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By Jeffrey H. Welsh

This report presents a study on the use of computerized, continuous remote monitoring systems for fire and explosive atmosphere safety in underground coal mines. The effects of these systems on the safety level in mines are investigated, and the relationship between mine safety regulations and computerized, continuous, remote monitoring is analyzed.

Jan 1, 1982

By E. J. Gleim

In the mining of coal the trend is toward more and more mechanization. This increased use of machinery to replace hand labor is assuming many new forms and presents a constantly changing aspect. Safety engineers must be alert if the many electrical problems resulting from these new installations are to be handled safely. Some of these problems present possible electrical hazards that may be overlooked by the safety engineer unless they are called to his attention by one who has made a special study of the conditions. The foregoing is especially true of conveyor systems of mining. The terms "conveyor systems" and "conveyor mining" as used in this paper refer to those systems in which various types of conveyors are employed to transport coal away from the working place. In some mines this means complete elimination of track, cars, and locomotives. In others it means that conveyors take the coal from the working place to a convenient loading point, from which transportation is completed by cars and locomotives.

Jan 1, 1941

By D. J. Bauer

A pure scandium solution was concentrated from 10-4 mole per liter to 0.5 mole per liter by continuous foam fractionation in a spaced, packed column. Recovery in the foam was 77 percent using a spaced, packed draining column with sodium n-methyl-n-"coconut oil acid" taurate as the surfactant. The technique was first studied batchwise in a small unpacked column to determine the more important variables. Optimum surfactant concentration was found to depend on scandium concentration. Extraction and, in general, enrichment ratios were highest in the 2.5 to 3.5 pH range at temperatures ranging from 50° to 70° C. An airflow rate of 136 ml./min. was satisfactory in the equipment used.

Jan 1, 1962

By Guy A. Johnson

The Bureau of Mines, through research and development contracts with the FMC Corp., has developed and tested two automatic fire sensing and suppression systems for large haulage vehicles. This work was undertaken to enhance driver safety, to lessen substantial property damage from fires on large trucks, and to increase the vehicle operator's productivity. One automatic truck fire protection system protects both the engine compartment and brake rid areas, while the second system is used in the engine compartment and fuel tank area. Both systems have redundant fire-sensing capabilities and manual override controls. Upon sensing flames and/or heat, the systems suppress the fire with pressurized, E-C class dry chemical. Both fire protection systems are flexible in design and can be modified for use on other mobile minim' equipment. Prototypes of both systems have been subjected to long-term, in-mine validation testing and actual Eire tests on 100-ton-capacity trucks at the Puma mine near Tucson, Ariz., and the Erie mine at Hoyt Lakes, Minn. During the 4-month endurance test of the first system at Pima, an accidental flash fire occurred in the test truck while it was working in the pit. The system successfully sensed and automatically extinguished the fire with no injury to the driver and little damage to the truck.

Jan 1, 1975

By D. N. Nilsen

The Bureau of Mines is investigating a method to recover Ni, Cu, and Co from low-grade domestic laterites through reduction roasting, leaching, sol-vent extraction, and electrowinning unit operations. The objective of this research is to develop processing technology that can convert low-grade domestic deposits containing critical metals into national reserves. As a part of this research, a solvent extraction system was investigated for the extraction of nickel and copper, followed by the separation and production of suitable electrolytes. Nickel and copper were coextracted from ammoniacal ammonium sulfate leach liquors (pH~9.5) with LIX 64N extractant in a laboratory-size mixer-settler continuous circuit. Three extraction stages resulted in >99-pct extraction of nickel, substantial copper extraction, and essentially no cobalt extraction from leach liquors. A crowd stage reduced the ammonia loading on the solvent by maximizing nickel loading. Residual ammonia was removed from the loaded solvent with a pH-controlled scrub. Nickel and copper loaded on the solvent were separated by selective stripping. Typical nickel strip circuit operation using electrolyte containing 90 grams per liter (g/l) Ni and 11.9 g/l H2S04 yielded >99.9 pct Ni stripped from the solvent in five stages. The copper loading on the recycled solvent was controlled in a copper strip stage using electrolyte containing 25 g/l Cu and 160 g/l H2S04,

Jan 1, 1981

By Thomas M. Barczak

The transverse loading requirement for stoppings as specified in the current Code of Federal Regulations is 39 psf. This measure is based on physical testing of a freestanding wall in accordance with ASTM E 72 specifications, where the dominant parameter is the tensile strength of the sealant. A new protocol based on arching has been developed to determine the true transverse load capacity of stoppings. Arching is achieved by the restraint of the stopping against the mine roof and floor, whereby compressive forces are developed within the wall. A laboratory procedure using the NIOSH Mine Roof Simulator (MRS) to simulate rigid-arching of stoppings was developed and verified through full-scale in-mine tests. Using this protocol, a systematic study of the design parameters that affect arching capability in block stoppings was conducted. The study included a theoretical assessment of arching and development of design formulations that can accurately define the transverse load capacity of various stopping constructions under various loading conditions. This approach should lead to a safer mine environment by matching the transverse load capabilities of the stopping design to the requirements in the mine to ensure proper ventilation control is maintained.

Jan 1, 2005

By M. M. Fine

This Bureau of Mines report describes the theory, experimental procedures, and the results obtained to date in the development of the Bureau's process for magnetically roasting iron ores using scrap iron as a means of reduction. Since magnetic separation is an operational step common to magnetic taconite plants, the preliminary research studies emphasized only the novel magnetic roasting step. The studies included the use of automobile scrap, ferrous reductants such as borings and turnings, and prereduced pellets. Technical feasibility of the process was demonstrated both on a bench- and pilot-scale. Quality magnetic concentrates with recoveries of over 90 percent were obtained from a direct shipping ore containing 59.5 percent Fe and from fine grained semitaconites with about 30 percent Fe.

Jan 1, 1966

By D. Harrington

The placing of much, sometimes practically all, of the burden of the expense of mine accidents on the shoulders of the mine operator by compensation laws, and the fact that the problem of protecting the life end limb of workers is now by public opinion largely if not wholly passed to each industry to solve (and present-day thought strongly supports the justice of both of these propositions), are forcing industrial organizations into accident-prevention. Work. This policy is being adopted not alone to protect the companies; in addition, executives alert to their opportunities and obligations are taking part in this work personally to protect themselves. The functions of industrial executives in accident-prevention work are becoming numerous and complex. Executives who are logical in their reasoning, quickly see that before a company can constantly ask or expect the workers to heed safety suggestions, the company and its officials must "put their house in order" by laying down a concrete, definite safety program. For mines this includes primarily adoption of a to a logical mining method, the installation of safe miming equipment and practice the netting forth in definite form (preferably do a printed pamphlet) of the company's minimum safety requirements, and the organization of its operating officials into an accident-prevention body. After the company has its own affairs so arranged that it can go to its workers with "clear, hands" in promoting a safety program, the real work begins; and this is especially applicable in mining.

Jan 1, 1939

By J. H. Russell

As part of its efforts to maximize resource recovery, the Bureau of Mines conducted studies to recover valuable byproducts from Western phosphate beneficiation tailings. Potential byproducts include phosphorus, vanadium, and uranium. The objective was to determine roasting and leaching conditions for maximum dissolution of vanadium from tailings containing approximately 13 pct P205 and 0.23 pct V. Sulfuric acid leaching tests were conducted with the tailings either as a dilute suspension dried, or in a roasted condition with or without NaCl added during roasting. More than 90 pct of the vanadium was dissolved by roasting at 850° C for 120 min with 8-pct NaCl and leaching at 75°C for 120 min with an excess of 2N H2S04, By roasting without NaCl and avoiding the difficulties of the chloride impurity, nearly 80-pct vanadium dissolution was achieved with an 800° C roast for 180 min. Quadratic regression equations were derived to relate vanadium dissolution to roasting and leaching conditions.

Jan 1, 1982

By Frank L. Wideman

This information circular describes methods used in mining inclined beds of phosphate rock in mines operated by San Francisco Chemical Co. in Rich County, Utah. The mines are on the western flank of the Crawford Mountains, a short, narrow range in northern Utah near the Idaho-Wyoming corner (fig. 1). The western front of the range is a conspicuous wall of folded and faulted sedimentary rocks that rises abruptly 300 to 600 feet above the floor of the adjacent Bear River Valley. Rex Peak, highest point in the range, is approximately 8,000 feet above sea level. The area surrounding the mines is sparsely populated. Randolph, the county seat of Rich County, has a population of 650. It is 10 miles southwest of the mines by road and the only town in their vicinity.

Jan 1, 1958

By Raymond M. Stateham

Climatic conditions are compared with roof fall occurrence from April 1, 1972, to December 31, 1975, by the Bureau of Mines. These comparisons indicate that humidity has a strong influence on roof fall occurrence rates. Cubic regression techniques are used to develop best fit curves. Statistical analysis of these curves indicate that both are sinusoidal and exhibit positive correlation with each other. The sine waves have a period of 1 year with maximum and minimum inflection points in August and February.

Jan 1, 1978

By W. G. Pariseau

A U.S. Bureau of Mines case study of pillar recovery in high-grade ore near the Ross shaft at the Homestake Mine, Lead, SD, has demonstrated the usefulness of the finite-element method for evaluating shaft pillar mining plans and shaft stability. This report focuses on mine measurements and calibration of the two-dimensional computer model and is the second in a series of three Reports of Investigations describing the Ross shaft study. In this study, borehole extensometers and other instruments were installed to provide data for model verification and to monitor the shaft. Results of the recalibrated two-dimensional model (UTAH2) confirmed the premining stability evaluation. However, after mining began, concern was expressed because cracks and other signs of ground motion appeared at considerable distances from the area of active pillar mining. In part 3 of the study, an intensive three-dimensional modeling effort using UTAH3 was initiated. The results again showed that the observed effects were within expectations and that the shaft would remain safe. Three-dimensional analyses of alternative pillar mining scenarios indicated that more of the shaft pillar ore reserve could be recovered than previously thought.

Jan 1, 2010

By R. E. Siemens

A process is being developed by the Bureau of Mines to selectively recover nickel and cobalt from low-grade domestic laterites. In laboratory evaluation of the process, the oxides in the laterite were selectively reduced with carbon monoxide at temperatures from 350° to 600° C. For material containing more than about 5 percent magnesia, pyrite additions or post-reduction heat treatments were necessary to achieve satisfactory nickel and cobalt extraction for this range of reduction temperatures. Multistage leaching of the reduced material at ambient temperature and pressure in the presence of oxygen, ammonium sulfate, and ammonium hydroxide extracted up to about 90 and 85 percent of the contained nickel and cobalt, respectively. The nickel was selectively recovered from the leach solution by solvent extraction and was then stripped from the loaded organic with dilute sulfuric acid to provide a nickel-rich electrolyte. Treatment of the raffinate with hydrogen sulfide resulted in the recovery of cobalt as a sulfide. The only contaminant in solution was magnesium which was removed by ion exchange or precipitation. In this process the energy requirements are relatively low and except for minor operation losses, only coke and oxygen are consumed.

Jan 1, 1975

By Arthur Metcalfe, Edward Thomas, A. J. Barry

"Early in 1947 the Bureau of Mines became interested in adapting suspension roof support to coal mining 5/ as a possible means of reducing the high rate of accidents from falls of roof. For a time the program made little progress be¬cause of the shortage of steel products after the end of World War II, but during the past 8 months this restriction has eased, and as of May 1, 1949, 114 mines had either started experimental work or had ordered materials and equip¬ment in anticipation of trial installations. It is estimated that 30 linear miles of roof in underground passageways have been secured by this method in recent months, and no lost-time roof-fall accident has been reported in these areas up to that date.Many coal-mining companies in widely separated localities have cooperated in making experimental installations. In very few instances are these companies entirely satisfied that they have arrived at the best solution in determining the most efficient adaptation to suit their particular conditions. Moreover, new ideas and modifications of the basic principle are constantly being brought to light and are being tested. Available test data is far from complete, and it is conceivable that some new idea will be developed to alter the present concept of proper technique; therefore, this progress report does not attempt to answer all questions that might arise in connection with this method of roof support; it simply recounts the experience acquired to date. Consequently, few references to costs are made. Up-to-date quotations on material and equipment used in suspension roof-support installations may be obtained from numerous mine-supply companies.The authors gratefully acknowledge the cooperation of mining companies whose personnel made possible collection of the information contained in this circular: Bethlehem Collieries Corp., Barrackville, W. Va.; Berwind-White Coal Mining Co., Windber, Pa.; Consolidation Coal Co., (Ky.); Jenkins, Ky.; Consolidation Coal Co. (W. Va.), Fairmont, W.Va.; Clinchfield Coal Corp., Dante, Va.; Consolidated Coal Co., St. Louis, Mo.; Hanna Coal Co., St. Clairsville, Ohio; Missouri Portland Cement Co., Sugar Creek, Mo.; Pocahontas Fuel Corp., Pocahontas, Va.; Reppert Coal Co., Dola, W. Va.; St. Joseph Lead Co., Bonne Terre, Mo.; and Tennessee Coal, Iron, & Railroad Co., Birmingham, Ala.The fundamental theory of suspension roof supports is not new; in fact, its application in the construction of beams predates mining itself. The basic principle involved is the reinforcement of roof rock with steel rods inserted in the roof and anchored therein at points where the rock is least likely to be affected by stresses resulting from mining. Such roof supports have been used in mines for many years in widely separated localities. The St. Joseph Lead Co., operating in southeastern Missouri, apparently was the first large mining company to prove the practicability of the principle by applying it in a systematic manner for securing roof for more than 20 years (fig. 1)."

Sep 1, 1949

In this Part, we have included copies of the flip charts and overhead projector viewgraphs used in the two briefings we conducted as part of this seismic detection and location task. The first one was an overview and problem definition briefing given to the seismic consultants on September 7, 1972. The second was a formal oral presentation of study results to technical staff members of the Pittsburgh Mining and Safety Research Center on November 21, 1972.

Jan 1, 1974

By R. E. Lindstrom

Electrooxidation techniques were investigated on a bench scale by the Bureau of Mines to determine the applicability of the process for extracting molybdenum and rhenium from low-grade molybdenite concentrates. Parameters affecting the extraction, such as pulp density, power consumption, reagent requirements for pH control, and electrolytic cell configuration, were studied. Molybdenum and rhenium extractions of 98 to 99 percent were achieved from several concentrates containing 4.76 to 28.6 percent molybdenum and 180 ppm to 1,000 ppm rhenium. Optimum results were obtained by maintaining pH values between 5.5 and 7.0 during electrolysis and allowing the final pH to rise to about 8.2. Reagent consumption was 4 to 6 pounds of sodium carbonate per pound of molybdenum extracted. The power consumption declined from a range of 12 to 25 kilowatt hours per pound of molybdenum extracted with immersion electrodes to 9.7 kilowatt hours with a bipolar flow-through cell; however, molybdenum extraction was independent of cell configuration.

Jan 1, 1973

By P. D. Bergman

To assess the efficacy and economics of producing power from coal, four open-cycle magnetohydrodynamic (MHD) processing schemes were selected for study. Each involved a different mode of coal combustion and level of gas cleanliness. The options considered were: (1) coal burned in a slagging combustor; (2) suspension gasification with slag removal prior to combustion; (3) parallel cyclone combustors, one operating fuel rich and the other operating with excess air; and (4) suspension gasification by the hot exhaust gases from the MHO duct with ash removed prior to combustion. Option 1 has the highest ash content in the combustion plasma and as a result would have the greatest operational difficulties associated with it. Options 2 and 4 have the cleanest MHD combustion plasma. For coal priced at $4/ton, the power generating cost of option 4,11.78 mills/Kw-hr, is the highest, with Option 1, at 9.04 mills/kW-hr the lowest. These costs may be compared with a conventional power cost of 9.92 mills/kW-hr for the late seventies. Capital costs of three of the four options were competitive with those of conventional thermal power plants employing stack gas S02 cleanup systems. Option 2 has the most favorable combination of operating characteristics and power cost. It was concluded that a clean, high-temperature working fluid can probably be produced from coal without leading to depressed system efficiencies and exorbitant capital costs.

Jan 1, 1973

By W. L. Cornell

The Missouri Pb ores are the only domestic Co resource being mined and processed for other metals; therefore, they present a viable short-term opportunity for Co production. Lead, zinc, and copper concentrates are produced from the ore. The Cu concentrate can contain up to 30 pct Co and the Pb concentrate up to 15 pct Co. Since Co is detrimental to the processing of the Zn concentrate; the remainder of the Co is rejected to the tailings. The tailings can contain as much as 50 pet Co originally present in the mined ore. Researchers at the U.S. Bureau of Mines have successfully tested on a continuous basis a process that recovers a bulk sulfide concentrate from mill tailings. The concentrate contains up to one-half of the Co and from 50 to 90 pct of the Pb, Zn, and Cu. Concentrate weight represents 10 pet or less of the total tailings.

Jan 1, 1989

By D. W. Butner

This report is concerned with the conditions affecting the methods and costs of mining phosphate rock in that part of the western phosphate field that is in Bear Lake and Caribou Counties in southeastern Idaho ( see fig . 1) . The area was selected because it contains most of the known phosphate reserve and because its geology has been studied more extensively than that of other sections . Deposits of phosphate rock on public land may be leased from the Government under the terms of the Mineral Leasing Act of 1920 , subject to the regulations of the Bureau of Land Management . Public interest in phosphate production is growing , as shown by an increasing number of applications for leases . Two mines are being operated steadily for the production of phosphate rock by companies that have also the necessary processing plants for the manufacture of fertilizer . Total western phosphate - rock production in 1947 is reported by the Economics Statistics and Division of the Federal Bureau of Mines to have been 1,193,000 long tons , mined in Idaho , Montana , and Wyoming . The average grade was 30.7 percent of contained phosphorus pentoxide (P205 ) ; the average value at the mines was $5.67 per long ton . Idaho contributed 905,000 tons , or somewhat more than 75 percent of western production . Western fertilizer plants took 23 percent of total production; 76 percent was exported . Strip mining accounted for 75 percent of the Idaho tonnage; the remainder was stoped from underground workings . Rock must contain a minimum of 30 percent P205 to be commercially useful for the production of superphosphate fertilizer by current acid treatment methods . Research by corporations and Government agencies has been directed toward the use of lower - grade ore . So far , only by smelting can rock containing as little as 25 percent P205 be used economically . Any development of processing or use pattern that would render the mining of , say , 20 percent rock profitable would have important effects in reducing the unit cost of mining . In the search for metallurgical improvements , consideration should be given to the saving of valuable components of the rock, such as vanadium and fluorine , both of which are present in the beds .

Oct 1, 1949

By D. J. Parker

The oft-repeated expression that the taproot of safety lies in the attitude of the management toward accident-prevention work is indisputable and has become almost an axiom. Trite and somewhat timeworn though the statement may be, it is nevertheless true that the supervisory force must earnestly support a policy of safety and maintain at all times a con¬ siderate regard for the welfare of the employee if that high degree of cooperation of the employee, so vital to the successful prosecution of any safety program, is to be expected. The responsibility for preventing accidents rests upon the management, and in the case of the Spring Canyon Coal Co. such responsibility is recognized and accepted with little or no reservation. This company, aside from the humanitarian aspects involved, believes that safety is good business and not a matter to be treated passively or in a perfunctory manner. The problems with respect to safety that have been met and wholly or partly solved can best be appreciated when some of the natural conditions, adverse and otherwise, existing at this operation are taken into consideration. Mine 1 is about 1 mile north of the town of Spring Canyon, Carbon County, Utah, and is served by both the Denver & Rio Grande Western and Utah Coal Route railways. During the year 1931 the mine produced 312,397 tons, approximately 10 per cent being derived from pillar workings. The normal daily output during the summer months is about 2,000 tons, and during the peak of production in the winter season the daily production varies from 2,500 to 3,000 tons. The number of miners varies from 87 in summer to 220 in winter, and the day men vary in number from 66 in the winter to 45 in the summer; 12 company men are employed the year around. The officers of the company are J. B. Smith, president, San Francisco, California; T. R. Stockett, general manager, Salt Lake City; and G. A. Murphy, superintendent, David Brown, assistant superintendent, and John Sullivan, mine foreman, all of Spring Canyon, Utah.

Dec 1, 1932