Search Documents

By Sidney Katell

This Bureau of Mines study estimates typical capital investments, operating costs, and selling prices for two bituminous coal strip mines in the Eastern and Interior provinces and a subbituminous coal operation in the Northern Great Plains province. The annual productions were based on tonnage required to fuel a 250-MM-scfd, high-Btu gas plant. The annual tonnage for the Eastern province mine is 4.8 million tons; for the Interior province mine, 6.72 mi 11 ion tons; and for the Northern Great Plains province mine, 9.2 million tons. It is assumed that the mines have a 20-year life. Wages and union welfare payments are considered as of May 12, 1974, under the terms of the Bituminous Wage Agreement of 1971, and costs for material and equipment are based on 1973 and early 1974 indexes . Initial capital investment varies: $45,358,600 for the 4.8-million- ton-per-year (MM tpy) mine in the Eastern province, $54,603,000 for the 6.72 MM tpy mine in the Interior province, and $29,871,000 for the 9.2 MM tpy mine in the Northern Great Plains province. Total capital invest-ments for the Eastern province mine, the Interior province mine, and the Northern Great Plains province mine are $61,070,000, $76,753,000, and $56,286,000, respectively. Corresponding selling prices for the coal, per ton, are $4.79, $4.23, and $2.66, assuming a 12-percent discounted cash flow rate of return after Federal income taxes. These studies are considered typical for the areas involved. Costs will vary depending on specific locations in these areas.

Jan 1, 1974

Development of automatic fire protection systems for large, mobile mine haulage equipment was initiated under Department of Interior's Bureau of Mines-FMC Corp. contract H0122053, "Improved Sensors and Fire Control Systems for Mining Equipment June 1972 to May 1973." After successfully designing and mock-up testing an effective economical automatic fire protection system, and after having demonstrated that the system could extinguish controlled fires on 100-ton capacity haulage trucks, USBM-FMC contract 110232059 was issued in June, 1973, to conduct further development and validation testing. This report documents technical progress and activity under the latter contract. Figure 1 shows areas of the two haulage trucks that were protected by the automatic fire protection systems tested during this program. Figures 2 and 3 are composites showing hardware and schematic diagrams of the systems tested.

Jan 1, 1974

By Madan M. Singh

The use of fluid jets for industrial purposes has received considerable attention in recent years. The convening of The First International Symposium on Jet Cutting Technology1 in April 1972 devoted solely to this subject probably heralds the coming of age of this new science. It is interesting to note the emphasis in the conference towards the cutting of rocks, minerals, and soils, indicating the attention being devoted to excavation and mining. The use of water streams for mining of minerals is not new. It is well over a century since its first application.2 But its use in coal mining has been somewhat restricted over the years. In the past 30 years the U.S.S.R. has successfully used water for coal extraction, and these techniques have been examined in 15 countries in recent years. In the United States research on various aspects of the method has been conducted for over 15 years,3 but success stories from the Soviet Union,4 JapanS and Canada6 in the last 5 years has spurred greater enthusiasm. IIT Research Institute has done pioneering work in the 7-12 13-15 area of water jetting for rock and coal breakage. It has just completed an experimental study involving mining of coal with a 50,000-psi and 100,000-psi jet in a stripping operation14 under the sponsorhip of the U. S. Bureau of Mines (Contract No. HOll1789). As a complementary program the Bureau initiated a project to design a water-jet coal-mining machine (Contract No. H0133119). IITRI was a successful bidder on this competitive procurement.

Jan 1, 1974

By John D. Spencer

Research on the development of new and improved methods for the discovery and production of oil and gas and production of fluid fuels from coal continued to be the major thrust of the Bureau of Mines energy research program during 1973. Crude oil recovery from tar sands and oil shale also retained a high priority in this work. Complementing this program were numerous studies aimed at accomplishing the objective of increased energy output with greater safety and minimum harm to the natural environment. This report summarizes research objectives and results and itemizes formal publications of the Bureau of Mines on energy and related subjects.

Jan 1, 1974

By Yi-Shen Li

This report has been prepared by Lockheed Missiles & Space Company, Inc. (LMSC), under United States Bureau of Mines Contract No. H0220040 dated 21 June 1972 for the design, development, fabrication, and certification of the One-Hour Self-Rescue Breathing Apparatus (PBA). The PBA is a self-contained, oxygen-generating, CO2-removing closed-loop breathing apparatus that provides a minimum of 1 hour of breathable atmosphere during escape from a mine with a contaminated or oxygen-deficient atmosphere. This Cost-Plus-Fixed-Fee (CPFF) contract has been successfully completed in a three-phase program. The Phase I tasks included the design, development, and fabrication of prototype units developed at LMSC in accordance with the requirement of the Code of Federal Regulations (CFR) Title 30, Chapter 1, Subchapter B, Part 11 (Appendix A), and was submitted to the National Institute for Occupational Safety and Health (NIOSH) for joint NIOSH and Bureau of Mines certification testing.

Jan 1, 1974

By M. D. Aldridge

The results of a four-year research effort aimed at developing a practical and effective electronic system for monitoring safety conditions throughout a coal mine by displaying, at a central location, remotely measured parameters are described. This document reports on the design details of the sensor packages and the data processing program used in an experimental monitoring system. The results of special ventilation monitoring experiments and several sub-system considerations are also described.

Jan 1, 1974

By Anatol Wojtowicz

This research program was conducted to determine if respirable coal dust emanating from a continuous mining machine can be suppressed more effectively by a high expansion foam than by the water sprays conventionally used. A high expansion foam system was developed and tested on a continuous mining machine under actual operating conditions. The utility of the system was demonstrated. Test results tend to show that foam application is more effective than water sprays in suppressing respirable coal dust. However, because of the extreme variability of the test conditions, scatter in the sampling data, and other factors, not enough data was obtained to form a firm conclusion that foam is more efficient than a water spray in suppressing respirable coal dust. Sufficient statistical data was obtained, however, to indicate that foam is more efficient than water in suppressing total float coal dust.

Jan 1, 1974

By E. E. Buban

A self-contained breathing apparatus has been developed to provide complete respiratory protection for a miner in an irrespirable atmosphere. The apparatus has the desired features of comfort, reliability, maintainability, and quick-donning capability. The apparatus is packaged in a moistureproof envelope and is protected in a shock absorbing, fiberglass resin carrying case. The apparatus is a small, lightweight, one-time-use device that can be readily worn on a miner's belt, requires no maintenance and is designed to have a shelf life of five years and a carrying life of three years. It is deployed to the use position in a period of 15 to 30 seconds. Man tests conducted in-house and at the National Institute of Occupational Safety and Health (NIOSH) testing laboratories established that this unit meets all performance requirements listed in the Code of Federal Regulations, Title 30, Part 11, Subchapter B, Subpart H (CFR 30, Part 11) for respiratory protective devices. The unit, which has received joint approval (TC-13F-37) on a prototype basis from the Mining Enforcement and Safety Administration (MESA) and NIOSH has: (1) Ten-minute service life under escape conditions. (2) Thirty-minute service life when the wearer is at rest. (3) Peak-to-peak breathing resistance of less than our inches water column height. (4) Inspired gas temperature of less than 135°F. (5) Breathing gas contents greater than 19.5 volume per cent of oxygen and less than 2.5 per cent carbon dioxin. (6) A weight (complete in carrying case) of 2.75 lbs. (7) A carrying case size of 6-1/2"x 5-1/8"x 3-1/8".

Jan 1, 1974

By C. Daniel Kealy

Dissolved and suspended solids are present in the free water of tailings ponds. This Bureau of Mines study was designed to identify the influences of the slime zone in preventing these solids from reaching the environment outside the tailings pond. The finite-element method was used to determine the rate of discharge of subsurface water from the Van Stone tailings pond in northern Washington. The slime zone was sampled and tested for the first time, and results were interpreted and incorporated into the mathematical model. Computer results were verified by installing and monitoring piezometers in the field and by a simulated (16- by 1/2- by 3 foot) laboratory model. Output from the numerical model defined critical seepage zones and revealed that proper pond design and maintenance can reduce pond seepage losses to a minimum. Minimization of seepage requires maintaining the pond water level over the slime zone. Sufficient physical, chemical, and limnological data were collected and analyzed to conclude that the only realistic reflection of synergistic effects is obtained by study of the indigenous biota in combination with quantitative chemical and physical data. Proper planning and management of the milling and waste disposal operations are the key to minimal pollution.

Jan 1, 1974

By W. E. Foreman

A mathematical model was developed to assess the costs for reclamation of surface mining using the shovel overcasting operation, the front end loader operation, and a backfilling operation. A literature review was made of the present laws in Kentucky, Pennsylvania, Virginia, and West Virginia pertaining to surface mining and of the various parameters that influence the input data for a mathematical model. It was determined that the working mathematical model would have to be applied on an area to area basis, preferably on a permit by permit basis in the area where surface mining was being done. To this end, a flexible model was developed with input data obtained from the area of study. The results of the study show that the cost per ton of coal for reclamation can be estimated for various reclamation levels. Validation of the model was done for selected permits from Virginia. It was determined that the permits could easily be used for input data to the model.

Jan 1, 1974

The Federal Coal Mine Health and Safety Act of 1969 limits to 2 milligrams per cubic meter (for dust containing a maximum of 5% quartz) the average respirable dust concentration to which individual miners may be exposed. Section 205 of the Act directs that an appropriate exposure formula for dusts with quartz content in excess of 5% be established. This formula, entered in F. R. Document 70-12351 filed September 16, 1970, is 10 milligrams per cubic meter divided by % quartz. Thus, the total respirable dust exposure permitted limits the quartz to a maximum of 100 micrograms. For example, if % quartz is 5%, 10 mg/5 = 2 milligrams, and (.05) (2 mg) = 100 micrograms. Similarly, if % quartz is 10%, 10/10 = 1, and (.10) (1 mg) = 100 micrograms, etc. If the % quartz is less than 5%, the 2 mg/M3 limit prevails.

Jan 1, 1974

Two different techniques were used to make measurements of the absolute value of electromagnetic noise in an operating coal mine, Robena No.4, located near Waynesburg, Pennsylvania. One technique measures noise over the entire electromagnetic spectrum of interest for brief time periods. With present instrumentation, the spectrum can be covered from 40 Hz to 400 kHz. It is recorded using broad-band analog magnetic tape, and the noise data are later transformed to give spectral plots. The other technique records noise envelopes at several discrete frequencies for a sufficient amount of tine to provide amplitude probability distributions. The specific measured results are given in a number of spectral plots and amplitude probability distribution plots. The general results are that at frequencies below 10 kHz, power line noise within the mine is severe. Impulsive noise is severe near arcing trolleys, and at lower frequencies near any transmission line. Carrier trolley phone signals and harmonics are strong throughout the mine whenever the trolley phone is in operation. Additional information beyond that included in this report may be obtained from the authors, who are with the Electromagnetics Division of the National Bureau of Standards.

Jan 1, 1974

By P. T. Brooks

A process for extracting 69 percent of the vanadium from weathered Nevada dolomitic shale containing about 1 percent V205 was developed on a laboratory scale by the Bureau of Mines. The process essentially is comprised of salt roasting, leaching with dilute sulfuric acid, solvent extraction, and precipitation of vanadium as ammonium metavanadate. Carbonaceous unweathered shale was less amenable to treatment. A preliminary cost estimate for mining and processing 1,500 tons per day of weathered shale indicated a production cost of about 1 dollar per lb of V205. Considering recent sales at nearly $1. 75 per lb of contained V205, larger scale testing to obtain more definitive process design and evaluation data may be warranted.

Jan 1, 1974

By G. L. Hundley

An anhydrous chlorination process has been developed by the Bureau of Mines for the production of copper, ferric oxide, and sulfur from chalcopyrite. The first part of the process is a chlorination step in which elemental sulfur and a mixture of iron-copper chlorides are produced. This paper describes the second step of the process in which the copper and iron chlorides are reacted with oxygen to selectively convert the iron chloride to ferric oxide and chlorine leaving the copper in the chloride form. The chlorides are pulverized and dropped countercurrent to a flow of oxygen in a vertical 20-cm-diam. reactor at 800° C. By leaching with brine, the copper chloride may be separated from the insoluble iron oxide and reduced to copper powder by electrowinning. It has been demonstrated that 70 to 80 pct of the iron can be converted to oxide in a single-stage operation with a chlorine content in the offgas of 80 pct. After removal of the oxygen, this chlorine could be recycled to the chlorination step. A two-stage operation will convert 98 to 99 pct of the iron in the mixture to insoluble oxides. The offgas from the second stage contains 70 pct chlorine.

Jan 1, 1974

By F. M. Carlson

Comparisons are made between the results of the Buckley-Leverett and Kern solutions, which describe immiscible displacement of oil by gas in a linear system and the results obtained from a less restrictive numerical model. This model takes into account the effect of compressibility of the oil and gas and the effect of allowing changes in the amount of gas in solution in the oil. These effects are best exemplified by imposing large pressure drops across the system. With these large pressure drops, comparison of the model solution with the Buckley-Leverett solution reveals that the Buckley-Leverett solution provides estimates of recoveries at breakthrough of the gas that are too low. In contrast to the model, the Kern solution predicts breakthrough recoveries that are too high. A modification to the Kern solution is presented to facilitate more accurate predictions of recovery at gas breakthrough for gas injection at pressures higher than the saturation pressure of the oil.

Jan 1, 1974

1. Domestic Production and Use: Twelve companies operated 31 primary aluminum reduction plants, three firms accounting for 66% of production. Washington, Oregon, and Montana accounted for 32% of the total production; Gulf Coast States, 25%; Northern States, 29%; and other Southern States, 14%. Output of primary metal in 1973 was valued at $2.2 billion. About 80% of the secondary recovery was from new aluminum base scrap and 20% was from old scrap. Aluminum consumption by 25,000 firms was centered in the East Central United States. Of aluminum consuming industries in 1972, building accounted for 28%; transportation 19%; electrical, 13%; packaging, 16%; and consumer durab1es, 10%.

Jan 1, 1974

By Robert Stefanko

Test procedures for evaluating underground coal mine trailing cable splices are formulated. The tests are utilized to evaluate several trailing cable splices. The laboratory results are compared with actual field observations and experience. The results are utilized to define quantitatively the generalized terms of the 1969 Health and Safety Act. Recommended specifications and procedures for testing by MESA Department of Approval and Testing personnel are included. Failure points in splices are detailed and presented for use by a MESA training program and manufacturers attempting to improve product quality.

Jan 1, 1974

This three-part report provides the results of an industrial engineering study that assessed the safety and efficiency of underground ore handling in U.S. metal mines. One of the primary findings of the study was the improvement needed in controlling muck size in the are handling stream. Oversize ore is causing much additional labor, creating work stoppages, and is a principal cause of accidents in metal mines. The specific objectives of the Present Systems Study were to determine and evaluate the productivity of existing ore handling systems in a representative group of underground metal mines, to relate the available historical accident record statistics of these selected mines to the specific operations in the overall ore handling operations, and to highlight the potential areas of improvement for each mine on the basis of productivity and associated hazardous index for each operation.

Jan 1, 1974

By M. D. Aldridge

The results of a four-year research effort aimed at developing a practical and effective electronic system for monitoring safety conditions throughout a coal mine by displaying, at a central location, remotely measured parameters are described. This document presents the general philosophy of an experimental system in an operating coal mine. The conclusions drawn from this experience are presented and a typical design for a large coal mine is described.

Jan 1, 1974

By Roger J. Morrell

Bureau of Mines laboratory experiments with reduced scale cutter and cutter forces were performed to (1) define the fundamental relationships governing disk cutter performance and (2) to develop a method of predicting disk cutter performance in soft, medium, and hard rocks. The rock cutting experiments were performed in four igneous and metamorphic rocks that ranged in compressive strength from 38,000 to 67,000 psi. A special testing machine called a linear cutter apparatus (LCA) was used to load and traverse a free rolling disk cutter across a smooth rock surface. Each pass of the disk produced a single crater, and runs were spaced to avoid breakage between craters. During each run the normal and tangential cutter forces were measured and recorded. The soft and medium rock data were obtained from previous Bureau experiments with disk cutters. Crater depth, tangential cutter force, crater volume, specific energy versus normal cutter force, and crater width versus depth are defined within this study. With the use of standard physical properties, performance prediction equations were developed using stepwise linear regression analysis techniques. A method of using these prediction equations to calculate the boring rate, the cutter spacing, and the torque and energy requirements of a full-scale boring machine was also developed.

Jan 1, 1974