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By J. I. Paige

The Bureau of Mines, U.S. Department of the Interior, conducts research on methods to minimize the requirements for mineral raw materials through conservation, substitution, and increased minerals and metals recovery from primary and secondary domestic resources. To further this goal, prior Bureau research had devised a pyrometallurgical technique (RI 8211) to recover metallic iron and copper from molten copper smelting furnace slags by carbothermic reduction. As a continuation of this Bureau research on the carbon injection technique, reverberatory and electric furnace slags were treated in an 800-kva electric arc furnace by simultaneously top feeding the slag and injecting coke breeze into the bottom of the molten bath. Results of the tests show that 76 to 89 pct of the copper and up to 48 pct of the iron contained in the smelting furnace slag were recovered in a metallic phase, while 56 to 82 pct of the carbon injected into the sys-tem was utilized as the reductant. Laboratory evaluation has shown that the metal product, which contains 86.9 to 95.0 wt-pct iron and 1.3 to 4.1 wt-pct copper, will be a satisfactory medium for recovering copper by cementation. The expected energy consumption for the process is 110 kwhr per ton of molten slag treated and 520 kwhr per ton of solid material charged.

Jan 1, 1982

By J. L. Konchesky

The Bureau of Mines investigated the main reactions of coal gasification by steam. Coal (minus 70 mesh)-water slurry was fed into a laboratory-scale tube-coil gasifier to show the effects of residence time (0.6 to 1.1 sec), steam-coal ratio (2 to 11 lb/lb), and temperature (1,600° to 1,900° F), at about 1-1/2 atm. Devolatilization was very rapid: about 70 pet of the coal's volatile matter evolved within 0.6 sec at about 1,600° F; temperature increase released more volatile matter until about 95 pct was driven off at 1,900° F. Devolatilization was not increased by raising steam concentrations and was only slightly increased by extending residence time. Below 1,600° F, there was no evidence of the steam-carbon reaction, but at 1,900° F more than 80 pct of the coal's fixed carbon was converted to gas; the conversion was increased Significantly by increased residence time and steam concentration. The water-gas shift reaction occurred simultaneously with devolatilization, and the steam-carbon reaction, approaching equilibrium with increased residence time and temperature and decreased steam concentration.

Jan 1, 1969

By Gary L. Hundley

As part of the U.S. Bureau of Mines program to reduce the Nation's reliance on foreign supplies for critical metals, a procedure was devised to separate and recover critical metals from mixed and contaminated super alloy scrap. The process uses both pyrometallurgical and hydrometallurgical methods to treat the scrap. The mixed scrap is converted to a matte containing 4 to 7 pct S by adding S directly to the molten metal. This matte is then granulated and ground to a minus 35-mesh particle size and leached with an HCI-CI2 solution. This process takes essentially all the Ni, Co, Cr, Fe, AI, and Mo into solution in a 3-h leach, leaving W, Ta, Ti, and Nb (Cb) in the residue. The Mo is recovered from the chloride leach solution by solvent extraction, and the Cr and Fe are recovered together by precipitation. The Ni and Co can be recovered individually by an existing solvent extraction-electrowinning process. The W is recovered by a caustic leach of oxidized Cl2 leach residue.

Jan 1, 2010

By Douglas A. Elkins

The unique characteristics of plasmas, their current applications, and ongoing research into new applications are described. Major technical and economic problems in application of plasma technology are discussed. Examples of potential applications of plasma in extractive metallurgy are described and evaluated. The report includes a selected bibliography of articles on plasma and related high-temperature technology.

Jan 1, 1969

By Jeran Paul W., Michael A. Trevits

Subsidence data gathered by the U.S. Bureau of Mines over a series of longwall panels in the Pittsburgh Coalbed were studied to obtain insight as to the role of time in the subsidence process. It was found that subsidence began essentially with undermining and was completed within 1 year. The progress of the subsidence was dependent upon location above the panel. Subsidence in the central area of the subsidence trough, where subsidence is the greatest, was about 90 pct complete by the time the face had progressed a distance equal to one overburden thickness beyond a particular surface point. For a point over the rib of the longwall panel, the subsidence was only about 60 pct complete at this time. Data from three other sites in the northern Appalachian Coal Basin were analyzed to determine if an anomaly or the true characteristics of the subsidence process had been observed. All sites behaved similarly in the central portion of the subsidence trough. However, the subsidence of points over and adjacent to the ribs of the longwall panels was site specific. The fact that movement across the width of the panel was not uniform should be taken into account in assessing damages or the potential for damages resulting from mining-induced subsidence.

Jan 1, 1995

Reduce longwall shearer operator's dust exposure by selecting the best drum water spray sys-tem for minimizing dust generated durinq cutting. Approach Three of the most commonly-used drum water spray systems were installed on the same set of shearer drums and compared to determine which system best suppresses dust. The spray systems studied were: ? pick-point flushing ? cavity filling ? water-through-the-it Instantaneous and gravimetric sampling instruments were used to measure the respirable dust exposures of the shearer operators and dust concentrations downwind of the shearer. The Three Systems: Longwall shearer drums are routinely equipped with internal drum spray systems since these systems have been shown to be more efficient than external systems in terms of dust suppression per gallon of water applied. All U.S. longwall shearer faces utilize some type of internal water delivery spray system. The two most common systems are bit-or pick-point flushing and cavity filling. Pick-point flushing uses nozzles mounted in the bit blocks or in special blocks immediately in front of the bits. Cavity filling utilizes spray nozzles installed in a pipe manifold mounted on the drum hub between the scrolls or along the edge of the vane scrolls; water is sprayed radially from the manifold towards the adjacent vane scroll.

Jan 1, 1986

By George E. Blandford

A deterministic model to assess the hydrologic impact of small watersheds subjected to unsteady storm events is presented. The overland flow model is based on the kinematic wave approximation coupled with a Green-Ampt infiltration equation. The Green-Ampt infiltration parameters are estimated using the USDA-ARS parameter estimation technique which is based on soil moisture-tension data. A Galerkin finite element formulation of the kinematic wave approximation is presented for the deterministic analysis of overland flow on small watersheds. The finite element formulation includes linear, quadratic and cubic Lagrangian one-dimensional spatial elements. A linear time variation is assumed which includes both explicit and implicit time marching algorithms, depending on the choice of the time weighting parameter. The implicit time algorithms result in a system of nonlinear equations which are evaluated using a modified Newton-Raphson iteration scheme. Initial solution estimates are generated using a linear finite difference procedure. The coupled infiltration overland flow model is tested using storm data for impervious surfaces, a laboratory soil flume, and two natural, USDA-ARS experimental watersheds.

Jan 1, 1983

By T. H. Jeffers

Significant amounts of cobalt are present in readily accessible spent copper leach solutions. The Bureau of Mines investigated the feasibility of extracting cobalt from these solutions in a multiple-compartment ion-exchange (MCIX) column. The effects of aqueous flow rate, resin flow rate, column height, and compartment height on cobalt extraction were determined. Cobalt extractions of 92 pct or higher were achieved at solution flow rates of up to 5.5 gpm/ft of column cross-sectional area and an aqueous-to-resin flow ratio of 40:1. Overall cobalt extraction increased as the column height increased, but cobalt extraction per unit of length was more efficient in 8-and 12-ftco1umns than in an 18-ft column. Solvent extraction procedures were utilized to purify and concentrate the MCIX column eluates and produce a cobalt sulfate solution containing 70 to 80 giL Co. Metallic cathodes containing over 99 pct Co were e1ectrowon from this solution. Zinc, nickel, and copper byproducts were also recovered during processing of the ion-exchange eluates. Estimated total capital cost for a commercial-scale 10,000 gpm of a spent leach solution containing 26 million. With credits for zinc, nickel, and copper estimated net operating cost was $9.36/lb Co.

Jan 1, 1987

The Ringelmann Smoke Chart fulfills an important need in smoke abatement work and in certain problems in the combustion of fuels. A knowledge of its history and method of preparation is, therefore, of interest to many. Since instructions on its use are not shown on the recent edition of the chart, those included in this revision of the previous Bureau of Mines publication now are a necessary complement to the chart, More detail regarding the use of the chart is included than was given in the earlier version.

Jan 1, 1967

By N. S. Dalal, B. Jafari, F. H. Y. Green, M. M. Suryan, V. Vallyathan

"Freshly ground and aged anthracite and bituminous coal samples were investigated by electron spin resonance (ESR) spectroscopy to detect the presence, concentration and reactivity of free radicals. Freshly ground anthracite coal produced greater concentration of free radicals than the bituminous coal, and the radical reactivity was also greater for the anthracite. The reactivity of the newly produced free radicals in the anthracite dust correlated with the dust's toxicity. Furthermore similar coal-based free radicals were detected in the lung tissue of autopsied coal miners, suggestive of persistent reactivity by the embedded coal dust leading to the progressive disease process. Results of the studies on the severity of coal workers' pneumoconiosis (CWP) and free radical concentration m lung tissue support this hypothesis.INTRODUCTIONCOAL WORKERS' PNEUMOCONIOSIS (CWP) has been an important topic of concern to miners, mining engineers, epidemiologists and medical researchers for decades. It is well known that the prevalence and severity of CWP differ markedly between different regions and mines despite comparable exposures to respirable dust (REISNER and RoBOCK, 1977; HURLEY et al., 1979). These variations in pathogenicity of coal mine dusts can only partially be explained by differences in the mineral composition and by rank of coal (CHRISTIAN and NELSON, 1978; CHRISTIAN et al., 1979; HATCH et al., 1980). Cytotoxity studies on mammalian cells do not correspond well with the human disease pattern (CHRISTIAN and NELSON, 1978; CHRISTIAN et al., 1979; HATCH et al.,1980; VALL YA THAN et al., 1988). For example, while epidemiological studies of coal miners (REISNER and ROBECK, 1977; HURLEY et al., 1979) indicate that the prevalence of CWP correlates roughly with the rank of coal, such correlation has not yet been established in biological studies, despite considerable effort (CHRISTIAN and NELSON, 1978; CHRISTIAN et al., 1979; HATCH et al., 1980). In order to help resolve this apparent paradox we have undertaken a systematic study to evaluate whether any correlation exists between the concentration of free radicals present in fresh or aged coal dusts from two well-characterized U.S. coals. This study was also prompted in part by observations reported in the literature that organic free radicals can be formed on the surface of freshly fractured coals (LEBEDEV et al., 1978; DULIBA and CLARKSON, 1984). In particular, ARTEMOV and REZNIK (1980) noted that the decay lifetimes and, hence, the reactivity of the organic free radicals formed on crushing Russian coals, .depended"

Jan 1, 1989

By R. August Heindl

[A proposes process for recovering manganese from open-hearth steel-plant slogs is indicated by the flow diagram shown in figure 1. Investigation of the process, the laboratory development of which was reported previously,4/ was expanded to a larger scale. Mixtures of flush slags and limestone were proportioned to have molar [SiO2] ratios of 1.5 to 2.2 and were fired at temperatures up to 2,400° F. In an oxidizing atmosphere. This produced clinker consisting principally me various combinations of the oxides of manganese, iron, aluminum, and magnesium aloe with a dicalcium silicate phase containing the phosphorus. Some tests were made with a continuous sintering machine of the traveling-grate type, but a rotary kiln was the most satisfactory apparatus for this operation. Material was fed at 150 to 200 pounds per hour after first being agglomerated either on the sintering or else binder extruding and drying finely ground mixture of the sing, limestone, binder, and water. Tests with slag; from tree different source indicated overkill manganese recoveries of 65 to 80 percent by ammoniacal-ammonium-carbonate leaching.]

Jan 1, 1955

By R. K. Koch

The Bureau of Mines produced several series of titanium castings in order to investigate the feasibility of producing commercial-grade titanium castings in bentonite-bonded olivine or zircon sand molds. The use of these molds for titanium casting was investigated as a possible alternative to the industrially used rammed graphite process. Parameters investigated were mold mixtures, mulling, gating, venting, drying, and mold washing. The investigators found that castings with superior ductility and fatigue life, compared with rammed graphite castings, could be made by fume-free pro-cesses in molds bonded by western bentonite, using either olivine or zircon sand. Zircon molds were satisfactory for both light-and heavy-sectioned castings. However, olivine molds were suitable only for light-sectioned castings because the mold-metal reaction became excessive during the pouring of heavy-sectioned castings.

Jan 1, 1981

By M. H. Marvin

This report presents the results of a program to develop backfilling techniques to mitigate undesirable effects of hydraulic borehole uranium mining. Large underground cavities, formed during the borehole mining process, can be backfilled to prevent ground subsidence and to allow mining of adjacent uraniferous sandstone. Three backfilling techniques were tested in the laboratory and in the field: bulk dumping of slurry into the borehole from ground level, slurry injection under water, and slurry injection above the cavity water level. These techniques were tested with sand and with sand and one percent cement (by weight) mixtures. The project was accomplished in four tasks: equipment preparation and transport, mining operation to generate a full-sized cavity, backfilling operation, and assessment through core samples and subsidence checks. The concentrations of cement mixed with sand proved to be inadequate to bond the sand. Bulk dumping resulted in a 30-degree angle-of-repose, much too steep to completely fill the cavity. Both slurry injection techniques filled the cavity satisfactorily. However, underwater injection is the recommended backfilling technique because the borehole water level does not need to be pumped down during backfilling. The borehole itself was filled by bulk dumping of slurry. In conclusion, backfilling of borehole mining cavities is entirely feasible, and the preferred method is slurry injection under water.

Jan 1, 1979

By R. C. Buehl

Pilot-plant tests have been in progress at the Bureau of Mines, Pittsburgh, Pa., on the recovery of manganese from open-hearth slag.3/4/5/ In the process, 1 the slag is first reduced in a blast furnace to make a high-phosphorus spiegeleisen containing 12 to 22 percent manganese. A slag containing 55 to 60 percent manganese is made from this spiegel by oxidation in a basic-lined converter. The metal from this blowing operation contains about 3 percent phosphorus, 1 percent manganese, and less than 1 percent carbon. Economic efficiency in the manganese-recovery process requires that this metal be converted into steel. Because of its high phosphorus content the metal is suitable for blowing in a basic-lined converter. In most of the tests described in this report, metal of this composition was used as the starting material in a 1-ton, side-blown, basic-lined converter. Although basic-lined converters are not used for steel production in the United states, in Europe a considerable portion of the steel is made in them. Open hearths largely have replaced converters for steelmaking in the United States; mainly because open-hearth steels have better physical properties than converter steels because of lower nitrogen and phosphorus contents. However, by improving converter design and operating technique during the past 15 years, metallurgists have found that low-nitrogen steels with physical properties equal to open-hearth steels can be produced in converters.6/ Tests at Jones & Laughlin steel Corp. with side-blown, acid-lined converters of 3 and 22 tons capacity showed that steel with a low nitrogen content comparable to that of open hearths operating on scrap charges could be made by surface blowing.7/

Jan 1, 1955

By R. Hogg

"Particles play an important role in our environment and in many aspects of human activity. Much of the Earth's surface - sand, soil, rocks - consists of particles, as do clouds in the atmosphere, smoke from fires, and dust in our homes. Many of the foods we eat - cereals, flour, instant coffee - and everyday items such as pharmaceuticals, cosmetics, detergents and other cleaning products are encountered in the form of particles. Inks and paints consist of very fine particles dispersed in liquids. Modem agriculture uses huge quantities of fertilizers and pesticides, largely in particulate form. The list could be extended almost indefinitely; particle systems are obviously an important part of our daily lives. But what do we know about them? For most people, the answer is probably: not much.We are all familiar with the three common states of matter: gas, liquid and solid. In many respects, particle systems should be regarded as a distinct class of their own. The particles themselves may be solid but we all know that a heap of sand is quite different from a solid rock. A cloud of liquid droplets - fog - has much more in common with a cloud of solid particles - smoke - than it does with a bucket of water. There are certain characteristics and properties which are unique to the particulate state. The behavior of any particle system is determined not only by the material from which the particles are made, but also by interactions among the particles and with their environment. These interactions become increasingly important as the size of the particles decreases, and for exceedingly fine particles, smaller than about one micrometer (0.000001 meters or 0.00004 inches), these interactions dominate and we enter the realm of colloidal systems.Particle SystemsA system in which discrete entities - particles -are dispersed in a continuous medium can be regarded as a particulate system. The particles and the medium can consist of a solid, liquid or gas. The various combinations and some common examples are listed in Table 1. The properties and behavior of these systems depend on the characteristics of the particles, the nature of the medium, and the relative abundance of the two phases. In general, it is the latter which determines the kind of behavior exhibited by the system.As a general rule, the behavior of particle systems follows that of the dispersed phase (the particles) at high concentration, and that of the continuous phase (the medium) at low concentration. For example, both powders and smokes consist of solid particles in a gaseous medium. However, in a powder the solids typically occupy over one half of the total volume; in many respects powders behave like solids. In a smoke, on the other hand, the particles may take up only a few parts per million of volume, so that these systems generally behave like gases."

Jan 1, 1989

By E. P. Youngman

The mining law of May 16, 1884, is still the basic mining legislation in Smeden. To satisfy a demand for a revision of the entire mining law, special commissions have been at work for a number of years; but present indications are that the work will require several more years for its completion. The changes contemplated would affect mainly the relations between the nine operator and the landemer, as the present law, according to general opinion, tends unduly to jeopardize the landowner's right in favor of the miner. The socialist party desires additional changes, especially in the direction of giving more direct control of the industry to the State, a control that it now seems to exercise through individual agreements with mining companies. Its control of the Lapland iron mines comes through its sharing the ownership with the Luossavaara-iirunavaara Altb. In this instance, the Government should be Considered as a private commercial body, since the agreement with the company

Apr 1, 1933

By C. L. Brown

Coal has been transported by belt conveyors in mines for many years; however, only since the beginning of the general mechanization period have complete transportation system of this type been employed. Aside from my complete belt-conveyor transportation systems, belt conveyors are frequently used in conjunction with other transportation. Many early installations, for the most part, were made without standards as a guide. As a result, some States have outlined certain requirements based more or less on experience following mine fires. Correlation of these regulations should result in more uniformity in connection with standardization of regulations. The National Electrical manufacturers Association has published standards for mining-belt-conveyor installations2/ that should be helpful to the coal-mining industry generally. Bureau of Mines Schedule 2F3/ requires certain controls for permissible-belt- conveyor drives, and similar requirements are listed in Bureau of Mines bulletin 514.4/ Committees of the American Mining Congress have prepared much valuable information concerning operation of belt conveyors, and a subcommittee on fire-resistant belting has been active. 5/

Jan 1, 1956

By Tobias W. Goodman, George N. Aul, Joseph Cervik

The Bureau of Mines conducted research to degasify a virgin block of coal in the Beckley Coalbed using long horizontal holes drilled in an array from the bottom of a ventilation air shaft. Eight horizontal holes and an in situ pressure hole were drilled in a radial pattern to depths ranging from 418 to 910 ft (127 to 277 m) and 205 ft (62 m), respectively. The investigation showed the shaft was in a basin saturated with water, which resulted in low gas flows from holes. The in situ pressure at 200 ft (61 m) into the coalbed was 79 psig (544.6 KN/m2). The aver- age gas and water flows for the eight holes were 94,100 ft3/day (2,665 m3/day) and 13 gal/min (49.3 l/min) . After 514 days of degasification, 18.7 million ft3 (0.53 million m3) of gas had been drained. Methane face emissions, which were measured as a section advanced toward the shaft, were reduced about 77 pct, emphasizing the value of drainage by this technique. All holes were grouted before the area around the shaft was mined.

Jan 1, 1982

By Philip G. Burkhalter

Total yield and backscattered electron coefficients were measured in this Bureau of Mines study in an microanalyzer as a function of atomic number and of primary crier: ;y in the 15- to 35-kilovolt range. The electron coefficients were obtained indirectly from measurements of the specimen electron current and the primary beam current collected in a Faraday cage and were measured with a precision better than 0.5 percent. Secondary electron emission was suppressed with opposing potential applied to a screen grid surrounding the specimen. The values of the backscattered electron coefficients agreed with published values within 5 percent.

Jan 1, 1965

By Will H. Coghill

[The supply of gravel spar and of acid spar is not well balanced. Gravel spar -- 85 per cent flourspar, 5 per cent silica -- gluts the market, whereas acid spar -- 98 per cent fluorspar, 1 per cent silica -- is somewhat scarce. Hence it is desirable to convert some of the gravel spar into acid spar. Knowledge of this condition prompted the Franklin. Fluorsrar Co. at Paducah. Ky., to enter into cooperation with the U. S. Bureau of Mines and the Missouri School of Mines and Metallurgy to improve the methods of fluorspar, milling so that morn acid spar would be available. The fluorspar company detailed Mr. Omar Greeman for the work. During the course of the investigation, while Mr. Greeman was also doing work for a master's degree in the School of Mines? an extensive study was made of gravity concentration of fluorspar ores. Decrepitation by heat treatment was also given a laboratory try-out. A part of tie time was spent on flotation; these notes relate only to the flotation. The results of one of the flotation runs is appended. The test was made in a 500-gram mechanical-agitation machine. The sample was ground to 100-mesh in a pebble mill.]

Jan 1, 1928