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By R. D. Leitch

Tests have recently been conducted by the Bureau of wines on the ignition hazard of exposing heated filaments of electric mine lam bulbs in an explosive mixture of methane and air. This investigation was undertaken in order to settle a question that had arisen in connection with the safety of miners? electric lamps. For several years, in view of former studies made by the Bureau and reported in Bulletin 524, the fact that the heated filaments of even low voltage, lour candlepower bulbs constitute a danger was generally accepted by the Bureau's engineers. These early tests, as well as subsequent tests, were conducted with Pittsburgh natural was as the testing medium.

Jan 1, 1925

By C. C. Clark, R. R. Backer, J. D. Vickery

This report presents the results of tests conducted by the U.S. Bureau of Mines to determine the transport characteristics of highly concentrated paste backfill mixes made from dewatered total mine tailings. The slurry concentrations of the mixes were all above 78 pct by weight with slumps ranging from 6.4 to 16.5 cm (2.5 to 6.5in). Laboratory material property tests and full-scale pumping tests were conducted using pipe diameters of 102,128, and 154 mm (4, 5, and 6 in) and a positive-displacement pump. The results indicated that the tested backfill mixes can be successfully transported as a stiff paste and identified the influence of and the interaction among the various mix and system variables.

Jan 1, 1995

Provide a rapid, reliable means of warning underground miners of a fire or other emergency. Approach An ultalow-frequency electromagnetic signaling system was designed, breadboarded, and tested at various under around mines. How It Works Current fire warning systems for underground mines, such as stench, audible alarms, and messengers, arc slow, unreliable, and seldom achieve total mine coverage. An ultralow-frequency electromagnetic fire warning alarm system with true through-the-earth signaling capabilities was developed to solve these problems. The system was originally designed for high-back room-and-pillar mines where stench systems are unusable due to the low velocity of mine air flow. However, the system has an application to all underground mines.

Jan 1, 1988

By D. K. Ingram, G. L. Mowrey, T. R. Rehak

Problem: Blasting is a hazardous component of surface mining. Serious injuries and fatalities result from improper judgement or practice during rock blasting. This paper describes several fatal injury case studies, analyzes causative factors, and emphasizes preventive measures. Method: This study examines publications by MSHA, USGS, and other authors. The primary source of information was MSHA’s injury-related publications. Results: During the 21-yearperiod from 1978 to 1998, the mean yearly explosive-related injuries (fatal and nonfatal) for surface coal mines was 8.86 (95% CI: 6.38 -11.33), and for surface metal/nonmetal mines 10.76(95% CI: 8.39 - 13.14). Flyrock and lack of blast area security accounted for 68.2% of these injuries. This paper reviews several case studies of fatal injuries. Case studies indicate that the causative factors for fatal injuries are primarily personal and task-related and to some extent environmental. A reduction in the annual injuries in surface coal mines was observed during the ten-year period of 1989 - 1998 [5.80 (95% CI: 2.71 - 8.89) compared to the previous ten-year period of 1979 - 1988 [10.90 (95% CI: 7.77 - 14.14)]. However, such reduction was not noticed in the metal/nonmetal sector, i.e., 9.30 (95% CI: 6.84 - 11.76) for the period 1989-1998compared with 11.00 (95% CI: 7.11 - 14.89) for the period 1979-1988. Discussion: A multifaceted injury prevention approach consisting of behavioral/educational, administrative/regulatory, and engineering interventions merits consideration. Impact on industry: The mining community, especially the blasters, will find useful information on causative factors and preventive measures to mitigate injuries due to flyrock and lack of blast area security in surface blasting. Discussion of case studies during safety meetings will help to mitigate fatal injuries and derive important payoffs in terms of lower risks and costs of injuries.

By E. G. Davis

The flash reduction of fine iron ore in a dilute-phase system was investigated at 500° to 900° C within a heated stainless steel tubular coil. Alabama brown iron ore and Mesabi semitaconite ore were fed into the coil concurrently with reducing gases of hydrogen and reformed natural gas, so that the velocity of the gas at the reaction temperature was sufficient to entrain and pneumatically transport the solids through the coil. Reduction is very rapid with retention time of the ore in the coil varying from 4 to 15 seconds. Variables affecting reduction are temperature, ore feed rate, and gas flow or velocity. Results of the studies show that a partially reduced product (10-to 25-percent reduction) can be made which, on subsequent magnetic concentration, yields a concentrate containing 64 to 70 percent iron with a 90-to 94-percent iron recovery. Maximum reduction of 77 percent was obtained when hydrogen was used in a four-stage reduction test to yield a product containing 61 percent metallic iron.

Jan 1, 1972

By Michael S. Wieland

The work-principle method was developed for theoretically resolving toxic fumes from non-ideal charge formulations. The whole description of a wanted process refers to macroscopic changes resulting from removing and imposing constraints that work one at a time to chronologically render trajectory terminal (key) states. The trajectory resolution utilizes a thermodynamic quasi-potential or negative work function, and numeric results require some appropriate standard thermodynamic (equilibrium) reaction code TDRC. The underlying method is unable to restrict reactions, tailor the work output or resolve states within the trajectory transitions, so the trajectory terminology is used somewhat figuratively. The work-principle model has the working fluid (reaction material) interacting with a tremendous reservoir (chamber air and walls), while forecasting the work performed upon a mechanical agent. Within the underground test chamber, the widening fume zone undergoes a decline in temperature, a reduction in reaction rates, resulting in out-of- equilibrium circumstances at the Q*-point, representing the measurement state. Rather than coping with the hard issues of non-equilibrium, the toxic fumes are resolved numerically for the Z-point, rendered by a zero-net- interaction energy constraint. Though other techniques require complex equation-of-state EOS for the whole trajectory, the work-principle formulation eludes the issue, requiring an EOS that works just for the terminal-state. Under the circumstances, the Z-state is reconcilable with the ideal-gas domain, and relevant TDRC results yield the restricted state in a numerical way for different charge formulations. The work principle makes it hard to remedy or to tamper with the resulting Z-point fumes: non-macroscopic trajectory readjustment is forsaken, terminal states are results rather than stipulations, and resetting the EOS formula constants would be ineffectual. Though the non-equilibrium portion remains unresolved, it is noteworthy that the work principle rigidly fixes the Z-state, thereby reducing the uncertainty for rendering reaction-rate models characterizing the non-equilibrium Z-Q* transition. Though more refinements are needed, some Z-point fume results are included to illustrate the threshold (minimum) resolving capacity of the work- principle formulation.

By Thomas M. Barczak

Longwall roof behavior is characterized by strata displacements in both the face-to-waste (horizontal) and roof-to-f1oor (vertical) direc-tions. The roof support structure provides resistance to this motion by translation of these displacements into vertical and horizontal support loading. Observations indicate that the shield reacts with both a vertical and horizontal force to uniaxial convergence (displacement). However, there are different magnitudes depending on whether the displacement is vertical or horizontal. This makes it possible to use supports as monitors of strata activity and loading. The Bureau of Mines examined this behavior using a linear elastic model of the support structure with two degrees of freedom. Vertical and horizontal load reactions were related to associated displacement actions of the strata. This was done by determining the stiffness of the shield under controlled vertical and horizontal displacement motions in the Bureau's mine roof simulator. This report provides example predictions of strata convergence and isolation of horizontal support loading due to vertical roof convergence using the linear elastic shield model. The report also examines efforts to determine strata behavior by direct measurement of support displacement.

Jan 1, 1987

Capture airborne coal dust generated by a continuous mining machine to reduce workers? dust exposure and to improve face visibility. Approach Develop a low-profile dust collector system which can be mounted on the boom of a continuous miner. How It Works When coal is mined with a milling head continuous miner, a substantial amount of coal dust (respirable and non-respirable) escapes the dust suppression sprays at the cutter head. This can cause poor visibility around the cutting head and can expose the workers to high levels of respirable dust. A practical means of removing this dust is with a scrubber mounted directly on the mining machine. Under a Bureau of Mines contract, a low-profile, machine-mounted dust collector (MMDC) was developed to avoid adding extra height to the continuous

Jan 1, 1983

By M. J. Sapko

The Bureau of Mines conducted laboratory-scale flammability experiments to investigate the possible use of water spray systems for inerting or quenching mine-gas ignitions, such as those encountered at the working face of a coal mine. The inerting results for premixed methane-air-water mixtures indicated that water droplets of less than 10 µm tend to be as effective as the vapor. Water requirements for inerting such mixtures were much smaller than those for quenching the sustained flame propagation by the application of water sprays. The minimum water mass concentration for quenching methane-air flames increased linearly with increasing droplet diameter (surface weighted mean) and decreased with increasing spray temperature, whereas the droplet surface area required per unit volume was essentially constant for a given gas mixture composition. Data extrapolations indicated that a quenching system may be feasible for the longwall mining application.

Jan 1, 1977

By L. B. Pankratz

Low-temperature heat capacities, high-temperature enthalpy increments, and the enthalpy of formation at 298° K were determined calorimetrically for vanadium subnitride (VN0.465). The low-temperature investigation gave S°298.15 = 6.379 ±0.005 cal/deg mole, and a combustion calorimeter investiga¬tion provided ?Hf°298.15 = -31.80 ±0.60 kcal/mole. The two quantities were combined with the high-temperature data to give standard values of enthalpies of formation and free energies of formation above 298° K. These and related thermodynamic functions were tabulated to 1,800° K. Similar data are included in the range of 298° to 1,600° K for the mononitride, VN.

Jan 1, 1971

Provide reasonably priced, reliable fire protection for large walking draglines. Approach Fire hazards on large draglines were analyzed, then appropriate automatic fire sensing and suppression systems developed and in-mine tested. How It Works Five fire hazard areas identified for special attention are: electrical control room, high voltage transformer enclosures, circuit breaker rooms, collector ring/roller path area, and the automatic lubrication rooms. Automatic fire sensing and suppression systems were separately designed for each area. The design of each system was tailored to the hazards and equipment protected. Spot thermal sensing and Halon 1301 suppression were specified for the electrical

Jan 1, 1981

By S. P. Sandoval, A. E. Clark, S. W. Yopps, J. S. Gomer

The U.S. Bureau of Mines conducted Cu exchange tests for six common clays under simulated in situ leaching conditions. Regression equations were obtained from the data expressing the Cu exchange capacity as a function of Cu concentration, pH, and temperature. Using these equations, an analysis was made of the impact each clay could have on overall Cu recovery. The results suggest that Ca and Na montmorillonite clays could have a major impact on Cu recovery and that attapulgite and illite clays could have a smaller, but still significant, impact. Kaolinite and ripidolite clays pose little threat to loss of Cu from in situ leaching solutions.

Jan 1, 1992

By Maria I. De Rosa

Table 10 and figure 4 show the number of fires and fire injuries occurring at the surface of underground coal mines by state during 199&1999. Table 10 also shows by state the risk rate, employees' working hours, and lost workdays. A total of 65 fires occurred in 10 states. Thirteen of those fires caused 12 injuries and 1 fatality (the yearly average was 6.5 fires and 1.2 injuries). Four fues and one fire injury involved con- tractors. The Ewhr value was 97 x l O6 hr (Irr = 0.025); the LWD value was 6,206. Pennsylvania had the most fues (20 fues and 5 injuries), followed by West Virginia (1 6 fires and 1 fatality) and Kentucky (1 5 fires and 3 injuries). Among these states, Pennsylvania had the highest injury risk rate value (Irr - 0.095). Table 1 1, partly illustrated in figure 5, shows by time period the number of fires, fire injuries, and fire fatalities; risk rates; employees' working hours; and lost workdays. The number of fires and fire injuries show a decrease followed by an increase during the five time periods, accompanied by a decline in employees' working hours throughout the periods (see table 11 and figure 5). The Irr values follow patterns similar to those shown by the injury values. Tables 12- 17 show the number of fires by ignition source, method of detection and suppression, equipment involved, location, and burning material by time period. Figure 6 shows the major variables during 199&1999. Table 18 shows the number of fire injuries per number of fires causing injuries and total fires by year, ignition source, equipment involved, and location.

Jan 1, 2004

By D. B. Dow

"Natural gas-gasoline is made by collecting in the liquid state the condensable hydrocarbon vapors that exist in different natural gases in varying amounts. In the richer type of natural gas the gasoline is generally recovered by compression and cooling. If exceedingly high pressure or low temperature is used, there is dissolved in the gasoline a large amount of very volatile material, which evaporates rapidly at atmospheric temperature and pressure.In the leaner type of natural gas, the gasoline vapors are selectively absorbed from the permanent gases by passing the natural gas through an absorbing oil. The gasoline is recovered by distilling the saturated oil, and as compared with ""compression"" gasoline is of high Baume' gravity and low vapor pressure. Before a volatile gasoline can be transported in tank cars, it is necessary to decrease its volatility in order to lessen the risk of fire or explosion, as well as to prevent excessive evaporation in transit. This can be accomplished either by weathering the gasoline, or by blending it with a more stable material, naphtha being commonly used in the weathering process the more volatile portions of the gasoline are allowed to evaporate and the losses in volume are very large, therefore, blending is preferable, wherever possible.It is very difficult, however, to produce by blending, in gasoline plants, a motor fuel which is equal to straight-run refinery gasoline. In order to make a blended motor fuel of a grade equal to straight-run gasoline, only a small percentage of natural gas-gasoline can be blended with the naphtha, consequently it is customary to blend the gasoline with only enough naphtha to enable It to be shipped to an oil refinery when the material is again blended to form a finished motor fuel."

Sep 1, 1921

By A. M. Stubbs

The Bureau of Mines has devised a procedure to selectively extract and recover chromic oxide (Cr203) from waste high-temperature shift catalysts that contain approximately 6 pct Cr and 62 pct Fe, both in oxide form. The Bureau's procedure consists of roasting the waste catalyst with sodium hydroxide (NaOH) or sodium carbonate (Na2C03) followed by water leaching. The chromium from the leach liquor was recovered utilizing an oxidation-reduction reaction with pH adjustment to form a hydrous chromic oxide (Crp3oXHp) precipitate. The roast-leach procedure produced chromium extractions greater than 89.7 pct, with product recovery in excess of 99 pct from the leach liquor. The costs of the NaOH and Na2C03 roast processes, including sizing and equipment-related recommendations, were determined by the Bureau's Office of Process Evaluation. The economic evaluation indicates that producing a Crp3 product, at the present time, is not competitive with the present-day cost of imported chromites. The estimated average operating cost for both processes was $5.44/1b of recovered Cr203 concentrate. However, this procedure offers a potential alternative to the disposal of this waste through landfiIl.

Jan 1, 1988

Continuous remote sensing of methane concentration in underground mines. Approach A methane transducer, developed as a fixed point rib-or face-mounted operating device, measures ambient levels of methane and produces a signal that is proportional to the measured concentration. How It Works The methane transducer, developed under contract for the Bureau of Mines, uses a catalytic-type sensor which will detect methane concentration. The transducer is mounted vertically, as shown. This type of mounting minimizes dust accumulation on the sensing element, which might cause degraded operation. The unit must not be located in an area where water can continuously drip or run on It. The transducer generates an electrical signal proportional to methane concentration at the sensor. A sensor failure output indicates the status of the sensing element A circuit within the methane transducer detects whether the sensing element is shorted or open. A high signal (approximately 8 Vdc) on the failure output Indicates the sensor element is operating In Its normal range. A low output (less than 1 Vdc) indicates an element fault. The methane transducer, enclosed in a stainless steel

Jan 1, 1982

By A. L. Engel

This publication describes further research by the Federal Bureau of Mines in beneficiating domestic manganese ores. The ores selected for treatment were typical of many manganese deposits in California and Nevada in that they have not been economical to mine because they are low grade or contaminated with siliceous minerals and are not amenable to physical concentration.3 4/ It would be desirable to develop a simple treatment method resulting in nearly complete extraction of manganese from these ores and applicable to small-scale operations. Sulfation reduction appeared to be such a method. The studies reported in this publication were directed toward sawdust or lignin-sulfonates as reducing agents. Sawdust, as waste from lumbering, and lignin-sulfonates, byproducts of woodpulp papermaking, are comparatively cheap and may be available in areas where manganese ores are found. Sugar, oils, and coal were also tried as reducing agents.

Jan 1, 1960

By S. E. Khalafalla

The Bureau of Mines investigated the metallothermic reduction of copper oxide as a function of temperature, reactant proportions, form of reductant, and gaseous environment, using iron and steel scrap reductants. The reaction proceeded rapidly with powdered iron at temperatures above 560° C, attaining over 95 percent copper metallization within 3 hours. The importance of inter-reactant contacts on the extent of the reaction was evident from the variable, but usually lesser, degree of metallization obtained with iron from tin cans and automobile steel scrap. Reduction decreased as the molar ratio of copper to iron increased between 1 and 3. The most favorable gaseous environment for the reaction was a static helium atmosphere containing about 0.6 percent water vapor. Ferrothermic extraction of copper from its oxides appears to be essentially a "solid-state cementation" process. While ordinary cementation processes must be preceded by leaching, the ferrothermic method avoids this generally slow step and also the water pollution caused by the leaching agents. Sulfidic copper concentrates could likewise be reduced with metallic iron following their complete oxidative roasting.

Jan 1, 1969

By John Durkin

Field studies have been conducted in a large number of coal mines throughout the U.S. to determine the effectiveness of electromagnetic techniques in locating men trapped underground following a mine disaster. Data from these tests have been used to generate models of expected signal and noise distributions as found above mines throughout the coal fields. These distributions have aided in placing the expected performance of a through-the-earth electromagnetic communications technique into a probabilistic framework. Results indicate an expected 45% probability of detecting a miner's signal from a depth of 1,000 ft, a depth which exceeds 903 of the coal mines within the U.S. and a 90% probability at a depth of 500 ft, a depth which exceeds 50% of the mines.

To develop a magnetic levitation transport system that can reduce the cost and improve safety in transporting coal from the face of underground coal mines to the surface. Background Many conventional mining operations use conveyor belts to transport coal from an underground face to the surface of the mine. The Mag-Lev Transport System design replaces conveyor belts with magnetically levitated coal haulage containers moving through a dedicated pipe¬line. Cost estimates, based on current design data, show the Mag-Lev Transport System would have operating and capital costs that are less than or equal to those of an equivalent-capacity conveyor belt system. The safety hazards associated with conveyor belt systems include exposure to moving parts and pinch points, potential fire hazards due to mechanical friction, and the exposure of miners to respirable dust. These hazards would be eliminated or significantly reduced by this novel technology. Approach The Mag-Lev Transport System uses magnetic levitation technology that allows noncontact, frictionless conveyance of a levitated body within a dedicated transit corridor. The mag-lev technology utilizes two types of permanent magnets coupled with an electronic position control system to achieve noncontact levitation. Levitation is provided by neodymium-iron boron (NdFeB) magnets mounted in the base of the haulage containers and inexpensive ceramic-5 magnets located in the bed of the transit corridor. An electronic position control system is used to overcome the inherent instability of the repelling permanent magnets. Proximity sensors, a signal processing circuit, electromagnetic actuators, and fixed ferrous side rails are the major components of the positioning system.

Jan 1, 1994