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By Steven J. Page

The increasing concern for dust control in metal and nonmetal mining prompted the Bureau of Mines to investigate the comparative effectiveness of three wet dust control techniques for face drilling. Previous attempts to achieve effective dust control on face drills with dry collectors have not met with success, the largest problem being sustained effective dust capture at the face. Results show that (1) foam-through-the-drill can provide 95-pct average total dust reduction in gypsum; (2) water mist-through-the-drill can provide approximately 91-pct average total dust reduction and 93-pet average respirable dust reduction in salt; (3) external boom-mounted water sprays can provide approximately 50-pet average dust reduction for both total and respirable dust in salt. The investigation showed that (1) foam and water in small quantities are very effective dust control techniques for face drills when applied through the drill steel at the point of dust generation, and (2) boom-mounted water sprays are only minimally effective for dust control on face drills.

Jan 1, 1981

By H. A. Tucker

This Bureau of Mines investigation was conducted to determine the appropriate quantities of rare-earth methals (REM) in the form of silicides to add to an alloy steel for the purpose of increasing toughness and ductility. The work was conducted in a vacuum induction furnace with the rare-earth additions required to deoxidize and desulfurize a simulated basic oxygen furnace (BOF) vacuum-degassed steel initially containing 0.013 to 0.016 percent sulfur. The product proved to be as good or better than the best basic electric furnace steel of the same composition made by the steel industry. Twenty-three experimental heats of 5 Ni-Cr-Mo-V steel were made, cast into 50-1b ingots, and hot-worked in a press and a rolling mill to ½ inch plates which were then heat-treated to 130/150 ksi4 yield strength. Impact and tension tests showed that the addition of 0.025 to 0.100 percent, or ½ to 2 lb per ton, respectively, of rare-earth metals when compounded with silicon were appropriate for increasing toughness and ductility. These quantities resulted in retained cerium contents between 0.014 to 0.025 percent, and increased the Charpy V-notch energy absorption and the percent reduction of area significantly as compared with base heats at the same sulfur content levels. All the test heats, including those with additions of REH of as much as 4 lb/ton, had greater Charpy V-notch energy absorption values than the base composition could have developed at the starting sulfur range of 0.013-0.016 wt pct.

Jan 1, 1968

This Bureau of Mines report summarizes the research, development, and evaluation demonstrations conducted by the Bureau of Mines under the Health and Safety Act of 1969 to improve the means of notifying miners underground, who are away from their own phone, that they are being called.

Jan 1, 1977

By A. V. Petty

In accordance with its objective to maximize minerals recovery from secondary domestic resources, Bureau of Mines conducted research on recycling chrome refractory wastes. Since 20 pct of the U.S. demand for imported chromite is used in the production of refractories, primarily for the steel, copper, and glass industries, samples of used chrome-containing refractories from copper converter and reverberatory furnaces were investigated to determine their potential for recycling. The samples were beneficiated using a combination of wet magnetic separation, flotation, and leaching techniques, and the concentrates were reformed into briquets for refractory evaluation. Small refractory test specimens produced from the beneficiated concentrates gave modulus of rupture values at 1,350° C comparable to those of commercial mag-chrome brick of similar composition; however, grinding the waste refractories to at least minus 65-mesh was required in order to liberate the metallic copper. Most of the copper was easily recovered using conventional beneficiation techniques, but the finely ground chrome concentrate would require briquetting, calcining, and crushing to produce a coarse grain suitable for recycling into secondary mag-chrome refractories.

Jan 1, 1981

By John Millhiser, Stephen J. Kravits

The U.S. Bureau of Mines preproduction Wireless Survey System (WSS) and its performance during an in-mine test are discussed in this report. The WSS was developed to reduce downhole surveying time in order to increase the efficiency of drilling long horizontal methane drainage boreholes in coal. Borehole survey data are electromagnetically transmitted from the WSS7s downhole guidance probe, via the drill rod, to the uph'ole subsystem in less than 1 min per survey transmission, regardless of borehole depth. The WSS7s in-mine test consisted of providing borehole survey data during the directional drilling of a 2,538-ft horizontal methane drainage borehole in the Pittsburgh Coalbed. By considering available drilling time, which does not include hydraulic drill downtime and the time spent traveling portal to portal, 24 shifts were needed to complete the borehole. Of the available drilling time during the tcst, 50 pct of the time was spent drilling and 50 pct surveying and maintaining the WSS to keep it operational. Previous Bureau experience indicates drilling efficiency was increased 108 pct because of the WSS, in comparison with using a commercially available wire-run directional survey instrument at 10-ft intervals.

Jan 1, 1990

By C. C. Shale

Electrical resistivities for various coal ashes in air and in a nitrogen atmosphere are given over the range 100° to 1,500° F. Resistivity of low-carbon ash in air is very high at low temperature, rises to a maximum at about 250° F, decreases very rapidly with increasing temperature to about 800° F, then decreases gradually to approach an asymptote at 1,500° F. Resistivity of high-carbon ash in air follows this same general trend at values which are much lower and are proportional to the carbon content. After the carbon has been burned off, resistivity of the remaining ash approaches the high values corresponding to low-carbon ash of similar chemistry. Two factorial experiments show the effects of temperature, particle size, chemical content, and compressibility on the resistivities of four fly ashes of widely different chemical composition in the temperature range proposed for coal-fired turbines. Resistivities of all low-carbon ashes tested fall in the range 106 to 107 ohm cm at 1,500° F and should be removable by electrostatic precipitators. Ashes containing carbon in excess of about 8 percent, however, have low resistivity (as determined in nitrogen), especially at high temperatures. Therefore, high-carbon materials may not be collectable in precipitators because the resistivity is below the minimum value necessary for precipitation. Consequently, high carbon residues from partial combustion of coal probably could not be removed effectively at high temperatures.

Jan 1, 1968

By Kevin Connor

The mineral industry continued to be an almost negligible contributor to the country's economy as the Government continued its 1979 ban on any mineral exploitation for export; a policy initiated at the end of 1979. A national program had been underway since that time to map and inventory all mineral resources so as to permit future exploitation of mineral wealth in the beat interests of the country and its inhabitants. In March 1982, the British Sulphur Corp. Ltd., under contract to the Burundi Government and the International Bank for Reconstruction and Development (World Bank), began a feasibility study of Burundi's phosphate deposits at Matongo-Bandaga for potential commercial exploitation. The 1-year project effort was to define ore reserves, conceptually design mining operations and processing facilities, estimate capital and production cost, and develop a regional market and distribution survey. Work completed during the year comprised geological exploration and reconnaissance and 1,200 meters of core drilling. Reserves in excess of 5 million tons of ore-grade phosphate were estimated available for mining. Rare earth mineralization was associated with the primary apatite. The associated carbonatite within the rock matrix was preliminarily assessed to be of value as a raw material for the manufacture of cement. The contract effort was valued at $1.2 million? Matongo-Bandaga is located approximately 40 kilometers north of the capital city of Bujumbura and alongside one of the country's few paved roads.

Jan 1, 1984

By Charles L. Kusik

As part of an effort to establish processes that could be exploited in case of adverse changes in international chromium production and trading patterns, this study was sponsored by the Federal Emergency Management Agency (formerly the Federal Preparedness Agency) through the Bureau of Mines, to experimentally determine the feasibility of recovering chromium from critical scrap metals containing significant quantities of this element. Based on a conceptual pyrometallurgical chromium recovery flowsheet developed at Arthur D. Little, Inc., the experimental program described in this report demonstrated key process steps for the recovery of chromium as ferrochromium in a batch process. The process involves oxidation of chromium into a slag phase, subsequent separation of the slag phase from the remaining metal, followed by reduction of chromium from the slag phase to produce ferrochromium.

Jan 1, 1981

By John Durkin

Information on vertical magnetic noise in the voice frequency band, both within and above coal mines, is needed for the evaluation of through-the-earth baseband electromagnetic communications at mines where horizontal loop antennas are used. This report discusses the theory of the source of electromagnetic noise, the propagation of this noise to an observation point above a mine, and its interaction with the local earth conductivity structure, which gives rise to vertical magnetic noise. The relationship of surface noise to underground noise is also discussed. Bureau of Mines investigators made surface and underground vertical magnetic noise measurements at a number of coal mines located through- out the United States. These data were modeled through regression analysis to characterize expected noise levels. The results are presented, including results in one-third octaves for use in evaluating the expected performance of through-the-earth communication systems by articulation-index studies.

By E. R. Cole

Bench-scale research at the Bureau of Mines has resulted in the successful development of a combination electrorefining-electrowinning method for recycling all the lead in scrap batteries. The method reduces energy consumption and eliminates toxic emissions, in contrast to present pyrometallurgical smelting, and the lead produced is pure enough for use in maintenance-free batteries. Anodes cast from molten lead scrap were electrorefined in 1-and 2-liter plastic cells using an electrolyte composition of 70 g/l Pb and 90 g/l free H2SiF6 (fluosilicic acid). Both reagent-grade and waste H2SiF6 were used. Cathode starting sheets were made from refined lead. Aloes, and later bone gelatin, and calcium lignin sulfonate addition agents were employed. The sludge remaining after separation of the lead metal was treated in a two-step leaching operation to solubilize the lead for recovery by electrowinning. Conditions for electrowinning were essentially the same as for electro-refining, except that insoluble Pb02-Ti (lead dioxide-coated titanium) anodes were used. The best results for both electrorefining and electrowinning were obtained with a current density of 170 amp/m2 and a cell temperature of 25° to 35° C. Cathode purity ranged from about 99.9 to 99.99+ pct Pb. Maximum energy consumption after 3 days, for electrorefining and electrowinning, was 90 and 700 kwhr per metric ton of refined lead, respectively.

Jan 1, 1981

By P. D. Laverty

The U.S. Bureau of Mines treated mixed and contaminated super alloy scrap by pyrometallurgical and hydrometallurgical methods to separate and recover metal values. Best results were obtained by leaching Zn-treated or atomized scrap with HCI-02 at 9SO C and 50 psig 02' This resulted in dissolving approxi-mately 98 pet of the AI, Co, Cr, Cu, Fe, Mn, Ni, and Zn while rejecting over 98 pct of the Mo, Nb, Ta, Ti, W, and Zr as an insoluble refractory residue. Chlorine was successfully substituted for HCI to leach Zn-treated scrap but was unsuccessful for leaching atomized scrap. The leaching solution was treated by pH adjustment and hydrothermal precipitation at 2000 C for 4 h to remove AI, Cr, Fe, and other contaminants as a filterable precipitate. Recovery of Co and Ni would be accomplished by solvent extraction and e1ectrowinning. Chromium recovery as a ferroalloy was demonstrated.

Jan 1, 1989

By A. G. Starliper

Research was conducted by the Bureau of Mines to determine feasible roasting methods for the removal and the recovery of germanium, cadmium, and lead as enriched fractions from sphalerite concentrates. The two types of roasting processes studied were: (1) Batch, with a stationary bed, and (2) continuous, with a suspended bed, Results indicated that either method gave satisfactory metallurgical recoveries} but the continuous process is recommended because of inherent advantages. Final products were enriched fractions that could be treated by conventional methods for production of metallic germanium, cadmium, and lead. In the batch process, the concentrates were placed in a large tube furnace and heated at 1,080° C, an average of 3 hours. During the heating period, inert, reducing} or sulfur-laden gases were passed over the stationary charge to convey the sublimed metal sulfides from the hot portion of the tube to a lower temperature condensing zone at the end of the tube, where the metal sulfides were collected on baffles and recovered. In the batch and fluidizing roasting processes alike, the gases passed over or through the charge and served only as carriers for the sublimates and as suspension media in fluidization roasting. Since both processes depended on the volatilization, at relatively high vapor pressures, of the sulfides of germanium, cadmium, and lead, it was imperative that very little oxygen come in contact with the charge to alter the sulfide minerals. Germanium has a high affinity for oxygen, but in this instance it was buffered by being in solid solution in zinc sulfide.

Jan 1, 1961

By Larry G. Stolarczyk

This report deals with the creation of an efficient method to determine if command, control, communication and monitoring (3cm) equipment in coal, metal and non-metal mines is susceptible to Radio Frequency Interference (RFI) from the Medium Frequency (MF) radio communications system. A qualitative and quantitative RFT test plan was developed for in-mine and laboratory evaluation of the equipment. The laboratory testing was accomplished using the TEM Test Chamber. Detailed information on the Test Plan and the TEM Test Chamber is included. During in-mine testing of the MF System some underground equipment malfunctioned when the transmitter's radiating antenna was in close proximity. Electromagnetic Compatibility (EMC) testing was done on three levels; Component (circuit or box), subsystems and system. Nine tables are included which show the results of testing various equipment for RFI.

Jan 5, 1986

By F. E. Spencer

This Bureau of Mines report provides a complete mathematical description of the algorithm employed by a general multiphase chemical equilibrium program developed particularly for the purpose of studying problems in coal combustion, although the generality of the program will allow its application to any equilibrium system in which an appreciable gas phase is present. When applied to coal combustion problems, the program predicts composition and quantity of slag and unconsumed carbon phases as well as calculates accurately the composition of the gas phase including trace species such as free electrons and ions which are important for predicting electrical properties.

Jan 1, 1973

By A. Gene Collins

The Bureau of Mines conducted a research study of the geochemistry of the Smackover Formation to determine what geochemical relationships are useful in exploration for and production of oil and gas. Samples of oil, gas, brine, and rock were collected and analyzed. The oilfied brines were analyzed by methods recommended by the American Petroleum Institute and by tentative methods of the American Society for Testing and Materials. The crude oils were analyzed by Bureau of Mines methods; the gas, by Bureau of Mines methods; and the rocks, by wet-chemical, atomic absorption, and neutron activation methods. The results were correlated and interpreted, and several geochemical relationships useful in exploration and production were found. These include the type and class of brine, organic constituents in the brine, redox potential, in situ temperature and pressure of brine, degree of sulfate and carbonate saturation of brine, and halide concentrations in the brine.

Jan 1, 1974

By A. Gene Collins

During recent years the interest in trace and minor constituents of oil-field water, petroleum, and their associated reservoir rocks has increased. The metals copper, nickel, lead, manganese, iron, zinc, and cadmium are not determined routinely in oilfield brine analyses. Determination of these metals and subsequent correlation of these data should yield information to aid 1n the interpretation of the origin of different waters. The methods of analyzing oilfield waters have several potential applications: (1) Aiding in the search for petroleum; (2) identifying sources of intrusive brines; (3) controlling corrosion; (4) controlling produced water; increasing knowledge of the geology of subsurface formations; (5) identifying incompatible waters in waterflooding operations; (6) increasing the knowledge of the flow of oil, gas, and water in underground formations; and (7) aiding in the identification and location of valuable mineral reserves. Some brines contain enough valuable minerals to be recovered commercially.

Jan 1, 1962

By Mark I. Copeland

The Bureau of Mines discovered that silicon and nickel additions can prevent the formation of copper alloys of Sn, Sb, and As on the surface of steel during reheating to hot-working temperatures. When molten, these copper alloys cause surface hot shortness during hot working. Wrought steels were reheated isothermally and by simulated industrial practice; the resulting surfaces were metallographically evaluated. The steels contained, In weight-percent, 0.20 C, 0.45 Mn, and up to 1.00 Si, 1.00 Cu, and 0.15 Ni, and up to 0.30 Sn, Sb, or As. The larger the Cu, Sn, Sb and As content of the steels, the greater the amount of silicon necessary to prevent copper alloy formation. A content of 0.10 Ni considerably decreased the amount of silicon necessary for copper steels containing tin and antimony, but not for those containing arsenic. Theories for the beneficial effect of silicon and nickel additions are presented.

Jan 1, 1975

By J. W. Montoya

The chemical, mineralogical, and physical properties of berylliferous tuff from Spor Mountain, Utah, were determined in laboratory research conducted by the Bureau of Mines. Two beryllium-bearing minerals--a hydrated form of bertrandite and a berylliferous saponite--were found to be present in the tuff. Each of the beryllium mineral forms predominated in samples from certain areas of the district. The possibility of practicably separating the beryllium minerals from the tuff by physical methods appears remote because of the complexity and nature of the mineral associations. Beryllium mineralization in the region occurs in a rhyolitic tuff usually overlaid by unaltered rhyolite. The beryllium is distributed erratically throughout the tuff in individual mineralized bodies. Many samples of mineralized tuff were examined and found to contain from 0.2 to 1.8 percent BeO. All samples contained a hydrated form of bertrandite that was nearly cryptocrystalline, whereas samples from one area also contained a berylliferous saponite of variable beryllium content. Neither mineral has been previously reported, although related bertrandite-like minerals have been found in the U.S.S.R. and berylliferous minerals of the montmorillonite group have been synthesized. Most of the minerals of the tuff are finely crystalline, intergrown, and have similar densities. The complexity and intimacy of the mineral associations, the difficulty of achieving effective mineral liberation, and the highly friable nature are characteristics that lead to the conviction that tuff of the type examined cannot be effectively concentrated by gravity, magnetic, electrostatic, attrition, washing, sizing, or flotation methods.

Jan 1, 1962

By Nicholas Kyriazi, John P. Shubilla

The National Institute for Occupational Safety and Health, National Personal Protective Technology Laboratory, has undertaken a study to determine how well self-contained self-rescuers (SCSRs), deployed in accordance with Federal regulations (30 CFR 75.1714), hold up in the underground environment with regard to both physical damage and aging. This report presents findings regarding laboratory-tested SCSRs in the seventh phase of testing from May 1999 to August 2000. The SCSRs were tested on human subjects and on a breathing and metabolic simulator. The results indicate that most of the apparatus, if they pass their approved inspection criteria, perform satisfactorily. The deployed CSE SR-100s, however, exhibited significantly higher inhaled carbon dioxide (CO2) levels than new units, as they did in the previous two phases. Several Draeger OXY K-Pluses that rattled when shaken were found to have potassium superoxide (KO2) particles throughout the breathing circuit, including the mouthpiece. Draeger investigated the problem and developed a shake test to detect damaged units. The durations of new Ocenco M-20s were statistically significantly longer than those of deployed units, although only by 2 min.

Jan 3, 2002

By J. Davitt McAteer

Dear Mine Operator, Training for new employees, refresher training for new employees, refresher training, and new task training can mean the difference between life and death for workers. Part 46 spells out how you can develop a training program to protect workers for on-the-job hazards. Together, labor, industry, and the U.S. Department of Labor reached a milestone with the development and publication of Part 46. We want to continue working together toward the next milestone, October 2000, when the regulations take effect. We want to make sure you have all the information you need about these new training requirements. Throughout the next 12 months, MSHA personnel will be holding regional meetings across the country, delivering information and sample training plans to your operation, and offering you help to develop your plan. If you are among the many operators who are already providing training to your workers, keep up the good work. The rule will tell you exactly what is expected. If you currently have no training program, we can help you develop one. A brochure is being distributed, which highlights the main provisions of the rule. It is designed to introduce the rule to you. More detailed materials will be delivered to you. If you want information right away, simply call us, or e-mail us. We also welcome your comments, suggestions, and success stories. Part 46 will be successful and beneficial to miners through our combined efforts. Together, we can make our mines safe and healthier for everyone. Sincerely, J. Davitt McAteer, Assistant Secretary of Labor Mine Safety and Health Administration

Jan 1, 1999