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By G. E. Norman, R. E. Michelutti

"One of the major objectives of Falconbridge has been and continues to be, to minimize the impact of its operations on the environment around its Sudbury operations.The approach to achieving this objective and the results, are discussed under the following topics .I . Sulphur Dioxide Emission Improvements.2. Effluent Treatment Improvements .3. Effect of the Envrionmental Improvements.Sulphur Dioxide Emission ImprovementsHistoryThe rejection of pyrrhotite in the concentrators is one method of reducing the amount of sulphur to the smelter and therefore the sulphur dioxide emissions. In the 1950s and 1960s, Falconbridge developed the capability to remove 54% of this pyrrhotite. Numerous attempts were made to increase this amount by treating the pyrrhotite for recovery of nickel and in some cases elemental sulphur. Processes tested and operated were: hydrometallurgical pilot plant, roast-leach commercial operation and nickel-iron refinery. None of these processes proved to be commerically successful for both technical and economic reasons. Falconbridge therefore redirected its efforts to reducing sulphur emissions by improving its smelting process under The Smelter Environmental Improvement Project. A major component of this project was the installation of a sulphuric acid plant to recover the S02 in the roaster off-gases."

Jan 1, 1984

By Shosei Serata

Serious floor heave of up to 2.4 m in a 2.4-m high mine entry was eliminated by applying the stress control method of mining, as a last resort, at the No. 5 coal mine of Jim Walter Resources, Inc., in the Black Warrior coal basin near Birmingham. Alabama. Underground observation of the first 3-room entry created using the stress control method is discussed here. The behavior of the test entry, which eliminated the heave problem, is analyzed in relation to similar studies conducted in a salt mine under similar ground conditions by utilizing finite element analysis.

Jan 1, 1984

By Robert S. Shoemaker

At this Symposium on Gold which is sponsored by The Metallurgical Society of AIME and the International Precious Metals Institute many distinguished authors will present the latest developments in the metallurgy of gold and in operating practices at mines and in refineries. It seems appropriate then, as the introduction to this volume to recall some of the history of gold and the metallurgical developments which have been accomplished, especially during the past 100 years and some of the people who have contributed so much to the metallurgy of gold. Of all the elements gold has been the most sought after since the earliest times. Perhaps the quotation from Virgil's Aeneid best describes man's desire for gold but Pliny the Elder also put it very well when he wrote in 79 A.D. that "Gold is the first of man's follies, silver the second". This quest for gold has markedly influenced man's history and through the efforts of the early philosophers and alchemists to turn base metals into gold the foundations for modern chemistry were laid. The pages of history literally teem with references to gold. Gold is the first metal mentioned in the Bible and was the source of Croesus wealth as well as the death of King Midas whose touch turned everything into gold. And of course almost everyone has heard of Jason's Argonauts and the golden fleece. They are the subject of one of the many drawings in Agricola's De Re Metallica published in 1556. The Argonauts were probably prospectors seeking the source of the placers in the region near-the Black Sea. The time was about 1200 B.C. and the placer miners recovered gold by trapping the particles in sheep's fleeces placed in sluices. After drying, the fleeces were shaken to recover the gold. Gold is not hydrophilic, or wetted by water and thus the oils in the wool aided in collecting the particles. Here we have perhaps the earliest reference to surface chemistry and the basis for concentration of gold by flotation.

Jan 1, 1984

The reasons for and the methods of inte- gration of the gold treatment plant with the existing nickel concentrator are discussed. The integration was accomplished in three stages commencing in May 1980 and attain- ing current throughput in December 1982. The problems encountered and their solution, including the design and construction of a new tailings dam are also discussed.

Jan 1, 1984

By Charles Fairhust

Although the term 'rock mechanics' started to become popular about the time of the First U.S. Rook Mechanics Symposium in 1956, study of the mechanical behavior of rock certainly pre-dates this event. Bucky, Phillips, Von Karman, Fayol, Galileo...the list of significant contributors can be traced back over centuries, - not surprising for the oldest structural material used by man. Started with a strong mining orientation by the Colorado School of Mines, University of Minnesota, and Pennsylvania State University, joined soon after by Missouri School of Mines and the University of Texas, the Annual U.S. Symposium on Bock Mechanics has evolved into the main U.S. form for discussion of all aspects of rock mechanics, basic and applied - tectonophysics to comminution; near-surf ace foundations to deep mine support design. Although dominantly a U.S. event the annual symposium has benefitted from regular and important contributions from abroad. It would be presumptuous to attempt a comprehensive statement of significant developments over the 25-year history of the U.S. Bock Mechanics Symposium. This anniversary address will attempt instead to present a personal view of developments that appear to be of broad general significance and that may indicate directions for the future. Among the developments to be discussed in the address arc the following: - Energy Basis of Book Fracture Early rock mechanics investigators often overlooked the important distinction between a failure initiation stress and structural collapse. Although essentially synonymous in the

Jan 1, 1984

Sinter mixes of three iron ore types were prepared with a range of water contents in a laboratory investigation. The mean diameter of the granulated mixes and the void fraction of beds of the mixes were determined experimentally. Pressure drop measurements over a range of flow rates were made in a laboratory permeameter with pressure tappings at several depths in the bed. The Ergun equation was applied to the results to determine the shape factor of the granulated mixes. The pressure readings down the bed were used to estimate the local void fraction in the bed using the Ergun equation and the calculated granule shape factors and it was found that there was a decrease in void fraction with depth in the bed. The significance of this and the variation of the shape factor values with the amount of water used for granulation is discussed in relation to the strength of granules of the sinter mixes.

Jan 1, 1984

By Mahesh C. Jha

Arsenical gold ores occur in many parts of the world, including numerous mines in Canada and the western United States. Free gold is often finely disseminated in the grains of sulfide minerals, arsenopyrite, pyrite, orpiment and realgar. Generally a sulfide concentrate is produced by flotation. Arsenical ores or concentrates are not amenable to direct cyanidation and therefore are considered refractory. A wide variety of roasting equipment and conditions have been used by the mills to remove arsenic and sulfur from these concentrates. The resulting calcine is easy to cyanide and gold is recovered from the cyanide solution by zinc dust cementation. Room-temperature potential-pH diagrams and high-temperature phasestability diagrams are presented to discuss the chemistry of the gold cyanidation, cementation, and roasting steps in the presence of arsenic. The environmental aspects of arsenic discharge are also included.

Jan 1, 1984

Roller seed screens were installed at The Broken Hill Proprietary Company Limited (B.H.P.) Whyalla pellet plant to replace vibrating screens on the green ball circuits. The installation of roller screens was justified by improving the sizing of the green balls. This improved sizing increased the yield of fired pellets produced from green balls thus decreasing the fuel consumption. The fired pellet sizing was improved also. This paper discusses the configuration of the roller screens installed at Whyalla, quality of green balls produced, advantages of roller screens compared with vibrating screens and future development of roller Screens.

Jan 1, 1984

By P. R. Bremmer

As part of a program to devise alternative technologies for producing alumina from domestic resources, the Bureau of Mines investigated the leaching of calcined kaolinitic clay to form basic aluminum chloride solutions. Bench-scale experiments were conducted for single-stage batch leaching with AICl3 solution and three-stage countercurrent leaching with substoichiometric HCI. Variable conditions of clay calcination and leaching were studied to determine their effects on aluminum extraction and pregnant liquor composition,

Jan 1, 1984

By R. Augsten, K. K. Feng, K. C. Cheng

"Methane emission and the desorption characteristics of vertical borehole coal samples of Greenhills multiple seams in the vicinity of Elkford, British Columbia were investigated. Three vertical boreholes at depths of 335 m, 380 m and 395 m were drilled along the west wall of an active open pit mine and 44 core samples from various coal seams were obtained for desorption studies.The results are presented in three tables and illustrated with six figures. The methane content was found to increase significantly at depths greater than 200 m. The adsorption equation by Kim and the properties of the coal have been used to predict the methane content and these were compared with the measured values by the direct method.IntroductionThe coalification of plant material in the sedimentary rock produces different ranks of co al and gases of various composition. The gas mixtures are retained in coal beds and rock strata under pressure. The gas content in a coal bed varies considerably depending on the rank of coal and the depth of overburden. The gas content is defined as the volume of gases adsorbed in a unit weight of coal materials. The net amount of gases remaining in a coal seam depends on the difference in the rate of generation of methane by geo-thermal heat and the rate of diffusion of the gases out of the coal bed through sedimentary cover. The major factor that causes the change in rank and the liberation of gases is the temperature, which is governed by the thermal conductivity of sedimentary cover and the heat flux through the underlying rocks. The rate of diffusion of the gases out of the coal is governed by the porosity of the overlying rocks and the degree of fracture. The measured values of gas content in major North American coal beds are from zero up to 24 cm3 per gram of coal(1,2). A gas content of 2.5 to 9 cm3/g is considered ""gassy"" and that of 9 cm3/g or higher is considered ""very gassy"" for underground mining(3). Normally, the gas mixtures released from bituminous coal in Canada contain 90 to 98% methane and the remainder is made up of CO2, N2, 02, H2, He and other hydrocarbons(4)."

Jan 1, 1984

By Richard P. Walters

This Bureau of Mines report reviews and assesses the technology for preparing electrodeposited coatings of the platinum-group metals from molten alkali metal cyanide baths. Methods are described for the preparation and purification of the cyanide electrolyte. Vacuum drying, fusion, and purity of the cyanide salts are discussed. Use of a sodium borosilicate test tube as a sodium-ion-conducting membrane for the addition of the desired platinum-group metal is described. The optimum plating parameters of potential and current density for Pt, Pd, Rh, Ru, and Ir coatings that result in the best deposits are given. A method for producing platinum-rhodium alloy coatings of predetermined composition is also described. The importance of careful substrate surface preparation is illustrated. While problems still remain with respect to coating porosity, careful application of the methods described permits the preparation of adherent, coherent electrodeposited coatings of the platinum-group metals.

Jan 1, 1984

Western Mining Corporation (W.M.C.) operates a nickel refinery at Kwinana, 30 km south of Perth. The refinery commenced pro- duction in May 1970, with a rated capacity of 15 000 tpa of nickel metal. A hydrometallurgical route was chosen as the most expedient way to produce nickel metal at a time when world demand for nickel was outstripping the supply. Later events dictated that an increase in production from the refinery be achieved. To this end, matte produced from Kalgoorlie Nickel Smelter, which was commissioned in 1972, was used in varying proportions as a complement to the concentrate initially utilised as input to the refinery. The effect of matte addition was to increase the capacity to 30 000 tonnes of nickel per annum. This was accompanied by other benefits which were 1. reduction in energy consumption per unit of nickel produced, 2. improved metal extraction, 3. improved precious metal recovery, 4. reduced production of ammonium sulphate by-product. Refinery operating results for the years 1970 to 1983 show how matte feed has improved refinery performance in these areas.

Jan 1, 1984

By D. Ott

Results of a research project on investment or lost wax casting will be presented. The project was concerned with various aspects of the process as they are typical for the production of jewellery from gold alloys. During these investigations testing methods for investment quality as well as for casting quality and the various process parameters were developed and charateristic defects as they occur in practice were traced back to their origin in the process. Investigated were various static casting and centrifugal casting methods in different atmospheres as well as vacuum casting in devices of different design. It was shown that independent of the method a close control of the many process parameters interfering with each other is essential for a quality casting.

Jan 1, 1984

Recent geological mapping has indicated changes to the stratigraphy of the Pine Creek Geosyncline. The new stratigraphy and interpreted depositional environments are examined in relation to the distribution and genesis of stratabound mineral deposits. Basinward correlations are made with near-shore carbonate and psammite-rudite units in the Rum Jungle region. Most other units in the same region are condensed, indicating long- lived supratidal, intertidal or shallow conditions during most of the depositional cycle. Units containing most of the mineralisation represent the earliest near-shore developments of strongly reducing partly pelitic and evaporitic conditions and contain mainly uranium and base metals. Restricted distal, strongly reducing facies with associated felsic volcanics are also well mineralised, and mainly contain gold, silver and base metals, although some deposits are probably genetically related to synorogenic or postorogenic granites. Mineralisation in other facies is almost all epigenetic hydrothermal in origin, although minor mineralisation is related to volcanics, or dolomitic parts of the sequence. Areas of potential mineralisation include near-shore environments in the north, and carbonate reefs along growth faults. Two suites of postorogenic felsic volcanics and related sediments deposited in shallow water within and around northwest and east-northeast rift systems, overlie the metasediments of the Pine Creek Geosyncline in the south. The suites have potential for volcanogenic deposits, mostly of uranium, gold and copper.

Jan 1, 1984

By J. H. Curran

In this paper, a numerical model for determining the stress and displacement fields around a crack of arbitrary geometry in a linear elastic medium is described. Accuracy and computational speed were the main considerations in selecting the numerical method and Propagation criteria used to model the growing crack. Some results regarding the stresses and displacements around a two-dimensional crack of arbitrary geometry are discussed.

Jan 1, 1984

By Gennaro G. Marino

Site conditions at several shallow room and pillar mines in Illinois are described and compared with the charac¬teristics of the subsidence profiles at the ground surface. The shape and magnitude of the subsidence profiles were found to be closely related to the thickness of the soil and rock over-burden the percent extraction of the coal, and the shape of mine pillars. The room and pillar mines were located at a shallow depth (from 112 to 220 ft), beneath flat to gently rolling terrain. Thickness of the coal seams ranged from 5 to 9 ft and at all sites was underlain by underclays. This information has been developed in order to improve techniques for evaluating the subsidence potential at sites within the Illinois coal basin. he results presented form a small portion of the work carried out by the University of Illinois with Illinois Abandoned Mined Lands Councils and the U. S. Bureau of Mines at the Minneapolis Research Center in Minnesota (Marino and Mahar, 1985). Presented in the paper are the modes of mine failures observed for Illinois room and pillar mines, an overall summary of the site geologic and mining condi¬tions, case histories of each mode of failure, a comparison of sag profiles, and then an empirical relationship between the site conditions and the maximum sag subsidence. The most ideal case histories are presented to illustrate fundamental behavior. A brief of the Paper is given in a summary and conclusions section.

Jan 1, 1984

By G. O. Kesse

The Republic of Ghana, located on the West Coast of Africa, is one of the West African countries rich in bauxite deposits. The main occurrences of bauxite deposits are at Sefwi Bekwai in the Western Region, Aya-Nyinahin in the Ashanti Region, Atewa Range near Kibi and at Mount Ejuanema both in the Eastern Region of Ghana. These bauxite deposits belong to the so-called blanket deposits as they are associated with erosion surfaces of old peneplains and occur as cappings on the flat tops of hills or mountains whose heights are generally greater than 600 metres above sea level. These deposits can also be classified as laterite-silicate bauxites since they have been formed under tropical weathering conditions. Genetic and mineralogical investigations have revealed that all bauxite deposits of Ghana are the result of indirect bauxitization processes, for the minerals of the weathering parent rocks have not been transformed directly into gibbsite. In all cases, lithomarge of kaolinitic clay can be recognised. The geology of the major occurrences of bauxite in Ghana shows that the Mount Ejuanema deposit is the only deposit associated with the Voltaian System of rocks. This rock System consists mainly of sandstone, shale, mudstone, conglomerates and pebbly beds. All the otter deposits are associated with the Birimian System of rocks which are made up of metamorphosed lavas,pyroclastic rocks, hypabyssal basic intrusives, phyllites, schists, tuffs and greywackes.

Jan 1, 1984

By He BQ

Static attachment of bubbles to solids is contrasted with dynamic attachment in flotation cells. The times of contact during particle-bubble collisions in dynamic attachment are compared with the induction time determinations and the kinetics of thinning of the liquid films separating solids and bubbles. The thinning is examined mainly in terms of electrostatic and dispersion (van der Waals) contributions to the disjoining pressure existing in the films. The local heterogeneity (on a molecular scale) of charge distribution invariably present at all interfaces (even at conditions of zero zeta potential) calls for some means to minimize possible electrostatic repulsions which arise when the electrical double layer at the air-bubble interface begins to overlap that present at the solid surface, on encounter between particles and bubbles. It is postulated that dipoles of frother molecules, owing to their ability to "flip over" (polarise), replace localized electrostatic repulsion by attraction within fractions of a milli- second, as long as the structure of the frother molecules is sufficiently "bulky" to maintain diffuse films (of mixed collector-frother) at the air/liquid interface of bubbles. The relaxation times of dipoles (signifying their "flipping over" ability) have to be shorter than the collision times between particles and bubbles for particle-bubble attachment to be facilitated under dynamic Conditions.

Jan 1, 1984

By Sloan GJ, Lysnar RD

Since the of Bergstrand's Geo-dimeter in 1946, and Wadley's Tellurometer in 1956, there have been numerous Electromagnetic Distance Measurement (EDM) instruments produced throughout the world by a variety of companies.This form of measurement has not merely replaced other methods of measurement, but has caused considerable change of emphasis in survey techniques. Major control surveys are now being accomplished using trilateration instead of triangulation. The surveying of open cuts or engineering work may be done in a fraction of the time and, in the majority of cases, to a greater degree of accuracy than with older methods.It is surprising that with this new tech-nology and development of EDM equipment which is compact, easy to use and no longer so expen-sive, no advance has been made in underground surveying. If we look at equipment being used by the majority of mining companies, we see that there have been very few changes since the Second World War. Very little research has been carried out to enable the surveyor to do his work more easily in conditions which, at the very least. are hazardous.

Jan 1, 1984

By Wilfried Ufer

[1. Einführung in die Problematik 1.1 Die Bedeutung des Schildausbaus Seit fast 30 Jahren ist die Konkurrenzsituation auf dem Primärenergiemarkt der Bundesrepublik Deutschland durch einen von Erdöl and Erdgas geführten and insbesondere gegen die Steinkohle gerichteten Verdrängungswettbewerb gekennzeichnet, der den Steinkohlenbergbau zu tiefgreifenden RationalisierungsmaBnahmen zwang. In diesem Zusammenhang kam es Anfang der 70er Jahre zur Einrührung des Schildausbaus, der eine erhebliche Produktivitätssteigerung in den Strebbetrieben zur Folge hatte and damit die Uberlebenschance des Steinkohlenbergbaus in der Bundesrepublik Deutschland enorm verbesserte. Der Grund hierfdr lag darin, daB der Schildausbau im Vergleich zu dem vor ihm eingesetzten Rahmen- and Einzelstempelausbau eine wesentlich hdöhere Ausbauleistung erbrachte, weil er sich weit weniger empfindlich gegen Hangendausbruche and aus dem Alten Mann hereinbdschende Bruchberge erwies. So erklärt sich auch die stürmische Entwicklung and die schnelle Verbreitung des Schildausbaus. Bereits 1975 stammte rd. 50 % der Fdrderung aus Schildstreben, 1990 waren es fiber 75 % and heute sind es fiber 90 %. 1.2 Die Staubentstehung beim Schildausbau Die Erfolge des Schildausbaus sind unbestritten. Jedoch nahmen :nit seiner Einführung die Probleme der Staubentstehung and Staubbekämpfung im Vergleich zum Ein zelstempel- and Rahmenausbau erheblich zu. MaBgebend dafür sind hauptsächlich folgende Gründe: - Abbau von dozen nit gebrächen, weichen Hangendschichten, die erst durch Schildausbau abbaubar wurden, - Zerkleinerung des auf den breiten Kappen aufliegenden Bergematerials infolge der höheren Ausbaustiltzkrafte des Schildausbaus, Zermahlen der sick in die Spaltabdichtungen hineinarbeitenden Bergestückchen, - Erhöhung der Wettergeschwindigkeit infolge der durch die Baufarm des Schildausbaus bedingter. Verkleinerung des Strebquerschnitts verbunden mit der Aufwirbelung and Aussichtung von Staub, - Aufwirbelung von bereits abgelagertem Staub im Bruchraum beim Hereinbrechen der Dachschichten. Die genannten Gründe treten zumeist nicht in jedem Abbaubetrieb gleichzeitig auf. Sie rind vielmehr u.a. abhängig vom Ausbautyp, von den Gebirgsverhältnissen and von der Abbaugeschwindigkeit. Trotzdem ergeben sich beim Vorrücken des Ausbaus in der Regel hohe Staubkonzentrationen, die deswegen besonders kritisch sind, weil es sich um quarzhaltigen Feinstaub handelt, der besonders gesundheitsschädlich ist. Die Hauptzutrittsstelien]

Jan 1, 1984