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By R. W. Stahl

One of the broad purposes of the Bureau of' Mines since its establishment has been conservation of mineral resources. As some of the coal beds approach depletion, especially those coals suitable for making metallurgical coke, more and more attention is being given to means of recovering a larger percentage of coal in place. The customary system of mining in the United States is by room and pillar, or some variation thereof, which leaves pillars of coal to support, the roof. In many operations, where the pillars are not systematically recovered, the loss of coal often amounts to 50 percent or more of the original deposit. In many instances in developing new mines, It is planned to recover chain and barrier pillars on retreat when the mine has reached established boundaries. Too often, however, mines are abandoned for some unforeseen reason before completion of mining without recovering any pillars. Usually, these pillars are lost forever. With this in mind, the Mining Division, Region VIII, of the Bureau; of Mines is encouraging mining by longwall methods. It is a generally known fact that almost all of the European coal is mined by longwall methods, which are conducive to a high percentage recovery of coal. A comparison between mining systems usually is on the basis of tons per man per shift. Unless all operating conditions are similar, such a comparison could be misleading. Generally, the output per man shift in European longwall mines is less than that obtained in room-and-pillar mining in the United States. In European mining, maximum recovery of coal is not only mandatory but it must be accomplished without major damage to surface by subsidence. These restrictions necessitate packing or stowing with consequential increases In manpower and decreases in output per man shift.

Jan 1, 1954

By T. A. Kubala

Electric discharge ignition has been reinvestigated in a modified Hartmann apparatus for lycopodium powder with air. Minimum stored energy to ignite air dispersions of lycopodium was 25 to 30 mj; ignition occurred with 1 gram of lycopodium dispersed into the 2.7-liter vessel. Ignition energy was measured as a function of the weight of powder used, although some reservations are expressed concerning the uniformity of the lycopodium-air mixtures. In particular, wall layers of lycopodium, remaining after dispersal of 1 gram of lycopodium, were as easily ignitable as the most easily ignited air dispersion. Thus, an unanswered question has arisen concerning the role of surface coatings in the flammability of all marginally ignitable mixtures.

Jan 1, 1981

By David L. Veith

Caustic scrubbing followed by silica flotation with cationic ether primary amine proved effective in upgrading commercial magnetic concentrates to supergrade products containing 2 percent SiO2, or less. Samples representing 41 million long tons per year of commercial magnetic concentrates from the Lake Superior region were tested by the Bureau of Mines. Bench-scale and pilot plant research indicated an estimated potential of 32 million long tons per year of superconcentrates to be available. Two pilot plant investigations yielded superconcentrates containing 1.1 and 1.9 percent SiO2 that were derived from commercial concentrates containing 7.0 and 4.2 percent SiO2, respectively. Corresponding iron recoveries were 90 and 93 percent at reagent costs of just over 33 cents per long ton of superconcentrates produced. Additional sources evaluated on a bench scale resulted in iron recoveries of 72 to 95 percent in products containing 1.7 to 2.0 percent Si02. Although reagent cost ranged up to 60 cents per long ton of superconcentrate, it is probable that these costs would be reduced in plant applications where benefits are derived from material and reagent recycle.

Jan 1, 1974

By Elaine T. Cullen, Albert H. Fein

Federal law mandates that all miners receive safety and health training when first entering the mining industry and at least 8 hours annually thereafter. Although the mining industry has historically relied on an experiential master-apprentice model for training new employees, the formal safety training provided to miners is generally done in a classroom, with mixed results. In a series of stakeholder meetings held by NIOSH across the West in 1997-2000, trainers identified significant gaps in materials that were available to teach new and experienced miners. They asked whether NIOSH could develop effective materials to fill these perceived gaps, as well as make training more effective for those who were required to attend, but who often refused to be attentive. Adult learning theories, social learning theories, mentoring, and storytelling were all employed in the development of a series of safety training videos that have become very popular in the mining industry. This Report of Investigations describes the theoretical frameworks that were used, the process that was developed to produce the videos, and the results of the evaluations as to whether or not they were effective in training new and experienced miners.

Jan 8, 2005

By D. Harrington, W. J. Fene

Explosions are a type of mine accident that can be prevented by known methods ; however , they continue to occur because some mining people are still negligent in adopting and using the known and , in general , readily available measures for avoiding these disasters . Although the frequency and severity of explosions have decreased during the past 5 years there is still much room for improvement . Pennsylvania is an excellent example of what may be done to prevent explosions ; this State had an explosion record by no means good during the decade before 1930 , but by the adoption of readily available and not very expensive safety measures it now has almost entirely eliminated explosions . Pennsylvania bituminous mines now have the enviable record of not having had a major explosion disaster in considerably over 4 years . fact , many of our mining States are showing definite progress in working mines without explosions ; and some of these , like Alabama , West Virginia , Wyoming , and others now operating with few if any explosions , have had anything but a favorable record in the past .

Jan 1, 1934

By Oliver C. Fursman, Lloyd H. Banning

This research was undertaken to determine the feasibility of producing steel from hydrogen - reduced , pyrophoric iron powder . Before steelmaking tests were begun , investigations were made to develop procedures for handling the pyrophoric powder safely , and melting tests were made in a single - phase , electric - arc furnace to determine inert gas requirements for preventing powder oxidation . Steelmaking tests were conducted in a conventional electric - arc furnace , usually by a two - slag basic procedure . Results of the research indicated that ( 1 ) pyrophoric powder can be handled safely and can be prevented from oxidizing excessively during charging and melting in electric - arc steelmaking furnaces ; ( 2 ) little , if any , more electrical energy is required for melting Cerro Bolivar iron powder per unit of contained iron than is required for melting heavy melting scrap ; ( 3 ) high - quality steel can be produced readily from high- grade iron powder , having recoveries up to 95 percent of the total iron ; ( 4 ) steel can be produced from simulated titaniferous , chromiferous , and manganiferous iron powders ; and ( 5 ) the electrical energy required for melting increases with increase in the proportion of slag - forming constituents in the furnace charge .

Jan 1, 1964

By J. B. Gayle

The Bureau of Mines studied the effects of air oxidation on the recovery of float coal. Both batch-and continuous-type tests were made on six bituminous coals, representing the range in rank of coals now commercially used for carbonization, and on one anthracite coal. The effects on flotation recovery of oxidation at 1000 C for periods up to 50 days were investigated using an alcohol-type frother and a kerosine-pine oil reagent. Two series of release analysis tests were made, using one medium-volatile bituminous coal. Float coal recovery was adversely affected by oxidation in all tests where the alcohol-type frother was used. Conversely, a small degree of oxidation improved recovery with kerosine-pine oil frother for some of the coals in continuous tests. Prolonged oxidation (beyond about 14 days) adversely affected float coal recovery for all coals, the effect being more pronounced for batch-type tests and for tests using alcohol-type frother. Reagent selectivity for the rejection of both ash forming and sulfur bearing minerals was reduced by oxidation. Severe reduction of reagent selectivity required only about 3 days' oxidation for alcohol-type frother but more than 10 days' oxidation when the kerosene-pine oil reagent was used.

Jan 1, 1965

By B. Dimitriades

Data on smog-forming reactivities of exhaust aldehydes are scarce. Such data were obtained by irradiating in a smog chamber typical exhaust aldehydes, individually and in exhaustlike mixtures. Observed reactivity manifestations were rate of nitrogen dioxide formation (RNO2) and yields of oxidant, peroxyacetyl nitrate, and formaldehyde. Results showed that exhaust aldehydes vary widely in reactivity. Formaldehyde showed high RNO2 reactivity but low oxidant yield; benzaldehyde, [m]-, and [p]-tolualdehyde were totally unreactive when irradiated individually; [o]-tolualdehyde was reactive. In mixtures, benzaldehyde manifested reactivity in terms of peroxybenzoyl nitrate yield. Exhaust aldehydes as a group are judged to be as reactive as the exhaust olefin group. The importance of the aldehyde contribution to exhaust reactivity and methods for assessing such contribution are discussed.

Jan 1, 1971

By L. O. Bacon

This Bureau of Mines report summarizes the results of laboratory work in the design of instrumentation for obtaining the dynamic tensile strength of rock at minimum loading. Minimum loading is defined as the lowest tensile loading by pulse reflection to cause fracturing. The instrumentation for obtaining dynamic tensile strengths of rock cores evolved into the use of a compressed-air pellet gun to impact one end of a rock core, suspended by wires, at increasing increments of air pressure. Maximum strain was measured on most or all of the impacts, and the strain at fracture of the core was obtained by extrapolating the pellet velocity-strain curve to the pellet velocity at fracture. Stress at tensile fracture was obtained from the maximum s train, and the dynamic Young's modulus was calculated from the rod velocity by using simple rod theory.

Jan 1, 1962

By R. M. Ray

The Bureau of Mines evaluated five commercial badge-type carbon monoxide dosimeters. Color changes in the badge reagent indicated the presence of carbon, monoxide. Possible effects of ambient conditions on dosimeter response to CO during or after coal mine fires or explosions were studied. Temperature and humidity changes did not change dosimeter sensitivity to CO. Contaminant gases such as CO2, N02, S02, and H2S had effects that varied with brands of dosimeters ranging from no effect to increased sensitivity to CO. Dosimeters tested after 6 months of storage showed an increase in failure rate as high as 25 percent. Tests were conducted to determine the effects on dosimeter time-for-color change caused by observer's sight (colorblind); lighting, and coal dust on dosimeters. No significant effects were observed. Observer variance was the most pronounced factor observed in all tests.

Jan 1, 1975

By Robert K. Koch

Laboratory-scale studies on defluorination of natural and synthetic fluorspars by pyrohydrolysis at 1,500° C. were made to determine the feasibility of developing a process for producing hydrogen fluoride from siliceous fluorspars. It was found that the reaction (at 1,500° C.) is not promising for process development, even though a silica-free offgas can be generated. The primary difficulty is the low hydrogen fluoride content of the offgases; an HF content of 6 percent was the best achieved. Previous research by the Bureau of Mines has demonstrated that offgases averaging 27 percent hydrogen fluoride can be produced under carefully controlled conditions at 1,280° C. The lower temperature process is a better method for production of HF. However, charges in which the CaF to Si02 mole ratio varied from 0.4 to 2 could be processed with similar results. Also, combined alumina and ferric oxide contents up to 25 mole-percent did not noticeably alter the rate of defluorination. Therefore, virtually any natural siliceous fluorspar would respond in essentially the same manner when exposed to water vapor at 1,500° C.

Jan 1, 1962

By Ronald D. Hill, Elmore C. Grim

To better appreciate the problems associated with surface mining, it 1s imperative that the stripping operation be understood. Surface mining is a very broad term and refers to any process of removing the earth, rock, and other strata in order to uncover the underlying mineral or fuel deposit. Strip mining is a type of surface mining in which the overburden is removed in narrow bands, one cut at a time. Strip mining methods employed to recover coal can be divided into two general types: area and contour.

Jan 1, 1974

By Kenneth J. Miner

Pittsburgh bed and Lower Freeport bed coals were tested in the U.S. Bureau of Mines two-stage froth flotation pilot plant, which utilizes a new flotation process to remove pyritic sulfur. The process consists of a first-stage coal flotation step to remove coarse, free pyrite and other refuse in the tailings. The clean coal froth concentrate is then repulped and treated with a coal depressant, a pyrite collector, and a frother to selectively float the remaining pyrite in a second stage. Results in the pilot plant were excellent, comparing well with those obtained in laboratory batch tests. That is, about 70 percent of the pyrite present in the Pittsburgh bed coal and about 90 percent of the pyrite present in the Lower Freeport bed coal were removed with excellent final clean coal recoveries.

Jan 1, 1973

By Stanton L. Tainter

"As an adjunct to its minerals-investigation program, the Bureau of Mines has developed a number of operating devices and techniques worthy of note. This paper, prepared under the supervision of J. H. Hedges, chief, Tucson Branch Mining Division, and under the general supervision of Lowell B. Moon, chief, Mining Division, reports upon certain methods devised to overcome difficulties encountered in cementing of diamond-drill holes at a Bureau of Mines project at Christmas, Gila County, Ariz.Pressure grouting was employed to recondition a caved hole it was desired to reopen and deepen. The hole, which had boon stopped 7 months previously at a depth of 488 feet, was caved below 449 feet in a contact zone of claylike, altered diorite and crumbly metamorphosed limestone. As other means of obtaining moderate pressure were not available, carbon dioxide gas, drawn from tank of liquid carbon dioxide through a pressure reducing and regulating valve, was used. The hole was reopened successfully with 12 grouting jobs.Another hole, where cawing from several water-bearing fractures between 202 and 232 feet gave trouble, was successfully cemented by the use of a grouting plug. An attempt to cement through the rods had failed, owing probably to agitation caused by water currents. Pressure grouting through the caning set above the cave could not be need, because water was forced up outside the casing when pressure was applied. The problem was solved by using a wooden plug 1-13/16 inches in diameter, which, when soaked in water, expanded to a tight fit in an AX hole. A hole was drilled through the plug, and a rubber flap valve was nailed to the lower end. In the upper end of the plug the hole was enlarged to fit loosely over an EX rod coupling finished smooth. The plug was lowered on the end of the drill rods to a point about 10 feet above the cave, where it was allowed to expand tightly to the hole. Cement grout was then pumped through the rods, and the rods were removed from the hole. After allowing time for the cement to set, the wooden plug was chopped out and drilling van resumed.Over 300 tests were made to determine the type of cement most suitable for use on the Christmas job, and the effect of cement-water ratio, temperature, and various admixtures on workability, setting time, and strength. The results of these tests, described in detail in the body of this report, indicate the desirability of thoroughly testing available cements when it is necessary to drill holes under difficult conditions that may cause failure.When it became desirable to reopen and deepen a caved drill hole, it was considered easiest to recondition the hole by pressure grouting, As other mans for obtaining moderate pressure were not available, a method utilizing carbon dioxide gas was employed. The hole was reconditioned successfully with 12 grouting jobs."

Nov 1, 1949

By R. F. Abernethy

Analytical results, including ash fusibility data, are presented by the Bureau of Mines for 10 major constituents in coal ash from 373 samples of commercial U.S. coals. Determinations of Si02, Al2O3, Fe2O3, and P2O5 were made by colorimetric methods, Na2O and K2O by flame photometry, Ti02, CaO, and MgO by a spectrochemical method, and SO3 by a gravimetric method. In bituminous coal ashes the silicon, aluminum, and iron calculated as oxides often make up about 90 percent of the ash.

Jan 1, 1969

The initial results from the magnetic sludge factorial experiment are summarized in Table 2. For ease in interpretation, the four separate variables are identified with the high and low level of each variable being represented by + and - signs, respectively. Several important relationships are evident from an inspection of the data in Table 2. For example, magnetic sludges were obtained only during the high temperature tests. Secondly, with the exception of the last three tests, there is an apparent correlation between settled sludge volume (or sludge settling rate) and pH. Data on residual dissolved Fee+ indicate that precipitation of iron is not complete at pH 8 and room temperature (Tests l, 3, 5, and 7). Although this should not have any confounding effect on the interpretation of the results, it is an important observation and an aspect of the overall conceptual process that should be considered carefully during any future developmental work. The data in Table 2 were employed more fully in the calculation of main effects and variable interactions for each of the three responses. For this purpose, a codified design and calculation matrix, shown in Table 3, was used. The derivation of this matrix is described by Davies.(9) The positive or negative signs for variable interactions are obtained simply by algebraic multiplication of the signs for each single variable involved in the interaction. Main effects and interactions are calculated by multiplying the response values (Table 2) by the corresponding effect elements (Table 3), summing the results, and dividing by 8. The resulting value for single variables is also sometimes designated as an average effect, since (for tyro levels of the variable only) it is simply the difference between the average response of all trials carried out at the first level of the variable (factor) and that of all trials at the second level. If the effect of one variable changes at different levels of another variable, the two variables are said to interact. The relative importance of the variable or variables in question is reflected by the absolute magnitude of the calculated main effect or interaction. First-order (two variable) interactions are usually easy to interpret in terms of the physical behavior of the system. Second- and higher-order interactions are often less readily understood, and are often of minor significance in any case. The main effects and interactions derived from the present study in the manner described above are listed in Table 4. It should be noted that

Jan 1, 1971

By Will H. Coghill

The jig men of the Tri-State (Joplin-Miami) zinc district complain about the flakiness of their mill feed. They believe that the flakiness of the composite grains of gangue and mineral are to blame for losses of zinc; that is, that the flaky grains in the jig tailings have higher zinc tenor than the cubical grains. Although the evidence which follows contradicts this belief, no effort is made to give a final and conclusive answer. On the other hand, there is outlined a positive and mechanical method which the operator may use to pursue this and similar investigations. DISCUSSION OF SCREENING METHOD Hand-sorting is obviously not satisfactory for separating cubical grains from flaky grains because the personal influence can not be removed. Screens, however, may be used with success. A set of each of two types of screens is required; namely, the square-hole type and the rectangular (rectang, oblong) type. The square-hole screens must be of the double Tyler scale; that is, the order of the sieves should be after the fourth root of two instead of the customary square root of two; close sizing is important. The size of the rectang screens may be selected by trials so that a part of the material already closely sized on the square-hole screens, will pass the oblong holes. Obviously, the cubical grains will remain on the rectang and the flaky grains will pass through. Hence the mode of operation is to screen first on square-hole screens and then split the products on the oblong-hole screens.

Jan 1, 1928

By G. W. Birge

The Bureau of Mines investigated the effect of temperature on the mechanical strength of cokes of the type normally used in blast furnace operations. Eight samples of industrially produced cokes were subjected to ASTM tumbler tests at temperatures as high as 1,100° C (2,012° F); these temperatures had no significant effect on tumbler results for cokes with stability indexes of 40.6 to 59.9. Two foundry cokes which were tested at only one elevated temperature (900° C) decreased slightly in tumbler stability. Iron are pellets made from a variety of ores and by various industrial methods were not significantly affected by temperature when tested in an oxidizing atmosphere at 1,000° C (1,832° F) by the tentative standard ASTM method.

Jan 1, 1966

By C. L. Brown

Among the more recent developments for breaking coal in mines is the Airdox system, in which high-pressure compressed air is conducted to the points of application by means of heavy-duty steel and copper tubing. Stray electric currents can be detected on y of the compressed-air lines, and evidence of such currents is rev led, by arcs and sparks when contact is made between the tubing and mine track or other equipment forming a current path with the track. Explosive gas is liberated in many coal mines; therefore, from the standpoint of safety, it is desirable to eliminate all possible sources of gas ignition, including stray electric currents. The purpose of this report is to reveal the source, magnitude, and possible methods of controlling stray currents in compressed-air lines that are used in connection with Airdox systems. Stray electric currents have been studied in most coal-mining localities in the United. States where Airdox equipment is used. The information given in this report is based on the find of these studies.

Jan 1, 1949

By R. H. Storch

The work described in this report was part of a Bureau of Mines program to appraise the titanium-mineral resources of Idaho. Part of the program included churn drilling of alluvial deposits that previous preliminary testing, primarily for rare minerals, had indicated to be potential sources of titanium minerals. The first spot churn drilling began in the Deadwood placer area, Valley County, Idaho, in July 1956 to determine both the amount and grade of the ilmenite, FeTi03. Ten holes, ranging in depth from 6 to 40 feet and aggregating 251 feet, were drilled; 54 samples were taken. The samples were sent to the Spokane field laboratory for concentration and visual estimation of the amounts of the more common minerals in the heavy sand concentrates. For specific determinations samples from each drill hole were composited and shipped to the Bureau of Mines laboratory in Albany, Oreg., where petrographic, quantitative X-ray spectrographic, and chemical analyses were made.

Jan 1, 1958