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Develop methods of enhancing and measuring the high-temperature softening and melting properties of iron oxide pellets reduced under simulated blast furnace smelting conditions. Approach Add dolomite and Limestone flux and a low-cost organic binder, such as starch, carboxyl methylcellose (CMC), or waste papermill sludge, to the iron oxide concentrate to produce hematite (ferric oxide) pellets with superior high-temperature metallurgical properties. Simultaneous increases in softening temperature, gas permeability, and enhanced metallization rates are sought to improve blast furnace productivity and energy efficiency. Background In the past, bentonite, an inorganic binder, was the only additive (binder) used in the production of pellets made from iron ore concentrate. Research has shown that the reducibility of conventional (acid) pellets can be increased by the addition of flux or an organic binder. The increase in pellet reducibility results in less wustite in the center of the pellet at high temperatures, such as those obtained in the cohesive zone of the blast furnace.

Jan 1, 1990

To develop an explosive charge that will effectively break rock in underground mines and that can be safely fired without the use of blast-holes or the need for stemming. Approach The Bureau of Mines developed a non-incendive, cylindrically-shaped explosive charge that will not ignite gassy or dusty atmospheres, even methane-laden air. How It Works Firing unconfined explosive charges in underground mines is prohibited by law since detonation in gassy or dusty atmospheres is extremely dangerous. However, there are advantages in using unconfined charges from both a safety and a production standpoint. Explosives can effectively break up large boulders, rocks and slabs when leveling roof falls and can dislodge overhangs which miners would other-wise have to dislodge manually, exposing themselves to

Jan 1, 1983

Permit quicker, safer clearance of hang-ups in the ore passes and chutes of underground mines. Approach Develop a device that can be operated from a safe distance to explosively propel a projectile into the hang-up. How It Works The Hang-Up Clearance Module, consisting of a stand, steel disk, explosive charge, and aiming device, is placed at a location convenient for line of sight aiming at the hang-up. This placement can be more than 100 feet from the target. Once aimed, the charge is remotely detonated, and the disk is converted by explosive force into a slug and propelled to the hang-up, bringing it down. The steel disk and an explosive charge are contained by a plastic casing. A small booster which is placed at the rear center of the explosive makes up the last component of the charge. Initiation is accomplished by standard means such as detonating cord or a number 8 blasting cap. When Initiated, a detonation wave travels through the explosive, inverting and consolidating the steel disk into a large slug. This slug is propelled at high velocity to the hang-up, delivering more than 5 million foot-pounds of energy on impact.

Jan 1, 1981

Detect fires in or near mine shafts, isolate smoke filled areas, and remotely extinguish fire. Approach A system (of sensors, automatic alarms, an aboveground control console, remotely operated ventilation doors, and sprinklers) has been built from off the-shelf components, and fire, tested in two mines. How It Works The system uses three different kinds of sensors that can detect the heat or smoke of a fire and automatically actuate alarms. When the alarm sounds in the control center on the surface, water sprays in the mine shaft and shaft station areas can be remotely turned on to deluge both the inside and the outside of the mine shaft's wooden support structure. To protect miners from toxic fumes, smoke control doors can be closed or opened, either remotely from the control center or directly by miners using the manual or electrical actuators at the door locations. Man doors built into each ventilation door allow persons to pass without opening the main door.

Jan 1, 1977

By Ivette E. Torres

Bulk carriers, freighters, and tankers are the three classes of seagoing vessels engaged in transporting mineral commodities. However, vessels in these classes are not exclusively devoted to mineral commodity transport. Bulk carriers move considerable tonnages of agricultural products as well as crude minerals, their concentrates, mineral fertilizers, and the like. Freighters, owing to their great variety, can be devoted wholly to hauling mineral products or wholly to nonmineral goods, as well as carrying mixed mineral commodities and nonmineral commodities. They include general cargo ships, full container ships, partial container ships, roll-on/roll-offships, and barge carriers. Tankers, although largely engaged in moving crude oil and refinery products, also transport liquid chemicals, molasses, wine, liquefied natural gas, and other fluids. Although physical characteristics of vessels such as size, draft, crew requirements, type of propulsion system, ratio of gross tonnage to cargo tonnage, and fuel costs have undeniable influences on shipping industry performance, problems of and changes in the quantity and types of materials moved also significantly affect the shipping sector of the world economy, and thus have a bearing on the minerals sector of that aggregate. Unfortunately, comprehensive global data reflecting changes in these critical variables are not published.

Jan 1, 1994

By John R. Benham

The Long Swamp RARE II area contains no prospects, claims, or mines. It has a low potential for ore deposits. There are no geothermal, oil, or gas leases in the area. APPRAISAL There are no mining districts in the study area. The nearest is Chewack Mining District, which is 6 mi (9.6 km) north of the area. This district had numerous claims located for tungsten; the principal tungsten ore mineral was wolframite. Wolframite was found here in 1898 by surveyors of the International Boundary Commission. The area was staked in 1908 and developed during 1915 and 1916. Only in 1936 was ore shipped; the 30 ton (27.2 t) shipment proved to be unprofitable for the claimants (Culver, 1945, p. 41).

Jan 1, 1982

Enable prospective in situ leach mine operators to evaluate the economic potential of an ore body by using a user-friendly, computerized in situ copper oxide leach mining cost model. Background As part of its research on in situ leach mining technology, the Bureau of Mines produced a 5-volume contract report that mining companies can use to design an in situ mining operation for copper oxide deposits. Written for the Bureau by the Science Applications International Corporation (SAIC) in 1988, the generic design manual also contains a computerized cost model for evaluating the economic feasibility of in situ leach mining for any specific copper oxide deposit. The cost model is to be used with Volume II of the contract report. But because of certain complexities associated with running it, the Bureau found that the model could be improved by making it more user friendly. Approach The approach taken by Bureau researchers to make the original model more user friendly was to incorporate a HELP function to define input parameters, and to enable the display of output on the monitor. An accompanying handbook, U.S. Bureau of Mines Information Circular (IC) 9284, contains further details on running, the 1990 model.

Jan 1, 1991

Identify specific sources and the relative levels of contribution of various components of longwall shearer operations to the total airborne respirable dust generated during mining. Approach A research investigation was conducted in two phases by the Bureau of Mines at five mine sites to identify specific dust sources and their relative importance during long-wall shearing operations. During phase I of the project the specific longwall mining elements identified for evaluation were: cutting, sumping, tramming, conveying, and moving roof supports. During phase II of the project, two dust sources were evaluated: clearance ring cutters cutting in six-inch web width increments, and loading operations. Investigation Results As a result of dust measurements, the gage cutters were determined to be the major dust-generating source on the shearer. These cutters, at 6-inch web depth, produce three times as much dust per unit volume as is produced at 30 inches full web depth. The following list of averaged values for the mines tested shows that shearer cutting generated averaged dust levels four times as high as those generated by conveying, and approximately five times as high as those generated in moving roof supports.

Jan 1, 1984

Assist in controlling or extinguishing fires that occur in abandoned mine lands (AML) by providing a compilation of information on past fire control projects, the estimated extent of the current problem, and factors affecting the occurrence, propagation, and extinguishment of AML tires. Conventional fire control methods and their probable effectiveness are evaluated. Background Fires that occur in abandoned coal mines, waste banks, and coal outcrops constitute a serious health, safety, and environmental hazard from toxic fumes, deterioration of air quality, and subsidence. Although fires on AML occur in every coal-producing State, the severity of the problem varies, with most underground fires occurring in Kentucky, Pennsylvania, and Wyoming. Surface fires are prevalent in Kentucky, Pennsylvania, and West Virginia. Methods to extinguish or control AML fires, including excavation, fire barriers, and scaling, are generally expensive and have a relatively low probability of success (see figures 1 and 2). Bureau of Mines Study The Bureau compiled information from a variety of sources and found that the problem of AML fires is a serious one. Such fires can involve a high degree of hazard and can be difficult and costly to control. AML fires usually involve smoldering combustion in outcrops, waste banks, or abandoned mines. Given the nature of these fires, it is unlikely that the extent of the problem or the cost of solutions will decrease in the near future.

Jan 1, 1992

Determine the appropriate spacing and alarm levels for carbon monoxide and smoke sensors used for fire detection in underground coal mine conveyor belt entries. Background Fire represents one of the most severe hazards in underground coal mines. Early-warning fire detection in underground coal mines is essential to successfully implement and execute evacuation and control measures. Both carbon monoxide (CO) and smoke sensors have the ability to provide reliable early-warning capability, provided that they are spaced properly and set at the appropriate alarm levels. The U.S. Bureau of Mines conducted a series of large-scale experiments where a small coal fire was used to ignite a conveyor belt at air velocities of 0.76 to 6.1 m/s. The test configuration was purposely designed to model a worst-case fire scenario for fires that develop within conveyor belt entries in underground coal mines. During the tests, CO and smoke levels were continuously measured to determine alarm times and alarm levels as the fire intensity progressed. The data from these tests indicated that for a given sensor spacing, the time to reach a preset alarm threshold depends upon the belt entry air velocity and cross-sectional area. Analysis of this data resulted in the equations and nomographs for CO and smoke sensor spacing, and alarm levels contained in Bureau of Mines RI 9380, "Fire Detection for Conveyor Belt Entries."

Jan 1, 1993

Improve mine refrigeration system efficiency while providing free electrical energy to mines. Approach Convert the potential energy of incoming mine water falling down long vertical shafts into electrical energy by means of a turbine-generator system located at the bottom of the mine shaft. How it Works Converting the energy of falling water into useful work is a well-developed engineering concept. Water flowing down long vertical pipelines into deep mines develops high pressure that can be used to operate a turbine-generator system at the bottom of the pipeline. A thermal energy recovery system of this type offers three advantages: 1. In systems without turbines, the potential energy of the water is converted to heat. The water temper-ture will automatically

Jan 1, 1985

Improve the dust control effectiveness of dry collection systems on surface coal mine drills. Approach Use a dust pelletizer to convert the respirable dust particles discharged by the dry collector into dust pellets that present no health hazard. Background Blasthole drills are well-known sources of respirable dust that can contain significant amounts of quartz. The drills frequently use a dry cyclone-filter type collector that can obtain dust reductions theoretically greater than 95 pct. However, surface mine drills using dry collectors typically have three major dust sources that significantly reduce the overall effectiveness of the collection system: (1) the dust collector dump cycle, (2) drill shroud leakage, and (3) leakage around the drill stem seal in the drill table.

Jan 1, 1989

Enhance hydraulic fragmentation technology by developing alternative grout sealing methods. Traditional grout scaling methods rely on chemical adhesion and require large contact areas to restrict high-pressure fluids. Fluid injection into rock requires economical and effective seals. With economical and effective seals, rock is easily fractured in tension by high-pressure fluid injection (fig. 1). Approach An innovative grouting technique was developed and tested by the Bureau. Slowly hydrating expanding chemicals are placed within a borehole and around a section of high-pressure tubing. Testing was conducted using 9/16-inch-OD smooth-walled injection tubes in 1.5-inch-ID holes. Seal lengths weir less than 10 inches and curing times were less than 24 hours.

Jan 1, 1989

Provide an economic alternative to drill-blast excavation with the same ability to excavate openings of varied orientation, shape, and size. Approach Develop an efficient, adaptable, mechanical excavation machine that produces unconfined tensile failure in rock. How It Works A drill-split fragmentation machine that combines a drill and a unique splitter has been developed. The drill and splitter are mounted on a carriage that positions the splitter in a hole immediately after it is made by the drill. The splitter creates force loads that cause the rock to fragment, and the process is repeated for excavation. The unique splitter applies both radial and axial loads to the rock mass, which produces an excavation action comparable to pulling a plug. This excavation action distinguishes the radial-axial splitter from typical demolition splitters, which require a free surface parallel to the axis of the splitter toward which to break rock.

Jan 1, 1989

Reduce methane levels around the shearer machine during longwall mining by directing more of the available airflow along the face and over the shearer body. Approach To address the entire mining cycle, two techniques were combined to dilute and clear the methane liberated from the face by the shearer during cutting. The first is the modified shearer clearer system, which is used during the entire face pass. This is combined with the walkway curtain which is used only during the headgate cutout. How It Works Methane ignitions are one of the most potentially serious hazards facing longwall mine operators. The high rate of coal extraction on longwall sections can liberate a significant quantity of methane during a pass. The modified shearer clearer is used to dilute methane concentrations along the entire face for both cut directions. The shearer clearer system, originally designed as a dust control technique, uses a series of water sprays located on the shearer body to direct more airflow along the face and over the shearer. (See Technology News issues, #112, #118, and #221). The only change from the original shearer clearer design is the addition of three sprays to the return-side splitter-arm/ shearer interface. The additional sprays help to ventilate the area behind the shearer body.

Jan 1, 1985

Reduce the number of accidents caused by slips and falls from large mining equipment. Approach A powered lift was developed that provides operators with a safer way of getting on and off large machines. How It Works The powered step is designed to lift personnel and materials to working levels on large machines. It eliminates hazardous blind steps and makes it unnecessary to climb on irregular surfaces made slippery by mud, ice, snow, and accumulations of grease. The step is powered by a self-contained electric/hydraulic unit which is connected to a vehicle's auxiliary power supply. When in the "down" position, the step rests about 15 inches above ground level. When the power unit is activated with an electrical switch located on the step, a Single cylinder attached between two lifting arms smoothly lifts the step. In conjunction with the lifting motion, a linkage and bearing arrangement on the mounting end of the lift arms causes the step to rotate towards the machine, so that the step moves in an arc from ground to platform level. When the machine Is operating, the step is automatically locked in the "up" position, protecting it against any damaging contact with obstructions. The step is lowered by activating a pressure release solenoid. An in-line orifice controls downward speed and prevents free fall. On most machines, additional control switches are conveniently located at ground level and in the operator's cab. Visual alarms and machine interlocks are provided where necessary to prevent machine operation when the step is In the "down" position. The powered step can be easily adapted to any type or model of large machinery.

Jan 1, 1981

Develop a curved ray geotomographic program with constraints to counteract non-uniqueness in order to improve the reliability of seismic tomographic imaging of geological structure in mining regions. Background Seismic tomography provides a two-dimensional image (tomographic reconstruction) of the distribution of the seismic velocity in geologic structures using measured travel times of seismic waves crossing the area. It can provide a more complete representation of features be¬tween boreholes than other crosshole processing methods that measure only average properties or borehole logging methods that measure properties only near each borehole. Seismic tomography has many mining applications. They include locating geologic structures of contrasting seismic velocity, detecting fractured regions where the seismic velocity is low, and monitoring solution injected above the water table where the increase in saturation increases the seismic velocity. Thus, tomographic imaging techniques show great promise for detecting and locating geologic hazards that affect the productivity, safety, and environment of mining operations.

Jan 1, 1992

Permit visual inspection of underground cavities dam the surface. Approach A closed circuit TV camera and a 35mm still camera are lowered down a borehole, and remotely operated. How It Works A platform holding the cameras, and other equipment is lowered on a graduated cable until the depth of interest is reached. Then a quartz lamp and the TV camera are turned on. The television picture is monitored at the surface and recorded on video tape. Areas of special interest are photographed with a 35mm still camera. These photographs contain more detail than TV images because photographic film is capable of higher resolution than a TV transmission.

Jan 1, 1979

Provide roof to floor closure rate measurements during underground mining, especially retreat mining of coal pillars, thereby helping the miners predict an imminent roof fall. Approach An electronic device and rugged potentiometric extensometer were developed to provide a means fur measuring total closure and the rate of closure. How It Works An intrinsically safe, battery operated instrument is enclosed in a rugged, hand carried field case. The unit is constructed using low-power, integrated circuits to provide minimal battery drain. Two digital Light Emitting Diode (LED) readouts are used; one displays the rate, the other displays the total closure. The unit will measure one extensometer continuously or two extensometers alternately. Two potentiometric extensometers with a closure measurement range of 6 inches are attached to the readout unit. As the roof to floor closure changes, the potentiometric resistance

Jan 1, 1982

Utilize innovative processing technology to prepare high-purity, ultrafine advanced ceramic powders with little or no contamination occurring during the milling process. Advanced ceramic materials made from these powders could substitute for high-temperature alloys containing critical materials such as chromium, cobalt, and nickel. Approach Modify and evaluate the Bureau's turbomill, developed earlier to grind a variety of ceramic raw materials (clay, mica, and talc), as a milling or size-reduction technique for hard and abrasive advanced ceramic powders, such as silicon carbide. Background Powders for producing ceramic materials, such as silicon carbide. silicon nitride, alumina, and zirconia, which arc being considered for use in severe applications requiring high-temperature and/or corrosion resistance, are very difficult to reduce to fine sizes for processing into finished parts. Traditional techniques of particle size reduction, such as ball milling and jet milling, are very energy intensive and/or slow. These traditional techniques often produce materials that have a nonuniform particle size distribution and are contaminated by the milling media or container.

Jan 1, 1989