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By Richard E. Dawes

Physical variables, a principal factor in the economies of mineral production, affect both capital and direct operating costs. By using a revenue-cost system for the framework, the analyses of revenue and cost categories demonstrate the relative importance of groups of physical variables, whether explicitly defined or not, to a lead-zinc mining operation. Physical variables affecting the producer represent about 60 percent of the total system influence as expressed by cost ranking. Other physical variables affect the remaining costs as controlled by the smelter, the transporter, and the landowner. Such resource conservation aspects as mineral losses due to mining method and mineral processing constitute a portion of the total revenue effects of physical variables. The physical variable revenue-cost system presented in this report offers a framework for cost-benefit analysis of mineral related research.

Jan 1, 1969

By L. J. Froisland

An integrated process for recovering metal from nonmagnetic auto-shredder reject scrap was investigated by the Federal Bureau of Mines. The methods used were air classification, water elutriation, screening, magnetic separation, handpicking, and heavy-media separation. Metal recoveries in this process were projected at 39 percent copper and copper alloys, 53 percent aluminum, 96 percent iron, and 98 percent zinc die cast. An economic evaluation of the conceptual process indicated that a facility designed to reclaim the reject scrap from 200 shredded automobiles daily could be profitable. Total investment in this plant was estimated at $321,000; the discounted rate of return before taxes was 53 percent.

Jan 1, 1975

Develop a method for mapping planar geologic features in deep underground mines where the presence of metal interferes with compass readings. Background A fundamental problem of mapping planar geologic features in deep underground mines is the presence of metal (water and air pipes, track, equipment, etc.), which affects the accuracy and consistency of compasses. Present geologic mapping methods include use of transits or theodolites, both of which are cumbersome and time consuming to use. To complicate the mapping, process each planar feature must be surveyed, and if that feature is not apparent on the opposite wall, it cannot be mapped. Another method of mapping is to stretch a tape measure between two survey spads and place a string along a planar feature on one wall and out into the opening until it intersects the tape measure. This method, in addition to being time consuming, is also inaccurate. Because detailed mapping of planar geologic features deep underground involves many repetitive measurements, a quick, accurate, and reliable method for making such measurements was necessary. The geolaser was developed to make such measurements in deep underground mines where metal interferes with conventionally used compasses.

Jan 1, 1990

By R. L. Wise

Heat content studies were conducted on burned shale, spent shale, and three grades of raw oil shale from the Green River Formation. Corrections were made for product enthalpies. The results were compared with previous work, indicating good agreement below retorting temperatures, but some differences at retorting temperatures. A general equation was developed relating heat content to oil-shale grade and temperature.

Jan 1, 1971

By B. T. Brady

Laboratory measurements by the Bureau of Mines indicate that failure in dry rock specimens measuring approximately 13 cm in length is preceded by tilt anomalies lasting a few milliseconds. The tilt behavior is qualitatively similar to that reported to precede earthquakes. Test results suggest that the time duration of this tilt anomaly for laboratory specimens of this length is independent of rock type, in agreement with theoretical predictions and other experimental data on rock failures including earthquakes.

Jan 1, 1975

By Edward D. Thimons, Jay F. Colinet

NIOSH conducted a strategic planning effort to identify those areas in mining with the greatest research needs. Data analysis and stakeholder input identified the need to reduce worker exposure to respirable crystalline silica dust as a high priority area. MSHA dust sampling data were analyzed to target the mining commodities and occupations with the greatest percentage of samples containing silica above compliance levels. In response, the Pittsburgh Research Laboratory (PRL) has implemented a multi-faceted research program to improve silica dust control for these problematic commodities and occupations. A review of silica compliance trends, PRL silica research programs, and recent control technology developments are provided here.

By E. Morrice

Techniques developed by the Bureau of Mines for the preparation of high-purity rare-earth metals and their alloys by electrolysis of the oxides in fluoride media are summarized. Cerium, lanthanum, neodymium, praseodymium, dysprosium, gadolinium, and yttrium metals, the mixture didymium, and specific alloys of these metals and samarium with iron, nickel, chromium, and cobalt were prepared. Individual metals were electrodeposited in the liquid state on tungsten or molybdenum cathodes. Alloys were prepared by electrodepositing the rare-earth metal on a consumable cathode, at a temperature above the melting point of the eutectic formed between the rare-earth element and the cathode material. Cells were designed for electrowinning metal products in gram and pound quantities, and methods for continuous electrowinning of cerium and lanthanum were developed.

Jan 1, 1968

By Ronald S. Conti

This paper describes technology and training that has been identified for underground emergency responders. Historically, underground mine rescue teams have only received training in the course of actual emergencies, or in simulated mine environments, usually on the surface, with placards to identify objects and hazards. Also, while U.S. Federal Regulations require all underground miners to walk escapeways and conduct fie drills every 90 days in a smoke-free environment, this does not fully prepare them for the conditions that will be encountered in real escape situations. Therefore, it is extremely important that miners are provided with adequate technology and that training simulations are conducted in a realistic manner. A series of mine rescue training and mine emergency response development (MERD) exercises, and in-mine smoke training was developed, conducted, and evaluated by state and company teams, and by National Institute For Occupational Safety and Health (NIOSH) personnel. The training exercises were held at NIOSH's Lake Lynn Laboratory (LLL) and operating mines during the past several years. This training resulted in improved technology and training for mine rescue teams, fire brigades, first responders, and miners in general. For example, existing technologies were identified to help responders during exploration and recovery operations. These included various chemical light shapes, strobe lights, light vests, and laser pointers to identify team members. Most of these devices may be used to mark underground areas and certain mine materials. Strobe lights were used for mapping out escapeways and lasers were used to negotiate travel through smoke. Thermal imaging systems allow rescue personnel to see in darkness and through dense smoke, and allows the user to easily locate missing or trapped personnel and heated areas. A hands-free communication system showed potential for enhanced communications between team members, the fresh air base, and command center. A new team lighted-lifeline allows for flexibility in movements of team members during routine tasks and allows them to easily find their fixed position on the lifeline. Of all the technology evaluated by underground personnel, laser lights and lifelines were most beneficial in leading personnel to safety and out of the mine in smoke-filled passageways. A positive-pressure inflatable escape device (IED)/airlock, was used to isolate the "hazardous" environment from fresh air and allow rescue team members to traverse through. An inflatable feed- tube partition that can rapidly block large openings such as underground passageways or tunnels and simultaneously provide a feed-tube for high-expansion foam generators was also deployed during the simulations. These technological advancements have improved the state of readiness for rescue personnel and have increased the chances of survival for all personnel escaping from underground emergencies.

By J. E. Zeilinger

This Bureau of Mines study was conducted to determine the sulfur reduction potential attainable when washing fine-size coal on a spiral concentrator. Crushed samples of Middle Kittanning and Bakerstown bed coals washed on the spiral provided pyritic sulfur reductions of up to 90 percent for the plus 200-mesh material. Pyritic sulfur reductions on the minus 200-mesh material seldom exceeded 30 percent; consequently, this material would require further treatment. The capacity of the spiral was 2 tph per unit when washing l4-mesh by 0 coal. The ability to remove pyrite combined with the higher-than-expected capacity makes the spiral worthy of consideration as a rougher-cleaner in new fine-coal desulfurization circuits.

Jan 1, 1976

By Michael S. Wieland

The work-principle from thermodynamics was used to formulate a model for predicting toxic fumes from mining explosives in underground chamber tests, where rapid turbulent combustion within the surrounding air noticeably changes the resulting concentrations. Two model constants were required to help characterize the reaction zone undergoing rapid chemical transformations in conjunction with heat transfer and work output: a stoichiometry mixing fraction and a reaction-quenching temperature. Rudimentary theory with an unsteady uniform concentration gradient was taken to characterize the combustion zone, yielding 75% for the mixing fraction. Four quenching temperature trends were resolved and compared to test results of ammonium nitrate compositions with different fuel-oil percentages (ANFO). The quenching temperature 2345 K was the optimum choice for fitting the two major components of fume toxicity: carbon monoxide (CO) and total nitrogen oxides (NOx). The resulting two-constant model was used to generate comparisons for test results of ANFO compositions with additives. Though respectable fits were usually found, charge formulations which reacted weakly could not be resolved numerically. The work-principle model yields toxic concentrations for a range of charge formulations, making it a useful tool for investigating the potential hazard of released fumes and reducing the risk of unwanted incidents. Keywords: Toxicity; Fumes; Explosives

By M. A. Elliott, H. H. Schrenk, L. B. Berger, John C. Holtz

"INTRODUCTION Among the hazards that may attend the use of Diesel engines in mines, tunnels, or other underground operations the presence of harmful or objectionable constituents in the exhaust gas must receive due consideration to prevent the formation of unsafe or unhealthful working environments in these places. Previous reports of this series have presented discussions of the composition of exhaust gas from engines in proper mechanical condition, 6/ the effect of adding some of the exhaust gas to the intake air of the engine, 7/ the effect of operation in atmospheres containing natural gas, 8/ and the effect on exhaust-gas composition of conditions that influence the characteristics of fuel injection in Diesel engines. In all these studies the properties of the fuels used were in general conformity with specifications usually recommended by the manufacturers of Diesel engines. In evaluating the physiological significance of the various components of the exhaust in these experiments, the toxic or objectionable gases determined were carbon monoxide, carbon dioxide, oxides of nitrogen, and aldehydes. Because of the low sulfur content of' these fuels, compounds such as sulfur dioxide and sulfur trioxide were not determined, although in discussion of the test results attention was directed to the fact that if fuels of higher sulfur content were used, the concentration of such compounds in the exhaust would become a significant factor in establishing the quantity of ventilating air required to furnish satisfactory dilut1on of the exhaust gas in underground working places."

Jun 1, 1943

By Dennis Dolinar, Christopher Mark, Gregory M. Molinda

In 1999, 2,087 unplanned roof falls were reported from 841 mines. Nearly 55% of all mines reported at least one roof fall, and nearly 17% of the mines reported five or more falls. In order to investigate the variables that contribute to roof falls, the National Institute for Occupational Safety and Health (NIOSH) compiled a national database of roof performance from 37 coal mines. Geotechnical factors and their effect on roof fall rates were compiled from over 1,500 miles of drivage. The factor that is the best predictor of roof fall rate is the Coal Mine Roof Rating (CMRR). For a low CMRR (#30), almost all cases have high roof fall rates. Conversely, high roof fall rates are rare for strong roof rocks (CMRR $ 60). Roof fall rates were also higher in deeper mines, probably because of greater stresses. Intersections were much more likely to fall than roadways, and four-way intersections were more prone to fall than three-way intersections. In a controlled comparison of the effect of increasing bolt length on roof fall rates, it was found that longer bolts reduced the roof fall rates in 11 of 13 cases. A relationship between the roof fall rate, the intersection span, and the CMRR was also found. Finally, a systematic method for tracking roof performance and geotechnical variables was demonstrated.

Jan 10, 2000

Design a high-production coal mining machine with inherent low dust generation and low frictional ignition potential. Approach Constant depth linear cutting (CDLC) provides a longterm solution to excessive dust generation from shearers and continuous mining machines through new design of the rotary drum culling system. Problems with rotary drum systems, which must be eliminated to control the dust generation at the source, include the effect of a con¬stantly varying depth of cut using fixed bit spacing, secondary fragmentation of already broken coal and, frictional heating of bits and entrainment of dust by fanning action due to high drum rotational speed, Each bit on a rotary drum enters the coal face at zero depth of cut, goes to some maximum depth at the horizontal centerline during sump, and exits at zero depth.

Jan 1, 1989

By Liming Yuan

In order to reduce fire hazards caused by spontaneous combustion in longwall gob areas, a computational fluid dynamics (CFD) study is being conducted by National Institute for Occupational Safety and Health (NIOSH) to simulate the spontaneous heating of coal in longwall gob areas. A CFD model was first developed to model the spontaneous heating process in a two longwall panel district using a bleeder ventilation system with a stationary longwall face. The spontaneous heating is modeled as the low-temperature oxidation of coal in the gob using kinetic data obtained from previous laboratory-scale spontaneous combustion studies. Heat generated from coal oxidation is dissipated by convection and conduction, while oxygen and oxidation products are transported by convection and diffusion. CFD simulations were then conducted to model the spontaneous heating in longwall gob area with a bleederless ventilation system. A single longwall panel with a bleederless ventilation system was simulated. The effect of gob permeability on the spontaneous heating was also investigated.

Jan 1, 2009

Predict the spontaneous combustion potential of a coal, using an expert system computer program. Background Approximately 15% of underground coal mint fires in the United States are attributed to spontaneous combustion. These spontaneous combustion fires frequently occur in worked-out or abandoned areas of a coal mine, This makes the control and extinguishment of the fire difficult and often requires large sections of the mine or even the entire mine to be scaled for long periods of time. A prior knowledge of the self-heating potential of the coal can be useful in preventing spontaneous combustion fires through the use of aggressive monitoring and control measures at existing coal mining operations, and in the planning oh new mines. Many factors can affect the spontaneous combustion process in a mine, including the self-heating potential of the coal, ventilation, geologic factors, and mining conditions and practices. Various test methods have been used to evaluate the relative self-healing potential of coals, including crossing point temperature and adiabatic heating methods, and oxygen adsorption techniques. However, these tests arc usually time-consuming and difficult to conduct, limiting their use to laboratories.

Jan 1, 1992

Reduce the airborne dust generated in a longwall coal face. Approach Reduce the rotational speed and increase the depth-of-cut of the longwall shearer. How It Works An Anderson-Mavor AM500 double-ended ranging drum shearer was fitted with drums specially designed to accept the large picks required for this testing program. Change gears In the shearer allowed rotational speeds of the drums to be set at 35, 45, 55, or 70 rpm. As deep cutting removes larger coal fragments, the specific energy requirements of the operation are reduced and less surface area results. Dust generation and shearer power consumption are also reduced. The lower rotational speed minimizes the fanning action of the cutterheads and thus reduces the amount of coal fines that become airborne.

Jan 1, 1981

By R. F. Abernethy

The work discussed in this report was done by the Bureau of Mines to develop a method for determining trace amounts of fluorine in coal. Samples of coal mixed with calcium oxide as a fixative agent for fluorine were ashed at 600° C and the residue was fused with sodium carbonate. The melt was dissolved in phosphoric and sulfuric acids and distilled to separate the fluorine) which was determined in the distillate by a SPADNS-zirconium spectrophotometric method. Fluorine determinations of 83 commercial coals ranged from 0,001 to 0.019 percent.

Jan 1, 1967

Efficiently clear ice and frozen materials from ore-handling equipment. Approach Compressed air-propane torches that develop a high energy flame jet were used instead of ordinary propane torches. How it Works A high velocity high temperature stream of gases impinges on the ice and frozen materials to both melt and blast them away. This hot gas jet is at 3,000°F temperature and moving at 3,000 feet per second. In the photograph below, the jet is being used to clear frozen taconite from a grizzly. The functions of the compressed air-propane torch are as follows. The air heater assembly, which is mounted on a wand, con-

Jan 1, 1980

By H. B. Carroll

The Bureau of Mines investigated the adaptability of the Meteorology Research Inc.2 (MRI) nephelometer and the Sinclair-Phoenix smoke meter for use in routine, analytical, smog-chamber experiments and to compare their responses to aerosol during these experiments. Both instruments' sampling systems were modified--smaller size sample input systems were studied using the nephelometer and a secondary sample system was added to the smoke meter to allow measurement of Aitken or condensate nuclei. Both instruments were easily adapted for use with small smog chambers and both displayed good precision and sensitivity to aerosol. A correlation was shown to exist between the two instruments' responses to aerosol. This correlation makes it possible to report the Sinclair-Phoenix measurements in visibility and/or mass units if desired.

Jan 1, 1973

By Fred N. Kissell

Methane flows and pressures were measured in mines in the Pittsburgh, Hartshorne, and Pocahontas No. 3 coalbeds. From the data, the permeability of each of these coalbeds was computed. It was found to depend strongly on the type of coal and on the amount of water in the coalbed, and it was found to increase with time. All of the coalbeds had a high-permeability zone adjacent to the face or rib, and the Pittsburgh bed exhibited directional anisotropy. Surprisingly, little or no overburden effect was observed.

Jan 1, 1972