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By W. E. Caspar, W. L. Eaton, W. M. Rohmiser, James Westfield, E. J. Podobrski, L. H. Johnson, S. H. Ash

A flood in mine workings is a crisis even if no lives are lost, and when the crisis is past and the excitement wanes there is usually a rapid return to unwarranted complacency in those regions where floods occur, even though the danger of imminent recurrence is known. Experience in flood control, regardless of its nature, has taught that in a flood the work does not cease when the emergency passes; rather, it increases as the water recedes. To do nothing, when it is known that a hazard exists, is inexcusable for those that should do something. To prevent floods in mines, data should be collected and something constructive done with those data, not alone for present conditions but for the future.

Aug 1, 1947

By Daryl E. Radcliffe

Ninety-seven roof bolts were instrumented with strain gages and resin-grouted in three areas of the Bear coal mine, Somerset, Colo., by the Bureau of Mines. Measurements taken with these instruments indicate roof support is achieved through a combination of point suspension and resistance to vertical and horizontal stresses caused by localized shearing in the roof. The localized shearing results in bending of the bolts, yielding due to high vertical stresses, and the transfer of high loads to the bolt head or plate.

Jan 1, 1980

Reduce spillage hazards and contamination when adding hydraulic nil to mining machine reservoirs. Approach An easily transported module, that delivers hydraulic oil directly into mining machines, was built and tested. How It Works The Hydraulic Oil Delivery Module is carried, from the oil storage area to the equipment needing oil, in the bucket of a scoop or other utility vehicle. Oil is pumped into the module reservoir from storage, or out of the module reservoir into the machine being serviced, through a long hydraulic hose. During long-term testing, the 115 foot long delivery hose made it possible to replenish the hydraulic oil in mining machines at the face with only limited interruption to the mining operation. (Figure 1 shows one! version of the module.) The compact Hydraulic, Oil Delivery Module consists of: an oil reservoir: a pump driven by a hydraulic motor; two high pressure, low volume oil lines, filters; and a low pressure, larger capacity delivery hose equipped with quick-connect-couplers. The high pressure oil lines are connected to the scoop's hydraulic power takeoff, which supplies the power to pump oil in or out of the module reservoir.

Jan 1, 1977

By J. W. Walkiewicz

The Bureau of Mines investigated alloys containing mischmetal (MM), cobalt, copper, magnesium, and iron for use in permanent magnets in place of the scarce samarium-cobalt alloys. The magnetic properties of MM-Co, MM-Co-Cu, MM-Co-Cu-Mg, and MM-Co-Cu-Fe-Mg alloys were evaluated. Magnets were fabricated by powder metallurgy consisting of arc-melting the metals, crushing and grinding the resultant alloys, alining and compacting the powder, and sintering the compacts. Magnetic values of MHc = 4.7 kOe, BHc = 4.07 kOe, Br = 6.81 kG, and (BH)max = 10.0 MGOe were obtained with a MM-Co alloy containing 36±0.5 wt-pct MM. By substituting copper and magnesium for part of the cobalt, the values for MHc and BHc were increased to 29.0 kOe and 5.89 kOe, respectively. This intrinsic coercivity value exceeded that of Sm-Co alloy obtained in our laboratory. The addition of iron to MM-Co-Cu-Mg alloys resulted in an increase of Br to 6.90 kG and (BH)max to 10.3 MGOe. Copper and magnesium contents of these alloys were optimized to obtain maximum values of MHc.

Jan 1, 1981

By J. W. Thompson

The Sullman, Picard & Ballot patent, No. 835120, is a process of concentrating ore which consists in mixing the powdered ore with water, adding a small proportion, a fraction of 1 per cent on the ore, of an oily liquid having a preferential affinity for metal- liferous matter, agitating the mixture until the oil-coated mineral matter forms into a froth and separating the froth from the remain- der by flotation. The process is known as an air-flotation process which consists in the use of a frothing agent in conjunction with such agitation of the ore pulp as will distribute the metallic particles of the ore throughout the mixture and produce bubbles of air and bring them in contact in the mixture with the metallic particles so dis- tributed. The bubbles will become attached to such metallic par- ticles, carrying them separately from the particles of gangue up through the surface of the mixture where they can be readily collected by skimming, by overflow, or by the use of other well-known devices. The air-flotation process was a patentable invention in the discov- ery made in March, 1905, and was not anticipated and is valid. Prior to that time there had been no suggestion in the arts that a propor- tion of 0.1 per cent of oil to ore or of any other fraction of 1 per cent of oil to ore would or might result in successful concentration. While the ascertainment that such a minute proportion of oil would affect a successful concentration of ore through a flotation process was a discovery, it was nevertheless of such a character, viewed with respect to the circumstances under which it was made, as to involve inven- tion and confer patentability. Claims 1 and 12 of the Sullman, Picard & Ballot patent, No. 835120, for a process of concentrating ore, known as the air-flotation process, are valid; but claim 9 is so indefinite as to render the claim void. The object of the Sullman, Greenway & Higgins patent, No. 962678, dated June 28, 1910, for improvements in ore concentration, is to separate metalliferous matter, graphite, and the like from gangue by means of oil, fatty acid, or other substances which have a prefer- ential affinity for metalliferous matter over gangue, and it is valid. The Greenway patent, No. 1099699, dated June 9, 1914, for improve- ments in the concentration of ores is invalid, as in view of the prior art the omission to use acid in the process can not confer patenta- bility.

Jan 1, 1917

By T. M. Barton

This paper presents several case studies in which a mechanics-based boundary-element program is used to back-calculate the surface subsidence associated with various panels at several northern Appalachian coal mines. The program used in this case study is called LAMODEL, which incorporates a frictionless, laminated overburden into a general-purpose displacement-discontinuity code primarily designed for calculating the stresses and displacements in coal mines or other thin-seam or vein-type deposits. In this paper, the program is used to calculate both the underground convergence and the resulting surface subsidence at five longwall panels and a room-and-pillar section. The fitted subsidence from the model is compared with the field measurements and analyzed. The results from this work show that the LAMODEL program is not as accurate as available empirical subsidence-predictive methods: the expected correlation between the geology and the optimum input parameters is not evident. However, for a mechanics-based program, LAMODEL does provide moderately accurate subsidence calculations, and it is one of a few programs that can even attempt to practically calculate both underground stress and convergence and the resulting surface subsidence.

By Gregory J. Chekan

In order to reduce waste and improve resource conservation, mine planning, and development, the U.S. Bureau of Mines is investigating multiple seam interactions associated with longwall mining. Longwall gate entry and panel stability have been influenced by previous mining in coalbeds above and below a mine in Virginia that operates in the Lower Banner Coalbed. Directly superjacent, approximately 115 ft, the Upper Banner Coalbed has been partially worked by room-and-pillar mining. Directly subjacent, approximately 730 ft, the Tiller Coalbed has been worked by partial room-and-pillar retreat mining. The study mine has experienced problems during development of gate entries in areas of overmining and undermining. It is anticipated that stress fields associated with adjacent mining may further affect gate entry stability and face advancement during the extraction of the longwall panel. To assess overmining and undermining effects on ground stability, the Bureau gathered geotechnical information at the site. Headgate entries and pillars were instrumented and monitored to study loading behavior as the longwall face approached and passed potential problem areas. Measurements indicate that although increases in average pillar pressure were greater than predicted values, previous mining in adjacent coalbeds had little effect on headgate stability.

Jan 1, 1989

By W. E. Lamont

The Federal Bureau of Mines conducted research to develop methods of removing phosphorus from the earthy, calcareous hematite ores of the Birmingham, Ala., iron district while simultaneously improving the grade and recovery of the iron values prior to furnacing. An attempt was also made to identify the phosphorus minerals present in the ores. The ores contained about 36 percent iron, 12 to 16 percent CaO, 15 to 20 percent hydrochloric acid insolubles, and 0.30 to 0.36 percent phosphorus. Fractions containing 5 to 15 percent phosphorus were isolated from the ores. Collophanite, Ca3P2O3?nH2O, a member of the apatite group, was the only phosphate mineral identified. Beneficiation methods using flotation and reduction roasting with magnetic separation yielded good grade iron concentrates, but were not as effective for reducing the phosphorus content of concentrates. Reduction roasting followed by fine grinding, magnetic separation, and acid leaching gave iron concentrates containing 62.5 percent iron and 0.04 percent phosphorus with an iron recovery of 82.9 percent and a phosphorus rejection of 93.7 percent. Reoxidation of reduced magnetic concentrates followed by acid treatment gave iron concentrates containing 58.1 percent iron and 0.02 percent phosphorus with 89.6 percent recovery of the iron and 96.5 percent rejection of the phosphorus.

Jan 1, 1973

By W. J. Pena, C. W. Owings

"Generally, the hazard of cool-dust explosions in tipples and cleaning plants is not given the consideration that is given it underground. This lack of consideration is probably due to failure to appreciate the potential hazard. An explosion in a tipple or cleaning plant is basically little or no different from an explosion underground. If bituminous-coal dust is raised into a cloud in the air and comes in contact with arcs from motor brushes, switches, or open flame, the dust is very likely to ignite, and flame will very probably propagate or extend through it if the quantity of dust per unit of air space is sufficient. The open space in a tipple or cleaning plant may reduce the violence of the explosion, but it is not likely to prevent ignition or propagation of flame.The movement of coal through a tipple or cleaning plant naturally puts into suspension a large amount of dust, which finally settles on exposed surfaces. Any disturbance that will put this dust into suspension in a sense enough cloud can result in the dust being ignited by an arc or open flame if one should be present. An explosion of bituminous-coal dust in a tipple or cleaning plant generally can be prevented either by keeping it thoroughly clean or by removing all sources of ignition, or both.The tests at the U.S. Bureau of Mines Experimental mine have shown that the explosibility of coal dust is proportional (other things being equal) to the ratio of the volatile matter to the volatile matter plus the fixed carbon, indicated thus:The volatile ratio for the Pittsburgh coal bed is calculated as follows:Therefore, as the volatile matter decreases the liklihood of ignition decreases; however, coal-dust explosibility depends on other factors also, such as fineness, dryness, and cloud density; and under some conditions other factors also intervene.Proof of the explosibility of coal dust in the absence of explosive gas has been shown in numerous cases in mines and mine plants and also by a series of tests. In these tests a dense cloud of dust is blown onto an open flame or an electric arc, almost invariably with resultant exploding of the dust. The Safety Division of the United States Bureau of Mines has made a number of demonstrations of the explosibility of Pittsburgh coal-bed dust, using a small gallery or box in which a cloud of coal dust is blown onto a lighted match; larger-scale tests have been made with an electric arc as the igniting agent. Bituminous-coal dust is readily ignited with a medium arc, but with low-volatile coals a larger arc is required. For test purposes, a 100-ampere arc has been used. Ignition has occurred readily under these conditions with Pocahontas No. 5 coal dust with ratios of volatile to total combustible of 0.232 to 0.253, and with Pocahontas No. 3 coal dust with a combustible ratio of 0.242. Lower Kittanning coal dust, with a ratio of 0.187, did not give definite ignitions, and Pocahontas No. 4 dust did not explode, although part of the coal-dust cloud ignited. It is probable that even the low-volatile coal dust will be found to be explosive with a higher-amperage electric arc as the initiating agent."

Jul 1, 1936

By Theodore Christos

The Bureau of Mines sponsored an investigation of the thermal oxidative degradation characteristics of certain solvents and hydraulic fluids used in underground mining operations. The following halogenated solvents were studied in view of their usefulness and their flame retardant property: tetrachloroethylene, C12C = CC12; 1, 1, 2-trichloroethane, CIH2CCHC12: and trichloroethylene, C12C = CHC1. The hydraulic fluids studied were representative of five groups approved by the Mine Safety and Health Administration for underground operation, namely: glycol-water solutions, mineral oil-water emulsions, synthetics other than phosphate esters, synthetic phosphate esters, and mixtures of phosphate esters with mineral oils and other ingredients. It was observed that the partially halogenated solvents present a greater potential toxic hazard than the fully halogenated materials, due not only to the easy production of hydrogen chloride but also to their ease of oxidation leading to the formation of phosgene and carbon monoxide. The pure phosphate esters exhibited the best thermal oxidative stability of the five groups of hydraulic fluids tested. A fluid containing phosphate esters mixed with mineral oils and other unidentified ingredients appeared to be the most hazardous On the basis that it produced very toxic acrolein and phosphine.

Jan 1, 1980

By Robert J. Timko

Water-jet-assisted cutting involves the use of a mechanical cutting bit in combination with a high-pressure water jet directed just in front of the bit tip. Such a jet can offer benefits in terms of improved cutting, reduced dust and fines, and improved bit wear. The Bureau of Mines, through a contract with the British National Coal Board, has re- searched the use of water-jet-assisted cutting on roadheaders. After several engineering design problems were overcome, this program led to the successful underground testing of these roadheaders. Today, more than 60 water-jet-assisted roadheaders are in operation around the world, and numerous others are on order. This paper details the evolution of these machines and the benefits to be gained by their use.

Jan 1, 1986

By R. Karl Zipf

MULSIM/NL (multiple scams, nonlinear) is a three-dimensional boundary-element method (BEM) program developed at the U.S. Bureau of Mines for stress and displacement analysis of coal mines and thin metalliferous veins. It can analyze one to four parallel seams that can have any orientation with respect to the Earth's surface. Three main new features distinguish MULSIM/NL from its predecessors: (1) nonlinear material models, (2) multiple mining steps, and (3) energy release and strain energy computations. MULSIM/NL has six material models for the in-seam material: (1) linear elastic for coal, (2) strain softening, (3) elastic plastic, (4) bilinear hardening, (5) strain hardening, and (6) linear elastic for gob. Detailed checks show that numerical stress and displacement calculations compare well to known analytic solutions for simple problems. The total energy release calculated by MULSIM/NL is comprised of three basic terms: (1) strain energy release from the mined-out material, (2) linear kinetic energy release due to change in gravitational potential over the mined-out area, and (3) nonlinear kinetic energy release due to nonlinear materials in the total backfill and gob area. The strain energy release term is modified to account for nonlinear stress-strain behavior in the unmined materials. Comparisons of these numerical energy release rate calculations with known analytic solutions show excellent agreement.

Jan 1, 1992

By R. B. Schluter

The Bureau of Mines investigated the flotation responses of two copper-nickel ore samples from the Duluth Complex with the objective of recovering bulk sulfide concentrates. One of the ores studied was taken from a test pit; the other was taken from a test shaft. The samples were quite similar except that the pit sample analyzed 0.35 pct Cu and 0.11 pct Ni and the shaft sample analyzed 0.69 pct Cu and 0.14 pct Ni. Flotation responses were studied in both laboratory and pilot plant tests. Pilot plant flotation responses were similar for both samples resulting in grades of 12.2 pct Cu and 2.5 pct Ni for the pit sample and 12.2 pct Cu and 2.1 pct Ni for the shaft sample. Weight recoveries were 2.5 pct for the pit sample and 5.2 pct for the shaft sample. Copper and nickel recoveries for the pit sample were 87 and 62 pct, respectively, and 92 and 73 pct for the shaft sample. Both concentrates contained small but significant values of cobalt and precious metals. Cobalt recoveries were low--less than 40 pct for both concentrates. Precious metals contents of the concentrates were 1.59 oz/ton for the pit sample and 0.99 oz/ton for the shaft sample. Silver was the predominant precious metal by weight, but platinum and palladium represented the highest values.

Jan 1, 1980

"There is considerable evidence that all mine dusts do not present the same health hazard. Rank of coal and composition, especially silica content of the mine dust, shape, and surface charge are risk factors that affect the incidence and severity of CWP. Current efforts of Center researchers involve characterization of:•,size/shape/composition•,surface and functional groups•,particle interactions.Work is underway to prepare and characterize respirable coal dust samples, and to develop and evaluate techniques and procedures for the characterization of respirable dust. A suite of standard samples including anthracite, medium volatile and high volatile bituminous coals, quartz, clay, and rock dust have been prepared and thoroughly characterized with respect to the distributions of particle size and compositions. A comparison of the morphology of the standard dust particles with similar particles collected in an underground coal mine is given in Figure 43. Samples of these characterized (Standard) dusts have been distributed among various research groups associated with the Center.The aerodynamic diameter of a particle is a particularly important characteristic since this parameter determines the point of deposition in the human respiratory tract. A 3-dimensional numerical model for theoretically determining the equivalent aerodynamic diameter of irregular shaped particles has been developed and used to analyze coal dust particles and a particle shadowing technique has been developed for .experimental 3-dimensional shape analysis (Figure 44). In the theoretical technique, the equivalent aerodynamic diameter of the particle is numerically determined from computation of the fluid drag on the particle. This allows the aerodynamic diameter of any regular or irregular shaped particle to be determined as a function of the particle's orientation or as an average over all particle orientations. The technique is quite accurate in that the aerodynamic diameter of several coal dust particles have been numerically determined to be within 5% of experimentally measured values."

Nov 1, 1988

By Fred Garcia, William P. Diamond

As part of its mine safety and health research program, the National Institute for Occupational Safety and Health, Pittsburgh Research Laboratory, has been investigating the geologic and mining factors influencing methane gas emissions associated with longwall mining. A primary focus of this research has been the consequences of increasing longwall panel dimensions, particularly face width, in gassy coalbeds. Continuous longwall face emission monitoring studies were conducted at two adjacent mines operating in the Pocahontas No. 3 Coalbed, where longwall faces were to be extended from 229 to 305 m (750 to 1,000 ft). Average longwall pass methane emission rates for 229-m (750-ft) wide faces were 61 % (0.072 m31sec (153 cfm)) higher at the VP-3 Mine than at the VP-1 Mine. It was predicted by regression analysis of methane emissions data from 229-m (750-ft) wide faces that extending faces to 305 m (1,000 ft) would increase methane emission rates by only 7%, or 0.009 m3/sec (20 cfm), to 0.144 mysec (304 cfm) at the VP-1 Mine. In contrast, it was predicted that extending faces to 305 m (1,000 ft) at the VP-3 Mine would increase methane emissions by as much as 13%, or 0.029 mysec (65 cfm), to 0.268 dlsec (567 cfm).

Jan 10, 1999

By Ralph B. Adair

The Bureau of Mines conducted laboratory and small-scale, continuous tests of weathered mica-pegmatite ores from Randolph County, Ala., to determine the feasibility of recovering commercial-grade mica concentrates by flotation. Two flotation methods were used in continuous tests for recovery of mica. One method utilized acid-cationic flotation for the recovery of coarse mica and alkaline-anionic-cationic flotation for recovering fine mica. This method yielded mica concentrates containing 98.6 percent mica with a recovery of 85.9 percent. The other method was based on the Bureau-developed alkaline-anionic-cationic method, and yielded concentrates containing 97.5 percent mica with a recovery of over 90 percent. In both methods, preconcentration of the ground ore on a Humphreys spiral was employed to reject over half of the feed in a product virtually free of mica.

Jan 1, 1968

By Nicholas Kyriazi, John P. Shubilla

A joint effort by the U.S. Bureau of Mines and the U.S. Mine Safety and Health Administration (MSHA) was undertaken to determine how well self-contained self-rescuers (SCSR's), deployed in accordance with Federal regulations (30 CFR 75.1714), survived the underground environment with regard to both impact damage and aging. This report presents findings regarding laboratory-tested SCSR's from 1982 through 1990. The SCSR's were tested on human subjects and on a breathing and metabolic simulator (BMS). These results indicate that most of the apparatus, if they pass their inspection criteria, perform as expected except for units with manufacturing defects or design deficiencies. However, when the apparatus are carried in and out of the mine daily and stored at the working section, they may suffer abuse. Physical signs of abuse, unless extremely obvious, are frequently not detected by the miners or mine operators. This poses a potential danger to a user in an emergency. Recommendations include improved training in inspection procedures.

Jan 1, 1992

By Suzann C. Ambrosio

The mineral industry in Burundi continued to be a minor contributor to the 1980 gross domestic product (GDP) estimated at $293 million in constant 1970 prices.2 Mineral export revenues, primarily from cassiterite, increased by a factor of 15 between 1979-80, reaching approximately $434,000 by yearend 1980. Gold, bastnasite, colombite-tantalite, and wolfremite continued to be exploited on a small scale, using manual and semimechanical methods. Despite a sharp decline in mining activities during 1979, attributed to a lack o? profitability and shortage of construction materials, the mining sector exhibited signs of recovery during 1980. The mineral exploration budget grew 32% over 1979 levels and was equivalent to approximately $42,000 in 1980. In addition, the Burundi Geographical Institute (IGE BU) was created in September 1980 and given responsibilities to collect cartographic, topographic, hydrogeologic, and other geomorphological data., SONIBUROM, the Burundian and Romanian Government joint mineral corporation, conducted mineral deposit inventories during 1979-80 and has been charged with exploiting some of these as yet unspecified resource areas. Another Burundian-Romanian effort, called Mabaya-Butahana, was initiated to search for gold deposits. Meanwhile on the Ruzizi plain, alluvial gold prospecting, with an estimated grade between 0.2 to 1.0 gram per ton, was carried out on a small scale.

Jan 1, 1982

By Bryan F. Ulrich

If resin-grouted roof bolts are not installed correctly, mine roof reinforcement can be affected, and roof falls can result. A bolt installation variable that is readily controlled by the mine operator is annulus thickness. The objective of this U. S. Bureau of Mines investigation was to study the effect of annulus thickness variations on the integrity of 3/4-in-diam resin-grouted bolts. Forged-head test bolts, 2 and 1 ft long, were installed in concrete blocks that had been drilled with 1-, 1-1/8-, 1-1/4-, 1-3/8-, and 1-1/2-in-diam bits. Standard pull tests were performed; then the concrete was broken away from the bolts so that grout mix quality could be inspected. It was found that the optimum annulus thickness is 1/8-in (l-in-diam drill hole), and as annulus thickness increases from the optimum, there is a corresponding decrease in grout mix quality, effective grout ratio, and axial stiffness.

Jan 1, 1989

By Charles C. Hwang

In this Bureau of Mines report, a previously developed theory of reverse stratified flow in ventilated duct fires is applied to mine-related ventilation systems that utilize an exhaust fan to supply the forced airflows. The coupling between a fire and the ventilation airflow in a single-entry duct is analyzed to relate the air velocity in the absence of a fire to air velocity during a fire. By combining the derived coupling equations with the results of the previously developed theory of reverse stratified flow, it is possible to calculate critical flow velocities required to prevent reverse stratified flow in the event of a duct fire. The sample calculations shown agree with the few experimental results available from small-scale tunnel fires.

Jan 1, 1978