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By P. A. Bloom

Arsenic-containing flue dusts are currently being stockpiled by several nonferrous smelters in the United States. These stockpiles are a source of environmental concern since the dusts can be transported by wind and contain water-soluble arsenic. The stockpiles also represent an alternate source of metals. To provide a quality environment, the Bureau of Mines investigated a process to make environmentally acceptable the discard of arsenic obtained from the treatment of arsenical flue dust. The process includes (1) leaching arsenic from a lead smelter copper dross flue dust, (2) fixing arsenic as an insoluble compound, and (3) recovering other metal values. Overall results of acid-leaching tests on lead-smelter flue dusts showed that H2S04 dissolved 80 to 90 percent of the As, Zn, and Cd, and up to 86 percent of the In. Pb, Ag, and Au remain in the residue, which can be recycled to the smelter. Indium was recovered from the strong acid leach solution by solvent extraction; arsenic was fixed in a stable form by precipitation with Fe2(S04)3 and CaO or CaC03.

Jan 1, 1982

By B. W. Madsen

As part of a program to maintain an adequate supply of minerals and metals to meet national economic and strategic needs, the Bureau of Mines conducted research to determine the diffusion coefficients for ferric ions in synthetic copper leach solutions. Determination of ferric ion diffusion coefficients in typical dump leach solutions is necessary for predicting leaching rates of copper from large-scale leaching operations and for optimizing concentrations of ferric iron in solutions to maximize leaching efficiency. Derivative chronopotentiometry, an electroanalytical technique, was used to determine ferric ion diffusion coefficients. The diffusion coefficient decreased dramatically with increasing concentration of iron in solution. An empirical model was used to relate the ferric ion diffusion coefficient to the total amount of sulfate in solution. Measuring the diffusion coefficient dependence on temperature yielded an activation energy of 5.5 kcal/mole of ferric ion. Activity coefficients of ferric ions as a function of concentration were calculated from diffusion coefficient data.

Jan 1, 1981

Reduce the noise levels to which operators of double-drum longwall shearers are exposed without compromising the operational effectiveness of the shearer. The Problem Noise produced by double-drum longwall shearers can be harmful to machine operators. Typical noise levels at the lead-drum operator position range from 100 to 105 dBA, and Federal noise regulations allow only one to two hours of exposure per shift at these levels. Noise radiated by the shearer cutting drum is the primary contributor to the overall noise level. However, test of a noise-controlled cutting drum developed by the Bureau of Mines reduced the operator noise level to 95 dBA, thereby increasing the allowable operating time to four hours per shift. Approach The key design aspect of the noise-controlled shearer drum is its reduced vibration-al response to coal-cutting forces. Laboratory studies have shown that these forces are concentrated in the low-frequency region (500 Hz and below). Since the cylindrical core and the cantilevered I plate-like helix of the standard shearer drum are easily excited by these forces (natural vibration frequencies be-

Jan 1, 1985

Provide an economic alternative to drill-blast excavation with the same ability to excavate openings of varied orientation, shape, and size. Approach Develop an efficient, adaptable, mechanical excavation machine that produces unconfined tensile failure in rock. How It Works A drill-split fragmentation machine that combines a drill and a unique splitter has been developed. The drill and splitter are mounted on a carriage that positions the splitter in a hole immediately after it is made by the drill. The splitter creates force loads that cause the rock to fragment, and the process is repeated for excavation. The unique splitter applies both radial and axial loads to the rock mass, which produces an excavation action comparable to pulling a plug. This excavation action distinguishes the radial-axial splitter from typical demolition splitters, which require a free surface parallel to the axis of the splitter toward which to break rock.

Jan 1, 1989

To identify the most successful methods now in use for controlling respirable dust in longwall mines using double-drum shearers. Approach Conduct dust surveys at six longwall mining sections that use double-drum shearers and are regularly in compliance with the Federal Respirable Dust Standard, to identify effective dust control techniques. The selection of mine sites was based on recommendations provided by the Mine Safety and Health Administration. Instantaneous and short-term gravimetric instrumentation make it possible to isolate longwall dust sources and to determine the effectiveness of dust control techniques. (These procedures were developed by the Bureau of Mines, and are described in detail in Technology News Bulletins 134 and 135.) Production levels, and seam heights at each of the six longwall sections were: 53", 700 tps; 60", 800 tps; 72", 1000 tps; 79", 1500 tps; 84", 2000 tps; 96", 1500 tps. Survey Results Three effective dust control techniques were identified. 1. Shearer Operators on Intake Side of Lead Drum-At all mines surveyed, an important factor in controlling dust exposures at the shearer is the use of a cut ting sequence that allows the shearer operators to work most of the time on the intake air side of the lead drum. Dust profiles, like those plotted from data at two mines (see the graphs), show the large gradient in dust concentrations that can

Jan 1, 1982

By W. M. Dressel

Over 2 million tons of steel furnace dust containing approximately 100,000 tons of zinc and 10,000 tons of lead are produced each year. Recycling of the dusts would conserve mineral resources, lessen land area requirements for disposal, decrease pollution problems, and aid in solving our balance of payment problem. Steelmaking dusts can be pelletized and thermally treated to remove lead and zinc and to reduce the iron oxide to form metallized pellets. In laboratory tests more than 99 pct of the zinc and 85 pct of the lead was volatilized from the dust by roasting at 1,000° C in carbon monoxide. The volatilized material can be collected and treated further for lead and zinc recovery. Reduction and volatilization of over 95 pct of the zinc and most of the lead was achieved by roasting self-reducing mixtures of steel furnace dusts and high carbon steelmaking wastes in an inert atmosphere at 1,100° C. Over 80 pct of the iron in the resulting pellets was metallized.

Jan 1, 1974

Provide reasonably priced, reliable fire protection for AN-FO haulers. Approach An automatic fire sensing and suppression system for AN-FO haulers was developed and on-vehicle tested. How It Works The system works in two ways to protect personnel from dangerous and unpredictable AN-FO fires. First the system senses and suppresses fires on the truck before they spread to the AN-FO in the bunker. This design was chosen because AN-FO truck fires generally start when combustible liquids (such as diesel fuel, hydraulic fluid or lubricating oils) are ignited by hot surfaces mainly on three areas: the engine, the transmission or the power take-off. These fires are quickly sensed by a linear temperature sensor strung throughout these three areas. The system then warns the operator and automatically suppresses the fire by discharging 30 pounds of multipurpose dry chemical extinguishing agent through a network of fixed hoses and nozzles. Second, this system includes six spot thermal sensors mounted inside the bunker on the truck to monitor the AN-FO temperature in case a fire does spread to the bunker area. If the bunker temperature rises to 190° F, a loud siren is sounded to warn nearby per-

Jan 1, 1981

By C. M. K. Boldt

This U.S. Bureau of Mines report presents a study of three typical tailings samples as potential cemented backfill in underground mines. The testing series was unique in that the pulp densities of the samples were all above 75 pct solids. Test results included dry density; slump; percent settling after 28 days of curing; tensile strength after 28, 120, and 180 days of curing; and unconfined compressive strengths after 7, 28, 120, and 180 days of curing. The physical properties of the various test mixtures were further analyzed using linear and nonlinear statistical methods to produce correlations and mathematical equations. Physical properties were used to determine the influence of mix additives and as input for numerical modeling studies of backfill. The mathematical relations were used as a predictive tool in determining the suitability of various materials as backfill.

Jan 1, 1989

By Michael J. Brnich

Since 1991, Pittsburgh Research Center (PRC- formerly part of the Bureau of Mines) researchers have recorded extensive interviews with 30individuals who are experts in the area of mine emergency response. These individuals, who have an average of 35 years of mining experience and 29 years of mine emergency response experience, related stories and observations from events that they experienced during their combined 850 plus years in mine emergency response. The purpose of this effort was to gather information that could be passed onto both today?s and tomorrow?s mine emergency responders to train and guide them in handling future events. This is the second of two articles which report experts responses to questions about training for future mine emergencies. During the interviews they discussed how training should be conducted, who should be trained, and what topics should be included. This article will cover the third area: Topics that should be included in training for mine emergency response managers.

Jan 1, 1997

By J. L. Konchesky

The Bureau of Mines investigated the main reactions of coal gasification by steam. Coal (minus 70 mesh)-water slurry was fed into a laboratory-scale tube-coil gasifier to show the effects of residence time (0.6 to 1.1 sec), steam-coal ratio (2 to 11 lb/lb), and temperature (1,600° to 1,900° F), at about 1-1/2 atm. Devolatilization was very rapid: about 70 pet of the coal's volatile matter evolved within 0.6 sec at about 1,600° F; temperature increase released more volatile matter until about 95 pct was driven off at 1,900° F. Devolatilization was not increased by raising steam concentrations and was only slightly increased by extending residence time. Below 1,600° F, there was no evidence of the steam-carbon reaction, but at 1,900° F more than 80 pct of the coal's fixed carbon was converted to gas; the conversion was increased Significantly by increased residence time and steam concentration. The water-gas shift reaction occurred simultaneously with devolatilization, and the steam-carbon reaction, approaching equilibrium with increased residence time and temperature and decreased steam concentration.

Jan 1, 1969

By David C. Oyler, Paul W. Jeran, William P. Diamond

The Bureau of Mines is cooperating with the U.S. Department of Energy in a directional degasification project at the Emerald mine near Waynesburg, Pa. This project is designed to combine the highly successful underground horizontal degasification technology with surface drilling methods. The objective of this program is to demonstrate that directional drilling can be used as a technique for degasifying coalbeds ahead of mining to reduce the hazards of methane-air explosions in coal mines. The directional hole at the Emerald mine is designed to start vertically and enter the Pittsburgh coalbed horizontally. A 3-inch-pilot hole entered the Pittsburgh coalbecl at a vertical depth of 999 feet, The hole will be reamed to 8-3/4 inches in diameter, and 5-1/2-inch casing will be cemented in place. Three individual 3-inch-diameter, 3,000-foot horizontal gas collection holes will be drilled into the coalbed in a “bird foot” pattern. A corehole and vertical dewatering hole have been completed at the anticipated coalbed intercept. The dewatering hole was drilled to130 feet below the Pittsburgh coalbed, a depth of 900 feet, and 880 feet of 7-inch-OD casing was cemented in place. Seven vertical holes for monitoring the extent and progress of degasification have been drilled within the horizontal drilling area.

Jan 1, 1979

By R. V. Ramani, R. Stefanko, G. W. Luxbacher

A computer model of an existing mine ventilation system can be executed using data developed from ventilation survey results. This model can then be used to analyze and evaluate proposed modifications to the system. The acquisition of field measurements during a ventilation survey and the corresponding development of this information into computer input data have been discussed in detail in the preceding chapters. In this chapter, the data are used in computer-oriented analysis of the mine ventilation system. The PSU/MVS was selected for use because of its advanced capabilities. MINE DESCRIPTION The mine chosen for this application is located in Western Pennsylvania. The Pittsburgh coal seam, having an average height of 5-1/4 to 6-1/2 ft, is mined under approximately 300 to 500 ft of cover. The mine preparation plant and shipping facilities are located at the seam outcrop along a river; mining has progressed from the outcrop to an area about 10 miles from the pit mouth so that there are extensive worked-out areas through which access is maintained to the current mining area. Coal haulage is by conveyor to an underground transfer point, located four miles from the pit mouth, and then by high speed rail haulage to the preparation plant. The rail haulage link is scheduled for replacement by a conveyor in the near future. Mining at the present time is limited to the room and pillar method using continuous miners. Longwall mining had been attempted in the past with only limited success; as a result, several panels originally laid out for longwall mining are currently being extracted by room and pillar work. The

Jan 1, 1977

By D. A. Doughty

The Bureau of Mines developed two methods for determining iron II and iron III in 2- to 5-mg samples of coal using electron paramagnetic resonance (EPR) spectrometry. One method used solid coal samples; the other method used aqueous solutions. The method using solid samples was more simple, technically, but required the use of X-ray fluorescent analysis, or another independent method, for determining total iron in the samples, and the results were subject to some uncertainty. The method using aqueous solutions appeared capable of greater certainty and did not require additional methods of total iron analysis but was more involved procedurally. The coals analyzed were found to contain much more iron II than iron III.

Jan 1, 1973

By T. A. Sullivan

Research undertaken by the Bureau of Mines in 1938 has resulted in the development of titanium from a laboratory curiosity to a commercial metal. Along with processes for producing the metal, it was necessary for the Bureau to develop methods for analyzing the metal, raw materials, and intermediate products. Some of the methods developed have been published.3 4 5/ General Services Administration (GSA) was responsible for purchasing titanium metal under Defense Production Act contracts with commercial producers. GSA designated the Federal Bureau of Mines to analyze this metal and establish its compliance with Government specifications. A substantial quantity of tin was found in some of the samples analyzed, and in July 1957 tin was added to the list of impurity elements to be determined. The specifications limited the amount of tin in titanium sponge to a maximum of 0.10 percent. A program was immediately initiated to investigate methods and techniques for determining tin in the range of 0 to 1.0 percent. A method accurate at the 0.10 percent level was necessary, as this level was the critical range for acceptance or rejection of the metal.

Jan 1, 1960

Develop improved blasting practices that can help to curb overbreak in highwalls at surface mines, thereby reducing the hazards of rock-falls to workers and equipment, The Problem The serious hazard in surface mining is the falling of rock from highwalls. Poor highwall stability is caused in part by geologic conditions, but often is aggravated by faulty blasting practices, where the explosive energy not only fractures the rock to be excavated, but also damages the rock that borders the excavation. This reduces the general stability of the hlghwall and increases the rockfall potential. The probability of injury to mine workers or damage to equipment associated with exposure to the highwall increases with the height of the highwall and the extent of its overbreakage. Most rockfalls occur in the first 15 days after a new highwall is exposed. This statistic is significant since most of the work below a highwall is done during this period. The area of greatest hazard is within 25 ft of the toe for rocks that fall vertically, and up to 90 ft from the toe for falling rocks that are deflected by the highwall during their descent, The workers most frequently involved in such accidents are dozer operators, ground laborers, and shovel operators or oilers.

Jan 1, 1985

By James E. Hill

TECHNOLOGY is best nurtured by a sympathetic climate that is a composite of many factors. Necessity is a highly motivating factor as illustrated by the abnormal surge of technologic development curing wartime. Other factors include appropriate timing, economic pressures, available personnel, and in some instances, legislative action. Problems of recent concern to mining technology have been the quality and quantity of available technical personnel and the possibilities of restrictive legislation. The quality and quantity of technically trained personnel may be inadequate to meet the rapidly increasing complexity of modern technology coupled with the growing demand for qualified personnel. The question of appropriate training was a subject for debate.2 The curriculum and methods of teaching have changed. Questions have been raised on the relationship of scientist and engineer, interdisciplinary versus specialized curriculum, undergraduate versus graduate training, and the place of the smaller schools versus the large university-research complexes that have developed at some universities. Various aspects of the subject of engineering education for the mining industry were discussed at the meeting on Mining and Mineral Engineering Manpower at the Michigan College of Mining and Technology, November 18-19, 1963. Meanwhile, the trend toward interdisciplinary training gathers momentum as illustrated by the establishment of the School of Engineering Science at Johns Hopkins, the Schools of Engineering and Applied Science at Columbia, Princeton, and Yale, the Division of Engineering and Applied Physics at Harvard and, more recently, the School of Engineering Science at Florida State University which cuts across the conventional areas of civil, mechanical, electrical, and chemical engineering.

Jan 1, 1964

By David S. Yantek, Paul Jurovcik, Eric R. Bauer

Workers in coal preparation plants, where vibrating screens are significant noise sources, are often exposed to sound levels exceeding 90 dB(A). The National Institute for Occupational Safety and Health, a major coal company, and a vibrating screen manufacturer conducted a cooperative study of vibrating screen noise. Rubber isolators reduced sound levels by 1 dB. Urethane screen panels did not reduce sound levels in this case. Drive noise was determined to be the dominant noise source on the screen. Damped side plates reduced vibration levels on the screen sides by 1 to 7 dB(A). Detailed results of the study are presented.

By Joseph Cervik

Gas occurs in coalbeds in an adsorbed and a free gas state. Adsorbed gas is stored in the micropore structure and its transport is governed by Fick's law. The free gas occurs in the fracture system and flows according to Darcy's law. These two modes of mass transport are interdependent. Production decline curves of coal-gas wells are of the constant percentage decline type and, thus, show no indications of flow characteristics peculiar to coal-gas reservoirs. The effectiveness of surface boreholes as a degasification scheme depends upon both good fracture permeability and a high fracture density. Conventional methods of reservoir engineering analysis are not applicable to coalbeds

May 1, 1969

By F. L. Wideman

Materials handled at metal and non-metal mines in the United States increased 10 percent compared with those of 1965 as a result of expansions in output at existing mines and development of others to meet increasing demands for mineral products. The tonnage of commercial materials mined or quarried increased as did the quantity of waste handled. Crude material from which metal or nonmetal products were derived comprised 71 percent (75 percent in 1964) of the total materials handled. Great strides were made in mining technology and there were indications that, in the future, earth moving by the mining industry will involve materials-handling systems of increasing size and complexity. Materials Handled.-Output of ore and waste at metal and nonmetal mines and quarries in the United States in 1966 totaled 3,518 million tons (3.213 million tons in 1965). The quantity of materials handled has increased at an average annual rate of 5 percent since 1962. Ore production increased 4 percent over that of 1965, also comparable to the average annual rate of increase in the last 5 years. Waste removal in 1966 increased 25 percent over that of the previous year.

Jan 1, 1967

Reduce the number of accidents caused by slips and falls from large mining equipment. Approach A powered lift was developed that provides operators with a safer way of getting on and off large machines. How It Works The powered step is designed to lift personnel and materials to working levels on large machines. It eliminates hazardous blind steps and makes it unnecessary to climb on irregular surfaces made slippery by mud, ice, snow, and accumulations of grease. The step is powered by a self-contained electric/hydraulic unit which is connected to a vehicle's auxiliary power supply. When in the "down" position, the step rests about 15 inches above ground level. When the power unit is activated with an electrical switch located on the step, a Single cylinder attached between two lifting arms smoothly lifts the step. In conjunction with the lifting motion, a linkage and bearing arrangement on the mounting end of the lift arms causes the step to rotate towards the machine, so that the step moves in an arc from ground to platform level. When the machine Is operating, the step is automatically locked in the "up" position, protecting it against any damaging contact with obstructions. The step is lowered by activating a pressure release solenoid. An in-line orifice controls downward speed and prevents free fall. On most machines, additional control switches are conveniently located at ground level and in the operator's cab. Visual alarms and machine interlocks are provided where necessary to prevent machine operation when the step is In the "down" position. The powered step can be easily adapted to any type or model of large machinery.

Jan 1, 1981