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By Albert W. Deurbrouck

Dense-medium cyclone tests in 4-and 8-inch-diameter units have shown the ability of cyclones to make sharp separations down to 100 mesh when washing coals of a finer top size than normally fed to dense-medium cyclones. The reduced top size of the feed apparently allows the finer size particles to report to the proper product by reducing the effect of very coarse particles in the congested separation zone of the dense-medium cyclone.

Jan 1, 1974

By D. J. Bauer

A pure scandium solution was concentrated from 10-4 mole per liter to 0.5 mole per liter by continuous foam fractionation in a spaced, packed column. Recovery in the foam was 77 percent using a spaced, packed draining column with sodium n-methyl-n-"coconut oil acid" taurate as the surfactant. The technique was first studied batchwise in a small unpacked column to determine the more important variables. Optimum surfactant concentration was found to depend on scandium concentration. Extraction and, in general, enrichment ratios were highest in the 2.5 to 3.5 pH range at temperatures ranging from 50° to 70° C. An airflow rate of 136 ml./min. was satisfactory in the equipment used.

Jan 1, 1962

By Theodore Christos

The Bureau of Mines sponsored an investigation of the thermal oxidative degradation characteristics of selected ingredients employed in the formulation and manufacture of conveyor belts. This work was done to supplement similar studies of samples from finished conveyor belts and thus provide basic data for correlation of the potential toxic behavior of a finished belt with that of the individual ingredients. This report covers the study of (1) basic polymers (styrene-butadiene, neoprene), (2) reinforcing fibers (Nylon 6,6, Dacron, viscose rayon), (3) flame-retardant plasticizers (tritolyl phosphate-isomeric mixture, tri-p-tolyl phosphate, tributyl phosphate, tris (dichloropropyl) phosphate), (4) plasticizers (diphenylphtha1ate, di-(2-ethylhexyl) sebacate), and (5) a vulcanization accelerator (2-mercaptobenzothiazole).

Jan 1, 1977

By Richard A. Thomas, Charles D. Litton, Kenneth E. Mura, Harry C. Verakis

Experiments were undertaken to evaluate the flammability of typical noise abatement materials used to line the cab interior of mobile mining equipment. The experiments were conducted using three different experimental configurations: 1. A ventilated tunnel test. 2. A full-size cab test where the interior surfaces were lined with the sample material and then ignited near the floor using a methane-air burner. 3. Standard ASTM E-162 tests using a radiant panel test apparatus. This paper describes the tests and presents the results obtained for 15 to 20 different materials of various chemical compositions and thickness. With one exception, materials that did not exhibit flame spread in the tunnel test also performed well in the full-scale cab test. All materials that had passed only a small-scale flammability test, such as SAE J369, failed dramatically in all three of the above test configurations. With one exception, all materials that performed well in the full-scale cab test had flame spread indices < 25, based upon the ASTM E-162 results. The lone exception had an ASTM E-162 flame spread index of 68. With regard to samples that failed the full-scale cab test, the carbon monoxide levels within the cab reached lethal concentrations in the range of 1.8% to 3.8% within 2 minutes from ignition of the sample—dramatically illustrating the severe fire environment that can result within the cab space.

By Alan H. Goode

As part of the Bureau of Mines program to broaden utilization of abundant low-quality mineral materials, the Tuscaloosa Metallurgy Research Laboratory conducted beneficiation studies on two Alabama clays. The main purpose of these studies was to develop improved plasticity and green strength in both clays and compare these improved properties with those of a typical ball clay. Whiteness of the clays was also considered. The results indicated that by adjusting the pH of the kaolin to approximately 9, a substitute for ball clay could be obtained. The investigation also showed that by a combination of attrition grinding and sodium dithionite leaching to remove iron, the underclay could be upgraded to a ball clay material.

Jan 1, 1975

By R. Barany

The heats of formation of gehlenite and talc were determined by hydro-fluoric acid solution calorimetry. The results are reported in terms of the constituent oxides (?H298.15 = -31.1 ± 0.5 kcal/mole for gehlenite and ?H298.15 = -44.9 ± 0.3 kcal/mole for talc) and in terms of the constituent elements (?H298.15 = -952.8 ± 0.7 kcal/mole for gehlenite and ?H298.15 -1,415.5 ± 1.4 kcal/mole for talc).

Jan 1, 1963

By James Rowland, Isaac Zlochower, Richard Mainiero, Michael Sapko

The National Institute for Occupational Safety and Health (NIOSH) carried out exploratory laboratoryscale studies to identify factors that may contribute to nitrogen oxides (NOx) production associated with non-ideal detonation of blasting agents. Explosive admixture with drill cuttings, loss of fuel oil in ammonium nitrate and fuel oil (ANFO) from wicking, ammonium nitrate dissolution with water, degree of explosive confinement, ANFO density, and critical diameter were identified as contributing factors to increased NOx production under the laboratory test conditions. Experiments were also conducted to examine the effectiveness of various additives in reducing the NOx production from ANFO, emulsion, and ANFO/emulsion blends. Aluminum powder, coal dust, urea, and excess fuel oil in ANFO formulations were tested and were found to reduce both the nitric oxide (NO) and nitrogen dioxide (NO2) production. Fumes measurements were obtained in the NIOSH underground closed chamber from the detonation of 4.5-kg (10 lbs) charges in schedule 80 seamless steel pipe and from detonations in light weight galvanized steel stove pipe. Some exploratory tests were also conducted with 0.8-kg (1.8 lbs) charges of pulverized ANFO initiated with 0.08-kg (0.18 lbs), 50/50 (Pentolite) boosters (in the NIOSH 12-ft (3.7-m) diameter steel sphere) to measure the degree of fumes production associated with post-detonation oxidation. Ammonium nitrate, emulsion and Pentolite boosters were also detonated in an oxygen-poor environment.

At the present time many coal preparation plants handle coal-clay wastes in one of two methods. In one method, the waste is processed in a thickener, followed by further dewatering through filtration, and subsequent blending with coarse waste refuse from the preparation plant. The resulting mixture is then disposed by stacking it in available storage locations. The coal-clay waste is often reslurried by rain or water from other sources, causing a potentially unsafe situation such as mud flows. The other method often used requires thickening and impoundment of the thickened slurry behind earthen dams which poses safety risks if structural failure of the dams occurs. To overcome these two problems, a flocculation method was developed which produces a stable agglomerated material resistant to reslurrying. How It Works The new method involves treating coal-clay waste with lime to raise the pH and flocculating the slurry with a nontoxic polymer of polyethylene oxide. The resulting floes are dewatered on a static screen and agglomerated. For extremely fine waste, further dewatering of the material is accomplished on a rotary trammel screen. The dewatered material may be ponded or mixed with coarse waste from the preparation plant to produce a stable mixture that can be stacked.

Jan 1, 1985

Develop technology that can reduce the dust exposure of a mine worker at the tailgate end of the longwall face by providing him with a clean split of air. Approach Use the jet spray air mover (JSAM) developed under a Bureau of Mines contract (refer to Technology News No. 117 for details on the development), to clean a small portion of the face air and to discharge the clean air behind a brattice partition. How It Works At most longwalls, air flows along the face from head-to-tail. Most of the airborne respirable dust generated along the face during mining is transported to the tailgate with the airflow. Any miner required to work at the tailgate is exposed to this dust. The only practical means of removing airborne respirable dust is with a scrubber. Simplicity and size made the JSAM the best choice for cleaning a portion of the tailgate air. The scrubber has no moving parts and is operated by water at low flow rates (<10 gpm) and fairly high pressures (250-500 psig). Many longwalls have sufficient water systems to supply the JSAM with adequate water pressures and flow rates. Also, the JSAM&apos;s size (4&apos;x 2&apos;x 1&apos;) allows it to be hung on one of the tailgate&apos;s shields or at some other convenient location. A clean split can be maintained at the tailgate by discharging the cleaned air behind a brattice partition at the work area. This should effectively seal off the clean air from the dusty air and provide the tailgate worker with a less dusty work environment.

Jan 1, 1983

1. Data from the Mine Safety and Health Administration (MSHA) indicate that a total of 44,015 employees worked in underground mining locations in 2003, corresponding to 44,778 full-time equivalent (FTE) workers. • Ninety percent of underground employees (n = 39,735) were mine operator employees. • Contractors comprised 10% of all underground mining employees (n = 4,280) and comprised only 5.8% of all underground FTEs. • The majority of underground employees worked for coal operators (73.0%; n = 32,130).

Feb 1, 2005

By F. W. Wood

Ingots of zirconium and other highly reactive metals such as titanium and hafnium produced by the consumable-electrode arc-melting process require conditioning before forging or rolling. A nondestructive, arc-conditioning technique has been developed as a substitute for lathe conditioning. The technique employs en electric arc under an inert atmosphere to fuse surface metal on the sidewalls of ingots without seriously affecting the general quality of the ingots. Advantages of the practice are Increased yields, lower accumulation of inferior scrap, and actual cost savings. The work cited in this report was done on zirconium. INTRODUCTION The consumable-electrode arc-melting process as practiced at the Bureau of Mines3 4/ has proved to be a technique for producing sound, homogeneous, commercial-size ingots of zirconium and its alloys. Ingots produced by this process, however, have as a characteristic a layer of partly fused metal on the sidewall to a depth of 3/16 to 3/8 inch. To prevent extension of surface imperfections during forging, the ingots are ordinarily conditioned by removing defective material in a lathe. If the metal were less reactive or the requirements less severe, the machine chips could be recycled and remelted. However, zirconium, being so oxygen sensitive, is contaminated by merely being machined despite extensive cooling of the tool bit. Further, being contaminated with oxygen, the chip metal upon remelting is 10 to 25 Brinell-hardnese numbers harder than the ingot from which it was machined. For this reason, the ingot specifications for naval reactor use have prohibited remelting machine chips, except as required for starting pads. Again, were zirconium less costly or less in demand this ever-increasing pile could be burned to oxide and recycled through the Kroll sponge process. Economics do not favor this, as melting feed stock has an estimated increase In value over oxide of about $8.80 per pound of contained zirconium. The efforts of the Bureau to solve the problem have been directed along two lines: To reduce the contamination of the machine chips produced and to reduce the quantity of the chips produced. This paper presents the technique developed to reduce the quantity of chips produced by arc-conditioning the remelted ingot.

Jan 1, 1955

By Bob Thomas, Syd Peng, Quanzhong Gu, Gene Wilson, Gerald L. Finfinger

Identifying the properties of overlying rocks in underground mining operations is important to ensure the appropriate roof support design is used to maintain stability of the mine entries. Recently J. H. Fletcher & Co. developed a monitoring and control system for roof bolters for the underground mining industry. The system records the drilling parameters used during roof bolt drilling and the information can provide insight into the physical properties of the roof strata. The parameters include thrust, rotational speed, torque and velocity and the measurements are collected every 0.1 second during the operation. The drilling parameters were analyzed to determine the application of identifying the strength of rocks being drilled from the measurements. The data was converted into the specific energy of drilling which is a measure of the amount of energy required for removing a given unit of rock during a drilling operation. The laboratory studies completed to date indicate a fairly high correlation between the specific energy of drilling and the unconfined compressive strength of :he rocks that were drilled. Additionally, the drilling parameters were shown to be effective for identifying the presence of fractures or bed separations between rock layers. The thrust, torque and specific energy of drilling were all good indicators for identifying the fractures or separations. Regardless of the drilling parameters used during the drilling experiments, the location of the fractures were identified. In order to determine the application of the drilling parameters for identifying roof rock properties, two series of experiments were conducted. The first series of experiments used three "manufactured" roof layers that had various rock samples embedded in concrete blocks. The rock samples included three types of sandstone, marble, and argillite. Another concrete block was poured with foam inserts to simulate large bedding separations (2 to 8-in). Two other manufactured blocks were constructed using high-strength concrete with cardboard layers embedded to simulate smaller fractures or bedding separations. The size of the cardboard layers varied from 1/8- to 1-in thick. One of the blocks had the cardboard layers embedded at an inclined angle to determine the effect of the orientation on the drilling parameters. A series of experiments was conducted with the rotational speed and the penetration rate held constant and the thrust and torque allowed to vary. The information collected from the experiments is used to determine the application of the drilling parameter measurements for identifying rock properties, fractures and bedding separations.

By Alfred E. Schwaneke

A versatile torsion creep tester was instrumented with electromechanical and servomechanical components to operate automatically and unattended, producing digital printed outputs. The apparatus uses an electrical system for applying torsional stresses, and a unique angular transducer as a null detector operating a servocontrolled strain measuring system with the digital readout. The tester is designed to measure the creep in single-crystal or polycrystalline zinc, zinc alloys, magnesium, magnesium alloys, or other metals and alloys. Applied stresses may be varied from zero up to 2,000 psi in the outermost fibers of a 1/8-inch-diameter, 4-inch-long specimen. Strain readings to 0.001 degree, equivalent to a strain of 2.73 X 10-7, may be made automatically from one every 5 seconds to one per month. The apparatus has provisions for programed temperature control and special atmospheres or vacuum operation. A discussion of applications of the system to other mechanical testing apparatus is included.

Jan 1, 1970

To develop a magnetic levitation transport system that can reduce the cost and improve safety in transporting coal from the face of underground coal mines to the surface. Background Many conventional mining operations use conveyor belts to transport coal from an underground face to the surface of the mine. The Mag-Lev Transport System design replaces conveyor belts with magnetically levitated coal haulage containers moving through a dedicated pipe¬line. Cost estimates, based on current design data, show the Mag-Lev Transport System would have operating and capital costs that are less than or equal to those of an equivalent-capacity conveyor belt system. The safety hazards associated with conveyor belt systems include exposure to moving parts and pinch points, potential fire hazards due to mechanical friction, and the exposure of miners to respirable dust. These hazards would be eliminated or significantly reduced by this novel technology. Approach The Mag-Lev Transport System uses magnetic levitation technology that allows noncontact, frictionless conveyance of a levitated body within a dedicated transit corridor. The mag-lev technology utilizes two types of permanent magnets coupled with an electronic position control system to achieve noncontact levitation. Levitation is provided by neodymium-iron boron (NdFeB) magnets mounted in the base of the haulage containers and inexpensive ceramic-5 magnets located in the bed of the transit corridor. An electronic position control system is used to overcome the inherent instability of the repelling permanent magnets. Proximity sensors, a signal processing circuit, electromagnetic actuators, and fixed ferrous side rails are the major components of the positioning system.

Jan 1, 1994

By R. P. Beyer

Low-temperature heat capacities and standard enthalpy of formation of copper difluoride (CuF2) were determined by the Bureau of Mines. The low-temperature heat capacities were determined from 11 to 302 K by adiabatic calorimetry. The enthalpy of formation was determined by HC1 solution calorimetry. The standard values of entropy (S°) and enthalpy of formation (?Hf°) at 298.15 K are l8.65±0.03 cal/deg mole and -129.02±0.29 kcal/mole, respectively.

Jan 1, 1978

Generate less respirable dust during mining by reducing the clogging and downtime of the water sprays on mining machines, especially on continuous miners. Approach An improved filtering system, having commercially available components, has been designed and tested. How It Works The improved filtering system shown opposite is mounted on the mining machine, where It traps particles of coal and pipe scale which cause most clogging of the water sprays. Water entering the system first flows through a ?Y" strainer, which screens out particles larger than 1/8 inch diameter. Next, the water whirls through a small hydrocyclone. Most of the remaining smaller particles are removed and pass Into the accumulator compartment built into the hydrocyclone. The water also flows through a final filter. This filter catches particles that might pass the hydrocyclone, especially during water spray start-up and shut-down, when the speed of the water flow is not sufficient for

Jan 1, 1976

To develop an in-mine water treatment system in which bacterial sulfate reduction and limestone dissolution continuously remove metals and acidity from contaminated drainage. Approach A section of mine tunnel was converted into a water treatment bioreactor by constructing cinder block dams and fang the area between them with a porous substrate mixture of limestone gravel and compost. Readily fermentable materials such as dairy whey, spent brewing yeast, or sugar were periodically added to the reactor. Mine drainage was impounded behind one of the dams and continuously percolates through the reactor substrate at a controlled rate. How It Works The reactor substrate soon becomes anaerobic after it is saturated with mine water. Under anaerobic conditions, sulfate-reducing bacteria consume the organic materials that are added to the reactor and generate hydrogen sulfide (HIS) and alkalinity. The H2S reacts with dissolved iron and heavy metals to form metal sulfide precipitates. The alkalinity raises the pH of the water and induces aluminum to hydrolyze and precipitate as aluminum hydroxide [Al(OH)3]. Additional alkalinity is generated by the continuous dissolution of the substrate limestone. Metal sulfide precipitates and Al(OH)3 are retained within the reactor, and the treated water is discharged. The underground location of the system allows year round operation.

Jan 1, 1994

By T. M. Kohler, G. L. Finfinger, D. M. Hyman, A. T. Iannacchione

The Bureau of Mines measured methane emission rates from an advancing salt face ranging from 15 to 56 ft3/ton (0.5 to 1.8 m3/t). Small room size, use of a continuous miner, and a well-defined ventilation system made possible air velocity and methane concentration measurements, These measurements, representing data from 18 production days, were con- ducted in an area of abnormally low grade salt, Methane emissions occurred primarily during the advance of the salt face by continuous miner.

Jan 1, 1982

By Byron M. Bird

"The prevailing practice of washing unsized coal, 1/2-inch and finer, to 1/8-inch and finer, on a table is subject to certain limitations which are commonly overlooked. In some instances good results are obtained by this method, but often the opposite is true and the efficiency of the washing operation is low. Although the separation taking place on a concentrating table is not fully understood, the actual distribution of particles of various sizes and specific gravities was determined a number of years ago by ore-dressing investigators. Hence this paper consists of an analysis of an old problem by new methods. The experimental data on which the discussion is based were obtained in the course of coal-washing investigations conducted by the U. S. Bureau of Mines at the Northwest Experiment Station in cooperation with the University of Washington and with certain coal operator: of that State.Experimental WorkThe general method of study has been to take a large number of zonal products from the table, and separate them according to specific gravity and size into their component parts. The table used is one of the standard commercial sizes with a diagonal deck. The coal to be washed is split into representative portions, which are stored in separate bins. One portion is used for ""timing as"" the table; the products are collected continuously in the same turned to the feed bin, and thus a closed circuit is completed. When the despite conditions on the table are obtained, coal is fed from one of the re. After the table is operating smoothly the entire product is minute; such a sample is sufficiently large to represent accurately the work of the table and at the same time to minimize the effect of beginning at the end next to the head motion, separate samples are made for each foot along the edge of the deck."

Jun 1, 1926

By Spencer P. Howell, J. F. Xrawshaw

"A recent premature explosion in a quarry that resulted in the death of nine men and the injury of several others, was directly traceable to a spark from a steam-shovel working under the face directly in front of the hole being loaded. This accident and similar accidents on record in the Bureau of Mines indicates the necessity for pointing out the dangers in quarries of explosives being ignited by sparks emitted from steam shovels and locomotives, and making recommendations for greater safety.Many premature explosions of which the following are examples, have resulted from sparks, both from steam shovels and passing locomotives. (A) The premature explosion occurred during August, 1920 at a limestone quarry, in a 100-foot drill hole, loaded with 1000 pounds of high-grade nitroglycerin and gelatin dynamites. This hole had been loaded with 500 pounds of 75 per cent strength gelatin dynamite, 300 pounds of 60 per cent straight nitroglycerin dynamite, and 200 pounds of 50 per cent straight nitro¬glycerin dynamite; but no steaming had been placed in the hole. The powderman loading the hole saw the spark enter the hole and was able to run a short distance before the explosion took place, thus escaping serious injury. The explosion of this first hole was transmitted to nearby hole similarly charged. The fall of rocks from these two holes buried the steam shovel and some of the gang of men working around it.(B) In September, 1909, in the Canal Zone, a steam shovel uncovered a misfired charge of dynamite. While the dynamite was being picked up the steam shovel continued working nearby. A spark from the shovel set fire to some loose dynamite spilled on the ground from the troken cartridges. This fire was transmitted to a hole which was being loaded close by and caused a premature explosion. One man was injured."

Nov 1, 1920