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Advances were made during 19b5 in many phases of a broad program designed to increase efficiency in the mining, preparation, and utilization of coal. Also recorded were achievements in activities devoted to mine health and safety, coal resources, and mine explosives. Featured in this report is a review of progress in environmental studies relating to coal mining and utilization. Environmental projects comprise a comprehensive program to facilitate mine reclamation and reduce air and water pollution associated with extraction and use of coal. Publications cited throughout this report present results of the coal program in greater detail. Organizations, institutions, and companies contributing to the program are listed in appendix A. Centers and laboratories conducting the coal research and related investigations appear in appendix B.

Jan 1, 1966

By R. S. Dean

The brief resume of the activities of the Metallurgical Division that appears annually in its progress reports series serves a useful purpose by making available a rather comprehensive but concise recapitulation of the current work, and publications of the division. An unprecedented opportunity to attack the problem of producing ferro-grade material from low-grade domestic manganese ores effectively was provided by the act designated as Public 667 of the 76th Congress of the United States, approved June 26, 1940, which made available an appropriation for "Expediting Production of Equipment and. Supplies for National Defense." Although the funds were not immediately available to the division, good progress has been made in the, solution of the many and diverse problems presented in the studies undertaken to determine the best methods for the recovery of useful products from a wide variety of manganese ores.

Jan 1, 1941

By Nicholas Kyriazi, John P. Shubilla

The National Institute for Occupational Safety and Health (NIOSH), Pittsburgh Research Laboratory, has undertaken a study to determine how well self-contained self-rescuers (SCSRs), deployed in accordance with Federal regulations (30 CFR 75.1714), hold up in the underground environment with regard to both physical damage and aging. This report presents findings regarding laboratory-tested SCSRs in the sixth phase of testing from mid-1996 to early 1998. The SCSRs were tested on human subjects and on a breathing and metabolic simulator. These results indicate that most of the apparatus, if they pass their inspection criteria, perform satisfactorily. However, the deployed CSE SR-100s exhibited significantly higher inhaled CO2 levels than new units, as in the previous phase. This will cause higher ventilation rates in most users, which will, in turn, result in higher breathing pressures, possibly causing users to prematurely remove the apparatus. CSE Corp. has developed a noise test that can identify apparatus suffering from chemical-bed degradation causing the early CO2 breakthrough. This test was added to the inspection criteria for the SR-100. In addition, several of the MSA Portal-Packs that passed their inspection criteria were found to have KO2 dust in their mouthpieces. Further investigations by NIOSH and the Mine Safety and Health Administration confirmed these findings, which resulted in the decertification of the apparatus and their removal from service.

Jan 1, 2000

By Christopher Mark

Perhaps the most significant development in coal mine ground control during the last century was the introduction of roof bolting during the late 1940’s and 1950’s. From an engineering standpoint, roof bolts are inherently more effective than the wood timbers they replaced. Roof bolts promised to dramatically reduce the number of roof fall accidents, which then claimed hundreds of lives each year, and they were initially hailed as “one of the great social advances of our time.” Roof bolting also emerged at a time of rapid technologic transformation of the coal industry, and greatly accelerated the transition to trackless, rubber-tired face haulage. The U.S. Bureau of Mines quickly became the new roof support’s strongest advocate. Some state agencies and miners were skeptical at first, but nearly everyone was soon won over. Case histories were reported showing that roof falls could be largely eliminated while productivity increased dramatically. Little wonder that, in the words of one contemporary observer, “roof bolting has been adopted more rapidly than any other new technology in the history of coal mine mechanization.” Yet by the end of the 1950’s, it was clear that roof fall fatality incidence rates had actually increased. It would be another decade before the superior ground support provided by roof bolts would clearly save lives. The story of how roof bolting was implemented by the mining industry, but took so long to live up to its promise, is a fascinating example of the interaction between economics, technology, regulation, and science. It still has important lessons for today.

By G. W. Jones

From evidence made available during the investigation, it was concluded that the first of a series of explosions occurred at 1:15 to 1:20 p.m. September 21, 1951, in an underground vault that housed pressure regulators on the gas-distribution lines that served Brighten. This explosion damaged the pressure regulators and permitted high-pressure gas to enter the distributing mains and individual-service lines. As a part of the gas-distribution system was not provided with means for protection against such excessive pressures, gas gained access to the interiors of many residences in this area and caused a series of disastrous explosions and fires, which took place during a period of approximately 2 hours after the initial explosion in the pressure-regulator vault. Two persons were killed in the first explosion in a residence, and a third person died of a heart attack attributed to the excitement that prevailed during the explosions and fires, Twenty-three persons were listed as injured. Forty-one residences were either destroyed or damaged - 11 by explosion and the remainder by fires, which developed as a result of gas leakage into residences. Fifteen residences were listed as "completely down" or "gutted." Unofficial estimates of property damage ranged from $1,000,000 to $1,500,000. In view of observations made and information obtained during the investigation, recommendations are presented in this report relative to the natural-gas distribution system in Brighton, which may be helpful in the prevention of similar accidents in this and other communities.

Jan 1, 1952

By A. George Stern

[In the examination of bentonitic clay suspensions used for oil-well drilling fluids3/ (and for other purposes, such as a core binder for foundry sand) it is important to have comparative tests for evaluating them. A satisfactory clay for these and other purposes should have the property of forming what is commonly called a "gel," but the measurement of this property has been a real problem. To date the solution has not been satisfactory, and some of the difficulties are considered in, this, paper, which describes a simple form of instrument (identified as an eykometer) for measuring the yield point under hydrostatic conditions of non-Newtonian clay suspensions, including those muds that are thixotropic. An oil-well drilling mud serves several functions, many of which depend on the "gel" characteristics of the mud. Among the more important functions are: (a) To plaster the sides of the hole to prevent caving of the walls; (b) to prevent the loss of the circulating fluid out of the hole by seepage; (c) to carry sand and cuttings out of the hole to the surface as they are formed by the rotary drill; and (d) when circulation of the fluid stops for shut-down or other unavoidable cause, to hold the cuttings in suspension by the setting up of the gel, thereby avoiding the difficulties that result when these cuttings are allowed to fall through the fluid and pack at the bottom of the hole.]

Jan 1, 1940

By George J. Conroy

To provide data as a basis for proposed acceptance standards and procedures covering permanent splices in trailing cables, the Bureau of Mines conducted testing programs on the flexure life in flat types W and G dc trailing cable splices and ground conductors. Primary reliance was placed on laboratory testing, although some cross comparisons were made at manufacturers' plants and mine operations Besides providing data for acceptance standards and procedures, results of the program should promote the general improvement of commercially available splice kits.

Jan 1, 1977

By Albert W. Deurbrouck

The performance characteristics of five hydrocyclone coal washers were evaluated to determine the sharpness and efficiency of separation that might be anticipated in commercial operation. The hydrocyclone overflows contained generally good clean coal products that would require little re-treating to remove misplaced high-gravity material. The underflows, however, contained from 63.6 to 36.7 percent of misplaced low-gravity material, which would require secondary cleaning to provide acceptable clean coal yields.

Jan 1, 1974

By F. D. Sutterfield

This study was conducted to provide experimental evidence on the effect of modifications of gasoline front-end composition on the photochemical specific reactivities of automotive emissions. Evaporative and evaporative-plus-exhaust emissions from an automobile operated with four fuels of different volatility and varying levels of C.-C5 olefins were irradiated in a 10040 environmental chamber at three sets of initial hydrocarbon-nitrogen oxides concentrations. Reactivity was measured and expressed in terms of rate-of-NO2 formation and dosages of oxidant, peroxyacetyl nitrate, and formaldehyde. The compositional changes that were necessary in reducing fuel volatility were found to have no significant effect on the reactivity of the emissions. However, replacing C4-C5 olefins with saturated components resulted in sharp decreases in all reactivity manifestations observed for the evaporative emission samples. A lesser influence (of C4-C5 olefin replacement) was found with the composite exhaust-plus-evaporative samples; the effect that was observed could be attributed to the evaporative emission portion of the sample. The data therefore suggest that saturation of front-end fuel olefins had no large effect on exhaust emission reactivity.

Jan 1, 1971

By Mary L. Pearson

Ibis report summarizes the results of the contract. Included are summaries of existing legislation pertaining to outcrop barriers and a state-of-the-art survey of outcrop barrier designs and related, mine closure techniques. Six sites were inspected in the field and are presented as case histories The data analysis presented includes a computer modeled seepage analysis, an overburden blew-out analysis, and a wedge stability analysis. The results tit these analyses are interpreted to form recommendations for coal outcrop barriers which will minimize seepage and the potential for failure. Supplementary support and reinforcement alternatives are also discussed.

Jan 1, 1981

By J. N. Geyer

During the early stages of the mining industry of the United States an apparently inexhaustible supply of high-quality, easily accessible coal made the product cheap and the attendant mining methods wasteful of recoverable coal. Because coal from advance places could be mined with less effort and a large outwit obtained as the entries advanced, much of the coal left in pillars to support the roof was lost. Squeezes often developed in these mined-over areas, or, if pillars were of sufficient size to-prevent squeeze, the roof would be so weakened by long exposure that any pillar recovery was extremely hazardous. As the value of unmined coal increased, a high recovery of the available coal became necessary. Numerous plans were tried during the period that followed, some of the methods proving successful while others were complete failures or only partly successful. As a better knowledge was pained of the roof strata and its behavior, however, pillar mining became more successful and methods suited to special roof conditions were developed.

Jan 1, 1933

By Rexford D. Singer

The purpose of this study was to evaluate the current literature on the use of calcium chloride and ligninsulfonates as dust suppressants with respect to potential adverse effects on health or the environment. Calcium chloride poses little internal hazard to man and animals, but toxicity to vegetation in and around the area of application should be expected. The effects, however, should be considerably less than those observed from using calcium chloride as a road deicer. Except for trout, ligninsulfonates seem to pose little direct systemic toxicity problems in aquatic organisms, animals and man or any problem with local vegetation. Because of a greater volume of information on its use and effects, calcium chloride is recommended over ligninsulfonates.

Jan 1, 1982

By E. A. Holbrook

The data in this bulletin were obtained during an investigation of screening practice by the University of Illinois engineering experiment station and the United States Bureau of Mines under a cooperative agreement between them and the State of Illinois Geological Survey Division. Earlier work on this subject includes a study of the general practice of coal preparation in Illinois, made in 1914 and published in 1916,1 and an investigation of Illinois coal-washing methods, results of which were published in 1912 in a bulletin 2 that contained complete information on the methods then in use for sizing washed coal. OBJECTS OF THE INVESTIGATION The present investigation was limited to a study of screening as applied in preparing mineral products with the expectation of obtaining more comprehensive information on screening machinery.

Jan 1, 1925

By K. Thirumalai

The feasibility of breaking hard rock by thermal weakening and subsequent mechanical impacting was tested, Field tests at a basalt quarry in Dresser, Wis., demonstrated that large hard-rock blocks (5 by 5 by 5 ft) could be effectively reduced in size by this method. A series of secondary breakage tests, using air-propane heating, resulted in an average heating cost of $0.36 per ton. This combination energy approach provides an alternate means of size reduction of large hard-rock boulders for quarry and for underground are chute and grizzly operations where mechanical methods, used alone, are ineffective.

Jan 1, 1975

By J. P. Dunford

This U.S. Bureau of Mines report describes the development of a yielding steel post for underground mine support. The report covers concept development, laboratory tests, modifications, and field evaluations. The objective of this work was to develop a stiff support member capable both of supporting high loads and yielding when excessive amounts of mine entry closure were present. The 6-to 7-ft steel post was designed to yield nearly 2 ft while maintaining a 45-ton (force) load. The post is a three-piece unit consisting of top and bottom telescoping legs and a separate foot bracket. It develops its load-carrying characteristics when the lower pipe, with an attached interference ring, is forced into the larger top pipe. Laboratory tests were used to determine critical loads and post performance for various post lengths. Field tests showed that the posts could perform in actual mining conditions. The post has the ability to provide support in highly yielding ground and also, because of its slender profile, enhance ventilation and provide more area for travelways and escapeways. The design is simple enough to allow for fabrication at most mine shop facilities.

Jan 1, 1989

By Alton Gabriel

During the fall of 1940, J. R. Thoenen of the Mining Division, Bureau of Mines, accompanied by the senior author, surveyed the more important domestic alunite deposits. Although the study was designed primarily as an economic survey, samples from a number of the deposits were collected to investigate the beneficiation of the lower-grade material.

Jan 1, 1942

By Alton Gabriel

During the fall of 1940, J. R. Thoenen of the Mining Division, Bureau of Mines, accompanied by the senior author, surveyed the more important domestic alunite deposits. Although the study was designed primarily as an economic survey, samples from a number of the deposits were collected to investigate the beneficiation of the lower-grade material.

Jan 1, 1942

By A. C. Fieldner, S. H. Katz

"Introduction.Recent experiments (Fieldner, A.C., Katz, S.H., Kinney, S.P., and Longfellow, E.S., Poisonous gas from carbon tetrachloride fire extinguishers, Jour. Franklin Institute, October, 1920, pp. 543-565), by the Bureau of Mines have shown that carbon tetrachloride extinguisher liquids when applied to fires produce small quantities of irritating and poisonous gases which may be dangerous in very closely confined spaces where conditions are such that the user can not escape without breathing the fumes. The results of the experiments have been confirmed in an independent investigation by the Underwriters Laboratories (Nuckalls, A.H., Corrosive action and products formed when carbon tetrachloride extinguisher liquids are applied to fires, Nat. Fire Protection Assoc. Quarterly, vol. 14, January, 1921, pp. 221-236) who conducted similar experiments for the purpose of determining the corrosive action of these fumes on metals. Both investigations showed that carbon tetrachloride vapor, hydrochloric acid gas, and phosgene were produced in addition to the ordinary products of combustion, such as smoke, carbon monoxide and carbon dioxide. The Bureau of Mines' tests were made by applying a one-quart extinguisher to a wood fire of excelsior in a gas-tight room of 1000 cubic foot capacity. The glass and metal construction of this chamber limited the experimental fire to very small dimensions. It was, therefore, deemed desirable to make a test on a larger scale in the entry of the Bureau's experimental mine in order to similate more nearly the practical use of carbon tetrachloride and other types of extinguishers in mines.Description of extinguishers.Two series of tests were made under identical conditions on different days. Commercial carbon tetrachloride extinguishers were used in the first series of tests and ""foamite firefoam"" extinguishers in the second series of tests."

Jun 1, 1921

This report provides the results of an industrial engineering study that assessed the safety and efficiency of underground ore handling in U.S. metal mines. One of the primary findings of the study was the improvement needed in controlling muck size in the ore handling stream. Oversize ore causes much additional labor, creating work stoppages and is a principal cause of accidents in metal mines. This report includes data on block caving, back cut and fill room and pillar, shrinkage stoping, and sublevel stoping.

Jan 1, 1974

By R. S. Dean

In addition to the normal work and that pertaining to strategic minerals, the Metallurgical Division has been made responsible for carrying on major investigations in the development of processes' for the treatment of low-grade domestic manganese ores that heretofore have failed to yield products suitable for the preparation of ferromanganese, an alloy essential to every ton of steel produced. These investigations are particularly important at this time because of their part in tucking this country self-sufficient with regard to manganese when the stock-piled ore becomes e exhausted and as foreign shipments of ferro-grade ore are cut off. The results indicate that there is a good probability of accomplishing this objective, while at the same time conservation may be promoted through the use of normally useless material from the large, low-grade ore deposits.

Jan 1, 1941