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By J. F. Barkley

"The fly-ash problem of the smoke-abatement engineer - who now might well be titled, ""Smoke and Fly-Ash Abatement Engineer"" - starts with the necessity for him to know what fly ash really is, what plants really create it, and how much is being created. Fly ash in this connection may be defined as all solid particles emitted to the atmosphere as a result of the combustion of fuel.COMPOSITION OF FLY ASHMuch can be learned about fly ash by studying samples with a strong magnifying glass or, preferably, a high-power microscope. As an example, figure 1 is a photomicrograph of an underfeed-stoker fly ash weighing 23.7 pounds per cubic foot, which passed a baffle-type cinder catcher and was caught by a Cottrell precipitator. Figure 2 shows a similar fly ash made at a higher stoker rating and weighing 36.2 pounds per cubic foot. The lighter ash contains more light, unconsolidated ash than the heavier. In both instances some of the ash has been fused to a glass, as is indicated by the spherical particles resembling marbles; however, the heavier dust contains more and larger spheres. With the faster burning and higher air pressures occurring at the higher burning rates, more of the larger fused spheres reached the precipitator.Such studies of fly ash frequently make possible correct determination of its source. For example, the Supreme Court Building, one of the finest of the Federal buildings in Washington, was having considerable difficulty with fly ash from some outside plant. It was thought to come from a nearby apartment house. A fly-ash trap was installed there, and care was taken in the operation of their underfeed stokers. The fly-ash nuisance continued. Microscopic examination of the fly ash found about the building compared with samples taken from the stack of the apartment house showed to the surprise of the accusing building superintendent that the present source was elsewhere. By the same means, the source was found to be a plant about ore-half mile away."

Sep 1, 1939

By George S. Rice, F. B. LANEY, A. J. Lanza, Edwin Higgins

Under its organic act the Federal Bureau of Mines is directed to conduct investigations relating to the improvement of health conditions in the mineral industries. This report describes the lead and zino deposits and the mining methods employed in the sheet-ground area of the Joplin district, Missouri, and discusses the causes and the methods of abating rock dust in the mines, the chemical and physical characteristics of the dust, and the quantities present in mine air. Although the preliminary investigation included a number of the "soft-ground" mines, the writer spent the larger part of his time in the sheet-ground mines, for in them alone was siliceous dust found in appreciable quantities. Some results of the preliminary investigation have been published by the Bureau of Mines in Technical Paper 105.a The territory covered in t~lCpreliminary investigation, during the period between November 7 and December 6, 1914, embraced parts of Jasper, Lawrence, Newton, and Greene Counties, Mo., and outlying districts in Kansas and Oklahoma. The remainder of the field work, to which 84 days during the period from February 9 to July 19, 1915, were devoted, was confined to the sheet-ground mines, the most important of which are situated in the vicinity of Joplin, Webb City, Carterville, and other smaller near-by towns in Jasper County, Mo.

Jan 1, 1917

By Daniel I. Carey

Current and potential dragline reclamation usage was evaluated for the U.S. coalfields based on data gathered and analyzed during field surveys, literature reviews and contacts with manufacturers. It was concluded that current wining plans have been adapted to federal and state strip mine and reclamation laws in ways which limit the potential for drag line reclamation systems at active mine sites. At abandoned conventional contour mine sites in steep-sloping areas such as central Appalachia, however, it was found that dragline reclamation systems have great potential application and may be the only practical solution to many reclamation problems. Alternative dragline systems were examined for restoring abandoned sites, and it was concluded that a tower excavator system offered superior characteristics and should be evaluated and developed under field conditions. A testing program was developed to provide a framework for the monitoring and analysis of cost, production and environmental data during a field demonstration of a tower excavator system.

Jan 1, 1981

By Thomas Fraser, E. A. Holbrook

The data in this bulletin were obtained during an investigation of screening practice by the University of Illinois engineering experiment station and the United States Bureau of Mines under a cooperative agreement between them and the State of Illinois Geological Survey Division. Earlier work on this subject includes a study of the general practice of coal preparation in Illinois, made in 1914 and published in 1916/ and an investigation of Illinois coal-w.ashing methods, results of which were published in 1912 in a bulletin 2 that contained complete information on the methods then in use for sizing washed coa 1.

Jan 1, 1925

By Reno M. Pappas, Christopher Mark

This report presents results of a U.S. Bureau of Mines study of longwall gob material. The objective of this work was to determine material stiffness properties of the gob for use in numerical models of rock mass response to longwall mining. Photographs of actual mine gob were digitized to obtain approximate particle size gradations of gob material. The gradation curve was shifted down to a lab- oratory scale, and 20 uniaxial compression tests were conducted. Varying the maximum particle size was not found to affect the stress-strain behavior, but changing the gradation appeared to influence the stress-strain behavior. The stress-strain relationship of the simulated gob material was nonlinear, the stress-secant-modulus relationship, was approximately linear, and the stress-tangent-modulus relationship was approximately a second-order polynomial function. Equations were generated from these curves, providing numerical modelers with a means to estimate gob moduli based on the stress level. In addition, the experimental data were statistically evaluated using multiple regression analyses, producing a series of equations to predict the secant and tangent moduli from the given stress level, bulking factor, rock strength, and thickness-to-width shape ratio of the particles.

Jan 1, 1993

By S. M. Runke

"During the past three years the Bureau of Mines has carried on an extensive research program at the Rolla Laboratory for the beneficiation of low-grade Arkansas baixites by ore dressing methods. As a result of this study a 50-ton pilot mill was designed and constructed at Bauxite, Arkansas, by the Bureau to continue the investigation on a semi-commercial scale. The built both to reduce the experimental work to practice and to obtain operating data that cannot be determined by laboratory or small scaleTen samples of bauxitic material were mined and stockpiled at the plant site to ensure an ample supply of material for milling in the pilot plant. These samples were obtained from various bauxite deposits in Saline and Pulaski Counties, Arkansas. The deposits were selected as typical of a wide range of bauxitic material which would necessitate treatment under different conditions and by various concentration methods. All of the samples contained a higher silica content than permissible in Bayer-grade bauxite and several contained so much iron oxide that the available alumina content of the ore was mate¬rially lowered. From data obtained by milling operations on these ten samples, milling characterietics of most of the ores in the district should be predictable. This paper summarizes the results obtained in the laboratory testing of representative samples of each stock pile, and the results of small scale continuous testing of the composite sample of the ten stock piles in the gravity-flotation pilot plant at the Rolla Laboratory."

Aug 1, 1946

By Hal J. Kelly

A number of problems that developed in processing the halloysitic clays of eastern Washington and northern Idaho were investigated by the Bureau of Mines. The deflocculating effect of tetra sodium pyrophosphate is compared with several other compounds, and on the basis of current theory, the advantage of sodium pyrophosphate as a deflocculating agent is explained. The adsorption of the sodium ion by clay in a clay"-water system was established by a radioactive tracer technique, and the deflocculating action of sodium pyro- phosphate was postulated. The effective dispersion of the halloysitic clays was limited by the occurrence of tightly bound aggregates of small, individual crystals. Disaggregation of the agglomerates was investigated by liquid extrusion and ball milling of dilute slurries and by extrusion of the clay in a plastic state. The greatest increase in the production of small particles was by high? pressure liquid extrusion.

Jan 1, 1963

By H. C. Miller

Several agencies of the Federal Government are engaged in research and fact finding relative to petroleum and natural gas, and others are concerned with carrying out the provisions of specific laws that affect these natural resources in their broad aspects. The Bureau of Mines, however, is the only Federal agency designated by law to engage in research in oil and natures gas production, chemistry, refining, and

Jan 1, 1941

By Henry Kreisinger, John Blizard, B. J. CROSS, C. E. Augustine

This report gives the results of 26 tests of a four-pass Edgemoor boiler fired with powdered coal at the Lakeside station of the Milwaukee Electric Railway & Light Co. The tests were made by the fuel section of the Bureau of Mines in cooperation with the research department of the Combustion Engineering Corporation and the operating department of the Milwaukee Electric Railway & Light Co. The object of the tests was to determine the thermal efficiencies and capacities obtainable by burning powdered coal under large central-station boilers, and the possibility of operating such boilers continuously at high efficiency and capacity without destructive effect on the furnaces and without difficulties in refuse removal. In any system for burning pulverized coal the furnace is the most important part because, to justify the cost of pulverizing, the powdered coal must be burned with higher efficiency than coal fired with mechanical stokers. In other words, it is the furnace that by giving higher thermal efficiency must pay for the installation, maintenance, and operation of the pulverizing equipment. No matter how simple the apparatus for the preparation of pulverized coal may be, or how simple the pulverizing process, unless the furnace is so designed that it can be operated continuously with high thermal efficiency, the whole system is a failure. For high thermal efficiency the coal must be burned almost completely with low excess air. But low excess air and complete combustion give high furnace temperature, which in turn causes erosion of the furnace lining and fusion of the ash; and removal of the fused ash is difficult. The necessity of complete combustion with low excess air thus brings with it these two important problems in the design of a furnace for burning powdered coal: 1, Prevention of erosion of the furnace lining; 2, easy removal of refuse from the furnace. For the purpose of solving these problems, the boiler tested was equipped with a furnace having hollow walls, through which about 60 per cent of the air needed for combustion passed before it entered the furnace. By passing through the hollow walls, the air cooled the furnace lining and prevented excessive erosion. A water screen was placed in the furnace about 3 feet above the bottom to keep the refuse deposited at the bottom from fusing and to make its removal easy. The design of the furnace, water screen, and burners was based on the experience gained in the previous cooperative tests1 with a smaller furnace, experimental water screen, and burners at the Oneida Street station of the Milwaukee Electric Railway & Light Co. The boiler tested had 13,057 square feet of heating surface. It was one of eight boilers fired with powdered coal, and was designated as boiler No. 8. The Lakeside station is the largest central station in the world that burns powdered coal exclusively. The coal used in the first five tests came from Illinois. The fuel in the other tests -:vas a mixture of Illinois and Pittsburgh coals.

Jan 1, 1925

By H. S. Auvil, L. D. Schmidt, H. G. Graham

"Several studies on the bulk density of coals prepared for byproduct-oven use were undertaken during the war by the Bureau of lanes in cooperation with the Office of the Solid Fuels Administrator and with the advice of the Coke Production Committee. The primary purpose of these studies was either to produce more uniform coke or to increase the throughput of existing facilities or both; the goal was increased Production of steel for war. As these studies were made, detailed reports were sent to the individual companies with whom the Bureau cooperated; also two reports,5/6/on the general subject of bulk-density control were published. In the course of the work, data were gathered that now prove of value in judging the merit of carious methods of testing bulk density and the limits of application of each method in byproduct-oven operations.Since the cessation of hostilities, the .Bureau section (Coke Production Survey Section) that conducted this work has been liquidated, but it was felt advisable to prepare a report on the accumulated experience so that it would be in a form available for the use of the industry and also as a base for any further research on the control of fluctuating bulk densities in coke ovens.It is hoped that the data and experiences recorded herein will be of material assistance to the many who have had difficulty in obtaining reproducible results in bulk-density testing. Since the data were gathered in the course of extending aid to individual plants in minimizing the deleterious effects of fluctuations in bulk density of oven charges on the quality and quantity of coke produced, certain desirable phases of an over-all investigation were not covered. However, on certain of these phases qualitative indications are available and the policy followed herein is that suggested by the American Society for Testing Materials Manual on Presentation of Data7/ that lacking quantitative information, relevant material should be included even though it ""may be qualitative in character, some may even be vague."""

May 1, 1946

By Roger F. J. Adam

This report summarizes the principles of safely working steep coal seam using longwall mining methods. It presents the state-of-the-art and identifies the problems which result from seam inclination. Details are given on foreign longwall faces achieving good records of safety and productivity when mining on 30 degree and 50 degree inclined seams. Recommendations for further research are suggested.

Jan 1, 1981

By R. I. C. Manning

The Old Dominion Co, at Globe, Ariz., like the: Phelps Dodge Corporation with which it is closely allied, considers safety a major operating problem. Safety is fostered by this company in consideration of both the humanitarian and economic aspects; the officials, take pride in promoting the welfare of employees, and the management has found that the safest way is the most eco¬nomical and that unless an organization is operated economically it can not continue to exist successfully. In planning and operating any safety, organization, terry things must be taken into consideration because an Enterprise can not be operated solely for safety any more than it can for any other single part of the operations. All work must be planned and executed for the common interest.

Jan 1, 1931

By R. F. Kehrman

Voice Frequency (VF) electromagnetic trapped miner location devices were tested for reliability and effectiveness in 93 coal mines. Tests included uplink pulsed CW, downlink pulsed OW and downlink voice evaluations. Frequencies were 630, 1050, 1950 and 3030 Hertz. Overburden depths varied from 70 feet to 1550 feet. Successful communications were established at 91 of the 93 mines. Data indicate the transmitters and receivers will operate in practically all coal mine environments. Reliability and accuracy as location devices appear to depend on noise, depth and presence of metallic objects which distort the magnetic field. In addition, theoretical models appear to define best case situations in terms of noise and conductivity. Minor hardware problems were encountered, mostly involving battery contacts, switches and antenna cables on the receivers. No hardware problems occurred with the transmitters.

Jan 1, 1978

By Paul Hatmaker

This paper covers briefly the particular field of dolomite and magnesium limestone; certain uses of high-calcium limestone are mentioned only to show more clearly the limita¬ tions of the magnesian rocks. Such a comparison is helpful because magnesium carbonate is essential for some uses; for others it is immaterial; and for many its presence in an appreciable amount is objectionable. Magnesium carbonate, occurring as a rock resembling limestone or dolomite, is described in United States Bureau of Mines Information Circular 6437, Magnesite. Other com¬ pounds of magnesium are described in United States Bureau of Mines Information Circular 6406, Magnesium Compounds (Other Than Magnesite). Limestone, geologically, is a rock composed essentially of calcium carbonate; commercially, however, the term may include dolomite and magnesium limestone.

Sep 1, 1931

By C. C. Anderson

"While conducting investigations in connection with the helium program of the Bureau of Mines, the Cryogenic Laboratory has improved an apparatus for the rapid and accurate determination of the helium content of natural gas and gaseous mixtures derived from that source. The separation of helium is effected by the use of activated coconut charcoal which, when cooled to liquid-air temperatures, absorbs the nitrogen and other constituents of the gas, leaving the helium in a. spectroscopically pure state. This absorptive property of activated charcoal was discovered- by Dewar3/ in 1875. Several years later, while conducting their original researches on helium in natural gas, Cady and McFarland employed the charcoal method for the absorption and removal of the common constituents of natural gas and constructed an efficient apparatus in which this operation could be effected.4/ Shortly after initiating the government's helium activities during the World War period, the Bureau of Mines adopted, with Minor modifications, the Cady and McFarland apparatus and method of analysis. Seibel.5./ described this modified apparatus and method of procedure as part of a publication on helium-bearing natural gas. Subsequently, the Bureau's apparatus for helium analysis has been simplified and improved to facilitate more rapid and positive operation. The apparatus and method of procedure now being used by the Bureau of Mines Cryogenic Laboratory arc described in this paper.The personnel of the Bureau of Mines Cryogenic Laboratory has improved and brought the helium apparatus described herein to its present state of perfection. The writer's contributions have been-of minor importance, and he wishes to give the various members and former members of the laboratory staff full credit for the improvements they have made. He also desires to express his appreciation for suggestions and criticisms offered during the preparation of this paper to the following members of the Petroleum and Natural Gas Division, Bureau of Mines, which now includes the Amarillo Helium Plant and Cryogenic Laboratory: H. A. Cattell, chief engineer; C. W. Seibel, supervising engineer of the Amarillo Helium Plant; W. M. Deaton, chemist-in-charge of the Cryogenic Laboratory; and H. S. Kennedy.The quantitative determination of helium in a gaseous mixture is accomplished by the removal of the other constituents from the sample, either by chemical or physical Means, leaving only the helium which can be measured directly. Chemical methods, when applied to natural gas, require the burning of the hydrocarbons in oxygen, the, absorption of the resulting carbon dioxide in a caustic solution, the removal of the excess oxygen in a suitable solution such as an alkaline pyrogallate, and the elimination of nitrogen by sparking or by combination with hot calcium or magnesium.. Such procedures are very slow and tedious compared with the physical method which employs the absorptive property of activated charcoal to effect the separation of the other constituents from the helium."

Jun 1, 1934

By G. T. Fisher

The material requirements of carbide cutting tools for machining steel and cast iron are dependent on WC bonded with Co, with additions of TaCand TiC. The Bureau of Mines is conducting research to devise substi-tute materials, based on Ni-alloy-bonded TiC, for C-5-grade cutting tool applications. This substitution would result in less dependence on foreign sources for Co, Ta, and W, and use of lower cost materials. In this preliminary study, the Bureau investigated the effects of composition and processing variables on the transverse rupture strength and hardness of Ni-alloy-bonded TiC to identify compositions that exhibit promising mechanical properties. Further systematic modification of these compositions by soild-solution strengthening additions would subsequently be evaluated to obtain cutting tool materials with requisite properties and performance for C-5 applications. Compositions for evaluation were prepared by a powder metallurgy method of cold-pressing and liquid-phase sintering. Complementary analysis of compositions included chemical analysis, X-ray diffraction, energy-dispersive X-ray spectro-scopy, and density measurements. Based on results of this investigation, promising compositions were determined to be 59.37TiC-25Ni-5Mo-lO.63Mo2C, 59.68TiC-25Ni-3.33Mo-1.77Mo2C-6.67W-3.55WC, and 59.35TiC-25Ni-l.67Mo-3.54Mo2C-3.33W-7.1WC.

Jan 1, 1987

By H. H. Storch

"INTRODUCTION The first paper of this series contained data concerning the behavior of polyhalite (K2S04.MgS04.2CaS04.2H20) upon calcination and subsequent leaching with water at 100° C. It was found that upon heating polyhalite to temperatures between 298 and 500° C. the water of crystallization is driven off, leaving, an amorphous mixture of K2S04, MgS04, and CaS04. Two transition points were located; one at 298° C. which coincides with the vigorous evolution of steam; and one at 551° C. which results in the formation of a hard mass of crystals. The latter probably consist of a solid solution If the compounds langbeinite (K2504, 2MgS04), potassium dicalcium sulphate (K2304. 2CaS04), and anhydrite (CaS04). The heat of decomposition of polyhalite at 298° C. was measured and found to be 66,000 ± 5,000 calories per mol. The optimum temperature of calcination with regard to subsequent extrac¬tion with two parts of water (at "" 0° C.) is 430 to 450° C. for 65 to 100 mesh material, if one half hour at the calcination temperature is allowed. The maximum concentration of K2S04 obtainable in the extraction of calcined polyhalite is 11.4 grams per 100 grams of water. This concentration of K2304 is considerably above the equilibrium value (3.6 g. per 100 L. of H20 at 83° C.) with respect to the solid phases polyhalite, potassium calcium pentasulphate, ¬and anhydrite. The figure 11.4 K. of K2804 per 100 g. of H20 is also somewhat than the equilibrium value (9,65 g. per 100 g, H20) with respect to the solid phases potassium calcium pentasulphate and syngenite."

Oct 1, 1930

By S. D. Hill

To help insure the continued viability of the minerals and materials sector of the U.S. economy, the Bureau of Mines is conducting research and disseminating technology that will result in more efficient minerals extraction. As part of this effort, a process is being investigated that involves an aqueous chlorine-oxygen leaching procedure to treat complex sulfide concentrates to produce ZnCl2. Subsequent fused-salt electrolysis of the ZnCI2 produces high-purity zinc metal. Previous reports described preliminary, small-scale research on the chlorine-oxygen leaching system and fused-salt electrolysis of ZnCl2. This report discusses the details of design, construction, and longterm, continuous operation of both monopolar and bipolar fused-salt cells. The effects of temperature, electrode gap, current density, electrolyte composition, and electrode configuration on current efficiency and energy consumption were determined for a ZnCl2-KC1-NaCl electrolyte system. Zinc metal was produced at the rate of about 50 lb/day in a monopolar cell which was operated continuously for 60 days with current efficiencies from 85.8 to 98.6 pct and an average power consumption of 2.1 kwhr/lb. Bipolar cells with several different electrode configurations were operated for 90 days. A current efficiency of about 70 pct and power consumption of about 1.7 kwhr/lb of zinc were achieved using a three-electrode-pair, bipolar assembly with a chlorine gas lift pump to circulate electrolyte.

Jan 1, 1981

By L. D. Tracy

This is the third of the series of reports on coal-mine royalties and leasing conditions in Illinois. The results of the study of District VI were published as Serial No. 2726, January, 1926, and those of District VIII as Serial No. 2745, April, 1926, of the Bureau of mines. The counties of Macoupin, Sangamon, and Montgomery, which are three of the principal coal-producing areas in the northern part of District VII, have been chosen for this report because these counties cover an entirely different part of the State than do the two districts already covered. Some leases in, Randolph and Washington counties are included as they are in the southern part of the district, and the data happened to be readily available.

Jan 1, 1926

By R. S. Dean

"Interest in the nitrogen content of steel has increased sharply in the last few years. Investigations have indicated that its presence in steel has an important bearing on high temperature brittleness3, magnetic properties4, room temperature hardening5, and shock resistance. The steel producer may therefore look forward with certaintly to the necessity of controlling this element in a considerable proportion of his product. The literature, however, reveals a great many contradictory statements concerning the percentage of nitrogen which must be present to produce given effects on the properties of iron and steel. Most of these arise from a misunderstanding of the nature of the iron-nitrogen diagram near the iron end and a lack of recognition of the effect of state of aggregation on physical properties although both have been fairly well worked out.My thanks are due to Mr. J. L. Gregg, Prof. R. H. Dowdell, Mr, R. F. Mehl and Mr. H. C. Vacher for suggestions in connection with the preparation of this paper, and to Mr. C. H. Hefty and Mr. G. T. Motok for furnishing a valuable bibliography and translations of articles by Must and Duhr.The iron-nitrogen diagram in the solid state, so far as it concerns the nitrogen content of commercial iron and steel, consists simply in a solubility curve increasing with temperature. The important thing about this solubility curve is that without cold wore the iron nitride when precipitated does not go into solution on heating for long periods below 300°C. This slowness of solution is probably due to the fact that iron nitride when present as a separate phase has at these temperatures an equilibrium pressure of several thousand atmospheres7 and that therefore each particle of iron nitride surrounds itself with a layer of nitrogen. The precipitation of such an unstable crystal presents points of interest thermodynamically but we can not go into these here. It is quite well established that it precipitate. It can not diffuse then unless this layer is broken through or the temperature and pressure are increased to a point where the nitrogen is absorbed at an appreciable rate in the surrounding iron. This rate will depend on the degree of unsaturation of the iron and the excess pressure of the nitrogen above equilibrium pressure. The degree of unsaturation is determined by the temperature alone so that the temperature at which the rate of solution of the nitride becomes appreciable will depend on the pressure of nitrogen developed. This, in turn, will depend on the balance between rate of decomposition of the nitride and the rate o: flow of the iron. In annealed iron, this temperature of appreciable solution rate is between 300 and 350°C.8 By cold work, however, the elastic limit of the iron is increased, and conditions for the nitride to go into solution are reached at a much lower temperature, giving rise to the so-called blue brittleness. This brittleness and hardening is due to iron nitride going into solid solution and is not precipitation hardening."

Mar 1, 1931