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By David A. Monaghan, Kenneth R. Maser, Adi R. Gurdar, D. Randolph Berry

APPENDIX B - DEVELOPMENT OF FOAM-CONCRETE SLURRY MINE SEALANT 1. Introduction This appendix describes the results of an experimental development and laboratory evaluation of foam-concrete as a rapid setting, lightweight, self-supporting mine sealant material. Foam concrete, otherwise known as Aerated Concrete, is a form of lightweight concrete whose structure consists of air bubbles held together by a hardened cement mortar. Its principal applications are found in roofing, insulation, shock absorbing, and backfill. The air bubbles in foam concrete are formed either by chemical reaction in the wet, placed mortar, or by introducing a stable foam into the mortar during mixing. The mortar is usually a cement slurry with fine sand or fly ash as filler. Our attention focused on preformed foam concrete, since this is most adaptable to field applications. Equipment is available,* which simultaneously mixes and pumps a slurry of foam concrete. Such a slurry can be produced at a rate of up to 50 yards/hr and has been pumped in a 2-inch-diameter hose 1000-feet horizontally and 250 feet vertically up without significant bubble deterioration. One very attractive feature associated with the use of foam concrete concerns site logistics. Foam concrete can be generated with densities as low as 20 lbs/ft3, and hence the total number of

Jan 1, 1973

Great strides have been made in recent years to reduce the disaster potential of underground mine fires. However, mines can still be caught unprepared for a fire emergency. Fires can grow too large before they are detected, warning systems can be too slow and uncertain to reliably signal the danger, and suppression systems can be inadequate to extinguish the flames. New mining systems and equipment may create unanticipated fire hazards, and new materials may generate highly toxic combustion products. This report contains papers that summarize recent significant developments from the Bureau of Mines mine fire protection research program relating to these problems. Certain of these findings are also applicable to surface mining operations. The papers fall into the general categories of fire detection and instrumentation, fire warning, fire suppression, diesel equipment, spontaneous combustion, and toxicity analysis of combustion products.

Jan 1, 1988

By T. E. Gray

This report describes the preparation characteristics of the more significant coal beds in Washington County, Pa. It is one of a series planned to determine coals suitable for producing metallurgical coke, either as mined or after beneficiation. More than 15 million tons of coal was produced in Washington County in 1956; 89.8 percent was cleaned mechanically in 10 cleaning plants. The Bureau of Mines has estimated that 2,280 million tons of recoverable coal remained in beds 28 inches thick or more as of January 1, 1954.

Jan 1, 1959

By Samuel P. Harteis, Eric S. Weiss

The National Mining Association and the Mine Safety and Health Administration requested that the National Institute for Occupational Safety and Health (NIOSH) conduct full-scale evaluations of a recently developed carbon fiber-reinforced polymer (CFRP) reinforcement technique for upgrading existing mine ventilation seals to withstand an explosion pressure of 50 psi or greater. The evaluation was conducted in the NIOSH Pittsburgh Research Laboratory’s Lake Lynn Experimental Mine (LLEM) near Fairchance, PA. The purpose of the evaluation was to determine the blast resistance of the CFRP reinforcement technique, designed to increase the strength of two types of existing 20-psi-rated in situ mine ventilation seals. Two candidate ventilation seals were selected to represent the 20-psi alternative seal designs typical of those used in mines prior to July 2006. Installed within the LLEM were (1) a 4-ft-thick pumpable cementitious foam seal using material with a designed 150- to 200-psi average compressive strength at 28 days and (2) a 24-in-thick, low-density cementitious block seal with a center pilaster and keyed to the floor and ribs. The materials necessary for the CFRP reinforcement technique were then installed on the outby (active) side of each seal, and the seals were subjected to explosion overpressures. Both seals with the CFRP reinforcement retrofit successfully withstood explosion pressures of 60 psi or greater during the full-scale evaluations in the LLEM.

Jan 1, 2008

By R. W. Stahl

Gas accumulation and dust suspension are the major safety hazards in coal stockpiling and reclaiming operations. This report presents a schedule of safety precautions and plant design features devised by the Bureau of Mines to reduce danger from these and other sources.

Jan 1, 1965

Measure tattling in cemented backfill when installation of bore-hole extensometers is not feasible. Problem To evaluate the amount of load that backfill carries during pillar recovery, information about how much the backfill settles after placement is often required. However, the composition of some backfills makes them difficult to drill and the installation of borehole extensometers almost impossible. Approach Bureau researchers have developed a vertical fill extensometer that can be cast in place as a stope is being filled. It consists of a baseplate, sections of steel pipe enclosed in loosely coupled polyvinyl chloride (PVC) pipe, and a top anchor assembly that contains a displacement transducer (fig. 1).

Jan 1, 1990

By T. Bieniawski

"INTRODUCTION The Congress theme ""Improvement of Mine Productivity and Overall Economics by Modern Technology"" is probably beat: addressed by the subtheme allocated to this Plenary Session. It is appropriate that .Theme 1 emphasizes the simple point that effective use of geotechnical information is the key to improving mine productivity. In essence, this means that: (1) geological and geomechanics, (rock mechanics) data must be collected in sufficient quantity and of high quality; (ii) data interpretation must be performed specifically for purposes of engineering design; (iii) innovative design approaches should be used to bring about Improvements in productivity and safety.While, each of these three aspects .may: seem obvious to any mining engineer it is a fact that the above sequence is seldom followed and as a result, mining engineering not infrequently lags, behind other branches of engineering when it comes to design creativity, efficiency and safety.. . After all, mining is still-one of the most hazardous occupations and we are gathered here to discuss, at the highest world professional forum, how to use more effectively the modern technology. This however, does not mean that mining engineers are less capable than other engineers or that their achievements are any lesser; far from it! Mining engineers are the cream of the engineering society on whose efforts depends the welfare of mankind. Moreover, they have produced minerals and coal evergrowing quantities against evergrowing difficulties. Yet, we must and can become even better because we are not making full use of the modern technology and rock mechanics knowledge already at our disposal, and. we are not being innovative enough to the full extent of .our capabilities."

Jan 1, 1989

By T. W. Beck

The National Institute for Occupational Safety and Health (NIOSH) conducratory and field tests to evaluate the effectiveness of dust collector bags for reducing dust liberation and operator exposure from a roof bolter’s dust collection system. The laboratory tests evaluated the bag’s effectiveness to contain dust and the effect on canister filter loading in both a bag and bagless condition. The dust emissions from the collector’s exhaust were also measured in each condition during laboratory testing and show that nearly 100% of the test dust fed into the collector was captured by the dust bags. Loading and pressure drop on the dust collector’s canister filter is greatly decreased when using the bags, enabling longer periods of drilling without filter removal/cleaning. The field results showed that, even though dust standards were met, respirable dust in exhausted emissions was reduced around the bolter. Laboratory and field results show that benefits from use of the bags are realized in all areas of operator exposure.

By C. Travis Anderson

"A recent critical study by Ralston3 of the iron system points out the importance of and necessity for work upon the preparation of ferrous oxide. Not only are ferrous oxide samples desired for determination of the important physical and chemical properties, such as specific heats and heats of formation, bat also information on the stability and behavior of this material is of considerable technical importance. Related. problems where the properties of Fe0 are important have to do with desulphurization of iron, the formation and occurrence of magnetite in copper smelter slags, and sulphur elimination in copperFerrous oxide also has valuable catalytic properties, as is demonstrated in nitrogen fixation.Pure ferrous oxide has never been prepared in quantities large enough to furnish adequate physical and chemical data on its properties. Only two or three experiments4 have produced a fraction of a gram in a state approximating purity and have collected evidence that has been sufficient proof of their having done so. Ferrous oxide is stable only above about 570°C., and below that splits into magnetite and iron according to the reactionUp to about 1920, those who had endeavored to prepare FeO made no provision for rapid chilling, so that although their product. may have had the proper iron oxygen ratio for FeO, in reality it-probably did not consist of pure FeO. The above reaction is reversible; above 570oC. magnetite and iron are supposed to recombine almost completely, and if so, should constitute a direct and easy method of preparation. The data, however, were somewhat conflicting, and the extent to which the reaction goes in either direction needed checking. Preliminary experiments on the interaction of molten Fe304 with solid Fe gave Fe0 of about 85 per cent purity, corresponding to. the approximate purity obtained by some previous investigators. The present work is concerned chiefly with the results cf repeated interaction between partly reduced magnetite and iron, and the calculations which may be made from such results. Repeated treatments are necessary, because molten impure ferrous oxide and iron can not be kept in contact for more than short periods of time."

Oct 1, 1928

By H. V. Makar

A study was conducted by the Bureau of Mines to determine problems associated with the use of ferrous fractions from urban refuse as melting stock for steelmaking and to evaluate the resulting steel products. The study involved 50-pound ingots from laboratory melts and 50-pound ingots from 1-ton electric-arc-furnace melts. The 50 pound ingots from the laboratory melts and the arc-furnace melts were hot rolled to provide material for mechanical and corrosion testing. Results obtained in the study include the following: Most steels rolled successfully and exhibited acceptable surface and edge condition. Tensile strengths of the plain carbon steels were not significantly affected by copper up to concentrations of 0.65 pct and were not affected by tin content up to 0.16 pct. Yield strength increased with increasing copper and tin contents, and impact strength decreased with increasing tin content. Hardness increased slightly with increasing copper content. In general, properties of the steel produced were not measurably affected by charge composition (that is, melting stock), melting practice, or method of scrap preparation.

Jan 1, 1975

By F. E. Spencer

This Bureau of Mines report provides a complete mathematical description of the algorithm employed by a general multiphase chemical equilibrium program developed particularly for the purpose of studying problems in coal combustion, although the generality of the program will allow its application to any equilibrium system in which an appreciable gas phase is present. When applied to coal combustion problems, the program predicts composition and quantity of slag and unconsumed carbon phases as well as calculates accurately the composition of the gas phase including trace species such as free electrons and ions which are important for predicting electrical properties.

Jan 1, 1973

By Everett A. Sondreal

Material and energy balances for stockpiled lignite were calculated by computer simulation techniques to determine the occurrence of spontaneous heating. Data on properties of lignite which affect spontaneous heating were required. In some cases, best values from reported data were utilized; in other cases, new data were developed. These include specific studies on the rate and conditions that influence oxidation, heat of oxidation, heat of wetting, specific heat, thermal conductivity, and permeability of stockpiles to air. These data are presented and discussed in detail for possible application to other studies. Results of computer simulations confirm past field experience on the storage of lignite containing as-mined moisture, and predict a greater risk of heat occurrence in stockpiles of dried lignite where experience is lacking. Successful storage was predicted for dried lignite of 20 pct moisture content, if it were cooled after drying and compacted to an interparticle void fraction of 9 pct (bulk density of 67 lb/cu ft) compared to 10 pet void fraction (72 lb/cu ft) for as-mined lignite.

Jan 1, 1974

To facilitate compliance with title 30 CFR 75.1001-1(b), which requires testing and calibrating of trolley line automatic circuit interrupting devices at intervals not to exceed six months. Approach Calibration of a circuit breaker ideally implies the passage of the expected fault current through the sensing circuit, and observing a successful circuit interruption at the preset level within a specified time. On trolley lines, the required current may be a few thousand amperes, with maximum duration well exceeding one-tenth of a second. Any method of obtaining this calibration current Involving the trolley wire can contribute to wire sagging and other permanent damage to the haul-age system due to the high energy dissipated during the test. Also, control to assure that exactly the required level and duration of current flow is obtained implies the use of equipment which is simply not available In the ordinary mine. Under a Bureau of Mines contract, a circuit to achieve the necessary calibration pulse was conceived and built. How It Works Two prototype units were fabricated and have been field tested by MSHA technical support engineers in under-ground mines. The equipment consists of an electronics Package 20 x 24 x 8 inches and weighing 93 pounds, including a side-mounted circuit breaker, with a set of 8 foot long detachable, AWG #4/0 leads with plier-type clamps. The total lead assembly weighs 21 pounds.

Jan 1, 1981

By Alexis M. Herman

It?s school vacation time again, and kid?s thoughts turn from textbooks and term papers to fun and play, includ­ing outdoor adventures. Old quarries can become swimming holes on hot summer days; sand and gravel piles look like interesting playgrounds; aban­doned mine shafts beckon explorers. But, for the unaware, all three mean danger. Already this year we have seen two stark reminders that mines and minors don?t mix. In Oklahoma, a 13-year-old girl drowned while swimming with friends in an inactive strip mine. In Maryland, a six-year-old boy playing on a quarry site, plunged more than 100 feet to the bottom of the quarry. Playing at such sites may seem like harmless fun, but every year dozens of children and adults are seriously hurt or fatally injured while playing on active and abandoned mine property. These accidents sometimes happen in traditional mining areas like the coal fields of Appalachia and the remote areas of the west. But the threat is anywhere there are active or abandoned quarries, sand and gravel pits, underground mines, or other mining operations.

Aug 1, 1999

By Gerrit V. R. Goodman, Charles D. Taylor, Edward D. Thimons

Future coal mining systems will be able to cut from crosscut to crosscut where advances could exceed 100 ft. However, limitations arise when ventilating such mining systems. In deep advance mining, there would be no workers at the face to advance ventilation tubing or curtain manually. Traditional methods also provide no means for maintaining face ventilation after the miner backs away from the face. U.S. Bureau of Mines research is studying means to provide effective ventilation at cut depths beyond the current limit of 40 ft. Several innovative ventilation schemes are currently being considered. One such method is the use of a jet fan to ventilate a deep cut. A jet fan is simply a freestanding fan using little or no ducting to direct the ventilation flow. Jet fan testing in a 90-ft entry revealed that higher exit velocities and greater penetration depth occurred when various configurations were used to confine and direct the air flow. Additional testing also indicated that 2,200 cfm of fresh air was delivered to the face 90 ft distant when a check curtain was used to limit entrainment around the fan. Without this curtain, this quantity dropped to only 1,000 cfm This testing indicated that a jet fan was capable of providing ventilation to a distant face area. It also highlighted potential problems, such as recirculation at the fan and reentrainment in the jet flow. Despite these potential problems, jet fans may be adequate for ventilating cuts exceeding 40 ft.

Jan 1, 1992

By Charles L. Kimbell

Annual global steel industry investment is partly mirrored in the data for selected market economy countries that appear in table 13 for 1988-90. No reasonably comprehensive 1991 data were available for inclusion in this study, and the partial reporting available was so incomplete that it was impossible to demonstrate whether the level advanced or declined from the 1990 level of nearly $15.5 billion. Moreover, with the radical changes that are now being effected in the steel industries of the states that were the U.S.S.R. and its CMEA partners, it is most regrettable that comprehensive and comparable data, both current and historic, on investment in this area are not available. Updated information on market economy country petroleum industry capital and exploration expenditures by geographic area has been included in table 14, and it is evident that there was a substantial upturn in investment in 1991. The level of almost $74.5 billion was 14.5 % above the 1990 level and included gains in every topical category and geographic area. The source of information for this table has been changed to the Oil and Gas Journal Database from the previously used Chase-Manhattan Bank study of Capital Investments of the World Petroleum Industry, which has been discontinued. Because of this source change, it has been necessary to modify the structure of the table somewhat, but its total scope of coverage is regarded as basically unchanged. It should be noted that the grand total, as well as some of the detail appearing for 1987, corresponds precisely with those in the previous source.

Jan 1, 1993

By J. C. White

A research study was conducted to devise a method for producing phosphoric acid directly from unbeneficiated Florida phosphate matrix. This research was performed as part of the Bureau of Mines, U.S. Department of the Interior, goals of improving minerals and metals recovery from domestic resources and of minimizing the environmental impact associated with mineral recovery operations. This report describes research in which unbeneficiated, dry, south-central Florida phosphate matrix was digested with sulfuric acid in a continuous-circuit, five-tank reactor to yield phosphoric acid and gypsum residue. Feed capacity of the reactor was 100 pounds (45 kg) of dry matrix per 24-hour day. When digestion was carried out at 185° F (85° C), acid filtration rates of up to 420 pounds of P20S per square foot per day were attained. Combined iron and aluminum impurities in the product filter acid were about 60 percent greater than values reported in commercially produced acid derived from concentrate. phosphate recovery was 87 to 90 percent of the phosphate contained in the as-mined matrix.

Jan 1, 1978

By James P. Bennett

To improve construction materials for emerging chemical and metallurgical technologies, the Bureau of Mines is investigating the acid resistance of ceramic materials. In the study described here, eight commercial ceramic materials comprising two red shale, two fire clay, a silica, a silicon carbide, a carbon, and a high-alumina brick were evaluated. Samples were exposed to 20 wt-pct HC1 at 50° C for 110 days. The test apparatus designed to evaluate the materials is described. Changes in chemical and mineralogical composition, cold crushing strength, volume, and weight, and leach rates of AI, Ca, Fe, K, Mg, Na, Si, and Ti ions were monitored. In general, the statistically significant physical property changes that occurred were small. In many cases, no changes were detected.

Jan 1, 1982

By Deborah A. Kramer

As part of the Nation's growing concern with the competitiveness of U.S. firms in the world economy, especially with respect to advanced materials, the Bureau of Mines assessed the actual and potential recovery and manufacturing capabilities for gallium and gallium arsenide (Gacis). GaAs has advanced from a laboratory curiosity to a material with important "high-tech applications within only the last few years, and although protected North American gallium supplies are currently considered adequate, consumption could grow to the point that this assessment would need reevaluation.

Jan 1, 1988

By Robert J. Timko

Water-jet-assisted cutting involves the use of a mechanical cutting bit in combination with a high-pressure water jet directed just in front of the bit tip. Such a jet can offer benefits in terms of improved cutting, reduced dust and fines, and improved bit wear. The Bureau of Mines, through a contract with the British National Coal Board, has re- searched the use of water-jet-assisted cutting on roadheaders. After several engineering design problems were overcome, this program led to the successful underground testing of these roadheaders. Today, more than 60 water-jet-assisted roadheaders are in operation around the world, and numerous others are on order. This paper details the evolution of these machines and the benefits to be gained by their use.

Jan 1, 1986