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By Je M. Oh

The U.S. Bureau of Mines is conducting research on the oxidation resistance and structural stability of Fe-(0-8)Cr-(0-16)Ni-(0-16)Mn-3.5Si-lAl alloys as potential substitutes for high-Cr stainless steels. Oxidation tests were conducted in air over the temperature range of 6000 to 9000 C for up to 1,000 h. Microstructures were analyzed at room temperature after hot rolling. The oxidation properties and the structural stability were found to be greatly affected by the Cr and Mn levels. Although substitution of Mn for Ni increased the oxidation rate, the Mn helped to stabilize the austenitic microstructure. Decreasing the Cr content or increasing the Mn content produced higher oxidation rates and earlier oxide spalling. In this study, reaction kinetics, oxide morphologies, and microstructure of the alloys were investigated using scanning electron microscopy, energy dispersive X-ray analysis, X-ray diffraction, and electron microprobe analysis.

Jan 1, 1989

By L. A. Stinnett

An investigation of hazardous surface openings of abandoned and inactive underground mines in the Black Hills area of South Dakota has revealed: (1) tracing legal ownership of mineral claims via county courthouses is confusing, complex, and oftentimes misleading, (2 ) in general, the selected mine openings in this investigation are to be considered relatively high in risks and hazard potential which poses a threat to the general public, (3) mine closure procedures and designs can generally be categorically implemented depending on the overall situation of the particular mine opening with subsequent unit costs' estimates, (4) few preventive state or federal legal measures exist to date concerning mine closures, and (5) liability damages relating to mine opening accidents usually involve expensive and complex common law cases.

Jan 1, 1979

By W. R. Hardwick

This information circular describes mining methods and practices at New Cornelia Branch, Phelps Dodge Corp., Ajo, Ariz. It is one of a series being prepared by the Bureau of Mines on mining methods, practices, and costs in various mining districts of the United States. The New Cornelia mine (fig. 1) is at Ajo, a town in southwestern Arizona (fig. 2) on Arizona State Highway 85 in the western part of Pima County. The [oncentrator] and smelter are near the mine (fig. 3). Copper ore is mined, crushed, ground, and concentrated, and the concentrates are smelted. Copper is cast in anode form and sent to the Phelps Dodge Corp. refinery in El Paso, Tex.

Jan 1, 1960

By P. R. Perry

This publication is a compilation of tested methods for the analyses of titanium tetrachloride, titanium sponge, and various intermediate materials and products. They are presented in concise form without the detail usually found in publication of new methods because many of them are modifications of well known procedures. The Electrometallurgical Experiment Station, Boulder City, Nev., has been developing titanium production methods since 1945. Most of this development was on a modified Kroll Process but also included work on sodium reduction and electrolytic methods. During these years a large variety of samples were analyzed. Most of the analytical problems were solved using published methods or modifications of the same. At the start, there were no published procedures for analyzing titanium sponge using spectrochemical methods. A great deal of study was given to testing several of the well known techniques, and some of them, such as direct sparking of the metal, proved to be completely unsatisfactory. Solution-spark techniques were finally tried, and satisfactory procedures were developed for some of the more common impurities. These spectrochemical methods were then put into routine use for several months before their publication.2/ Some new modifications have been made, and techniques have been developed to determine other impurities found in titanium sponge and tetrachloride. All spectrochemical methods used in 1954 are included in this publication.

Jan 1, 1955

By Mildred Nadler, Alvin Kaufman

To aid industry and Government in planning water developments the Bureau of Mines in 1963 canvassed mineral producers to determine water use in 1962. Water use by the mineral industry comprises only 2 percent of the water withdrawn by industry as a whole. The major water-using mineral industries are natural gas processing, phosphate rock, sand and gravel, and iron ore. Analysis indicated the following conclusions: 1. Total water use and new water intake is dependent on the quantity of material processed and the process water requirements of the particular indus- try or commodity. 2. Recirculation is dependent on the processing requirements of a par- ticular commodity, the manner in which the water is used, cooling and condens- ing requirements in certain large industries, the quality of new water intake, and the need to treat new and discharged water. 3. Consumed water is dependent on the quantity of water recirculated, the temperature and humidity in the area, and the proportion of water used for cooling and condensing. 4. A threefold increase in water use by the mineral industry by 1985 is forecast.

May 1, 1965

By Daniel Harrington

On the night of June 8, 1917, the flame of a carbide lamp accidentally set fire to the uncovered and frayed insulation of an armored power cable near the 2,400-foot level of the North Butte Mining CO.'s Granite Mountain shaft. How this, insulation accidentally became exposed is explained on page 15. The highly flammable oiled fabric set fire to the shaft timbers, and as this is a downcast shaft the fire spread with great rapidity, soon filling the mine workings with smoke and gas. At the time 410 men were working underground, 247 of whom escaped by various means, but most of the 163 remaining were probably overcome soon after the fire started, and perished. Only two men were actually burned. The cause of the disaster was purely accidental. The immediate effect was the unexpected reversal of normal conditions; the ultimate effect was great loss of life and the destruction of the main hoisting shaft, putting it temporarily out of service. The work of rescue and fire fighting continued eight days. The following pages present an attempt to draw some practical conclusions and suggestions from this disaster. The property of the North Butte Mining Co. consists of about 220 acres in the northeastern part of the Butte district, Montana. Next to the Anaconda Copper Mining Co. it is the largest producer of the district. In 1916, the year before the disaster, there were 1,160 men employed. The output was 560,947 tons of ore, which yielded 24,498,181 pounds of copper, 1,047,063 ounces of silver, 1,712 ounces of gold, and 412,953 pounds of zinc. The profit was $2,479,595. The total development work for that year was 21,694 feet. During the first half of 1917, the year of the accident, the daily tonnage of ore averaged 2,000, an increase of 400 tons over that of the year 1916.

Jan 1, 1922

By Pamela J. Watson

The U.S. Bureau of Mines has demonstrated in laboratory tests that drilling with surface-charge-neutralizing concentrations of polyethylene oxide (PEO) polymer solutions simultaneously improves penetration rates and extends bit life. The applicability of this additive to improve drilling performance in coal measure rocks was demonstrated under field conditions at an abandoned mine land site in Pennsylvania and a producing coal mine property in Ohio. Penetration rate improvements ranging from 15 to 50 pet were obtained when core drilling through a variety of coal measure lithologies. Drilling cost analysis indicates that the small added cost of using the polymer is more than offset by the savings that result from demonstrated increased drilling penetration rates, which translate into drilling cost savings of about 10 to 30 pct. This report also gives chemical analyses of a variety of coal measure rocks and some corresponding local drilling water samples, obtained from a wide geographical base, along with threshold concentrations of PEO required to effect the improved drilling performance in these rocks. From these data, the threshold PEO concentrations needed to ensure improved drilling performance can be estimated for any coal measure rock suite. Proper techniques for mixing PEO solutions are also presented.

Jan 1, 2010

By A. J. Kauffman

The alluvial deposits of the Pacific Northwest have been investigated and worked with varying degrees of intensity since about the middle of the 19th century. Earlier efforts, of course, were centered about the placer-gold content of the deposits; later, the Oregon beach sands were exploited for their chrome content, and, still more recently, deposits in Idaho were worked for their content of monazite, a rare-earth mineral which also contains significant quantities of thorium. The composition of alluvial deposits seems to depend mainly upon the nature of the source rock from which the detrital material was derived and upon the resistance of the individual mineral grains to the agencies of weathering and transportation. The processes of crushing and concentration used in ore dressing are applied in a leisurely but nonetheless effective manner when exposed rock masses are eroded by natural forces. Weathering effects a continuous disintegration and chemical decomposition, wherein resistant minerals are set free as individual grains and new minerals are formed. Erosion carries these detrital products down the slopes into natural waterways, where a mechanical separation of heavy particles from light is accomplished by the running water. The accumulation of such resistant, heavy particles through the ages has resulted in formation of the black-sand deposits. In addition to the associated gangue minerals, heavy sand deposits in the Pacific Northwest may contain the following constituents of possible economic value: Gold, platinum, chromite, ilmenite, magnetite, garnet, zircon, monazite, columbite-tantalite, and radioactive blacks.

Jan 1, 1956

By Rexford D. Singer

The purpose of this study was to evaluate the current literature on the use of calcium chloride and ligninsulfonates as dust suppressants with respect to potential adverse effects on health or the environment. Calcium chloride poses little internal hazard to man and animals, but toxicity to vegetation in and around the area of application should be expected. The effects, however, should be considerably less than those observed from using calcium chloride as a road deicer. Except for trout, ligninsulfonates seem to pose little direct systemic toxicity problems in aquatic organisms, animals and man or any problem with local vegetation. Because of a greater volume of information on its use and effects, calcium chloride is recommended over ligninsulfonates.

Jan 1, 1982

By The Staff, Explosives Research Center

The principal activities of the Bureau of Mines Explosives Research Center from July 1, 1962, to June 30, 1963, are described briefly in part 1. Part 2 gives short abstracts of publications that appeared during fiscal year 1963; in general, the research reported in these publications antedates the report period.

Jun 24, 1964

By Galen G. Waddell

Dilation and contraction of the rock surrounding horizontal access open-ings of a deep mine were analyzed during stope advance to determine what type of measurements, made with relatively inexpensive instrumentation, would best reflect the rock behavior. A variety of instruments, mostly mechanical extensometers, were used. Detailed descriptions are given of Down-the-hole extensometers, floating rockbolt clusters, transit surveys, and other instruments and measuring techniques. Although all of the radial-deformation-rate graphs illustrated useful rock behavior data, the most informative graphs were compiled from data procured with the radial extensometers that penetrated, to various depths, the rock around the access openings. An analysis is given of measurement data on the rock around lateral drifts and across and adjacent to the nearly vertical vein of the Star mine, Burke, Idaho. Several useful relationships were found between the rock deformation rate and the stoping process. Information was produced on the elastic state of rock around an underground opening, effectiveness of stope support, rheology of rock, zone of influence around stopes, effectiveness of rockbolts, axis of maximum strain in a plane perpendicular to the long axis of the lateral, and other phenomena. This information could be of particular value in determining location, design, and support of underground openings.

Jan 1, 1966

By F. M. Jenkins

Longwall mining systems are used to mine approximately 50 pet of the world's total underground coal production. Single entries are the predominant method of longwall development in Europe and Asia, where mining conditions are more severe than those encountered in the United States. During the 1970's and early 1980's, the U.S. Bureau of Mines and the U.S. mining industry invested nearly $20 million in single-entry and related research. This report reviews the accomplishments of single-entry research in the United States and describes two U.S. single-entry field projects: the Sunnyside single-entry project in central Utah and the tunnel-boring project in northern West Virginia. Also discussed are a single-entry study conducted by North American Mining Consultants (NAMCO) and a single-entry design study conducted by Ketron, Inc. This Bureau report compares the resulting technology with European counterparts to further assess the utility and efficiency of U.S. systems.

Jan 1, 1990

By M. D. Carver

This publication describes development by the Bureau of Mines of a quality evaluation procedure for certifying the adequacy of production lots of Kroll process zirconium sponge the Bureau had produced for reactor applications. After the procedure was devised, the next step was to apply it in controlling the quality of one-half million pounds of zirconium sponge com-prising 259 production lots, called blends, originating at the Metallurgy Research Center of the Bureau at Albany, Oreg. The Bureau concluded that the evaluation method developed was adequate and that by this method the zirconium blends having impurity levels or other property values outside specification limits were differentiated and thus were diverted from nuclear energy end uses. The research was performed under contract for the Bureau of Ships, Department of the Navy, and for the Atomic Energy Commission (AEC).

Jan 1, 1960

By W. F. Faragher

The principal equipment in the catalyst plants at Ludwigshafen-Oppau was inspected and is presented in the form of flow sheets for the manufacture of four of the principal catalysts. The equipment is in many cases of special design rather than stock items that was built by the company and modified in the coarse of the growth of the high-pressure synthesis of hydrocarbons in Germany. It is believed that if the manufacture of catalysts were to be undertaken elsewhere, the selection of equipment for the operations involved could be made successfully from the guidance furnished by this rather general report. Five additional catalysts are described, also. II. CATALYST 5058 FROM FRESH TUNGSTIC ACID In a supply tank of about 2,000 liters capacity, 500 kg. of tungstic acid (W03.H2O) that contains about 92-93 percent of W03 is dissolved at 60-70° C. in 1,500 liters of mother liquor. The solution is-effected by stirring for about 1-1/2 hours. The mother liquor is obtained from a previous, lot of catalyst and is first adjusted to a concentration of 13 percent 1H3 by passing in gaseous ammonia. The solution is allowed to stand without stirring for 1 hour, then is pumped into the saturating vessel through a cloth filter (three-quarters hr. to one hr.). The saturator is purged with H2S and thereafter the solution, which has been cooled to about 75° C., is heated in an atmosphere of hydrogen sulfide with stirring to about 70° C. This charge is slowly cooled to 50°, and then more rapidly to about 20° C. (time of cooling 6-7 hours).

Jan 1, 1946

By H. R. Shell, Robert C. Johnson, Wilbur H. Warwick

Alpha silicon nitride fibers , Si3N4 , were successfully grown in graphite crucibles by a new method utilizing silicates and silicon ( S in equations below) as sources of silicon and using carbon , aluminum , and silicon as reducing agents (R in equations below ) . The basic reaction mechanism is believed to be generally as follows : 1,300 - 1,500 ° C S + R + N₂ SiO + RO + N₂ › 3Si0 + R + 2N₂ _1,300 - 1,500° C 3RO + Si¸N • ( 1 ) ( 2 ) A build - up of coatings on the solid raw- material particles hindered the evolution of silicon or silicon monoxide vapor and thereby slowed down further formation of silicon nitride fibers . Free oxygen in the crucible caused the formation of amorphous silicon dioxide ( SiO2 ) fibers . This problem was solved by passing , entering , and exiting gases through layers of lump graphite inside the reaction vessel . The silicon nitride fibers grew best around 1,400 ° C. Nitrogen flow rates from 4 to 6 liters per minute were adequate . The fiber widths were generally only a few microns whereas their lengths sometimes reached one - quarter inch or more . Chemical and X- ray analyses indicated that bulk fiber samples were usually 80 to 90 percent Si3N4 . The fibers had good oxidation resistance to about 1,260 ° C. Thermal shock resistance was excellent . Electrical resistance was determined .

Jan 1, 1964

By Lawrence G. Houk

Monazite sand is the only commercial source of cerium, other rare-earth metals and thorium. Although used in rather small quantities, it is essential to many industries. The United Unites is entirely dependent upon British India and Brazil for its supplies. Monazite sand or sand imported under the tariff classification for monazite was shipped to the United States in greater quantities, in 1940 than ever before. About 75 percent of our imports was from British India and most of the remainder from Brazil. If need be, Brazilian production can be expanded to supply all of our essential requirements, and the theater of war expands in the Pacific Brazil may supersede India as the principal source. PHYSICAL PROPERTIES The mineral monazite is generally honey yellow or may vary from greenish yellow to clove brown. The grains are small and resinous in luster, and range from subtranslucent to opaque. The specific gravity varies

Jan 1, 1943

By Frank A. Peters

This Bureau of Mines report is the second of a series of process evaluations planned to determine the relative processing costs of producing metallurgical-grade alumina from low-grade aluminous materials. Included in these evaluations are recommendations for additional research and development to improve the processes and to lower their costs. The design for each process is based on published work. The processes considered in this report are designed to extract alumina as aluminum chloride from calcined clay with 20 percent hydrochloric acid and to remove the silica residue by filtration. Iron is removed by one of the following processes: Isopropyl ether extraction, in which iron chloride is extracted before decomposing the aluminum chloride; gas precipitation, in which the aluminum chloride is precipitated with hydrogen chloride while leaving the iron chloride in solution; gas precipitation-isopropyl ether extraction, in which the aluminum chloride from precipitation is extracted with isopropyl ether, if necessary; caustic purification, in which a crude alumina is produced and then purified by a modified Bayer operation; or sinter purification, in which a crude alumina is produced and then purified by a lime-soda sinter operation. For plants producing 1,000 tons of alumina a day the estimated operating costs per ton of alumina are: [Isopropyl ether extraction process $ 65.09 Gas precipitation process 89.04 Gas precipitation-isopropyl ether extraction process 119.65 Caustic purification process 73.79 Sinter purification process 80.47] The estimated fixed capital costs per annual ton for these plants on a Marshall and Stevens chemical equipment basis of 240.0 are: [Isopropyl ether extraction process $229.03 Gas precipitation process 287.16 Gas precipitation-isopropyl ether extraction process 356.59 Caustic purification process 266.48 Sinter purification process 279.13]

Jan 1, 1962

By J. P. Powell

Systematic waterflooding was first tried in Washington County, Okla., in 1937, when a 40-acre project was begun in secs. 24, 29, 32, and 33, T. 27 N., R. 13 E., jointly by the Keener Oil Co. and the Phillips Petroleum Co. The property later was sold to Lee Morrison. A second project was begun in 1941 in sec. 14, T. 6 N., R. 12 E., by the Oklahoma Oil Corp. Both projects were abandoned by the end of 1942. A third project was begun in 1945 and the fourth in 1948, but 1949 actually was the beginning of intensive waterflooding development in Washington County. The results of previous waterflooding projects are described in Bureau of Mines Reports of Investigations.2 3 4/ Oil production in the county followed a similar trend, dropping to a low of 990,000 barrels in 1945, then steadily increasing until 1956, when more than 4 mil-lion barrels of oil was produced. Most of the increase in oil production is directly attributable to water injection.

Jan 1, 1957

By F. E. Armstrong

A program with the objective of developing a fast, accurate instrumental method of analyzing mine dust for incombustible content has been underway in the Bureau of Mines for several years. Several prototype instruments making use of a gamma-ray backscatter technique have resulted. Although extensive laboratory testing has shown that these instruments are accurate under laboratory conditions, only extensive field testing will prove their ultimate practicality and usefulness. This report shows that under most conditions these devices are at least as accurate as the volumetric method and much faster in use. Other data obtained during the same study concerning mine dust are presented; these concern moisture content, sample bulk density distribution, and some particle size distribution information.

Jan 1, 1973

By Forrest T. Moyer

In 1969, the number of fatal injuries in the coal mining industry was lower than in any previous year and the number of nonfatal injuries was lower than in any preceding year except 1968. Fatal injuries in 1969 totaled 203 with frequency rates of 0.85 per million man-hours of worktime and 0.36 per million tons of coal These rates were new annual lows. Nonfatal injuries totaled 9,917 with frequency rates of 41.76 per million man-hours and 17.42 per million tons. The severity rate for fatal and nonfatal injuries combined was 7,359 days lost or charged per million man-hours. The average severity was 173 days lost or charged per injury. These statistics represent the injury experience of an average of 133,302 employees per day working an average of 225 days in 5,955 coal mines for a total of 237-5 million man-hours worked and a coal output of 565 2 million tons

Jan 1, 1973