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By E. R. Cole

Bench-scale research at the Bureau of Mines has resulted in the successful development of a combination electrorefining-electrowinning method for recycling all the lead in scrap batteries. The method reduces energy consumption and eliminates toxic emissions, in contrast to present pyrometallurgical smelting, and the lead produced is pure enough for use in maintenance-free batteries. Anodes cast from molten lead scrap were electrorefined in 1-and 2-liter plastic cells using an electrolyte composition of 70 g/l Pb and 90 g/l free H2SiF6 (fluosilicic acid). Both reagent-grade and waste H2SiF6 were used. Cathode starting sheets were made from refined lead. Aloes, and later bone gelatin, and calcium lignin sulfonate addition agents were employed. The sludge remaining after separation of the lead metal was treated in a two-step leaching operation to solubilize the lead for recovery by electrowinning. Conditions for electrowinning were essentially the same as for electro-refining, except that insoluble Pb02-Ti (lead dioxide-coated titanium) anodes were used. The best results for both electrorefining and electrowinning were obtained with a current density of 170 amp/m2 and a cell temperature of 25° to 35° C. Cathode purity ranged from about 99.9 to 99.99+ pct Pb. Maximum energy consumption after 3 days, for electrorefining and electrowinning, was 90 and 700 kwhr per metric ton of refined lead, respectively.

Jan 1, 1981

By John H. Thompson

Recent studies ** at the Pittsburgh Experiment Station of the Bureau of Mines have revealed some interesting facts as to the probable behavior of steamed coke in the blast furnace . The literature on the chemistry of the blast furnace was tho roughly reviewed , and with this information in mind , the probable behavior of the coke sulphur in the blast furnace was deduced . Enough small - scale tests were conducted to furnish a check on most of the important deductions , and the conclusions derived therefrom accord with what is already known in regard to the forms of sulphur in coke , and fit in well with the general opinion concerning blast-furnace reactions .

Aug 1, 1923

By M. J. Beus, M. K. Larson, J. K. Whyatt

U.S. Bureau of Mines researchers reviewed an in situ stress estimate developed from measurements of overcore strain taken at test sites on the 7300 and 7500 levels of the Star Mine near Mullan, ID. Although the field measurements of overcoring strain were found to be useful, significant deficiencies were found in the stress estimation procedure. A new stress estimate was developed incorporating statistical methods and an improved understanding of stress concentration factors for interpreting overcore strains recorded by doorstopper cells. Spatial variability of overcore strains and the implications for stress field variability were explored.

Jan 1, 1995

By W. R. Reed, J. A. Organiscak

Surface mining operations use large off-road haul trucks extensively to move material at mining properties. Past research, using the United States Environmental Protection Agency’s (EPA) emissions factors for unpaved haul roads, has shown that haul trucks generate the majority of dust emissions from surface mining sites, accounting for approximately 78%-97% of total dust emissions. Observations of dust emissions from haul trucks show that if the dust emissions are uncontrolled, they can be a safety hazard by impairing the operator’s visibility. This increases the probability for haul truck accidents (See photos above). However, the greatest long-term health hazard of dust generated from hauling operations is due to inhalation of the respirable dust [median diameter <4 micrometers (µm)] and tho­racic dust, which is equivalent to the EPA’s definition of PM10 [particulate matter with a median diameter <10 µm]. Exposure to respirable dust has long been considered a health hazard at surface mining operations, especially if silica dust is present. There are two legislative acts that regulate the air quality for mining operations: the Federal Coal Mine Health and Safety Act of 1969 and the Clean Air Act of 1970. The Federal Coal Mine Health and Safety Act of 1969 established the limits for dust in the work place for health and safety pur­poses. The Clean Air Act of 1970 regulates air emissions from facilities from an envi­ronmental perspective.

By T. A. Henrie, D. C. Fleck, D. G. Kesterke

Uranium metal was electrowon from uranium dioxide dissolved in fluoride melts . The UO₂ was fed directly to the cell in a continuous manner . Electrolysis was performed at 1 , 200 ° to 1,300 ° C in electrolytes composed of UF4 , LiF , and BaFa . A single regulus of metal was collected in a confined area of the crucible . Product purity of 99.8 percent was attained . Carbon was the major contaminant . Compartmented cells were studied as a means of confining the oxide feed to the vicinity of the anodes .

Jan 1, 1964

By James V. Luxner

The airflow and methane distribution patterns developed in an equipment-free entry 6.5 feet high and 12 feet wide, ventilated by line brattice operated blowing to or exhausting from the face, were determined by the Bureau of Mines for varying conditions. Results of these studies show that blowing line brattice systems of face ventilation are more effective than comparable exhaust systems. The face ventilating efficiency of any line brattice system is dependent upon the method of ventilation, the face distance, the tight rib distance, the volume of air delivered to the end of the line brattice, and the volume of methane released at the face. Experimental results indicate that maximum face ventilation efficiency is achieved when the inby terminus of the line brattice is installed 5 feet from the face and at a distance less than one-third the entry width from the nearest rib. Analyses of data are based upon the ability of a face ventilation system to dilute methane in the immediate face area.

Jan 1, 1969

By Michael J. Brnich

Since 1991, Pittsburgh Research Center (PRC-formerly part of the Bureau of Mines) researchers have recorded extensive interviews with 30 individuals who are experts in the area of mine emergency response. These individuals, who have an average of 35 years of mining experience and 29 years of mine emergency response experience, related stories and observations from events that they experienced during their combined 850 plus years in mine emergency response. The purpose of this effort was to gather information that could be passed on to both today?s and tomorrow?s mine emergency responders to train and guide them in handling future events. This is the first of two articles which report the responses that these experts gave when asked how they think people who may have to respond to a future mine emergency should be trained. During the interviews they discussed how training should be conducted, who should be trained, and what topics should be included. This article will cover the first two areas: what training methodologies would be most effective and who needs to participate.

Jan 1, 1997

By John Jordan, Steven J. Knoll, Douglas Tesarik, Theodore J. Williams, David K. Denton, Douglas F. Scott

Highly stressed rock in stopes continues to be a primary safety risk for miners in underground mines because this condition can result in failures of ground that lead to both injuries and death. Personnel from the Spokane Research Laboratory of the National Institute for Occupational Safety and Health studied two methods for identifying stress in rock. A seismic tomographic survey, finite-difference analysis, laboratory measurements of compression wave (ultrasonic) velocities in rock cores, and site geology were integrated to evaluate the use of seismic tomography for identifying induced pressures in an underground pillar at the Edgar Mine, Idaho Springs, CO. Electromagnetic (EM) emissions were also investigated in the Galena Mine, a deep underground mine in Idaho, in an effort to determine if these emissions could be used as indicators of impending catastrophic ground failure. Results of this research indicated that (1) seismic tomography appears to be a useful tool for determining relative stress in underground pillars, while (2) EM emissions do not appear to be significant precursors of impending catastrophic ground failure.

Jan 1, 2004

By D. Dolinar, T. P. Mucho

Horizontal stresses are caused by global plate-tectonic forces. During 1995 alone they were largely responsible for the closing of two longwall mines in the United States. This paper presents six case histories from Pennsylvania, West Virginia, Kentucky and Alabama. In each case, a mine encountered roof falls or difficult ground conditions at the headgate caused by horizontal-stress concentrations. The problems are detailed, and the control measures adopted are described. In most cases, nearby longwall panels without stress concentrations were trouble free. The paper also discusses detailed measurements that were made at two adjacent Pennsylvania longwalls. One headgate was oriented to avoid a horizontal-stress concentration, and the other was not. Eliminating the stress concentration dramatically reduced roof support loads and roof deformation. The paper concludes that proper panel orientation and sequence is the key to maintaining headgate ground control. The optimum orientation is not parallel to the maximum horizontal stress, as previously thought, but rather it is 20° in the stress shadow of the gob. Other stress-control techniques, including artificial support, are briefly discussed.

By Fred N. Kissell

A parachute-type stopping intended for changing the course of mine ventilation air during mine emergencies has been designed and tested. Some production uses are also visualized for metal mines. Preliminary tests in the laboratory and underground indicate that the parachute stopping is a workable concept, but further developmental research is required.

Jan 1, 1975

By Ralph L. Brown

"IntroductionThe accumulation of gummy and resinous deposits in consumers' gas meters began to assume serious proportions about 1917. As the trouble developed and spread in the years following, it manifested itself in several ways, which ultimately began to the expressible in distinctly economic terms, more specifically in terms of costs; in 1922 an organized and fundamentally based investigation of this trouble was begun. In an earlier paper*** a short statement of the occurrence and costs of the deposition was given and at the same time an analysis of the problem, as well as well as a general plan of attack, was presented. That plan included two general phases, first, a chemical study of typical was 1 quarry or 2 cosinous content , mauformly consituents, rmln and selected subjects; and secondly, a comparative survey of plants affected and sufficient therewith, attention being paid to construction, operation, meter conditions and related data. In reporting progress in the axtual investigation, it was definitely set down that the basis of the gummy deposits was the unsaturated hydro consulting from the carburxtion of the water-gas with oil. That the presence of oily-gas condensate was closely associated with and largely"

Jul 1, 1923

By W. H. Ode, W. A. Selvig

"INTR0DUCTIONAccording to the Standard Specifications for Classification of Coals by Rank of the American Society for Testing Materials (A.S.T.M. Designation: D388-38).1/ high-volatile bituminous coals, subbituminous coals, and lignites are classified on the basis of calorific values on the ""moist"", mineral-matter-free basis. The moist basis refers to coal containing its natural bed moisture but not including visible water on the surface of the coal. It is assumed that the natural bed moisture of coal in the ground represents the moisture-holding capacity of the coal when in equilibrium with air at approximately 100 percent relative humidity. This moisture is sometimes referred to as inherent moisture as opposed to extraneous moisture, which wets the surface of the coal.To simplify procedures for determining the moisture-holding capacity of coal it is assumed, for all practical purposes that the moisture content of coal when brought to a standard condition of moisture equilibrium in an atmosphere of 97 percent relative humidity and 300 C. represents the bed moisture of the coal. The A.3.T.M. specifications provide that this condition of moisture equilibrium shall be obtained by bringing the coal to a standard condition of moisture equilibrium at 300 C. in a vacuum desiccator containing a saturated solution of potassium sulfate (97 percent relative humidity) according to the procedure proposed by Stanfield and Gilbart. 4/ No mention is made in the specifications for bringing partly air-dried samples to their natural bed moisture condition probably because of the hysteresis effect that has been noted by various investigators. 5/ In this connection it has been found from sorption studies that the adsorption and desorption curves for lignite are not entirely reversible. The hysteresis effect has been explained by some investigators as resulting from shrinkage of the lignite during drying, which causes a collapse of some of the capillaries, so the dried lignite cannot take up as much water as it held originally."

Apr 1, 1953

By John C. Ferm

This report contains a summary of Phase I and complete results of Phase II portions of a study of geologic factors associated with roof falls in mines on the Pocahontas #3 coal seam in southern West Virginia and southwestern Virginia. Principal objectives of Phase I was the selection of five mines that best portrayed the spectrum of roof and mining conditions and Phase II consisted of a measurement and documentation program for each of the five mines. The documentation measurement program included reconnaissance mapping, detailed mapping, joint measurements and coring roof rock. 1.2 PHASE I RESULTS The results of Phase I consisted of the selection of the following five mines for detailed study: Virginia Pocahontas #3 (Island Creek Coal Company), Bishop (Consolidation Coal Company), Shannon Branch (Allied Chemical Company), Keystone II (Eastern Associated Coal Company) and Macalpine-East Gulf (Westmorelenad Coal Company). In addition, Phase I results, which were based on questionnaire data, indicated that the kind of rock in the roof --gray sandstone, crystallized sandstone, laminated sandstone and shale, grey shale, slickensided shale, and rider seams could be associated with good and bad top areas. Also presence of vertical separations, bolt length, entry and cross-cut width, length and torque on bolts and depth of overburden seemed to be related factors. These data provided a focus for the Phase II measurement program.

Jan 1, 1975

By J. C. Franklin

An experiment was conducted by the U.S. Bureau of Mines and the Canada Centre for Mineral and Energy Technology (CANMET) to measure the emanation rate of radon from cemented unclassified mill tailings in two dewatered stopes of a uranium mine at Elliot Lake, Ontario, Canada. The radon was monitored upstream and downstream and in both stopes to determine the concentration in the stopes and the amount exhausted from both stopes. The emanation rate was determined to be 0.55 pCi/cm2 sec-1 from the mill tailings, which is approximately 1,000 times higher than the average flux in the mine before backfilling.

Jan 1, 1982

By H. W. Leavenworth

Research was conducted by the Bureau of Mines to develop a technique to grow metallic fibers from a sulfide mineral. In this research, chalcopyrite (CuFeS2) was made sulfur deficient, and the remaining sulfur partitioned to the iron in the mineral to liberate metallic copper, or to the copper to liberate metallic iron. The metals formed on the surface as fibers and in the interior as spherical particles. Fiber growth is very fast. Lengths of 3 to 4 cm form in a matter of minutes, and the diameter of individual fibers is less than 1 µm. The mechanism of fiber growth is explained, and the reactions are reversible as predicted. Copper fibers can be made to grow from the surface at 400° C or to dissolve back onto the solid surface and be replaced by iron fibers at 625° C. Growth and dissolution can also be controlled to form copper/iron duplex fibers.

Jan 1, 1974

By C. M. McCulloch, Maurice Deul

A geologic study of Mines 32 and 33 in Cambria County, Pa., was conducted as part of a methane control research program. Areas of high methane emission and roof instability are encountered which are related to the structural and stratigraphic features that characterize the geologic setting of these mines. Locally the folds trend N 20° E ±2°, the direction of the butt cleat in the Lower Kittanning coal. The face cleat strikes at N 69° W ±2° and the systematic rock joint in the surface bedrock strikes N 67° W ±2°This suggests that a directional stress oriented N 70° W produced the folds and influenced the directions of coal cleat and systematic joint sets. Analysis of SLAR indicates three directions of prominent regional lineation: N 39° E, N 31° W, and N 70° W. Little gas was encountered during development mining; large volumes of gas are encountered when roof falls. Most of the gas comes from strata above the mined coal; therefore, to control methane, roof instability must be controlled. Roof falls and high rates of methane emission are most likely where less than 30 feet of many thin layers of limestone, shale, and sandstone occurs between the Lower Kittanning coal and the next coal and in zones along the margins of a sandstone channel.

Jan 1, 1973

By Robert W. Geehan

"INTRODUCTION The Bureau of Mines, in cooperation with the Federal Geological Survey, explored the Crowell fluorite mine by core drilling in 1945. Claims investigated are in sec. 14, T. 12 S. R. 47 E., M. D. B. & M., in southern rye County, Nev., about 5 miles east of 'Beatty.The twelve holes drilled by the Bureau totaled 3,661 feet. During 1945 the mine operator drove extensive exploration drifts, in part to verify results of the Bureau's work. The drilling program was designed to test for extensions of ore bodies known in the mine.The Crowell mine has shipped Ore to steel plants on the west coast for the past 20 years. During the war this market called for all the fluorite the mine could produce, but previously there were periods when it was difficult to sell ore or concentrates.ACKNOWLEDGMENTSIn its program of exploration of mineral deposits, the Bureau of Nines has as its primary objective the more effective utilization of our mineral resources to the end that they make the greatest possible contribution to national security and economy. It is the policy of the Bureau to publish the facts developed by each exploratory project as soon as practicable after its conclusion. The Mining Branch, Lowell B. Moon, chief, conducts preliminary examinations, performs the actual exploratory work, and prepares the final report. The Metallurgical Branch, R. G. Knickerbocker, chief, analyzes samples and performs beneficiation tests. Both these branches are under the supervision of Dr. R. S. Dean, assistant director.Special acknowledgment is due to Glenn Allen, district engineer;A. C. Johnson, chief, Reno Division, Mining Branch; S. R Zimmerley, chief, Salt Lake City Division, Metallurgical Branch; W. R. Thurston of the Federal Geological Survey for advice on geological problems; and J. Irving Crowell, Jr., operator of the property, for his cooperation."

Nov 1, 1946

By D. W. Frommer

The investigation reported in this paper is one of several included in a broad program of developing new or improved concentration processes for the oxidized and partly oxidized deposits of lead and zinc, A sample from the Playter lease, Newton County, Mo., containing pyromorphite was successfully concentrated by fatty acid flotation to a grade of over 62 percent lead. Owing to the presence of a high content of slime-size values, the overall recovery of lead at that grade was limited to 44 percent. DESCRIPTION AND HISTORY OF PROPERTY The mineral pyromorphite is a chlorophosphate of lead containing 76.4 percent lead, and, although it occurs frequently in association with other lead minerals, it is considered a minor ore mineral of lead. The manner of occurrence of oxidized lead minerals, including pyromorphite, which frequently are no larger in grain size than the clay with which they are found, militates both against development of a simple beneficiation process and high recovery. The profitable exploitation of such deposits depends not only on a successful treatment procedure but a highly favorable metal market as well. For these, and perhaps other reasons, very little research has been done on the recovery of pyromorphite from its deposits.

Jan 1, 1956

By D. M. Soboroff

Etchants containing hexavalent chromium and sulfuric acid are used in a variety of surface-finishing operations. When the resultant spent solutions are discarded, substantial quantities of chromium are lost and pollution prob¬lems are created. To minimize the undesirable environmental effects while improving metal and minerals recycling technology, the Bureau of Mines is conducting research on a method for the economic inplant recycling of these waste etchants. Trivalent chromium, produced when the etchant reacts with a sub¬strate, is oxidized in the anode chamber of a diaphragm cell; other metals, dissolved during the etching operation, are transferred to the catholyte. When waste brass etchants are treated in this manner, all of the trivalent chromium is oxidized and more than 40 percent of the copper and zinc is removed. Similar copper removal and chromium oxidation are achieved with waste printed circuit board etchants and rinse waters from plastic etching operations. The electrical energy needed to regenerate 1 kg sodium dichromate is less than 9 kwhr. Regenerated brass etchants evaluated by two companies equaled or exceeded the performance of fresh etchants.

Jan 1, 1979

By David C. Oyler

Methane-drainage holes must be completely filled by grout before mining to prevent the emission of large quantities of gas during mine-through, which would constitute an explosion hazard. In November 1980, seven horizontal holes at the multipurpose borehole, a small-diameter shaft drilled as a Bureau of Mines coalbed methane-drainage installation on the property of the Federal No. 2 Mine, Monongalia County, WV, were plugged using a sodium silicate gel grout. This report de- scribes the grout mix and the use of the grout at the multipurpose borehole, and discusses the results observed upon mine-through of the holes in early 1981. Cost data for the sodium silicate grout are also presented.

Jan 1, 1984