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The Auscoke project has reached-a stage where a pilot plant nominally able to produce 100 t.p.d. of coked briquettes is being brought on stream during Nov. 1971 . The targets for this stage of the project are to establish the technological and economic value of Auscoke for the iron blast furnace, and to verify the commercial feasibility of large scale plants. The project originated at the B.H.P. Central Research Laboratories (C.R.L.) and work to date has shown that using a two stage contin- uous process, strong large coke can be produced at good productivities from medium or low volatile poorly caking coals. General features of the pilot plant and processing are discussed.

Jan 1, 1972

By George S. Koch

In preparing diamond-drill core samples for assay at the Homestake mine, Lead, S. Dak., 5-foot intervals of core are processed through three stages, crushing, grinding, and pulverizing, and portions of the core material are discarded after splitting at each stage of preparation. Then two 1-assay-ton fractions are taken from the pulverized material and assayed. This report investigates alternative methods of sample preparation. The consequences of crushing, grinding, and pulverizing all rather than part of the core are appraised through the statistical analysis of assay results from 118 5-foot intervals of core. Evidently, a substantial improvement in precision at small additional expense is obtained by grinding most or all of the core before splitting. Pulverizing all of the core would be desirable only if doing-so would cost less than assaying five random splits from each interval. Graphs and tables detail appropriate procedures to obtain specified precisions. The experimental design and methods can be applied to similar problems in preparing core and other geological samples.

Jan 1, 1972

By I. D. Shah

Thermal decomposition of copper (II) sulfate (CUS04) and copper (II) oxy-sulfate (CuO?CUS04) are important steps in the overall oxidative roasting of covellite (CuS) and chalcocite (Cu2S). Nonisothermal thermogravimetric techniques were used to investigate the decomposition reactions in flowing Na and air. Thermal decomposition of CUS04 and CuO?CUS04 followed "linear" kinetics with an apparent activation energy of 55±2 and 66±3 kcal per mole decomposed, respectively. These apparent activation energies comply with those previously reported when isothermal kinetic techniques were used. The addition of oxygen decreased the rate of decomposition, while small amounts of iron which were admixed with CuO?CUS04 did not have a significant effect. Neither oxygen nor iron had any appreciable effect on the apparent activation energy of the decomposition reaction.

Jan 1, 1972

The facilities used and techniques employed in the manufacture of steel and iron rolls at the Steel Foundry, B.H.P., Iron & Steel Works, Newcastle are described.

Jan 1, 1972

By G. J. Dickman, W. N. Thomas

The factors involved in selecting, a drive system for a grinding mill, including gearing arrangement, motor selection, and electric-supply system limitations are reviewed. Equipment costs are evaluated on a dollar per horsepower basis and starting performance is analyzed, the latter making use of a recently developed computer program. The present interest in large-diameter grinding mills and the rapidly rising cost of the drive in proportion to the cost of the mill establishes a need to explore the drive system in detail. The drive for a 7 to 8,000 hp mill will cost from $350 to $600,000 which represents nearly half the total cost of the mill package, and requires as much building space as the mill proper. Some of the drive components require a longer time to manufacture and the installation time and costs are equal to those for the mill. It is apparent that the drive has become a dominant factor in the overall mill design consideration. A new plant requires a tremendous investment in both time and money. With the high degree of competition in the mining industry, low capital cost is an exceedingly important factor in the development of a project. It is just as important, however, to insure that the equipment is going to perform satisfactorily for the anticipated life of the project without adding unplanned operating, maintenance, and replacement costs. This is the position in which the engineer or designer usually finds himself and is really one of his primary functionsestablishing a realistic compromise between cost and performance. Large primary grinding mills can represent a major portion of the cost of a plant and the drive system accounts for a substantial part of this cost. These facts justify a careful analysis of the drive requirements and all of the factors involved in ultimately arriving at the best system for the lowest cost. A number of excellent papers have been published on various aspects of mill drives. The authors have used information from these papers in making a study of a drive for a 7600-hp, 32 x 12-ft autogenous mill. This was a broad investigation, including mechanical and electrical design, layout, performance, and maintenance considerations, and overall economics leading to the selection of the optimum system for that mill. This paper was developed from the study and includes information applicable to large mills in general. For a successful and economical application, the drive must be considered as a system and all of the components analyzed to determine their effect on the system. This requires the participation of the mill designer, gear, and other mechanical component manufacturers, motor manufacturer, plant designer, and operator. A careful analysis of the mill torque requirements is first necessary to provide a basis for selection of the mechanical and electrical drive components. Because of manufacturing limitations on the size and capacity of gearing available for these low-speed applications, an evaluation of costs for various gear ratios and configurations in conjunction with motor speeds is required. Consultation with the power-supply company is necessary to determine limitations on motor-starting disturbances and to analyze operating costs on the basis of existing rate structures and low characteristics. Finally, consideration must be given to the drive arrangement and its affect on plant layout, space requirements, and location of auxiliary equipment for the selected process. There are presently three basic schemes for driving a mill. The first is a direct drive by a motor operating at mill speed with no gearing. The second is by a higher-speed motor through a trunnion-connected gear drive. The third is by a motor through the more conventional pinion and ring-gear with the option of an interposing gear box to permit greater motor speed than pinion shaft speed. [(Fig. 1.)] Several manufacturers have or are presently developing motors which drive the mill directly without the use of gears. One arrangement has the motor armature intimately surrounding the mill shell-discharge spout or extension of the trunnion journal. The motor stator is then supported independently and surrounds the shell or trunnion-mounted rotor. Another variation utilizes an independent mill-speed motor connected to the trunnion by a drive shaft and flexible couplings.

Jan 1, 1972

By B. C. Morrison

Because of U.S. Forest Service regulations and the consequent cost of leaving several diamond drill holes open at the same time, it was necessary to develop an electrical method that could be used in one hole at a time to extend known mineralization. This was achieved by balancing the surface current electrodes so that the two potential electrodes in the hole being surveyed were in the same equipotential surface. This condition eliminated stratigraphic response but enhanced any asymmetry due to ore between the hole and either current electrode. This method was successfully used in mineralized holes at West Fork, Reynolds County, Mo., to show the direction in which to extend the drilling into areas of better mineralization.

Jan 1, 1972

By John A. Teeter

"A SHORT WHILE AGO I enquired about The Mining Society of Nova Scotia. In all honesty I was apprehensive about addressing such a body if it was highly geared to the technical aspects of discovering and obtaining mineral resources. I was told that this would not be the case. Rather, there would likely be in attendance a broad cross section of people from business, industry and government and from across Canada and the U.S.A. Thus there would be an interest in a free-wheeling discussion of the prospects for industrial development in Cape Breton. Accordingly - being one who hates to miss an opportunity - I intend to exploit the invitation of your executive by being, over the next short while, frankly promotional. I would like to talk about what I consider to be some of the most important attributes of Cape Breton for industrial development and identify some of those prospects. Secondly, I will quickly review some of the things the Cape Breton Development Corporation is doing these days to stimulate some of that industrial development."

Jan 1, 1972

By H. Carroll

An ozone detector was built and evaluated for its applicability in smog-chamber studies. The detection method is based on the reaction of ozone with ethylene and the measurement of resultant chemiluminescence. In the first phase of evaluation, the detector's response to ozone was studied as a function of several instrument parameters, and optimum conditions were defined for the maximum and most stable responses to ozone. In subsequent evaluations, the method was checked for sensitivity, precision, and interferences and was compared with two alternative methods. Results showed the chemiluminescence method to be acceptably sensitive and precise for smog-chamber studies and superior to the Mast ozone meter and KI (colorimetric 1 percent neutral-potassium iodide method) methods in that it is specific for ozone.

Jan 1, 1972

By M. A. Sochocky

Rod mills were developed, as a logical substitute for the rolls crusher when larger tonnages had to be handled, on a continuous basis. Today, with even larger tonnages to process, the trend is to install larger equipment, automate the plant and develop the highest availability possible, in order to cut costs. The rod mills, because of design limitations in size and speed 1'2, are not able to meet these new requirements. The autogenous mill was a timely development and serves as an excellent alternative for ores that are suitable to this type of grinding. When ores are not amenable to autogenous grinding, selection of a flowsheet is dictated by liberation characteristics and unit operations to be used for mineral recovery.. The following alternatives are available: (a) Multiple rod mills, capable of drawing no more than 2000 HP each, followed by ball mills. (b) Gyradisc crusher followed by two stages of ball mill grinding.3 (c) Tertiary crushing followed by closed circuit single stage ball mills grinding to approximately -100 mesh, as in the copper industry. (d) Tertiary' crushing followed by two-stage, ball milling. Each stage will operate in closed circuit with either screens or cyclones. It is this last alternative, particularly as it

Jan 1, 1972

By M. C. Irani, Maurice Deul, M. G. Zabetakis, T. G. Bobick

This survey was conducted to determine the magnitude of the methane emission and control problem in U.S. bituminous coal mines. The resultant data indicate that the emission rate for any given coalbed depends primarily on the coal production rate and on mine depth, as well as on the nature of the coalbed and the surrounding strata. An excellent correlation was found between (1) the methane emission rate and (2) the product of coal production rate and mine depth for the mines in the Pittsburgh, Pocahontas Nos. 3 and 4, and the Illinois Nos. 5 and 6 coalbeds. The highest total emission rates found in U.S. bituminous coal mines were as follows, in million cubic feet per day: Monongalia County, W. Va., 39; Marion County, W. Va., 30.4; McDowell County, W. Va., 13.1; Washington County, Pa., 11.9; Greene County, Pa., 11.4; Buchanan County, Va., 21.6; Jefferson County, Ala., 10.3; and Franklin County, Ill., 6.6.

Jan 1, 1972

By M. G. Zabetakis

The method of moving averages was found useful in assessing the nature of methane emission in coal mines. Emission rates were influenced markedly by the presence of abandoned oil and gas wells in the vicinity of the mine. Such wells appeared to increase the flow rate of methane into the mine by a factor of 2 to 30 in an active mine in the Pittsburgh coal seam.

Jan 1, 1972

By R. R. Faddick

A mineral slurry data hank has been compiled, containing slurry pipelining data on sixteen ores, concentrates, and tailings. The data bank it in the form of a computer print-out all they necessary system constants and headloss data for each mineral commodity. The purpose of the data bank was to assist in the development of a universal head loss correlation for mineral slurries, if such a thing exists. Present headloss correlations were tested and found to be inconsistent for the various mineral slurries. Consequently, a different approach was taken, that of compiling a library or Stanton diagrams relating friction factor and Reynolds numbers for a given slurry in a given pipe diameter. The advantages of the diagrams arc demonstrated and discussed. While this correlation shows excellent potential, it is necessary that additional work, both theoretical and experimental, be performed. In addition, two equations are given from which a design velocity may be obtained to minimize deposition or formation of bedload. The equations are based on data taken from the mineral slurry data bank.

Jan 1, 1972

By R. R. Swanson

Liquid ion exchange is becoming more and more important in hydro-metallurgical processing and recovery of metals. The key to success for this process are reagents which have suitable operating characteristics. One of these important characteristics is a relatively fast phase separation rate in the extraction and stripping circuits, as this greatly affects the size of plant required. A test for measuring phase separation rate is needed to help evaluate liquid ion exchange reagents. Such "a test also would be useful for evaluating carrier solvents that are used for diluting the re-agents. In fact, one standard test method would be very desirable as it would provide a common basis for comparing reagents and sol-vents. The phase separation test described in this paper has been used successfully for several years with the copper reagent, LIX®64N. The test is set up for feed liquors containing low copper concentrations. For other types of systems, modifications in procedure probably would be necessary. However, this test and the associated apparatus could be the basis for a standard phase separation test.

Jan 1, 1972

By Still RF

Sintering of lead and zinc concentrates is practised by Sulphide Corporation Pty. Limited to provide both desuiphurised lump sinter feed, for simultaneous reduction to zinc and lead in the Imperial Smelting Process blast furnace, and sulphur dioxide gas for sulphuric acid manufacture. From November, 1969 a 20 percent increase in production rate has been obtained through improvements in operating technique. A gradual increase in bed permeability was achieved by modifications to the feed mix conditioning equipment and by improving moisture control. However advantage could not be taken of the higher permeability to increase sulphur elimination because the hardness of the lump sinter decreased. Higher throughput, better quality sinter and more stable sintering conditions were however made possible by simultaneously: 1. reducing segregation and compaction in the sinter bed, by narrowing the discharge opening of the main layer feed hopper, 2. reducing the sizing of sinter returns to give a closer size spectrum of particles in the feed mix, and 3. increasing the sulphide sulphur content of the feed mix to give higher bed Temperatures.

Jan 1, 1972

By J. C. Jaeger, G. A. Wiebols, N. G. W. Cook

It is usual practice in engineering to design a stable structure by ensuring that the stresses in the elements of the structure are always less than their strength, which may be defined as the yield stress, the ultimate stress, or the fatigue stress, according to the type of the load. Such restrictive design is not practical in the design of underground excavations since the rock surrounding such structures is usually failed, but only occasionally does this give rise to instability of the structure. Thus, while the usual criterion for the design of a stable structure is certainly sufficient, it is not necessary for underground excavations. A proper understanding of the conditions necessary for stability is vital to the useful application of rock mechanics knowledge to the design of underground structures. Most tests on the properties and strength of brittle rocks are disrupted at or near maximum load by the rapid release into the specimen of energy stored in the resilience of the testing machine. This is in contrast with a phenomenon, which may be observed frequently, where the rock immediately surrounding an excavation is both failed and subject to stress. By postulating a complete stress-strain curve for rock, it can be shown that failure is unstable or stable, depending upon whether the stress-strain curve of the rock lies inside or outside the stress-strain characteristics of the applied stress. Stability is, therefore, a function of the stiffness of the system applying the stress relative to that of the failing rock. Many workers have established that the strength of rock specimens under a lateral hydrostatic confining stress varies linearly with confining stress, in a way which may be expressed by the equation CT=Co+K[o]3

Jan 1, 1972

By P. S. Lewis

Shortage of natural gas is reviving interest in low-Btu fuel gas made by gasifying coal in fixed-bed producers. The Bureau of Mines gasified strongly caking Pittsburgh bed coal over test periods lasting four days in an experimental gas producer located at Morgantown, W. Va, Mechanical stirring throughout the fuel bed was effective for keeping the fuel moving and this stirring made the operation successful; hence, the gas producer was named the stirred-bed producer. Nuclear density gages were applied as control instruments to indicate coal flow and fuel level, and to record the frequency and location of void spaces in the bed, The gas, of nominal 140 to 165 Btu/scf calorific value, could be burned in a boiler for generating steam.

Jan 1, 1972

By A. J. Forney

A high-Btu gas was made at the Bruceton, Pa., laboratories of the Bureau of Mines to demonstrate the feasibility of using the gas as a nonpolluting fuel for automobiles. The pilot plants at Bruceton were revised to combine the processes of coal gasification, gas purification, and catalytic methanation in one overall system. Tests in the Bureau's test automobiles at Bartlesville, Okla., showed the Synthane gas was less polluting than natural gas.

Jan 1, 1972

By John W. Tieman

The increasing magnitude of our nation's pollution problems seems to stem from two main factors: urbanization and technical advance. In 1920, less than half the country's 106 million people lived in cities. Forty years later, the urban population accounted for 70 percent of the nation's 179 million. It is predicted that by the end of the century, 95 percent of the U. S. population, estimated at 280 million, will live in urban areas. As these people live increasingly in city concentrations, their residues also concentrate. With technological advances to support the increasing population, the variety and quantity of goods that we use also increases. New materials and processes result in increases in pollutants, some of them new. The harmfulness of these pollutants is sometimes known, but sometimes only suspected. One pollutant of concern at the present time is sulfur dioxide, the product of combustion of sulfur-containing fuels. Research on processes to remove sulfur oxides from flue gas has been in progress for many years. Pioneers in this field were the British who, in the early 1930's, installed a full-scale flue gas scrubbing unit on a 120 MW boiler using alkaline water from a Thames estuary plus chalk. Since that time, various methods have been studied by many investigators. Federal laws covering air pollution started with the 1955 Air Pollution Control Act. With the advent of the Air Quality Act of 1967, and subsequent publishing of criteria and available technology for control of sulfur oxides in January 1969, the clamor for information on commercially available control techniques to remove sulfur from fossil fuels has rapidly increased. Although many state-of-the-art papers have deluged the literature during the past several years, the research going on in the area of sulfur oxides control is of such importance that periodic reviews are justified. It is the purpose of this paper, therefore, to again review the state-of-the-art, but this time from the stand-point of what is immediately commercially available

Jan 1, 1972

By John F. Gartner

"Traditionally, the geologists of Canada have been occupied with the tasks of finding new mineral bodies, locating gas and oil fields or hunting for economic deposits of industrial minerals. A very minor percentage of graduate geologists have applied their skills to solution of the ""urban blight"" or employing their understanding of ""Nature"" for the optimum use of land by mankind. However, things are changing quickly. The role of the geologist in the planning process is being established. It is an exciting time! Geologists are now being consulted on a wide range of urban planning problems. These vary, tor example, from assessment of the geological environment for the new communities of Erin Mills and Meadowvale, which will have total populations in excess of 100,000 people (truly a satellite city), to a complete geological/ geohydrological assessment of the new sanitary landfill for the city of Guelph.Use of geologic techniques and methods for urban studies must be enhanced with certain skills not taught, in the past, to the geologist. These include airphoto interpretation, soil mechanics, geohydrology, municipal engineering and highway engineering to mention a few. The geologist has the unique training to assess the natural environment and to discover, warn and explain the implications of man's attempt to command his environment."

Jan 1, 1972

By C. Dinis da Gama

In mining, all unit operations are closely interrelated, and the results of blasting are probably the key factor within that sequence. The drilling program prior to blasting is just as dependent upon the desired rock fragmentation as are the loading, hauling, and mechanical crushing operations which are economically and technically influenced by the results of blasting, namely, the size and scatter of the product. What is known today as optimum blasting is the process of designing a blast in order to obtain a certain degree of fragmentation so that overall mining costs are minimized. Applying this criterion often results in a different program than when an individual blasting pattern is chosen only on the basis of the lowest operational cost for that pattern, disregarding what comes before or after the blast. [Fig. 1] shows the characteristic variation of mining unit costs with the degree of fragmentation, or the maximum size of blocks obtained from blasting. From the figure, it can be seen that optimum breakage must correspond to the lowest total costs, but reducing drilling-blasting costs only does not achieve such an optimum solution. Methods of designing surface or underground blasting operations should comply with the optimization criterion, but this compliance is feasible only if a detailed mining system analysis is available. Therefore, predictions of costs of loading, transporting, and mechanical breakage of ore as a function of its size will define a narrow range of variation for drilling and blasting parameters in order to get the minimum total costs.

Jan 1, 1972