel, dump and crusher areas); the effect of operations such as turning, braking, loading and dumping; the influence of payload; the effects of malfunctions in suspensions; and the influence of haul route surface quality. It is shown that with respect to payload, while structural fatigue damage is increased with payload, the structural damage per unit of payload does not change significantly for moderate increases in payload above the nominal value. Finally, on the basis of these results, recommendations are made for haul route design and operational practices which will increase the structural fatigue life of haul truck frames.

Jan 1, 1986

Provide a means of recovering precious metal values from finely ground tailing materials. Approach Determine the procedures needed for agglomerating the finely ground material for subsequent heap-leach cyanidation of the precious-metal-bearing tailings. Applying Agglomeration/Heap-Leaching to Fine Tailings Agglomeration technology was developed by the Bureau of Mines to provide cost-effective recovery of precious metal values though better heap leaching of clayey or low-grade ores. While many precious metal producers have adopted this technology to reclaim precious metals from crushed ores and wastes, other operations have experienced problems in using the heap leaching technique effectively on piles of fine tailings. In contrast to the coarser ore and waste material, most tailings piles contain more than 50 percent minus 200 mesh materials with no coarse material. Fine particles and clays present in the pile can impede 8 uniform flow of the leaching solution through the heap, thus preventing efficient and cost-effective precious metals recovery.

Jan 1, 1986

By R. J. Matetic

The impact of longwall mining on the local hydrological regime has become an important environmental focal point. Unfortunately, only a few studies have addressed the timing and range of well fluid level fluctuations and the associated ground movement. Furthermore, even fewer studies have determined the influence of longwall mining on water quality. The U.S. Bureau of Mines is providing insight into this environmental concern through a program of field case studies. One such study was conducted in Cambria County, PA where five observation water wells were drilled above two adjacent longwall panels. In this study, three wells were completed as nested piezometers and the remaining two served as producing wells. The piezometers were positioned along a line oriented subparallel to the longwall face and were located at the centerline of each panel and over the intervening chain pillars. The piezometers were designed to monitor fluid level fluctuations in both shallow and deep water-bearing zones. Slug tests were conducted before and after mining to characterize changes in hydraulic conductivity of the respective water-bearing zones. Pressure transducers and data loggers were installed to provide continuous fluid level fluctuation data as mining developed through the study area. The producing wells were drilled to provide water quality information. One well was located directly above the centerline of a panel and the other was positioned over the panel's set-up rooms. The wells were designed to simulate domestic use and were produced daily, for four hour intervals, throughout the study. Samples of the produced water were collected before and after mining progressed through the area. In addition, an array of monuments was installed near the study wells and was periodically surveyed to characterize mining-induced surface deformations. This study shows that: a) the observed changes in ground water chemistry did not affect the potability of the water; b) short-term major water level fluctuations occur at the approximate time of undermining; and c) water level recovery begins before the process of subsidence is complete.

Jan 1, 1986