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By Frank C. Stevens

The availability, cost and use of fuel and electricity for the cement industry is difficult to predict with a great degree of accuracy because the historical pattern of factors affecting energy was disrupted during the years 1972, 1973 and 1974. Forecasting is both an art and science and is based on .the premise that the best indicator of the future is the past. Statistical data is used to guide economists and businessmen in their predictions of the future. Even though the energy picture is changing, it is believed that electricity and fuel will be available for the cement industry in the foreseeable future, and this energy will be more costly in relation to the other items that are part of the manufacturing costs for portland cement.

Jan 1, 1977

By G. R. Giuliani

Hanna Mining Company's Groveland Mine is located in the Upper Peninsula of Michigan. The low grade iron ore deposit consists of a mixture of magnetite and hematite with chert, jasper, quartz and various iron silicates (1). The ore is beneficiated by magnetic separation and anionic flotation of the iron minerals with chemical depression of the silica. The magnetic concentrate makes up about 75% of the concentrate. The concentrate is pelletized at the rate of 2.0 million LTPY of pellet production. The concentrator facilities were started up in 1959 and the concentrate was marketed as sinter feed until 1963 when the concentrator was expanded and the pelletizing plant was added. The pellet plant now consists of regrinding, elutriation, filtering, balling and induration. The pellet machine is a straight grate which employs updraft drying and cooling and downdraft drying, preheat and firing. It is necessary to regrind the concentrate before pelletizing. The con-centrate is 60% passing 325 mesh, with a surface area of ±lOOO cm2/Gm, and must be ground to about 83% passing 325 mesh, 1600 cm2/Gm blaine surface area, for pelletizing. The energy for regrind has been reduced from 12.5 KW per LT to 8.80 KW ate of 2.0 million per LT. This was the result of changes made in the concentrator where originally a coarse spiral concentrate, instead of the magnetic concentrate which is screened on fine screens to reduce the coarse fraction and prevent overgrinding before flotation, was produced. Also in 1968 an additional concentrating line was added to the concentrator which employs more grinding power than the other three lines. The demand for a high iron grade and lower silica pellet resulted in the investigation of different schemes of upgrading the reground concentrate which had more iron values liberated during grinding for surface area. The reagentized material presented many problems, mainly in selectivity trying to flot the iron and with high reagent consumption having to dereagentize the concentrate for amine silica flotation, in the various flotation systems tried. Tests were then conducted with elutriation (2) which proved satisfactory by removing the lower specific gravity, fine gangue material from the heavier material with the

Jan 1, 1977

By Paul R. Wieber

This paper describes the U. S. Energy Research and Development Administration's (ERDA) program to develop in situ coal conversion processes, especially gasification, he potential of this technology, the technical directions being explored, and the program strategy to carry the process concepts toward commercialization are emphasized. The geographic location of the U. S. coal resources and a market analysis are described. Commercially successful in situ coal processes could add over a trillion tons of coal to the U. S. coal reserves. The economics of these processes is compared with surface gasification independent studies show this process to be 25Z cheaper than surface gasification for Western coals. The major projects are briefly described. The Linked Vertical Well process is in the lost advanced stage and shows great promise. The last test produced a low-Btu gas averaging 171 Btu per standard cubic foot for average pro¬duction rates of 5.5 million standard cubic feet per day. The other projects are Packed Bed, Longwall Generator, and Steeply Dipping Beds.

Jan 1, 1977

Declining from surface provides access, haulageway, ventilation and provision for ser- vices for stoping and development. Three boom jumbos and 3.8 m3 capacity diesel loaders are used in decline development, the majority of which is driven at a gradient of 1 in 9. Primary ventilation is drawn from the mine through raisebored airways and high pressure contra rotating fans provide secondary ventil- ation. To meet schedules a special decline crew was formed on similar lines to a mining con- tractor. The basis of payment for the mining party was changed and the net effect was to accelerate development. Ground conditions demand constant support and this is achieved with chemical anchor rock bolts, multistrand grouted bolts and shotcrete. Major local shear zones are encountered and when they are to be driven through, a combina- tion of the above methods, involving a spiling technique, is used.

Jan 1, 1977

By M. Perišic

Requirements concerning determination of geometric characteristics and estimate of reserves and grade may in various mineral deposits significantly differ and by no means can be completely envisaged. Therefore, program writing which would in advance meet all requirements is from a practical point of view impossible. Programming for each particular project is also unacceptable solution, due to many facts, among which is ever growing scope of work and the terms to be met. Therefore, conventional method of programming proved to be ineffective. The team of the Mining Institute experts came to the conclusion that the solution of facing problems lies in the idea of introducing specialized programs, instead of complex ones. Each of them represents a functional entirety. Procedure of complete mineral deposits computer processing is described by a problem-oriented programming language which was designed for that particular application. One or more than one specialized programs are called by one instruction so that the program in that language can have a few hundred time less instructions than an equivalent FORTRAN program. Besides description of the program system and programming language the paper also covers some aspects of its application in solving complex problems.

Jan 1, 1977

By Edward S. Hsia

Pluor Utah has been closely associated with the engineering and construction of earth bottom thickeners for porphyry copper operations, for the counter-current decantation circuit of a gold cyanide plant and similar applications in mineral processing. During the past 13 years, some 18 of these thickeners have entered service and the bottoms have proved to be watertight structures with no particular problems encountered. In the course of this work, technological advances have been realized in the procedures for engineering and construction of these units to assure watertight basins and achieve all possible economies in construction. This paper describes the successful application of engineering and construction techniques for a number of these thickeners.

Jan 1, 1977

A study of drilling data at various stages of development of an orebody show that the semi-variogram, used for calculating the accuracy of block estimates can be ill-defined if too few data are available. The consequencesin this case are to have blocks supposedly more accurately known than is possible at the early drilling stage; such a result being potentially dangerous. However, as the amount of data increases the recalculated, semi-variograms approach the underlying semi-variogram of the deposit and the calculations made using them become more reliable and robust.

Jan 1, 1977

The task of designing stable high walls and spoil piles in strip coal mines, and stable openings with controlled roofs and floors in underground collieries - within the constraints normally imposed by economics - depends upon a reliable assessment of rock mass strengths and rock mass reactions under a variety of stress conditions. Of the geological factors influencing internal friction and cohesion within rock masses, many may be determined qualitatively or empirically from bore-hole evidence. Rock types, descriptions and properties of intact rocks, location of boundaries, limits and degrees of weathering, potential for slaking or decomposition of rocks when exposed, bedding characteristics, the nature of rock anisotropy and the likely effects of water on rock mass properties can be assessed from bore- hole data. Discontinuities, whether they be major such as faults and dykes, or minor such as joints and fractures, present a greater problem, and in most instances the mine geologist must resort to additional techniques to describe or predict their occurrence, nature, frequency, intensity or physical properties. Information on ground water and seam gas is available from bore-holes within certain levels of reliability.

Jan 1, 1977

Minerals are vital to any industrialized civilization. Annually, the United States uses more than 4 billion tons of new mineral materials, or about 40,000 pounds per person-about half being mineral fuels and the other half being metals and nonmetallics. Stable and economic domestic mining, mineral, metal, and mineral reclamation industries are essential to the economy. The value of United States energy and processed materials of mineral origin exceeds $200 billion annually. Although a number of minerals are imported, especially some designated as "strategic and critical," most U.S. mineral supplies are derived from the domestic mines and processing facilities that you will be seeing, reading about, and visiting as you use this visitor guide. We hope you enjoy your experiences. This pamphlet, a guide to mining and mineral operations that may be observed or visited and some other points of interest relating to minerals, is intended to aid tourists and students who are interested in mining. Some may wish to study our Nation's romantic past; others may plan to enter the minerals industry as a career; still others may have a primary interest in conservation practices. The pamphlet is also intended to aid State and local officials, Chambers of Commerce, and mining firms in answering some of the many questions of tourists and students.

Jan 1, 1977

By Shrivastava P

The iron orebodies of the Pilbara region are formed by supergene enrichment of banded iron formation and rarely do such processes produce orebodies with uniform grade distrib- utions. The orebodies being mined or developed have to be worked to grade/quality constraints imposed by contractual agreement rather than natural characteristics. Hence it is imperative to use a non-biased ore reserve calculation method. The geostatistical study of a typical iron orebody is presented. Emphasised are the geological characteristics of the orebody manifested as a variable grade distribution of iron and impurities; the determination of variogram model; subsequent uses of the model for computation of ore reserves and kriged lock estimates; computation of dispersion variance and conditional simulation of orebody.

Jan 1, 1977

Proper technical appraisal of a coal deposit and the determination of optimum open- pit mine design can only be made after detailed examination of a number of interrelated geographical and geological factors. Initial evaluation of the geography and the overall attitude of the coal measures can often determine the most likely coal mining technique. Conclusions reached in the early stage of the investigations frequently dictate the quality and quantity of particular types of data required from further drilling of the deposit. In many cases, insufficient information relating to the overall engineering aspects of a coal deposit is derived from drilling. Little or no attention is paid in the exploratory phase to such things as the specific gravity of selected overburden samples, floor conditions, clay content of the overburden and selected strength tests on cores. This is a direct result of geologists treating coal deposits purely in geological terms without sufficient consideration being given to the engineering parameters required for a proper evaluation of the deposit.

Jan 1, 1977

By Ann G. Kim

The Bureau of Mines estimated the methane content of a coal, which depends primarily upon rank and pressure, from the adsorption equation V kpn, where k and n are constants related to rank. By incorporating corrections for moisture, ash, and temperature, and estimating pressure and temperature as a function of depth, the methane content of coal in place can be estimated from the following equation: [ ] Values calculated with this equation generally are in reasonable agreement with direct determinations. By assuming a standard moisture and ash content, and using the hydrostatic head to estimate pressure, a graph of rank and depth versus gas content was constructed. Although estimated values were consistently high for several high-volatile bituminous coals from an area where the pressure is known to be less than hydrostatic, the estimated methane content for most coals shows reasonable agreement with values determined by the direct method.

Jan 1, 1977

Minerals are a fundamental component of the Nation" material and economic base. Without a continuous supply of minerals to meet growing and changing needs, the basic character of our society would be very different. The importance of minerals to the United States was reemphasized by the Congress in I970 when it enacted the Mining and Minerals Policy Act, which stated that it is the continuing policy of the Federal Government in the national interest to foster and encourage private enterprise in (I) the development of economically sound and stable domestic mining, minerals, metal and mineral reclamation industries, (2) the orderly and economic development of domestic mineral resources, reserves, and reclamation of metals and minerals to help assure satisfaction of industrial, security and environmental needs, (3) mining, mineral, and metallurgical research, including the use and recycling of scrap to promote the wise and efficient use of our natural and reclaimable mineral recources, and (4) the study and development of methods for the disposal, control, and reclamation of mineral waste products, and the reclamation of mined land, so as to lessen any adverse impact of mineral extraction and processing upon the physical environment that may result from mining or mineral activities.,.

Jan 1, 1977

By John M. Sharp

John M. Sharp, Jr. (Assistant Professor of Geology, University of Missouri, Columbia, Mo.)-Geothermal gradient and surface temperature data anomalies are potentially useful tools in mineral exploration, These data, however, may reflect a number of geologic and hydrologic processes as well as the thermophysical properties of the geologic materials. The author presents a relatively simple model which may be of value in mineral exploration. The lack of consideration of other processes, however, limits its usefulness. For instance, because of erosion or sediment deposition over geologic time the land surface must be considered a moving boundary in such a model. Evaluation of this effect coupled with annual surface temperature and thermal conductivity variations can result in temperature profiles such as shown in [Figs. 4 to 7]. These effects and others, such as ground-water movement," must be considered and filtered from the data before proper interpretation is possible. Another assumption which should have been discussed is, why were the observed mean surface temperatures not used for extrapolation of the gradients in [Figs. 4, 6, and 7?] Conductive heat transport responds to the actual boundary (land surface) temperature, not to theoretical temperatures in the absence of perturbations. Benfield presents a theoretical model for calculating perturbations in the geothermal gradient for erosion and sedimentation. The temperature (T) at any time (t) and any depth below the surface (x) is given by [ ] where T is the mean surface temperature, G, the geothermal gradient, v, the rate of erosion (or sedimentation),[ ], the long-term rate of change of T0, and k is the thermal diffusivity of the rock. Using the author's values and a rate of erosion of 1.54 cm per yr for a period of 10,000 yr, a thermal profile as shown in [Fig. 10] will be generated. A thermal diffusivity of 0.0164 sq cm per sec was used, corresponding to a thermal conductivity of 0.0082 cal per cm per sec per C. In [Fig. 11], a sediment deposition rate of 3.0 cm per yr for a period of 1000 yr was used to generate the subsurface temperature profile. A surface temperature of 24.3°C was used, as specified in [Fig. 9, 7], was set equal to zero for both cases. Superposition on the generated profiles in [Figs. 10 and 11] of the annual surface temperature variation perturbation (which may be calculated in a number of ways) will yield profiles similar to those in [Figs. 4 and 7]. Similar profiles can also be produced by regional ground-water flow. Models like the author's can be of value in mineral exploration. Other processes, however, which affect surface temperatures and gradients must first be considered, calculated, and filtered from the data if anything but the crudest qualitative interpretation is to be made. Robert C. Edmiston (Author's reply)-Professor Sharp has raised three objections to my interpretation of the subsurface temperature data I collected at Silver Bell. These are: 1) No correction was made for erosion or sedimentation,

Jan 1, 1977

By R. G. Coyle

This paper describes a model of operating policies in an underground metal mine. The purpose of the model is partly that the problem of controlling a mining operation in the face of shocks from its economic environment is interesting in its own right, and also as an input to a larger research project on policy-making in mining companies. The model includes, mining, development and milling sectors together with cash flow and finances. In particular, it shows how the policies used to control the various sectors in the face of environmental shocks from metal prices and changing state of the system are connected by feedback loops. The use of feedback theory differentiates the model from 'ordinary' simulation and assists in the design of 'robust' policies which always achieve effective control. This model is the first stage of a major project and approximations have been made, simply to get the model going. The purpose of this paper is to show the kind of output this type of model produces, to lay our explicitly what is in the model and above all, to invite contributions from mining people on what the model should show and what should be put into it. We claim no virtues for this model. It is just a research tool so that later models will be more worthwhile and useable in practice.

Jan 1, 1977

By Gregory Dybalski

The purpose of this paper is to illustrate the forecast capability of the econometric model of the cobalt industry1/ as utilized by the Federal Preparedness Agency. Forecasts from this model are illustrated from the premise that the leading producer continues production of cobalt. An alternate forecast is presented where the model structure is altered to reflect the condition where the leading producer leaves the market. All estimations and forecasts presented here are shown for illustrative purposes. The cobalt industry is highly concentrated; one company, owned by the Zaire government, accounts for approximately three-fifths of world production. The cobalt supply outside of Zaire is determined by the level of activity of copper or nickel markets, as cobalt is mined as a by-product of copper or nickel. The demand for cobalt reflects a diversified usage pattern; cobalt is used mainly in heat and corrosion-resistant materials, high- strength materials and permanent magnets. According to 1974 U.S. consumption data superalloys accounted for 22%, magnetic alloys 18%, cutting and wear-resistant materials 13%, and catalyst 7%. Foreign consumption is probably similar in terms of usage categories, but the relative order of the categories is in variance.2/ The Cobalt Model The cobalt model's object is to explain consumption, supply and price movements by utilizing statistically estimated equations. Central to the econometric model is the role of Zaire as the profit-maximizing "dominant firm". Zaire sets the price that is most profitable for itself. The price of cobalt depends on industrial demand, production of other firms, and net exogenous purchases, such as government

Jan 1, 1977

By P. A. Young

The historical background of on-strand cooling is given, together with a resume of recent practical developments. Laboratory test procedures are then considered in detail, for both productivity and quality parameters, with particular reference to the design of the Ravenscraig No 3 machine (Scotland). A heat transfer model is presented for a porous sinter with propagating cracks. The influence of cooling/sintering area ratio, sinter strength, granulometry, return fines, coke consumption and FeO levels are examined in relation to economics. A detailed comparison of capital and running costs for two different strands, designed for identical duties, but with off or on-strand cooling, is then given.

Jan 1, 1977

By K. J. Liles

The Federal Bureau of Mines conducts a comprehensive test program on clay and shale at the Tuscaloosa Metallurgy Research Center. All samples are subjected to standard preliminary ceramic tests, which include firing formed briquets at temperatures ranging from 1,000° to 1,250° C to identify firing range and colors, and quick-firing to determine bloating characteristics. Materials that shop potential as structural products are further tested after either extrusion or dry-pressing. If the quick-fire test is positive, bulk samples can be fired in a rotary kiln to evaluate their potential as light- weight aggregate A number of miscellaneous tests also can be conducted if requested. These tests determine properties such as refractoriness (pyrometric cone equivalency), oil-bleaching characteristics, oil absorbency, viscosity for drilling-mud applications, sand-bonding properties for foundry usage, and pelletizing characteristics.

Jan 1, 1977

By P. B. Ritter

The feasibility of redesigning and adapting the all- secondary-explosive, low-voltage, electric safe detonator for use as a delay detonator has been demonstrated. Experimental results have shown that operational characteristics can be adjusted to allow direct competition of safe delay detonators with commercial delay blasting caps. Five different experimental delay period models have been developed and tested. Test results are given and results are evaluated. Subsequent simplified and improved designs for practical and economical mass production are described. Design concepts to meet Bureau of Mines voltage withstand, incendivity, and spark sensitivity requirements are included. Recommendations are made for experimental procedures to ready the safe delay detonator for mass production and extensive use in mining and other industries.

Jan 1, 1977

All companies and individuals who embark on a business venture incur costs. For the most part these costs can be conveniently categorised, firstly into capital and operating costs and then into the various elements of these major cost centres. Although the nature of expenditure naturally differs as between industries certain broad cost types are characteristic of all heavy industries. The capital costs of gaining access to an orebody, equipping a new mine, building a treatment plant and perhaps refining and smelting facilities are likened to capital expenditure by a manufacturer on new plant and equipment required for an expansion or new product innovation. Similarly the day to day costs of labour and materials employed in the running of a mining operation can be likened to similar costs in other heavy industry. There is another group of costs that are not so easily categorised. Most industries incur unavoidable costs that do not form part of the direct or capital costs of physical production. These costs include taxes and other payments to government and research expenditure. The mining industry has a particularly heavy burden of non-production costs and it is the objective here to highlight and analyse a few of them. These costs are exploration expenditure, infrastructure expenditure, royalties and income tax. This is not to suggest that these are the only major non-production costs that the mining industry needs to bear. The industry may incur significant costs for environment protection, land tenure maintenance and on liaising with Government on a wide variety of matters. It is for reasons of subject manageability that the list is confined to the four costs mentioned. For the mining industry, exploration and infrastructure expenditure, royalties and income tax have several distinguishing features. Firstly, they are generally proportionately large costs. Exploration and infrastructure expenditure for example, could well exceed mine development costs. Depending on how royalties are levied, they may be very high in relation to profits earned and many in fact exceed profits. Secondly, except for income tax, they are costs that are generally not payable by other industries. Exploration expenditure is in some respects comparable with industrial research and development. However, because mines are wasting assets exploration is necessary for survival, and it is likely to form a larger part of costs per dollar of profits or sales than R&D. It can therefore be said that exploration is of far more significance to the miner than R&D is to the typical industrial company. Furthermore, unlike exploration expenditure, R&D results are transportable and patents permitting, transferable. The infrastructure burden that miners must carry is unique to the industry. Whereas urbanised industry is not usually liable for the capital cost of power, water, transport, townships and community facilities, the miner must finance these projects himself. Neither the payment of royalties, nor of course, income tax are unique to the mining industry. Royalties are more properly described as a unique charge on some primary industries but however described, they are a charge that manufacturing and service industries do not have to pay. Whilst we all pay income tax, the mining industry's uniqueness derives from the special problem that the industry has in arriving at annual net income in view of the capital intensity of the industry, partly due to expenditure on infrastructure, the indefinite life of capital equipment and its unpredictable residual value, funds expended on exploration and long lead times associated with a mine development. The third distinguishing feature of these costs is that, with the possible exception of exploration expenditure, they are heavily influenced by the policies and actions of Government. As such the industry has a responsibility to promote the industry by emphasising its potential to improve national product including exports and by requesting that the Government provide for the industry in its long term planning and seek its co-operation to prevent the industry incurring inequitable penalties relative to other industries.Finally, exploration and infrastructure expenditure are significant because they are front-end charges on a project. When due allowance is given the time value of money and the deferment of income from a mining development to which they relate, exploration and infrastructure expenditure assume greater importance than the raw money expenditure suggests. For all these reasons, exploration and infrastructure expenditure, mining royalties and mining income tax are worthy of detailed study. This is the purpose of this paper. The objective is to examine the determinants that give rise to them and provide some thoughts on their impact on on-going and potential mining developments and, where relevant, to make some suggestions as to how they may be minimised.

Jan 1, 1977