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By D. A. Livingstone

"INTRODUCTORY REMARKS BY PANEL CHAIRMAN - D. A. LIVINGSTONEThe mining industry has progressed significantly from the dusty mines and mills of decades past to the modern processing complexes of today, and improved technology has made great strides in eliminating debilitating lung discuss. More recently, the public's environmental awareness is also working to enforce more stringent regulations and controls in tl1e matter of dust in working places.There are numerous excellent texts and handbooks outlining the principles of collection of dust produced in the various unit operations entailed in the crushing, screening and the transport of ore. However, it is painfully obvious that dust emanating from belt return idlers and scrapers, take-up pulleys, skirting, larger and deeper chutes, clean-up operations, etc., which I choose to refer to as fugitive dust, presents some seemingly unmanageable difficulties, or at least difficulties inordinately costly to correct. Possibly static electricity is adding to the difficulties. In my view, these problems are magnified in many of our B. C. operations where ore from open pit mines in cold climates is frequently crushed in unheated buildings, thereby precluding the simple and obvious use of water sprays for dust suppression.It is hoped that the presentations and discussion which follow will emphasize some of these unusual problerr.s and suggest corrective measures, either tried or planned."

Jan 1, 1976

By Harry M. Mikami

Refractories are heat-resistant, generally nonmetallic materials used as the linings of furnaces or high temperature vessels in the steel, iron, nonferrous metals, glass, cement, lime, ceramic, chemical, petroleum, paper, and power and heat generation industries. Refractories must have structural strength at high temperatures but also, in many applications, must simultaneously resist chemical-physical corrosion-erosion from stags, metals, granular solids, or gases. Among the major uses are the pyrometallurgical processes for producing iron, steel, copper, aluminum, nickel, lead, zinc, etc. Rotary cement kilns, glass tanks, refineries, utility boilers, chemical and ceramic (including refractories) plants, and a myriad of other smaller scale users employ refractories in the high temperature parts of their operations. Thermal, chemical, and structural conditions under which refractories are used differ widely so there is a great variety of refractories to fill the various needs. Two major classifications are the "basic" and "acid" types. Basic refractories include magnesia and chromite, singly and in combinations, dolomite, and forsterite (olivine). The acid category includes aluminosilicates, alumina, and silica. There are a number of other specialized types such as carbon, graphite, silicon carbide, zircon, and zirconia that have important applications but are used in much smaller amounts than the major categories. Physically, refractories can be divided into bricks and shaped products on the one hand and unshaped or monolithic products (also termed specialties) on the other. There are many further subclassifications and divisions, a discussion of which is beyond the scope of this chapter; see Refs. 2 and 9. Raw materials for the principal basic refractories are magnesia and chrome ore. Magnesia, generally termed magnesite or periclase, is obtained mainly from seawater or saline brines extraction, but substantial amounts are produced from mined magnesite (MgCO3). Dolomite (CaCO3•MgCO3), another important basic refractory, is obtained entirely from mined sources. Acid refractory raw materials are: fire clays, flint clays, kaolin, and other natural clay minerals; aluminosilicate minerals such as kyanite, andalusite, sillimanite, pyrophyllite, bauxitic clays; calcined refractory grade bauxite, alumina from the Bayer process for the alumina group; and quartzitic rocks for silica refractories. The total value of all refractories shipped in the United States in 1974 was $989 million, a record to that date. Of this amount, about 73% represents bricks and shaped products and 27% is in nonshaped or monolithic products which comprise mortars, cements, castables, plastics, and ramming and gunning mixes. Fig. 15.4E.1 shows the rising value of all U.S. refractory shipments in the period 1948-1974. Values of brick and shapes paralleled

Jan 1, 1976

By R. H. Jefferson

An electrochemical method to selectively determine sulfur dioxide in the presence of sulfur trioxide was investigated. A hydrophobic gas-permeable membrane separates the gas sample solution from an internal filling solution containing a fixed quantity of chloride ion and a sufficiently large excess of sodium bisulfite so that its concentration may be considered constant. Sulfur dioxide diffuses through the membrane to dissolve in the internal filling solution and liberates an equivalent quantity of hydrogen ions. The electromotive force between a precision-ground, flat-ended pH electrode, which acts as the sensing element, and a chloride sensing electrode, which acts as the reference element, gives a direct measure of S02 in the gas sample solution. Calibration curves in water, tetrachloromercurate (TCM) , and citrate buffer absorption solutions were closely parallel with slopes in their linear segments, ranging from 57 to 52 mv/decade of S02 concentration. The slopes compare reasonably well with the theoretically expected slope of 58 millivolts at 21° C. The water standard curve was linear with respect to the logarithm of S02 concentration from 1 to 1,000 ppm S02; the TCM standard curve was linear from 10 to 2,000 ppm S02; and the citrate standard curve was linear from 30 to 5,000 ppm S02' The high efficiency and nontoxicity of citrate favor it as a substitute for the conventionally used TCM in the absorption solution.

Jan 1, 1976

It took me nearly nine months to make the move from Arizona to Berkeley, opening an office and planning our new home. While I was in Warren Dorothy had rented two rooms for my office In the new California Commercial Union Building at 315 Montgomery Street in San Francisco. She made such a good choice that this remained my address for more than 50 years Dorothy had also looked over many lots In Berkeley, and took an option on the one that pleased her the most. It was a beautiful lot, or rather three, as we took three lots to protect our view. The only possible drawback was that it was in a new district and there were only two houses within two blocks. No one could tell how the area would develop but we liked it so much that we bought the lots on the spot and signed a note to guarantee payment. Dorothy's good judgment was shown by the fact that after 50 years we are still glad to be living on the same property, at 168 Southampton Avenue. We arranged a meeting with the distinguished architect Bernard Maybeck-and employed him to design a house for us. Dorothy spent most of her time with Maybeck planning the house and an attached studio for her, and she later wrote an amusing essay on her dealings with Maybeck. They were so successful that even now we could not think of any changes we would have wanted. It took several months to design a house that suited Dorothy and would fit on our hilltop. I was glad to overcome some of Maybeck's scorn for "only an engineer" by showing how, by rotating the studio addition 45º, it would fit the lot without serious excavation. We finally signed a contract with Maybeck, borrowing so much money that it scared us. First Consulting After short jumps to the gold mines in the Secret Pass District near Kingman, Ariz., and to the Espiritu Santo prospect adjoining the rich

Jan 1, 1976

By David Hoadley, Kenneth R. Maser, Ashok B. Boghani, James E. Billar, D. Randolph Berry, Mackenzie Burnett, Robert H. Trent

SUMMARY AND CONCLUSIONS This report describes a study to develop a detailed set of guide¬lines and equipment recommendations to be used as a guide for mine operators, mine inspectors, and equipment manufacturers in implementing the emergency escapeway standards for metal and nonmetal underground mines. It was sponsored by the United States Bureau of Mines. The first part of this report reviews the historical background of metal and nonmetal mine fires and the development of present and proposed mandatory standards. This is followed by a discussion of the survey of representative mines and how the proposed standard effects these mines. The remainder of the report covers technical discussions of each escapeway component including a comprehensive computer sim¬ulation of mine evacuation. Following the technical discussion of each group of escapeway components is a list of the pertinent guidelines. A study of past mine fires indicates that a serious commitment by operators to the proposed escape standards would be instrumental in saving lives in the future. The most significant event in a recent mine fire, in which no deaths resulted, was the very early discovery of the fire. The evacuation was orderly thanks to careful preparation by the mine personnel. However, the mine was possibly only spared a real disaster because of the discovery of the fire almost at its inception. Installation of automatic fire and smoke warning devices may be the single most important step in preventing future disasters. The self-rescuer has saved many lives in mine fires. Men have also died while attempting to use them. The reason men died was either because the unit was not working or the miner did not understand how or when to use it. There is no good excuse for either of these conditions occurring. Regular maintenance and inspection should prevent unit failures. Frequent instruction on when and how to use the self¬rescuer would prevent confusion and potential fatalities. A means of

Jan 1, 1976

By Roger N. Kust

Because ammonia can form complex ions with certain of the transition metals, such as copper and nickel, it has long been of interest to extractive metallurgists interested in leaching or separating these metals. Although it is a relatively expensive reagent, ammonia is amenable to recycle because of its volatility. In development of processes utilizing ammoniacal leaching or separation schemes, information regarding solution vapor pressures, pH and solubility limitations is needed. There is voluminous literature on ammonia-water systems generated by the urea industry. However, frequently the systems of interest to metallurgists differ significantly in concentrations of ammonia used, the temperatures of interest. Furthermore, the differences arising from the presence of metal values in solution must be comprehended. There is surprisingly little information readily available regarding systems of practical interest to metallurgy. As a result, those interested in ammonia-based processes end up either doing expensive laboratory research to obtain necessary data or overdesigning the process. Another approach to obtaining desired information about ammoniacal systems is to attempt to calculate from first principles the various solution properties. This paper is being presented to illustrate what can be accomplished by estimating the state of equilibrium in an ammoniacal carbonate system from available thermodynamic information making simplifying assumptions when needed.

Jan 1, 1976

By Robert D. Thomson

Land use is the single most important element affecting the quality of our physical environment. .The minerals industry is a user of land and by its very nature, directly affects the landscape. Mining is a very visible activity. Producers of sand and gravel, crushed stone, clay, cement and lime operate right at the interface of the public. These production sites must be located near population centers. People are more travel oriented than years ago and through use of the expanded interstate highway system visit remote and little-visited areas. They visit communities on their vacations, places they enjoy on weekends and places they drive past on business trips. Although not residents of these localities, they have a strong interest in changes that occur in the landscape. As a result, the public has a greater concern today about mining and its use of land. From 1930 through 1971, the minerals industry used 3.65 million acres, or 0.16 percent of the land mass in the United States (4)2/. Of the total 3.65 million acres utilized, about 59 percent was accounted for by the area of excavation, 20 percent by disposal of overburden and other mine wastes from surface mining, 13 percent by disposal of mill or processing wastes, and 5 percent by disposal of underground mine wastes; the remaining 3 percent was subsided or disturbed as a result of underground workings. Nonmetallic minerals and fossil fuels each accounted for 43 percent of surface land used during 1930-71; the metal mining industry utilized the remaining 14 percent.

Jan 1, 1976

By Leigh J. H

A history is given of the dust control techniques developed and applied by the mining companies at Broken Hill. A history of the regeneration works undertaken since 1936 is out- lined. Particular emphasis is placed on the stabilization of mine residue dumps which are located throughout a belt of mining leases in the middle of the city and which began in 1937. The establishment of vegetation for dust control techniques is discussed in detail and a case study is given of the successful revegetation of the sides of a 650 metre long, 350 metre wide and 35 metre high residue dump.

Jan 1, 1976

By J. Wyn Prior

The seismic refraction technique is probably the most popular geophysical method of bedrock profiling in geotechnical site investigations but is somewhat restricted by the inherent assumptions in the method. This paper describes how Hales' method of profile interpretation is modified to overcome the assumptions of increasing velocity and layer thickness with depth when only first arrival data is available. A further expansion of Hales method enables presentation of refraction data in a form whereby bedrock features, such as changes in velocity, relief and dip in particular, are more readily recognized. Characteristic curves of the more common bedrock features are presented as an aid to bedrock feature recognition.

Jan 1, 1976

By Lee M. Manna

Approximately 10,000, 10-Ton, 4 wheel, 2 truck, coal mine cars are in general service in U. S. Mines. None are equipped with an automatic braking system. Very few are equipped with hand or parking brakes. The report lists major manufacturers of the car and develops estimate as the percentage represented. It complies physical specification of cars of major car manufacturers, and develops a composite clearance diagram. It then discusses a pneumatic system employing truck components for an automatic system that could be used as an add-on unit. The components are listed and priced and a schematic circuit is developed for the system. Recommendations as to future programming are made.

Jan 1, 1976

By Baafi EY, Appiah HK

The Prestea Goldfields Ltd of Ghana, West Africa has produced over 170 t of gold with average grade of 11 g/t since 1912. The deposits occur in a wide shear zone which closely follow the Birimian-Tarkwaian contact. Both the Birimian and Tarkwaian systems are of Precambrian age. Underground exploration is carried out to delineate ore bodies by means of AX size diamond drilling at 50 m sampling intervals. After the orebody has been delineated, development work is carried out by exposing the gold reef. Channel sampling is then carried out at about 3 m intervals in both the stope and stope drives. A channel sample length is commonly 0.6 in, but may vary depending on physical characteristics of the reef. The values of channel samples are linearly combined to obtain the average reef or slope values and/or widths of the exposed sections. The sampling practice and methods of improving the efficacy of sampling at the mine are described.

Jan 1, 1976

By F. P. Haver

Primary lead is produced in the United States by the pyrometallurgical smelting of lead sulfide (galena, PbS) concentrates, which poses sulfur dioxide and lead air pollution control problems. The Federal Bureau of Mines has investigated an alternative hydrometallurgy procedure that does not generate gaseous sulfur oxides and diminishes the potential for the escape of lead into the atmosphere. The procedure involves leaching galena flotation concentrates with ferric chloride (FeC13) solution to obtain lead chloride (PbC12) and elemental sulfur as expressed by the following chemical reaction: PbS + 2FeC13 ? PbC12 + 2FeCl2 + S°. At 100° C, over 99 pct of the PbS in the concentrate is converted to PbCl2 in less than 15 min. The leach solution, composed of brine (NaCl) containing slightly more than the theoretical required amount of FeC13, dissolves the PbC12 as it is formed, leaving a residue of elemental sulfur plus gangue. High-purity PbC12 (>99.9 pct) crystallizes from the leach filtrate on cooling and is electrolyzed in a low-temperature, fused-salt cell to obtain corroding-grade metal (>99.94 pct Pb). Spent leach solution (FeC12) is regenerated for further use by reaction with the chlorine obtained in the electrolysis of lead chloride. Other values, such as Ag, Cu, Zn, and S°, are recovered by additional treatment of either the leach solution or leach residue.

Jan 1, 1976

By Zoltan Susanszky

The total available energy in an explosive charge is seldom fully utilized in industrial operations. For this reason more explosive is normally used to perform a job than we would calculate. In an explosive detonation some energy is generated as waste energy which can not be efficiently used. This results in added expense and possible environmental damage. This waste energy can create problems in metal forming with explosives and during commercial underwater blasting operations.

Jan 1, 1976

By Robert M. Dreyer

AGGREGATE With an annual domestic production of over 1.6 billion tons at a value of over $2 billion (see Table 15.1.1), the production of aggregate (crushed rock, sand, and gravel) is a basic industry of utmost economic importance. Because of the role of aggregate materials as essential ingredients of concrete, asphalt surfacing, and plaster, their delivered prices are major factors in determining the cost of construction. The annual domestic production comes from nearly 10,000 plants. About 15% of these plants account for over one-half the production. In a rapidly inflating economy, the average mine sales price of aggregate has remained relatively stable. The actual mine sales prices, however, vary greatly depending on quarrying costs in various parts of the country. Of much more importance in construction costs, however, is the delivered price of aggregate. This varies for each job, depending on the distance from the quarry and resulting transportation costs, as well as the initial cost at the mine. Because of a proliferation of regulations limiting new quarries in the vicinity of the encroaching urban sprawl, the average distance which aggregate must be transported has been increasing rapidly. Although it is impossible to derive an average delivered cost for aggregate, it should be noted that even an increase of only $1 per ton in average delivered cost over the last decade (probably a minimal assumption) would mean an annual cost $1.5 billion higher than ten years ago. In recent years, structural engineering considerations, as well as an increasing use of lightweight concrete blocks, have resulted in a rapidly increasing demand for lightweight concrete and plaster, the essential ingredient of which is lightweight aggregate. Principal lightweight aggregates are: pumice, slag, perlite (thermally expanded hydrous volcanic glass), vermiculite, and expanded shale, formed by the thermal expansion of shale and slate. The United States now has the capacity to expand, annually, over 13 million tons of shale and slate and to expand over 600,000 tons of perlite. In locating a site for aggregate production. the following factors must be considered: (1) tonnage available; (2) quality of aggregate (including local variations); (3) distance from major use areas; (4) transportation costs, including those resulting from present and possible future haulage restrictions; (5) zoning regulations; (6) operating costs, including the cost effects of compliance with local regulations governing blasting, air pollution, water pollution and drainage, noise levels, and operating periods. At one time, locating a suitable site for the production of crushed rock, sand, or gravel, in most areas, was regarded as an extremely simple task. In the past few years, however, finding a site for profitable production of aggregate has assumed ever-increasing com-

Jan 1, 1976

By Fenton Scott, Patrick Hannon

Some occurrences of lead-zinc mineralization in Mississippian carbonates of central Nova Scotia are briefly described. The results of geophysical and geochemical prospecting are presented. Because the deposits do not give a positive response to these indirect techniques it is necessary to site exploratory drilling through the development of geological concepts.

Jan 1, 1976

By Edwarde R. May

The Flambeau volcanogenic massive sulfide deposit located in northwestern Wisconsin occurs within the southern lobe of the Canadian Precambrian Shield. The steeply dipping tabular body occurs in a complex pile of cyclic schistose intermediate to felsic fragmental volcanics. No chloritic alteration pipe is recognized but adjacent rocks have undergone magnesia metasomatism and subsequently were metamorphosed to the upper greenschist and lower amphibolite facies. Although modest in size the deposit is of special interest in that it has an extensive and well preserved supergene enrichment blanket. Economic minerals found within a pyritized quartz-sericite schist are chalcocite and bornite overlying primary chalcopyrite.

Jan 1, 1976

By H. C. Ko

Calorimetric determinations of low-temperature heat capacities and standard enthalpy of formation were made by the Federal Bureau of Mines for basic aluminum sulfite, A1203?2.0S02?5.3H20. The standard values of entropy (S°), enthalpy of formation (?Hf°), and calculated Gibbs energy of formation (?Gf°) at 298.15 K are 85.2±0.1 cal/deg-mole, -943.1±1.2 kcal/mole, and -820.7±1.2 kcal/mole, respectively.

Jan 1, 1976

By T. W. Healy, D. R. Dixon

The mechanism of activation of ZnS by metal ions and the subsequent flotation induced by xanthate has been considered as a surface redox reaction. By ultraviolet (UV) irradiation of ZnS suspensions, the normally inert ZnS is caused to react with xanthate in the absence of activator. By similar UV irradiation, the rate of adsorption-exchange of activator ions at the ZnS-H2O interface is also increased. Mechanisms of these reactions are proposed and compared to current electrochemical and semiconducting models of sulfide flotation.

Jan 1, 1976

By J. C. Gerdeen

SAP-S information on the following element types are included in this appendix: Type 1. Three-Dimensional Truss and Bolt Element Type 4. Two-Dimensional Finite Elements Type 8. Variable-Number-Nodes Thick Shell and Three-Dimensional Elements Type 9. Two-Dimensional Joint Element (to be used with Type 4 elements) Type 10. Three-Dimensional Joint Element (to be used with Type 8 elements) Additional SAP4 elements, Types 2, 3, 5, 6, 7 and 12, are also contained in SAP-S and information on these elements is readily available in any SAP4 user's manual. These elements are as follows: Type 2. Three-Dimensional Beam Elements Type 3. Plane- Stress Membrane I-r .n Elements Type 5. Three-Dimensional Solid Elements (8 Node: Brick) Type 6. Plate and Shell Elements (Quadrilateral) Type 7. Boundary Elements Type 12. Three-Dimensional Straight or Curved Pipe Elements

Jan 1, 1976

By Stephen A. Hare, O&apos

Powder metallurgy processing of commercial Raney nickel powders was examined. The typical angular particle shape, in conjuction with aluminum present in a eutectic phase, facilitated interlocking leading to excellent green strength after compaction. Density and porosity as influenced by the compacting pressure were studied over the range of 37.5 to 207 meganewton per square meter (MN/m2). Sintering in an inert atmosphere from 575° to 850° C caused a volume increase which is attributed to a solid state reaction between Al and Ni2Al3 phases. The reaction is 3Al + Ni2Al3 ? 2NiA13. A thermal pretreatment of 70 hours at 700° C was required to prevent this reaction from occurring during sintering. Density and porosity as a function of compacting pressure and sintering temperature were determined after a thermal pretreatment of the powder.

Jan 1, 1976