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By E. R. Cole

The Bureau of Mines developed a procedure that enables substitution of zinc cathodes for the aluminum cathodes normally used in commercial zinc electro-winning. Using zinc cathodes eliminates the necessity for stripping and makes it possible to electrowin zinc from solutions derived from material containing excessive amounts of soluble fluorides; for example, zinc concentrates obtained as a byproduct of fluorspar mining in Kentucky and Illinois. To demonstrate the viability of using zinc cathodes, fluoride-containing zinc concentrate was roasted, leached, and purified according to current commercial practice. Electrolysis was carried out in 0.8-, 1-, 5, and 10-liter cells at 35° to 40° C with a cathode-current density of 8 amp/dm2 in a solution containing 65 g/l Zn++ and 200 g/l H2S04 using PbO2 anodes. Zinc deposits were produced on zinc cathodes with good morphology and excellent current efficiency (90 to 94 pct) in solutions containing enough fluoride (~0.5 g/l, F+) to cause sticking of zinc to aluminum cathodes. The approach described has failed previously because of severe solution-level corrosion of the zinc cathodes. The present investigation found that the use of a simple mechanical barrier to prevent oxygen migration from the anode was sufficient to prevent solution-level corrosion of the zinc cathode starting sheet.

Jan 1, 1979

By John L. Edwards, Anthony T. Iannacchione

There has been a persistent need to forecast roof falls so that miner’s exposure to hazardous underground environments can be minimized. Several monitoring techniques have been developed and are used today with varying levels of acceptance in the mining industry. This paper examines the potential for monitoring microseismic emissions activity as a means of forecasting roof falls. The use of this activity to forecast roof falls has drawn only limited attention, resulting in a lack of published field performance data. This deficiency is being partially addressed by analyzing data obtained during longwall mining at Moonee Colliery in 1998. The Moonee data base contains a wealth of information concerning roof fall forecast parameters and the seismic alarm criteria used to develop these forecasts. Four seismic alarm criteria were developed and used by Moonee with varying degrees of success. Roof falls were forecasted 73% of the time with average forecast times of 54 minutes. Ninety percent of the predicted roof falls had a warning time, i.e., the time between warning and roof fall event, of greater than 1 minute. The fraction of forecasted roof falls decayed logarithmically as a function of warning time, until only 20% of events were predicted more than 100 minutes prior to roof falls. False alarms occurred in 50% of the warnings. Many of the false alarms were quickly followed by a cessation in mining which could have temporarily halted the on-going failure process. If mining had continued immediately after the false alarms, a roof fall may have occurred soon after. The microseismic activity collected from Moonee Colliery demonstrates that techniques to forecast roof rock instabilities in underground mines are possible.

By LaMar G. Evans

The rapid determination of uranium in ores by radiometric means was investigated by the Bureau of Mines. Among the various procedures and schemes tested, two showed most promise. They were the ratio scheme developed in the Bureau's Tucson, Ariz., laboratory and the equilibrium method developed by the Canadian Department of Mines and Technical Surveys. The ratio method is a simple, empirical procedure for classifying the state of equilibrium in ores by measuring their radioactivity by means of a Geiger-Muller counter under three different conditions, using filters. The principal merit of the method is in providing a clue as to the reliability of equivalent uranium determinations.

Jan 1, 1958

By J. Roth

The purpose of the present study is to increase the safety of explosive storage. This was accomplished by: a) review of the histories of recent and past magazine explosions to define causes and trends; b) observation of present-day explosive storage conditions and practices at active mines; c) examination of existing Federal regulations on explosive storage to determine whether they address all conceivable safety problems, whether they contain redundant or obsolete standards, and whether their intent is clearly stated; d) recommendation, for safety improvements and for revision and clarification (if necessity) of governmental regulations. Magazine explosions are rare. A recent increase in magazine explosion frequency must be attributed to a large increase in deliberate (criminal or malicious mischief) explosions. Fires of various origins account for the remaining explosions of the past decade. During 1884-1926 several lightning-generated explosions occurred in non-metal magazines, but none recently. It appears that the contents of a well-constructed, metal magazine are immune to direct lightning strikes, regardless of whether the magazine is grounded or not grounded. Grounding a metal magazine cannot be harmful, but it may well be superfluous. Magazines were observed at 34 widely separated mines and storage problems were discussed with personnel at these mines. In general, storage conditions and practices were found to be satisfactory. Usually, only small quantities of explosives are stored on mine property since most explosives are brought in by suppliers when needed. MSHA and BATF standards on explosive storage appear to cover safety aspects adequately. However, certain revisions are recommended to clarify some of these standards and to reduce inconsistencies in their enforcement.

Jan 1, 1983

By Millard M. Gilkey

This Bureau of Mines report presents results of a detailed study of water usage in the Wyoming mineral industry along with projections for the future In 1964, the mineral industries of Wyoming used 20 billion gallons of new water, nearly all self-supplied, and reused 72 billion gallons, a total usage of 92 billion gallons. Consumption amounted to 2.8 billion gallons. About one-half of the 20 billion gallons of new water was obtained from [srface] sources and the rest from ground water. Reported costs, covering power and maintenance, for the self-supplied new water at mineral industry operations ranged from less than 1 cent to 20 cents per thousand gallons and aver-aged 8 cents. At one mineral-related operation, water was hauled by truck to supplement a well supply. The cost was $2.00 per thousand gallons delivered. However, the supplemental requirement was only 10 gpm. Cost figures for the recirculation of water, covering power and maintenance, averaged 2 cents. In terms of water usage, the value of product for the entire industry was $25 per thousand gallons of new water intake and about $180 per thousand gallons consumed. The study revealed that Wyoming has a water deficiency but that the shortage is less severe than in the arid Southwest. Projection of the water needs of the Wyoming mineral industries indicates that the demand for new water will increase from the 20 billion gallons used in 1964 to 25 billion gallons in 1980, a 25-percent increase. The projected new-water requirement for the year 2000 is 40 billion gallons, a 100-percent increase compared with the 1964 figure.

Jan 1, 1967

By D. L. Neylan

The Bureau of Mines evaluated various methods for identifying sources of mercury vapor in excess of the threshold limit value (TLV) of 0.05 mg of mercury per cubic meter of air set by the American Council of Government and Industrial Hygienists (ACGIH) for mines and mineral processing plants. Chemical spot tests and portable devices for mercury determination were evaluated, based on information from published sources and performance in laboratory tests. Among the parameters examined were sensitivity, interferences, cost, ease of use, and other factors pertinent to field application, More than 50 methods were evaluated. The investigators found that many readily available methods are suitable for identifying sources of mercury vapor in mines and mineral processing plants. The best method appears to be one that uses a commercially available mercury test paper sensitive only to mercuric ions. For some of the more promising chemical spot tests, this report includes step-by-step instructions for field application.

Jan 1, 1983

By J. M. Goris

Cable bolt supports are becoming an important ground control technique in underground mines in the United States and Canada. They show great versatility and are adaptable for use with many mining techniques, they have high load-carrying capacities, they can be installed in small areas with low roots, and they are cost effective. Investigators in a number of research institutes in North America have conducted studies to assess the material and support properties of cable bolts, evaluate their support capabilities under various mining conditions, and provide design criteria for using cable bolt supports as roof control systems under varying mining conditions. While conducting these studies, personnel have collected important information on the history, application, performance, and economics of these supports. This U.S. Bureau of Mines report documents this information so that ground control personnel unfamiliar with cable bolt supports can gain an understanding and appreciation of their use. A comprehensive bibliography of technical information on cable bolt supports was selected by the authors and is also presented.

Jan 1, 1994

By J. M. Pugliese

The Bureau of Mines, in support of its overall goal of helping to meet future U.S. demand for minerals, undertook this study to aid the quarry entrepreneur and/or operator in developing quarries near urban areas. In response to increased environmental concerns, the quarry operator often must take steps beyond those required in the last decade toward gaining permits for quarrying near metropolitan areas. Following the steps suggested in this report should increase the chances to obtain the permits to open and develop a quarry. Each task and question in the general plan flow diagrams are described in detail, with the flow diagrams aimed at the goal of acquiring the necessary permits. The appendixes include (1) types of projects for which Environmental Impact Statements (EIS's) may be prepared and Federal agencies responsible for preparing them, (2) State contacts for information regarding environmental impact assessment requirements and mining and mineral land reclamation laws, (3) a checklist of environmental inventory factors, (4) a tabulation of different regulations that affect mining in Michigan and the number of townships and counties that have each of the listed regulations, and (5) environmental logic associated with site selection. A central recommendation is that the quarry entrepreneur and/or operator coordinate plans at the beginning with local government officials (such as township supervisors and/or city and county planning board members), State and Federal officials, and public groups that will be affected.

Jan 1, 1979

By Franklin D. Cooper

This Bureau of Mines report reviews in detail the foundry coke situation in the United States in 1975. It discusses intrinsic production problems and identifies opportunities for modifying operating practices so that the quality and yield of foundry coke can be enhanced without unnecessary investment in new equipment. Major topics include operating data and attendant practices and problems, the relationship of carbonization phenomena to coke quality and yield, environ- mental impacts of foundry coke plant operations, suggested research and development opportunities, and data on components of oven charges and on foundry coke production and shipments.

Jan 1, 1977

By Fred V. Carrillo

Of the total quantity of secondary copper and zinc that became obsolete in the United States from 19b1 through 1970, more than 11 million tons of copper and 10 million tons of zinc were not recovered. These estimates are based on a study of the flow and recovery of old copper and zinc scrap by consumption end-use. This report describes (1) where copper and zinc are being used; (2) when they become obsolete and available as secondary metal; (3) how they are being collected for recycling; and (4) how much might be recovered from scrap that presently is not being recycled.

Jan 1, 1974

By Lawrence K. Barker

Crude shale oil produced by underground retorting of Green River Formation oil shale was hydrogasified over a cobalt-molybdate-on-alumina catalyst at operating temperatures ranging from 800° to 1,300° F, pressures of 500, 1,000, and 1,500 psig, and a liquid hourly space velocity of 1.02 volumes of oil per volume of catalyst per hour (Vo/Vc/hr). At a temperature of 1,300° F and pressure of 1,500 psig, 94 weight-percent of the liquid feed was converted to gas containing 72 volume-percent methane. With two reactors in series at a temperature of 1,170° F in reactor 1 and 1,260° F in reactor 2 and a pressure of 1,500 psig, 97 weight-percent of the liquid feed was converted to gas with a methane content of 75 volume-percent. Liquefied petroleum gas (LPG) was hydrogasified at operating temperatures ranging from 500° to 1,400° F at a pressure of 500 psig over a cobalt-molybdate-on-alumina catalyst. Similar experiments were made with an empty tubular reactor. The data indicate that gasification reactions in the presence of a cobalt-molybdate catalyst change from predominantly a catalytic (carbonium ion) reaction to predominantly a thermal (free radical) reaction at temperatures greater than 1,100° F. The data also indicate that a reaction temperature of 1,350° F is necessary at the space velocities used in this investigation to make a synthetic natural gas (methane content of 90 volume-percent) from in situ crude shale oil.

Jan 1, 1975

By J. C. Kerkering, S. M. Miller, P. C. McWilliams

Researchers at the U.S. Bureau of Mines investigated the use of close-range photogrammetry and subsequent stereo digitizing to obtain data from rock fracture roughness profiles. The photogrammetric process yielded results that were acceptable but somewhat inferior to those obtained by a mechanical profilometer. On the basis of this study, further pursuit of photogrammetry as a data collection method in mining is proposed. Fractal geometry was investigated as a means of measuring the roughness of rock fracture profiles. Four fractal algorithms were used: divider method, modified divider method, box method, and spectral method. A comparison of the methods gave ambiguous results. Brown's modified divider method provided the best means of obtaining the fractal dimension. Shear strength estimates were obtained using the parameters of the modified divider method and Myers' Z, measure. Because of differences in results when comparing the different ways of obtaining the fractal dimension, future users of fractals in studies of rock fractures are advised to cross-check their results carefully.

Jan 1, 1993

By John R. Parker

Work places of an underground coal mine are required (30 CFR 1719) to be illuminated while self-propelled equipment is used. Permissible machine mounted systems have been developed and applied satisfactorily to many mining operations. However, some low seam and thin seam equipment has been difficult to illuminate because reliable, direct current systems and compact, low output, low glare luminaires were not available. This program resulted in the design and prototype construction of compact, low glare luminaires and AC and DC power systems, particularly suited to resolving illumination problems on low and thin seam mining equipment. Design objectives were based on enhancing the prospects for thin seam illumination solutions through definition of a product which could challenge markets enjoyed by higher glare luminaires and through reduction of technical risks associated with any new product development as well as the MSHA certification process.

Jan 1, 1982

By Kenneth L. Rubow, Virgil A. Marple

"INTRODUCTION Respirable dust is defined as the dust which penetrates to the alveolated regions of the lungs. Due to the size selective nature of the particle removal mechanisms in the nasal passages and lung airways, criteria defining respirable particles must be a function of the particle size. Three criteria defining respirable particle penetration are shown in Figure 1. These criteria have been defined by the British Medical Research Council (BMRC), the American Conference of Governmental Industrial Hygienists (ACGIH) and German TBF 50-11 (1).The quantity of respirable particles in an aerosol can be measured by use of two-stage samplers. The first stage consists of a particle preclassifier with penetration characteristics corresponding to one of the respirable penetration curves in Figure 1. The large nonrespirable dust particles are removed from the airstream in the preclassifier and the smaller respirable dust particles pass on to some device which can measure their concentration (the respirable dust concentration).Instrumentation for the measurement of respirable coal mine dust has been limited by the severe conditions existing within the coal mine. The conditions of particular importance are the methane atmosphere, high humidity, and the general non-laboratory type environment. The most severe of these conditions is the methane atmosphere since any electronic or electric powered instrumentation must be intrinsically safe to operate in such an atmosphere.In spite of the difficulty of sampling respirable dust within the mines, many instruments have been developed for in mine use. Although these instruments operate under a variety of principles they generally fall within two categories: personal samplers and area samplers.A personal sampler is worn by the mines while he is performing his duties in the mine. These devices are generally small, light weight and require little power so as not to interfere with the miner's ability to work."

Jan 1, 1988

By Irving Hartmann

The Experimental Coal Mine of the Bureau of Mines has served principally as a valuable and unique testing laboratory for studies of the explosibility of coal dust and mine gas; studies of the numerous complex and interrelated chemical and physical factors that govern the ignition of coal dust and the propagation of mine explosions; and studies designed to develop measures for preventing explosions or reducing their destructive effects. These researches, coupled with educational efforts by the Bureau of Mines and enlightened safety consciousness in the mining industry, had fruitful results. This is evidenced by the remarkable reduction in the frequency of major coal-mine explosions and the number of fatalities from explosions since the Bureau of Mines was established. Despite this progress, further important unresolved problems arise; these are due in part to changes in mining conditions and methods, which have brought about increased production of fine coal dust in highly mechanized operations. To solve the new problems, research must be continued without interruption. The results of many very recent and current studies in the Experimental Coal Mine are summarized briefly, and pertinent studies by European mine-safety-research organizations are listed.

Jan 1, 1957

A new horizontal borehole packer for use in coal beds has been developed. This packer utilizes a principal of operation which has not previously been used. The resulting packer is less costly to purchase, can be easily repaired in the field with inexpensive expendable parts. This report describes the development and testing of the new packer and the evaluation of commercially available packers.

Jan 1, 1971

By William W. Adams

A general increase in employment prevailed in the stone-quarrying industry of the United States during 1941 compared with 1940. Likewise, more accidents occurred to men working in and about the quarries, with the result that the accident-frequency rate for the industry as a whole was higher in 1941 than in the previous year. Reports from operating companies to the Bureau of Mines, covering open and underground quarries, as well as rock-crushing and rock-dressing plants, cement mills, and limekilns at or near the quarries, showed a total of 86,123 men employed and a total of more than 22 million man-days of labor performed during 1941. The total working time of the industry averaged 260 days per man. Measured in man-hours, the volume of work equaled 173 million, an average of 2,011 man-hours per employee.

Jan 1, 1943

By F. D. Wang

This report presents a structural-mesh-generating computer program for the two-dimensional finite-clement method of mine structural analysis of single and multiple openings in nonhomogeneous rock mass. This program greatly reduces the amount of input data required and the chances of error which otherwise are large owing to the large amounts of data and the complex mesh involved. The program description, a user's guide, example problems, and program listing are included.

Jan 1, 1971

By F. A. Penning

Improved skips, with lightweight cylindrical bodies, have made a significant contribution to advancing mine hoisting technology. New concept skips of aluminum bodies with rubber lining; fiberglas bodies with polyurethane liners have been designed and fabricated for field testing at an operating mine. New design, adjustable guide rollers have shown improved ride characteristics with noticeably less wear. Major reductions have been made in stress levels and stress concentrations. Field experience has shown the practicality of the approach. Guide alignment has been measured using the Guide Alignment Measuring System (GAMS). Analysis has been applied to interpret the data. Field measurements in an operating shaft and a test tower have shown the agreement in data from GAMS and plumb wires. Reproducibility has been demonstrated. The data are useful to realign shafts, to use as s maintenance tool, and to evaluate the maximum safe hoisting speeds. The surveys are made at several hundred feet per minute and the system is self-contained. Dynamics of skip-guide interaction has been analyzed using the computer program SKIP II. The effects of speed, weight, type of guides, kind of misalignment have been studied. Resonance has been demonstrated and factors that eliminate resonance have been identified. Data from the GAMS surveys are applicable to the SKIP II program. Interaction between the hoist rope and the mine conveyance has also been studied. Computer programs and closed-form solutions are presented. Economic impact of lightweight skips is presented for an existing mine and for a new mine. Reduction in rope size has a profound effect when using a lightweight skip for the same capacity. Increased productivity can be realized by keeping maximum rope pull the same while increasing skip capacity. Examples and charts project the significant savings in capital expenditure for new installations.

Jan 1, 1985

By A. G. Galaitsis

This report summarizes the work performed under the USBM Contract No. J0245001. The purpose of this work was to expand and improve the scope and accuracy of the method developed under USBM Contract No. J0113056 for the prediction of the number of overexposed workers in the mining industry. A significant portion of the noise data were acquired during mine visits-that took place in the-course of this contract. These data were obtained with time-resolved dosimeters which among other things store a time history of the sampled noise for an eight hour work period. The remainder of the noise data have been obtained from MSHA files and from other BoM-sponsored projects. The report reviews the prediction model, discusses the model's assumptions and approximations, describes the function of the developed software, offers typical examples on the use of the software and includes plots of the newly acquired noise data records.

Jan 1, 1986