Search Documents

Aluminum alloys are used in two broad classifications: wrought and cast. Wrought alloy products, which are formed into final shape by rolling, forging, extruding. etc., contain low percentages of alloying elements; whereas cast aluminum products, which generally are not worked before use, may contain higher percentages and a somewhat different selection of alloying elements. For example, wrought aluminum alloys usually contain less than one percent silicon and cast alloys contain as much as 18 per-cent silicon. While there are good techniques available for separating aluminum alloys from mixed scrap, there are no efficient ways to separate wrought aluminum from cast aluminum. The high levels of silicon, iron) copper, and zinc from the cast alloys make wrought-cast mixtures unacceptable for wrought alloy production. Consequently, separated wrought aluminum scrap commands a premium price on the market. Since increasing amounts of mixed aluminum alloys are being recovered from automobile scrap, this separation is important for efficient recycling of these alloys. Approach The difference in thermo-mechanical properties between the two classes of aluminum alloys is used as the basis for the separation process. Casting alloys lose their ductility within a certain temperature range while wrought alloys remain ductile. As temperature increases, aluminum alloys gradually become weaker, and at a certain temperature, each alloy loses strength and ductility due to incipient melting in localized areas. For casting alloys that temperature generally lies between 520° to 560° C, but it is above 600° C for most wrought alloys. Mild crushing, therefore, in the proper temperature range will result in complete fragmentation of the casting alloys but only plastic deformation of the wrought alloys. A simple screening step then is used to separate the oversize wrought pieces from the fragmented cast alloys.

Jan 1, 1984

Develop an environmentally feasible method of mining shallow oil sands without removing overburden. Approach Oil sands are extracted through a single borehole by cutting into the sands around the borehole with a high pressure water jet, and pumping the resulting slurry to the surface. Although oil can be extracted from shallow fields by open-pit mining methods, this type of mining may create significant environmental impacts, including; (1) disruption of the surface, (2) accumulation of waste rock piles, (3) accumulation of tailings, (4) damage to the ground water quality, and (5) surface water pollution. The borehole mining system developed and successfully field tested by the Bureau of Mines offers a method for extracting oil from oil sand with minimal disturbance to environmental quality. (For examples of other applications of borehole mining, see Technology News Nos. 95, 63 56, and 48.) How It Works Prior to the start of mining operations, baseline conditions for ground subsidence and ground water quality are established at the test site so that the degree of subsidence and changes in ground water quality can later be determined. Oil sands mining is conducted using the Bureau of Mines borehole mining system. The borehole mining tool consists of a 12-inch-diameter pipe string and accessories capped with a three passage swivel terminated with a mining section. The mining section has an auger at the bottom. Four slurry inlet holes and an eductor are located above the auger, and a single cutting nozzle is located near the top of the mining section. The tool generates a high velocity water jet that erodes and slurrifies ores. The slurry is drawn into the inlet of the eductor which lifts the slurry to the surface where it is deposited into a slurry discharge sump. To detect evidence of subsidence, surveys of the land surface are made at regular intervals during, and until 30 days after, the termination of the mining operations. Samples of ground water from the borehole and two adjacent monitor holes are taken on alternate days during the mining operations, and are later analyzed to determine if any ground water contamination has occurred.

Jan 1, 1981

By Edmund S. Leaver

This information circular is written is response to the marry requests for information on the recovery, or reason for poor recovery, of fine gold by the amalgamation process. Checking Gold Content Experience has shown that in many cases error has been made because the true told content of a particular sample or deposit was not known. Fire assays of representative samples give accurate results and should be considered final in determining the gold content.

Jan 1, 1928

By Thomas Varley

"Concentration, ore-dressing, or the dressing of minerals are common terms used in metallurgy and indicate processes of separating valuable minerals from worthless gangue. It is understood, of course, that the products from such processes, being separated from the various minerals and gangue, are ready for commercial sale or for further treatment by smelters and refineries.Gravity concentration takes advantage of the difference in specific gravity of the various constituent minerals and gangue of waste material in the ore. The two most common forms of concentration by this means are jigging and table concentration. Jigs usually are used in the separation of relatively coarse material and the tables for the finer material, the line of division in general being about 20 mesh.There are mar factors to be considered .before a decision can be made as to what method would be best adapted to the successful treatment of an ore and only by careful experiments can this be determined. Among the important factors to be considered are. The nature of the minerals present, their physical and chemical relations to the gangue material, and the gangue material itself. Perhaps the most important is the number of minerals present and their relation to each other.Metals exist in ores in three principal forms -- sulphides, oxides or carbonates, and native. Concentration by gravity methods is in general best suited to sulphide ores, although in some places considerable success has, been obtained in the concentration of oxide ores by gravity methods."

Apr 1, 1920

By Gregory M. Molinda

The Bureau of Mines conducted an investigation into the occurrence of outbursts of salt known to be responsible for explosions, fatalities, and damage in domal salt mines. The purpose of the investigation was to develop a basis for predicting these outbursts based on geologic and associated physical properties of salt. The investigation was conducted at the Cote Blanche salt mine in southern Louisiana. Because outbursts are the primary mode of methane emission into the mine, more than 80 outbursts, ranging in size from 1 to 50 ft in diameter have been mapped. These outbursts generally are aligned and elongate parallel to the direction of salt layering. More than 200 salt samples, both random and selected, were tested for methane content. It was found that outburst zones are well correlated with high methane content. Detailed mapping also revealed that the zones are well defined, with salt crystal size abruptly increasing upon entry into the zone. The intensity of folding and kinking of the salt layering within the outburst zone also appears to increase. An interbedded sand layer occurring throughout the mine does not appear to be a significant source of methane. However, fine-grained salt may be related to outburst occurrence.

Jan 1, 1988

By John R. Reeves

The principal oil aha.le in Indiana ie known as the New Al'baZ\Y shale. It 11 ot Devonian age, and ia usually correlated with, although not certainly of the 1ame age a,, the Antrim shale of northern Michiga.. the Ohio shale of Ohio, and the Chattanooga shale ot Kentucky. Termescae • a."ld Georgia. The nqtmal thickneaa of the formation 1n Indiana 1e a.bout 100 faet, ltbough 1n the region of its out­ cro;l the tall th!::kne,111 io rarely exposed because cf the general d:.p of the strata, which is 11 about 30 feet per mile to the west. With the exception ot thin local pha1e1, the entire thickness is oil shale,

Aug 1, 1922

By Homer J. Ballinger

A multiple drill carriage or "jumbo," which is believed to be unique in both design and performance, was constructed and has been in use for the past year at the Bureau of Mines experimental oil-shale mine near Rifle, Colo. This jumbo mounts four long feed percussion drills and is so designed that two men can operate all four drills. Before the jumbo was placed in operation, a minimum of eight man-shifts was required to drill 72 fifteen-foot holes in headings 60 feet wide and 27 feet high. The sane round is now drilled by two men in about 6 hours. Over 500 feet of drilling per man shift is easily and consistently accomplished. Use of the jumbo has resulted in a 75 percent reduction in drilling labor and a substantially lower drilling cost.

Jan 1, 1950

By Roger J. Morrell

The Bureau of Mines conducted drag cutting experiments in hard, abrasive rock in an effort to extend the capabilities of an experimental kerf-core mining machine. The basic kerf-core mining machine cannot be used in hard, abrasive rocks because of the high wear experienced by the kerf cutters. These experiments were conducted in an effort to develop a method of preweakening the rock ahead of the kerf cutters in order to reduce the high cutting loads and hence the higher wear rates experienced by the cutters. The two "preweakening" techniques studied were indenting with mechanical wedges and single and double slotting with diamond saws. The best cutter force reduction achieved with mechanical indenting as 70 pct, whereas double slotting achieved force reductions of up to 99 pct. Conceptual designs of preweakening systems that could be retrofitted onto the basic kerfing cutterhead were developed for both the indenting and the slotting techniques. A high-energy impactor with wedge bit was used for the indenting method, and high-pressure water jets were used for the slotting method. A preliminary technical and economic analysis was performed for both of these full-scale systems to illustrate the methodology and to point out the important technical and economic factors that must be considered.

Jan 1, 1987

Although the technology involved in removing material from below the earth's surface has a long history, communication systems in underground workings are relatively new to the industry. Communication equipment did not begin appearing in underground mines until the early 1900's. Figure 1-1 shows a miner using a Western Electric standard telephone set for underground mines in 1913. These early phones were essentially the same as those used aboveground, except that they were enclosed in cast-iron boxes as protection against moisture, acid fumes, and gases. In the 1950's, the Chesapeake and Potomac Telephone Co. of West Virginia introduced a telephone set for use in explosive atmospheres that was designed around the philosophy of explosion containment. To contain an explosion within the telephone set required a 39-pound casing, which greatly limited portability. [ ] Both of these telephone sets required "pipe" or conduit, not a very practical item for a 100-squaremile coal mine. A common thread prevalent in the first 40 years of design and development is that the primary effort was placed on the telephone set. In the early 19701s, as work began on the design of modern communication systems for use in underground mine environments, the following requirements were established: 1. Must meet intrinsic safety standards .--This applies not only to coal mines, but to other explosive environments. 2. Must be compatible with the environment.--The system must with- stand dust, moisture, and corrosive conditions. 3. Must be rugged in structure.-- The system must withstand maintenance by 10-inch pliers and 4-pound hammers, as well as impact from a falling piece of roof. 4. Must be size-flexible.--Whatever is built must be sized for the small operator as well as the large companies. 5. Must be a total system in design.--The system must be intrinsically safe, including cable, power supply, and station set. 6. Must work with present telephone system.--The system should be compatible with aboveground communications already in place; it should not be the single cause of change in aboveground communications. 7. Value-added pricing.--The system should be reasonably priced so that savings created by its introduction will more than offset the installation cost.

Jan 1, 1984

Reduce mine worker dust exposure by capturing airborne coal and quartz dust generated by a continuous mining machine. Approach Install a water-powered scrubber system operating at 1,000 psi on the side of a continuous miner boom. Dusty air under the boom is drawn through the scrubber, and cleaned air is discharged into the face return. How It Works Most coal mines use exhaust face ventilation to send fresh air over the miner operator, and contaminated air behind the line curtain to the section return. The difficulty with exhaust face ventilation is that the line curtain should be within 10 feet of the face for maximum effectiveness. If the line curtain is not extended properly, or water sprays for dust control are poorly installed, dust rolls back toward the operator. A scrubber mounted on the mining machine will effectively reduce this dust rollback and the dust in the return airstream.

Jan 1, 1989

By James H. Aase

Selected glacial lake clay deposits in Minnesota were sampled, tested, and evaluated to determine their suitability for use as a bonding agent in iron ore pellet manufacturing. Preliminary tests conducted on clay samples obtained from five ancient glacial lake basins identified the clays in the Lake Agassiz glacial lake basin near Cook, Minn., as having the greatest bonding potential. An auger drilling program was conducted to obtain substantial quantities of representative material for detailed testing. The drilling indicated the presence of large clay reserves in excess of 500 million tons within the 12-square-mile area investigated. Bench scale tests indicated that the bonding properties of Cook area clays, when activated with relatively small quantities of sodium carbonate monohydrate (Na2C03?H2O), imparted excellent strength characteristics to iron ore pellets. Larger scale continuous pelletizing tests were made to confirm the bench scale results. These tests indicated that use of 1 percent activated clay alone as binder gave the iron ore pellets an overall strength slightly lower than with 0.75 percent bentonite, considered the industry standard. Use of 0.5 percent activated clay plus 0.5 percent bentonite produced better pellet strength qualities than use of 0.75 percent bentonite alone, without increasing the silica plus alumina content. The data from both bench scale and larger scale continuous tests suggest that the Cook, Minn., clays can be utilized after activation either alone or in combination with bentonite at an economic advantage over present pelletizing practice with bentonite.

Jan 1, 1968

By P. L. Swanson, S. Billington, F. M. Boler, L. H. Estey

Stabiity analyses of fractured and faulted rock masses require delineation of the position, extent, and orientation of geologic discontinuities. The size of the smallest active discontinuity that may potentially be resolved using the spatial distribution of microseismic event locations is limited by the accuracy and precision of the location methods. At a hard-rock mine in the Coeur D'Alene mining district of northern Idaho, two data sets consisting of calibration blast signals from a known source site and origin time and microseismic event signals were recorded using a stope-wide accelerometer array. These seismic signals are used to quantify various sources of error in event location. Five factors influencing source location errors are examined in this US. Bureau of Mines study: (1) biases of the numerical source location techniques, (2) receiver array geometries, (3) uncertainties in receiver positions, (4) errors in picking arrival times, and (5) uncertainties in seismic velocity structure, including the effect of mine openings. In addition, synthetic data (accelerometer positions, travel-time picks and wave velocity) are used to determine the effect of known systematic and random errors on source location calculations. It is shown that the commonly accepted association of minimum travel-time residuals with the best location solution does not necessarily hold true when there is a systematic error in seismic velocity. Recommendations are made for increasing the accuracy and precision of locations of microseismic events detected under similar field conditions.

Jan 1, 1992

By W. P. Stroud

In this U.S. Bureau of Mines report, the conditions required for the direct reconstruction of a tomogram from observed line integrals are examined. Because of the limited access to the working faces in coal mines, the special case of access to only two opposite faces is emphasized. Classical matrix methods were used for small dimensional (2 by 2, 3 by 3, and 4 by 4) applications to determine the limitations and the requirements for a solution. The results for large (n by n) grids were then inferred and generalized from those of the smaller grids and matrices. Limited access tomography is found to be appropriate for in-seam hazard detection from seismic and microwave data, but it is shown that additional data must be added to obtain a direct solution.

Jan 1, 2010

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

By D. Harrington

We Americans pride ourselves that ours is the greatest, most advanced and most civilized nation in the world, yet statistics indicate that apparently we have little appreciation for the lives and limbs of the people whose efforts give us whatever greatness we possess. The latest available statistics indicate that the annual accident death rate per 100,000 of population is nearly 80 or far higher than that of any other country in the world except Chile; is more than double the rate in Hungary, Netherlands, Ireland, Belgium, Denmark, Italy, Germany, Norway, Sweden, and Finland; is nearly double that of England, Wales, the Union of South Africa, New Zealand, Japan, Australia, and Scotland; and is 25 to 40 percent greater than Switzerland, France and Canada. To make matters worse, from the viewpoint of mining; the latest available statistics give mining by all adds the worst accident rate of the major industrial occupations in the United States, the accident severity rate for mining in 1935 being listed by the National Safety Council as 10.14, the next highest rate being 4.52 for construction, and the average rate for 30 main industries being 1.58. IMPROVEMENT IN SAFETY RECORDS Offsetting to a slight extent this rather dark picture is the fact that starting about 1930 the mine-accident rate in both coal and metal mining began to fall, reaching an all-time "low" in metal mining in 1932 and in coal mining in 1933. It now appears probable that the year 1936 has again lowered the accident rate in coal mining and this, together with the fact that the years 1933, 1934, 193 5, and 1936 all set much lover accident rates in coal mining than ware achieved for any similar previous period, gives hope that the trend is definitely in the right direction, though from the above figures mine-accident severity has a long, tedious road to travel before it becomes as low as the severity rate of all other major industries in the United States.

Jan 1, 1937

The Sago Mine Disaster, on January 2, 2006, placed renewed focus on several different aspects of safety in the underground coal mining industry. One area which received increased attention since Sago and other underground coal mining events is the concept of Safety Culture. This report describes the results of a pilot Safety Culture Assessment implemented at a small Appalachian underground coal mine, hereafter referred to as the Mine. The purposes of this pilot assessment were to (a) evaluate the feasibility and usefulness of a methodology for assessing safety culture that had previously been developed for use within other industries, (b) to initiate an investigation into the understanding and defining of the existing safety culture of the underground coal mining industry, and (c) provide meaningful and useful recommendations for the participating mine for their consideration in their ongoing quest to enhance their existing safety culture. This pilot assessment was conducted in July 2007. The report provides information regarding the presence or absence of safety culture characteristics within the Mine. Observations regarding the characteristics of the Mine?s safety culture that should be sustained are presented. Areas in need of attention and management focus to improve the Mine?s safety culture are presented as well as recommendations for moving forward. Safety culture characteristics that are important for the existence of a positive safety culture have been identified to include: - Safety is a clearly recognized value in the organization. - Accountability for safety in the organization is clear. - Safety is integrated into all activities in the organization. - A safety leadership process exists in the organization. - Safety culture is learning driven in the organization. - A process for establishing a strong and effective Safety Conscious Work Environment (SCWE) is in place. Performance objectives are associated with each of the safety culture characteristics and particular behaviors and attitudes have been identified that can be measured to evaluate these objectives. Using a methodology originally developed with the support of the U.S. Nuclear Regulatory Commission, an assessment of selected organizational behaviors and attitudes was conducted to evaluate the Mine in terms of these safety culture characteristics and their associated performance objectives. The methodology involves obtaining a variety of quantitative and qualitative information, using multiple data-gathering methods. The information collected is largely based upon the perceptions of the individuals in the organization. The evaluation is a ?point in time? snapshot of the Mine, but cultural beliefs and assumptions do not change quickly. The feasibility and usefulness of the methodology was successfully demonstrated during this pilot assessment. All aspects of the methodology including functional analysis, structured interviews with accompanying behavioral scales, work observations, and the paper and pencil

Aug 1, 2007

By N. S. Dalal, X. Shi, V. Vallyathan

"INTRODUCTIONThis paper summarizes our recent investigations of the potential role of silicon-oxygen based free radical species in the biochemical mechanism of the lung injury caused by the inhalation of freshly fractured silica. The impetus for this study came from the following observations. Inhalation of crystalline silica is associated with the development of acute and chronic silicosis. Chronic silicosis is characterized by the development of sharply marked concentric fibrotic nodules in the lung. This occurs over a period of several decades with the development of progressive respiratory impairment. In contrast, acute silicosis is manifested by the filling of the alveoli with an amorphous lipoproteinaceous exudate within a short period after exposure, and rapid development of respiratory disability often leading to fatality. Most studies on the pathogenesis of silicosis have focused on the elucidation of cellular mechanisms of cell injury and the development of chronic silicosis. Because pulmonary responses to crystalline silica are distinctly different for · the acute and chronic silicosis, we hypothesized that the acute response is associated with some unique properties of ·freshly formed silica particle surfaces, due to the formation of some reactive chemical species caused by the rupturing or the silicon-oxygen bonds. In occupations involving drilling, tunneling and sandblasting operations acute silicosis can be correlated with this unique surface reactivity of silica. The formation or reactive species was demonstrated, using electron spin resonance (ESR) spectroscopy (Dalal et al., 1986; Fuibini et al., 1987; Hochstrasser and Antononi, 1972). Grinding of quartz crystals under ultra high vacuum (10-10 torr) leads to the formation of Si- and SiO• radicals and these radicals are quenched by exposure to air and other gases (Hochstrasser and Antonini, 1972). ESR signals have also been reported from micronized quartz samples that were evacuated at 413 K (Bolls et al., 1983). In order to find a more direct relationship of such radicals to acute silicosis, we made ESR measurements on quartz dusts freshly ground in ambient air and found- that indeed grinding under ambient environment leads to the formation of the Si• and SiO• type of radicals which decay on storing the dusts in air or in biological buffers (Dalai et al., 1986; Vallyathan et al., 1988). The Si• and SiO radical formation on grinding has also been reported by Fubini et al. (1987). In addition, we recently found that •OH radicals are generated in aqueous suspensions of freshly ground quartz (Dalai et al., 1988; Shi et al., 1988; Vallyathan et al., 1988). We have subsequently carried out detailed cytotoxicity and biological assays on freshly made as well as aged quartz dusts. As summarized below, the results provide new insight into the biochemical mechanism of acute silicosis."

Jan 1, 1988

By John C. Edwards

A two-dimensional, time-dependent, mathematical model has been developed that describes fire spread along the walls of a ventilated duct. The model is based on the assumption that the leading edge of the fire zone propagating along the wall surface coincides with the isotherm for the fuel ignition temperature. The model includes gas-phase energy transport via radiation and forced convection inside the duct and solid-phase energy transport by conduction into the fuel lining. Product gases emitted from the fire zone are assumed to mix uniformly with the ventilation gas to produce an optically dense gas mixture at the combustion temperature that enters the preheat region. Numerical solutions of the model equations for a coal-lined duct (simulated coal mine entry) have been used to investigate the effects of tube radius, air velocity, combustion temperature, and optical density of the soot-laden gas upon the terminal fire spread rate.

Jan 1, 1977

By E. J. Gleim

Many people consider the mining of coal to be an extremely hazardous occupation; but it should be remembered that most large industries have to meet special conditions which, if not dealt with properly, might become hazards to life and property. Mining men may not always be fully aware that some practices and certain equipment that is incorrectly designed or maintained can lead to dangerous conditions. In endeavoring to help the coal-mining industry to prevent accidents and disasters, the Bureau of Mines has engaged in a program of education on conditions and practices that must be avoided. An effective way to teach safety is by visual demonstration. For example, it is generally known that certain kinds of electrical flashes have ignited explosive atmospheres in mines, but actually to see and hear explosions caused by electrical sparks of different size and character under laboratory control is likely to teach a much more emphatic and lasting lesson than would be learned by merely reading about them. The interest manifested by those who witness the demonstrations seems to prove that this is true. The purpose of the demonstrations is not to discourage the use of electricity in mines, but rather to indicate what types of equipment (including some generally regarded as harmless) can ignite gas and what safeguards have been developed to prevent such ignitions. It is hoped that this information will improve the ability of mining men to cope with underground hazards.

Jan 1, 1937

By George S. Rice

"The successful use of the gas mask by the American Army it France in combatting the poisonous gases of German .shells caused many Army men to feel that the as masks were proof against any kind of gas which might be encountered. The result has been that from time to time there have been reported in the press, deaths of former army men through using their masks to enter various kinds of gases such as illuminating gas, gasoline vapor, and the gaseous atmospheres produced by mine fire. Such a case has just been reported from a mine, in Copperopolis, California, where a former Army man lost his life in descending a mine shaft filled with the fumes of a mine fire. Another man who, in attempting to rescue him, merely used a dust respirator, lost his life also.While the American type of the Army gas mask was developed by the Bureau of Mines for the War Department, and since the war a section of the Bureau's in¬vestigative force has been developing industrial gas masks for certain specificgases, the Bureau has repeatedly called to the attention of the public the fact that such masks have serious limitations and in no case should a gas mask be used in underground workings for the reason that there may be an insufficient amount of oxygen to breathe, (and the gas mask does not supply oxygen) or there may be present carbon monoxide, which the Army mask will not remove, and there always is some carbon monoxide produced by a mine fire or by a coal-mine explosion, or by a blast of dynamite or other explosive.It is true that the Bureau has been developing a mask which may take care of a small percentage of carbon monoxide, that is, one per cent and under, but in mine fires and after explosions, there may be, and frequently is, a much larger percentage of carbon monoxide in the mine atmosphere. Masks such as these, for small percentages of carbon monoxide and associated gases are for use in connection with industrial surface plants, as for example, on the top of a blast furnace or around gas producers in the open air."

Oct 1, 1920