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By Michael J. Magyar

The Federal Bureau of Mines has developed a hydrametallurgical method to recover aluminum, aluminum oxide, and fluxing salts from aluminum salt slags. The slag is leached with water at room temperature to produce a saturated brine slurry. Screening of the slurry yields an aluminum-rich fraction that can be returned to the dross furnace. The remaining slurry is vacuum filtered, yielding a clear brine solution and an aluminum oxide filter cake. Evaporation of the clear filtrate produces a high-purity fluxing salt for reuse in the dross furnace. Over 80 pct of the metallic aluminum is recovered in the aluminum-rich oversize fraction, while essentially all the fluxing salts are recovered by evaporation. This report contains the final results of an investigation on a process research unit scale, an economic evaluation of the method, and recommendations to further improve the process.

Jan 1, 1979

By Michael T. Nigbor

This Bureau of Mines publication identifies the significant environmental issues associated with the potential development of strategic and critical minerals in the Stillwater Complex, MT. The Stillwater Complex contains deposits of Cr, platinum-group metals (PGM), and Ni. Issues that must be addressed prior to minerals development include the effects mining, milling, and smelting will have on the land, water, and air, and methods of minimizing the environmental impacts.

Jan 1, 1985

By W. T. Westbrook

This Bureau of Mines report contains methods for analyzing iron are for total iron, ferrous iron, metallic iron, silica, manganese, aluminum, calcium, magnesium, phosphorus, titanium, carbon, sulfur, moisture loss, and ignition loss by wet chemical methods. Some are modifications of standard umpire methods; others have been developed by the Bureau of Mines to provide a com-bination of speed and accuracy. They are suitable for a high volume of samples and/or control situations, and for situations in which instrumental results must be verified. These methods have been used to analyze taconites, native ores, some foreign ores, and metallurgical products.

Jan 1, 1975

By Bolmerm R. L.

This information circular describes the application of modern methods and equipment in sinking a vertical, 916-foot-deep by 16-foot-diameter, concrete-lined access shaft for the Harold D. Roberts tunnel near Montezuma, Colo. Although the access shaft was merely a construction facility to expedite completion of a 23-mile water-diversion tunnel, a circular shaft of this type would be equally adaptable for mine development or other purposes. Comparable sinking methods and equipment could be used for similar shafts within a wide range of sizes and depths. SUMMARY In addition to excavation and support of the basic access shaft to tunnel grade, the overall sinking project involved initial preparation of a surface site and plant, subsequent construction of a tunnel-level station and loading pocket at the shaft bottom, and ultimate conversion of the basic shaft into a hoisting and access facility for tunnel operations. The sinking period for the basic shaft approximated one year. Actual tunnel operations through the converted shaft began on April 3, 1958, approximately 19 months after the project was initiated.

Jan 1, 1961

By Thomas M. Nasiatka

This report briefly describes the present state of the art and the technological highlights of tunneling from its inception to the present. The discussion is concerned primarily with tunnels driven through relatively competent rock for mine development and various civil purposes. In addition to pinpointing the major technological breakthroughs in tunneling, this report indicates their general effect on the speed of tunneling. The tunneling speeds are based upon data from approximately 80 tunnels listed in the appendix. These data include length; cross section shape and dimension; type of rock; tunneling method; method of breaking, loading, and transporting the rock; average linear progress rate; and cost in values during the period of construction. Most of the tunnels described have diameters of 15 to 30 feet.

Jan 1, 1968

By J. A. Gutierrez-Rodriguez, R. J. Purcell, F. F. ApIan

"Based on contact-angle measurements and the work of adhesion equation, the hydrophobicity of a wide variety of coals was found to decrease with decreasing rank, fixed carbon and total carbon content and with increasing oxygen and hydroxyl content. The estimated hydrophobicity, based on the water-sessile-drop contact angle, is '\.. 20% for lignite, increases with increasing rank up to a maximum of 'V70% for low (LV) and medium (MV) volatile bituminous coals and then decreases somewhat for anthracite. Using the captive-bubble technique, the calculated hydrophobicity ranges from '\.. 0% (below HV A bituminous rank) to a maximum of 55% for L V-MV coal. The former estimation is believed to be the more accurate. While the water-sessile-drop contact angle as measured on a polished-coal surface is usually larger than that shown by the captive-bubble method, the two values were found to converge at""' 95% relative humidity. It is proposed that the surface of coal consists of three kinds of sites: strongly hydrophobic, weakly hydrophobic and hydrophilic. The sessile-drop technique measures the total hydrophobic sites whereas the captive-bubble method measures only the more strongly hydrophobic sites. A water film covers the weakly hydrophobic sites preventing their detection by the captive-bubble technique.INTRODUCTIONCoal is a mixture of the degradation products of plants and of mineral matter. The appearance and properties of a specific coal is determined by the nature of the original vegetation and the extent of the physical and chemical changes which have occurred after deposition. The coalification process may be considered to have started with peat formation followed by a transition to lignite due to burial under sediments and metamorphic processes. Further metamorphic transformation to bituminous coals and, finally, under intense metamorphic action, to anthracite causes the carbon content and rank of the coal to increase. With such a wide variation in their genesis and composition, equally wide variations in the degree of hydrophobicity of different coals may be expected. It is the purpose of this paper to provide a means of estimating the hydrophobicity of a given coal sample based on rank parameters."

Jan 1, 1989

By Raja V. Rarnani, Robert L. Frantz

"Mining is one of the oldest of human occupations. The awareness of occupational illnesses associated with mining, even in ancient times, is evident from the writings of Hippocrates (460-370 BC), Pliny and Elder (AD 23-79), and Galen (AD 131-210). Georgius Agricola (1494-1535), in his De Re Metallica, refers to the diseases of miners and the need for their control through good planning and operating practices and responsible management (Schwerha, 1989). Coal workers' pneumoconiosis (CWP), often called Black Lung disease, is an occupational disease which results from inhalation of coal mine dust which usually contains relatively small amounts of free crystalline silica.A pneumoconiosis is best defined as the accumulation of dust in the lungs and the tissue's reaction to its presence [Lapp and Castranova, 1993]. Silicosis is the name given to the fibrotic disease of the lungs caused by the inhalation of dust containing silicon dioxide, primarily in the free crystalline form. Silicosis is the older and more well known of these mineral pneumoconioses. In contrast, CWP was not recognized as different from silicosis until the pivotal work of Collis and Gilchrist [1928].The U.S. Bureau of Mines (USBM) still regards worker exposure to respirable aerosols in mines as the most serious health problem in mining [USBM, 1994]. The National Institute of Occupational Safety and Health (NIOSH) is considering recommending a reduction in the standard for occupational exposure to respirable coal mine dust from 2 mg/m3 to 1 mg/m3 [NIOSH, 1993]. The Mine Safety and Health Administration (MSHA) may require new criterion for sampling procedures in the mine that would evaluate the ambient dust concentration in the mine atmosphere based on a single sample, instead of the current practice of averaging five samples (MSHA, 1992; Ramat* 1993). Several high-production longwall mining faces currently have extreme difficulty meeting the existing dust standards, and some already operate at reduced production levels to achieve mandated levels [USBM, 1993]. The importance of adequately protecting the miners from high concentrations of coal mine dust, as well as of reducing the incidence and severity of the Black Lung disease, cannot be overemphasized. The importance stems, first and foremost, from the humanitarian viewpoint and, second, from the perspective of the overall welfare of the coal industry.The histopathologic hallmark of CWP is the coal macule (Balaan, Weber and Banks, 1993). Autopsy or open lung biopsy reveals the coal macule to be an amorphous mass of coal particles, dust-laden pulmonary macrophages, reticulin, and collagen. No pathognomonic signs or symptoms identify workers with CWP. A CWP diagnosis requires that the worker experienced the appropriate dust-exposure setting (e.g., underground coal mining) and duration (usually 10 years or more) and, has the characteristic chest radiograph. Based upon the International Labour Organization (ILO, 1980) international classification, pathologists and radiologists have established case definitions for characterizing the pathology and the appearance of CWP on chest radiography (Weeks, 1993). CWP appears in two principal forms: simple, with small opacities, and complicated, with opacities larger than 10 mm in diameter. For all practical purposes, diagnosis of CWP in the living miner is wholly dependent upon the chest radiograph interpretation."

Jan 1, 1995

Coal research and related activities in 1964 by the Bureau of Mines resulted in many advances in the production, preparation, and utilization of this valuable natural resource. Mining research during the year was marked by work on hydraulic mining, coalbed degasification, mine drainage control, mine sealing, strip-mine rehabilitation, and quenching of mine-refuse fires. Bureau research continued to produce information leading to increased safety in underground mining. Such research included roof and rib control via bolting and bonding, pressure monitoring of coal and mine rock during mining operations, and development of safety devices for detecting conditions leading to roof falls. Other safety work was continued on methane detectors, coal-dust suppression, and mine ventilation equipment and techniques. Mine explosion and explosives research, mine equipment and materials, safety rule modernization, and safety education and training of mine workmen were continued. Coal storage and preparation work in 1964 ranged from freezeproofing of lignite for rail shipment, through washability studies of coals and washing equipment, to research on new ways to remove ash and sulfur from coal. Electric power production, which accounts for a major portion of the market for coal, received further study. Unique power generation systems, including coal-burning gas turbine and megnetohydrodynamic generators, were intensively investigated. Conventional power systems were improved through continuation of work on furnace performance, powerplant stack gas purification, and engineering and boiler water service.

Jan 1, 1965

By H. W. Wainwright

One phase of the research and development work on synthetic liquid fuels conducted by the Bureau of Mines at Morgantown, W. Va. in cooperation with West Virginia University deals with the purification of synthesis gas.2/ Most of the experimental studies on gas purification have been directed toward the removal of organic sulfur from gas, either catalytically or by adsorption with activated carbon. An important part of the purification program has been the development of suitable analytical methods for determining organic sulfur compounds. As the total sulfur content, organic and inorganic, of purified synthesis gas should not exceed 0.1 grain per 100 cubic feet, the need for accurate analytical methods is apparent. It is also apparent that such methods must be rapid if one wishes to evaluate various processes for removing sulfur from gas. The organic sulfur found in most gas produced from coal is usually present as carbon disulfide, carbon oxysulfide, methyl and ethyl mercaptans, and thiophene, with the exception of thiophene, the remaining organic sulfur compounds respond similarly to catalytic treatment and can be removed effectively. Not only does thiophene resist most catalytic treatment, but it poisons some catalysts, rendering them ineffective in removing the other forms of organic sulfur.

Jan 1, 1950

By A. W. Decora

Gas-liquid chromatography has been applied to separating basic nitrogen compounds, such as pyridines and amines. Close-boiling compounds have been separated by exploiting structural and polarity differences, using selective liquid substrates dispersed on specially prepared solid supports. Development of these special supports was necessary in order to obtain symmetric peaks for basic nitrogen compounds; solution of this problem was important in applying gas-liquid chromatography to the analysis of basic nitrogen compounds found in shale oil. Attempts to analyze shale-oil tar bases by conventional gas-liquid chromatographic techniques, using Chromosorb4/ or Celite 545 as the support for a nonpolar liquid substrate, resulted in asymmetric peaks. These asymmetries were caused by adsorption of sample vapors on the solid support. Symmetric peaks were obtained when strongly polar liquid substrates were used on either Chromosorb or Celite. However, a solid support giving symmetric peaks only with strong polar substrates restricts the choice of substrate, and frequently, desired separations cannot be achieved.

Jan 1, 1961

By Maria I. De Rosa

The U.S. Bureau of Mines conducted a study to determine if correlations exist between the chlorine or nitrogen contents of materials and the hydrogen chloride (HCI) or hydrogen cyanide (HCN) concentrations evolved during the thermal decomposition of these materials. Hydrogen chloride, hydrogen cyanide, and carbon monoxide (CO) were found to be the primary toxic gases evolved during the combustion process. The experiments were carried out in a 20-L furnace with 1-g samples. The furnace temperature, rising from ambient, was set at 1,000 °C with an airflow of 10 L/min. The variables measured were the gas loads (milligrams per gram) of HCI, HCN, CO, and CO2 (carbon dioxide); CO and CO2 concentrations as a function of time were also measured. Other variables included the average concentrations of submicrometer smoke particles and particles' average diameter, mass of particulates, sample and furnace temperatures, and sample weight loss. The data indicate that there are significant correlations between the percentage of chlorine or nitrogen contained in the original samples and the HC1 or HCN concentrations evolved during the combustion of the materials. These correlations may be used to predict and evaluate a material's toxic hazard during combustion.

Jan 1, 2010

By C. M. Dice

This paper is one of a series being published by the Bureau of Mines on milling methods and costs. It describes briefly the procedure followed in concentrating hübnerite or? at the Ima tungsten mine, Lemhi County, Idaho. In October 1911 the Ima mill was utilizing combined gravity-concentration, flotation, and magnetic-separation units for the recovery of a tungsten concentrate and a pyritic silver concentrate approximately 120 tons of ore averaging 0.5 percent W03 is treated daily. The concentrates produced average 66 to 67 percent WO3.

Jan 1, 1943

By R. E. Peterson

The Bureau of Mines has undertaken beneficiation investigations on samples representing large tonnages of oxidized taconites in order to develop and evaluate applicable technologies for producing iron oxide concentrates from these materials. Information derived from the investigations can be used to expand the domestic iron raw-materials base and to establish the impact these taconite deposits may have on future national iron ore requirements. This report describes a process that includes reduction roasting, magnetic separation, and flotation, applied to a western Mesabi Range sample taken near Coleraine, Minn. The sample contained 36.8 pct iron and 46.0 pct silica, and represented 0.5 to 1 billion tons of crude material. An average of 962 lb/hr of oxidized taconite was roasted with 33 lb/hr of lignite in a 35-foot-long rotary kiln. Pulverized lignite and natural gas maintained the kiln operating temperature at 850° C. The roasted taconite was beneficiated by magnetic separation and cationic flotation in a 900-lb/hr pilot plant and yielded a product analyzing 68.1 pct iron and 4.6 pct silica, and containing 82.4 pct of the iron in the kiln feed.

Jan 1, 1981

By Aner W. Erickson

Magnetite iron deposits on Tolstoi Mountain were examined as part of the investigations by the Bureau of Mines of iron and copper ores on Prince of Wales Island. The Tolstoi Mountain project was a part of a program for investigating mineral deposits in Alaska, under the general supervision of R. S. Sanford, acting branch chief.

Jan 1, 1948

By S. L. Ausmus

The work covered in this report is a continuation of an earlier feasibility study by the Federal Bureau of Mines and points out improvements in the skull-melting method for casting reactive metals such as titanium, zirconium, and hafnium. Machined graphite molds with laminated sections can be reused many times. Large tube sections can be produced by spin casting. Graphite powder is the best expendable mold material, but binders for this use must be compounded carefully. The effects of current and furnace atmosphere on the dependent variables of the casting technique are shown. Because of developments in casting technology for titanium which eliminate the basic problems of melting and pouring the metal, opportunities for improvement in the method have increased. The mold material and gate and riser configurations require particular attention. The limits of application of the casting method have yet to be defined. New knowledge in anyone of these areas could result in marked improvements and simplifications in casting methods.

Jan 1, 1960

By John B. Gayle

During studies of the various methods for determining and specifying the factors that indicate whether a particular coke is better or worse than other cokes for metallurgical uses, questions arose as to the precision of screen-analysis tests on coke. Although the usual index of precision, the standard deviation of the test result, gives a measure of the precision of these data, the experimental determination of the standard deviation for a particular set of conditions requires tests on a large number of duplicate samples. Because this procedure necessaily involves a great deal of labor, an equation for predicting standard deviations from theoretical considerations has been developed. Results predicted with this equation agree satisfactorily with the experimental values and are applicable to tests on coal, coke, gravel, and other bulk materials.

Jan 1, 1952

By A. F. Jolly

As a part of ongoing research into the sulfidation partitioning of selected complex minerals, the U.S. Bureau of Mines conducted research designed to selectively recover Cu from sulfidized chalcopyrite (CuFeS2). Ferric chloride (FeCI3) solutions leached >90 pct of the Cu and <20 pct (sometimes < 10 pct) of the Fe in the sulfidized concentrates. Cupric chloride (CuCI2) leaches were even more selective, solubilizing essentially 100 pct of the Cu and < 5 pct of the Fe. In contrast, leaching non-sulfidized CuFeS2 with either FeCl3 or CuCl2 showed that somewhat more Fe than Cu dissolved. These studies demonstrate that Cu is substantially more leachable from sulfidized CuFeS2 than from nonsulfidized CuFeS2? The Cu-and Fe-bearing constituents generated as sulfidation products, CuS (covellite) and FeS2 (pyrite), respectively, are differentially dissolved. The solubility of Fe from pyrite in sulfidized CuFeS2 is much lower than the solubility of Fe from complex nonsulfidized sulfide where Fe and Cu are bound in the same crystal lattice. Thus, the Cu dissolves selectively, producing a high-Cu filtrate from which Cu can be recovered by cementation or by electrolysis. Flotation of CuS-FeS2 mixtures indicates partitioned phases can be physically separated if effective liberation can be achieved. Magnetic separation tests yielded less promising results.

Jan 1, 1991

By H. A. Dierks

The work and costs involved in controlling three large fires in abandoned mines in the anthracite region of Pennsylvania are presented in detail. The work was done under authority of Public Law 89-4. Three basic control techniques were successfully employed by the Bureau of Mines: (1) forming underground fire-containing barriers by systematically flushing incombustible material into mine voids, (2) excavating an isolation trench around the fire area, and (3) complete excavation of hot and burning material in the fire area. When methods 2 and 3 were used, the excavations were subsequently back- filled with incombustible material. Preliminary location of fire perimeters by the standard use of patterned 6- and 8-inch-diameter boreholes is discussed. Investigations into air-borne infrared scanning, shallow subsurface thermal anomalies, and the use of helium to trace the movement of mine air currents are covered. Although they are costly and time consuming, boreholes have proven to be the most efficient means to date of obtaining necessary subsurface fire data. Infrared scanning was ineffective in delineating fires under more than 30 feet of cover. Helium-tracing was shown to have a good potential for determining possible hazards to adjacent residential areas from traveling mine fire gases.

Jan 1, 1971

By G. R. Hopkins, E. M. SEELEY

According to reports received by the Bureau of Mines, Department of Commerce, as of Jamary 1, 1930, there were 1,035 natural-gasoline plants in the United States, with a total daily capacity of 10,516,000 gallons. (These data do not include one small plant in Alaska.) The last similar survey, that of Jamary 1, 1928, showed a total of 1,155 plants of 8,048,000 gallons daily capa- city. This in two years time the number of plants has decreased by 120, but the total capacity has increased 2,468,000 gallons or 31 per cent. This is roughly equivalent to the gain in production over the same periodi Over half of the increase in total capacity was registered in California, where the development of flush oil production having a comparatively high gas-oil ratio in such fields as Santa Fe Springs led to construction of some new plants and material enlargement of others. Of the total plants, 999 were operating on Jamary 1, 1930, and 36 were shut down. This compares with 1,060 operating and 95 shut down two years ago, which indicates a tendency to dismantle plants as soon as they become obsolete or umrofitable. The total daily capacity of the plants operating on Jamiary 1, 1930, amounted to 10,278,000 gallons, or 98 per cent of the total, leaving only 238,000 gallons, or 2 per cent, for the shut-down plants. This contrasts with the refining industry, which usually has 5 per cent of its total capacity idle; the difference is due to the relative ease with which a refiner can secure a crude supply as against the difficulty the natural gasoline manufacturer has in reestablishing his gas connections. During 1929 the average total daily capacity of the operating plants was 9,899,000 gallons, while the average daily production amounted to 6,015,000 gallons. This indicates that the plants operated during 1929 at 61 per cent of their capacity. Although over 60 plants were dismantled in Oklahoma during 1929 the State continued to rank first in total mumber. California was second in mumber of plants with 165, and was one of the few States that showed a gain since the

Jul 1, 1930

By J. S. Dunning

Recent developments in energy conversion, mining and minerals processing, pollution control, and chemical equipment have placed in-creased demands on heat-resistant alloys. Higher corrosion rates from oxidation, hot corrosion, and sulfidation have increased consumption of materials that contain critical and strategic minerals and in many cases have limited productivity. The Bureau of Mines is conducting re-search on substitute materials having greater resistance to high-temperature corrosive atmospheres above 6000 C compared to austenitic stainless steels such as AISI 304, 316, and 310, with the goal of conserving critical metals such as Cr and Ni. The substitute materials are based on Fe-Cr-Ni-Al compositions. Aluminum additions to Fe-Cr-Ni alloys significantly improve high-temperature corrosion resistance, particularly sulfidation resistance. In the alloy, devised by Bureau researchers, aluminum additions are held in the form of a second-phase precipitate, 8NiAl. Minor additions of Ti, Mn, and Si improve workability.

Jan 1, 1984