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By Theodore L. Turner

This Bureau of Mines report describes calcination of kaolinitic clay in a direct-fired 2-1/2- by 24-ft rotary kiln at 750° and 775° C. Methods for preparing kaolin feed materials and characterization of calcined products are discussed. Approximately 99 pct of the alumina in a typical eastern Georgia kaolin was soluble in HC1 after calcination at either 750° or 775° C.

Jan 1, 1982

By J. E. Allison

As part of a Bureau of Mines research program to conserve critical and strategic metals, an aqueous electrodeposition method for preparing stainless-steel-type coatings was studied. Chromium powder (averaging 3 J1.m diam) was suspended in a ferrous-nickelous sulfate electroplating bath and occluded in the electrodeposited Fe-Ni alloy matrix. Subsequent heat treatment of the resulting composite coating formed the ternary alloy. The occlusion process was affected by the quantity of Cr powder suspended in the electrolyte and by the microstructure and composition of the electrodeposited matrix. Coatings containing up to 21 wt pct Cr were deposited from an electrolyte containing 20 vol pct suspended Cr powder. Heat treatment at 1,100° C for 8 h homogenized the composite coating. Deposition of 44Fe36Ni20Cr alloy coatings (250 J1.m thick) on AISI 1020 carbon steel rods, followed by heat treatment, provided complete protection of the carbon steel during exposure to a boiling 65-pct-HN03 solution. Corrosion rates of 0.6±OA mm/yr for the coating in the boiling HN03 approximate that of 304 stainless steel. Practically shaped electroforms have been prepared by the coating method.

Jan 1, 1989

By T. R. Achenbach

1. This, the final report to the U. S. Bureau of Mines on the program with the subject title, presents the data obtained from June 29, 1973, to April 20, 1974. 2. Operating in the Illinois #6 coal seam, the effectiveness of foam opposed to water was compared in reducing respirable coal dust. A combination of 39 foam generators and 14 water sprays were used during the foam tests. Sixty one water sprays were operated during the water tests. Data from 24 shifts using foam and 21 shifts using water are presented. 3. Additional work on foam generator design should be undertaken to provide coverage to a wider area with foam. 4. The general attitude of those working on the foam program and with the miner at the face was positive. It is urged that the work be continued. 5. The minor respiratory irritations evidently caused by an aerosol effect of the surfactant should be investigated. 6. The statistical analysis of the tests will be made and reported by the U. S. Bureau of Mines.

Jan 1, 1974

By H. Tomlinson

"PURPOSE OF REPORTThe purpose of this report, which is the third of a. series on the coal mines of the Western States, is to give the findings of a study of the causes and methods of prevention of accidents from falls of root and coal in the mines of Lincoln County, Wyo. The three mines covered in this report, referred to as A. B. and C, account- for 9 per cent of the coal production in the county and nearly 9 per cent of the State's total production. For comparative purposes some statistical data are presented bearing upon the relation of injuries to their causes, to tonnage produced, to men employed, to days worked, and to days lost as the result of injuries.FATALITIES IN WYOMINGTo show the necessity for this study, Table 1 given the fatalities that occurred during 1928 in the bituminous—coal mines of the United States, of the State of Wyoming of Lincoln County, and in Mines A, B, and C, followed by a brief description of the Kemmerer coal dis-trict, its coal beds and immediate roof, thickness of cover, dip of coal beds, methods of mining timbering for roof support, roof testing, and supervision. All of these factors must be considered in any plan outlined to prevent accidents resulting from falls of roof and coal.ACKNOWLEDGMENTAcknowledgment is made to the officials of the operating companies for their cooperation and assistance during the study and collection of data to complete this report.GENERAL INFORMATIONLocation and Ownership The mines included in this report are within 18 miles north and south of Kemmerer, Lincoln County, Wyo. (fig. 1), and are owned and operated by various coal companies to supply the domestic, smelter and railroad markets. They are severed by branch lines of the Oregon Shorty Line Railroad Coal production and men employed underground in the three mines are indicated in essential detail in Table 2."

Sep 1, 1932

By T. G. Carter, R. I. Miller

First, the influence of variation in the

Apr 1, 1995

By J. L. Holman

The Bureau of Mines is conducting research to improve technology for the recovery of strategic and critical metals, such as cobalt, nickel, and chromium, that are lost in bulk and particulate superalloy-type scrap because it has not been possible to process mixed contaminated scrap efficiently. The research approach involves melting and casting mixed superalloy scrap into soluble anodes for electrodeposition of Ni-Co alloys by controlled-potential electrolysis. The initial experimental results described in this report are from electrolytic tests us-ing alloy anodes cast from elemental nickel, cobalt, and chromium, the main constituent metals of superalloys. Baseline data and operating parameters are necessary for Ni-Co and Ni-Co-Cr alloys before detailed experiments can be conducted on the more complex superalloy scrap. This basic research assessed the effects of cathode potential, S04:CI electrolyte ratio, electrolyte pH, stirring rate, deposition time, cathode current density, and chromium concentration on cathode current efficiency, alloy deposit composition, and deposition potential at a cell temperature of 55° C.

Jan 1, 1985

By H. R. Babitzke

As part of a continuing project to develop refractory metal alloys for high-temperature structural applications, the Bureau of Mines applied solid solution and precipitation strengthening techniques to improve the properties of columbium alloys. The purpose was to investigate the effects of hafnium, tungsten, and boron on the formability, strength, and oxidation resistance of columbium. The experiment was of factorial design with two replications which called for 72 ingots of 36 basic compositions, weighing 150 grams each. Hafnium, tungsten, and boron were evaluated at 3, 3, and 4 levels, respectively. Values of alloy content are all in atomic percent. The highest strength observed was 29,000 psi at 1,200° C for alloys Cb-15Hf (No. 3), Cb-7.5Hf-5W-2B (No. 14), and Cb-15Hf-5W-2B (No. 15). At 1,200° C, the ternary alloy Cb-15Hf-5W (No. 6) which has shown good properties in previous Bureau of Mines investigations was the most resistant to oxidation For boron additions, the alloys oxidized more readily with increasing amounts of this element. The fabricability of the alloys high in boron became increasingly difficult, resulting in an inadequate number of alloys required for a complete statistical analysis for all the tests. As a result of the decrease in ductility, an insufficient quantity of tensile samples were available for a proper analysis for the high-temperature strength data.

Jan 1, 1970

By William J. Campbell

Three types of X-ray analytical instrumentation were compared for applications in the secondary brass and bronze industry. The instruments were a conventional X-ray spectrograph, a portable X-ray spectrograph, and a radioiso-topic X-ray analyzer using balanced filters. The following two general applications were considered: Rapid identification for sorting scrap metals and quantitative analyses to provide guidance in the melting and casting of alloys. Twenty-three analyzed copper-base alloys were used as standards. Although the alloys varied widely in composition, matrix correction procedures were not necessary except for copper. The conventional X-ray spectrograph provides positive identification of the alloys and quantitative values for the six elements investigated--aluminum, copper, iron, lead, tin, and zinc. Equivalent results were obtained with the portable X-ray spectrograph for those elements whose characteristic X-rays are in the wavelength range of the instrument. The radioisotopic X-ray analyzer distinguishes certain groups of alloys and provides quantitative determinations for copper, lead, tin, and zinc. The sensitivity of the analyzer was marginal for the determination of small concentrations of elements of atomic number 26 or lower.

Jan 1, 1972

By D. A. Buckingham

Engineering and economic evaluations were performed by the Bureau of Mines on 14 Frasch sulfur, 1 native sulfur, and 21 metal sulfide operations in 11 market economy countries. The evaluation included discounted-cash-flow rate-of-return economic analyses at 15 pct to determine the average total cost of production of these two commodities and the potential availability of elemental sulfur (8) and pyrite concentrate. The Bureau evaluated the potential availability of elemental sulfur and pyrite concentrate. Approximately 279 million metric tons (Mmt) of pyrite concentrate at 46 pct 8 is potentially recoverable from 422 Mmt of in situ metal sulfide ore. Nearly 89 pct of the total pyrite concentrate is available at an average total cost of production below the January 1984 pyrite concentrate market price ($43/mt). About 185 Mmt 8 is potentially recoverable from 253 Mmt of in situ elemental sulfur. About 99 pct of this sulfur is available at an average total cost of production below its January 1984 market price ($131/mt).

Jan 1, 1986

Simulation and Analysis of Media Behaviour in the Tower Mill by Discrete Element Method for Estimating the Power Draw and Spatial Distribution of Grinding Process The trends to the Tower Mill (TM) for grinding the materials are increased recently due to its unique merits. Among the various considerations of this machine, the main important items are increasing the efficiency of grinding as more as possible while keep the power consumption, manufacturing and maintenance costs as less as possible. Because this grinding process includes a huge numbers of media particles (ball or other shapes) that are interacted with each other and body of the machine, the DEM (Discrete Element Method) way is a very useful and essential step to getting confident evaluations. Because the DEM simulation is a very young scientific field and proper commercial software are very rare and still under modification, at first step, a FORTRAN code is developed for DEM simulation of two laboratory Tower Mill models (KM5 and KD5). The simulation and experimental results matched each other properly. Then one another DEM software was implemented to perform simulation of bigger models (huge numbers of balls), meanwhile could handle the complex 3D geometry data. The simulation and experimental results were compared and analysed in detail for not only laboratory but also for industrial models (KW5, KWD5, KWD50, KW300F, KW700F and KW1500) without any manipulation or compromising of the parameters of simulation. Some numeric data of industrial models are hidden here due to confidential reasons. The relative velocity of balls (ball-ball and ball-TM body), dissipate energy, interacted forces and stresses during the process are the key outputs of DEM simulation for design this machine. Therefore the main important processes in a Tower Mill machine are recognised and consequently some horizons of development of this machine are distinguished.

Sep 13, 2010

By James A. Brierley

Wastewater from uranium mines in the Ambrosia Lake district near. Grants, New Mexico, U.S.A., contains uranium, selenium, radium, and molybdenum. The Kerr-McGee Corporation has a novel treatment process for waters from two mines, sections 35 and 36, to reduce the concentrations of the trace contaminants. Particulates are settled by ponding, and the waters are passed through an ion exchange resin to remove uranium; barium chloride is added to precipitate sulfate and radium from the mine waters. The mine waters are subsequently passed through three consecutive algae ponds prior to discharge. Water, sediment and biological samples were collected over a 4-year period and analyzed to assess the role of biological agents in removal of inorganic trace contaminants from the mine waters.

Jan 1, 1981

By Mark S. Sanders

This report presents recommended visibility requirements for continuous miner, shuttle car and scoop operations and details the methodology used to generate them. A task analytic approach was used to define information requirements and visual features which served as sources of information. Information requirements were prioritized and the location of visual features determined. From this analysis, visual attention locations, containing one or more important visual features, were identified. A total of 71 locations-were identified for continuous miners, 54 for shuttle-cars and 54 for scoops. A procedure was developed for assessing whether operators in existing machines could be expected to see the visual attention locations. The procedure makes use of a Human Eye Reference Measurement Instrument (HERMI) designed for this project and an outside-in photographic procedure for documenting compliance with the recommendations. A sample of continuous miners, shuttle cars, and scoops were used to test the procedure. Results are presented in the report.

Jan 1, 1981

By T. G. Carter

Support system design for tunnels and underground excavations has for many years relied heavily on the use of rock mass classification systems and the Hoek-Brown failure criterion as a means for characterizing rock mass behaviour. Because of their development, both the GSI system and the Hoek-Brown criterion admirably characterize most ?normal? rockmasses from the viewpoint of their behaviour for rock excavations. They, however, run into difficulties when applied at the two ends of the rock competence scale. This is largely because block size and incipient strength are such that rockmass behaviour in these domains tends not to be controlled by interblock shear strength but rather by material strength. At the low end of the rock competence scale (UCSi <<15 MPa and GSI generally <30) discontinuities play less of a role and rock mass strength tends to matrix strength. Similarly, at the high end of the scale (GSI >>65, mi>>15), because discontinuities are now widely spaced, block size becomes so significant that again, intact material behaviour rather than the fracturing becomes the dominant factor controlling rock mass strength. In this paper several case examples are presented to illustrate the application of the high-end (spalling) and low-end (weak ground) transition Hoek-Brown relationships proposed by Carter, Diederichs and Carvalho (2007) as a basis for better defining rockmass behaviour at the extreme ends of the rock competence scale.

Jan 1, 2008

By Vincent Jue

In December 2009, the Italian High Speed Rail Network AV began running over the full 1000 km system length from Turin, at the foothills of the Alps to Salerno, on the seacoast south of the volcano Mt. Vesuvius. It runs through Alpine rivers, highly seismic active zones, mountains, river plains, and through some of the most densely populated areas in Europe as well as some of its most expensive real estate. The Italian High Speed Network?s technical/economic constraints and its regulatory/socio-environmental concerns well may mirror similar obstacles set to confront the nascent California High Speed Rail Program. The two types of constraints must be dealt with together to reach the best construction solution. It is estimated that more than 20% of Italian High Speed Rail Network costs were spent on ground engineering including over 150 km of tunnels, 200 km of viaducts and bridges and 650 km of embankments and trenches. However, it also is estimated that 25% of costs were spent on social and environmental integration of the new rail lines including over 6 square miles of green offsets, 160 km of anti-noise walls, and 300 agreements for socio-environmental work. This paper will look at four examples of innovative ground engineering solutions, each with its own intricate set of constraints: ? Foundation system for viaducts across the ?Po? and ?Ticino? rivers. ? Soil consolidation under railway embankments ? Requirement of short tunnels for physical and environmental reasons ? Construction of railway stations in a confined right of way

Jan 1, 2010

By Verne E. Hooker

Stress-relief techniques and instrumentation have been developed through many years of research in the Federal Bureau of Mines and successfully used to determine the in situ state of stress in rock. This paper describes the drilling equipment and accessories for use with the Federal Bureau of Mines three-component deformation borehole gage. Operation and calibration procedures for the deformation gage are discussed in detail. Site selection and overcoring procedures are included to provide a complete working knowledge for surface or underground applications.

Jan 1, 1974

By Edwin E. Maust

In response to the ever- increasing demand for high temperature materials, the Bureau of Mines instituted a program for the study and development of superrefractories, One of the major tools obtained for use in this research was an image furnace of the double-paraboloidal mirror type. Although extensive theoretical analyses of solar furnace performance may be found in the literature, comparable detailed information on the double-paraboloidal-mirror image furnace has been nonexistent. This report presents an analysis based on an investigation undertaken to ascertain the limitations and characteristics of the furnace so that it can be used most effectively. The quantitative determination of the energy available at the image, the control of this energy by mans of a 60-inch iris diaphragm, and its variation with position and time relative to the heat source used have all been dealt with in detail. The quantitative results were obtained using a specially designed waterflow calorimeter and these measurements, in conjunction with the theoretical analysis, are used to present a fairly complete description of the furnace and its capabilities.

Jan 1, 1962

By David A. Larson

Preliminary laboratory experiments have been conducted by the Bureau of Mines to define the influence of bit geometry on methane ignitions as a step toward establishing safer mining-machine operating parameters. The experimental system was designed to simulate the operation of a continuous mining machine, using a drum-type cutterhead of normal diameter with a narrow cross section, permitting full-diameter drum cutting tests to be run on material representative of sandstone lenses (or inclusions) in coal seams. Two conical bit types were tested at shallow depths of cut with three drum speeds. Bits that rotated in the mounting block during testing did not produce ignitions. The ignition frequency for used bits was three to four times greater than for new bits at the same kerf depth.

Jan 1, 1983

By J. B. Zadra

Tungsten metal, chemically equivalent to commercial grade, is produced by electrolysis of impure tungsten compounds or scheelite in an alkali, phosphate or borate electrolyte. A preliminary investigation of fused-bath electrolysis shows the effect of electrolyte composition, temperature, and current density on current efficiency, yield, crystal structure, and purity of product. Experiments show that tungsten can be electrowon from scheelite in a fused alkali, phosphate, or borate bath with similar results. Studies on electrolyte composition show that the addition of sodium chloride is essential to both electrolytes in treating scheelite. Although its main function is to react with or flux the CaO, it also increases the bath fluidity. Temperature studies revealed optimum ranges between 900° and 1,100° C.; 900° C. proved satisfactory for tungsten trioxide, and 950° to 1,050° C. for scheelite. Current efficiencies were satisfactory for all current densities ranging from 10 to 57 a./dm.2. Yields were 400 to 650 g./kw.-hr. over the same current-density range. Crystal size and purity of the product are functions of temperature, current density, and amount of impurities in the electrolyte. Deposited crystals vary in shape from spherical grains to clusters of dendritic hexagonal needles, and in size from smaller than 35 to 570 microns. The purity of the tungsten metal produced ranges from 99.7 to 99.94 percent.

Jan 1, 1959

By Raymond W. Hiteshue

Experiments were conducted al temperatures of 480° to 800° C. and hydrogen pressure of 6,000 p.s.i.g. to determine the effect of coal residence time on the conversion of a high-volatile bituminous C coal to liquid and gaseous products when using a semicontinuous apparatus designed fur rapid heating and cooling of reactants. The objective of the studies at high temperatures was to determine if appreciable quantities of coal could be converted to gaseous hydrocarbons and low-boiling liquid hydrocarbons. Experiments at lower temperatures were designed to indicate shifts in product distribution with respect to temperature and to learn more about the general mechanism of the reaction when using close control of coal residence time. One percent molybdenum, based on m.a.f. (moisture-and ash-free) coal, was used throughout this investigation. At 800° C., 6,000 p.s.i.g., and "zero" residence time) the yield of gaseous hydrocarbons was about 38 percent and the yield of oil about 4.5 percent, based on m.a.f. coal. With IS minutes residence time, under the same conditions, the yield of gaseous hydrocarbons was approximately 80 percent with no increase in yield of oil. Apparently at 800° C., and hydrogen pressure of 6,000 p.s.i.g. coal was rapidly carbonized to char with expulsion of volatiles. Char was then slowly hydrogenated to gaseous hydrocarbons without production of oil.

Jan 1, 1962

By E. D. Calvert

The objective of this research was to examine variations in melting and forging practice for four titanium-base alloys and to determine their effect on the resultant product. Of particular interest was the evaluation of the skull-casting technique. The data should serve as a guide to producers and consumers of titanium products. Physical properties of four titanium-base alloys in ingot form and in sheet form were evaluated and correlated, where possible, with variations in the melting and casting procedure. Consumable-electrode melting was used throughout, but arc current and furnace backfill pressure were varied, and ingots were formed both by melting directly into a water-cooled copper mold and by skull melting followed by pouring into a graphite mold. Alloying metal additions for the alloys tested were (1) 8 percent manganese, (2) 6 percent aluminum and 4 percent vanadium, (3) 6 percent molybdenum and 2 percent aluminum, and (4) 16 percent vanadium and 2.8 percent aluminum.

Jan 1, 1962