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By Laurance L. Oden

The Bureau of Mines is developing melting data for binary combinations of the alkaline earth fluorides and yttria to facilitate the formulation of slag compositions. The present report deals with the CaF2-Y203 system for which solidus and liquidus temperatures and solid solubilities were determined. The information is presented as the phase diagram. All specimen compositions were blended from high-purity materials and encapsulated in Mo or Pt20Rh prior toheat treatment. Liquidus temperatures were determined by ceramographic examination of heat-treated and quenched specimens. Solidus temperatures were determined by differential thermal analysis and by electron microprobe analysis of quenched specimens. Terminal solid solubilities were derived by parametric methods. The peritectic system was found to be pseudobinary due to the formation of yttrium oxyfluoride at temperatures near the liquidus. The peritectic point occurs at 7 mole pct Y203 and 1,438° ± 5°C. The terminal solid solubility of Y203 in CaF2 decreases from 7 mole pct at 1,438° C to 1 mole pct at 1,100° C, and the solubility of CaF2 in Y203 decreases from 9.5 to 7 mole pct over the same temperature interval.

Jan 1, 1970

By T. H. Jeffers

The Bureau of Mines conducted a laboratory investigation of copper electrowinning from electrolytes produced by solvent extraction. The purpose of the research was to gain a better understanding of the fundamental relationship between copper electrowinning conditions, anode corrosion, and cathode purity. Processing variables were evaluated in a cyclic semicontinuous system in which the depleted electrolyte was used to strip copper from loaded organic extractant. For the production of high quality copper cathodes, the electrolyte was dosed with cobalt and stripped of organic solvent extraction reagent. An optimum cobalt addition of 60 ppm, and removal of the entrained extractant with activated carbon provided the best conditions for electrowinning copper containing the least amount of lead and controlling anode corrosion. As little as 13 ppm of the entrained organic extractant, LIX 64-N, significantly accelerated anode corro-sion. However, the addition of 1,000 ppm of organic diluent kerosine did not affect anode corrosion. After cobalt dosing and removing the entrained extractant, cathodes containing less than 2 ppm lead were consistently electrowon at widely varied current densities, electrolyte copper and acid concentrations, and temperatures. Dosing of the electrolyte with selected impurities including magnesium, aluminum, manganese, and iron did not affect the cathode purity. However, 0.05 giL of chloride ions markedly increased anode corrosion and the sub-sequent transfer of lead to the cathode copper.

Jan 1, 1985

By John M. Popovich

Disposing of coal mine waste at the surface has been and continues to be a problem which has yet to be resolved within the coal mining industry. A possible solution to this problem is to return the refuse back into the operating underground mine generating the waste material. It is believed that the approach described will provide an inexpensive and pratical solution to the problem. The designed system is installed and operable at the Millers Cove Energy Company, Inc. property in Lee County, Virginia. This system limits surfact facilities to a minimum size. It incorporates state-of-the-art hydraulic transport and backfilling technology and equipment to systematically backfill areas within the active mine. It maximized the benefits of reducing treatment of coal wasts while it minimizes environmental impacts on groundwater. The system approaches the problem in a manner to maximize benefits and minimize risks. The cost of returning coal waste back underground at the Millers Cove site is estimated at $0.67 per ton of marketable coal (1982 dollars), which is slightly higher than their surface disposal cost of $0.61 per ton of marketable mat (1982 dollars). The underground disposal costs do not include cost savings that should be realized within the preparation plant and treatment facilities at the surface. Preliminary tests of the system were conducted at the surface; funding restrictions prevented an in-mine trial. Efforts should continue to demonstrate the feasibility of solving the problem of refuse disposal. The installed system and plant at Millers Cove should provide the opportunity to test an underground disposal operation. This report contains guidelines to pursue this opportunity.

Jan 1, 1986

By Willard L. Hunter

The research described in this Bureau of Minus report was conducted to improve the chromium-iron ratio of offgrade chromite. Two methods were used: (1) Iron was selectively reduced from chromite by carbothermic reduction in an electric-arc furnace, and (2) a mixture of carbon, chromite, and sometimes fluorspar was chlorinated to remove a substantial part of the iron. Chromite concentrate from the Mouat deposit in Montana and from northern California was used in the test work. Chromium-bearing slag and chromite that had been beneficiated by a roast-leach process were each smelted to produce high-carbon ferrochromium. Iron was selectively reduced in a laboratory-scale., electric-arc furnace. Carbon additions to the smelting charges varied from 40 to 100 percent of the stoichiometric requirement, and slag basicities were varied from 0.4 to 1.0 chromium-iron ratios of more than 4:1 were obtained with 89 percent recovery of chromium in a chromium-bearing slag.

Jan 1, 1962

By William C. Cooley

A technical and economic study was made of the feasibility of establishing an underground hydraulic coal mine in the Wilkeson-Carbonado coal field approximately 25 miles southeast of Tacoma, Washington. The deposit contains reserves of more than 200 million tons of generally high quality metallurgical coal. It is located in nine seams of minable thickness in a complex, folded and tectonically disturbed set of anticlines and synclines. Typical dip angles are up to 60°, with minable seam thicknesses of 6 to 17 feet. A mine plan was made for a 2 million TPY mine (clean) using two shafts to access the deposit to a depth of 2500 ft. The mining method uses monitor jets to break coal by sublevel retreat mining, fluming to a sump and pumping the minus 0.25 inch coal to the surface and to a preparation plant. The plus 0.25 inch coal is hoisted by skip. Cleaned met coal would be shipped by rail for export. A middlings product would be sold as thermal coal. Assuming a coal price of $48 per short ton (FOB the mine) for the met coal and $35 for the middlings, the return on investment is estimated at 20% after taxes. The many uncertainties about the geological conditions and the specific mine design parameters make the economic analysis and conclusions somewhat tentative. A second mine could also be developed in the eastern section of the reserves to produce 1 million TPY of clean coal and is expected to have similar economics. Recommendations are made for a Test Mine and a Pilot Mine leading to a production mine.

Jan 1, 1983

By Nils A. Eilertsen

This Bureau of Mines report describes the unit cost procedure for estimating direct development costs within a cave block in an undercut block caving mine. Costs of supervision, labor, equipment, and supplies are combined to build a unit cost for each type and size of mine development opening in the block. These costs are then combined to estimate the direct cost for developing a ton of ore. Operating data from several domestic metal mines are combined with a hypothetical mining system to illustrate the costing procedure.

Jan 1, 1975

By Mark S. Stagg

Blast-induced ground vibrations from surface coal mine, quarry, and construction blasting were measured and analyzed for frequency content and duration characteristics. Eighteen commercially available ground vibration measurement systems were evaluated in the field and laboratory for linearity, accuracy, and crosstalk. Buried, surface, and sandbagged transducer placement methods were compared, along with peak and vector-sum measurements. The recommended minimum frequency ranges for ground vibration instrumentation are 2 to 150 Hz for coal mine and quarry blasting, and 5 to 200 Hz for construction and excavation blasting. When higher or lower frequency vibrations are possible, as in construction blasting or for a quarry shot close to a residence, care should be taken to insure proper choices of instrumentation and vibration criteria. Several instruments operating in these ranges are available, and all but one of the seismographs tested fell within ±3-dB accuracy limits (+41 pct, -29 pct). Waveform recordings of all three ground vibration components are recommended as the peak amplitude and frequency may vary among the three. Peak or vector-sum readings are adequate if only amplitude levels are desired. The soil density matched box should be anchored or buried, particularly for high-frequency, high-amplitude construction blasting.

Jan 1, 1980

By William W. Adams

The quarrying and related industries of the United States improved their safety record in 1938 by reducing their accident-frequency rate to a lower acid more favorable position than it has occupied at any time except 1935 since comparable accident statistics became available in 1916. The rates for 1935 and 1938 were identical. The number of men employed in 1938, although smaller than in 1936 and 1937, was larger than in any other year since 1930. Volume of employment, as measured by the number of man-hours worked in the industry as a; whole, likewise was larger than in any year since 1930 except 1936 and 1937. Reports from operating companies to the Bureau of Mines, United States Department of the Interior, showed that 77,497 men were employed in 1938, a decrease of 6,597 compared with 1937. This figure represents the average number of employees for the period during which the quarries and plants were active during the year, which in 1938 averaged 223 workdays per employee compared with 241 in 1937. A total of 17.3 million man-days or 133.8 million man-hours of work was shown for the industry as a whole, which indicated a weighted average of 7.75 hours per man-shift. Reports for 1937 showed a total of 158.3 million man-hours for the entire industry and an average workday of 7.81 hours. Accidents resulted in the death of 82 employees, 5 more than in 1937, and in 5,027 nonfatal injuries involving disability for more than the remainder of the day on which the injuries were received. The number of nonfatal injuries was 1,321 less than in 1937. As the number of deaths and injuries was reduced more, proportionately, than man-hours of employment, the accident-frequency rate per million man-hours of work declined, the rate for 1938 being 38.19 compared with 40.59 for 1937. In other words, accident occurrence to the average employee was 6 percent more favorable in 1938 than in 1937 on the basis of actual number of accidents and actual number of man-hours worked during the 2 years.

Jan 1, 1940

By D. D. Hamilton

The ISMS program provided for the development and demonstration of equipment modifications for improved safety in both conventional and continuous coal mining systems. This report documents the success of the program in identifying accident hazards in underground coal mines with 4-to 8-foot seam heights, in designing modifications to reduce the hazards, and in demonstrating improved safety through extended underground use of the ISMS equipment.

Jan 1, 1977

By Wesley T. Holmes

This report describes the first phase of an investigation aimed at obtaining a wider knowledge of the problems involved in smelting titaniferous magnetites. Liquidus temperature measurements were made on selected slag compositions in the titania-alumina-silica-calcia-magnesia system. Both the melting-holding-quenching method and the hot-stage microscope method were used in the tests. Liquidus temperatures of slags studied ranged from 1,217° to 1,667° C. The lowest liquidus temperature of the slags occurred when the difference between CaO plus MgO and Si02 was less than 12 weight-percent. Liquidus temperatures were also lowered when Si02 was substituted for Ti02 plus Al2O3 when CaO and MgO levels were held constant. Improved methods for the measurement of liquidus temperatures on very small samples are described.

Jan 1, 1968

By R. Karl Zipf, Francois E. Heuze

Stress analysis programs such as MULSIM/NL, LAMODEL, MinSim 2000, and EXAMINETAB are used in the mining industry to analyze stresses and displacements in coal mines, platinum mines, gold reefs, and tabular-type deposits. These relatively simple numerical models can efficiently simulate yielding and failure of a rock mass near a mine opening and subsequent stress transfer. The main input parameters for these models are a family of nonlinear stress-strain curves for the in-seam material. For many applications of these models, such as in coal mining, extensive field measurements and observations exist from which to estimate these stress-strain curves and calibrate the numerical models; however, such measurements are lacking for other types of mines. A three-step method is presented to determine nonlinear stress-strain curves for boundary-element (BE) programs used in many mining applications. The method requires a suite of laboratory-scale strength tests at various confining pressures. Note that this analysis uses laboratory-measured strength and modulus properties of alluvium. The dependency of the mechanical properties of alluvium on scale has not been established, although more tests are being planned. However, it is believed that the relative comparisons performed are valuable regardless of scale effects. First, the FLAC2D computer program is used to model the laboratory tests and determine cohesion (c) and friction angle () for a Mohr-Coulomb material model. Second, another FLAC2D model uses the c and values to calculate vertical stress and strain around a single opening in the rock mass. This model calculates the stress-strain path of points at various distances from the opening boundary. Finally, based on these stress-strain paths, the stress-strain curves needed for a BE analysis are derived. This three-step method was demonstrated in a large, flat-lying underground test facility in very weak rock. The BE analyses agreed well with observations of failure at the test facility and provided a basis for evaluating the behavior of alternative layouts.

By Jesse J. Brown

Over 60 simple; were prepared and forwarded to Dr, S. Z. Toma, TPO, PMSRC as a result of this project. Included among these samples were various low temperature forms of silica. Samples of quartz, cristobalite, and tridymite with iron, manganese, and titanium impurities present were prepared. In addition, a long series of samples both wet ground and dry ground for times from 1/2 to 8 hours were prepared. Numerous miscellaneous samples were submitted which included kaolinite, calcite, muscovite, illite, montmorillonite, Ba3(P04)2, and YPO4 among others, in response to special requests from the TPO. The silica rich portion of selected binary (CA 203-Si02, In 203-Si02, Li20-Si02) Na20-Si02, PbO-Si02, SnO2-Si02, Sn02-Si02 BaGa204-SiO2 and SrGa204-Si02) and ternary systems (Na20-Ga203-Si02 and Li20-Ga203-Si02) was investigated to determine the effects of solid solubility on the stabilization of the high temperature forms of tridymite. In addition to the determination of the extent of these crystalline solubilities, observations were made. on the mechanism of the transformation of silicic acid to tridymite and the rate of the reaction in the presence of foreign ions,

Jan 1, 1973

By Richard C. Wang

The U.S. Bureau of Mines established a wire rope research laboratory to examine the factors that affect the safety and the useful life of wire rope. In the most recent work, two 32-mm 6x27H flattened strand ropes were degraded on a bending fatigue machine. The two tests were run at constant loads of 285 and 347 kN or safety factors of 2.5 and 2. Nondestructive and tensile strength tests were performed on samples of the ropes to determine the relationship between rope deterioration and rope breaking strength. Neither the area loss nor the number of broken wires measured from nondestructive tests could be used as clear indicators of the loss of strength. However, it was found from the tensile tests for both rope specimens that the strength loss was associated with the reduction of breaking strain. This suggests that measuring the strain of many short sections of a rope in the elastic region may locate the high stress sections and thus delermine the condition of the rope.

Jan 1, 2010

By John W. Colburn

A tractor-integrated version of an explosive ripping system was developed for mining application. This system utilizes diesel fuel and a tractor-mounted blower supplying 30 psig compressed air to a two-stage combustion chamber to produce a high pressure (600 psia) gas charge. The charge is rapidly released into the rock formation near the tip of the ripper. The system, mounted on a D9 tractor, was tested at several quarry and mining operations to investigate rock fracturing effectiveness. Although the results of comparative ripping passes conclusively demonstrated that the system increases rock fracture, performance of the system is strongly dependent on rock morphology and properties as well as basic performance of the tractor-ripper. The theory of conventional and explosive ripping modes is described and existing correlations of seismic velocity and ripper performance are shown to be in error.

Jan 1, 1977

By S. J. Rodgers

This report presents guidelines on methods of dust control in conventional coal mining operations. The normal mining cycle and equipment used in a room and pillar conventional section are described. Main ventilation, section ventilation and face ventilation are discussed in detail. Proper installation of line brattice, maintenance of proper air flows at the face and split ventilation are stressed. The effects of maintaining the end of the line brattice near the face are described. The advantages and disadvantages of blowing and exhausting face ventilation are presented. The use of water sprays on cutter bars and loading machines is described. The design of a nonclogging water spray system developed under a Bureau of Mines contract is presented. Other methods of reducing dust exposure are discussed and include alternative procedures for shot firing and administrative controls.

Jan 1, 1983

By Foster Fraas

One of the lithium minerals most widespread in the earth's surface is spodumene (Li20-A1203-4Si02), a lithium aluminium silicate. For some time, deposits of this mineral were known to exist in the Black Hills of South Dakota, but it was only quite recently that Hess4/ pointed out the great magnitude of the low-grade deposits in forth Carolina. The theoretical lithia (Li20) content of spodumene is 9.04 percent. The only other minerals with such high lithia content are the phosphates, but these occur only in pockets and are not in extensive deposits5/. Actually, however, the lithia content in spodumene is never found to be this high, being nearly always below 7 percent for the pure mineral, and part of the lithia is apparently replaced by other alkalies.

Jan 1, 1937

By J. S. Hansen

To improve mine safety, the Bureau of Mines has conducted a search for better materials and systems to anchor roof bolts. This report describes a study on the ability of a gypsum-based anchoring medium to withstand short- and long-term loads. Results showed that 2-ft-long bolts anchored with gypsum that was injected as plaster slurry at a 0.370 water-cement ratio and cured for 10 min sustained pull test loads equal to the ultimate strength of the bolt steel (about 37,000 lb). For comparison, the minimum required capacity is 17,600 lb. Long-term loads of 15,500 lb were sustained with estimated 10-yr movement of less than 1/2 in. Two-foot-long bolts anchored with gypsum installed in a cartridge in which the water was contained in tiny capsules sustained a pull test load of about 30,300 lb at a 0.319 water-cement ratio and 10-min cure time. At a 0.288 water-cement ratio, load capacity was about 37,000 lb. The lower load capacities of cartridge-installed bolts resulted primarily from the remnants of the water-wax capsules. Above 10,000 lb, creep movement of cartridge-grouted bolts appears excessive, but longer bolts may be capable of resisting creep better.

Jan 1, 1985

By Brian P. Stapleton, Bill M. Stewart, Joel R. Warneke, Curtis C. Clark

Of the 28 accident/injury classifications listed by the Mine Safety and Health Administration, handling materials is second only to roof falls in terms of generating the highest number of reportable accidents in active underground coal mines. Two materials-handling activities that cause numerous injuries each year are the categories of “handling supplies or material, load and unload” and “moving power cables.” Mechanization and mine worker activity training are two methods that can aid in preventing these injuries. This paper describes three mechanical methods—the mobile manipulator, the in-mine hoist, and a cable-handling system—being developed and tested at the Spokane Research Laboratory of the National Institute for Occupational Safety and Health. Two of the devices are specifically designed for loading, unloading, and moving supplies and materials, and the third device is for handling trailing cables in the confined spaces of coal mines. Also described are safety solutions developed for underground coal mines geared to showing miners safe and unsafe ways of performing various materials-handling tasks.

By G. Ahnell

Throughout portions of four (4) heavily mined Appalachian states subdivided by the Mine Safety and Health Administration (MSHA) as: District 3 -Northern West Virginia and Maryland; District'" -Southern West Virginia; District 5 -Virginia; and District 6 -Eastern Kentucky, active coal mine waste embankments associated with mechanical and/or chemical coal processing facilities of various levels of coal preparation were inventoried. For each site plant specifications, disposal techniques, embankments' characteristics, and coal source data were accumulated. Mapping at 1: 24, 000 and 1: 250,000 scale and Disposal Site Characterization forms were developed to present the findings. Associated abandoned surface and underground openings near each site were also indicated as well as locational data for each site and the areas environmental conditions - temperature, precipitation and vegetation types. A state-of-the-art review of coal preparation, waste disposal, and alternative uses of coal waste is also included.

Jan 1, 1982

Although the mining industry has achieved record-low fatalities and injuries for each of the last three years, there are still too many miners injured or killed in this nation ís mining operations. Many mining injuries or deaths might have been prevented by using risk assessment to identify and control or eliminate the hazards associated with a task. To focus attention on the importance of conducting risk assessments in keeping mining workplaces safe and healthful, MSHA introduced this initiative on October 12, 2004. This initiative is called SLAM. SLAM is an acronym for Stop, Look, Analyze, and Manage. The steps involved in SLAM are: Stop ñ stop and consider the work involved Look ñ look for and identify the hazards Analyze ñ analyze what needs to be done Manage ñ manage safety by developing and implementing controls Everyone should be aware of the risks of an accident before beginning a task. It may not always be obvious that performing a seemingly routine task could result in an accident. That is why conducting a risk assessment is so important. Itís important to remember that over time a mining workplace seldom remains unchanged. Risks must be assessed whenever procedures or processes change, whenever new tasks are started, or non-routine tasks are performed.

Jan 1, 2005