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By Franz R. Dykstra

DEFINITIONS The ores of iron are classified in three general categories: direct shipping, concentrates, and agglomerated-i.e., pelletized or sintered. Direct Shipping As the name implies, direct-shipping ores are shipped as mined or, perhaps, after screening. Generally, direct-shipping ores are hematitic (R203), magnetitic (R304), or limonitic (2Fe2O3.3H20) in nature. Grades of direct-shipping ores vary widely. Prices are frequently related to the historical Mesabi standard of 51.5% iron, although certain premium lump ores may contain up to 68% iron. The use of direct-shipping ores is diminishing as the advantages of beneficiated ores become evident and reserves are depleted. Concentrates Where the nature of the deposit and economics allows, certain ores are upgraded. This may include no more than washing and screening, or may be as elaborate as fine grinding followed by magnetic, gravity, or even flotation procedures for separation. Coarser concentrates may be smelted "as is.'; Fine concentrates usually are sold as sinter feed. (Sinter, as used here and in the following, refers to a process by which a fine ore-carbon mixture is agglomerated at elevated temperatures on a direct-fired moving grate to eliminate fines and improve chemical and physical homogeneity.) Agglomerates-Pellets or Sinter The development of economic techniques of mining and concentrating taconite (fine-grained, ferruginous jasperoids) led to the introduction of the iron-ore pellet, which is now becoming the major form in which iron is introduced into the furnace. The tremendous reserves of magnetic taconites of the northern United States and Canadian Precambrian shield had been recognized for many years. A century of mining has seen the reserves of the direct-shipping or "red ores" of the Minnesota, Michigan, and Wisconsin ranges approach depletion. Research started in the 1930s has seen the evolution of motives and techniques to concentrate these stubborn refractory ores. The efficacy of concentrate pellets in iron-making has been such as to induce mines throughout the world to grind, concentrate, and pelletize otherwise shipping-grade ores. Table 14.1A.1 shows typical analyses of iron ore. Marketing-Prices of iron may be quoted on a value per long-ton (2240 lbs) or metric-ton (1000 kg or 2204 lb) basis, or on a value per long-ton-unit or metric-ton-unit basis. One iron unit represents 1 % of contained iron per ton. (Thus, a price of $0.45 per iron unit for ore containing

Jan 1, 1976

By D. L. Jones

The leaching of natural chalcopyrite was studied in both ferric sulfate and ferric chloride solutions. The chemistry of the two reactions is quite different, with substantial sulfur oxidation occurring only in sulfate solutions. Ferric chloride is a more effective reagent, for the leaching rate is greatly increased with finer particles and higher (Fe+++), and unaffected by high (Fe++); none of these advantages are found with ferric sulfate. In addition, the morphology of leaching appears to be different, with ferric sulfate leaching preferentially along fissures or grain boundaries. The kinetics were found to be linear over an extended period, rather than parabolic as reported elsewhere. An explanation of the observed phenanena is proposed using the electrochemical theory of leaching, and experimental measurement of the mixed potential of the mineral during leaching.

Jan 1, 1976

By Robert Carlson, Hugh McMillan

During 1967, the Metropolitan Sanitary District of Greater Chicago adopted a policy of land application as a method of using the solids produced in the wastewater treatment process. Research by the Agronomy Department of the University of Illinois, several demonstrations on farm land, reclamation of acid strip-mine spoils, fertilizing a land fill, and reclamation of an alkaline sand waste pit showed the value of using wastewater solids to reclaim marginal and submarginal lands. To launch the Solids-On-Land Program, 10,000 acres of land in Fulton County, Ill., was purchased, part of it previously strip-mined for coal. The Sanitary District initiated a water monitoring program, constructed holding basins, leveled the land, awarded a liquid fertilizer transportation contract, installed a distribution end application system, and began application and crop production. During 1972, the Sanitary District completed the first year of application and harvested the first corn crop. The corn yielded 60 bu per acre while the previous year in a demonstration field it yielded 56 and 13 bu per acre, respectively, on treated and untreated strip-mined land.

Jan 1, 1976

By Philip E. Sanker

The Bureau of Mines conducted small-scale batch and semicontinuous tests on the reduction of zinc sulfide with iron according to the reaction ZnS + Fe ? FeS + Zn to determine reaction kinetics in the temperature range 1,000° to 1,400° C and to investigate the potential use of a scrap iron reductant. Batch tests indicated that a temperature of at least 1,300° C with a 1:1 mole ratio of Fe to ZnS is needed for good zinc recovery. Semicontinuous tests were conducted, using four zinc concentrate samples, containing various percentages of copper, cadmium, and lead, which were reacted with iron and iron contaminated with iron oxide and tin in an externally heated graphite furnace. Analysis of the zinc metal and FeS matte reaction products showed cadmium to be entirely in the zinc metal, copper to be in the FeS matte, and lead to be about 60 pct in the zinc metal and 40 pct in the matte. Tin reported to the matte, and none was detected above the O.OS-pct level in the zinc. Sulfur dioxide was not detected in the offgas when up to 20 pct of the iron was replaced by Fe203.

Jan 1, 1976

By A. A. Janke, G. J. Vogel, W. M. Swift

The combustion of fossil fuels in a fluidized bed of calcined limestone particles is a potentially efficient and economically attractive process for the generation of steam for electric power production and other uses. The process results in greatly reduced emissions of both sulfur oxide and nitrogen oxide pollutants. Development work, evaluations, and design studies are being carried out by various organizations under contract with the Department of Interior (Office of Coal Research, OCR) and with the U.S. Environmental Protection Agency, (EPA). The Atomic Energy Commission's Argonne National Laboratory is one of the principal participants in the development program under interagency agreements with EPA and OCR. The principal reasons for developing fluidized-bed combustion, its advantages and disadvantages over conventional combustion methods, and some of the potential applications of the process are covered in this paper. The participants in the multiorganizational program, the sponsoring agencies, the general status of development of the overall project, and the chief program areas that still require resolution are discussed. The main features of the program of work at Argonne National Laboratory and the results achieved so far are also included.

Jan 1, 1976

By A. J. Lynch, E. V. Manlapig, J. S. Hall, G. C. Thorne

Modelling of industrial sulphide flotation based on data collected in several flotation plants is discussed. A mechanistic approach is used in which it is recognised that flotation is a two stage pro- cess with concentration occurring both in the pulp and in the froth. The important features of the model, which is a kinetic model, are – 1. for each particle species there is a range of flotation rates which corresponds to the range of particle sizes, 2. the flotation rates of the liberated gangue particles which have no hydrophobic properties are dependent on the flotation rate of water and are controlled by variables such as the air and frother addition rates, and the pulp level, 3. as an approximation the valuable sulphide particles may be regarded as being present in two groups with high and low flotation rate constants, 4. increase in the addition rate of collector tends to increase the proportion of sulphide particles which are in the high flotation rate constant group. The actual flotation rate of each group of particles is a combination of an "inherent" flotation rate and a flotation rate which is dependent on the flotation rate of water, 5. at particular air and frother addition rates and pulp levels there is a physical limit to the rate at which particles can be transported into the concentrate and this is recognised in the model. The model has been used to study the steady state and dynamic properties of flotation circuits in operating plants. The assessment of the behaviour of composite particles is difficult because of the problem of quantitatively describing the surfaces of mineral particles. A method which is being developed to measure unpolished particles is described briefly.

Jan 1, 1976

By E Emery Jr Gray

A need for more delay periods other than those normally manufactured throughout the explosives industry rarely occurs. This paper will discuss one such incident from an analytical view through practical application.

Jan 1, 1976

By J de Cuyper, V. M. Lovell, W. Freyberger

The recovery of apatite from the phoscorite ores occurring in the Transvaal, Republic of South Africa, involves a flotation process that is particularly difficult to characterize from a fundamental point of view. However, the reagents used, (tall oil fatty acid, nonylphenyltetraglycol ether, sodium silicate, and sodium hydroxide) can successfully bring about a separation of apatite from dolomitic calcite, which is the most troublesome gangue component. Recently, it has been demonstrated with some flotation feeds that the addition of certain polysaccharides can improve the flotation significantly. It has been shown that the metallurgy obtained is closely linked to the nature of the froth, and this, in turn, is influenced, often dramatically, by the presence or absence of certain of the reagents. The character of the froth depends less on the inherent frothing ability of these reagents than on the presence or absence of fine mineral particles in the froth, and on their surface characteristics and state of aggregation. The polyglycol ether and the polysacchar- ides have been shown to affect these properties, and it is suggested that a major function of these reagents is to modulate the properties of the fine particles in the pulp, thereby changing the character of the froth and giving rise to improved results.

Jan 1, 1976

By Frederick B. Henderson

On 10 August 1976, The Geosat Committee was organized in Denver to institute The Geosat Program. This program is an industry backed effort to evaluate and help select optimum space remote sensing systems for geological purposes. It is believed that the recommendations of The Geosat Committee can be supported by industry as additional exploration tools which can materially benefit industry and the Nation with respect to our energy and other natural resources needs. Appended is a general summary of The Geosat Committee Organizational Meeting and general review of The Geosat Program. The Geosat Workshop Report. The Geosat Committee, and The Geosat Program will be reviewed at a special afternoon session, Friday, 3 September.

Jan 1, 1976

By Richard V. Wyman

The genesis of ore deposits has been tied to plate tectonics through differential petrogenesis in subduction zones. However, many mineral districts, especially in the Basin and Range province of United States and Mexico, appear unrelated to any possible subduction zones or to plate boundaries. It is proposed that the pattern of mineral belts is related to mantle plumes which have been overridden by an advancing continental margin.

Jan 1, 1976

By Carl R. Peterson

This report describes the development and testing of a prototype tunneling machine. Principal efforts were aimed at testing of the fragmentation subsystem of a continuous drill and blast hard rock excavation machine suitable for use in underground mining and tunneling applications. The concept utilizes a unique self -shielding spiral blasting pattern that permits efficient performance with relatively small single shots, while at the same time directing major blast fragments at right angles to the tunnel axis. A major accomplishement was the development of a remote controlled, loading and initiation system in which explosive slurry and a detonator are Simultaneously placed (pumped) into the blasthole via a loading hose. The special electric long-delay detonator is inductively ignited upon emplacement, and the machine remains at the face during the blast.

Jan 1, 1976

By H. H. Kellogg

The Process Fuel Equivalent (PFE) for nine different flowsheets for production of anode copper from sulfide concentrates has been evaluated and compared for a set of uniform conditions and a "standard" concentrate analysis. The processes considered are: reverberatory smelting, (wet-charge and hot-calcine charge), electric furnace smelting, Outokumpu flash smelting (2 versions), mom flash smelting, Noranda Continuous Process (2 versions), and the Mitsubishi Continuous Process. The energy required for the numerous processes auxiliary to the principal smelting processes-¬roasting, drying, air compression, gas handling, dust collection, slag cleaning, acid manufacture, etc.--are separately evaluated and incor¬porated into the process comparisons. The factors in process design that lead to important energy savings are: use of fuel rather than electric energy; use of oil or coal rather than natural gas; maximum use of oxygen enrichment of the process air; drying of charge before smelting, or, even better, drying and preheating of charge by partial roasting in a fluid-bed; recovery of waste heat from all major hot process gases.

Jan 1, 1976

By J. R. White, S. W. Lambert, C. M. McCulloch

Examination of several coalbeds in Walker County, Ala., Cambria, Greene, and Fayette Counties, Pa., and Raleigh and Wyoming Counties, W. Va., indicates that cleat orientations are similar throughout a vertical sequence of strata. Studies of cleat orientation were carried out in underground mines that are operating in separate coalbeds vertically above one another. The data show that over a vertical separation of 100 to 400 feet, the average difference in coal cleat orientation between mines is 04° for the face and 08" for the butt cleat. Variations of coal cleat direction between coalbeds examined in strip-mined areas show similar values. Cleat orientations measured at outcrops agree well with the directions measured underground, suggesting that the amount of vertical separation between coalbeds has little effect on the resulting differences in cleat directions. The largest variation of cleat directions between adjacent coalbeds occurs where a large horizontal distance separates two sample locations. Cleat orientations for deeper coalbeds are most reliable where the data are taken from directly above.

Jan 1, 1976

The success of the In-Plant dust collection at the Albion Reid Quarry Plant situated at Para Hills, South Australia, is discussed in the light of co-operation at the design stage with particular emphasis on the duct- work and filter design. Other dust control facilities at the Plant are mentioned.

Jan 1, 1976

By T. Katayanagi, J. Shimoiizaka, K. Nakatsuka

Feldspar has been separated from silica by cationic collector using hydrofluoric acid as an activator of feldspar (1,2). Recently, one of the authors developed a new flotation process separating feldspar from quartz without using hydrofluoric acid. Presently, some silica sand mills are operating to introduce this process in Japan (3). In this flotation, feldspar is floated from silica using normal alkyltri-methylene diamine acetate together with sodium petroleum sulfonate as collectors in a hydrochloric or sulfuric acid circuit of about pH 2. From fundamental studies, it was found that, though the aliphatic diamine by itself did not adsorb on feldspar sufficiently to give a satisfying flotation in acidic circuit., the adsorption of collector was promoted by the simultaneous use of petroleum sulfonate and resulted in sufficient flotation of feldspar. On the other hand, quartz did not float in this flotation process. The application of this flotation was attempted for some types of natural samples and satisfying results were obtained. Further, an example of practical plant was introduced and the advantages in the process are emphasized.

Jan 1, 1976

Sampling and sample preparation systems at the Hamersley Iron Pty. Limited port of Dampier, W.A., were developed for two separate objectives. 1. The need for rapid determination of physical properties. On stream size analysis enables lump ore and pellet- ized ore physical properties to be monitored and controlled whilst shiploading is in progress. As a control procedure this facility allows optimum shiploading rates con sistent with physical quality control. 2. The need for accurate chemical analysis. Chemical analysis on ship- loading forms the final link in overall quality control procedures encompassing the operation of mining, railway and port blending. Thus maintenance of specification products with minimum variation in chemical characteristics is ensured.

Jan 1, 1976

By R. Woods, O. A. Kiehn, C. A. Born, F. N. Bender

Development of the flotation reagent scheme at Climax Molybdenum Company's mine at Climax Colorado is reviewed. Features of the mineralogy, milling practice and background of reagent changes are outlined. Special attention is given to the hitherto unpublished details of the application of depressants for copper and lead impurities. The present rougher flotation reagent scheme utilizes a neutral hydrocarbon oil, low in unsaturates and wax, as collector with a sulfated coconut oil emulsifier and pine oil frother. Lime and sodium silicate are used as rougher conditioning and slime dispersant agents. Chalcopyrite and galena impurities are de- pressed in both rougher and cleaner plants by stage addition of Nokes reagent and sodium cyanide to yield a metallurgical grade molybdenite concentrate containing greater than 90% molybdenite and less than 0.5%, 0.1% and 0.05% iron, copper and lead impurities, respectively.

Jan 1, 1976

By K. O. Bennington

Thermodynamic properties were determined by the Federal Bureau of Mines for lithium metasilicate (Li2Si03) and lithium disilicate (Li2Si205). Their enthalpies of formation were investigated by hydrofluoric acid solution calorimetry. The standard values are ?Hf°298 -393.8 ± 0.8 kcal/mole for Li2Si03, and ?Hf°298 -611.8 ± 1.0 kcal/mole for LiSi205. Enthalpy increments above 298 K were measured by copper-block drop calorimetry from 298 to 1,404 K for Li2Si03, and from 298 to 1,281 K for Li2Si205. Low-temperature heat capacities were determined adiabatically from 6 to 305 K for Li2Si205 only. The derived standard entropy is S°298 = 29.20 ± 0.10 cal/deg-mole. The various experimental data were combined with other data from the literature, and resulting properties of ?Hf°, ?Gf°, and log Kf were tabulated as a function of temperature.

Jan 1, 1976

President Robert Wilson opened the meeting at 9:00 a.m. He introduced William A. Bear, General Manager Bear Coal Company, Inc., Somerset, Colorado, who presided over the session. George Nugent, Peter Kiewit Sons' Company, Sheridan, Wyoming, presented a most interesting film "Montana Mine Reclamation." His biography follows: George Nugent first entered the coal business in 1943 when he developed Peter Kiewit Sons' Co.'s first coal mine-Big Horn Coal Company at Sheridan, Wyoming. Since that time he managed an expansion program for P.K.S. in mining that resulted in the development of two other producing mines - Rosebud Coal Sales Company at Hanna, Wyoming and Decker Coal Company at Decker, Montana, in which Pacific Power and Light is a partner. Applications are now pending for a third mine. Black Butte, a joint venture of P.K.S. and Rocky Mountain Energy Company, near Point of Rocks, Wyoming. Nugent is a Past President of the Wyoming Chapter, Association of General Con- tractors, Wyoming Mining Association and Rocky Mountain Coal Mining Institute. He was President of Big Horn Coal Company and Rosebud Coal Sales Company as well as Manager of the Mining Division of Peter Kiewit Sons' Co. and Decker Coal Company when he retired Jan. 1, 1975.

Jan 1, 1976

During the past year a number of significant advances in geostatistics have been published. These were presented at the 13th APCOM Symposium in Clausthal, Germany and at a NATO Advanced Study Institute on Geostatistics in Rome, Italy. Of greatest importance is the work that has been done in establishing methods which correctly predict the cutoff grade-tonnage curves, and the average grade of ore-tonnage curves for deposits in which ore and waste are intermingled. Grade-tonnage curves based on estimates made from widely spaced exploration data have been found to underestimate the grade of ore and overestimate the tonnage present. This problem has been remedied by the calculation of conditional probability distributions for the unknown grade of a block. Another advance has been made in the field of geostatistical estimation for deposits in which a trend is present. Previously a technique known as universal kriging has been used, which involves much subjective judgement as to the trend fitted. A new technique, generalized increments, allows computer estimation of such deposits with much less subjective judgement. Computational efficiency of geostatistical methods has continued to improve to a point where a geostatistical estimate can be obtained for little more than the cost of any other computerized method.

Jan 1, 1976