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By R. D. Groves

Laboratory research has demonstrated that high - grade copper powders can be produced under controlled conditions from cement copper products . The technique should enable small producers to prepare a directly marketable product by means other than smelting and electrolytic purification . A continuous drum- type precipitator was the preferred unit for producing fine - sized particles of cement copper that were further processed by chemical digestion in a copper sulfate solution , by reduction and sintering in a hydrogen atmosphere , and by grinding to a powder . The effects of variables related to all stages of the process were investigated . Treatment of leach solutions from three different sources resulted in copper powders containing 99.2 to 99.8 pct Cu , apparent densities of 1.97 to 2.25 grams per cu cm , good powder flow rates , and a size distribution of 54.9 to 60.1 pct minus 325 - mesh material .

Jan 1, 1964

By John R. Bartels

In laboratory testing, the Bureau of Mines established criteria by which common resin-grouted roof bolting systems can be evaluated and compared. Ultimate strength and stiffness were determined for nonten-sioned full-column, point-anchor, tensioned full-column, and debondable resin-grouted bolts, and for variations on full-column boltsn Bolt per-formances were compared using the performance of the 3/4-in full-column resin-grouted bolt as the standard. New and innovative systems can also be qualitatively compared against this standard. Since the medium into which a resin-grouted bolt is installed is one of the most important parameters affecting bolt performance, various host mediums were used in the testing: sandstone, concrete, simulated coal, simulated shale, and plaster. Bolt performances expected in other mediums can be inferred from the response patterns obtained in these mediums. Results indicate several functional differences among bolt types. Where resistance to shear is important, point-anchor bolts may outperform nontensioned full-column bolts at a lower cost. In medium-to soft-strength rock, tensioned full-column bolts perform best. Also, varying the resin-steel ratio seems to have little effect on the properties of a full-column bolt, when proper resin mixing is ensured.

Jan 1, 1985

By Gary E. Sherman

Preliminary economic mining feasibility studies were conducted by the Bureau of Mines to estimate mining costs in the Juneau gold belt area of the Juneau Mining District, southeastern Alaska. Investigations were conducted on the economics of two mineral deposit types: (1.) Berners Bay vein gold deposits, and (2.) stockwork gold deposits containing gold, silver, and lead. Cost estimates were developed using the Bureau of Mines Cost Estimating System (CES). Discounted cash flow return on investment (DeFROI) was calculated using the Bureau's MINSIM computer program. Underground mining of a Berners Bay vein gold deposit was found to be economic (15 pct DCFROI) at a recoverable metal value of $353.67/mt for a 100 mtpd shrinkage stoping mine with a 10 yr mine life, $324.76/mt for a 20 yr mine life, $138.63/mt for a 500 mtpd longhole stoping mine with a 10 yr mine 1 ffe, and $127.50/mt for a 20 yr mine life. Block caving mining of a large stockwork gold deposit was found to be economic at a recoverable metal value of $15.28/mt for a 18,000 mtpd mine with a 20 yr mine life.

Jan 1, 2011

This report summarizes the results of several field tests conducted by Collins for the Bureau of Mines under contract S0122076 and contract H0232056. The field projects represent a part of Collins continuing effort on a broad study of coal mine communications. These experiments analyze the propagation characteristics of radio signals in a working coal mine environment. The intent of the program is to provide basic propagation loss characteristics by which we may evaluate various approaches to an integrated mine communications system. The goal of such a system is to satisfy both operational and emergency communications needs in the mine.

Jan 1, 1974

By Juh W. Chen

A process for recovery of energy from waste coal fines was investigated. The process, which was developed through laboratory, bench, and pilot plant scale experiments, consists of mechanical cleaning followed by high temperature oil agglomeration and pelletization. The process can produce a quality product under an economically and environmentally acceptable condition. Waste coal fines with ash less than 35: and HHV greater than 6,000 BTU/1b have been upgraded to a product with less than 15% ash and HHV Greater than 11,500 BTU/lb. A computer model has been developed to optimize the processing costs and to perform economic evaluation of specific sites. Ultimately tine model can be utilized to establish a priority listing for a region in assisting the determination of reclamation strategy.

Jan 1, 1983

By Jeffrey Y. Foley

The Bureau of Mines sampled surface exposures of podiform chromite in the Caribou Mountain-Melozitna ultramafic belt in the Kokrines-Hodzana Highlands, central Alaska. Fieldwork began in 1979 as part of an assessment of the mineral potential of lands adjacent to the trans-Alaska pipeline corridor, for the Bureau of Land Management, and continued through 1981 as a Bureau of Mines investigation. The belt comprises six complexes of which the three closest to the pipeline corridor were investigated. Concentrations of chromite disseminated in dunite host rock make up mineralized intervals ranging in thickness from less than an inch to 5 ft and in grade from 3 to 23 pct chromium. The largest occurrence has an exposed strike length of 80 ft. Bulk surface samples were collected from 10 of these exposures, and beneficiation tests on the samples produced concentrates of metallurgical, refractory, and subindustrial grades. Part I--this report--describes the fieldwork; part II--1C 8916--describes the beneficiation work.

Jan 1, 1983

By George W. Healy

The direct retorting of zinc sulfide concentrates in the presence of lime and carbon was examined on a laboratory scale with ten-gram charges of loose mix or fifteen-gram ones of pellets. A slow stream of nitrogen swept through the furnace tube over the boat of reactants, carrying with it the zinc vapor, which condensed on a rolled-up steel sheet near the exit, permitting weight of zinc produced to be obtained after completion of a run. Variables explored were percent of theoretical reagents, temperature, and time. During the runs gas samples were analysed periodically, and the content of CO2, CO and nitrogen were obtained. The quantities of the carbon gases could be calculated because the nitogen flow rate was measured. The gases were also examined for sulfur species, but neither COS nor SO2 could be detected at maximum sensitivity. Zinc recovery increased with excess carbon and lime and with temperature. It ranged from 77% at a ten percent deficiency to 90% at a ten percent excess at 1100°C. Going to 1200°C and theoretical reagents gave 93% recovery. Increasing time from 200 minutes to 300 minutes increased zinc yield by up to 10%. Results from sphalerite and a commercial concentrate from AMAX gave generally similar results. The reaction rate of zinc sulfide as sphalerite and of calcined sphalerite indicated that the latter reacted almost twice as fast, and recovery of zinc was five percent higher. Though the retorting step using sulfide, lime, and carbon proved to be non-polluting, it was feared that on storage the calcium sulfide in the residues would decompose, giving off noxious gases. Consequently the stabilization of the residues by oxidation was essayed. Because of the presence of unreacted zinc sulfide, the first product of oxidation was S02. Reaction of CaS to CaSO4 was incomplete, going from 20% at 800°C to 90% at 1200°C. Thus the non-polluting nature of the process as a whole is in doubt, and its economics are likely to be unfavorable compared to the traditional way of calcining the concentrates, followed by retorting of the oxide with carbon.

Jan 1, 1982

By R. J. Evans

The generation and disposal of solid waste from electric utility plants using a lime or limestone wet-scrubbing system and the potential effects on the environment were estimated for 1975 and 1980. The study indicated that in 1975 approximately 5.8 million tons of desulfurization solid waste (50 percent solids) will be generated. In 1980, when it is estimated that desulfurization will become commercially accepted, approximately 71.4 million tons of this material will be generated for disposal and/or utilization. The desulfurization waste material when combined with lime, fly ash, and water may have potential for use as a roadbase material, landfill reclamation, and synthetic aggregate.

Jan 1, 1974

By John M. Dale

Sulfur is a plentiful, low cost, unique material whose physical properties can be altered and employed in structural applications. This program was undertaken to develop an optimum sulfur based formulation for use as a coating to both seal and support mine walls. The initial effort in the program was devoted to a laboratory study of the physical and mechanical properties of a variety of sulfur base coatings that were specifically formulated for this application. Concurrent with formulation development, laboratory equipment and techniques were developed for spray applying the sulfur based coatings to the ceiling and walls of a structure that simulated the interior of a mine. Much of the formulation work was guided by the experiences encountered when attempting to spray the formulations overhead. One hundred parts of sulfur modified with 10 parts of talc, 3 parts of milled glass fiber, and 2 parts of dicyclopentadiene was found to be a fire retarded, low odor, low eye irritation, sprayable formulation for sealing and strengthening mini, walls. An invention disclosure on this formulation was submitted to the Bureau of Mines and a patent application was filed. Various mineral samples were obtained and adhesive strengths of the formulation to these samples in both the wet and dry state were measured. With the development of an attractive sulfur based coating material, attention was directed to the design, fabrication, and testing of a portable spray application unit so that coatings might be applied in the field to various rock surfaces and earth formations for further evaluation. The unit was fabricated in the Southwest Research Institute shop. Once operational, the unit's capabilities were field tested and demonstrated at three separate locations. Upon completion of the field testing, the unit was shipped to the Spokane Mining Research Center where Bureau personnel were instructed in the use of the unit.

Jan 1, 1972

By J. P. McGee

The Bureau of Mines is doing research and development work on a coal-fired gas turbine plant initially developed by the Locomotive Development Committee, (LDC) of Bituminous Coal Research, Inc. The Bureau is redesigning the turbine blading and some of the auxiliary equipment, and is reerecting, the plant at the Morgantown (W. Va.) Coal Research Center. The present goal is a 1,500-hour run at virtually the same operating conditions used by the LDC in their final 1,100-hour test with the turbine. This will allow the Bureau to properly evaluate the new blade design. Erosion of the turbine blades (particularly the roots) by ash in the hot gases from the combustion of coal was the most serious problem in extended operation in earlier experimental work. New blades made of Stellite6 are being fabricated for the stator and rotor, and armored wear strips of titanium carbide will be inserted in the blades at the areas of probable maximum ash velocity and concentration. The trailing edges of the rotor and stator blades are being thickened and thinned, respectively, to induce the ash to travel to the casing and prevent it from returning to the base of the rotor blades. The first stage rotor and second stage stator blades are being removed to provide an annular space for maximum quantities of coal ash to centrifuge to the casing. Additional blades will be added to most of the rows in the stator to stop secondary flow of dust-laden gas toward the rotor. A contract has been awarded for fabrication of the new blades. The 1,500-hour run will be started as soon as the new blades are installed.

Jan 1, 1962

By J. T. Dunham

Zirconium has possible use in industry where severe corrosion conditions are encountered because it resists attack from a variety of corrosive environments. However, very little experimental testing has been done to evaluate the corrosion behavior of zirconium when simultaneously subjected to high tensile stresses and exposed to corrosive environments. This investigation was initiated for an evaluation test, but was limited to environments consisting of ferric chloride solutions which were known to attack zirconium and were shown to promote stress-corrosion cracking in preliminary tests. Tests for cracking susceptibility were conducted by the Bureau of Mines to show the effect of stress, solution concentration, air aeration of solution, and the method of mechanical processing. Tensile stress was applied to the specimens by a constant-load method which proved more reliable than a constant-strain method.

Jan 1, 1961

By Robert D. Perry

This report describes methods of reclaiming abandoned or inactive tailings ponds and dams. The investigated sites were selected tailings deposits adjacent to metal mines in the southwestern United States and the Pacific Northwest. The basic data developed for each site consisted of the following: a review of existing literature; a site visit that included sampling of the tailings and surrounding materials; laboratory and engineering studies; and development of reclamation plans. Laboratory tests determined the gold and silver content of each tailings deposit and the chemistry of the tailings and surrounding materials. Reclamation plans that include approximate costs were developed for five tailings deposit sites. These ranged in size from 52,000 to 103,000,000 tons. Our conclusions on the remining potential of each site are based on the tailings assay and other technical data. This study concludes that remining as a reclamation tool is feasible at certain sites. Included in this report is a remining program as part of the overall reclamation plan for two sites. Our preliminary results indicate that remining as a reclamation tool is feasible for only one of them.

Jan 1, 1981

By C. W. Davis

There are four parts to this circular and, respectively, they list firms in the Eastern (pp. 5-8), Southern (pp. 9-10), Central (pp. 11-15) and Western (pp. 16-22) United States and Provinces of Canada. Before listing the laboratories and the work performed there, it is proper to make clear what is done and what is not done by Federal bureaus, States, and Territories, as well as by Canada and Mexico. FEDERAL Bureau of Mines. - The Bureau of Mines does not make assays, analyses, or tests for individuals or firms unless they be incidental to investiga¬tions that are of possible benefit to the entire mineral industry. All significant results obtained in this way are made public through published reports. Any mineral sample sent to this Bureau for simple identification will be subjected to a cursory examination.

Jan 1, 1938

This report describes the work performed by Mine Research Company in developing a prototype mobile roof shield during 1971-1972 for the U. S. Bureau of Mines, along with background information leading to the design decisions adopted for the project. In addition, the report evaluates the choice of design and analysis and the results of the project in terms of future possibilities of mobile roof support systems. The report begins with the discussion of the problems of designing, building, and using mechanical and hydraulic roof support in coal mines. It then gives a historical summary of past work with discussions of the design choices made for previous roof support systems.

Jan 1, 1973

By William C. Cooley

This report includes a review of all relevant data on underground hydraulic coal mining technology collected during Phases I and II of the contract. Data collection and analysis procedures are discussed. Information is included on past and existing underground hydraulic coal nines in the USSR (27 mines), Poland (1 mina), Germany (1 mine), Japan (1 mine), Canada (1 mine), China (1 nine), as well as underground tests conducted in the United Kingdom (2 mines), and in the United States (5 mines). Data is also included on Czechoslovakia and New Zealand. In all operational hydraulic mines, coal is transported underground in flumes. In most cases, bituminous coal is broken by monitors with nozzle diameters larger than 16 mm (0.63 in.) and jet pressures of 50 to 125 atm (710 to 1780 psi). Technical design and performance data are included on all key types of equipment and components which have been developed for, used in, or which could be potentially be used in hydraulic coal mining systems. Data sheets are presented on 180 types of equipment, divided into 24 major categories. Where available, sketches, drawings, photographs, and price estimates are included. Data are included on pitching coal seams in the United States which potentially can be mined by hydraulic methods. Preliminary conclusions are presented, subject to revision as a result of economic feasibility studies to be completed during Phase III. An outline is presented of the final report, which will include economic studies and recommendations for research and development.

Jan 1, 1975

By Elmer E. Buban

A lightweight compressed oxygen rescue breathing apparatus (RBA) for rescue and recovery missions has been developed by Mine Safety Appliances Company under contract to the Bureau of Mines. The apparatus is a positive pressure, closed circuit system of 4 hours duration. The weight of the complete apparatus, including an optional cooler, is slightly over 30 pounds. Weight reduction over currently available RBAs is achieved through the use of lithium hydroxide for scrubbing C02 in place of conventional chemicals and the use of a composite glass fiber/ aluminum shell cylinder for oxygen storage in place of steel cylinders. Positive pressure is maintained in the breathing circuit at all times by applying a constant spring force to the breathing bag. The harness has been designed to reduce the work of the wearer by redistributing the weight of the apparatus to the wearer's hips.

Jan 1, 1981

By W. I. Nissen

This Bureau of Mines report presents the design for a commercial-sized flue gas desulfurization (FGD) demonstration plant that uses the citrate process. The goal of the Bureau's citrate process is to minimize the undesirable environmental impacts of industrial plants emitting SO2-bearing gas. The FGD plant is located at the George F. Weaton powerplant, Monaca, Pa. Construction was completed in April 1979 and will be followed by preliminary testing and a 1-year testing and evaluation program. Design capacity of the FGD plant is 156,000 scfm of 0.2-volume-percent-SO2 flue gas yielding about 16 tons of sulfur per day. The plant is intended to (1) clean fly ash, SO2, and Cl- from the gas while cooling the gas in a venturi scrubber, (2) absorb SO2 from the gas using 1,200 gpm of a countercurrent-flowing citric acid-sodium citrate-sodium thiosulfate solution, (3) react the absorbed SO2 in two 13,000-gal stirred closed vessels with added H2S, thus precipitating elemental sulfur and regenerating the citrate solution for recycle, and (4) recover the sulfur from the slurry by air flotation, followed by melting in a heat exchanger and separation from the occluded citrate solution in a sulfur decanter at 35 psi and 135° C.

Jan 1, 1979

By Mark S. Sanders

The purpose of the present study was to develop and test improved Type V workvests for use on dredge operations. The goal was to design workvests that would be more comfortable to wear, would interfere less with task performance, and would better meet the needs of dredge workers. It was hypothesized that by attaining these goals, the resulting vests would be worn more often and would be kept buckled more of the time than traditional vests. The study involved three major phases. In Phase I, visits were made to dredge operations and a definition of the problem was developed. Problems with current vests were identified and working conditions and tasks surveyed In Phase II, prototype vests were developed and laboratory tests were per-formed to assess comfort and interference. In Phase III, the prototypes were modified and field tested with actual dredge operators and workers.

Jan 1, 1985

By C. E. Brechtel

A testing program was conducted to design a cemented backfill fur hydraulic placement in underhand cut and fill mining of a steeply dipping coal seam. The testing evaluated the use of three different backfill aggregates, locally available at the coal mine, with Portland cement and five different pozzolans, including a Class F fly ash, a Class C fly ash, a cement kiln dust and ground smelter slag. Both viscosity and uniaxial compressive strength of backfill mixtures with different pozzolan and Portland cement contents were used to evaluate their suitability. Based upon the results of preliminary testing, an optimum mixture of alluvial sand with six percent Portland cement and ten percent Class F pozzolan was chosen for further compression testing.

Jan 1, 1985

By L. D. Johnson

On a project which is to develop a system to suppress coal dust explosions, a facility has been built and several devices tested. The facility is a 317-foot, 4.5-foot diameter shock tube and to date 53 tests have been carried out with methane-air and methane/coal dust-air as the explosive mixtures. Suppression of slowly propagating (up to 300 ft/sec) flame fronts has been successfully carried out on two tests using the dry chemical extinguishing agent Purple K. Delivery of the material directly into the flame front Seems to be required if effective suppression is to be accomplished.

Jan 1, 1972