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By Adam K. Smith

Over-exposure to noise remains a widespread, serious health hazard in the U.S. mining industry despite 25 years of regulation. Most other categories of illnesses and injuries associated with mining have improved, with the exception of hearing loss. In order to reduce cases of Noise Induced Hearing Loss (NIHL) in the mining industry, retrofit acoustic treatments and controls are being developed to subdue noise at the source. The Mine Safety and Health Administration (MSHA) coal noise sample data collected from 2000 to 2005 has determined that continuous mining machines rank first among all mining equipment whose operators exceed 100% noise dosage. The continuous mining machine conveyor, used to move coal from the cutting face to the rear of the machine, has been identified as a dominant noise source. A dual sprocket conveyor chain was tested as a potential solution. Sound power level measurements conducted at the Pittsburgh Research Laboratory (PRL) accredited reverberation chamber showed a 3 dB reduction in the A-weighted sound power level when the dual sprocket chain was implemented. Underground results show an 8-hour Time Weighted Average (TWA8 hrs) reduction a 3 dB for continuous mining machine operators. Utilizing this newly developed noise control, along with previously proven controls, provides continuous mining machine operators an opportunity to be within the MSHA-Permissible Exposure Limit (MSHA-PEL).

Jan 1, 2009

By F. W. Hoertel

Near-optimum parameters were determined by the Bureau of Mines for vapor deposition of rhenium on heated copper substrates by hydrogen reduction of rhenium hexafluoride (ReF6). High-purity deposits of nearly 90-percent theo¬retical density were obtained with the reaction chamber at 250° C, with an H2 to ReF6 volume ratio of 25 to 1, and with an ReF6 flow rate of 5 grams per hour. Some rhenium deposited as a loose, black powder. When the established near-optimum parameters were carefully followed, this could be minimized but never completely avoided. Varying the reaction chamber pressure, both above and below atmospheric, yielded excessive quantities of rhenium powder. Deposition efficiencies, based on only the coherent metal, ranged between 70 and 75 percent. Massive deposits contained only spectrographic traces of impurities. The average microhardness (Knoop, 100-gram load) of vapor-deposited rhenium was 907. Limited research on the deposition of rhenium-tungsten alloys by reduction of the mixed hexafluorides produced deposits in which linear composition gradients were pronounced; this nonhomogeneity was attributed to the wide variation in optimum hydrogen-reduction temperatures of the two hexafluorides (250° C for ReF6 and 550° C for WF6). Using deposition temperatures between 250° and 550° C did not eliminate the composition variations.

Jan 1, 1967

By D. I. Bleiwas

Bureau of Mines personnel evaluated the potential availability of nickel from 151 deposits in 18 market economy countries and selected 126 for detailed analyses. An evaluation was made of tonnage-cost relationships indicating the quantity of nickel available at various total costs of production expressed in dollars per pound nickel, including a 15-pct rate of return on the invested capital. The 126 deposits studied contain approximately 73 million metric tons (t) of nickel. An estimated 52 million t is available from laterite deposits, of which less than 2 pct could be produced at $3.50/lb Ni, about equal to the average published price of nickel in 1981. Approximately 21 million t of nickel is available from sulfide deposits, of which about 10.0 million t can be produced at $3.50/lb. Sensitivity studies performed for both laterite deposits and sulfide deposits indicate that the total cost of nickel from laterites is most sensitive to increases in energy costs, and that sulfides are most sensitive to increases in labor costs; sulfides are also sensitive to changes in byproduct revenues. In 1983 the Nickel Mountain mine in Oregon was the only U.S. producer, though development continued on the Gasquet property in California. Of the total 5.1 million t of recoverable nickel in the United States, about 20 pct is available at or below $3.50/lb.

Jan 1, 1984

By Thomas Fraser

About 24 per cent of our total production of bituminous coal is used in industrial power plants. As regards fuel conservation, therefore, the recovery of unburned fuel from furnace refuse presents interesting possibilities. Considerable attention has been given to this problem in the past, but because of the comparatively low initial cost of power plant fuel in the pre-war period little progress, has been made in this direction in the United States. Because of the higher price of coal in Europe more attention has there been given to the problem. In Germany a process has been developed for separating unburned coal in refuse by using an electromagnetic separator In the United States the use of mechanical stokers enabled low-priced screenings of high ash content to be used, so that even with relatively high percentages of combustible material remaining in the refuse, the loss in money is not excessive. If the price of screenings returns to the pre-war level around $1.00 per ton the process proposed here will probably not be especially interesting, except where the freight charges are very high. However, if the price of delivered coal continues high, such a process should result in considerable saving. The cost of continuous operation of such a refuse treating plant should not exceed 75 cents per ton of fuel recovered.

Jan 1, 1921

By Eugene Frey

"INTRODUCTION The Good Fortune mine was sampled by an engineer of the Bureau of Mines in June 1944. Project 984 was set up under the strategic minerals program to make old workings accessible for this sampling program. Actual operations commenced June 1, 1944, and were completed June 30, 1944.The deposit was visited and discussed briefly by Sidney H. Ball 3/ of the Federal Geological Survey in the summer of 1906 and by H. M. Chance 4/ several times from 1887 to 1900.LOCATION AND ACCESSIBILITYThe Good Fortune mine is situated in the Hartville mining district in Platte County, Wyo., approximately 9 miles northwest of the town of Guernsey. The property is about 100 miles north of Cheyenne, Wyo. (fig. 1).ACKNOWLEDGMENTSIn its program of exploration of mineral deposits, the Bureau of Mines has as its primary objective more effective utilization of our mineral resources to the end that they make the greatest possible contribution to national security and economy. It is the policy of the Bureau to publish the facts developed by each exploratory project as soon as practicable after its conclusion. The Mining Branch, Lowell B. Moon, chief, conducts preliminary examinations, performs the actual exploratory work, and prepares the final report. The Metal¬lurgical Branch, O. C. Ralston, chief, analyzes samples and performs beneficiation tests."

Aug 1, 1947

By J. A. Organiscak

In the United States, respirable coal mine dust exposures are limited to a 2 mg/m3 time weighted average for a working shift. If the silica content of the sample exceeds 5 percent, the 2 mg/m3 standard is reduced according to 10- (% silica) to limit silica dust exposures to 100 µg/m3. Examinations of dust sampling data collected by the federal coal mine inspectorate showed that roof bolter occupations continue to be at risk for overexposure to respirable silica dust. Testing at the Pittsburgh Research Laboratory of the National Institute for Occupational Safety and Health assessed the effectiveness of a canopy air curtain for controlling occupational exposures to respirable silica and coal dusts. Initial testing found that zones of higher velocity airflow shrank as distance beneath the canopy increased. This suggested that protection from occupational dust exposures would likely decrease as distance beneath the canopy increased. Further testing revealed that coal dust reduction efficiencies were most affected by changes in interference air velocity and, to a lesser extent, changes in canopy air quantity. However, respirable silica dust percentages under the canopy were not affected by such changes and, in fact, were not significantly different from silica percentages measured outside the canopy. This implied that the air curtain was equally effective on both respirable coal and respirable silica dust particles.

By J. H. Maysilles

The Bureau of Mines is conducting research on various technologies to recover alumina from domestic resources for feedstock to existing aluminum smelting capacity as a means to reduce dependence on imported bauxite, which represents 93 pct of U.S. aluminum requirements. One of the more promising technologies being investigated is the hydrochloric acid leaching of kaolinitic clay. In the hydrochloric acid leaching technology, alumina is recovered from iron-free aluminum chloride leach liquor and separated from impurity elements by sparging the liquor with HC1 gas to crystallize aluminum chloride hexahydrate (ACH). A large-scale crystallizer with a 336-gallon usable volume was constructed and operated to obtain engineering and design data for potential scale up and to demonstrate the ability of the technology to produce specification grade alumina. Test campaigns involving about 1,400 hours of operation were completed. ACH meeting all chemical purity requirements could not be produced by a single crystallization, but was produced by recrystallizing the product from the calcined kaolin clay leach liquor. Product crystals with a size distribution of more than 80 pct plus 100 mesh and 65 pct plus 65 mesh were made at a rate of 10 pounds of ACH/(hr)(ft3). The zirconium tube heat exchanger used to maintain constant process temperature operated with an over-all heat transfer coefficient of 420 to 500 BTU/(hr)(ft2)(°F).

Jan 1, 1981

By J. H. Maysilles

The Bureau of Mines is examining a variety of low-grade uranium ores because projections indicate that an appreciable percentage of future U.S. uranium production will be derived from resources containing 0.01 to 0.1 percent U308. One possible source is represented by a granitic material from Wyoming; the available samples contained 0.06 and 0.12 percent U308. Tests were conducted to explore the general leaching characteristics of this potential resource. The material responded to both acidic and alkaline leaching techniques. Conventional acid leaching extracted 93 percent of the uranium in 18 hours; the required acid addition was 50 to 100 pounds of H2S04 per ton of ore, and the oxidant addition was 3 pounds of NaCl03 per ton of ore. The acid consumption continues after maximum uranium recovery has been reached; this effect may complicate heap or in situ leaching with acidic solutions. Some variation in reagent requirements was noted between the two ore samples. Conventional carbonate leaching with strong solutions at 85° C extracted 94 percent of the uranium in 24 hours. These granitic materials also showed some response to dilute carbonate solutions, and the results suggest that the material may be chemically amenable to heap or in situ leaching with dilute carbonate solutions.

Jan 1, 1977

By John Durkin, Roy J. Greenfield

This report discusses the configuration and system deployment for the postdisaster surface seismic system for detecting and locating trapped miners. It analyzes the results of 15 field tests to define a signal model, background noise levels, and subarray performance. A waveform modeling procedure is described and compared with observed waveforms. The resulting similarity indicates that the major factors affecting the signal amplitude, waveform, and spectral character are understood. A model is presented which gives the signal amplitude as a function of source type, source depth, and horizontal off- set between source and receiver. Using this model a curve is presented which gives the range at which a signal will be detected for different signal and noise levels. Finally, and most important relative to the mission of the sys- tem, the ability of the system to detect signals on one or more subarrays is put into a probabilistic framework. For a strong source it is almost certain that a subarray directly over the source will detect the signal. After signal processing, it is highly likely that signals will he detected on sufficient subarrays to locate the trapped miner. Location errors have been found to be less than 100 ft in the majority of cases. Techniques have been used that can reduce the location errors to this level even when soil layer variation between subarrays is severe.

Jan 1, 1981

By Guy A. Johnson

The Bureau of Mines, through research and development contracts with the FMC Corp., has developed and tested two automatic fire sensing and suppression systems for large haulage vehicles. This work was undertaken to enhance driver safety, to lessen substantial property damage from fires on large trucks, and to increase the vehicle operator's productivity. One automatic truck fire protection system protects both the engine compartment and brake rid areas, while the second system is used in the engine compartment and fuel tank area. Both systems have redundant fire-sensing capabilities and manual override controls. Upon sensing flames and/or heat, the systems suppress the fire with pressurized, E-C class dry chemical. Both fire protection systems are flexible in design and can be modified for use on other mobile minim' equipment. Prototypes of both systems have been subjected to long-term, in-mine validation testing and actual Eire tests on 100-ton-capacity trucks at the Puma mine near Tucson, Ariz., and the Erie mine at Hoyt Lakes, Minn. During the 4-month endurance test of the first system at Pima, an accidental flash fire occurred in the test truck while it was working in the pit. The system successfully sensed and automatically extinguished the fire with no injury to the driver and little damage to the truck.

Jan 1, 1975

Bahrain's oil revenue increased from $337 million2 in 1916 to $378 million in 1977. Despite the increase in value, petroleum receipts made up only 584 of all Government income in 1877, compared with 74% in 1976 and 83% in 1975. Bahrain became an oil producer in 1932 with the discovery of the Awali oilfield, and since that time, the Awali oilfield has produced over 600 million barrels of crude oil. Awali production in 1977 was 21.2 million barrels. Bahrain shares the revenue from the Abu Safah oilfield, located in the Persian Gulf north of Bahrain, equally with Saudi Arabia. Revenue from the Abu Safah oilfield was approximately $179 million or 47% of oil revenues in 1977. Output from the Abu Safah oilfield was 48 million barrels, an increase of nearly 30% over 1976 output. The Bahrain Petroleum Company (BAPCO). the nation's only oil-producing company, was owned 40% by California Texas Oil Corp. (CALTEX and 60% by the Govern¬ment. The Government established Bahrain National Oil Co. (BANOCO) in 1976 to administer the Government's share of BAPCO, oversee exploration concessions, and manage domestic marketing of petroleum products. The Government announced its intention to acquire 100% control of crude oil and natural gas production. CALTEX was to retain complete control of the 250,000-barrel-per-day oil refinery near Sitrah.

Jan 1, 1981

By Pete G. Kovalchik, Lynn A. Alcorn, Rudy J. Matetic, Adam K. Smith

Over-exposure to noise remains a widespread, serious health hazard in the U.S. mining industries despite 25 years of regulation. Most other categories of illnesses and injuries associated with mining have improved, with the exception of hearing loss. Mine Safety and Health Administration (MSHA) coal noise sample data collected from 2000 to 2002 show that 65% of the equipment whose operators exceeded 100% noise dosage is comprised of seven different types of machines. The continuous mining machine is first among all the equipment with 35% of the noise overexposures. The ational Institute for Occupational Safety and Health (NIOSH) is conducting research to reduce excessive exposure for operators of continuous mining machines and preventing additional cases of oise Induced Hearing Loss (NIHL) by developing low-cost retrofit noise controls for mining equipment. This paper describes a noise control for reducing the noise overexposures of continuous mining machine operators. Underground results show a 26.4% and 27.4% noise exposure reduction for the continuous mining machine operator. This research is providing the mining community with an additional noise control to be utilized on continuous mining machines, therefore reducing operator noise overexposure. Utilizing this newly developed noise control, along with previously proven controls for the continuous mining machine chain conveyor, will provide operators of these machines an opportunity to be within the MS HA-Permissible Exposure Limit (MSHA-PEL).

By Ruth A. Holmes

A Bureau of Mines method for recovering nickel, cobalt, and copper from low-grade domestic laterites is described, which includes the unit operations of solvent extraction and electrowinning. Previous Bureau work indicated that addition of Na2S04 (sodium sulfate) to the nickel electrolyte improved current efficiency in nickel electrowinning. The present study determines the compatibility of Na2S04 with nickel strip-ping in the solvent extraction operation of the Bureau method. The effect of adding 100 g/l Na2S04 on nickel stripping, phase disengagement, and pH was determined in comparative laboratory-scale tests. In continuous-circuit testing, Na2S04 reduced stripping efficiency to the extent that five, instead of four, strip stages were required for complete stripping of nickel from the loaded solvent. In tests made in a phase-disengagement cell that had a variable settler area, the addition of Na2S04 did not significantly affect phase separation characteristics. The pH of the nickel electrolyte in the temperature range of 20° to 65° C was also unaffected by the addition of Na2S04. An economic evaluation showed that the energy saved by adding Na2S04 to the electrolyte would more than offset the cost of adding another stripping stage.

Jan 1, 1983

By H. S. Caldwell

Molten zinc, condensed from zinc vapor, was used by the Federal Bureau of Mines to leach aluminum from an aluminum-silicon alloy made by carbothermic reduction of silicious aluminum ores. Zinc requirements were minimized by re-fluxing condensed zinc in a low-pressure, Soxhlet-type distillation unit. The minimum ratio of zinc used to aluminum in the crude alloy was approximately 2:1. When the system pressure was reduced from atmospheric pressure to 100 microns or less, the rate of aluminum extraction increased by a factor of 20. Leaching rates were much higher when the zinc vapor was condensed directly on the crude alloy than when molten zinc was passed over the alloy in the absence of appreciable zinc vapors. Observations indicated higher extraction efficiencies from crude alloys containing greater amounts of iron. Complete extraction was obtained with negligible loss of zinc. Assuming complete removal of zinc, the aluminum products will contain 1 to 6 percent silicon and about 0.5 percent iron plus titanium. The leached crude-alloy residue is a highly friable spongelike material containing about 80 percent silicon, several percent iron and titanium, with the remainder aluminum. This extraction method has been patented (Patent 2,810,637) and assigned to the Government. Research and development investigations are continuing at the College Park Metallurgy Research Center.

Jan 1, 1961

By Wesley G. Holtz

A project to demonstrate the feasibility of retorting oil shale by the Paraho vertical retort process was carried out at Anvil Points, Colorado during 1974 to 1976. As a part of the demonstration project, laboratory and field tests were performed to determine the physical and chemical properties of the retorted shale for use in the development of eventual full-scale disposal plans. The material which exits from the Paraho retort is classified as a non-plastic silty gravel by the Unified Soil Classification System. The particles have an apparent specific gravity averaging near 2.60 and a mass specific gravity averaging near 2.00. The material can be compacted by normal laboratory and field construction methods to about 90 to 100 pounds per cubic foot dry density depending upon the degree of compactive effort applied. The addition of moisture does not improve compactibility appreciably. When high compactive effort is applied the retorted shale is classed as impervious to water flow. The compacted retorted shale exhibits shear strengths in the same order as those observed for silty gravel soils. If the compacted material is cured (long tune simulation testing) prior to strength testing considerable strength gain can be obtained from cementing action. The amount of cementing developed is dependent upon heat treatment and other operating modes of the retort.

Jan 1, 1976

By D. E. Kirby

The electrochemical reduction of AlC13 was investigated as a process for the production of aluminum. An externally heated, single-compartment cell with a rammed refractory lining was used with molten KCl-NaCl-AlC13 electrolyte. Aluminum was deposited qt 700° to 760° C with a current of 100 to 200 amperes on a molten aluminum cathode. Chlorine was evolved at a graphite anode and collected and measured to provide a quantitative evaluation of the AlC13 reduction. Aluminum was removed from the cell by siphoning or ladling. Granular AlC13 was added periodically to replenish that depleted from the electrolyte. Concentrations of 7.5 to 17.5 percent AlC13 in the electrolyte were optimum for operation. Anode current efficiencies of 83 to 85 percent were attained, using anode current densities of 5.9 amperes per square inch and an anode-cathode distance of 4 inches. The chemically bonded, alumina liner was resistant to attack by aluminum and chlorine but susceptible to erosion at the surface of the electrolyte. Titanium diboride proved suitable for the electrical connection to the molten aluminum cathode. Aluminum of a purity equal to or better than 1100 series metal was electrowon continuously from commercial AlC13 for a period of 4-1/2 months.

Jan 1, 1970

By Kermit G. Davis, Sean Gallagher, William S. Marras, Kimberly Kovacs

This study evaluated spinal loads associated with lifting and hanging heavy mining cable in a variety of postures. This electrical cable can weigh up to 10 kg per metre and is often lifted in restricted spaces in underground coal mines. Seven male subjects performed eight cable lifting and hanging tasks, while trunk kinematic data and trunk muscle electromyograms (EMGs) were obtained. The eight tasks were combinations of four postures (standing, stooping kneeling on one knee, or kneeling on both knees) and two levels of cable load (0 N or 100 N load added to the existing cable weight). An EMG-assisted model was used to calculate forces and moments acting on the lumbar spine. A two-way split-plot ANOVA showed that increased load (p<0.05) and changes in lifting posture (p<0.05) independently affected trunk muscle recruitment and spinal loading. The increase in cable load resulted in higher EMG activity of all trunk muscles and increased axial and lateral bending moments on the spine (p < 0.05). Changes in posture caused more selective adjustments in muscle recruitment and affected the sagittal plane moment (p < 0.05). Despite the more selective nature of trunk EMG changes due to posture, the magnitude of changes in spinal loading was often quite dramatic. However, average compression values exceeded 3400 N for all cable lifting tasks.

By G. S. Scott

In the course of the Bureau of Mines investigation relative to the causes, behavior, and control of anthracite-mine fires, attention was directed toward the correlation between the temperature of oxidation and the gaseous oxidation products in the range of temperatures between 100° and 350°C4/. These tests, made on a high-grade anthracite to determine the amount of oxygen consumed and the mounts of carbon dioxide, carbon monoxide, hydrogen and methane evolved when air was passed through samples of the anthracite at various elevated temperatures, showed that the gases evolved and their relative proportions vary with temperature, constitute a means for determining the probable temperature of the anthracite, and thus permit detection of incipient heating beers dangerous fire hazard exists. As the relationships mentioned are affected somewhat by the amount of previous oxidation of the coal, it was deemed desirable to know to what extent they might vary owing to this cause. It was also considered desirable to have a means for estimating the extent of oxidation from the gas analysis, as this would permit a more accurate estimate of probable temperature. Finally, it seemed desirable to know how much the composition of coal might vary over an extended period of oxidation, since this was previously suggested5/ as a possible means for estimating the probable maximum oxidation temperature to which a sample of coal had been subjected.

Jan 1, 1940

By G. S. Scott

In the course of the Bureau of Mines investigation relative to the causes, behavior, and control f anthracite-mine fires, attention was directed toward the correlation between the temperature of oxidation and the gaseous oxidation products in the range of temperatures between 100° and 350°C4/ These tests, made on a high-grade anthracite to determine the amount of oxygen consumed and the amounts of carbon dioxide, carbon monoxide, hydrogen and methane evolved when air was passed through samples of the anthracite at various elevated temperatures, showed that the gases evolved and their relative proportions vary with temperature, constitute a means for determining the probable temperature of the anthracite, and thus permit detection of incipient heating before a dangerous fire hazard exists. As the relationships mentioned are affected somewhat by the amount of previous oxidation of the coal, it was deemed desirable to know to what extent they might vary owing to this cause. It was also considered desirable to have a means for estimating the extent of oxidation from the gas analysis, as this would permit a more accurate estimate of probable temperature. Finally, it seemed desirable to know how much the composition of coal might vary over an extended period of oxidation, since this was previously suggested5/ as a possible means for estimating the probable maximum oxidation temperature to which a sample of coal had been subjected.

Jan 1, 1940

By W. E. Wallace, P. Bolsaltis, M. J. Keane, B. L. Rauaboni

Thermal treatment of respirable size silica dust samples results in marked changes in their hemolytic activity. These changes can be correlated with changes in the characteristics of the particle surface as measured by infrared spectra, zeta potentials, and specific surface area. Silica samples from various sources (Min-U-Sil, fumed silica, and a NIOSH standard sample) were heated or calcined at temperatures ranging from 100-1095C. The hemolytic activity of the crystalline materials decreased after thermal treatment. The behavior of the fumed material was found to be more complex. Material of very large surface area (small particle size) exhibits an initial increase in hemolytic activity upon calcination. This result confirms other experimental observations pointing to a particle size of maximum toxicity. Tre changes in hemolytic activity can be related to infrared spectra and zeta potentials of the materials. The absorption band in the 3200-4000 cm-1 frequency region of the fumed material disappears upon heat treatment while a sharp, characteristic band at 3750 cm-1 increases in intensity. Zeta potential measurements conducted in the pH range of 2.0-10.5 exhibit a unique change in zeta potential v.s. pH profile with heat treatment. These findings indicate that the removal of active surface silanol groups by calcination results in reduced cytotoxicity, as measured by a hemolysis test.

Jan 1, 1988