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By F. Garcia, J. Cervik

Recent advances in the commercial separation of gases using membranes have renewed interest in the possibility of applying this technology to the recovery of methane ( CH4 ) from mining operations . This Bureau of Mines report briefly reviews the history of the development of membranes for gas separation , the theory of how they work , and their application to the separation of methane from air and associated problems . However , methane -air mixtures are difficult to separate with membranes because the pertinent gas couples , 02 - N2 , 02 - CH4 , and N2 -CH4 , have poor separation characteristics , as indicated by their separation factors of about 3 or less . Even if these separation factors were substantially higher , there is doubt that methane could be recovered economically from the low concentrations in mine ventilation exhaust ( 2 vol pct or less ) . The exhaust pressures are not sufficient for adequate separation . The power cost of compressing the methane recovered . these mixtures would far exceed the value of New discoveries could make separation of gob hole methane - air mixtures practical . These mixtures have much higher concentrations of methane (from 30 to 100 vol pct ) ; however , for safety reasons , be limited to gob gas with 60 vol pct CH4 or more .

Jan 1, 1988

By Kathleen J. D?Amico

THIS SUMMARY is identical to the summary given in volume III of this series of mineral production in the United States (including Alaska and Hawaii), its island possessions, the Canal Zone, and the Commonwealth of Puerto Rico and of the principal minerals imported into and exported from the United States. For further details on production see commodity and area chapters. A summary table comparing world and United States mineral production also is included. Mineral production may be measured at any of several stages of extraction and processing. The stage of measurement used in the chapter is normally what is termed "mine output." It usually refers [ ]

Jan 1, 1958

By R. V. Ramani, R. Stefanko, G. W. Luxbacher

Comprehensive ventilation surveys are made to review the adequacy of the mine system with regard to both statutory requirements and/or company policy, to evaluate improvements to the current ventilation system and to plan for £stun expansion. If computer simulation is to be used for these purposes, accurate quantity and pressure measurements become an absolute necessity since the validity of the computer generated output is heavily dependent on the accuracy of the input data. Consequently ventilation surveys that are run to generate input data for computer simu¬lation must use the best data collection procedures to guarantee as accurate results as are possible. These requirements have led to modifications in procedures that are used for routine ventilation surveying. McElroy and Kingery (1957) have recommended that pressures be measured independent of quantities since minor changes in mine conditions have a greater effect on absolute pressure measurements than on quantity measure¬ments. They estimate that, for large mines, a pressure survey may take only 1 to 3 days while the corresponding quantity survey would require 1 to 3 weeks. Although this procedure would undoubtedly lead to more ac¬curate pressure measurements, its use for the development of computer input data is not recommended for the following reasons. Atkinson's equation, H = RQ2, is used in computer oriented analysis to develop the airway resistance, R, based on quantity and pressure loss measure¬ments. It can easily be seen that since R a 1/Q2 and R a H, the effect of errors in quantity measurement is, in fact, more significant than those in pressure measurement. If the quantity and pressure measure¬ments are made at different times another problem results. Minor changes in quantity that may occur in the time between the pressure and quantity

Jan 1, 1977

By R. B. Tippin

Research investigations conducted on five ore samples show the applicability of heavy liquid separation (HLS) techniques to mineral processing. Under proper operating conditions, semicontinuous tests in small fluid cyclones yielded 90 percent sink-float concentrates with recoveries exceeding 90 percent on minus 35-mesh ore samples of kyanite, potash, spodumene, fluorspar, and beryl. Although none of the ores were examined in detail, their response to this novel concentration method provides basic examples that are typical of the process. Various aspects of cyclone design and operational characteristics of heavy liquid cyclone circuits were studied which demonstrated the flexibility of HLS by using multiple units connected in series. A comparison of two heavy liquid solutions, tetrabromoethane and methylene bromide, exhibited their individual advantages and limitations. Unique problems relative to this process are discussed including liquid viscosity, mineral composition of the ore, toxicity, and material handling hazards.

Jan 1, 1968

By D. L. Pool

To increase metal recoveries and to minimize pollution by improved extraction technology, the Bureau of Mines investigated a hydrometallurgical technique to recover copper, lead, nickel, and cobalt from lead smelter mattes. The metals were converted from insoluble sulfides to soluble chlorides using a HCI-CI2-02 leaching system. Parameters studied in a 50-gallon, glass-lined reactor were the ratio of hydrochloric acid to chlorine, chlorine consumption per pound of matte, oxygen reaction pressure, and temperature. The matte material used contained, in percent, 19.7 Cu, 52 Pb, 2.9 Ni, 1.5 Fe, 0.38 Co, 0.19 As, 0.41 Zn, and 0.12 Cd. Extraction of Cu, Pb, Ni, Co, and Cd ranged from 92 to 98 pct, with concomitant extractions of Fe and As of <0.1 pct. The Cu and Pb were recovered as electrowon metals, while the Ni, Co, and Cd were recovered as mixed hydroxides.

Jan 1, 1981

By M. D. Marshall

This handbook is for the engineer or person responsible for the storage and removal of material from bins and silos in the minerals industry. The objective of the handbook is to prevent bin-related accidents by eliminating problems which require workers to enter bins. It provides basic information on handling materials so that knowledgeable decisions can be made on bin design and accessories to minimize flow stoppages. Materials are classified in terms of their flowability, and bin design and accessories suggested for each classification. A method for classifying a material is also given, and the various types of material flow aids reviewed. Safety around bins is the basic theme of the handbook. Federal regulations are reviewed and additional suggestions presented to prevent bin accidents. New equipment for releasing material hang-ups is reviewed.

Jan 1, 1984

By Frank D. Lamb

Pyrophyllite, a hydrous aluminum silicate (Al2 Si4O10 (OH)2 ) has been mined in North Carolina and marketed without beneficiation for the past 100 years, but recent demands for higher-grade material indicate that an economical concentration method is needed for at least a part of the pyrophyllite production. Past production has depended upon selective mining and hand sorting, which is often unsatisfactory because of the finely disseminated character of the ores. The major impurity in North Carolina pyrophyllite ores is quartz, which accounts for the abrasiveness of the commercial product. Since pyrophyllite is only slightly heavier than quartz, those ores cannot be beneficiated by simple gravity-concentration methods. Some separation can be attained by differential grinding and air classification because of the difference in hardness of the two minerals) but the separation is not sharp. Froth flotation of pyrophyllite from Quartz has never been attempted commercially, but if the demand for high-grade material is sufficient, it would seem that this process offers the most premise of being economically feasible.

Jan 1, 1950

By Alla D. Mah

Thermodynamic calculations for antimony and its compounds have been hampered by the lack of adequate basic thermal data; much work rains even to fill the more important gaps. This paper supplies heat and free energy of formation values at 298.15° K, for the sesquioxide and tetroxide, based upon new measurements conducted by the Bureau of Mines. The heats of formation were obtained by combustion (bomb) calorimetry, and the free energies of formation were obtained by combination of heat and entropy data. The new values are believed to substantially improve the accuracy of thermodynsunic considerations involving these oxides.

Jan 1, 1962

By R. E. Lindstrom

Separation efficiency of a 4 percent divinylbenzene (DVB) resin is not altered over a wide range in temperature. A 12 percent DVB resin, however, exhibits a marked sensitivity to temperature. When flow rates are high at ordinary temperatures, 4 percent DVB resin exhibits higher efficiency, but at 200° F. both resins are equal in performance. Effective separation of rare-earth mixtures may be obtained with hydrogen as a retaining ion by maintaining column temperatures above the solubility of ethylenediaminetetraacetic acid (EDTA) in the free acid form. Slightly lower separation characteristics were obtained with this method as compared with copper as a retaining ion, Recovery of 99 percent of the EDTA from spent eluting solutions that contain copper has been accomplished by a calcium-copper displacement reaction followed by EDTA precipitation. Impurities in the product are correspondingly low. Recoveries of EDTA from holmium solutions with sulfuric acid are substantial; however, those from yttrium solutions are quite modest. Radiotracer experiments show the presence of approximately 0.1 percent yttrium contamina¬tion in the recovered material. The study presented is one phase of a broad research program designed to assist the technology of separating and purifying rare-earth elements.

Jan 1, 1961

By Daniel N. Tallman

To provide technology for achieving more efficient water filtration systems for the mineral industry, the Bureau of Mines performed demon-stration filtration tests at three iron ore mines and one steel mill. A comparison of equivalently sized magnesium oxide (MgO) and sand filters showed that MgO had a higher capacity and could operate at higher fil-tration rates than sand. In demonstration tests when alum (AlK(S04)2) was the coagulant, suspended solids breakthrough occurred even though the pressure across the filter (head loss) was 7 psig or less. Under these circumstances, the MgO demonstrated 20 to 100 pct greater filtra-tion capacity, defined in terms of the volume of water filtered before breakthrough. When an organic floccu1ant was used at one location, head loss was the run-limiting factor; the filters essentially plugged with-out any solids breakthrough.

Jan 1, 1985

By Daniel Edelstein

The supply of arsenic trioxide in 1982 was adequate to meet domestic demand. Allocation of supply by major domestic and foreign producers that began in 1977 ended during the first quarter of 1982. Major demand was about evenly divided between industrial chemicals and agricultural chemicals. Domestic Data Coverage.-Commercial- grade arsenic trioxide and arsenic metal were produced by only one U.S. company. In order to prevent disclosure of proprietary data, arsenic production data have been withheld.

Jan 1, 1983

To minimize support costs and to improve ground control by improving wood-crib design and utilization through the development of engineering methods that will match the placement and performance of the wood cribs to the load conditions imposed by the mine environment. Background While wood cribs are used extensively to stabilize mine openings, their utilization is often based on historical practice or trial-and-error rather than on engineering design. This has led to conservative crib utilization where more capacity than is necessary is employed or inadequate capacity is provided when mine conditions worsen. Critical design parameters, such as the stiffness of the support structure, are often ignored. Optimum crib design and employment is becoming increasingly important as the utilization of wood cribs increase due to the growth of longwall mining, and as the cost of wood continues to rise. A single longwall operation will spend as much as a million dollars per year on the support of the gate roads.

Jan 1, 1994

By D. G. Kesterke

Research was conducted to determine the feasibility of extracting elemental oxygen from silicate-bearing melts by high-temperature electrolysis. The method was based on a modification of existing processes for electrowinning metals from their oxides dissolved in molten halide systems. Electrolyses were performed at temperatures ranging from 1,050° to 1,250° C in boron nitride cells that incorporated a silicon carbide cathode and an iridium anode. The electrolytes contained volcanic scoria as the oxygen source, plus mixtures of BaF2 and LiF as fluxing agents. Cell gases containing almost 14 volume-percent oxygen were obtained. The average anode current efficiency for several experiments of extended duration was calculated to be 55 percent. Cell design and operating conditions are described, and some of the problems associated with the process are discussed.

Jan 1, 1971

Provide a low-maintenance, reliable means of generating bubbles and controlling bubble size for column flotation. Approach Commercial sparger systems used in flotation columns to process minerals provide only limited means of controlling the size of bubbles generated and the rate of air injection. Generally, these limitations are a detriment to flotation performance, particularly in recovering coarse or fine mineral particles. In addition, conventional bubble generation systems require frequent maintenance, often requiring shut-down of the column itself for repairs. To permit greater control of the bubble size generated in the flotation column and to eliminate the counter-productive problems associated with the operation of current air sparger systems, the Bureau of Mines investigated alternative methods for generating bubbles. Based on the investigation, an external bubble generation system was designed, developed, and laboratory and commercially tested.

Jan 1, 1987

Continuous remote sensing of air speed In underground mine airways. Approach An ultrasonic technique measures a form of air turbulence which is proportional to air velocity. How It Works The stainless-steel enclosed transducer consists of a sensing head with circuitry, and a telemetry card. The sensor uses a patented ultrasonic technique to measure a form of turbulence created In the air. This turbulence, known as vortex shedding, is related to the air speed through the sensor. Air flowing past a cylindrical post creates vortices which flow down the air stream on both sides of the post. Pulses from an ultrasonic transmitter pass through the vortices to a receiver; the effect of the vortices on the pulses is a measure of air velocity. The transducer contains a telemetry card, known as an accessor, which transmits reports on air velocity through a pair of wires to a monitoring system. The accessor contains an analog-to-digital converter and digital telemetry circuitry required for computer system operation. The transducer does not contain any read-outs or alarms and air velocities are displayed by means of a centrally located

Jan 1, 1982

Reduce costs of surface mine reclamation by improving bulldozer operating efficiency. Approach A draft power indicating system helps bulldozer operators adjust blade height and other controls for maximum load movement, by continuously indicating the rate at which work is being done. How It Works This system continuously measures both the push of the blade against the overburden, and the true ground velocity of the bulldozer. It multiplies those quantities to determine the real work rate of the machine. The system consists of a velocity sensor, a blade load sensor, processing circuits, and a work-rate indicator. The processing circuits include an analog multiplier which has an output signal representing the draft power (velocity x load = power). The draft power, or pushing power is a measurement of the work rate at that moment.

Jan 1, 1979

By John C. Edwards

To have the capability to predict the development of localized spontaneous heating within a porous coalbed that is subjected to forced air ventilation or in an otherwise quiescent environment in which buoyancy develops, the Bureau of Mines developed three time-dependent mathematical models, which were used to calculate the temperature increase associated with chemisorption of oxygen by the coal. In each model, spontaneous heating is driven by an Arrhenius first-order reaction between the oxygen and coal. Two models are two-dimensional, and one is one-dimensional. In the first two-dimensional model, a constant-velocity forced convection airflow is specified; and in the other, buoyant flow is allowed to develop in the absence of forced convection. The third model evaluates the airflow from Darcy&apos;s law and a specification of the pressure at the surface of a one-dimensional porous coalbed. Numerical computations demonstrated how each model could be used to predict the onset of spontaneous heating when the porous coalbed was subjected to constraints of an imposed internal heat source or a high- temperature airflow. The effects of particle size and coalbed compaction upon spontaneous heating were examined with the third model.

Jan 1, 1990

By Clarence O. Babcock

ROCK BEHAVIOR has proved of national interest in a variety of fields. The behavior of rock consequent to a nuclear blast was used to detect such blasts, as criteria for the design of underground military defense installations that would resist nuclear blasts, and for judging the feasibility for peaceful uses of nuclear explosives. An obvious peaceful application of nuclear explosives would be for large-scale rock excavation, and plans were presented during the year to improve the present Panama Canal or create a new canal by this method. These plans were based largely on earlier crater tests that demonstrated rock behavior when subjected to a buried nuclear blast. A knowledge of rock behavior under impact was used to evaluate the materials of the moon by means of the geometric configurations visible in the close-up pictures of the moon surface taken by the U.S. rocket Ranger 7. The composition of the moon must be considered in devising methods for taking samples of the surface layers or in designing underground shelters as bases for future explorations of the moon.

Jan 1, 1965

Provide an accurate, reliable means for determining when a sealed mine or mine section can be safely reopened after a fire. Approach The Bureau of Mines performed a research investigation that resulted in the development of a mathematical formula for deriving a quantity, called RATIO, which can be used to define when a sealed mine or mine section has returned to safe recovery conditions after a fire. Research Results There were two major results from this Bureau research. Over a period of several years, the Bureau of Mines conducted six experiments at its Bruceton Experimental Mine in Pennsylvania. The experiments involved sealing the mine after several tons of piled coal had been allowed to burn continuously for 2 to 3 days. Although gas data obtained during the experiments revealed nothing significant, measured smoke particle levels were found to correlate with the stages of combustion and temperatures of the smoldering coal pile. Moreover, it was found that no smoke particles are produced when high-temperature smoldering exists deep within the mass of the coal pile since the smoke particles are filtered by the coal surrounding the hot region. Smoke is emitted into the mine atmosphere only if combustion is occurring near exposed surfaces. As suggested by these findings, any decision to recover a sealed mine area based primarily upon the absence of smoke particles is not a wise derision.

Jan 1, 1988

To perform comprehensive economic evaluations on both existing and proposed mineral operations. Approach A comprehensive computer model was developed which is capable of evaluating the economics of an entire mineral recovery operation, including exploration, acquisition, infrastructure, mining, milling, smelting, refining, transportation, taxation, and return of and on capital. How it Works The MINSIM (MINe SIMulator) economic evaluation concept was developed by the Bureau of Mines in 1967. The initial versions used a continuous discounted cash flow rate-of-return (DCFROR) to measure the effect of changes in expected revenues and costs. Subsequent enhancements to the program have expanded and strengthened MINSIM, especially the addition of an option which determines total production cost (i.e., the commodity selling price that a mineral recovery operation would require in order to obtain a target rate of return), an expanded capacity for evaluating by-products from a mineral property, and significantly broadened taxation determining capabilities. The MINSIM computer program uses essentially the same procedures and calculations that are performed in a manual economic evaluation, although the program accomplishes its tasks much more rapidly and accurately, An experienced mineral economist may require a week to evaluate a single mining operation with the same detail and consistency provided by MINSIM in a matter of seconds of computer time.

Jan 1, 1983