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By M. J. Ankeny, J. J. Forbes

The United States Bureau of Mines often receives inquiries from the mineral , petroleum , and allied industries concerning the essential steps to be taken in the formation of Holmes Safety chapters and councils . The purpose of this circular is to answer in a general way such inquiries and to relate briefly the history and work of the Holmes Safety Association to the present date .

Jul 1, 1931

By H. W. Kilau

The Bureau of Mines evaluated synthetic fluorspars as substitutes for natural fluorspar in basic oxygen steelmaking using a high-temperature rotational viscometer and a quarter-ton basic oxygen furnace (BOF). Consider-able variation in stability and BOF slag fluidizing properties were found when using the initial synthetic products, but improved synthesis methods produced synthetic fluorspars that were generally comparable to natural fluorspar in laboratory testing. Trials in the furnace showed the synthetic products to be operationally the equivalent of natural fluorspar. Higher sulfur and phosphorus contents in some of the synthetic materials did not adversely affect the steel chemistry. Analyses of wet scrubber samples showed evidence that the pelletized synthetic fluorspars experienced greater physical and chemical disintegration than did natural fluorspar. It was also found that operation of a BOF without fluorspar is possible when making low-carbon steels because iron oxide is intrinsically generated as the slag fluidizer.

Jan 1, 1981

By J. E. Geier

This Bureau of Mines report reviews hypotheses for the mechanism by which water jets reduce the specific energy of cutting for drag bits. Several of these hypotheses are shown to be inconsistent with published evidence and new observations. The notion of a limiting cutting speed, above which water jets would be incapable of rendering assistance, is shown to be improbable. The hypothesis that seems most plausible is that specific energy reductions are mainly due to the erosion of crushed materials from in front of the bit. This hypothesis leads to a prediction that, for a given rock type and jet-bit configuration at a constant depth of cut, the reduction in bit forces should be a function of dM/dx, the jet energy spent per unit length of cut. This dependence upon dW/dx is shown to be consistent with other workers? results.

Jan 1, 1987

The Mine Safety and Health Administration (MSHA) defines an independent contractor as any person, partnership, corporation, subsidiary of a corporation, firm, association or other organization that contracts to perform services or construction at a mine. Contractors that perform specific types of work are required to report the number of employees who work at coal mines and noncoal mines.

Jan 1, 2008

In 2005, 14,666 mining operations reported employment statistics to the Mine Safety and Health Administration (MSHA).1 Almost half (48.5%) were sand and gravel mines, followed by stone mines (30.6%), coal mines (14.1%), nonmetal mines (5.0%), and metal mines (1.8%).

Jan 1, 2008

By George Watkin Evans

The United States Geological Survey has estimated 1 that the State of Washington contains 11,412,000,000 tons of bituminous coal and 52,442,000,000 tons of subbituminous coal, in beds more than 14 inches thick. As the present rate of production is about 4,000,000 tons a year, Washington apparently contains coal enough to supply Pacific coast markets for many years. The character of the coal beds of Washington renders the production of clean coal very difficult, and a considerable proportion of the output is washed before it is marketed. In 1915 Washington ranked fifth among the States in the amount of coal washed, though only twentieth in total output. In that year 37.9 per cent of the coal produced in the State was treated in surface cleaning plants.

Jan 1, 1924

By A. M. Evans, J. H. Soulé

"INTRODUCTION Deposits of iron ore in Cherokee County, Tex., have been worked at various times in the pact, and the ore has been smelted in small local blast furnaces.Recently it was proposed to establish a charcoal blast furnace with a wood distillation plant to produce charcoal for fuel and byproducts. Financial assistance from the Reconstruction Finance Corporation was sought by George Easley and associates to enable them to purchase, move, and erect the furnace and build the required accessory plants. The furnace was to be moved from Pembroke, Fla.In August 1941, the Bureau of Mines was asked by the Office of Production Management to check the development work of Easley and associates and to ascertain (1) the iron-ore reserves, (2) the cost of mining ore and delivering it to the blast furnace, and (3) the grade and character of the ore. The Bureau of Mines was advised, while the investigation was in progress, that approximately 1,000,000 long tons of measured reserves would be sufficient to demonstrate the feasibility of operating the properties.Although deposits of iron ore are widely distributed in Cherokee County, only the Pryor Mountain, Banks and Cherokee, J. P. Acker, and Citizens State Bank tracts were sampled thoroughly by the Bureau of Mines. The iron-ore rights on these are owned by the New Birmingham Development Co., the Cherokee Development Co., or by individuals. Options to lease the ore rights were obtained by Easley, who obtained options on the Hawes Peach Orchard and Bradford tracts, also, which were examined only cursorily by the Bureau."

Aug 1, 1947

By H. C. Fuller

Depletion of iron ore in the Nation's large deposits has directed attention to other sources. One of these is the titaniferous iron ore of the Iron Mountain, Wyo., area. Tests were made to determine the feasibility of smelting this ore, which contains about 20 percent titanium dioxide (Ti02), in an electric-arc furnace to produce pig iron. Initial tests, which were made in a 30-pound-capacity induction furnace, demonstrated that the iron could be easily reduced to metal and that limestone was a suitable and effective flux. Larger scale tests then were made in a 50-pound-capacity electric-arc furnace to obtain the more detailed information necessary for the planned continuous operation of a still larger arc furnace. The principal facts determined by preliminary batch-smelting studies were that (1) 9 pounds of limestone flux was required for each 100 pounds of ore smelted, (2) expensive coke was not required because coal proved to be a satisfactory reductant (near stoichiometric carbon was optimum), and (3) overreduction, which produced a viscous slag, must be avoided.

Jan 1, 1961

By J. W. Eckerd

The crushing of chestnut-size (1-5/8 by 13/16 inch) Pennsylvania anthracite in four commercial crushers (impact) jaw) hammer-mill) and gyratory types) was studied by the Bureau of Mines to determine which could produce the largest proportions of buckwheat Nos. 1 and 2 sizes (9/16 by 3/16 inch). Single pass dry and wet crushing techniques and the effect of stage crushing were evaluated. Calculations were made to show the effect of closed-circuit reduction on production rates and yield of the various sizes. The data show that the gyratory crushers produced the greatest percentage of the desired sizes. A ring-type hammer mill produced the greatest tonnage of buckwheat No.1 and rice (14.9 tons per hr.) during dry grinding tests) but the yield of these sizes was only about 55 percent) as compared with 62 to 70 percent for the gyratory crushers. The impact and jaw crushers produced the smallest amount of buckwheat and rice and the largest quantity of oversize material.

Jan 1, 1960

By J. L. Holman

In conjunction with its research program on separation, recovery, and recycling of metal, mineral, and energy-based materials in urban refuse, the U.S. Bureau of Mines is developing means to reuse and recycle plastics discarded in raw municipal waste. Experimental work on plastic waste from a community collection has produced some guidelines for systematic methods of processing, including air classification, cleaning, separation, and use or disposal. Sink-float methods are a practical means of separation into types. Methods for final disposition of the plastic waste include refabrication, thermal decomposition, and incineration.

Jan 1, 1972

By Paul W. Johnson, Ralph C. Kirby, Frank A. Peters

An evaluation is presented for a process designed , on the basis of published work , to extract alumina as potassium alum from clay using sulfuric acid and potassium sulfate . The silica residue is separated by filtration . Ferric iron is reduced to ferrous iron , and the alum is crystallized from the solution , leaving the ferrous iron in solution . The alum crystals are separated from the solution and redissolved for feed to autoclave decomposition . In an autoclave the alum is partly decomposed to a basic alum , recovering five - ninths of the sulfuric acid and two - thirds of the potassium sulfate without using an acid plant . The basic alum is decomposed by calcining , and the potassium sulfate is then removed by washing with water . Operating costs for a plant producing 1,000 tons of alumina a day are estimated at $ 96.15 per ton of alumina . The fixed capital cost is estimated at $ 155 million . This process is not competitive under current economic conditions with the production of alumina from bauxite by the Bayer process . Improvement in leaching , basic alum decomposition , and washing could reduce the costs and improve the product which contains some potassium .

Jan 1, 1963

To develop a conceptual design for an automated longwall mining system, one should know what has been done, what is being done today and what is being planned for tomorrow. The bibliography referenced and discussed in this report provides a good source for that knowledge. To scientifically determine where attention should be focused to up-grade a system, the system must be quantized as far as possible. The Mechanization Profile of Appendix A-I is discussed in this report and has been used to analyze and determine the degree of mechanization currently in use and/or described in the literature for all three major elements of the long-wall system, namely, Winning, Roof Support and Haulage. The charted profiles make it self-evident where attention and design effort is needed to remove human operators from the face of the mine.

Jan 1, 1975

By J. B. Zadra, J. M. Gomes, Don H. Baker

Electrolytic deposition at 1,000 ° C in an electrolyte essentially consisting of 7 parts sodium pyrophosphate , 2 parts sodium chloride , and 1 part sodium tetraborate yielded tungsten of 99.9 percent purity . Scheelite concentrates containing 25 to 73 percent WO, and varying quantities of iron , lime , and silica were used as feed materials for the electrolysis . The metal contained less than 0.01 weight - percent each of iron , calcium , silicon , aluminum , carbon , and oxygen . Modification of the electrolyte permitted deposition of equal - quality metal from scheelite concentrates containing higher quantities of iron , calcium , and silica . The electrolytic separation of molybdenum and tungsten was accomplished by minor variations in the operating procedures .

Jan 1, 1964

By Lindsly. Ben E.

"The recovery or partial recovery of the oil remaining in oil sands after the usual methods of production have become unprofitable is perhaps the greatest problem in the petroleum industry today. The amount of this oil remaining in the sand is variously estimated by those familiar with the subject to be 25 to 90 per cent of the original content.2Lewis3 states, ""The estimate of 80 to 90 per cent of the oil left underground does not seem incredible.""It is estimated by the writer that approximately 91 per cent of the oil originally held in the Elliott pool, was still in the formation on January 1, 1924, and that it would take at least 12 years, at the 1923 rate of production, to further reduce this quantity by one per cent of the original content.The progress made in the oil industry during the past few years relative to the prevention of evaporation losses; to improvement in cracking processes, whereby the gasoline yield from many crudes has been doubled and trebled; to the increased recovery of gasoline from natural gas; and many other developments, remarkable as they are, can be applied only to that comparatively small portion of petroleum products which are raised to the surface. A device or process which would cut development costs to one-half would probably result in a much smaller profit to the oil industry, than the profit derived from an additional 10 per cent recovery of the total amount of oil in a pool. Various methods have been used and many others proposed, for the increase of oil recovery from normally depleted sands.In France, oil sands are being mined by means of shafts and galleries. In other places, notably the Bradford, Pennsylvania field, the yield has been increased by means of water flooding, wherein water is introduced into the sand to displace oil, and drive it to producing wells."

Oct 1, 1926

By T. F. Mitchell, J. V. Batty, R. R. Wells, R. Havens

"INTRODUCTION )ne of the most important wartime activities of the Bureau of Mines was the search for new sources of minerals necessary to the prosecution of the war. As a part of the investigation of strategic mineral deposits in the United States under the Strategic Minerals Act (Public 117, 76th Cong., 1st Sess., Ch. 190), examining engineers of the Bureau of Mines investigated and sampled various deposits of chrome ore in California, Idaho, Montana, Oregon, and Washington, and those deposits that warranted further study were explored by diamond drilling, trenching, and drifting, as re¬quired. During these investigations, samples were submitted to the Ore Dressing Section of the Salt Lake City Station for metallurgical testing. This paper gives data summarizing results obtained from laboratory ore-dressing studies of the chrome ores submitted.Although the deposits range widely in geographical location, the mineral occurrence of all of them is strikingly similar. Chromium, in all of the ores tested, is present as impure chromite or chromium spinel. Although pure chromite (FeCr204 or FeO.Cr203) contains 68 percent chromic oxide, the iron may be replaced in varying amounts of magnesium, and the chromium may be replaced similarly by aluminum and ferric iron. In studying concentration methods as applied to chrome ores, the composition of the chrome mineral is of fundamental importance, because it is manifestly impossible to produce a high-chrome concentrate from a low-chrome chromite by any mechanical process.In all but one of the ores, the gangue material consists of olivine or altered olivine minerals such as serpentine, antigorite, and chrysotile. The exception, the Antelope or from Montana, has a gangue chiefly composed of actinolite, chlorite, and talc."

Jun 1, 1947

By Thomas M. Barczak

Wood cribs are used extensively by the mining industry to stabilize mine openings. While the cost per crib is relatively low, their extensive use can result in annual mine costs of over $1 million. In an effort to improve the utilization of these supports and to reduce ground control hazards, the U.S. Bureau of Mines has developed engineering methods to assist mine operators in wood-crib design and employment. Design and employment criteria are established based on the strength, stiffness, and stability of the crib structure in relation to the load conditions imposed by the mine environment. Models have been developed based on full-scale tests in the USBM's Mine Roof Simulator that compute the capacity of wood cribs of various configurations and material constructions as a function of displacement of the crib structure due to roof-and-floor convergence. These models permit the comparison of the loading characteristics and costs of employment of different crib designs, and in conjunction with roof behavior models, provide a means to determine the optimum design and employment strategy.

Jan 1, 1993

By Michael Gibbons

A method of monitoring roof stability in underground mines by detecting the changes in resistivity of roof material was tested. The device built by the USBM was tested over a 16 month period at the White Pine Copper Mine in White Pine, Michigan. Three falls of ground were monitored by means of as many as 11 sensors. Data indicate a correlation between changes in resistivity and impending structural failure. Problems were encountered with the high roof electrode impedance in the winter and spring due to the drying out of the roof material. Difficulties also developed in obtaining a permanent bond between the roof rock, the conductive epoxy and the electrode plate. Some data were lost due to timer and fuse problems within the unit. These were eventually rectified.

Jan 1, 1979

By J. L. Reuss

The Bureau of Mines investigated the technical feasibility of smelting copper concentrates containing chalcocite (Cu2S) and native copper using nonpyritic sulfur-bearing materials to aid matte formation. The procedure consisted of combining various proportions of commercial chalcocite concentrate, smelter slag, fluxes, and matte-forming constituents to produce charges of comparable compositions. The mixtures were charged in fire-clay crucibles and smelted in an induction furnace at 1,300° C. The research proved that either sulfur or gypsum can replace pyrite as a matte-forming material, and that gypsum produces an exceptionally high-grade copper matte. The addition of small quantities of metallic iron to the nonpyritic smelting charge furthers the removal of sulfur, improves the recovery of copper, and makes it possible to utilize gypsum as the exclusive flux and matte-forming ingredient, thereby eliminating the necessity of adding limestone.

Jan 1, 1968

By Carl L. Bieniewski

U.S. molybdenum production increased fivefold from 18.2 million pounds in 1946 to 90.5 million pounds in 1966, and constituted 87.3 percent of the total free world supply in the 1946-66 period. Mining development in other free world countries in the next few years may reduce the magnitude of the U.S. position, although similar development planned for the United States may counteract some of the relative gains by those countries. In 1966 two-thirds of the reported molybdenum consumption in the United States by end uses was as an alloying element in steel. Molybdenum also has important use as an alloying element in iron and high-temperature alloys. Consumption of molybdenum metal for making fabricated parts has increased in the past few years, especially in the space and nuclear industries. Molybdenum compounds are used mainly for making pigment, catalysts, and lubricants. Based on producer reports of shipments of primary products to domestic customers, U.S. consumption of molybdenum increased from 16.5 million pounds of molybdenum in 1946 to 65.6 million pounds in 1966. U.S. molybdenum reserves are now estimated to be 5.9 billion pounds of recoverable molybdenum, an increase of 2.1 billion pounds above previous estimates. Molybdenum ores account for 71.4 percent of the reserves, copper ores for 22.3 percent and copper-molybdenum, tungsten, and uranium ores for 6.3 percent. Several methods for predicting future demand are illustrated and estimates of demand using these methods were made for 1975. Based on present capacities and announced company plans for future developments, estimates of annual production were made for 1967 through 1975 for the United States, Canada. Chile, Peru, and the free world. These data indicate that molybdenum production in 1975 for the free world is expected to be 246 million pounds with the United States producing 68.2 percent and Canada, Chile, and Peru 30.3 percent.

Jan 1, 1970

By Bruce K. Cantrell, Jon C. Volkwein

Exposure to mineral aerosol is an occupational health hazard in mining and mineral processing industries because of the risk of developing pneumoconiosis. Agricola (1556) described this hazard for metal mining in Carpathia. He described shortness of breath and consumption, conditions that are now associated with asthma and emphysema. By the end of the nineteenth century, several respiratory diseases were known to affect miners, including silicosis and coal workers' pneumoconiosis (Fletcher, 1948; Seaton et al., 1981). For example, silicosis, not tuberculosis, was clearly recognized as the hazard in the Vermont granite quarries and stone-cutting sheds (McFarland, 1927). The Gauly Bridge Tunnel disaster in the mid-1930s caused the deaths of an estimated 700 workers by acute silicosis and focused the nation's attention on this disease (Cherniack, 1986). By the mid-twentieth century, it was clear that risk of simple pneumoconiosis is associated with a miner's cumulative exposure to mine aerosol in the respirable size range and that prevention lies in reducing that exposure through regulation (Seaton, 1986). In the United States, regulation of mine worker exposure to airborne mine dust is the responsibility of the Mine Safety and Health Administration (MSHA) in the U.S. Department of Labor. The key legislation relating to improved mine worker health was the Federal Coal Mine Health and Safety Act, enacted in 1969 (U.S. Congress, 1969) and subsequently amended as the Federal Mine Safety and Health Act of 1977 (U.S. Congress, 1977). MSHA receives technical assistance from the National Institute for Occupational Safety and Health (NIOSH). NIOSH also provides recommended exposure limits (RELs) for contaminants to MSHA. MSHA's regulation of mines includes the establishment of a dust standard administratively based on the these RELs. Some mine operators must submit a dust control plan designed to meet the dust standard. Periodic mine inspections determine if mines are com- plying with both the dust standard and the dust control plans (MSHA, 1991). The most common dust measurements are those for respirable dust (according to the definition given in Fig. 26-7), that is, the fraction of aerosol particles able to reach the gas exchange region of the lungs. The other health-related size fractions (inhalable and thoracic-see Fig. 25-1, and "total" dust) are also occasionally measured. A "total" dust measurement is defined by the common practice of the last 30 years or so, using 25 mm or 37mm plastic cassettes (e.g., from PAL, MIL, SKC ). The types of mines have been categorized