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Lower noise exposure levels for operators and cleanup personnel working in portable nonmetallic mineral crushing and screening plants.

Jan 1, 1983

By Dave D. Ferris

Today the coal industry is beginning to use some very fundamental economic evaluations to determine the most economical circuit to produce a specified saleable product. The fundamental economic methods used are standard return on investment and net present value calculations. By utilizing these economical evaluations, one can justify a larger capital expenditure and realize more return for an investment over the life of a coal property.

Jan 1, 1983

By J. B. W. Bailey

The Noranda Horne smelter in Quebec, Canada has change considerably during the last two decades to accommodate varying custom concentrate receipts, closure of the Horne mine, better working conditions, environmental programmes, new technology and increased energy and labour costs. This paper highlights the reasons for changing the smelter from two calcine charged and one wet charge reverberatory furnaces fired by coal to a smelter using. tonnage oxygen oil, natural gas and coal in a single wet charged reverberatory furnace and a Noranda Process continuous Reactor. The current operation 1 described, including three major topics; the use of oxygen/fuel burners on the charge banks of the reverberatory furnace which has increase the smelting rate from 680 to 1100 tonnes of concentrate per day; the oxygen enrichment of the Noranda Process converting air to achieve smelting rates of over 1800 tonnes of concentrate per day; the converting of the mixture of 73 percent copper matte produced from the Noranda Process and the 33 percent copper matte produced from the reverberatory furnace.

Jan 1, 1983

By Keith T. Griffiths

INTRODUCTION The Empress Nickel Mine is situated forty-eight kilometres west of Kadoma in the Zhombe Communal Land of Zimbabwe. The mine came into operation in late 1968 based on a proved and probable ore reserve of twenty million tonnes. The initial production rate was 55 000 tonnes per month from underground. This was boosted to 85 000 tonnes per month in mid 1970 when the opencast operation came into production. The mining method at Empress is sub-level open stoping with main haulages mined at ninety metre intervals and sub-levels at eighteen metres. The extremely wide ore body of up to one hundred metres in width has necessitated leaving extremely large rib pillars and sill pillars in position to maintain mine stability and to act as regional support of the hanging wall. In early 1976 the opencast operation had reached its final economic depth and it was then necessary to increase underground production to 85 000 tonnes per month. Since a large portion of the ore reserve remained in both rib and sill pillars, it was necessary to embark on a positive pillar recovery programme. For this reason it was decided to introduce a sandfilling programme for the mined-out stopes and a modified system of sub-level open stoping with post filling of the lower stopes. ORE BODY GEOLOGY AND GEOMETRY The Empress orebody outcrop has a strike length of nine hundred and fifty metres on a north west - south east axis. It is a steeply dipping (65' - 75') tabular orebody of gabbroic rock which has been extensively altered. The north west - south east strike length of nine hundred and fifty metres on surface reduces to some two hundred

Jan 1, 1983

By Steven M. Shope

An essential element of the Bureau of Mines electromagnetic location and communication system for trapped miners is a quantitative knowledge of the surface and above-surface electromagnetic fields created by an underground transmitter. The field solutions given in this report use approximations in which the displacement currents are negligible for low frequencies. The earth is represented by a homogeneous half-space model in which a dipole source is immersed. The vertical magnetic field equipotential contours at and above the surface are graphically mapped. The volumes of the regions bounded by these contours are directly related to the geometrical zones of signal detectability. Knowledge of the detectability zones will enable the proper search strategies to be developed for airborne detection of trapped miners.

Jan 1, 1983

By V. Rajaram

Rock reinforcement systems are used in open pit and underground mines to stabilize the rock mass in-situ and provide safe working conditions. Significant progress has been made to date in the design and implementation of rock reinforcement systems to accommodate bad rock conditions and larger excavations. However, the rationale for the design of rock reinforcement systems remains essentially the same and can be categorized into three groups, namely 1. to create a beam of competent rock in stratified formations, 2. to resist sliding motion in jointed rock, 3. to passively support the superincumbent loads in highly stressed ground. Case histories of the rock reinforcement sys¬tems that illustrate these design approaches will be presented in this paper.

Jan 1, 1983

By Catherine C. Kilgore

The Bureau of Mines investigated the availability of lead and zinc from 104 domestic mines and deposits. Fourteen primary lead and fifty-three primary zinc operations with in situ demonstrated resources containing 27.3 million metric tons (t) of lead and 53 million t of zinc were subsequently evaluated. Potentially 17.5 million t of lead and 2.4 million t of byproduct zinc could be recovered from 14 primary lead operations. Economic evaluations performed in constant January 1982 dollars determined a long-run total cost per pound of recoverable commodity. Including a 15-pct discounted-cash-flow rate of return (DCFROR), 59 pct of primary lead was potentially available at or below $0.32 per pound of lead. Potentially 40 million t of zinc and 5.6 million t of byproduct lead could be recovered from 53 primary zinc operations. Ninety percent of the recoverable zinc is potentially available from currently nonproducing mines and deposits, and a weighted average of their long-run total costs was determined at $0.98 per pound of zinc. At a breakeven (0-pct) DCFROR, these non producing operations had a weighted average long-run total cost of $0.58 per pound of zinc. Sensitivity analyses illustrated that operations that recover byproducts were most sensitive to fluctuating metal prices, producing operations were more sensitive to increased smelter treatment charges, and nonproducing operations were impacted most by the DCFROR.

Jan 1, 1983

By Floyd L. Prestridge

A test of a solvent extraction (SX) pilot plant featuring electrostatic coalescence has been performed by C-E Natco at the United Nuclear uranium mill in Church Rock, New Mexico. Operating in parallel with the United Nuclear SX system, the C-E Natco electrostatic SX pilot plant exhibited comparable extraction efficiency to the United Nuclear system which utilizes conventional mixer-settlers. The C-E Natco pilot, however, operated at much higher liquid loading rates and exhibited less communication between the aqueous phases of the extraction and stripping circuits.

Jan 1, 1983

By Peter Babik

"Cable TV networks are extensively used throughout Canada for TV signal distribution. Mobile/portable radio communications are also used extensively throughout all sectors of industry. There are numerous manufacturer supplying these industries with a wide variety of equipment and accessories.IAL's underground radio communications system combines the techniques of cable TV and mobile radio to produce a flexible communications system with most of the advantages of both systems. Standard off-the-shelf mobile, portable, base-station and repeater equipment can be used. The equipment may need modification to be customized to particular end user requirements, but does not require a complete new unit redesign. Likewise, the cable TV distribution equipment is off the-shelf, with some items requiring modification for underground system application.Radio communications can be provided wherever the cable system is extended. Where traffic or type of activity warrants it, multiple radio channels can be provided on the same cable. Certain radio channels could also be used with data channels for control or supervision of remote equipment or environmental conditions. In addition, the same cable can be used to distribute or monitor signals from remote TV cameras in selected or dangerous areas. The system can be interfaced to a telephone system, if required, to provide extended communications to above-ground workshops, offices, medical stations or even hospitals and other emergency services.IntroductionReliable communications among personnel throughout an underground mine area have long been the dream and goal of various mine operations personnel. The system to be described was designed to meet this objective."

Jan 1, 1983

By R. A. Rabnett, G. Paget, Patrick Walsh

"Tumbler Ridge, Canada's newest resource community, has been developed differently than have been other resource communities.Since its conceptualization, emphasis has been placed on the establishment of a traditional municipal government at early a stage as possible.Planning f or the community goes back to 1977. By then, extensive study by provincial agencies had shown a new resource town would be required to exploit north east coal. The Ministry of Municipal Affairs, in conjunction with a consultant named R.A. Rabnett began the extensive Tumbler Ridge conceptual plan.The results of the conceptual plan are evident in the organizational and planning goals of Tumbler Ridge. In every aspect from the election of officials to some financial matters, the town functions as a normal municipality. With the resource companies of the North East Coal Development within its municipal boundaries. Tumbler Ridge has been able to debenture its capital projects against its municipal tax base.The town's ability to function as a normal municipality is enhanced by its control over Crown land it has purchased from the province. This gives it further control over the development of the community and helps in establishing agreements with the resource companies and the provincial government to ensure that housing and service needs are met. While resource company representatives sit on certain municipal committees, their roles are advisory in nature.The community continues to move toward full municipal status and will have a fully elected Council by 1986.BackgroundPlanning for the development of northeast British Columbia coal resources began in 1976 under the aegis of the provincial Cabinet Committee on Coal Development. A series of subcommittees were established including a Townsite/Community Development subcommittee. The Ministry of Municipal Affairs chaired this subcommittee and continued as the lead agency for the provincial settlement planning effort over the period 1976 to 1981."

Jan 1, 1983

By Roy E. Peterson

The Bureau of Mines conducted bench-scale research to evaluate materials which showed potential as low-cost reductants for use in the ironmaking industry. These materials were lignite, subbituminous coal, coal char, tree trimmings, refuse--derived paperboard, used crankcase oil, and peat. To compare their effectiveness, the materials were tested in the reduction roasting of nonmagnetic taconite and, except for oil and peat, in the reduction of iron oxide pellets to metallized pellets. Reduction was conducted in a 18-cm-diameter, rotary drum, which was externally heated in an electric furnace. Over 92 pct of the iron was magnetically recovered from a nonmagnetic taconite after roasting with any of the reductants, but greater quantities of reductant were required to achieve this when the waste materials were used. The fossil fuels were also more effective for metallizing pellets, although metallizations above 90 pct were also obtained with tree trimmings and refuse paperboard. However, refuse paperboard had to be frequently recharged to the furnace because it depleted rapidly.

Jan 1, 1983

By Byron S. Gottfried, Guan Qi Zhao, John W. Tierney

Equations for predicting the performance of vacuum filters and centrifuges used for coal dewatering are presented. These equations are the basis for a dewatering module which has recently been added to the Coal Preparation Plant Simulator developed at the University of Pittsburgh under the sponsorship of the Department of Energy. The module provides for mechanical degradation in the centrifuge; loss of fines to centrate or filtrate; changes in size and gravity distribution; changes in ash and sulfur content; as well as final moisture content of the dewatered product. Inputs to the module are the flow rate of the coal to be dewatered, a washability analysis of the coal, and parameters describing the operation of the vacuum filter or centrifuge. Typical results obtained using the module are presented. There are adjustable parameters which can be varied to match plant operation or experimental data if desired.

Jan 1, 1983

To provide a means for mechanically separating and recovering nonferrous metals continuously from non-magnetic reject material produced at scrap automobile shredding facilities. Approach The Bureau of Mines developed a water elutriator system that separates metals from shredded scrap auto-mobiles based on differences in specific gravities. A premium-quality product, containing aluminum, magnesium, lead, zinc die cast, copper, copper alloys, and stainless steels, is obtained. How It Works Mixed nonmagnetic reject material currently being separated at automobile shred-ding facilities is introduced onto the top of an upwardly flowing vertical column of water. The water, overflowing a weir in the top of the vertical column, carries with it the floating, lightweight waste materials, mostly combustibles, while the heavier pieces sink through the rising water. Medium-density substances such as glass, rubber, and heavy plastics are carried off through a side port, located in the upper third of the column. The cleaned, mixed metal product sinks to the bottom and is continuously removed from the base of the column with a bucket elevator having perforated buckets. All three categories of material are removed from the system on separate wire mesh belt conveyors. Most of the water drains through the belts into a holding tank and, after settling, is recirculated back through the elutriator column. The purity and recovery of the metal product are influenced by two elutriator operating variables: the flow rate of water through the vertical column, and the height of the overflow weir at the top of the column.

Jan 1, 1983

By D. K. Steele

An 18-in-diam column water elutriator was designed, tested, and operated by the Bureau of Mines for recovering nonferrous mixed metals from automobile shredder rejects. The waver elutriator separated metals from nonmetals contained in shredded nonmagnetic rejects. The unit was constructed and integrated into a local automobile shredding operation. Nonmagnetic rejects from the automobile shredder were fed onto the surface of a column of rising water. Dense materials fell through the rising water and were collected as a sink product at the bottom of the column; medium-density materials were removed as an intermediate product in a water flow through a discharge port located between the overflow and sink; and light materials were immediately carried out in the overflowing water at the top of the column as a float product. Nearly 99 pct of the mixed metals were recovered from the nonmagnetic rejects as a 70-pct-metal concentrate. Other operating conditions yielded a 93.7-pct-pure-metal product resulting in a 93.1-pct metal recovery. Float rejects are combustibles, light plastics, foam rubber, and minimal amounts of coated and uncoated copper wire. The middling discharge contained mainly medium-density rubber, plastics, glass, rock, coated and uncoated copper wire, and frequently some thin-sheet stainless steel and wrought aluminum. Maximum metal recovery in the operating program was achieved using a water velocity of 52 fpm (650 gpm). Maximum purity was obtained with a velocity of 88 fpm (1,100 gpm). .Water was recycled through a 12,000-gal baffled clarifying tank. Entrainment water losses with the float and middling rejects averaged 50 gpt of reject feed. Records maintained by the shredder operator show a 34-pct increase in nonmagnetic metals recovery during a 1-yr operation of the water elutriator as compared to recoveries from a previously used air classification system.

Jan 1, 1983

By Wallace W. Roepke

Research on coal cutting at the Bureau of Mines Twin Cities Research Center (TCRC) has evolved from a purely mechanical approach, specifically to reduce dust or frictional methane ignitions, into an understanding of the complexity of the cutting system relationships. Achieving an understanding of these relationships requires a wide variety of testing techniques and equipment. Laboratory facilities and the associated equipment exist for shallow to deep cutting in both coal and coal-inclusive rock with any desired bit type. Research efforts with this equipment are providing insight for significant advances to help solve the problems of pneumoconiosis and frictional ignition. This effort will ultimately affect both respirable dust and methane ignitions at the face through better bit design and will increase the salable percent of run-of-mine (ROM) coal processed. It will also affect the design of rotary-drum cutting continuous mining machines (CMM) and longwall machines. This report describes the main features of the coal cutting research facilities at TCRC.

Jan 1, 1983

By R. C. Hartviksen

"The Drumbo Mine is a new gypsum mine located at exit No. 32 of Highway 401 between Woodstock and Kitchener, Ontario. The flat-lying 6-foot (1.8-metre) bed of gypsum is near the base of the Silurian Salina Formation, about 380 feet (116 metres) below surface. The mine is owned and operated by Westroc Industries Limited. A shaft, 12.5 feet (3.81 metres) in diameter, was drilled and then lined with a liner-sinking technique new to this continent. The shaft was completed in the fall of 1977. Gypsum production was started in December 1978, employing a conventional room - and - pillar method of mining.Historical BackgroundA brief mention of gypsum in the Drumbo area is included in a survey of the Ontario gypsum industry by Guillet. This occurrence was discovered in 1958 when National Gypsum conducted some widespread diamond drilling. Western Gypsum Products Limited acquired leases in 1960 and concentrated a drilling program in Blenheim Township near the village of Drumbo; 79 holes were drilled in an area of 1900 acres (770 hectares). Mining rights were then acquired for 170 0acres (690 hectares). A test shaft, 44 inches (1.1 metres) in diameter, was drilled to obtain a 50-ton (45-tonne) bulk sample. This opening will be used as an emergency escape way and for ventilation.Westroc Industries Limited, a wholly owned subsidiary of BPB Industries, has its head office at Mississauga, Ontario and operates gypsum board plants at Mississauga, Vancouver, Calgary, Winnipeg and Montreal. Other gypsum mines are at Windermere, B.C. and Amaranth, Manitoba."

Jan 1, 1983

By R. D. Young, E. A. Harre

Nitrogen exists in two broad categories commonly designated as elemental nitrogen and fixed nitrogen. Elemental nitrogen is found in nature as a diatomic molecule and constitutes about 78%, by volume, of the earth's atmosphere. Fixed nitrogen is a common term used for nitrogen that is chemically bound to other elements. Although elemental nitrogen is very abundant, nonleguminous plants cannot utilize nitrogen unless it is in the chemically combined form. The content of this chapter is confined to fixed nitrogen since the uses and properties of elemental nitrogen and the fixed nitrogen compounds are different. Certain bacteria associated with legumes are able to fix atmospheric nitrogen, but not to the extent required by succeeding nonleguminous crops. The need to use fertilizers containing fixed nitrogen compounds to grow food crops has been recognized for hundreds of years, and from antiquity farmers have used organic wastes such as animal manures, vegetable wastes, sewage sludge, fish scraps, etc., containing these compounds for fertilizers. These organic materials have a low nitrogen content, however, and cannot support large-scale food production. Known commercial-size deposits of natural nitrates containing much higher nitrogen content exist only in Chile, and the possibility of the discovery of other significant deposits is remote. The Chilean deposits were the major source of nitrogenous fertilizers until the Haber-Bosch process for the production of synthetic ammonia was developed. In the Haber-Bosch process, nitrogen reacts with hydrogen at high temperatures and pressures and in the presence of a catalyst to form ammonia. Modern plants use air, water, and natural gas or other hydrogen sources to produce the ammonia that is now the key building block of the fixed nitrogen industry. Several major problems that developed in the 1970s continue with the nitrogen industry into the 1980s. These are (1) the continuing sharp escalation in the cost of feedstocks for ammonia production as well as all energy sources, and (2) the very steep increase in the investment cost of production facilities. More than 75% of the fixed nitrogen produced domestically is consumed as fertilizers. The types of materials used as fertilizers have changed significantly during the past years. There has been a trend from the use of low-analysis fertilizers to types which contain high percentages of plant nutrients. The average plant nutrient content (N + P2O5 + K2O) of fertilizers used in the United States has increased from 18% in 1930 to 32% in 1960 and today approaches an average of 44%. In the case of nitrogen fertilizers, the low analysis natural nitrates (16% N) gave way to ammonium sulfate (20% N) after about 1920. After World War II, ammonium nitrate (33.5% N) previously used in munitions, became established as the leading nitrogen fertilizer. Urea use as a fertilizer (46% N) began in the 1960s, and in the past 10 years has become the world's leading solid nitrogen fertilizer. Nitrogen Materials Anhydrous Ammonia-Anhydrous ammonia is a colorless gas at ambient temperatures and pressures and has a sharp pungent odor. Anhydrous ammonia is stored and transported as a liquid in high-pressure cylinders and tanks at ambient temperature, and in low-pressure tanks, barges, and ships at -28°F. Anhydrous ammonia is applied directly at 4 to 7-in. depths in the soil as a high-pressure liquid by special applicators, after which it expands to a gas that dissolves in the soil moisture or is absorbed on soil colloids. In other systems ammonia is metered into irrigation water and is thereby introduced into the soil.

Jan 1, 1983

This paper reviews factors involved in the feasibility stage of underground mine project development. Emphasis is placed on the need to first select the best method of extraction and make the most accurate assessment of the expected output even with the uncertainties which may exist in structural interpretation, ground stress, geotechnical factors, and industrial conditions. The subsequent engineering planning should be undertaken from the point of view of the face requirements and is subject to constraints imposed by the method of work and nature of the deposit and, in the case of access, to surface constraints and services.

Jan 1, 1983

By Lu Yang

In the last two decades, acid iron ore pellets have established their predominant position as the iron-bearing burden material for blast furnace ironmaking in North America. It is a general practice that pelletization plants are asked to produce pellets of certain chemical composition and in a narrow range of sizes. A minimum amount of fines created during handling and transportation is desirable. Such a requirement is often expressed indirectly by the minimum compression load causing a pellet to break. The behavior of pellets inside a blast furnace, of course, is very important for a smooth and efficient operation. Before its melting in the lower part of a blast furnace during this period of several hours the behavior of pellets depends on their properties after induration as well as conditions inside each furnace. Among properties of indurated pellets, the ability to maintain their physical integrity in the burden and to be reducible are most important. To maintain the integrity of pellets (i.e., minimal low temperature breakdown, swelling and softening) so that there will be adequate overall permeability for certain wind rate and local permeability for gas/solid contact for reduction. A higher reducibility will moderate the adverse effects of swelling and softening and contribute to a smooth operation and efficient use of heat and reductants in a blast furnace. An article devoted to the relationships between the quality of iron ore pellets and blast furnace practice has been published elsewhere(1); therefore, no further discussion is needed here. The mechanism of strengthening of iron ore pellets during firing has been the subject of investigation of many authors(2). There is no doubt that the bridging of the growing hematite grains, particularly starting with magnetite concentrates, is very significant in the production of strong pellets. Recently, there are many reports from blast furnace operators that they have noticed the adverse effect of LTB in their plants. It is obvious that the strength derived from bridged hematite grains may disappear when hematite is converted to magnetite with thorough breakdown of grain structures. It is suggested that some other strengthening mechanism may be required in order to improve the LTB index of acid pellets. The influence of porosity on both compression strength and reducibility follows regular patterns. It has been suggested(1) that the amount of liquid slag in pellets during firing determines to a large extent the porosity, hence, indirectly, strength and reducibility.

Jan 1, 1983

By Scott G. Britton

This chapter is concerned with the construction of the dynamic component of belt haulage systems. The dynamic system includes the belt line and tailpiece extension and retraction movements in a production system where mine management is continually placing the belt in the most effective operating position. Correct installation of the belt and tailpiece during an extension is very important for many performance reasons. Two of the most important reasons are to eliminate spillage and safely operate the belt line. This chapter is divided into three major discussions. The first discussion looks at analyzing the parameters of effective belt line construction. This includes a review of the parameters and management tools needed for proper scheduling of a move-up. The second major discussion topic centers on efficient procedures for a belt line extension. Topics such as site preparation, tailpiece breakdown and setup, stringing the belt line and structure, plus operating and maintenance tasks needed after the belt line is installed and running, are covered. The third discussion presents a list of conveyor and conveyor component manufacturers who provide services and products to the coal mining industry. Again, any discussion on underground haulage systems must generalize much of the site specific design approaches to be practical. This text will mention, where applicable, some of the alternatives available to construction engineers in designing belt line systems.

Jan 1, 1983