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By R. N. Johnson

This report is a summary of the work performed for the Bureau of Mines to evaluate the feasibility and desirability of a movable in-pit crusher combined with conveyors to substantially reduce or eliminate truck or train haulage in large open-pit non-fuel mineral mines. The report includes an introduction and summary of previous work, an analysis of movable crusher system components, a description of the selected system, a review of possible movable crusher system applications, and finally requirements for future work to bring about the general availability of such systems. It was clear from the program that there is a real need for movable in-pit crushers.

Jan 1, 1982

By A. C. Fieldner

"Decline of the Beehive Coke OvenTwenty years ago a favorite theme of the crusader for fuel conservation was the enormous waste of valuable by-products incurred in the manufacture of blast-furnace coke in beehive ovens. Indeed, there was good reason for arousing the national conscience to this needless' loss of an irreplaceable mineral resource. In 1910, 83 per cent of the coke production was made in beehive ovens, from which surplus gas, tar, light oil, and ammonia, aggregating in value (at 1910 prices) 40 million dollars annually, were discharged into the atmosphere.In 1929, proportions were reversed and 90 per cent of the production was made in by-product ovens. The average value of by-products obtained in the production of 1 ton of coke in 1929 was $3.60, as compared with $1.16 in 1910, although the value of a ton of coke had increased only from $3.47 to $4.80. As shown in Figure 1,1 the production of by-product coke progressed rather slowly until 1915. War needs suddenly expanded the demand for coke and the by-products benzol and toluol for the manufacture of explosives. Except during the depression of 1921, this accelerating rate of production was maintained up to 1929, largely at the expense of beehive plants. The 1929 production of 60 million tons of coke will probably remain a record-breaking figure for several years. The developments which are now in progress in long-distance transmission of rural gas and in the utilization of volatile petroleum products and refinery gases for augmenting, city gas supplies may retard an other- wise accelerating demand for coke and coke-oven gas for domestic and industrial heating, Trends in Value of By-ProductsThe increasing value of by-products in comparison to the value of coke is shown in Figure 2. In 1913, the average value of by-product coke was $3.38, the value of the by-products per ton of coke was $1.41, and the cost of coal per ton of coke was $3,27, In 1929 not shown in figure) the value of the coke had risen to $4.80 per ton, the value of the by-products to $3.60, and the cost of coal per ton of coke to $5.07. The by-product values in were 155 per cent higher than in 1913, although the coke value had increased only 25 per And the cost of the coal 55 per cent. Actually the increase or the total value of coke plus by-products in this period was very little more than the increase in the coat of the coal, being 55per cent for coal and 60 per cent for coke plus by-products."

Mar 1, 1931

By Kung-Lee Wang

This report describes the linkage of all mining sectors with all other manufacturing, services, and final demand sectors of the U.S. economy. Besides being a basic data source, it provides a framework for aggregate economic impact analysis with respect to the mining industries. The framework is an open-static input-output model specifying 48 mining industries as classified in the Standard Industrial Classification Manual for all mining activities and 76 nonmining industries which collectively exhaust, all economic activities. The 124-sector model used in this report is an expansion of the preliminary 82-industry aggregation estimates made by the Department of Commerce. In the expanded model, 48 ruining industries are substituted for the original 6. The methodology used to ascertain the industry-by-industry procurement cost estimates and product ion flows necessary to the construction and expansion of the basic 82-sector model included personal interviews, case studies of specific mining activity analysis, and published and unpublished data from the Bureau of Mines and the Census of Mineral Industries, The end products of this study are two tables arranged to show the direct purchases necessary for each industry to support the level of economic activity and the total purchases generated in each industry throughout the economy by each $1 of aggregate economic demand in 1958. The tables may he used for economic impact studies and market analysis by firms engaged in or closely associated with the mining industries. Some illustrations of their usages are presented.

Jan 1, 1967

By J. D. Davis

THIS-report gives results of in investigation of the carbonizing properties of 18 coals, including 2 from Alaska, 12 from British Columbia, 3 from Washington, and 1 from Utah. Each coal was carbonized in the standard 13-inch Bureau of Mines-American Gas Association (BM-AGA) retort at 900° C. Plastic properties were determined by the Gieseler and Davis methods, and agglutinating and free-swelling properties were determined by standard methods. Expanding properties were measured in the Bureau of Mines sole-heated oven. From the results of the tests on these single coals, three coals from the Crowsnest area in British Columbia, representing Elk River Nos. 4, 9, and 10, were selected for blending with the Utah coal, which was from the Lower Sunnyside bed, Horse Canyon mine, Emery County. Lower Sunnyside also was blended with Wilkeson -Nos. 2 and 3 (Washington) coals, Pocahontas No. 3 from McDowell County, W. Va., and the Oklahoma low-volatile coal used in the blend carbonized at, the Provo, (Utah) coke plant at the time this investigation was started. Most of the blends contained 3 percent hard pitch, which is the proportion used at the Provo plant. The blends were also carbonized in 13-inch BM AGA retorts at 900° C. High-volatile B coal from the No. 3 bed, Evan-Jones mine, Lower Matanuska, Valley, Alaska, yielded poorly fused coke or char. M-bed coal from the Chickaloon mine, Upper Matanuska. Valley, Alaska, ranked as medium-volatile bituminous and coked strongly. It expanded 39.6 percent in the sole-heated oven at a. charge density of 55.5 pounds per cubic foot..

Jan 1, 1952

By G. Boehler

The purpose of this program is to demonstrate the feasibility and practicality of noise control for secondary and tertiary crushers in surface non-coal mining plants and mills. It is a part of the broad Bureau of Mines program to reduce noise in mines to levels mandated in the Coal Mine Health and Safety Act. Utilizing the results of previous contractual research efforts in which noise levels of secondary crushers had been measured, two noise enclosures were designed and evaluated for the REXNORD Symons 7-ft diameter secondary and tertiary crushers installed at the Jackson County Iron Company, in Black River Falls, Wisconsin. The first enclosure had a circular shape following closely that of the crusher and was built up entirely of quick-release panels which can be handled by the crusher operator alone. The second enclosure was octogonal in shape and can be rapidly removed, partially or totally using an overhead crane. Both enclosures fully satisfy the noise reduction objectives and permit daily and long-term maintenance of the crushers. Cost analyses show the cost of the enclosure to be less than 10 per cent of the cost of the crusher, the cost of the octagonal enclosure being estimated at only 60 percent of that of the circular one, e. g. $15,000 against $25,000. It is concluded that the octagonal enclosure best meets the needs of the Jackson County Mining Company and it is recommended that an experimental enclosure be built at the earliest possible time, as proof-of-concept.

Jan 1, 1977

By E. V. Deshayes, W. E. Young

"INTRODUCTION The Camp Bird mine was investigated by Bureau of Mines engineers 3/ September 22 and 24, 1942, and April 29 and 30, 1944. In a subsequent report and supplement, it was recommended that core drilling be done below the 14th. level to determine if commercial ore existed at greater depths, and particularly if ore existed in the vein or adjacent thereto where it passes into the sedimentary formations estimated to underlie the volcanics approximately 400 feet below the 14th level.Seven diamond-drill holes aggregating 3,956 feet were drilled. Four of these holes were under the Hematite ore body and three were under the Big Discovery ore body. Two holes under, the Hematite ore body wore directed at angles but little steeper than the angle of dip of the vein and penetrated the sedimentaries beneath the volcanics close to the vein. Enough low-grade ore was found at the base of the Telluride conglomerate to indicate the presence of a large body of low-grade zinc sulfide ore. Two holes were directed to crosscut the vein at a depth of approximately 125 feet below the 14th level. No commercial ore was cut, but the vein showed the average width and same general characteristics as at the 14th level. One hole under the Big Discovery ore body was directed to crosscut the vein and test the base of the Telluride conglomerate in the footwall block. No commercial ore was found in either the vein or the sedimentary horizon. One hole was directed to test the base of the Telluride conglomerate in close proximity to the vein in the hanging-wall block. This hole was lost approximately 100 feet short of its objective, and a third hole was drilled to accomplish this same thing. The third hole was stopped approximately 50 feet short of its objective when failure of equipment caused a recess of the"

May 1, 1948

By Edmund S. Leaver, R. S. Dean, T. L. Joseph

The metallurgy of manganese has developed along the lines of iron metal¬ lurgy. Enough high-grade ore has Been available so that by reduction with carbon it could be turned into an iron-ma.nga.nese alloy and a slag containing some 9 to 15 percent manganese. More siliceous ores have been smelted in the blast furnace to form iron-silicon-manganese alloys called spiegel. When lower-grade ores came in for serious consideration, which lias only been since l°l4, two types of processes received the most consideration — hydrometallurgical processes to produce a concentrate which could be smelted like the higher-grade ore and processes involving concentration of the manga¬ nese from manganiferous iron ores by preferential reduction of the iron (184)1. Special chapters in this bulletin are devoted to the production of ferro¬ manganese from ore, the hydrometallurgy cf manganese, and the Bureau of Mines modification of the preferential reduction process. Other methods of producing manganese alloys from low-grade or refractory ores have been suggested and may find future application. Manganese has a very high affinity for sulphur and is particularly adaptable to concentration by matte smelting. According to Betts (26), manganese silicate may be smelted with pyrite to give manganese sulphide and iron silicate. This method would be applicable to concentration of either the silicate or carbonate ores. The sulphide, once obtained, could be roasted to oxide and reduced in the usual way. Another possibility for the production of manganese from silicate ores involves their reduction by silicon or manganese silicides. Swedish Patent 52290, February 25, 1925. covers the reduction of a slag rich in manganese by silicon-manganese alloy containing more than 10 percent silicon, Joseph H. Brennan (38.) describes the concentration of manganese iron ores by partial reduction with silicon. Beckett (7,4,19) describes the reduction of manganese dioxide with a manganese silicide for the production of standard ferromanganese. Beckett gives as a typical alloy, manganese 64.4, silicon 24.6, and as a typi¬ cal ore, 5S.5O manganese as MnO^. The product of the reaction between these two is 80.11 percent manganese and 1.22 percent silicon.

May 1, 1934

Research 84 highlights significant studies conducted during the past fiscal year at Bureau facilities and offices. Readers who want more information about the projects and studies summarized here can contact the researchers whose names and locations appear with each summary. General information on Bureau of Mines programs is available from the Office of Technical Information, 2401 E Street, NW., Washington, DC 20241. A listing of principal officials, a location map of field facilities, and a selected bibliography of publications and patents issued on Bureau developments during the past 3 years are provided.

Jan 1, 1984

By G. W. Grove, E. E. Quenon

"INTRODUCTION During September, October, and November 1946 the Safety Division of the Bureau of Mines, off' the United States Department of the Interior, Pittsburgh, Pa., tested four new types of self-contained breathing apparatus and approved them in accordance with Schedule 13C. Approval was granted with the proviso that certain specifications outlined on the approval plate be made fully effective, and with the understanding that established safe practices in training in the care and use of self-contained breathing apparatus are of major importance.The excellent records made during the past 30 years in the safe use of self-contained breathing apparatus, some of which required the almost continuous wearing of apparatus during several hours daily for days, weeks, or months, may be attributed largely to the Bureau's system of rescue organizations, selection of physically fit rescue workers, effective training, and educational work done in rescue and recovery operations during fires or following disasters and in the care and use of self-contained breathing apparatus. Loss of life during wearing of breathing apparatus was due almost invariably to poorly assembled or otherwise defective apparatus, poor physical condition of the wearer, or insufficient training or some incorrect procedure.The newly developed breathing apparatus are of much simpler design than the conventional type used for the past several years; however, it is just as important to select rescue crews carefully and to train them properly in the care, use, and limitations of the new types of apparatus as for the older long-established types, if anything like safety is to be achieved in using them. The Bureau of Mines considers that 1/2-hour and 3/4-hour self-contained breathing apparatus should be used only as auxiliary equipment in mine rescue and recovery work, and their capabilities and limitations should be well understood by those who wear them."

Jul 1, 1947

By H. A. Doerner

"The following report is submitted, in compliance with the request made by the Honorable W. H. Sproule, Chairman of the Committee on Mines and Mining, to the Director of the United States Bureau of Mines, that the bureau investigate the most modern processes for the production of radium from its ores. A thorough search of technical publications and patent office files was made. Outstanding authorities on the subject as well as persons claiming novel or secret methods were interviewed.Unlike most other elements, it is not possible for radium to occur naturally in a pure or concentrated form. This is because radium is one of a series of unstable elements which, by a constant, spontaneous, atomic disintegration, change from one element to the next in the series. Uranium is the ""grandparent"" of radium. The rates at which radium atoms are ""born"" and ""die"" are so related that only one part of radium can exist in equilibrium with three million parts of uranium. Consequently radium is only found associated with uranium minerals, and the ratio of radium to uranium is never more than one to three million. Since uranium is a rather rare element, the scarcity of radium is almost beyond comprehension. Nevertheless minute traces of radium can be detected in nearly all rocks.The carnotite ores of Colorado and Utah were the chief source of radium for many years.In the fall of 1922 news of the very rich deposits of radium ore discovered in the Belgian Congo caused most complete cessation of domestic production. The Congo ore contains pitchblende and a number of alteration products, including the new minerals bequerelite, curite, krasolite, stasite, and dewindite. Reports indicate that a considerable amount of ore containing over 50 per cent uranium oxide has been produced. It seemed certain that radium could be extracted from the Conga ore at a much lower cost than from the relatively low-grade carnotite; and in order to preserve their elaborate marketing organizations, the larger American producers made agreements with the Belgian syndicate to market the foreign product in this country. The retail price of radium has been held at $70 per milligram, but large orders are filled as low as $50. Extraction of radium from carnotite by the usual methods does not appear to be profitable at that price with one exception, all American firms ceased production after their accumulated stocks of ore had been treated. The United States Radium Co., which continued to treat carnotite for several years, finally shut down its plant."

Dec 1, 1930

By A. C. Fieldner

ONE of the important functions of the Bureau of Mines is the, analysis of coal from every coal-mining State and Alaska. These analyses are being published for use of Government officials and the public. In connection with analytical data showing composition and quality of coals of the States, consumers, Producers, and the general public will be interested in a brief description of the geologic structure of the coal basins, typical mining conditions in the several districts, and the principal economic data of the industry. These publications have therefore heel) designed to include such features to present concisely the principal facts regarding occurrence, reserves, duality, characteristics, production, and uses of coals of each producing State.

Jan 1, 1952

By C. A. Geffen-Fowler

This report, sponsored by the Bureau of Mines, presents the results of an examination of the safety of the Blind Shaft Borer (BSB) shaft sinking system and an alternative modified BSB design concept in comparison to conventional shaft sinking technology. Detailed study of the two systems was also performed to identify and recommend design changes for optimum safety conditions. A comparison of the BSB systems with conventional shaft sinking was made on the basis of relative risk levels. Risk incorporates both the frequency and the potential consequence of accidents. A safety evaluation of the component operations of the two BSB systems was performed using a Failure Modes and Effects Analysis (FMEA) methodology. The results of this analysis show generally that both BSB systems are safer than conventional shaft sinking. The potential risk of conventional shaft Sinking operations could be reduced by over 30%, on the average with the use of the original BSB system, and by an average of about 10% with the modified BSB. Design change recommendations to further improve the safety of these systems include a better fire suppression system, improved man haulage systems and more compact hydraulics. An operational safety manual was also developed for the modified BSB system.

Jan 1, 1981

By D. Harrington

A uniform hoisting-signal code for mines hoisting from more than one level, if adopted by all mining States, would be beneficial to employees and owners alike and should largely reduce the number of hoisting accidents. Misunderstood hoisting signals cause many shaft accidents involving injuries to men, damage to equipment, and loss of production from the resultant delay. Many of the metal-mining States have adopted codes for hoisting that are effective within the borders of that State but usually entirely different from the signal code, if any, in use in an adjoining State. For many years safety engineers have recognized this lack of uniformity as a distinct hazard, but a uniform code has never been adopted by the States or by the mining industry in those States that have not incorporated signal codes in their mining laws or mining regulations.

Jan 1, 1944

By David Bendersky

The principal objectives of this study are to: (1) survey electrical practices in metal and non-metal mines, (2) survey electrical practices in metal and non-metal mills, (3) clarify the federal regulations governing electrical practices in metal and non-metal mines/mills, (4) analyze electrical accidents, and (5) make recommendations aimed at improvement of the safety of electrical practices in metal and non-metal mines. Information was obtained from literature searches, accident reports, visits to 27 mines and 12 mills, and discussions with knowledgeable industry and government people. The various electrical power systems and practices at the mines and mills visited are described. Similarities and differences based on the type of mining and the minerals being mined or milled are presented. The federal regulations governing metal/non-metal mine/mill electrical practices (Code of Federal Regulations, Title 30, Sections 55.12, 56.12, and 57.12) are presented and discussed. Explanations of each regulation are provided in an appendix. The attitudes of mine/mill operators towards the federal regulations are described. An analysis of the electrical accidents in metal/non-metal mines and mills during the period 1972-1978 is presented. Recommendations, including specific research and development activities, aimed at improvement of electrical safety in metal/non-metal mines are submitted.

Jan 1, 1980

By Clyde L. Holmberg, Paul Zinner

"INTRODUCTION In view of the large tonnage of low-grade iron ore and iron-bearing material known to exist at the western limits of the Gogebic range, the Bureau of Mines undertook an investigation of the area for the purpose of evaluating the iron-bearing formations as sources of iron for possible future utilization.After 6o years of exploration an, development on the Gogebic range, the area investigated by the Bureau represents the known western limit of direct-shipping ore mined from operations on the Gogebic range.An area about 2 miles in length between the villages of Pence and Iron Bolt in Iron County, Vic., was selected for investigation, and trenches wore excavated through the overburden and fully across the iron-bearing formation to obtain 108 bulk samples for beneficiation tests. Exhaustive tests involving gravity and flotation methods, magnetic separation, and magnetizing roasts followed by magnetic separation were conducted on the samples to determine the ammability of the individual formations and the entire iron-bearing zone to beneficiation.Empirical data on the character and mineral content of the formations arc tabulated herein, as well as the results of the beneficiation tests."

Dec 1, 1947

On June 20, 1972, Ocean Energy was awarded Contract No. H0220055, entitled Portable Task Luminaire System Development. Initially, this was a 12 month program consisting of three phases: Phase I -- Design of the Luminaire System and Battery Chargers, Phase II -- Fabrication of Prototype Units, Phase III -- Fabrication of Production Prototype Units and Battery Chargers. In addition to developing the Portable Task Luminaire System, however, this contract was amended a number of times in the course of the program to include the development of a Low Coal Portable Task Luminaire, a Rib Mounted Luminaire System, and a Machine Mounted Luminaire System, all based upon the same high frequency fluorescent lighting and safety technologies involved in the Portable Task Luminaire. This report covers the activities of this program as amended, and includes the development and fabrication of all of the systems. This report constitutes the final fulfillment of the contract.

Jan 1, 1974

By Wilson Blake

Rock preconditioning in advance of mining was shown to be an effective means of rock-burst control based on the results of a field demonstration carried out on the 7700 level of the Hecla Mining Company's Star mine. Mining through the preconditioned zone was characterized by greatly reduced rates of released seismic energy and no bumping or rock bursting occurred within the preconditioned zone. Mining above the preconditioned zone was characterized by greatly increased rates of released seismic energy and rock bursting, particularly where the vein became very narrow in waste zones. This increased incidence of rock bursting points out the need for stope preconditioning to be carried out on an entire stope block basis. The data obtained from the monitoring of the mining above the preconditioned zone on the 7700 level will be extremely useful in evaluating any future stope block preconditioning experiments on the lower levels or the Star mine.

Jan 1, 1980

By E. G. Baglin

As part of an effort to decrease U.S. dependence on imports of critical and strategic metals, the Bureau of Mines investigated three leaching methods for extracting the base metals and recovering platinum-group metals (PGM) from matte prepared from Stillwater Complex flotation concentrates. Because of a limited supply of natural material, synthetic matte of composition similar to matte prepared from natural concentrates was used to devise the extraction sequences. The validity of the sequences was verified with matte prepared from Stillwater concentrates. In two-stage matte leaching, first-stage H2S04 leaching extracted 99 pct of the nickel and iron from the matte but negligible amounts of copper and PGM. Second-stage oxidative leaching with Fe2(S04)3 or FeC13 solubilized more than 98 pct of the copper and no precious metals. Sequential leaching, in which acid and oxidizing lixiviants were added sequentially to the matte without an intervening filtration step, extracted 99 pct of the Fe, Ni, and Cu. A roasting-leaching technique, in which the residue from first-stage leaching was roasted between 360° and 500° C before a second leaching with H2S04, solubilized 98 pct of the copper. The three leaching methods yielded high-grade PGM residues containing more than 98 pct of the PGM in the matte.

Jan 1, 1982

By L. McWilliams, L. D. Patts, J. D. Noll, S. E. Mischler

Elemental carbon (EC) is currently used as a surrogate for diesel particulate matter (DPM) in underground mines since it can be accurately measured at low concentrations and diesels are the only source of submicrometer EC in underground mines. A disadvantage of using EC as a surrogate for DPM is that the fraction of EC in DPM is a function of various engine parameters and fuel formulations, etc. In order to evaluate how EC predicts DPM in the underground mining atmosphere, measurements of total carbon (TC; representing over 80% of the DPM) and EC were taken away from potential interferences in four underground metal/non-metal mines during actual production. In a controlled atmosphere, DPM mass, TC, and EC measurements were also collected while several different types of vehicles simulated production with and without different types of control technologies. When diesel particulate filters (DPFs) were not used, both studies showed that EC could be used to predict DPM mass or TC. The variability of the data started to increase at TC concentrations below 230, µg/m3 and was high (>+20%) at TC concentrations below 160 µg/m3, probably due to the problem with sampling organic carbon (OC) at these concentrations. It was also discovered that when certain DPFs were used, the relationship between DPM and EC changed at lower DPM concentrations.

By Frank Cook

In this two-year study, an evaluation of mining and reclamation practices at 159 randomly sampled surface coal mines in the United States was conducted. It is concluded that reclamation practices in most of the 22 coal-producing states were adequate during 1975, but that improvement in reclamation performance was desirable in the acid area of the central U. S. and in mountainous southwestern Virginia. Productivity improvements should result from research to determine efficient or optimal operating procedures for dragline stripping of single and multiple seams, surface mining of lignite, multicut and multiseam haulback mining on steep slopes, mountaintop removal, and surface mining in swampy or deeply glaciated areas. Specific candidate research projects are discussed in this report.

Jan 1, 1976