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By R. J. Leary

The technologies of contemporary iron and steel production and of direct reduction processes have been studied to identify and estimate the potential effects of direct reduction on mineral consumption and the problems raised thereby for the Nation's mineral supply to the iron and steel industry. Contemporary patterns of mineral raw material and energy consumption were determined from a study of the 1964-70 period. Major changes were observed in requirements for 14 of 20 principal commodities. Average practice in 1970 was compared to best practice to estimate the potential effects of implementing existing technology without recourse to direct reduction. Potential effects of direct reduction were estimated by comparing the mineral requirements for 95 percent reduced pellets with 1970 best practice technology for two cases of use: (I) complete substitution for hematite pellets in blast furnace burdens, and (11) partial substitution (40 percent) for scrap in electric furnace steel charges. Effects upon mineral supplies are described; important collateral factors are analyzed, and the principal metallurgical, industrial, and environmental consequences of implementing direct reduction are discussed. Major effects of direct reduction on the domestic steel industry and its mineral supply system are foreseeable. Direct reduction will (1) create a large demand for low-gangue iron ore; (2) relieve the dependence of the steel industry on coking coal, and (3) permit great increases in furnace productivity, both in blast furnace ironmaking and electric arc furnace steelmaking.

Jan 1, 1973

By John A. Johnson

For the purpose of comparing the amounts of dust produced by various mining operations, samples of atmospheric dust were collected during a complete cycle of drilling, blasting and mucking at or near the face of the Bureau's Mount Weather testing adit while the efficiency of several types of stemming in metal-mine blasting was being investigated. ACKNOWLEDGMENTS All gas samples were analyzed in the laboratory of the Bureau of Mines Gas Section at Pittsburgh, Pa.

Jan 1, 1939

By C. W. Owings

A few of the more progressive mining companies have taken precautions to safeguard employees or man-trips. Specially constructed men-cars -have been provided with special devices or mechanisms to stop the cars on slopes, if the hoisting cable should break. Cars have been equipped with safety chains to connect and hold them together if a coupling should break. Steel frames covered with heavy wire netting have been placed over cars to reduce injuries to the riders from roof fails on slopes. A safety cable passing from the front car to a point above the cable socket on the slope hoisting cable is used frequently as a precaution in case the socket loosens o the main cable breaks at the socket. Such devices are commendable, but the percentage of man-cars and man-trips protected is relatively small - entirely too small. Man-trips that travel level haulage roads are rarely protected safety devices, and haulage roads are seldom inspected by mine officials to determine the condition of roof and ribs.

Jan 1, 1935

By T. A. Sullivan

The processing of sweated aluminum electronic scrap was investigated to develop methods for recovering the aluminum and concentrating the other metals, including copper, lead, gold, and silver, into a product that can be separated by known methods. Two molten-salt electrorefining processes were developed and tested. The first process utilized a three-layer refining cell with a BaCI2-NaF-AIF3 electrolyte, which operated at 750° to 850° C. The second process used an all-chloride electrolyte of NaCI-KCI-AICI3 at 750° to 800° C, with separate anode and cathode compartments. High-quality aluminum was recovered that averaged 99.8-percent pure in the three-layer cell and 99.6-percent pure in the compartment cell. Over 94 percent of the aluminum was recovered with cathode current efficiencies of approximately 90 percent in both methods. The copper, lead, tin, silver, gold, and other metals were concentrated threefold in an anode product. Separation of lead and part of the tin by liquation from this product seemed feasible. The anode product was smelted to prepare a 96-percent copper bullion that contained 690 ounces of silver and 65 ounces of gold per ton, with 98 percent recovery of these values.

Jan 1, 1972

By Henry C. Meeves

The Bureau of Mines, between 1956 and 1963, examined 18 major pegmatite districts in Arizona, Colorado, New Mexico, South Dakota, Utah, and Wyoming to evaluate their content of beryllium, a material in short domestic supply that has become increasingly important to modern industry. This examination report includes the salient statistics on the production of pegmatite minerals other than quartz and feldspar; and brief descriptions of 170 specific pegmatite deposits.

Jan 1, 1966

By Linneas Laage, Thomas Weber, William Pomroy

"Underground mine fires can significantly influence mine ventilation airstreams, in some cases throttling or even reversing airflows. As a result, the performance of a metal and nonmetal mine stench fire warning system, which depends on the ventilation to carry the vital warning signal, under fire conditions is different from performance under nonfire conditions. The safety of underground miners can be jeopardized if the warning signal is delayed. This Bureau of Mines report describes research to investigate fire and stench warning system interactions. A computer model is presented that permits quantitative analysis of stench warning signal delays as a function of fire location and intensity. The results of a case study involving computer simulations of stench distribution in a hypothetical mine network subject to various fire exposures are also discussed. This case study illustrates a technique for identifying the areas within a mine that are subject to unacceptable warning signal delays, thereby enabling preemptive action by mine personnel, such as redeployment of stench injectors. INTRODUCTIONFires are an ever-present threat to the safety of underground miners. Since the smoke and toxic gas produced by a mine fire can be spread rapidly by the mine's ventilation system, mine evacuation must be accomplished as quickly as possible in the event of fire. In metal and nonmetal mines, the most common means of passing the fire warning signal to each miner is the stench system. The typical stench system utilizes ethyl mercaptan, a highly odoriferous organic compound, injected on the surface into the compressed and/or ventilation airstreams. Upon smelling the stench, workers evacuate the mine according to an emergency preplan.Although the stench system has been used successfully for over 60 yr, it has several serious shortcomings, owing to certain chemical properties of ethyl mercaptan and to certain performance characteristics and limitations of present injection systems.Recent Bureau research succeeded in upgrading the overall safety and effectiveness of the stench system through the use of a superior stench odorant and the development of improved stench injection equipment (1).4 This research has also investigated a specialized computer simulation model capable of calculating the precise concentration of stench in any mine ventilation network branch at any time after stench release (2). An adaptation of the computer model now enables the analysis of stench system and ventilation system interactions under the influence of a mine fire."

Jan 1, 1987

By Terry G. Montgomery, Eric S. Weiss, John E. Going, Kenneth L. Cashdollar

The Pittsburgh Research Laboratory (PRL) of the National Institute for Occupational Safety and Health (NIOSH) and the Mine Safety and Health Administration (MSHA) conducted joint research on dust explosions by studying post-explosion dust samples. The samples were collected after full-scale explosions at the PRL Lake Lynn Experimental Mine (LLEM), and after laboratory explosions in the PRL 20-L chamber and the Fike I m3 chamber. The dusts studied included both high- and low-volatile bituminous coals. Low temperature ashing for 24 h at 515 °C was used to measure the incombustible content of the dust before and after the explosions. The data showed that the post-explosion incombustible content was always as high as, or higher than the initial incombustible content. The MSHA alcohol coking test was used to determine the amount of coked dust in the post-explosion samples. The results showed that almost all coal dust that was suspended within the explosion flame produced significant amounts of coke. Measurements of floor dust concentrations after LLEM explosions were compared with the initial dust loadings to determine the transport distance of dust during an explosion. All these data will be useful in future forensic investigations of accidental dust explosions in coal mines, or elsewhere.

By William J. Karwoski

To improve rock-burst control in deep vein mining, a field demonstration has been carried out by the Bureau of Mines to test a new rock-burst control concept--rock preconditioning in advance of mining. The procedure is to fracture the major rock-burst-prone zone during the development of each level before production mining. This allows initial mining to begin in a preconditioned zone and later mining from the level below to end in a prefractured or preconditioned pillar zone that is relatively burst-free. This full-scale field demonstration was carried out On the 7700 level of the Hecla Mining Co.'s Star-Morning mine. An expected burst-prone zone along the main vein between 7 and 10 crosscuts, some 250 feet long by 40 feet above and below the level, was preconditioned by blasting a fanlike ring of drilled holes from each crosscut. The drill holes, up to 100 feet long and 4 inches in diameter, were loaded with high explosives and shot. About 4,550 feet of drilling and 9,000 pounds of explosives were involved in the effort. Comparison of preshot and postshot data from monitoring instrumentation indicated that the blasting did fracture the rock in the planned zone and did result in an immediate stress decrease and softening of rock. The field data compared favorably with predicted results from a finite-element computer model simulation of the destressing. Based on observations made during mining and on the data from the Hecla rock-burst monitoring system, there is no doubt that this preconditioning in advance of mining demonstration resulted in much-improved rock-burst control during first-floor mining. It was also concluded that preconditioning the vein was more effective than preconditioning the wall rock.

Jan 1, 1979

By R. L. Balmer

This information circular, which describes the methods and costs of sinking a small underground shaft with steel supports at the Keystone mine of American Smelting and Refining Co., near Crested Butte, Colo., is one of a series being prepared by the Bureau of Mines on current shaft-sinking practices in various mining districts of the United States. Preparations for sinking a combined exploration, development, and production shaft from the lowest level of the Keystone mine began early in 1957. This vertical, three-compartment, 6-1/4-by 16-foot rectangular shaft was to be sunk in separate stages or lifts so as to correspond with the progress of an associated lateral exploration and development program. The first section of the shaft was collared and sunk to a depth of 209 feet between September 1957 and April 1958. Because of the depressed base-metal market, the mine was shut down as soon as the initial phase of the exploration and development program had been completed and before any deeper sinking could be attempted.

Jan 1, 1962

By L. G. Marshall

This report describes dredging and processing of sand and gravel from a glacial-fluvial deposit in the Raccoon River valley near West Des Moines, Iowa. Preliminary cleaning and separation of the sand and gravel at the dredge site with subsequent transportation to separate plants and the production and disposal of the various grades of aggregate material are also described. The geology of the deposit is summarized. A tabulated summary of costs in units of labor, power, and supplies is included.

Jan 1, 1963

By Lee Ann Gardner

This U.S. Bureau of Mines publication presents a case study of the processes used in permitting the Nome Offshore Placer Project, a gold mining project offshore Nome, Alaska which operated from 1985 through 1990. The mining project, developed by Western Gold Exploration and Mining Company, Limited Partnership (WestGold), used the BIMA, which was at the time the largest bucketline mining vessel in the world, to dredge gold from the ocean floor. This case study reviews the permitting process from the regulators' and industry's perspectives, as well as characterizing the efficiencies and inefficiencies associated with this case. The Federal, State and local laws applicable to the Nome Offshore Placer Project are identified, agency jurisdiction and interagency relationships are explored, and the chronology of the permitting process is examined. The regulatory authorities for both environmental monitoring and post-mining monitoring are delineated. Significant milestones affecting the project and required regulatory submittals are also included. The case study of the Nome Offshore Placer Project is detailed with respect to agency involvement and coordination, approaches to permitting from both the regulators' and developer's perspective, environmental issues, and permit stipulations which were unique to the project. The advantages and disadvantages of these topics are discussed.

Jan 1, 1992

By J. M. Kuchta

Bench-scale test methods were developed by the Bureau of Mines for use by the Department of Transportation in the classification of solid and liquid oxidizers. A burning rate test is recommended for evaluating the fire hazard of solid inorganic oxidizers when mixed with a red oak sawdust as the reference combustible. A spontaneous ignition test is proposed for evaluating liquid and solid inorganic oxidizers which may decompose violently or ignite spontaneously when unmixed or mixed with the wood sawdust under unconfined conditions. Test results are compared for various representative oxidizers and a classification system is proposed for use in the government transportation regulations.

Jan 1, 1972

By Robert Blickensderfer

Tungsten alloys with high-temperature strength properties, comparable to the best of alloys recently developed by others, were produced by a new process called here the oxyreaction process. The process involved additions of a powder of a reactive metal compound, ZrN, ZrW2, or HfW2, to a base metal powder, tungsten, which contained some oxygen. The powders were blended, compacted, sintered, and extruded. During sintering, diffusion and internal oxidation occurred to produce reactive-metal oxide particles and solid solutions. A dispersion of oxide particles could be precipitated by heat treating. The oxyreaction process circumvents many of the agglomerating and coarsening problems encountered in the current methods for dispersing a stable oxide in a metal. Oxyreaction strengthening results from solid-solution strengthening and from dispersion strengthening produced by the reactive metal and its oxides. At a test temperature of 1,650° C, the alloys prepared from WW, had tensile strengths up to 70,000 psi and stress-rupture lives up to 142 hr at 10,000 psi stress; the alloys prepared from ZrN powders had tensile strengths up to 80,000 psi and stress-rupture lives up to 27 hr at 10,000 psi stress. Tensile strengthening in the alloys was attributed to Zr in solid solution or to Zr-O-W structures too small to be observed in an electron microscope replica. Stress-rupture life was attributed to a dispersion of submicron Zr02 particles which precipitated and grew to 0.05-to 0.2-micron size during the test. Tensile strengthening and stress-rupture life were dependent upon both the zirconium and oxygen contents with the maximum occurring at roughly 0.9 atomic pot Zr and 0.9 atomic pot 0. Studies of the details of the oxyreaction process were made on the W-ZrW2 alloys and three general steps were determined: (1) The reaction of 0 in tungsten powder with ZrW2 to form relatively large Zr02 particles; (2) the dissolution of remaining ZrW2 into the W matrix and partial internal oxidation to form ultrafine but sparse zirconium oxide particles and possibly to establish Zr-O-W structures; (3) the development of ultrafine Zr02 particles during high-temperature aging.

Jan 1, 1971

By Donald E. Redmon

Industrial engineering departments perform staff duties and are most effective when sincerely supported by management. In accordance with the needs and desires of the mining companies involved, various industrial engineering functions have been adopted widely at western metal mines during the period 1950-60. Newly organized departments usually conduct method and equipment studies, work-measurement programs, and establish and maintain production standards. Supervisor-training programs and courses are effective in showing the relationship between supervisory responsibility and the purpose for which industrial engineering is practiced. Industrial engineering staffs of western metal mines are composed predominantly of personnel from within the companies. Experienced industrial engineers, not necessarily experienced in mining, frequently are hired by a company to help establish the department. Management consultants frequently are called upon to advise management and instruct department personnel in industrial engineering practices. Some departments have developed satisfactory industrial engineering programs without benefit of formal industrial engineering training or advice.

Jan 1, 1962

The Bureau of Mines annually publishes statistical data reflecting technological trends in the minerals industry (metals and nonmetals except fuels). This report outlines recent developments and trends and the technology outlook for mining practices and metallurgical processing based on a review of the minerals industry during the past 2 years. A historical statistical series which indicates trends in the minerals industry has been extended with 1970 data. In addition, data are given from a 5-year Bureau of Mines cyclic canvass of froth flotation plants. Data for 1970 are compared with those of 1960 and 1965.

Jan 1, 1972

By J. P. Morris

The Bureau of Mines investigated the mechanics of fuming of iron-carbon melts during top-blowing with oxygen. Melts weighing 45 lb were prepared in an induction furnace and blown with oxygen by means of water-cooled lances. The rate of fuming was measured and correlated with the operating variables. The data showed that the primary cause of fuming was a boil at the bath surface in the impingement zone of the oxygen jet. Nucleation of the carbon monoxide bubbles producing the boil was apparently brought about by the precipitation of an oxide phase. The actual fuming mechanism involved partial oxidation and vaporization of bubble films and fine metal spray generated by the bursting of the bubbles. Bubbles that formed outside the impingement zone produced little fume. The distribution of trace elements between the metal and fume strongly indicated that the fume contained fine spray particles as well as particles that had condensed from vapor. The rate of fuming was found to be proportional to the carbon content of the metal) the concentration of oxygen in the jet) and the bath temperature) provided that a continuous boil occurred. In the absence of a boil) very little fume was produced.

Jan 1, 1967

By Walter B. Lenhart

This paper is one of a series on milling methods and costs being. published by the Bureau of Mines. The milling practices and special problems relating to grinding, tailings disposal, and choice of a treatment process at the Cardinal mill are discussed. The property of the Cardinal Gold Mining Co. is about 18 miles southwest of the town of Bishop, Inyo County, Calif., at an altitude of approximately 8,500 feet. The camp has been designated Bishop Creek by the postal authorities. The property comprises 33 mining claims, including fractions and millsite in sections 19, 20, 29, and 30, T. 8 S., R. 31 E. These claims are located in a general way along the strike of a band of quartzite.

Jan 1, 1938

By Jeff Kravitz, John Kovac, Wayne Duerr

Since 198 1, Federal mining law has required every miner working in underground coal mines to have a self-contained, self-rescuer (SCSR) available for use in emergencies. Some miners that have escaped from fires using SCSR's have reported that they had to remove their mouthpiece to talk during escape, thus compromising the protection afforded by the SCSR. If miners are in thick smoke during an escape, they may have trouble if they become separated from their group. The visibility can be so poor that separation can occur at very short distances. To address this problem, two-way, FM radios were built into the SCSR to improve the ability to communicate should the miners be separated over relatively short distances. The SCSR prototypes built and used in testing included both two-way radios and improved mouthpieces. Comparison studies were conducted using combinations of the new and old mouthpieces, and trials using the radio or not using the radio. Subjective judgments indicate that communication ability was significantly improved using the prototype devices. Communication problems have been encountered with teams using standard voice- powered communications systems. Mine rescue teams perform rescue and recovery work under extremely hazardous conditions, life lines are a standard part of mine rescue team equipment. Leaky feeder and quasi-leaky feeder life line communications systems provide significant improvements over standard systems. These improved systems allow all members of the team to communicate with each other and their base of operations. These innovations will significantly enhance the safety of mine rescue operations.

By Doris M. Hyde

Mineral output and trade in the Central American countries were directly or indirectly affected by the sometimes violent civil unrest and recessionary economic developments that have pervaded the region for several years. Central American countries found their foreign exchange export earnings and traditional market areas shrinking while essential import costs were rising. Restricted spending measures were adopted by governments and private industries. Domestic investment funds for mineral development and exploration projects were among the first casualties of these austere budgetary measures, especially since weak demand and depressed mineral prices diminished the probability of a favorable cost-benefit ratio. The lack of physical security and political stability also discouraged private foreign investment. The United States Congress enacted the Caribbean Basin Economic Recovery Act of 1983 (19 U.S.C. 2702), more popularly known as the Caribbean Basin Initiative (CBI). This legislation was designed to stimulate economic recovery and promote economic development by increasing private investment and trade in the Caribbean Basin countries. The act provided for the elimination of U.S. duties on most trade items imported directly from eligible Caribbean countries, provided at least 35% of the product value originated in the region. The financial assistance components of the CBI were to be supportive of the basin's private sector as well as assist general economic stabilization programs.

Jan 1, 1985

By Rose L. Ballard

This chapter summarizes data on crude nonfuel mineral production for the United States, its island possessions, and the Commonwealth of Puerto Rico. Included also are the tables that show the principal nonfuel mineral commodities exported from and imported into the United States and that compare world and U.S. mineral production. The detailed data from which these tables were derived are contained in the individual commodity chapters of volume I and in the State chapters of volume II of this edition of the Minerals Yearbook. Although crude mineral production may be measured at any of several stages of extraction and processing, the stage bf measurement used in this chapter is what is normally termed "mine output." It usually refers to minerals or ores in the form in which they are first extracted from the ground, but customarily includes the output from auxiliary processing at or near the mines.

Jan 1, 1983