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By I. D. Shah

The Bureau of Mines investigated the sequence of principal chemical reactions taking place during the roasting of covellite (CuS). Practically all covellite is converted to digenite (Cul.SS) before oxidation to Cu20 begins. Part of the Cu2O is then converted to CuO, which in turn forms CuS04 through CuO?CuS04 as an intermediary. CuS04 and CuO'CuS04 decompose at 600° to 700° C to yield CuO and S03 (g) as final products. An overall mechanism is proposed for chemical reactions occurring at different interfaces of partially oxidized CuS pellets.

Jan 1, 1970

By D. G. Kesterkel

Low-melting thoriurnrbase binary alloys or metal solutions were prepared by two different techniques involving the electrolysis of ThO2 dissolved in fluoride melts. Experiments were performed at 950° to 1,250° C using electrolytes containing ThF4 and various alkali and alkaline earth fluorides. In the first method, electroreduction of ThO2 and deposition of thorium on a nickel or iron cathode formed a molten alloy that dripped off and collected on the bottom of the cell, or in a tungsten cup. An electrocodeposition technique was used to prepare thorium-base alloys or solutions containing nickel, iron, chromium, or manganese. Electrolytic reduction of the component metal oxides and simultaneous deposition of the two metals on a tungsten cathode yielded a liquid alloy product. Complementary experiments were performed on the fused fluoride electrowinning of dendritic thorium from Th02 at 1,075° to 1,200° C in which thorium crystals were recovered and arc-melted into buttons. Major contaminants were aluminum, carbon, copper, iron, oxygen, and silicon, totaling 0.2 percent.

Jan 1, 1966

By Albert J. Rambosek

The results obtained in a study of the stress conditions existing in a drill bit-point area and in the underlying rock, when the bit was in full but nonpenetrative contact with the rock, are presented. This investigation by the Bureau of Mines was the preliminary exploratory phase of a long-range program of research on rock drilling to establish criteria for the maximum economically feasible rate of rock penetration. The photoelastic technique of experimental stress analysis was the principal method used to obtain the data. Transparent models and transmitted light were employed to investigate patterns in drill-bit models and isotropic materials under the bit when subjected to a concentrated static load. Comparative stress data for anisotropic rock were obtained by the reflective photoelastic technique. Brittle lacquer and an extensometer were used obtain supplementary information wherever substantiating data were desired to check photoelastic results. The zone of maximum shear occurs along an arc near the contact face of the bit. The stress distribution pattern in an isotropic model rock near the area contacted by the bit was nearly a mirror image of that exhibited within a similar areal zone of the bit. The stress pattern in granodiorite specimens was similar, though not symmetric, to the pattern in the isotropic model rock. The asymmetry of the stress pattern in the granodiorite was attributed to the anisotropic characteristics of the constituent minerals of various sizes.

Jan 1, 1963

A revolutionary development in blasting materials has occurred in recent years. Ammonium nitrate, sensitized by the addition of a small percentage of No. (class) 2 diesel fuel or other suitable petroleum product, has been adopted as a low-cost, efficient blasting agent2 in a wide variety of mining, quarrying, and heavy construction operations. Moreover, the ready availability of the component supplies throughout the Nation, together with the ease of formulating them into effective blasting agents, has made it possible for the blaster himself to prepare the mixes at the site of use. Recently, most established explosives manufacturers have begun supplying premixed AN-FO (ammonium nitrate-fuel oil) or a comparable product to various mining operations. However, many individuals and small business establishments are marketing premixed products prepared in facilities that are often poorly constructed and poorly located. Although these blasting agents have partly or wholly displaced explosives such as dynamites in many applications, there are some blasting operations in which the fuel-sensitized ammonium nitrate agents do not appear to be well adapted. As long as the hazards they present are clearly understood and respected, ammonium nitrate-based blasting agents have important safety characteristics when prepared under competent factory control or field-mixed under equivalent close control. This publication attempts to summarize the knowledge of those hazards and to incorporate practical ways to cope with them.

Jan 1, 1963

By Lisa Steiner, Robin Burgess-Limerick

Working with or near underground coal mining equipment is hazardous because of the multiple sources of energy and adverse environmental conditions. Of the 4169 injuries reported to Coal Services during the three years to June 2005,447 were associated with continuous miners, 232 with LHD (load-haul- dump) vehicles, 140 with shuttle cars, and 140 with personnel transport - a total of 959, or 23% of all injuries reported during the period. An analysis of the injury narratives accompanying these injury claims highlights a number of opportunities for controlling injury risks. Using the frequency of reported injuries for the prioritisation of risk control strategies has limitations because of the tendency to underestimate the importance of relatively uncommon but potentially high consequence events. Injury reports also underestimate the contribution of risk factors such as whole body vibration, which have a long-term cumulative contribution to an elevated risk of injury. However, taking these limitations into consideration, the results of the injury narrative analysis suggests the following hazards as the highest priority for elimination or control: • handling continuous miner cable • strain while bolting • slipping off continuous miner platform • inadvertent or incorrect operation of bolting controls, and operation of controls while a person is in a position of danger • hitting potholes or other roadway abnormality • collisions while driving underground vehicles

By H. E. Hilliard

The Bureau of Mines investigated hydrometallurgical procedures for concentrating precious metals from a mechanically processed metal fraction of obsolete military electronic scrap. Feed material for the leaching procedures described in this report was the high-tension-separated metal concentrate obtained as a fraction from mechanically processing partially stripped electronic units. Initial pretreatment with a 20-wt-pct-NaOH solution solubilized most of the aluminum. After washing, the resulting residue was incinerated to destroy any organics attached to metal particles. The incinerated residue was leached with 20-vol-pct H2S04 solution using two methods, countercurrent pressure and ultrasonic-aided leaching to solubilize the base metals, predominantly copper. Silver was recovered from the base metal leach residue using 50-vol-pct HN03, and gold contaminated with several percent palladium was recovered from the silver leach residue using aqua regia. The impure silver and gold plus palladium products represent about 1.5 wt pct of the high-tension-separated metal concentrate. Included is a three-step process evaluation study of mechanical processing of general electronic scrap and two hydrometallurgical procedures for leaching high-tension-separated metallic concentrates obtained from the mechanical processing step. Process evaluation concluded that only mechanical processing is economically viable.

Jan 1, 1985

By B. K. Shibler

A highly flexible laboratory-scale fluidized-bed reactor was designed, constructed, and successfully operated continuously at temperatures up to 1,300° C during an investigation of thermal methods for decomposing gypsum. This report discusses briefly the many problems encountered in developing the 10-inch-diameter reactor and describes its design and construction in sufficient detail to enable other research organizations to build a comparable unit. The reactor consists of a 10-inch-inside-diameter vertical tube which can be varied from 6 to 10 feet high; it is formed from 2-and 3-foot sections of silicon carbide pipe. The tube is surrounded by a 3-inch heating space formed by an outer 4.5-inch-thick circular wall of insulating firebrick. A cone-shaped fluidizing chamber is bolted to the bottom of the reactor. Fluidizing gas enters through the bottom of the cone, and ore is introduced by means of a screw feeder connected to an inlet located just above the gas port. A silicon carbide overflow tube of 1.25-inch inside diameter extends upward into the reactor. The depth of the bed is controlled by substituting different lengths of overflow tube. Twin dust-recovery systems, each composed of a cyclone and Fiberglas filter, are attached to two gas outlets at the top of the reactor tube. The reactor is designed for research on both exothermic and highly endothermic reactions. It can be fired externally by means of four natural gas burners that jet tangentially into the annular space at the base of the reactor. Alternatively, it can be fired internally, using a mixture of air or oxygen and natural gas as the fluidizing medium. A separate instrument panel contains flowmeters, manometers, an automatic program controller, and a multiple-point recorder for printing a record of the temperatures measured by thermocouples located at critical points in the reactor.

Jan 1, 1963

By L. B. Berger

Each winter brings its toll of deaths and serious accidents from the deadly gas, carbon monoxide. Newspapers carry warnings to the public of the dangers of this gas, and frequent now items retort the finding of persons dead or unconscious from the effects of carbon monoxide, yet these accidents continue. Either those warnings are not read, or they are unheeded by people who feel that "It can't happen to me." It can happen to you - carbon monoxide is no respecter of persons, as evidenced by items appearing daily in newspapers all over the country. Carbon monoxide has been a threat to human safety as long as man has used fire to keep himself warm and to cook his food. The burning of any fuel that contains carbon may produce carbon monoxide. This is true of solid fuels such as coal, coke, and wood; of liquid fuels such as oil, gasoline, and kerosene, and of gaseous fuels such as natural or manufactured gas. In the process of combustion the carbon in the fuel unites the chemically with tat oxygen of the air to form carbon dioxide (CO2), however, if the supply of air is not adequate, combustion is incomplete and carbon monoxide (CO) will be formed.

Jan 1, 1943

By BUREAU OF MINES

This paper is a revision of Reports of Investigations , Serial 2541 , which was published in November , 1923 , for the benefit of State mining inspectors , safety engineers of mining companies , and others interested in electrical safety inspection in mines . It presents the important points that should be watched by inspectors and briefly reviews the work of the Bureau of Mines in testing of electrical apparatus and equipment to determine their permissibility for use in gassy coal mines .

Jan 1, 1929

By L. F. Willmott

Pulverized high-volatile A bituminous coal was gasified with oxygen and superheated steam in a pressure-gasification pilot plant equipped for slurry feeding. The minimum ratio of water to pulverized coal that could be pumped satisfactorily as a slurry was about 1 to 1. Heating this slurry produced a suspension of coal in superheated steam having a steam-to-coal ratio greater than the 0.3 to 1 proportion that is considered optimum for pressure gasification of pulverized coal. A steam separator removed enough steam to provide ratios down to about 0.5 to 1, but a 0.3 to 1 ratio was not achieved. Gasification of Sewickley coal produced a synthesis gas containing about 36 percent H2, 46 percent CO, and 13 percent CO2, Gas output, gas composition, and coal and oxygen requirements were Virtually the same as for a pilot plant equipped for fluidized-coal feeding. Typical results from the slurry-fed plant at 300 psig were carbon gasified, 95 percent; coal requirement, 34 lb/M (thousand) std cu ft CO + H2 produced; oxygen requirement, 365 std cu ft/M std cu ft CO + H2 produced. The results showed that the two feeding methods are equally satisfactory from the standpoint of gasification. A choice between a fluidized-coal gasification process or a slurry gasification process depends on considerations relating to the coal-feeding phase itself, including capital and operating costs, manpower requirements, safety, and flexibility of operation.

Jan 1, 1962

By Verne S. Mutton, William A. Slivensky, Eric S. Weiss, Kenneth L. Cashdollar, Deepak R. Kohli

The National Institute for Occupational Safety and Health (NIOSH), Pittsburgh Research Laboratory, cooperated with Tecrete Industries Pty. Ltd. and BHP Australia Coal in a research program to evaluate the strength characteristics and air leakage of four seal and two stopping designs for use in underground coal mines. A fundamental safety research area for NIOSH is to eliminate the occurrence of coal mine explosions or to mitigate their effects. One approach to achieve this goal is to develop new and innovative seal designs that provide increased explosion isolation protection for the mining personnel against ignitions that originate from within the gob or. other worked-out areas of the mine Full-scale seals and stoppings were constructed in the Experimental Mine at Lake Lynn Laboratory near Fairchance, Fayette County, PA. They were ail--leakage tested, then subjected to a series of explosions with average pressure pulses ranging from 25 to 500 kPa (3.5 to 72 psi). Instrumentation measured seal displacement and acceleration as a function of time, providing data to assist in the development of numerical models 1'01- future seal design. All three seals designed with Meshblock wire forlnwo~-k ant1 a lnonolithic shotcrete core withstood the first explosion test, which generated an avcr-age rnaximu~n pressure of - 140 kPa (-20 psi) while maintaining acceptable air leakage rates. These seals I-anged from 175 to 325 mm thick. They included a 2.7-m-high by 325-mm-thick seal that was tesled 27 hr after completion against this - 140-kPa explosion pressure, a special requirement of the test program. This seal survived explosions with pressure pulses up to 300 kPa (43 psi). The 2.3-m-high by 325-mm-thick Meshblock seal survived three explosion tests with overpressures up to 455 kPa (66 psi) and satisfied the air leakage criteria. A I ,200-mm-thick plug seal was constructed of two Gunmesh formwork walls in-filled with shotcrete and a 3,450-kPa (500-psi) strength Aquablend core. This plug seal survived three explosions with pressure pulses ranging 11-om 150 lo 430 kPa (-22 to 62.5 psi) with no measurable postexplosion air leakage. Two Gunmesh stoppings with thicknesses 01' 40 and 75 inln withstood explosion overpressures of 23 and 115 kPa, respectively. Anchoring all seal and stopping designs into the roof, ribs, and floor with steel "rootbolts" provided very effective boundary constraint that is critical to the performanceofstructures subject to explosion overpressures.

Jan 8, 1999

By S. D. Sanders

Goals of the Bureau of Mines include utilizing readily available minerals as substitutes for scarce mineral commodities and minimizing occupational hazards associated with mineral processing occupations. Therefore, the Tuscaloosa Research Center investigated using rapid-set cement as a suitable molding sand binder for small ferrous castings; currently petroleum-based binders are used. Substitution of a rapid-set cement would eliminate organic vapors associated with the petroleum-based binders; these vapors constitute occupational hazards and environmental pollutants. A binder containing 60 percent white portland cement (WPC) and 40 percent calcium aluminate (CA) would be an acceptable and economic substitute for petroleum-based binders where the foundry requirements are compatible with its limitations. It produced a set time and a pattern strip time of less than 1 hour. Cement, sand, and water mixtures developed compressive strengths from about 40 to 75 psi after 2 hours and from 120 to 130 psi after 24 hours. Tensile strengths of 18 to 22 psi were obtained after 2 hours, increasing to 30 to 35 psi after 24 hours. The addition of about 1 percent polyphosphate to the sand-cement-water mixture doubled the compressive strength and increased the tensile strength about 50 percent after 4 hours, but also increased the set time from 30 minutes to 1 to 1-1/2 hours. Po1yvinylacetate (PVA) resin latex additions resulted in rapid strength development. When castings were poured into the cement-bonded molds, the surface finish was fair to good on gray iron castings, but some areas of burn-on were present on steel castings. Using a graphite wash on the cement-bonded molds produced good surfaces on gray iron castings.

Jan 1, 1979

By Nick Derick

The continued growth of steel production in the Western States is contingent upon the development of new iron ore sources. Recent development of economical techniques for concentrating and agglomerating taconites has focused attention on the low-grade magnetite deposits near Atlantic City, Wyo., as potentially important sources of iron ore for blast furnace smelting. Therefore, the Federal Bureau of Mines has made comparative evaluations of blast furnace burdens that incorporate pellets produced from Atlantic City concentrates. The Bureau also has evaluated the relative effect of Utah coke on blast furnace performance, using a high-quality Eastern coke as a basis for comparison. This work was done in the Bureau's experimental blast furnace at Bruceton, Pa. Tests determined the maximum wind rate that could be used while a continuous stock movement was maintained in the furnace. The furnace was operated at wind rates ranging from 800 to 1,400 std. c.f.m., them maximum limit of the blowers for the 1.75 in.-diameter tuyeres used. Using a normal Utah ore burden and Utah coke, the furnace went into a tight hanging condition with a wind rate above 950 std, c.f.m. Using the experimental pellet burden again with Utah coke, the wind rate could be increased to 1,000 std, c.f.m. and probably to 1,050 std. c.f.m, before tight hanging occurs. This represents an increase of 5 to 10 pct. in the wind rate. The experimental results indicate an accompanying increase of iron production, as much as 8 pct.

Jan 1, 1961

By Barry Beith

This report details a study which was designed to assess the effect of retroreflective material on detection and form recognition of workers in the mining environment. Further, the study attempted to determine an optimal configuration of retroreflective material with respect to amount and placement on the body to facilitate detection and form recognition. The study involved a one-fifth scale simulation of the perceptual task found in the underground low seam coal mine. Four different configurations of reflective material were presented in various body positions, common to low coal miners, at three different locations in the visual field, i.e., 10, 25, and 45 degrees from focal line-of-sight. All reflective configurations significantly improve detection and form recognition over configuration (cap only) worn by miners. As the amount of reflective material increased, accuracy also tended to increase. Based on the configurations investigated by this study, the Armband configuration (i.e., refectorized armbands, belt, self-rescuer and battery pack) was determined to be optimum. It is recommended that an actual field evaluation be made using the Armband configuration to establish if simulator results are generalizable to the underground mining environment.

Jan 1, 1980

By Thomas M. Barczak

Longwall roof behavior is characterized by strata displacements in both the face-to-waste (horizontal) and roof-to-f1oor (vertical) direc-tions. The roof support structure provides resistance to this motion by translation of these displacements into vertical and horizontal support loading. Observations indicate that the shield reacts with both a vertical and horizontal force to uniaxial convergence (displacement). However, there are different magnitudes depending on whether the displacement is vertical or horizontal. This makes it possible to use supports as monitors of strata activity and loading. The Bureau of Mines examined this behavior using a linear elastic model of the support structure with two degrees of freedom. Vertical and horizontal load reactions were related to associated displacement actions of the strata. This was done by determining the stiffness of the shield under controlled vertical and horizontal displacement motions in the Bureau's mine roof simulator. This report provides example predictions of strata convergence and isolation of horizontal support loading due to vertical roof convergence using the linear elastic shield model. The report also examines efforts to determine strata behavior by direct measurement of support displacement.

Jan 1, 1987

By Donald O. Rausch, Robert H. Merrill, David W. Wisecarver, S. Jackson Hubbard

Results are reported for stress - relief borehole - deformation measurements made in three underground openings near open - pit mines in the Ruth mining district , Nevada . A total of 134 deformation measurements were made in 8 boreholes . These measurements determined the regional stresses in the horizons above , below, and at the elevation of nearby open - pit mine floors ; knowledge of these stress conditions is considered essential information relative to certain aspects in the designing of stable pit slopes . The determinations indicate that the stresses in the district are due to the gravitational load of the overburden in a confined stress field .

Jan 1, 1964

The Bureau of Mines conducted a field study to assess the performance of various chain pillar configurations in terms of gate road entry sta-bility. Vibrating wire stressmeters (VWS's) were installed in four consecutive gate road chain pillars. Field data collected during panel retreat were analyzed to gain a better understanding of the mechanics of vertical load redistribution in gate road chain pillars as it relates to ground control problems. Several different pillar configurations were investigated including abutment-yield and yield-abutment-yield designs. VWS data indicate that average pillar loads were lower and appeared abutment-yield pillar arrangement was utilized. port the occurrence of severe roof and pillar to stabilize when an Data analyses also supdeterioration that was visually observed in the tailgate entries during panel extraction.

Jan 1, 1988

By C. B. Daellenbach

A prototype particulate size analyzer system was developed that would rapidly determine size distributions of homogeneous and two-mineral materials in the 74-micrometer (200-mesh) to 7-micrometer size range. The system sizes particles in a series of hydrocyclone elutriation steps and senses the weight of the five sized fractions by nuclear attenuation techniques. Size distribution of materials was determined from experimentally developed mathematical relationships that existed between particulate weight and the measured transmittance of gamma rays from an Americium-241 source. In the developmental phases, size distributions of three minerals (quartz, magnetite, and hematite) and a laboratory prepared two-mineral mixture of quartz and magnetite were accurately determined by the prototype system. In later stages of the investigation, semiconcentrates, an intermediate magnetic product from a taconite plant, were evaluated. Using 25-gram feed samples of this industrial material, the analyzer system was found to predict weight percentages for individual size fractions with an accuracy of ±0.85 percent or better at a 95-percent confidence level.

Jan 1, 1974

By Roy E. Peterson

The Bureau of Mines conducted an investigation to produce metallized pellets from domestic iron ore superconcentrates using lignite and subbituminous coal as reductants. Feed materials for the metallizing process consisted of commercially indurated iron oxide pellets and green pellets prepared from upgraded domestic concentrates with graphite or limestone as internal additives. Durability of the green pellets during metallization was investigated in tests conducted in a 7-inch-ID rotating drum furnace. Test results indicated that the major cause of pellet disintegration with the concentrates used was the tumbling action during reduction rather than forces generated within the pellets. In larger scale tests made in a 34-inch-ID by 35-foot-long kiln, the previously indurated pellets were metallized with lignite at 1,030° C with little disintegration. A 96-percent level of metallization was obtained in pellets having an average compressive strength of 420 lb. In subsequent, similar tests using green pellets containing graphite or limestone, pellet disintegration was more severe, with 10 to 40 percent of the feed being lost as dust. The surviving pellets had metallizations ranging from 88.3 to 94.4 percent and compressive strengths ranging from 60 to 68 lb.

Jan 1, 1976

By Arne Landsberg

Accessory metals, although valuable resources, present possible environmental concern in the smelting of base metals. The Bureau of Mines, U.S. Department of the Interior, has undertaken research to define the chemistry involving these metals. Arsenic in copper smelting is the first to be investigated. Roasting, the first step in many copper smelters, was chosen for initial investigation because of the potential for arsenic removal in this primary process. Simple, static-bed, vaporization experiments were devised to obtain the data in this study. Ancillary transpiration and mass spectrometry were also used to delineate conditions necessary for arsenic volatilization from a roaster feed. For nearly complete arsenic removal, a temperature of 650°-700° C, a reducing atmosphere including carbon monoxide, and a source of sulfur were found to be essential.

Jan 1, 1980