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By C. R. Summers

In response to the Coal Mine Health and Safety Act of 1969, mandatory noise standards have been developed that specify time-noise limits of mine personnel exposure. Most affected by elevated noise levels is the pneumatic roof bolter operator, both in terms of levels near or in excess of 115 dbA and in terms of length of exposure. Therefore, the principal emphasis of this Bureau of Mines report is on pneumatic drill noise control. It is not the intent of this report to suggest any drill redesign; instead, methods are suggested to reduce the noise level by complementing existing machines. An integral muffler system and a separate muffler system were tested in an attempt to lower pneumatic drill noise levels. Pneumatic drills, when new, operate at about 115 dbA when drilling in sandstone. Using the drill muffler systems, it was possible to decrease the noise level of a 115-dbA stope drill to approximately 100 dbA.

Jan 1, 1974

By Robert W. Freedman, Robert L. Craft, William G. Humphrey

As part of a continuing effort to reduce the weight and bulk of equipment that mining personnel must carry underground, the Bureau of Mines and the Mining Enforcement and Safety Administration (MESA) investigated accurate and convenient gas samplers for use by mine inspectors in sampling mine atmospheres. The samplers are septum-stoppered glass vials commonly used for routine blood sampling. These lightweight, compact samplers yield results comparable with those obtained with conventional bottle samplers of 250-ml nominal capacity.

Jan 1, 1975

By Robert W. Freedman

As part of a continuing effort to reduce the weight and bulk of equipment that mining personnel must carry underground, the Bureau of Mines and the Mining Enforcement and Safety Administration (MESA) investigated accurate and convenient gas samplers for use by mine inspectors in sampling mine atmospheres. The samplers are septum-stoppered glass vials commonly used for routine blood sampling. These lightweight, compact samplers yield results comparable with those obtained with conventional bottle samplers of 250-ml nominal capacity.

Jan 1, 1975

By E. G. Valdez

Iron foundries that melt automobile scrap produce flue dusts averaging about 32 percent zinc and 6 percent lead. Some is sold to smelters, but because of the meager return and difficulty in handling, most of the dust is discarded. As part of the Bureau of Mines program to find uses for mineral wastes, research was initiated to develop an economical process to recover zinc and lead from the flue dust. Research encompassed the extraction of zinc and lead by fuming, leaching, and agglomeration. Controlled vacuum fuming of zinc to produce Prime Western zinc and a lead-rich residue was the most effective method for treating the dust. This process involved two distillations, or fumings, with carbon and methane as reductants, and resulted in recovery of 91.4 percent of the zinc in a Prime Western grade product, and 98 percent of the lead. Hydrometallurgical techniques involved several leaching methods, but the simultaneous extraction of iron, manganese, and copper resulted in contamination of the solution and made the zinc recovery processes too complicated. Agglomeration was done by pelletizing or briquetting the dust for possible use as feed to a zinc smelter.

Jan 1, 1975

By M. E. Poad

Structural properties of steel-fiber-reinforced shotcrete and polymer-impregnated shotcrete, both plain and fiber-reinforced, were investigated by the Federal Bureau of Mines, Spokane Mining Research Center. The research center has found that flexural strengths can be increased by as much as 106 percent, and splitting-tensile strength by 50 percent, by introducing randomly oriented steel fibers. A slight decrease of compressive strength was found in the fiber-reinforced shotcrete. Polymer-impregnated shotcrete exhibited a threefold to fourfold increase in compressive and splitting-tensile strength. The techniques of preparing shotcrete with the dry process, using both fast-set agents and regulated-set cement, are described, along with the results of physical-property testing. Physical properties include compressive and splitting-tensile strengths, tangent and secant moduli, and stress-strain curves for plain shotcrete, fiber-reinforced shotcrete, and polymer-impregnated plain and fiber-reinforced shotcrete. Flexural strengths for plain and fiber-reinforced shotcrete are also reported. Steel-fiber shotcrete is the more promising of the new structural materials for ground support, and additional research is recommended.

Jan 1, 1975

By A. Landsberg

Chlorination of sulfide minerals and several prepared metal sulfides was studied. The resulting data were analyzed with respect to kinetics of the reactions and application to nonpolluting methods of winning metals from sulfide ores. Sulfides of iron, copper-iron, nickel, lead, zinc, silver, bismuth, arsenic, rhenium, molybdenum, and tungsten were investigated at temperatures up to 600° C. Copper-iron, lead, and zinc sulfides showed at least some product-controlled (parabolic) kinetics at the lower temperatures within the temperature ranges studied, but only nickel and silver sulfides had chlorination rates controlled by parabolic reaction kinetics in the commercially important temperature range of 450° to 600° C.

Jan 1, 1975

By L. A. Johnson

The Bureau of Mines analyzed three cores from the south Seep Ridge area of the P. R. Spring tar sand deposit of northeastern Utah. Four tar sand zones are indicated in the area. The zones range in average thickness from 13 to 24 ft. The total net thickness of the tar sand in the three coreholes ranges from 71 to 112 ft. The tar sand occurs between the depths of 27 and 254 ft. It has good porosity, 25.6 pct of bulk volume; high permeability before and after oil extraction, 819 and 2,218 md, respectively; but a relatively low oil saturation, 36.5 pct of pore volume. Gravity of the oil ranges from 8.20 to 16.5° API.

Jan 1, 1975

By J. E. Tress

The Bureau of Mines has developed a process to utilize waste heat from electric arc steelmaking furnace gases to preheat the ferrous material charged to the furnace. Four heat exchangers were designed, tested, and operated successfully on 1-ton electric arc furnaces. Briquets and pellets were charged continuously, both countercurrent to the hot furnace offgasses and at ambient temperatures. A comparison of the electrical energy consumed in each situation showed that preheating can lower energy requirements as much as 15.6 percent.

Jan 1, 1975

By D. H. Desy

The Bureau of Mines has conducted research on the ignition of methane-air mixtures by sparks caused by frictional impact of aluminum alloys on rusted steel at typical coal mine fan speeds. The objectives were to establish the incendivity of aluminum alloys under these conditions, to investigate differences between aluminum alloys, and to evaluate substitute materials for the aluminum-steel combination. With a specially designed apparatus, three commercial aluminum casting alloys and a number of experimental aluminum alloys were tested for incendivity of the frictional impact against rusted steel in flammable methane-air mixtures. All aluminum alloys tested produced some ignitions. Of the experimental alloys, the harder alloys and those containing silicon tended to be more incendive than the others. With the normal experimental conditions, constructional steel, stainless steel, brass, and plastic did not cause ignition of methane-air mixtures in frictional impact against rusted steel. Some ignitions occurred with constructional steel at high speed in more flammable gas mixtures enriched with oxygen. From these findings, it is suggested that constructional material combinations other than the aluminum-steel combustion would minimize this inc endive hazard. A detailed description is given of previous research, and comparison is made with present results where appropriate.

Jan 1, 1975

By F. P. Haver

Because State and Federal agencies have limited the amount of sulfur oxides that can be discharged to the atmosphere, most copper smelters plan to convert the S02 in offgases to sulfuric acid. In some cases, however, it might be preferable to use a nonsmelting method to fix the sulfur in the form of a discardable product. Research by the Federal Bureau of Mines has shown that sulfur in copper concentrate can be converted into insoluble anhydrite (CaS04) by roasting the concentrate with lime (CaO). After leaching the calcine to recover metal values, the residue may be discarded without harm to the environment. The process can use a rougher flotation product, thus reducing separation costs and saving valuable minerals (for example, molybdenite) that are now lost in making cleaner concentrate. In tests, rougher concentrate was pelletized with the theoretical amount of lime and roasted for 1 hour in a 6-1/2-inch-ID by 11-foot-long rotary kiln at 700° C. Sulfur retention was about 97 percent. Leaching the calcine with 20 percent RCI extracted approximately 99 percent of the copper, 73 percent of the iron, and 91 percent of the molybdenum. After the molybdenum was removed from the leach solution by adsorption on activated carbon, copper with a purity in excess of 99 percent was obtained by cementation on sponge iron. The strip solution then could be spray-roasted at 500° C to recover the RCI for recycle and obtain F2O3 as a byproduct.

Jan 1, 1975

By F. P. Haver

A method to recover copper and elemental sulfur from chalcopyrite concen¬trate, using a ferric chloride leach, CuFeS2 + 3FeCl3 ? CuCl + 4FeCl2 + 2S, was reported by the Federal Bureau of Mines in 1971 (Report of Investigations 7474). Since that time, additional work has been done to improve certain steps in the procedure; that is, the recovery of sulfur from the leach residue, the recovery of copper and iron from the leach solution, and the regeneration of the leach solution. It was determined that over 99 pct of the elemental sulfur in the leach residue could be extracted at ambient temperature with an ammonium sulfide solution. Heating the pregnant solution precipitated crystals of rhombic sulfur (99.5 pct purity) and liberated ammonia and hydrogen sulfide for recycle. Copper with a purity in excess of 99 pct was obtained from the leach solution by electrolysis, using a diaphragm cell, with an energy requirement of less than 0.7 kW-hr/lb. Metal was deposited as a weakly adherent powder that could be easily dislodged from the cathode and withdrawn continuously from the cell in the form of a slurry. During electrolysis, part of the Fe(II) was oxidized to Fe (III) at the anode so there was no chlorine evolution. The leach solution was regenerated by direct oxidation of the spent electrolyte with air or oxygen in a turboaerator at 80° C. This precipitated the iron dissolved during leaching in an easily filterable form, Fe203.xH20, and converted the remaining Fe(II) to Fe(III).

Jan 1, 1975

By Neil B. Young

Carbonate minerals constitute a major fraction of the oil shale in Colorado's Green River Formation. Quantification of carbonate minerals is important for the characterization of oil shale, particularly because of their thermal activity in production of oil from shale. The carbonate minerals found in this oil shale are nahcolite (NaHCO3), dawsonite [NaA1(OH)2CO3], dolomite [(Mg1-xFx)Ca(CO3)2], calcite (CaCO3), and ferroan [(Mg1-xFex)CO3]. Although carbonate minerals can be removed by acid extraction from the balance of the oil shale, direct determination of carbonate minerals is complicated by the occurrence of the same cations in more than one mineral. A method for assigning the acid-soluble cations to the individual carbonate minerals was developed from two assumptions based on oil shale geochemistry: (1) Calcite and ferroan do not occur together, and (2) the ratio of iron and magnesium is the same in dolomite and ferroan. These assumptions were tested by the Bureau of Mines by applying the technique for assigning cations to 219 samples from the saline section of the formation. The reported carbonate mineral amounts were compared statistically with X-ray diffraction peak heights, verifying the cation assignment method.

Jan 1, 1975

By M. C. Irani

The Bureau of Mines, in cooperation with the Mine Safety Appliances Co., has developed a new methane analyzer system for underground applications. Methane enters coal mine ventilation air from the breakup of coal at the active face, from the collapse of roof rock during retreat mining, and from the ribs abutting virgin coal. Each source contributes varying amounts to the total emission, depending upon rate of mining, type of mining, and the character of the coalbed and adjacent strata. The evaluation of individual parameters of methane emission requires the continuous monitoring of individual mine sections over a long period of time. The methane analyzer system was developed to meet this need. The system has been installed and operated in an active mine in the Pittsburgh coalbed. The system and details of its installation and calibration are described. Data are presented to substantiate its reliability.

Jan 1, 1975

By H. B. Carroll

The performance of commercially available portable instrumentation for detecting nitrogen dioxide, sulfur dioxide, and hydrogen sulfide was evaluated. Length-of-stain detector tubes from several manufacturers were included in the study. The instruments were evaluated in atmospheres with 50-and 80-percent relative humidities at 75° F and containing test gas concentrations of 0.1, 0.25, 0.50, 1.0, 1.5, and 2.0 times the threshold limit values. The results from the gas analyzers were correlated with the known contaminant concentration by calculating and plotting an estimated line of regression, confidence limits, and correlation coefficient for each detector system. An increase in the relative humidity from 50 to 80 percent at /5° F changed the instrument response to the contaminants. The uncertainties in detection precision reported are for the observer-instrument system. The main difference or inconsistency in toxic gas concentrations determined with length-of-stain tubes resulted from the observer's interpretation of the results rather than from a predominant difference in the tubes.

Jan 1, 1975

By Lawrence K. Barker

Crude shale oil produced by underground retorting of Green River Formation oil shale was hydrogasified over a cobalt-molybdate-on-alumina catalyst at operating temperatures ranging from 800° to 1,300° F, pressures of 500, 1,000, and 1,500 psig, and a liquid hourly space velocity of 1.02 volumes of oil per volume of catalyst per hour (Vo/Vc/hr). At a temperature of 1,300° F and pressure of 1,500 psig, 94 weight-percent of the liquid feed was converted to gas containing 72 volume-percent methane. With two reactors in series at a temperature of 1,170° F in reactor 1 and 1,260° F in reactor 2 and a pressure of 1,500 psig, 97 weight-percent of the liquid feed was converted to gas with a methane content of 75 volume-percent. Liquefied petroleum gas (LPG) was hydrogasified at operating temperatures ranging from 500° to 1,400° F at a pressure of 500 psig over a cobalt-molybdate-on-alumina catalyst. Similar experiments were made with an empty tubular reactor. The data indicate that gasification reactions in the presence of a cobalt-molybdate catalyst change from predominantly a catalytic (carbonium ion) reaction to predominantly a thermal (free radical) reaction at temperatures greater than 1,100° F. The data also indicate that a reaction temperature of 1,350° F is necessary at the space velocities used in this investigation to make a synthetic natural gas (methane content of 90 volume-percent) from in situ crude shale oil.

Jan 1, 1975

By B. W. Madsen

Research by the Bureau of Mines has shown that treatment of open pit waste by crushing and sizing followed by flotation of the fines and leaching the coarse fraction results in greater metal recoveries than obtained by leaching only. Tests with a chalcocite-bearing quartz monzonite mine waste sample that had been crushed to minus 6 inches and screened on 1/2 inch yielded copper and silver recoveries of 71 and 22 percent, respectively, by the combined flotation-leaching process, compared with 48 percent of the copper and no silver recovered leaching the run-of-mine material. Copper was more readily leached from the coarse material with the minus 1/2-inch fines removed than from material with the fines included. The improved leaching was attributed to improved permeability and the associated improved circulation of air to the interior of the ore column. Cost estimates showed that the proposed intensive treatment of mine waste will require a greater capital investment and higher annual operating costs than conventional milling and dump leaching process. However, the income from the additional metal production offsets the increase in capital investment and operating costs, resulting in additional profit.

Jan 1, 1975

By H. R. Appell

The Bureau of Mines studied the conversion of a variety of cellulosic wastes, for example, sawdust, bovine manure, sewage sludge, urban refuse (free of metal and ceramics), etc., to heavy oils. The objective of the investigation was to determine the scope of the reaction and elucidate the chemistry involved. The reactions took place in the presence of synthesis gas and water or carbon monoxide and water under conditions of elevated temperatures and pressures. Waste conversions above 90 pct, often near 99 pct, with oil yields in the range of 40 to 60 pct, were obtained in the temperature range of 250° to 425° C and pressure range of 1,500 to 4,000 psig. Because mild conditions were sought, most of the experiments were conducted at temperatures of 250° to 350° C and pressures of 1,500 to 3,000 psig. In general, lower viscosity products were obtained at higher reaction temperatures. Conversions and oil yields were significantly increased by operating in the presence of a high-boiling oil; either anthracene oil or oil recycled from the process was satisfactory. Synthesis gas containing 50 pct carbon monoxide gave satisfactory results as a replacement for carbon monoxide. Cobalt molybdate on alumina catalyst, used with sodium carbonate, gave a product of lower viscosity and lower oxygen content than sodium carbonate used as the sole catalyst. The waste-to-oil process has been successfully investigated in continuous flow equipment as well as in batch autoclaves.

Jan 1, 1975

By Peter D. Lohn

The Bureau of Mines conducted both laboratory and field investigations to study the effectiveness of medium-pressure (up to 30,000 psi) water jets in controlling the generation of airborne respirable dust during the hydraulic fragmentation of coal. Laboratory studies were conducted at the Farmington High Energy Test Site of the Twin Cities Mining Research Center, and field studies were carried out at the Humphrey No. 7 mine, Mount Morris, Pa., in the Pittsburgh coalbed. The water jets were produced by commercially available triplex pumps. The dust samples were collected by midget impinger samplers, and analyzed by electronic and optical counting techniques. Respirable dust concentration for a full-scale production model was projected at below 2 mg/m3, the maximum exposure allowed by the Federal Coal Mine Health and Safety Act of 1969.

Jan 1, 1975

By Fred N. Kissell

Air recirculation caused by dust scrubbers at coal mine working faces was examined by the Federal Bureau of Mines with regard to the potential hazards caused by a possible buildup of methane gas. A theoretical analysis indicated that there was no apriori way to predict the effect of scrubber recirculation on methane concentration levels. Experiments conducted in a full-scale model of a working face area indicated that methane levels were dependent to a great extent on the location of the scrubber exhaust, but that the scrubber recirculation did not substantially increase the methane concentration above those levels that would have prevailed were the scrubber not in operation. An analysis of two underground scrubber trials showed that the scrubbers had no significant effect on methane levels, and a review of explosions attributed to recirculation showed that these were characterized by a lack of fresh air as well as recirculation. It was concluded that high methane levels are due more to a lack of fresh air than to recirculation.

Jan 1, 1975

By Donald N. H. Chi

This Bureau of Mines report is concerned with a theoretical study of the aerodynamic response of a single mine entry to flame-induced disturbance. The unsteady, one/dimensional, compressible flow equations were solved using the method of characteristics. This study was primarily undertaken to determine the feasibility of extending the method of characteristics to study the aero-dynamic response of complex mine networks. It was demonstrated that although the technique has merit in studying the complex wave interaction in single entries, it appears to be too unwieldly and too expensive for network analysis. Effort was also directed at a further study of the dispersion and filtering characteristic of aerodynamic disturbances in mine passageways.

Jan 1, 1975