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By Larry A. Haas

The U.S. Bureau of Mines investigated the use of organic binders as substitutes for bentonite in agglomerating iron ore concentrate. Over 30 organic binders were evaluated at several dosage levels in laboratory tests. The binder groups producing the greatest green pellet strengths were natural gums (guars carboxyl methyl celluloses) and gelled starches. The nongelled and alkalized starches, starch acrylic copolymers) wood-related products, and dairy products were less effective but better than bentonite. The highest wet pellet drop numbers were obtained with binders that had a medium plate water absorption value (>500 and <10)000) in distilled water and a high slurry viscosity (>75 cP) at 6 pet solids. The highest dry compressive strengths were obtained with binders that gave the highest adhesive tensile strength (>4 kg/ cm2) on iron oxide lap-joint substrates. Pellets with 0.1 pct organic binder had lower compressive strengths and reduction disintegration indices than those with 1 pct bentonite, but higher reduction rates. Pellets with carboxyl methyl cellulose and gelled starch had higher softening temperatures than those with bentonite. Overall, the most promising binder is gelled starch. Its price makes it more cost effective than carboxyl methyl cellulose, and its pellets have metallurgical properties superior to those of bentonite pellets.

Jan 1, 1989

1. In 2003, a total of 1,972 coal mining operations reported employment to the Mine Safety and Health Administration (MSHA). Coal mines comprised 13.7% of all mining operations. • Bituminous mines comprised 92.5% (n = 1,825) and anthracite mines 7.5% (n = 147) of coal mining operations. • More than 70% of all coal mines were located in three states: Kentucky (29.0%), West Virginia (20.9%), and Pennsylvania (20.2%). • Bituminous coal mines reported the production of over 1 billion coal tons.

Feb 1, 2005

Develop a means for estimating vertical stress conditions in or around an underground mine so that appropriate measures for ground control can be taken before hazardous conditions arise. Background High vertical stress in an underground mine could cause or enhance hazardous ground control conditions which might lead to accidents, fatalities, and loss of reserves. An understanding of the vertical stress conditions at the mining level would allow a mine operator to take precautions that will minimize the occurrence of ground control problems. A knowledge of the underground stress conditions prior to mining could be used as an aid in future mine plan development to avoid or minimize ground control problems. Approach The Bureau of Mines developed a computer program for calculating the vertical stress resulting from the pressure of overlying rock masses on a mine or geologic surface at various depths.

Jan 1, 1990

By Arthur L. Murray

"Putting safety over , " using the accepted meaning of the word " Safety " as the elimination of personal injury , resolves itself into the prevention or disassociation of a combination of two distinct circumstances . Opportunity for accidents is afforded by conditions that are likely to cause injuries , but such injuries are effected only when the human body is placed in a position to be injured . As will be discussed later , in mining , as in most other industries , the degree of safety experienced depends upon the disassociation of these two circumstances , first , by making working conditions as free from hazards as possible , thus affording the minimum opportunity for accidents to occur , and secondly , the training of employees to recognize dangerous conditions and adopt measures to protect themselves and their fellow employees against injury . The responsibility for preventing accidents rests upon every person employed in an industry from the directing head down through the individual workers , and the safety of that industry will be proportionate to the extent that each member appreciates and accepts his individual responsibility . Hence , safety becomes decidedly a personal equation . Whether the personal equation will be so applied as to result in the greatest freedom from accidents , however , depends largely upon the initiative of those directing the industry . Putting safety over in a small mine presents the personal equation in a more intensified manner than the same endeavor in a large mine . Large mines , owing to their size and financial standing, can usually main ta in and support an effective safety organization with one or more directors who devote all their time to the supervision of safety work . Most small mines with a limited number of employees and limited capital can not afford and are not justified in supporting a paid safety organization , and must depend upon the close cooperation of their working force in maintaining safe working conditions . On the other hand , if proper supervision is exercised the small mine has in some respects advantages not afforded by the large mine . The limited workings in a small mine should afford less opportunities for dangerous conditions to arise and permits more frequent inspection of the entire mine . The small working force permits more latitude in the selection of employees known or believed to be either safe workers or amenable to safety educational work. Likewise , a small working force facilitates the carrying on of safety educational work and allows a closer personal contact between the superintendent and his employees .

Mar 1, 1923

By Bill M. Stewart, Philip W. Patton, Curtis C. Clark

Handling materials in underground mines continues to be a major safety problem. To help reduce materials-handling injuries, researchers at the Spokane Research Laboratory of the National Institute for Occupational Safety and Health are investigating those materials-handling tasks in underground mines that appear to generate a high number of injuries. Data from the Mine Safety and Health Administration for the years 1989-1999 were studied to find out if there were any trends in materials-handling accidents and if so, to determine what tasks were involved and the sources of injuries. Several underground coal and metal mines we revisited to document innovative materials-handling technologies. Considerations for safety training and mechanization needs for continued reduction in materials-handling injuries are described.

This part of the final report treats some problems related to coal mine carrier frequency communication systems using the trolley wire/track transmission line. This work was undertaken for a brief period of time during the summer of 1972 to help understand, quantify, and improve some of the trolley wire carrier system behavior observed and/or predicted. Calculations and estimates of transmission line characteristic impedance, inductance and capacitance per unit length, mine motor loading effects, parallel line effects, and connection impedances are presented in Chapter I. Chapter II treats the design of r-f isolators for reducing the undesired and troublesome r-f loading that mine motors present to the trolley transmission line. Chapter III treats a diversity method for combatting standing wave nulls. I. CALCULATIONS RELATED TO TROLLEY WIRE COMMUNICATIONS A. ESTIMATION OF INDUCTANCE AND CAPACITANCE PER UNIT LENGTH OF TROLLEY LINES To estimate the L and C per unit length of trolley lines, we use the eccentric line model of Section G of this Chapter, "Characteristic Imped¬ance Estimates for Mine Trolley Lines." The capacitance per unit length for an eccentric line is given by (1)

Jan 1, 1974

By Stephen D. Cramer

The solubility of methane, carbon dioxide, and oxygen was measured in brines at temperatures from 0° to 300° as part of Federal Bureau of Mines research on the corrosion of metals in high-temperature geothermal and mineral processing environments. Solubilities were measured by the technique of extracting pure gas, dissolved at pressures where Henry&apos;s law was applicable, from known volumes of brine. The results were smoothed with respect to temperature. The solubility, expressed in terms of the Henry&apos;s law constant, reaches a maximum at temperatures ranging from 60° to 100° C for methane and oxygen, and from 160° to 170° C for carbon dioxide. The Henry&apos;s law constant increases, that is, gases are salted out of the brines, in the presence of dissolved salts. Salting-out coefficients are strongly dependent upon temperature. The temperature dependence of the Henry&apos;s law constant for geothermal brines is different from that for sodium chloride brines owing to the more complex chemistry of the geothermal brines. The solubility of oxygen and carbon dioxide in brines exposed to air saturated with water vapor and at a total pressure of 760 mm Hg is reported for temperatures from 0° C to the normal boiling point.

Jan 1, 1982

By Ann G. Kim

The Bureau of Mines estimated the methane content of a coal, which depends primarily upon rank and pressure, from the adsorption equation V =kpn, where k and n are constants related to rank. By incorporating corrections for moisture, ash, and temperature, and estimating pressure and temperature as a function of depth, the methane content of coal in place can be estimated from the following equation: [ ] Values calculated with this equation generally are in reasonable agreement with direct determinations. By assuming a standard moisture and ash content, and using the hydrostatic head to estimate pressure, a graph of rank and depth versus gas content was constructed. Although estimated values were consistently high for several high-volatile bituminous coals from an area where the pressure is known to be less than hydrostatic, the estimated methane content for most coals shows reasonable agreement with values determined by the direct method.

Jan 1, 1977

By Benjamin Petkof

Production quarry blasts in three rock types were photographed with a high-speed camera. Analysis of the films showed that step increases sometimes occur in the horizontal velocity of the broken rock. These step velocity increases were observed only in the first foot or so of rock movement. This observation indicates that the gaseous products of the explosion do additional work on the rock after it is crushed and cracked by the initial compressive-stress pulse and the reflected tensile-stress pulse. The observed initial fly-rock velocity is compared with the calculated fly-rock velocity for reflection spalling. A mechanism possibly causing the velocity increases is discussed. INTRODUCTION When a small concentrated charge of explosive is detonated at the bottom of a drill hole near a free surface, two modes of rock failure have been observed; both are associated with the stress pulse generated in the rock by the detonating explosive. The first mode of failure is the crushing and radial tensile cracking associated with the initial passage of the compressive-stress pulse as it propagates outward from the explosion. This type of rock failure is usually confined to the immediate vicinity of the charge hole. The second mode of failure is the tangential and radial tensile cracking associated with the tensile-stress pulse that is reflected from the free surface. This mode of failure is commonly called scabbing or spalling and has been shown to be a primary cause of rock failure in crater formation at one free surface. (3).4

Jan 1, 1961

By Fred C. Turin, William J. Wiehagen

This study examined musculoskeletal injury risk at four mining sites: underground coal, underground limestone, surface copper, and surface phosphate. Each site offered opportunities to investigate musculoskeletal disorder (MSD) injury risks and how those risks might be identified and categorized. The National Institute for Occupational Safety and Health (NIOSH) worked with these sites to (1) identify work activities that showed evidence of MSD injury risk, (2) examine physical risk factors that can lead to MSDs for a handful of work tasks at each site, and (3) develop a set of ideas for problem-solving to help reduce risk factors for examined work tasks. For each site, NIOSH implemented a plan that was refined over the time period of this study. The plan consisted of four steps. The first step was to use mine injury records, a musculoskeletal discomfort questionnaire, front-line supervisor interviews, and a list of management concerns to identify work groups and work activities that have significant evidence of MSD risk factors. The second step was to select work tasks for evaluation. The third step was to interview those who do the work and make observations to characterize the MSD risk factors and musculoskeletal symptoms that exist for target tasks. The final step was to conduct brainstorming sessions with workers who perform the work or have a stake in the production task. The brainstorming sessions served to identify general strategies (ideas) for reducing MSD risk factor exposures. A final report of findings was presented to mine management and workforce representatives at each site. The risk factors and ideas for improvement identified for each site were specific to the target tasks examined. These target tasks were diverse, but there were some key similarities. For instance, jobs were found at each site that required a significant amount of manual work involving the upper extremities and low back. Handling heavy and awkward objects, forceful arm and shoulder exertions, and working in awkward postures were common for a variety of jobs across the four sites.

Jan 8, 2004

Develop an improved downhole geophone system with enhanced signal/noise ratio for collecting cross-hole seismic data used in tomographic reconstructions. Background The Bureau of Mines is conducting research in the use of cross-hole seismic tomography for detecting and monitoring leach solution flow during in situ mining. This technique requires the use of a downhole seismic energy source in one borehole and a downhole wall-locking receiver (geophone) in another borehole separated from the first by the region to be investigated. Bureau research personnel chose a commercially available air gun for use as the downhole seismic energy source. Unfortunately, commercially available downhole wall-locking geophones that the Bureau tested were difficult to operate in the field, often unreliable and generally inadequate in terms of their signal/noise ratio. Therefore, research personnel began to experiment with an alternative down-hole geophone design that could be used to collect adequate data in a wide variety of borehole and cross-hole field situations. Approach An attractive alternative geophone design would be one that would incorporate a pneumatically operated wall-locking system. As an integral part of the Bureau&apos;s existing field system, a portable, high- pressure/low-volume air compressor would have sufficient capacity to operate the air gun as well as several small high-pressure pneumatic linear actuators. This approach was the simplest and most compatible with the research activities being conducted at the site.

Jan 1, 1991

1. In 2001, a total of 7,131 sand and gravel mining operations reported employment statistics to the Mine Safety and Health Administration (MSHA). Sand and gravel mines comprised 48.8% of all mining operations, the largest percentage of all mining sectors. Sand and gravel mines are distributed throughout all 50 states. The median number of operator employees per sand and gravel mine was 3.0.

Jul 1, 2003

By Robert J. Hundhausen

This paper describes the methods and costs of sinking a 2-compartment shaft at the Hope mine, Clark Fork, Idaho. The Hope mine is owned by the Hope Silver-Lead Mines, Inc. Albert E. Nash, of Clark Fork, is president and manager.

Jan 1, 1948

By H. C. Ko

The Bureau of Mines maintains an active program in thermochemistry to provide thermodynamic data for the advancement of mineral science and technology. As part of this effort, the standard enthalpy of formation at 298.15 K, ?Hf°, for 2CdO-CdSO4 was determined by HCI acid solution calorimetry to be -345.69 ±0.61 kcal/mol.

Jan 1, 1983

By I. D. Shah

The copper-nickel ore of the Duluth Gabbro Complex in northeastern Minnesota is a large potential domestic resource of cobalt and platinum-group metals. However, because of the low grade of the primary metal values (0.5 pct Cu, 0.15 pct Ni), the private sector has assigned a relatively low priority to the development of technology for processing this ore, anticipating that mining probably would not begin until the mid-1990&apos;s. Furthermore, preliminary processing flowsheets considered by the mining companies centered on the primary metal values. As part of an effort to help provide the basis for technology to recover critical and strategic minerals from domestic resources the Bureau of Mines is investigating methods to recover all of the mineral values, in the Duluth Gabbro material, with particular attention to the byproduct critical minerals. A key step in this process is the removal of a relatively large amount of iron present in the bulk sulfide flotation concentrate to permit subsequent extraction of mineral values. This report describes a direct smelting method that removes most of the iron and produces a copper-nickel-cobalt matte, an intermediate product from which the metal values subsequently are separated. Copper, nickel, and cobalt grade and recovery data are presented for the direct smelting method. Test results showed that under certain conditions some of the mineral values reported to the slag, requiring slag cleaning to recover them.

Jan 1, 1983

By A. J. Kraemer

[A great deal of interest has been manifested in the question of sulphur in fuels for automobile engines. Many different opinions have been expressed with respect to the effect of sulphur in gasoline on engine wear and engine performance. A wide difference of opinion exists as to the permissible limit of sulphur content for satisfactory operation.]

Jan 1, 1927

By C. R. Stephan, N. B. Greninger, J. R. Lipscomb

The U.S. Bureau of Mines and the U.S. Mine Safety and Health Administration (MSHA) are participating jointly in a research program to evaluate the strength characteristics and air-leakage resistance of various proposed seal designs for use in underground coal mines. The full-scale seals were constructed in the USBM&apos;s experimental mine at the Lake Lynn Laboratory, air-leakage tested, then subjected to pressure pulses of 20 psig or greater. bjected to pressure pulses of 20 psig or greater. In experiments prior to this study, seven seal designs using solid-concrete blocks were tested. Only the standard-type seal passed the explosion and air-leakage criteria. Tests also were performed on four seals constructed with low-density foam blocks. All four of these seal designs withstood the pressure pulse. In more recent studies, nine cementitious foam seal designs of varying thicknesses and densities were investigated. Six of the nine designs successfully survived the explosion overpressures. Six wood- block convergence seals also have been tested. The typical 3-ft-thick, wood-block seal design currently used in many coal mines did not maintain its integrity, in the absence of convergence forces, following the explosion test. Five modified wood-block seals successfully withstood the 20-psig pressure pulse. Based on these tests, three alternative seal construction materials, cementitious foam, low-density foam block, and wood, have been approved by MSHA for use in underground coal mines.

Jan 1, 1993

By Andrew D. O. O’Brien, Linda J. McWilliams, Joe L. Howell, Douglas E. Pollock, Jeanne A. Zimmer, Andrew B. Cecala

A quick, safe, and effective method has been developed that allows workers to clean their dust laden work clothing periodically throughout the day. For the mining industry, this technique is much more effective than the current federally approved method of using a vacuuming system. This newly designed method is relatively inexpensive and can be easily installed at any operation to allow workers to clean their clothing without contaminating the worker, the work environment. or co-workers to elevated respirable dust levels. This clothes cleaning process uses an air spray manifold to blow dust from a worker&apos;s clothing in an enclosed booth, which combines the dust for capture and removal by a baghouse dust collector. Since the air exhausted by the dust collector causes the booth to be under negative pressure. no measurable quantities of dust were ever measure escaping from the booth to contaminate the work environment and/or other workers. The worker performing the cleaning process is required to wear a half-mask fit- tested respirator with an N 100 filter, hearing protection, and full seal goggles. Dust samples taken inside the respirator of test personnel performing the clothes cleaning process showed very minimal to no respirable dust. This clothes cleaning process was performed in less than 20 seconds and was significantly y cleaner than either the Federally approved method of vacuuming, or the most common method or using a single compressed air hose. It was also determined during this research that polyester-cotton blend coveralls clean more effectively than coveralls which are 100 percent cotton. The newly designed clothes cleaning process has potential application to any industry where workers&apos; clothing becomes contaminated with most any type of dust or product.

By Stuart Lipoff, John E. Trombly, Paul Brien, O&apos

System objectives and design criteria for an in-mine ULF radio paging system are discussed. Coding formats, frequency and bandwidth selection criteria leading to the system design are discussed. The prototype call alert transmitter and pocket page receiver is functionally described. The report includes circuit descriptions, schematics, parts lists, printed circuit fabrication and assembly drawings. The report concludes with an estimate of the manufacturing cost for each assembly.

Provide a full-scale test facility where the effectiveness of all types of subsidence abatement techniques can be evaluated under controlled conditions. Background Subsidence is ground movement resulting from the collapse of overlying strata into a mine void because of failure of the mine roof, mine floor, or support pillars. The failure may propagate to the surface and be expressed as a depression, cracks, or a sinkhole. The surface expression of such features may be delayed until long after mining has been completed. Subsidence has the potential to affect more land area than any other type of abandoned mine land problem. Subsidence also causes direct damage to real property, with significant financial loss and more importantly, presents a danger to public health, safety, and general welfare. Subsidence-related problems are considered to be one of the most important abandoned mine land issues. Backfilling of mine voids is the most common stabilization method used to abate subsidence and protect surface structures. Backfilling or placement of material is performed by hydraulic flushing or pneumatic stowing, using either in-mine or remote methods. The majority of the past subsidence abatement projects has been performed using remote methods from single or multiple boreholes. Other subsidence abatement techniques arc available. For example, various point support methods are used to protect small areas of the land surface and surface structures, without completely filling the mine void. These may be more appropriate under different conditions. Little documented information is available concerning the capability of the various backfilling methods for completely filling a mine void or providing long-term structural strength. Therefore, the Bureau of Mines developed a laboratory for controlled evaluation of backfilling technologies.

Jan 1, 1991