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By R. L. Zick, J. D. Byars, T. P. Mucho

Recently, a large Pittsburgh seam longwall mine was nearing depletion of a major portion of its current reserves and had begun to develop in a different direction from its original portal area to access additional reserves. This meant that a large area of the mine would be abandoned and sealed. However, continued use of the original mine portal area required that the water accumulating in the abandoned mine would eventually need to be pumped to the surface. This would be in addition to the discharge water associated with the new portion of the mine. Several pumping and sump options were investigated to handle the quantity and quality of the anticipated discharge water. This paper describes some of these options, their advantages and disadvantages, and the final engineering decisions. Some problems and unanticipated outcomes, as well as the eventual solutions are discussed, including: (1) estimates of pump requirements, (2) water pool size, (3) eventual water quality, (4) anticipated inflows, and (5) integration into the overall mine water system.

This publication summarizes the in-house and contract research and development projects programed for fiscal pear 1980 by the Bureau of Mines under its Minerals Environmental Research activity. The document provides a mechanism for interested parties, including potential contractors, to gain insight into ongoing and projected work of the Bureau's environmental research efforts. Research to identify and correct environmental problems associated with mining and metallurgical operations has long been an integral part of the Bureau's mission. Through the years, efforts of various Bureau programs have yielded valuable information on the origin and control of many of these problems. With the reorganization of the Bureau of Mines in 1979, the Minerals Environmental Technology program was structured to consolidate these efforts into a single program that will systematically investigate al aspects of mining- and processing-related environmental pollution and damage-from initial discovery of the mineral resource to ultimate return of the land to productive use. In fiscal year 1980, the Bureau received an appropriation of about $21 million to conduct research and development work on these problems.

Jan 1, 1980

By James E. Aplin

Previous studies have shown that fracturing of roof strata precedes ultimate failure, and that the fracture development causes an accompanying increase in the apparent resistivity of the strata. Using this principal, a microprocessor controlled resistivity roof fall warning system (RRFWS) was developed that automatically sequences through and records up to 32 electrodes that may serve as either voltage or current electrodes. This capability permits increased coverage with a minimal number of required electrodes. The data is stored in a nonvolatile memory and on an optional printout, making the system nonsusceptible to loss of mine-power. To further save battery power, the system's electronics shut down between readings, except for a carbon molybdenum steel real-time clock. At a preprogramed interval, the RRFWS reactivates and repeats the sequence. If the absolute change or the rate of change of resistivity exceeds a predetermined limit the system is capable of sounding an alarm. In addition to the monitor, a stainless steel mod led split-set electrode was also developed that permits long-term corrosion-free contact.

Jan 1, 1983

By J. Sottile, J. L. Kohler

Component failures in the electrical control circuits of mining machines account for a large percentage of the total downtime of the machine. Once a failure has occurred it is always a tedious and usually a time-consuming task to locate the failed component. Moreover, the pressure to quickly locate the cause of a delay can lead to compromises in safety. Thus an onboard diagnostic system, essential for an automated machine, would be a very useful addition to existing machines. This report details U.S. Bureau of Mines development of a generic procedure for synthesizing diagnostic systems for electrical-control-circuit failures in mining machinery. A continuous mining machine is used as the testbed to illustrate the application of the developed methodology. Substantive differences among mining machine control circuits made it impossible to achieve a generic diagnostic system, but a generic approach for the synthesis of the diagnostic system was possible. As the research progressed, it became apparent that an algorithmic approach was better than an expert- system-based implementation. A prototype system was constructed and used to evaluate the diagnostic system. Prototype implementation issues are also examined.

Jan 1, 1993

By D. D. Runnells

This study focused on the chemical reactions between uranium tailings fluids and cores of subjacent bedrock from the site of the Cotter Corporation uranium mill at Canon City, Colorado. Actual and synthetic tailings fluids were forced through cores of bedrock. The pH of the effluent solutions was the dominant control on the behavior of dissolved species in solution. The pH depended on the presence or absence of calcite cement in the rocks. Calcite neutralized acidic raffinates and caused the precipitation of iron, manganese, aluminum, and possibly uranium. Chloride, sulfate, and sodium were not retarded upon passage through the cores, and sulfate and chloride should be useful as tracers of escaping tailings fluids. Zinc, copper, cobalt, nickel, uranium, and vanadium exhibited high mobility under acidic conditions and were strongly retarded at elevated pH. Calcium was released due to dissolution of calcite and ion-exchange. Magnesium was not retarded in concentrated solutions, but showed moderate retardation in dilute fluids. Potassium and ammonium both showed early retardation followed by breakthrough and mobility. The behavior of molybdenum was strongly dependent on pH, with retardation at low pH and mobility at elevated pH. Selenium was highly mobile under all conditions. Selenium should be a better tracer than molybdenum for many situations. Precipitation of carnotite appears to control the solubility of uranium and, possibly, vanadium. With the exception of the precipitation of aluminum and silica, all reactions were rapid.

Jan 1, 1983

By Herman O. Ankenbruck

Analyses of statistical data indicate that haulage accidents are one of the largest sources of injuries and fatalities in underground coal mines, and that the rate of accidents in transportation has been increasing during the past few years. These previous analyses were performed by correlating accident or fatality data at a rather high level of miner activity. In this present investigation, underground surveys were made by observing conditions and activities in some detail at a rather low level of activity in an attempt to understand factors contributing to hazards in the specific situations observed. The aim of the current study was to derive preventive measures that might obviate the hazardous conditions and unsafe acts observed; and, following this, to provide recommendations for additional research and development to reduce accident potential in underground transportation. The major project tasks are diagrammed together with the task outputs in figure 1-1. Initially, a preliminary study of ell underground haulage operations was performed in order to establish the kinds of data needed and to provide the rationale leading to the data requirement. At the same time, the various types of haulage equipment used for each operation were defined. A preliminary analysis of each type of haulage operation was performed in order to establish the sequence of tasks required to operate haulage equipment. These tasks were transferred directly onto observation forms, and were used in developing interview forms. In parallel with the task analysis, a review was made of accidents and hazards that might occur during each type of operation.

Jan 1, 1975

By Irving Hartmann, John Nagy

"The pressures produced by dust explosions are frequently so great and are developed so rapidly that widespread destruction of manufacturing equipment and buildings results. Experimental data on maximum pressures and rates of pressure rise produced in a closed vessel by numerous metal powders and by dusts used in the plastics industry were published in two previous Bureau of Mines papers.4/5/One means for reducing structural damage is provision in the enclosing walls and/or roof of rapidly opening explosion-relieving devices or relief vents through which the pressure of an incipient dust explosion can be quickly dissipated. The vents can be simply unrestricted or free openings: hinged or pivoted sash which swing outward at a predetermined internal pressure; fixed sash, with light wall anchorages; scored glass panes; light wall panels; monitors or skylights; poppet-type vent closures; paper, metal foil, or other diaphragms that burst at low pressures; pull-out diaphragms, or other similar arrangements.The use of pressure-relief vents is recommended in the dust-explosion codes of the rational Fire Protection Association,6/ and recently a special committee on explosion venting has been organized. However, technical data on which the design and distribution of relief vents can be based are meager. An experimental study on venting grain-dust and cornstarch explosions was made by the Bureau of Chemistry and Soils, United States Department of Agriculture.7/ Tests on cork fines, cinnamon, starch, barley dust, and a phenolic plastic were made in a laboratory-scale (0.1-cubic-foot) apparatus by the engineering department of the Factory Insurance Association.8/ A study on the venting of explosions of acetone-air mixtures was made by the Bureau of Mines.9/The object of the present investigation is to extend the limited knowledge on the effectiveness of pressure-relief vents of different types, shapes, and sizes. The aim is to determine the venting requirements in equipment and structures of various dimensions and shapes for dusts of widely different explosive properties. On the basis of such accumulated information, together with theoretical considerations, it is hoped that ultimately it will be possible to recommend correct venting for most operations in which a dust-explosion hazard exists."

May 1, 1946

By B. J. Barfield

Standard erosion plots (4.6 m by 22.1 m on 9 percent slope) were constructed on the Alston Surface Mine of Peabody Coal Company in Western Kentucky to evaluate the effects of placement technique and density on the erodibility and eroded size distribution from mine spoil and reconstructed topsoil. PLots were constructed with a dozer and scraper pan from shale spoil material, topsoil (A horizon) and subsoil (B and C horizon mixture) using soils stockpiled at the Alston Surface Mine. Plots were evaluated under fallow conditions with a tilled plot surface and two compacted conditions. One compacted condition was generated by tracking the surface with a dozer and rolling with a loaded scraper pan. The second was generated by rolling the surface with a solid wheel compactor. Rainfall was supplied with the Kentucky Rainfall Simulator at a rate of 63.5 mm h-l with the plots in three different soil moisture conditions; dry, field capacity, and very wet. Runoff was evaluated for flow rates, sediment concentrations, and aggregate and primary particle size distributions. Sediment yields and the Universal Soil Loss Equation E130 indexes were calculated from the data for each plot. The erodibility was calculated from the tilled plot data using a weighted soil loss and E130 value from the dry, field capacity and wet runs, and a cover management factor calculated for every other condition. For the topsoil and subsoil plots, sediment yield was greatest for the dozer scraper pan plots and lowest for the tilled plots. For the shale plots, erosion rates from the wheeled compacter plots were the highest and tilled plots the lowest. Average erodibilities were 0.14, 0.38, and 0.41 tons ac h ft-1 tonf-1 in-1 hundred ac-1 for the shale, subsoil, and top-soil plots. Cover management factors for each plot were 1.29, 1.42, and 1.17 for shale, topsoil and subsoil plots compacted with the solid wheeled compacter and 1.29, 3.79, and 2.51 for shale, subsoil, and topsoil plots compacted with the dozer scraper pan conbination. The accuracy of the Wischmeier erodibility nomograph was evaluated on the data collected. Erodibilities were accurately predicted for the topsoil plot and poorly predicted for the sub-soil plot. The accuracy of the CREAMS procedures for predicting the composition (size distribution) of eroded particles was also evaluated. The composition was well predicted for the topsoil plots, moderately well predicted for the shale plots and poorly predicted for the subsoil plots.

Jan 1, 1983

By E. Chilton

The National Institute for Occupational Safety and Health (NIOSH) has been conducting re-search to determine the influence of mining machine mounted water sprays on airflows and methane concentrations at the face when blowing ventilation systems are used. Tests were conducted in a full-scale ventilation gallery. Airflow speeds and directions were measured at several locations near the face with ultrasonic anemometers. Methane was released from the face and concentrations were measured in the entry at locations above the mining machine using fixed point methanometers. Changes in airflow speed, direction, and methane concentrations were correlated with water spray operations. The test results using different spray arrangements and water pressures showed that operation of the machine-mounted sprayers can improve face ventilation effectiveness by increasing the velocity of airflow moving toward and away from the face. The improved ventilation resulted in reduced methane levels near the face.

By F. P. Haver

Primary lead is produced in the United States by the pyrometallurgical smelting of lead sulfide (galena, PbS) concentrates, which poses sulfur dioxide and lead air pollution control problems. The Federal Bureau of Mines has investigated an alternative hydrometallurgy procedure that does not generate gaseous sulfur oxides and diminishes the potential for the escape of lead into the atmosphere. The procedure involves leaching galena flotation concentrates with ferric chloride (FeC13) solution to obtain lead chloride (PbC12) and elemental sulfur as expressed by the following chemical reaction: PbS + 2FeC13 ? PbC12 + 2FeCl2 + S°. At 100° C, over 99 pct of the PbS in the concentrate is converted to PbCl2 in less than 15 min. The leach solution, composed of brine (NaCl) containing slightly more than the theoretical required amount of FeC13, dissolves the PbC12 as it is formed, leaving a residue of elemental sulfur plus gangue. High-purity PbC12 (>99.9 pct) crystallizes from the leach filtrate on cooling and is electrolyzed in a low-temperature, fused-salt cell to obtain corroding-grade metal (>99.94 pct Pb). Spent leach solution (FeC12) is regenerated for further use by reaction with the chlorine obtained in the electrolysis of lead chloride. Other values, such as Ag, Cu, Zn, and S°, are recovered by additional treatment of either the leach solution or leach residue.

Jan 1, 1976

By Richard F. Zaffarano

The Bureau of Mines compiled information for the nonspecialist about natural gas liquids recovery from hydrocarbon streams in natural gas processing plants. Attention is directed to the impact of the technology of processing and the quality of gas processed in view of the increased availability of natural gas for processing. Significant changes in product and market trends within the natural gas processing industry are highlighted. Fixed capital-plant costs for grassroots, refrigerated-oil absorption and conventional adsorption schemes, adapted from published studies, are presented giving ranges of cost estimates for medium-sized plants. Marketed products of the natural gas processing industry are briefly discussed in relation to automotive air pollution problems and approaches to their control.

Jan 1, 1970

By S. J. Davenport

The increased consumption and importation of fluorspar and cryolite (1)3/ in recent years, and especially the addition of fluorine compounds to drinking water in the United States, have aroused renewed interest in the properties of such compounds and possible health hazards incident to their use. It has been suggested that the issuance of a revision and elaboration of Information Circular 7311, The Hazards of Hydrogen Fluoride Poisoning in the Mineral and Allied Industries, which hay been out of print for some time, would be opportune. Fluorine minerals have been known since the Middle Ages. Fluorine was isolated in 1886 by Moisson (2).

Jan 1, 1954

By Harold A. Watson

A method for measuring leakage of vapors into a chemical-cartridge half-mask facepiece during simulated use is described. The respirator, fitted with high efficiency cartridges, is worn in a dichlorodifluoromethane (CC12F2)--air test mixture while a series of timed activities (facial movements, varied breathing, exercise, etc.) is performed. Complementing other tightness tests, this method is useful particularly for studying face fit and the effect of facial movements on leakage. The concentration of CC12F2 within the facepiece is monitored continuously to observe the immediate effect of physical activity on leakage. A composite sample is collected simultaneously in a plastic bag as a measure of average leakage during the 18-minute test period. Leakage, reported as percent, is calculated from the concentrations of CC12F2 within the facepiece and in the test atmosphere.

Jan 1, 1970

By Stephen C. Tadolini, Thomas M. Barczak, Paul McKelvey

A new generation of hydraulic mine support prestressing devices has been developed. These thin-walled steel shells are machine-welded and can be inflated with water or any liquid to provide prestressing for a wide variety of roof support products ranging from Can supports to props and cable bolts. With an expansion capability of several inches, depending on the geometry and size of the unit, they can also establish roof contact eliminating the need for wooden wedges or crib blocks that are commonly employed with several standing roof support products. Capable of withstanding pressures from 1,000 to 6,000 psi, these cells are able to transfer roof loading into the support structure without rupturing. A recent development has been the addition of an inexpensive yield valve that provides control of the maximum pressure and load development on the support. This paper examines the performance capabilities of these inflatable prestressing units and the impact they have on the performance of various support systems, including an evaluation of the overall stiffness of the support system and the load control during yielding of the prestressing unit. Recommendations are made regarding the design requirements of the prestressing unit to optimize the support performance. A summary of mine applications using this technology is provided with general comments regarding their impact on ground control.

By B. W. Gandrud

This is the third report published by the Bureau of Mines concerning the washability of Black Creek coal. Both of the former reports.5/6/ dealt with the Black Creek coal at the Bradford mine, Dixiana, Ala., near the northeastern extremity of the Warrior field, whereas the present report is based on float-and-sink tests of coal from what is presumably the Black Creek bed near the southern extremity of the field. Although the Yolande Coal & Coke Co., owners of the property at Yolande No. 6 slope, consider this opening to be on the Black Creek bed, the authors do not feel that there is as yet positive proof that this correlation is correct. There has been little or no development of the Black Creek bed in the Yolande Basin in the past, and a positive identification of the bed at Yolande No. 6 will have to await further exploration and development. The Yolande No. 6 is an exploration slope 3/4 mile north of Rockcastle, Ala. The slope is approximately 400 feet from top to bottom on a dip of 180. As far as the authors can ascertain, coal has never been produced commercially from the Black Creek bed in the southwestern part of the Warrior field. Exploration work in the past has indicated that the Black Creek coal in this area is extremely friable and high in sulfur. Extreme friability would naturally discourage its use as a domestic and railroad fuel, and high sulfur content would be a disasvantage in its use for coking coal. The present study of this coal has been made with particular reference to sulfur elimination on the assumption that it would make a good coking coal provided enough of the sulfur could be eliminated by washing.

Jan 1, 1939

By Wils L. Cooley

This report analyzes electrical accident data in the metal/non-metal mining industry. Accidents are categorized to determine their root causes. Special attention is given to accidents associated with inadequate or defective grounding of mine power systems. Recommendations are made concerning proper grounding practice, especially for dredges and for quarries in hard rock or sand. The costs of instituting the recommended practices are estimated for model mine power systems which are based on field data obtained from 37 mines and several electrical contractors. The expected benefits of various suggested safety practices are also estimated.

Jan 1, 1981

By Harry R. Nicholls

The objectives of this investigation were to determine the strain propagation laws for a strain pulse in salt and to compare the seismic effects from the detonation of different explosives in salt. The investigation showed that a strain propagation law of the type, e = K(R/W 1/3 ) n, and a strain energy propagation law of the type, Ea/W 1/3 = K(R/WI/3)b , are valid in salt. A change in the regression law coefficient, n , was noted with strain level. A similar change in b was inferred because strain energy is proportional to the square of strain amplitude. Particle velocity data may be used interchangeably with strain data under the test conditions.

Jan 1, 1962

To be able to continuously monitor the noise to which underground workers are exposed as a better way to help prevent hearing damage. The Approach: The Bureau of Mines has developed a Time-Resolved Audio Dosimeter which can be worn by miners to record noise level every 30 seconds and store It in a miniature solid state memory. Figure 1 is a photo of the dosimeter. [ ] How It Works: Acoustical noise is picked up by a micro-phone and fed to a sound level meter which produces a d-c voltage proportional to the A-weighted sound pressure level. (As specified by federal regulations, the A-weighted sound pres-sure level approximates the response of the ear by discounting the higher and lower frequency components of the noise.) This d-c voltage controls an oscillator which, together with related circuitry, produces a pulse train having a frequency that's proportional to the noise level.

Jan 1, 1975

To improve the ventilation of large-opening under-ground stone mines by using stoppings made from stone left in place. Background Underground stone mines typically use large room-and-pillar openings with little ventilation control. Stone miners may be exposed to contaminants that include silica dust, diesel particulate matter (DPM), exhaust gases, nuisance dust, and face shot (blasting) fume gases. The health risks from breathing these fine particles and toxic organic materials are well documented. Although contaminants such as dust or diesel exhaust can be some-what controlled at the source, the escaping contaminants are often diluted and removed from work areas using ventilation with minimal controls. In many cases, current mine ventilation practices use trial-and-error techniques to improve ventilation. The growing realization of the importance of a healthy work environment along with increased regulations will require many stone mines to implement new ways to improve ventilation. In-place stone stoppings are one option. Mine air flows from one point to another because of a pressure differential between those points. This pressure differential is established using a mechanical fan in conjunction with separations (stoppings) between high-pressure (intake) and low-pressure (return) airways. The separation of intakes and returns is an important concept that is used in most other types of mines. Normally, air moves through underground stone mines with minimal control technology. Fans are placed in locations where they are thought to be most beneficial, and intakes are not separated from returns. In a few smaller underground stone mines, proper ventilation can be achieved with a few strategically placed fans. However, as these mines increase in size, moving adequate quantities of air through-out the mine becomes harder, and separation of intakes and returns becomes a problem. Building traditional mine stoppings to separate the intake and return airways in entries with a cross-section area often exceeding 800 ft2 is difficult. The stoppings must be able to withstand both the dynamic pressure from face shots and the static pressures created by the fans. Construction and maintenance difficulties, as well as high costs, are the main factors preventing these traditional mine stoppings from gaining wide acceptance by the stone mining industry.

Dec 1, 2002

By David Schlain

IN 1942 the Bureau of Mines began to develop the Kroll process for use in the large-scale production of titanium. Titanium and titanium alloys are now commercial metals. These metals are relatively expensive, but It is now evident that they will have important industrial uses and that in many instances these will be related to their remarkable corrosion resistance. This bulletin presents the known corrosion properties of titanium and its alloys in useful form. In marine environments titanium is highly resistant to corrosion and does not pit, or undergo crevice corrosion, stress corrosion, or corrosion fatigue. Titanium is also highly resistant in many salt solutions, including most chlorides. It is very resistant to corrosion in nitric acid solutions. It is also resistant to white fuming nitric acid. However, it may react violently with red fuming nitric acid. In phosphoric acid solutions titanium has rela¬tively good resistance to corrosion, but it has less resistance to sulfuric acid and still less to hydrochloric acid solutions. Titanium corrodes very rapidly in hydrofluoric acid Solutions. It is very resistant to corrosion in many organic chemicals. However, it has only moderate resistance to formic acid solutions and poor resistance inn oxalic acid solutions. Titanium does not corrode in dichloroaretic acid but, corrodes rapidly in 100 percent trichloroacetic acid at 100° C. Titanium is resistant to barium, calcium, magnesium, ammonium, and sodium hydroxides. Titanium is inert in wet chlorine, bromine, or iodine gases. However, in dry chlorine gas titanium reacts rapidly enough to ignite. It also reacts rapidly with dry bromine gas, but, it is resistant to dry iodine gas. When titanium is exposed to red fuming nitric acid solutions with high nitrogen dioxide content and low water content, it corrodes, undergoes stress-corrosion cracking, and becomes pyrophoric. This occurs more readily with some titanium alleys, such as titanium-8 percent manganese. A fresh titanium surface immersed in water or in an aqueous solution and in contact with an oxygen-rich atmosphere under sufficientt pressure is unstable and will ignite spontaneously. Inherently an active metal, titanium has a tendency to become less active in environments containing oxidizing agents such as air, oxygen, chlorine, or ferric, cupric, or platinic ions. Titanium is more noble than most structural metals in roost, environments and its excellent corrosion resistance is generally not, affected by contact with these metals. However, some of the other metals corrode faster because of contact with titanium. Titanium undergoes anodic polarization readily, so that even when it is the less noble member of a galvanic couple it may corrode less because of the contact. Titanium alloys often have corrosion properties and electrochemical characteristics similar to those of commercially pure titanium. Titanium alloys containing noble metals, zirconium, molybdenum, vanadium, tantalum, or copper sometimes have better corrosion resistance than pure titanium.

Jan 1, 1964