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By A. E. Raddatz

In an attempt to develop technology to use domestic resources in place of imported bauxita, the Bureau of Mines investigated sulfurous acid leaching to extract alumina from kaolin. The process consists of leaching the calcined kaolin with a 30 wt-pct S02 solution at 60° C and 160 psig for 17 hours, fil¬tering the leach slurry, precipitating monobasic aluminum sulfite from the filtrate at 110° C and 60 psig, a& decomposing the sulfite in the spent liq¬uor at 150° C and 55 psig to produce crude alumina. Purification of the crude alumina was accomplished using a modified Bayer process. Results from closed-circuit tests employing the sulfurous acid process showed that overall extraction of alumina from kaolin was 67 pct. Production of 1 ton of alumina would require 3.6 tons of calcined kaolin, 0.7 ton of sul¬fur dioxide, and 8.4 tons of water. After purification by a modified Bayer process, the alumina product contained the following; impurities, expressed in weight-percent: Fa203, 0.009; S, 3.6; Si02, 0.07; Ti02, 0.002; K20, 0.017; and P205, 0.03.

Jan 1, 1981

By William P. Stroud

Chemical alteration of the compressive strength of sandstone has been investigated by the U.S. Bureau of Mines (USBM). Successful development of this technology would offer an attractive alternative to the methods now used for stress control in mines. Sandstone cores were stressed to failure under uniaxial compression at two different strain rates. Specimens saturated with either distilled or tap water showed an average 14% reduction in stress at failure compared with those dried in vacuum. Samples saturated with dilute solutions of aluminum chloride, hydrochloric acid, and polyethylene oxide showed no statistically significant difference in failure stress compared with those saturated with water. By contrast, compressive strength of the cores was increased some 7% by saturation with the nonpolar solvent carbon tetrachloride. No correlation was found between zeta potential and compressive strength.

Jan 1, 2010

By H. M. Lawrence

"The land-pebble district, the larger of the two producing areas of Florida, is situated in Polk County and in the eastern part of Hillsborough County. About 80 per cent at the phosphate rock produced in the United States in recent years has been mined from this area. The phosphate ores, locally termed matrix. are beds of sands and clays containing the phosphate pebbles, considered to be Pliocene in age, derived by marine action from underlying Miocene phosphatic marls, and are covered by practically barren sands and clays that have been deposited more recently. Open-pit mining is practiced; hydraulic mining, which has been intensively developed in this district, is used exclusively for mining the matrix and, by some companies for removing the overburden, although drag-line excavators have become established and are proving economical for stripping operations. From the pits the matrix is pumped to adjacent washing plants for beneficiation. The product of the washers. after drying, enters the world markets as Florida pebble phosphate.In this district recovery of the phosphate pebbles by the washing plants has not been particularly effective in the past. The screening, designed to effect a seperation at about 20 mesh (0.033 inches), has not been well controlled. Washer rejects discarded to the waste dumps have contained appreciable amounts of material analyzing above the minimum commercial grade - 66 per cent B.P.L. (bone phosphate of lime). Such losses of commercial fractions should be considered avoidable, and have been discussed at length in a previous paper.3"

Jul 1, 1930

By G. R. Hopkins

The average heat requirement per barrel of crude processed in the United states rose from 555,000 B. t. u. in 1939 to 579,000 B. t. u. in 1940, although crude runs increased from 1,237,840,000 barrels to 1,294,162,000 barrels in that period. Thus the almost invariable rule that the average amount of heat needed to refine a barrel of crude oil declines when total crude runs to stills increases was broken. (See fig. 1.) The reasons underlying the apparent loss in fuel efficiency in 1940 are quite obscure. There is little question but that the principle of heat exchange, the most important fuel saver, was used as extensively in 1940, as in 1939. A few companies replaced purchased power with electricity made at their plants, but for the country as a whole purchased electricity increased 7 percent, as compared with a 5-percent gain in crude run to stills. Furthermore, the premise the more complex the products the more fuel required -does not hold, as the yield of ?complex" products, including gasoline, declined in 1940.

Jan 1, 1942

By W. W. Adams

"The main purpose in the compilation of accident statistics is to reveal conditions that may result in injury to persons or property so that remedial measures may be applied. For practical reasons it is usually found necessary to restrict inquiry to conditions which actually have caused personal injury, and to omit those which nay, but have not yet, resulted in damage, Fortunately or unfortunately, there is a sufficient number of the former to indicate the existence of hazards so numerous as to require all of the attention which the industry can devote to the subject.Two years ago, the Bureau of 'mines, in cooperation with the National Safety Council, undertook an intensive campaign to obtain more complete and satisfactory information regarding mine accidents than had theretofore been available. Since 1911 the bureau had been receiving annual summaries from all companies operating metal mines, showing, in a general way, the number and causes of accidents that occurred during the preceding year and the number of men employed at the mines. Monthly summaries of fatal accidents at coal mines were received from the state inspectors, showing the number of deaths attributed to each of 22 main causes of accidents, Information for individual coal mines was not furnished.While this information, nation-wide in scope, is indispensable because it epitomizes the progress or retrogression in the industry as a whole, and serves as a background of specialized studies, yet certain classes of acci¬dents, for example, those that are more or less peculiar to specific districts or mines, require an analysis in greater detail than is possible on the sole basis afforded by the annual summaries.The need for more specific information was realized some years ago in the State of Pennsylvania in connection with the administration of the workmen's compensation law, The mining industry is well acquainted with the val¬uable studies of accidents, particularly nonfatal accidents, in the mines of that State being conducted by Mr. Rush N. Hosier."

Sep 1, 1924

By T. M. Ruff, W. G. McCoy, M. J. Beus, S. Iverson, W. Hasz

Technology to enhance safety during mine hoisting has been developed by researchers at the Spokane Research Laboratory of the National Institute for Occupational Safety and Health. Assessment of current hoisting technology suggests that monitoring conveyance position and load directly from the skip or cage top offers several significant safety advantages. Wireless data transmission schemes and a package consisting of sensors, batteries, and a charger mounted on the wire rope and skip have been developed. A state-of-the-art automated hoisting test facility was constructed to test the concept in a controlled laboratory setting. Field tests in a fill-size shaft are underway.

By G. R. Hopkins

The average heat requirement per barrel of crude processed in the United states rose from 555,000 B. t. u. in 1939 to 579,000 B. t. u. in 1940, although crude runs increased from 1,237,840,000 barrels to 1,294,162,000 barrels in that period. Thus the almost invariable rule that the average amount of heat needed to refine a barrel of crude oil declines when total crude runs to stills increases was broken. (See fig. 1.) The reasons underlying the apparent loss in fuel efficiency in 1940 are quite obscure. There is little question but that the principle of heat exchange, the most important fuel saver, was used as extensively in 1940, as in 1939. A few companies replaced purchased power with electricity made at their plants, but for the country as a whole purchased electricity increased 7 percent, as compared with a 5-percent gain in crude runs to stills. Furthermore, the premise -the more complex the products the more fuel required -does not hold, as the yield of ?complex" products, including gasoline, declined in 1940.

Jan 1, 1942

By A. E. Raddatz

The Bureau of Mines is investigating methods for recovering tungsten from domestic resources. A calcine-quench-leach (CQL) technique was developed for the extraction of tungsten from the Golconda, Nev., hot springs ores. The deposit contains disseminated tungsten that cannot be beneficiated by conventional techniques and must be treated by hydro-metallurgical methods. The CQL procedure consists of calcining the ore at 900° C for 3 hours, quenching in a solution containing 1.5 parts of Na2C03 and 1.5 parts of NaOH per part of WO3 in the ore and at a solution-to-ore ratio of 3 to 1, leaching at 200° C and at 250 psig for 3 hours, and filtering and washing the residue. A series of closed-circuit batch tests showed that 92 pct of the tungsten was extracted from a sample containing 2.32 wt-pct W03. The pregnant solution contained 11 g/l W03.

Jan 1, 1982

By F. P. Haver

The Federal Bureau of Mines developed a 10,000-ampere cell to determine the economic feasibility of producing high-purity electrolytic titanium from mill scrap or offgrade sponge. Operating variables were investigated, matetial handling procedures were established, and the cost of electrorefining titanium was determined. The prototype cell produced premium-grade metal (<100 Brinell hardness number (B.h.n.)) from very impure Kroll sponge at a processing cost of less than $0.60 per pound. Refined metal was deposited at the cathode in the form of coarse (85 percent plus 34-mesh), hexagonal crystals of a titanium when the cell was operated an 850° C. A cathode current density of 1,000 amperes per square foot and a molten sodium chloride electrolyte containing approximately 5 percent by weight of soluble titanium were used. In continuous operation, at the optimum number of ampere-hours, (40,000), the current efficiency averaged slightly less than 60 percent. It was possible to supply large enough amounts of electric current for electrolysis to maintain the temperature of the bath, thus reducing overall power consumption to less than 5 kilowatt-hours per pound of metal refined.

Jan 1, 1961

By Murray Jacobson

Facts obtained by the Bureau of Mines on the dust-explosion hazard in air of materials used in the plastics industry are presented for 313 samples studied in the laboratory. Information is given on ignition temperature of dust clouds and layers, minimum explosive concentration, minimum energy required for ignition, explosion pressure and rates of pressure rise, amount of inert dust required to prevent ignition and flame propagation, and, in some instances, on the limiting oxygen concentration in an atmosphere to prevent ignition by spark and by heated surface. The effects of particle shape, additives, and resin structure on explosibility are discussed. Relative explosibility of the materials is related to the ignition sensitivity and explosion severity and is denoted by an empirical index. Recognition of the degree of hazard will facilitate adoption of adequate measures for preventing ignition and explosion during manufacturing or processing.

Jan 1, 1962

By Robert C. Weisner

Current production costs and market conditions in the potash industry of the Carlsbad area were studied to determine the potential values of the potash mineral resource that would be lost or foregone if the Waste Isolation Pilot Plant (WIPP) facility is constructed on the proposed site in that area. The purpose of the WIPP project is to investigate the possibility of developing a nuclear waste disposal plant in the salt formations at the site. Analyses were made of all potash deposits determined to be in the site. Mining and processing under the most favorable recovery systems were considered. Value determinations were based upon estimated operating and capital costs of current mine-mill operations in the Carlsbad area. This study was made for the Energy Research and Development Administration (ERDA) by members of the Federal Bureau of Mines Minerals Availability System staff.

Jan 1, 1979

By Robert W. Waytulonis

The Federal Bureau of Mines contacted 29 organizations--mine maintenance departments and equipment manufacturers--concerning service experience and construction of diesel exhaust-gas water scrubbers. Scrubbers are used primarily on mobile diesel-powered mining equipment subject to 30 CFR 36. Because the scrubbers cool exhaust gas and act as flame arresters, their failure would compromise safety in underground mines. Scrubber maintenance problems and frequency and modes of failure were identified, and construction materials and techniques were evaluated. Three failed scrubbers were randomly selected from two cooperating mines, and their modes of failure were determined. In conjunction with failure analyses, mine water and scrubber water solution samples were chemically analyzed to characterize corrosive properties. Sludge and mineral deposits and different types of corrosion and metal fatigue were identified as problems leading to scrubber failure. The corrosion process is explained; maintenance practices, construction materials, and manufacturing methods that could be used to reduce premature failures and allow longer effective scrubber life are identified; and basic changes in scrubber design are suggested. If type 304 stainless steel is used throughout the scrubber and regular maintenance is performed, long, dependable service can be expected. Other materials such as 304L, 316, or other more exotic steel alloys may be necessary under certain conditions.

Jan 1, 1982

This chapter summarizes data on crude mineral production for the United States, its island possessions, and the Common-wealth of Puerto Rico. Included also are tables that show the principal mineral commodities exported from and imported into the United States, and that compare world and U.S. mineral production. Except for the mineral fuel commodities, the detailed data from which these tables were derived are contained in the individual commodity chapters of volume I and in the State chapters of volume II of this edition of the Minerals Yearbook. In October 1977, responsibility for the collection of data on mineral fuels-coal, petroleum, natural gas, and natural gas liquids-was transferred to the newly created Department of Energy. Although chapters covering these commodities will no longer appear in Volume I of the Minerals Yearbook, quantity and value data have been included in most of these summary tables to maintain statistical consistency in State and national value of overall crude mineral output. This shift in responsibility has also resulted in changes to the composition of the "Nonmetals" and "Mineral Fuels" groups in table 1 and table 2. The commodities-asphalt and related bitumens (natural), carbon dioxide (natural), helium, and peat-have been removed from the "Mineral Fuels" group, and are now included under the "Nonmetals" group. There has been no change in the components of the "Metals" group.

Jan 1, 1980

Reynolds Metals Company announced plans to increase its rate of production of primary aluminum by 17 thousand tons per year by the end of February. Other producers were expected to increase operating rates during the first quarter of 1976 (see table 10 pg. 29). CHROMIUM -Under the Trade Act of 1974, a petition was filed July 16, 1975, with the U.S. International Trade Commission (ITC) by the Tool and Stainless Steel Industry Committee for Import Relief and the United Steelworkers of America, AFL-CIO, for import relief for certain stainless and alloy tool steel products. The Commission determined on January 16, 1976, in a report to the President, that increased quantities of imports of stainless steel sheet and strip, plate, bar, and rod and alloy tool steel except ingots, blooms, billets, slabs, and sheet bars were a substantial cause of serious injury or threat thereof. The Commission recommended import quotas for the period 1976 through 1980. The President has 2 months in which to act, with his decision subject to a Congressional override.

Jan 1, 1976

By Daniel Ng

The U.S. Bureau of Mines-Michigan Technological University mine ventilation mainframe program was successfully adapted for execution in a personal computer (PC). The hardware requirement can be as modest as 256 kilobytes (33) of random access memory (RM) and two floppy disk drives. A version compiled for a PC possessing 512 Kb RAM has arrays dimensioned to accommodate 512 separate mine airways and junctions, and it contains all the features and capabilities of the original version. It has successfully analyzed all the ventilation networks tested, including a very large commercial mine (404 airways, 237 junctions, and 5 fans). In all cases the PC version produced practically identical results as obtained from the mainframe computer. In all respects, the PC version performed the same as the mainframe version with the exception of execution speed When a numerical coprocessor is employed, execution time can be reduced by more than 50%.

Jan 1, 1989

As part of the Bureau of Mines program for conserving domestic mineral resources, a survey was made of the methods used for identifying scrap metals. Because of the large number of alloys currently being scrapped, correct identification of these materials is essential if they are to be recycled effectively. The methods and instruments used to identify scrap metals are described and evaluated. These include object recognition, color, density, magnetic testing, spark testing, chemical spot testing, thermoelectric measurements, eddy current measurements, and elemental analysis by chemical and instrumental methods. Other potential techniques are discussed also.

Jan 1, 1982

By Donna L. Anderson

The first section of this U.S. Bureau of Mines report includes a discussion of the navigational tasks performed by operators of mobile mining equipment, with the focus on the navigational information and guidance techniques required by continuous mining machine operators. Some previous research and attempts in remote and autonomous navigation of continuous mining machines are mentioned. Issues of research in autonomous navigation of various other mobile robots are presented, with attention focused on their applicability to a continuous mining machine navigating in the mining environment. Conclusions are stated on methods of automating the navigational tasks of a continuous mining machine, and a decision to concentrate initial attempts on the tasks of autonomous face navigation is defended. The second section of this report includes a presentation of the Bureau&apos;s proposed solution for autonomous face navigation of a continuous mining machine, which includes the employment of a mobile roof support as a reference for guidance in the face area, and a navigational guidance system for the continuous mining machine.

Jan 1, 1989

By K. L. Whitehead

An examination of 60 mines, 11 illumination hardware manufacturers, and Q mobile face-equipment manufacturers was conducted to determine the state of the art of mine-illumination hardware, define lighting system installation and maintenance problems, and assess personnel acceptance of lighting. Longwall and mobile face-machine illumination were studied. Major problems on room and pillar installations include damage of exposed components, electrical failures, and reduced lamp life, with extreme variability in the degree of these problems. Most longwall systems had low or moderate maintenance requirements, cable damage being the most significant problem. Most mobile face-equipment operators liked their machines&apos; lighting systems, but many complained of glare and other problems. Longwall lighting was unanimously accepted by face personnel, and most complaints were minor. Based on the survey, general installation and maintenance guidelines have been established, addressing hardware design aspects, approaches proved effective to minimize problems, and improper practices noted which are detrimental to effective lighting.

Jan 1, 1981

By Gerald L. Finlinger

This Bureau of Mines publication reviews underground methane drainage programs being conducted in various coalbeds. Equipment used in drainage programs such as drills, underground pipelines, and methane monitoring systems is described.

Jan 1, 1980

By J. E. Allison

As part of a Bureau of Mines research program to conserve critical and strategic metals, an aqueous electrodeposition method for preparing stainless-steel-type coatings was studied. Chromium powder (averaging 3 J1.m diam) was suspended in a ferrous-nickelous sulfate electroplating bath and occluded in the electrodeposited Fe-Ni alloy matrix. Subsequent heat treatment of the resulting composite coating formed the ternary alloy. The occlusion process was affected by the quantity of Cr powder suspended in the electrolyte and by the microstructure and composition of the electrodeposited matrix. Coatings containing up to 21 wt pct Cr were deposited from an electrolyte containing 20 vol pct suspended Cr powder. Heat treatment at 1,100° C for 8 h homogenized the composite coating. Deposition of 44Fe36Ni20Cr alloy coatings (250 J1.m thick) on AISI 1020 carbon steel rods, followed by heat treatment, provided complete protection of the carbon steel during exposure to a boiling 65-pct-HN03 solution. Corrosion rates of 0.6±OA mm/yr for the coating in the boiling HN03 approximate that of 304 stainless steel. Practically shaped electroforms have been prepared by the coating method.

Jan 1, 1989