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By G. W. Elger

This report describes pilot-plant studies and an economic evaluation of a process developed by the Federal Bureau of Mines, Albany Metallurgy Research Center, to produce synthetic rutile from a rock-type ilmenite concentrate. In this process, ilmenite blended with coke and lime is smelted in an electric arc furnace to separate most of the iron as salable pig iron and to form a titania-enriched slag of low iron content, which is treated with oxygen and titanium pyrophosphate. The titanium oxides are converted to crystalline rutile; the phosphate glass contains most of the associated impurities. The treated slag is ground and leached with sulfuric acid to liberate rutile crystals, which are concentrated by physical methods. In pilot testing conducted to obtain data for a cost estimation, a synthesized product containing about 88 wt-pct TiO2 and less than 2 pct FeO was extracted from a rock-type ilmenite concentrate containing about 45 wt-pct TiO2. The estimated fixed capital cost (on a mid-1975 basis) of a plant producing 500 tpd of synthetic rutile is $28,290,100. Based on 330 operating days per year, the estimated operating cost for this process is $351 per ton of synthetic rutile. The estimated selling price of synthetic rutile made from rock-type ilmenite is $344 per ton, based on a credit of $160 per ton of pig iron and a 20 pct interest rate of return on investment after taxes.

Jan 1, 1976

By C. I. Pierce

The Bureau of Mines used an electrolytic tank model to investigate the response of guard electrodes of different dimensions under different simulated reservoir conditions. Sandstone disks from the Berea and Connellsville Formations were used as resistive beds in the model, and agar gel or water was used as conductive beds. In the experiments, bed thickness, hole diameter, mud resistivity, and bed resistivity were varied. The guard electrode is an excellent tool for determining true bed resistivity in the thin-bedded oil reservoirs of the Appalachian area. Vertical resolution and resistivity values are good when there is little or no invasion. Resistivity values are near true bed resistivity in beds thicker than about six hole diameters when the electrode-to-hole-diameter ratio is close to 1. However, low-resistivity muds cause false peaks to appear on the logs near bed boundaries in thick beds, and for resistive beds having a thickness approximately three to five times the hole diameter, apparent resistivities tend to be excessively high when mud resistivity is low.

Jan 1, 1966

By Byron S. Gottfried

This Bureau of Mines report presents a method for combining the distribution curves at different specific gravities of separation, for a given piece of coal-cleaning equipment and a given raw coal feed, into a single, generalized distribution curve normalized with respect to specific gravity and, therefore, independent of the specific gravity of separation. Illustrative generalized distribution curves, based upon Bureau of Mines collected data on industrial operations, are presented for five different types of coal-cleaning equipment. The well-known concept of probable error is extended to the generalized distribution curve. It is shown that the conventional probable error is directly proportional to the specific gravity of separation. A number of sample calculations, illustrating the use of the generalized distribution curve and generalized probable error, are presented in the appendix.

Jan 1, 1977

By Daryl R. Tweeton

The Bureau of Mines conducted experiments to measure the influence of environment on the friction and wear of a steel-quartz system at several speeds and loads. In each test a quartz block was pressed against a rotating ring of low-carbon steel. Environments used were moist air, dry air, dry nitrogen, water, aqueous oleylarnmonium acetate (ClsH35NH3+-OCOCH3), and aqueous aluminum chloride (A1C13). The sliding speeds were 2.2, 13, and 33, cm/sec, and the loads were 6.8 and 13.6 kg. The coefficient of friction, the wear, and the roughness of the surfaces were measured, and the wear debris was examined. The coefficient of friction was significantly lower in moist air at 2.2 cm/sec than for any other combination of environment and speed employed, and was generally an inverse function of the oxidizing ability of the environment. The coefficient of friction increased somewhat with increasing load. The wear of the steel rings was greatest in dry air at all speeds and loads. The wear of the quartz blocks at 180 rpm was greatest in dry air, but at 12 rpm it was greatest in nitrogen. Friction and wear in aqueous oleylarnmonium acetate and in aqueous aluminum chloride were similar to effect in water alone.

Jan 1, 1976

By E. C. Tarpley, H. M. Cooper, R. F. Abernethy

The standard method of employing preliminary air-drying to determine the moisture in coal has been criticized with respect to the loss of heating value from excessive air-drying. By this method, the coal is air-dried at approximately 10-15° above room temperature with the loss in weight being less than 0.1 percent per hour, and then the residual moisture at 105°C is determined. The total moisture is calculated from these two values.

Feb 1, 1948

By S. H. Ash

Tunnel driving is recognized as one of the most hazardous of occupations; this is a reflection of the high accident severity rates and resultant high compensation and similar costs in this industry. Most tunnels are driven by contractors who bid for the jobs, taking into consideration the prevailing industrial insurance rates at the time the bids are placed. After the bid is secured the contractor then attempts to complete the job at the minimum cost to himself. In a sense the accident-cost item is fixed for at least one year when a policy is secured. Time is generally an important factor not only for the contractor, but also for the insurance carrier and the assured. If the assured represents a private interest, the cost burden usually is ultimately placed on the general public which avails itself of the service contemplated; if the project is a governmental enterprise the cost burden unquestionably falls upon the general public involved and on the general tax payer. For these reasons it is of vital interest to the public that accidents not only be kept at a minimum as a humanitarian objective, but also because the accident-cost burden, too frequently not even realized and considered to the degree that it should be, can assume proportions that materially affect the cost of the enterprise. The basic industrial insurance rate for tunneling in California in 1932 contemplated an earned premium of 12.12 percent of the labor pay roll. The State has been particularly engaged in large construction enterprises, some of which involve high accident cost rates, notably structural-steel bridge building, which contemplates an earned premium of 19.65 percent of the labor pay roll. When this figure is compared with the much lower rates that apply to other industries it is apparent that a heavy toll in human wreckage is taken by such engineering projects, which must be viewed as monuments to human suffering as veil as to human achievement.

Jan 1, 1933

By J. J. Burns

Disasters such as occurred at Oppau, Germany, in 1921, at Tessenderloo, Belgium, in 1942, and in this country at Texas City, Tex., in 1947 clearly indicate the explosive hazard associated with the manufacture, storage, and transport at ion of ammonium nit rate The importance and extent of the hazard may be Judged from the large amount of ammonium nitrate produced and transported annually in this country. Between July 1, 1947, and June 30, 1948, it was estimated that the United States produced 461,528 tons of ammonium nitrate commercially for agricultural purposes alone .5/ In addition, U. S. Army Ordnance plants have manufactured and shipped 779,730 tons of ammonium nitrate fertilizer to Germany, Japan, and Korea.6/

Jan 1, 1953

By G. R. Hopkins, A. B. Coons

A survey of the petroleum pipe lines by the Bureau of Mines as of May 1, 1923, shows that on that date there was a total of slightly more than 90,000 miles of pipe lines in the United States, having a capacity of approximately 15,750,000 barrels, which is equivalent to one-fourth of the nation's average production for one month. These lines varied in diameter from 2 to 16 inches, the weighted average being 6 inches. The total pipe-line milenge was about equally divided between trunk lines and gathering lines, though the capacity of the former was about four times that of the latter. This was due, of course, to the difference in average diameter, that for the former being 7.4 inches as compared with 3.7 inches for the latter. The common size for trunk lines was 8 inches, and for gathering lines 2 inches. Oklahora, with 19,180 miles of pipe lines, is the leading State in total mileage, with Texas second and Pennsylvania third. From point of trunk lines alone Texas is considerably ahead of any of the other States, a position which it owes to its size and to the growth in the rovement to its Gulf ports. Cali- fornia, though the leading State from point of production, ranks only seventh in pipe-line mileage. This is due to the fortunate location of the Los Angeles Basin fields, some of which are within sight of the refineries to which their oil is delivered or of the port of San Pedro through which their oil is shipped. The last survey of this nature, made in the spring of 1924 by the U. S. Geological Survey, recorded a total mileage of nearly 83,000 with a capacity of approximately 14,450,000 barrels. This indicates an increase of 9 per cent in both mileage and capacity during the two years.

Jan 1, 1927

By J. Whyatt

A package of bench design programs is being publicly released by the National Institute for Occupational Safety and Health (NIOSH). These programs are designed to provide a probabilistic estimate of the likelihood that various widths of catch bench will be retained. Program modules address the mechanisms of plane, plane step path, and wedge failure. Results are drawn from statistical and geostatistical descriptions of fracture characteristics and other input parameters, and reported as the statistical chance that a given width of catch bench will survive, that is, that a catch bench will remain wide enough to catch rolling and sliding material and prevent such material from posing hazards to miners operating below. The capabilities and application of this software are demonstrated through a case example. Comparing bench width estimates obtained using geologic data with actual widths is a key step in verifying that a program is appropriate for particular site conditions and that proper statistical descriptions of fracture parameters for that site have been developed. Such verification efforts improve confidence, and hence usefulness, of this method for designing future slope benches. Development and release of these programs appears particularly timely given recent progress in photoanalysis methods, which promise to greatly reduce the cost of collecting fracture data.

Jan 1, 2004

To address the safety of programmable electronics-based mining systems before this technology proliferates in the mining industry.

Jan 1, 1999

By J. R. White, S. W. Lambert, C. M. McCulloch

Examination of several coalbeds in Walker County, Ala., Cambria, Greene, and Fayette Counties, Pa., and Raleigh and Wyoming Counties, W. Va., indicates that cleat orientations are similar throughout a vertical sequence of strata. Studies of cleat orientation were carried out in underground mines that are operating in separate coalbeds vertically above one another. The data show that over a vertical separation of 100 to 400 feet, the average difference in coal cleat orientation between mines is 04° for the face and 08" for the butt cleat. Variations of coal cleat direction between coalbeds examined in strip-mined areas show similar values. Cleat orientations measured at outcrops agree well with the directions measured underground, suggesting that the amount of vertical separation between coalbeds has little effect on the resulting differences in cleat directions. The largest variation of cleat directions between adjacent coalbeds occurs where a large horizontal distance separates two sample locations. Cleat orientations for deeper coalbeds are most reliable where the data are taken from directly above.

Jan 1, 1976

By Van E. Shaw

Bastnaesite is a natural rare-earth fluorcarbonate of the cerium group that affords an abundant and high-grade source of the lighter rare-earth elements. A simple and efficient method has been developed by the Bureau of Mines for extracting rare-earth compounds from this mineral. Digesting of a flotation concentrate with sulfuric acid converts the rare-earth compounds from fluorcarbonates to sulfates. Action of the acid releases gaseous com-pounds of fluorine and silicon, leaving the sulfated material free of these elements; carbon dioxide from carbonate decomposition is eliminated at the same time. Calcining the sulfated material at 1,200° F. renders the gangue constituents insoluble, whereas the rare-earth sulfates are left in water-soluble form. Leaching with water yields a solution of pure rare-earth sulfates. Bastnaesite could become prominent as a source of cerium-group rare-earth elements. It is rich in the light rare-earth elements and comparatively easy to process; reserves of the mineral are extensive enough to supply a greatly expanded market for many years.

Jan 1, 1959

Develop geophysical techniques suitable for enhancing miner safety. Specifically, to use geophysical methods to detect hazardous conditions in a rock mass in deep underground mines as well as to assess the mechanical integrity and monitor changes of the rock.

Jan 1, 1997

"An active list of permissible explosives was published in September 1935 as part of United States Bureau of Mines Report of Investigations 32S6, under the title ""Active List of Permissible Explosives and. Blasting Devices Approved. Prior to July 31, 1935."" This list included 154 brand names,Changes in the list that have been authorized subsequently placed 24 addi¬tional brands of permissible explosives on the active permissible list as a re¬sult of tests, changes in brand names, or transfer from the inactive list. Eight permissible explosives were transferred from the active to the inactive list. The present active permissible list contains 170 brand names. The brand names of the permissible explosives placed on the active list are as follows:Black Diamond Nu-Gel No. 4 By test.Black Diamond Special A,do.Burton 11, L. F. By change in name,Burton G, L. F. By test.Columbia B By change in name.Columbia C Do.Columbia D Do.Columbia E Do.Columbia. F Do.Columbia G Do.Columbia 1 Do.Columbia 2 D.Columbia 3 DoColumbia 4 Do.Columbia-Gel 1 Do.Columbia-Gel 2 Do.Genite 5, Do.Genite 7, Do.Genite G Do.Lump Coal C By test.Peerless No, 1 By transfer from inactivePeerless No. 8, L. F. Do.Tri-State Special No. 1 Do.Unilite No. 2 Do."

Dec 1, 1936

By W. R. Huff

This report describes the development and operation by the Bureau of Mines of a pilot plant designed for using high-volatile A bituminous coal-in-water suspensions as a source of preheated coal and superheated steam in the pressure gasification of coal with oxygen. Figure 1 on page 2 is a block diagram of the integrated gasification process, in which a total of 70 tons of coal was fed from slurry and gasified. The present work included (1) development of equipment and methods both for mixing pulverized coal and water to produce slurry and for pumping and metering the slurry at gasification pressure; (2) development of equipment for heating the flowing slurry and, because slurry that can be pumped produces more steam than is necessary as a gasification reactant, developing equipment for removing and metering the excess steam; and (3) demonstration of the process under actual gasifier operating conditions, at a coal rate of about 800 pounds per hour and gasification pressures in the range 100 to 300 pounds per square inch gage. By using the forced-convection principle, a flow of slurry made from a caking, high-volatile A bituminous coal can be continuously heated to 600° F. in a coil-type heater. The flow rate and concentration of the slurry and the temperature gradient along the length of the heating coil must be closely controlled. In a radiant-type heater, involuntary reductions in flow rate, even momentary, can lead to coking and plugging of the heater coil.

Jan 1, 1961

By Gregory J. Chekan

As part of the initial investigation and validation of a new boundary-element formulation for stress modeling in coal mines, the underground stresses and displacements at two multiple-seam coal mines with unique stress problems were modeled and predicted. The new program, LAMODEL, calculates stresses and displacements at the seam level and at requested locations in the overburden or at the surface. Both linear elastic and nonlinear seam materials can be used, and surface effects, multiple seams, and multiple mining steps can be simulated. In order to most efficiently use LAMODEL for accurate stress prediction, the program is first calibrated to the site-specific geomechanics based on previously observed stress conditions at the mine. For this calibration process, a previously mined area is "stress mapped" by quantifying the observed pillar and strata behavior using a numerical rating system. Then, the site-specific mechanical properties in the model are adjusted to provide the best correlation between the predicted stresses and the observed underground stress rating. Once calibrated, the model is then used to predict future stress problems ahead of mining. At the two case study mines, the calibrated models showed good correlation with the observed stresses and also accurately predicted upcoming high stress areas for preventive action by the mines.

Jan 5, 1999

By R. D. Leitch, C. A. Taylor

Trinitrotoluene is made by the direct nitration of toluene by a mixture of nitric and sulphuric acids . The exact procedure varies , but the product , where Grade I of TNT is desired , is similar , and consists largely of material that has a melting and setting point of 80.6 °c . The purification consists of draining off the liquid portions , including the acid and liquid nitro compounds . The mass is crushed and washed until the TNT is acid - free . It may still have a low-melting point due to the presence of material of lower nitration. Other isomers also have the same effect . The crystal mass may be washed with a solution of sodium sulphite , thiosulphate , sulphuric acid , or with an organic solvent such as alcohol , benzene , or carbon tetrachloride , Where a very pure product is desired , the TNT is separated by fractional crystallization from solution in organic solvents . The TNT is If it forms In some cases the material is melted during purification . agitated as it cools to prevent solidification in a solid mass . in a solid mass , this is broken up and screened . There has been some question as to the effect of the different methods of purification on the strength and sensitiveness of TNT , although all methods left a product that would give satisfactory tests .

Sep 1, 1923

By Richard F. Hewlett

Computing average grade and tonnage either for an entire ore deposit or for individual blocks of ore is a continuing problem in mining. As part of a research program, investigating application of statistical techniques to mine sampling, Bureau of Mines engineers at the Denver Mining Research Center have made extensive use of an electronic digital computer for developing mine sampling theory, simulation of ore deposits, and analysis of mine sample and assay data. This report is one of a series describing use of the digital computer for rapid solution of computing problems in the mining industry.3 4 Development of a computer program to compute ore reserves by the commonly used triangular method was necessary so that results could be made available for analysis within hours.

Jan 1, 1963

By By Staff

"These proceedings consist of papers presented at a Bureau of Mines Technology Transfer Seminar on postdisaster survival and rescue research. Several seminars are held each year to bring the latest results of Bureau research to the attention of the mining industry as quickly as possible.INTRODUCTIONThe postdisaster research program is directed toward research and development of technology and equipment that increases the chances of a miner surviving or being rescued after an underground mine disaster. A disaster is an accident of major proportions, and it may result in the entrapment of miners whose normal egress from the mine is cut off. This often necessitates a rescue operation and a means of keeping the trapped miners alive while they await rescue. The Bureau is currently pursuing research to develop the technology that will enhance the ability of miners to survive such an occurrence. The research is divided into two basic problem areas, survival and rescue. Both areas are concerned with the inability of miners and rescue teams to cope with the postaisaster environment, such as toxic gases, unstable roof conditions, water flooding, and lack of oxygen. In addition, research is also conducted to find ways of locating and quickly reaching trapped miners. Most of the research conducted by the Bureau has been directed toward the postdisaster problems associated with coal mines. However, most of the research results are also applicable to noncoal mines as well.The papers presented in these proceedings address some of the recent research conducted by the Bureau of Mines that has been directed toward the postdisaster problems outlined above. The topics covered range from an overview of the technology developed for oxygen selfrescuers to training programs for mine rescue. Any questions or comments pertaining to this research are encouraged and appreciated. Open file report (OFR) references in the proceedings listed as available from NTIS may be obtained from the National Technical Information Service, Springfield, Va. 22161, and are also available for reference at Bureau of Mines facilities in Denver, Colo., Twin Cities, Minn., l3ruceton and Pittsburgh, Pa., and Spokane, Wash.; the Department of Energy facility in Morgantown, W. Va.; the National Mine Health and Safety Academy, Beckley, W. Va., and the National Library of Natural Resources, U.S. Department of the Interior, Washington, D.C."

Jan 1, 1982

By Richard A. Thomas, Isaac A. Zlochower, Gregory M. Green, Kenneth L. Cashdollar, Martin Hertzberg

This paper reports the results of flammability studies for methane, propane. hydrogen, and deuterium gases in air conducted by the Pittsburgh Research Laboratory. Knowledge of the explosion hazards of these gases is important to the coal mining industry and to other industries that produce or use flammable gases. The experimental research was conducted in 20 L and 120 L closed explosion chambers under both quiescent and turbulent conditions, using both electric spark and pyrotechnic ignition sources. The data reported here generally confirm the data of previous investigators, but they are more comprehensive than those reported previously. The results illustrate the complications associated with buoyancy, turbulence, selective diffusion, and ignitor strength versus chamber size. Although the lower flammable limits (LFLs) are well defined for methane (CH,) and Propane (CA), the LFLs for hydrogen (HZ) and its heavier isotope deuterium (D2) are much more dependent on the limit criterion chosen. A similar behavior is observed for the upper flammable limit of propane. The data presented include lower and upper flammable limits, maximum pressures, and maximum rates of pressure rise. The rates of pressure rise, even when normalized by the cube root of the chamber volume (V 1/3), are shown to be sensitive to chamber size.