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By William W. Adams

Reports for the calendar year 1923 that have been transmitted to the Bureau of Mines of the Department of the Interior by mine officials of the various coal-producing States show that accidents in and around the coal mines resulted in the death of 2,452 men. The output of coal during the year, as reported to the United States Geo- logical Survey, was 641,476,000 tons; hence the fatality rate per million tons was 3.82 as compared with 4.15 for 1922, a decline of about 8 per cent. The average rate for the decade ending with 1922 was 4.11. This reduction of 8 per cent in the fatal-accident rate per million tons is equivalent to the saving of 210 lives--that is, had the fatality rate of 1922 continued through 1923 the number of lives lost would have been 210 more than they actually were. Not only was there a net reduction in the fatality rate from all causes combined, but each of the main causes of coal-mine fatalities also showed a decline. Falls of roof and coal, which generally account for nearly half of all deaths in coal mines, were responsible for 1,158 fatalities in 1923, which represents a rate of 1.81 per million tons as compared with 1.90 in 1922. (See Table 2.) Haulage accidents underground usually cause about 17 per cent of all fatalities, and the reports for 1923 show that 413 deaths were due to this cause, indi- cating a rate of 0.64 per million tons, as against 0.71 for the previous year. Gas and dust explosions killed 372 men, the fatality rate being 0.58; the rate for 1922 was 0.65. Seventy-five deaths were due to electricity, for which class of accidents the fatality rate per million tons was 0.12 as compared with 0.16 the year before. Powder and other explosives caused 114 deaths, representing a rate of 0.18 as compared with 0.19 for 1922. Of the 2,452 fatal accidents during the year, 2,249 occurred under- ground, 46 in shafts, and 157 on the surface. At bituminous coal mines the number of deaths was 1,943, of which 1,816 were under- ground, 31 in shafts, and 96 on the surface. At the anthracite mines

Jan 1, 1923

By C. Travis Anderson

"Nickel is an essential metal in stainless steel, armor plate, and nickel steels and also in nonferrous alleys, such as monel metal and cupre-nickel, which are used in marine service. Nickel is one of the metals that must be greatly restricted in civilian use to provide the amounts needed for our War program. Consequently, it is desirable to investigate every possible substitute.The 5-cent coin no z in use contains 2.3 percent nickel. At the end of 1941, about 450 tons of nickel was being consumed annually to produce these coins. If the nickel used for that purpose in 9141 had been diverted to military use, 15,000 tons of armor plate could have been produced. As nickel is vitally needed for military as well as essential civilian products, it would seem desirable to substitute some other alloy for the 25 percent nickel alloy now being used. The Bureau of Mines has been asked to suggest possible substitutes.The substitute should have physical properties similar to the alloy now being used. It should have a metallic appearance and ring and a reasonably white color, so to be distinguishable from the present 1-cent coin. It should also be reasonably resistant to corrosion."

Aug 1, 1942

By Christopher Mark

This proceedings volume contains papers presented at W U.S. Bureau of Mines (USBM) technology transfer seminars on New Technology for Longwall Ground Control. These seminars were conducted in Washington, PA, on April 12, 1994, and Denver, CO, on May 10, 1994. The papers herein describe several new, highly practical USBM technologies now available for ground control in longwall mines, including lie Coal Mice Roof Rating (CMRR), cable bolts, the MULSIM/NL model, and the Wood Crib Performance Model. Other significant topics addressed include longwall panel layout, coal pillar design, horizontal stress in longwall mines, roof support selection for gate entries, and ground control monitoring.

Jan 1, 1994

By Henry Kreisinger, WALTER T. RAY

This preliminary bulletin was written as the first of a series of several on the significance of drafts in steam-boiler practice, the succeeding bulletins to be along the same lines but of a more advanced character. The conclusions arrived at are tentative, and are the result of a study of one of the many problems growing out of a general plan of the United States Government to increase the efficiency with which the coals of the country are being used. Greater efficiency requires better boiler and furnace design. The experimental study of drafts on which the conclusions presented in this bulletin are based formed part of the fuel-testing investigations that were carried on by the technologic branch of the United States Geological Survey and have been transferred to the Bureau of Mines. The experiments made seem to indicate that it is possible to double or treble the capacity of a plant without making any radical changes the furnaces and boilers. These increases require about double and treble the quantities of air to be put through the fuel beds and boilers. It also seems probable that rebafHing the boilers will often permit the capacity to be doubled or trebled, while still getting more steam than formerly per pound of coal for uses outside the boiler room. These experiments were undertaken with the object of clarifying ideas concerning the passage of air through fuel beds and boilers. Measured weights of air were passed through two beds of lead shot, series, one of which remained always the same and represented a boiler; the other being varied as to size of shot and depth of bed, and representing a fuel bed. Careful observations were made of the weight of air passing through the beds per minute. All data were plotted in many charts, so as to permit the study of them from several points of view. A number of laws were deduced bearing on the relative amounts of power required to force air through fuel beds of various thicknesses, composed of various sizes of coal, and through boilers of various lengths and areas of gas passages. An important part of the discussion relates to an increase in the capacity of boilers by increasing the amount of power applied to pressure and exhausting fans and thus forcing several times as much air through the fuel beds and boilers. may be possible, as a result of these investigations, to raise the rate of working the boiler heating surface to three or even four times its present value. Such an increase would undoubtedly mean new designs of grates, stokers, furnaces, and boilers, especially fitted for high rates of working. Fan equipments designed to supply three or four times as much air under several times the pressure would be provided with more efficient engines, thus giving an additional factor favoring high-capacity working. It must be borne in mind, as stated above, that the results are tentative. It will cost money to force gases at high speeds through fuel beds and boilers, and there will soon be pressing need of such quantitative data as will enable the largest possible part of the energy imparted by the fans to be advantageously utilized. We desire, to thank our superiors, especially Messrs. L. P. Breckenridge and D. T. Randall, for their helpful criticism and suggestions.

Jan 1, 1911

Norton Co., a manufacturer of abrasive products and diamond drilling and coring bits for oil and gas exploration, is building a $19.1 million addition, scheduled for completion in late 1980, to the Huntsville, AL. The plant makes alumina-zirconia abrasive grains used in grinding wheels and coated abrasives. ALUMINUM Martin Marietta Aluminum Inc. announced plans to expand production capacity of its 112,000-ton-per-year primary aluminum smelter at Goldendale, WA to 177,000 tons per year. The $125 million expansion was scheduled to come onstream in 1981. The Aluminum Company of America announced plans to restart a fourth potline during October at its 185,000-ton-per-year Point Comfort, TX primary aluminum smelter.

Jan 1, 1979

The U.S. economy continued to expand during 1986, although at the slowest pace since 1982 when the current business expansion began. Real gross national product (GNP) grew about 2.6%, slightly below 1985 growth but significantly below that of 1984. The continuing expansion was fueled pre-dominantly by rising personal consumption expenditures as well as growing Government purchases of goods and services. Fixed investment, although positive, failed to grow at the rate of the overall economy. The trade deficit, which increased more than 30% over the record 1985 level, continued to depress economic growth despite significant declines in the price of petroleum and the value of the dollar. On a more positive note, domestic employment continued to grow--increasing over 2 million from the 1985 level--and inflation and interest rates declined. The unemployment rate dropped slightly to 7.0%. Of direct importance to the mineral-producing industries, expenditures for consumer and producer durables as well as investment in residential construction each grew faster than the overall economy, but investment in nonresidential structures fell more than 10% from the 1985 level. The level of real capital spending declined about 3% in 1986, following strong gains in 1985 and in 1984. Capital expenditures for new plant and equipment bottomed out in the second quarter and expanded in the third and fourth quarters. The decline in the first half of the year was partially attributed to uncertainty arising from the then-proposed tax bill. Also, there was little impetus for corporations to invest in new capacity since factories were operating at less than 80% of capacity during most of the year, in part because of continued competition from imports.

Jan 1, 1986

The value of processed materials of mineral origin was estimated to have exceeded $297 billion in 1991. U.S. raw non fuel minerals production in 1991 was estimated at $30.8 billion, a 5.8% decline from that in 1990. This estimate was based on data for the first quarter of 1991 (in some cases two quarters) for most of the 21 minerals that for many years have accounted for more than 95% of the industry's production value. The value of minerals production has increased in all but 4 of the last 30 years. The metals component of production value has fluctuated much more than the industrial minerals component, reflecting the greater volatility of metal prices. Employment in metal mining rose slightly in 1991, but this gain was more than offset by a decline in employment in industrial mineral mining, resulting in an overall decline of 3.0% to 164,600 workers in 1991. Prices of several major metals declined during 1991, reflecting weakness in the economy, causing some metal mines to shut down or reduce operations.

Jan 1, 1992

The revised estimate of coal production in January 1977, is 39 million tons -- down 12 mi 11 ion tons compared with production in January of last year, largely as a consequence of the snow storms and cold. The major coal-hauling railroads operating in Eastern and Midwestern States reported to the Bureau of Mines that they loaded approximately the same number of cars for the week ended February 5, as in the preceding week. The Bureau of Mines estimates that U.S. coal production for the week ending February 5, 1977, was approximately 8.5 million tons, or nearly 3.5 million tons less than production for the corresponding week in 1976. Coal production from January 1 - February 5, 1977, was approximately 47.8 mi 11 ion tons compared with production of 63.5 million tons for the corresponding period in 1976. As of the first week in February, river and truck shipments of coal in the Eastern U.S. were about one-half of the normal traffic. Despite the freezing weather and ice and snow conditions of rivers and highways and reduced rail shipments, there was reportedly little or no shortage in coal supply to consumers. Inventories at electric utility plants and steel company coke plants at the beginning of the severe weather were sufficient in most cases for at least 30 days" operations. There have been no reports of coal shortages at other industrial plants.

Jan 1, 1977

The domestic mineral and material industry grew in some key sectors and declined in others during 1993; overall, the industry was poised at yearend for stronger growth in 1994. Metals production is expected to increase with anticipated growth in U.S. motor vehicle sales. There also may be increased demand for industrial minerals in 1994 based on domestic highway and building construction. Additional information on events, trends, and issues in the mineral and material industry is presented below and in the commodity sections that follow. Overall Industry Performance The value of processed materials produced from minerals in the United States during 1993 is estimated to have been about $326 billion, an increase of 5% compared with that of 1992. The estimated value of U.S. raw nonfuel minerals production in 1993 was $31.6 billion, about 1 % less than in the preceding year. The value of domestic minerals production has risen in 28 of the last 33 years.

Jan 1, 1994

By James T. McCartney, Joseph D. Davis

For more than 10 years coke-oven technologists have been investigating the expanding properties of coal on a scale larger than that afforded by laboratory test tubes. Koppers 4/ was among the first to realize that coals can not be differentiated satisfactorily with respect to expansion in coke ovens by the simpler test-tube methods; in his first method 80 grains of fine coal were coked in a cylinder heated from the bottom, so that the zone of fusion (plastic layer) advanced from the bottom to the top. The scale of test was too small; it has been modified by other investigators, but without significant improvement in practical application of the results. Somewhat later Koppers and Jendne 5/ experimented with a small-scale coke even, one wall of which was movable, in which the layer-coking in a coke oven could be simulated closely. This oven was heated from both sides. Their results with this oven showed a peak in the time-pressure curves near the end of the coking, period when the two plastic layers, advancing from opposite walls, meet. They also found that although the smaller oven was heated from one side only and did not show the Pressure peak characteristic of two-sided heating, it still gave results entirely too high. Russell built an oven similar to the movable-wall oven of Koppers and Jenkner and compared results obtained in it on Beckley expanding coal with these obtained on the some coal in the Altieri 7/ small-scale apparatus. Both tests were conducted at the same constant pressure, but heating was from two sides in Russell's oven and from one side in the Altieri tester. Russell found that the two types of test gave comparable results under constant pressure conditions even though the heating procedures were quite different. He showed later, however, that a "borderline" coal 8/ that contracted in the Altieri tester at constant pressure developed a peak pressure of 4 pounds per square inch in the movable-wall oven heated from both sides at constant volume. He concluded from this that testing at constant volume gave results more accurately indicative of dangerous expansion tendencies than those at constant pressure. He also found that heating from both sides in this oven gave higher pressure than heating from one side only.

May 1, 1942

By F. Fraas

ELECTROSTATIC methods are used to separate and concentrate or purify granular particles derived from ores or various synthetic and agricultural products. Compared with other separation methods that require many technological refinements, the electrostatic attraction of fibers, grass, and seeds to charged surfaces clan be accomplished under the most primitive circumstances, and the early development of this method of beneficiation seemed very promising. Precise application of the method to provide high selectivity, however, is a complex procedure, and interest in this method declined. During this period Mr. O. C. Ralston initiated a Bureau of Mines research program oil electrostatic separation. It is the purpose of thins publication to describe the development of the electrostatic method of particle separation from the early beginning to the present resurgence of interest. Most of the information for this description bas been derived from references, a few of which were not available for thorough review. Much information has been drawn from the investitions of the Bureau. Acknowledgments Mr. O. C. Ralston, former Chief metallurgist of the Bureau of Mines, began the research program on the subject and did research on the mils literature. Both Mr. Ralston and Mr. H. B. Johnson, former president of the Huff Electrostatic Separator Co., furnished patent references. A critical review by Mr. F. D. Lamb, Research director, and Mr. M. J. Spendlove, Supervisory metallurgist, Bureau of Mines, College Park Metallurgy Research Center, lifts been of much value in preparing this report.

Jan 1, 1962

By K. E. Stanfield

This report presents the results of analytical studies made on two series of oil-shale samples from the Mahogany ledge of the Green River mine the character of the various grades of oil shale that are being mined and processed into shale oil and refined products at the Bureau of Mines Oil-Shale Demonstration Plant at Rifle, Colo. The analytical work was part of a synthetic liquid fuels program being conducted at the Petroleum and Oil-Shale Experiment Station, Laramie, Wyo. The 16 oil shales ranG6d in color from a gray brown ( or a sample that assayed 10.5 gallons of oil per ton to a very dark brown for a sample that assayed 75.0 gallons of oil per ton. In general, the samples were similar as to the types of organic and inorganic matter that they contained but varied widely in the amounts or these constituents. The principal constituents were calcite, dolomite, illite, and yellow organic material, while the minor constituents were quartz, feldspar and plagioclase feldspar, pyrite, marcasite, analcite, opal, black organic material, and small woody fragments. Some micro-fossils, spores and pollen grains were found also.

Jan 1, 1951

By D. A. Larson

The Bureau of Mines conducted basic experiments to study the process of crack propagation with a wedge indenter. The work was conducted under plane stress conditions in a hard, brittle limestone. The purpose of these experiments was to first gain an understanding of the basic crack propagation process under a sharp indenter, and second, to determine how the crack propagation process could be used to improve mechanical fragmentation systems. Three methods of rock fracture with the wedge indenter were investigated in this program. These were the confined indentation tests, the unconfined splitting tests, and the edge chipping tests. The confined indention tests represent worst case conditions for crack growth and formed the lower bound on fracture efficiency. The unconfined splitting tests represented best case conditions and fixed the upper bound of fracture efficiency. The edge chipping tests represented an idealized fragmentation process based exclusively upon the highly efficient fracture propagation process. Edge chipping achieved a specific energy of 25 in lb f/in3 compared to conventional drag cutters, which required a specific energy of at least 2,385 in·lb f/in3? Thus edge chipping is up to 100 times more efficient than conventional drag cutting. Because of these promising results, more work is planned with the fracture propagation process in three dimensions.

Jan 1, 1987

By Robert S. Hill

"In November 1942, a preliminary report on the Swartz Mining District by John H. Soule, an engineer of the Bureau of Mines, recommended an exploratory program of diamond drilling. The existence of zinc and lead deposits in this region had been known for many years. In 1943 and 1944, the Federal Geological Survey made a detailed study of the same area. Later work done by the Bureau of Mines in this district followed the suggestions made by these geologists.3/In the latter part of 1944, Felix A. Vogel, Jr., another Bureau engineer, made a study of the Grey Eagle mine in the Kingston Mining District, a few miles northeast of the Swartz district, and his recommendations for diamond drilling were followed in so far as funds permitted. Drilling was started in October 1943 and was completed in June 1945.4/In its program of exploration of Mineral deposits, the .Bureau of Mines 'Ms as its primary objective the more effective utilization of our mineral resources to the end that they make the greatest possible contribution t national security and economy. It is the policy of the Bureau to publish the facts developed by each exploratory project as soon as practicable after its conclusion. The Mining Branch, Lowell B. Moon, chief, conducts preliminary examinations, performs the actual exploratory work, and prepares the final report. The Metallurgical Branch, R. G. Knickerbocker, chief, analyzes samples of ore and performs beneficiation tests. Both these branches are under the supervision of Dr. R. S. Dean, assistant director.With respect to this report, special acknowledgment for assistance is due to C. H. Johnson, chief of the Rolla Division, Mining Branch, and to various members of the Geological Survey."

Sep 1, 1946

By H. Foster Bain

The war has brought about many changes in the Western States, and some have deep pr sent or potent al economic significance. The West has been feeling severe growing pains for a number of years. Especially since the beginning of preparation for national defense and through the period of

Jan 1, 1945

For the sixth year in a row, the value of nonfuel mineral raw materials produced in the United States set a new record, reaching almost $17 billion in 1977. Data provided by the Bureau of Mines show that the 1977 value of domestic nonfuel mineral production exceeded the 1976 value, $16.7 billion, by 2 percent. The $17 billion worth of minerals was the basis for approximately $770 bill ion worth of processed materials of mineral origin. Output of metals decreased $360 mil lion in 1977, while that of nonmetals increased $670 million. Of the 22 metals produced, output of 12 increased, and the value of 13 increased. Among the 46 nonmetallic minerals produced, the quantity of 27 increased, and the value of 34 increased.

Jan 1, 1978

By Francis J. Fratttali, Verda McLendon, Stanley J. Green

"INTRODUCTION During the first phases of the war emergency the shortage of aluminum prompoted the Bureau of Mines to investigate methods for using low-grade bauxites of high silica content and also clays as raw-material sources of this strategic metal. The Bayer process treats low-silica bauxites to provide the industry with a major portion of the purified alumina, which contains very low percentages of silica and other impurities. One of the methods investigated in the laboratories of the Bureau of Mines for low-grade materials is the lime-soda sinter process, which was studied on a pilot-plant scale. In this process, the alumina content of the alumina-bearing minerals Bs made water-soluble by sintering the raw material with limestone and soda. Simultaneously, the siliceous material is rendered insoluble. The sinter is extracted with an alkaline liquor, and the resulting extract liquor is treated as follows to recover the alumina: (1) Autoclaving with lime to remove silica as a zeolitic complex and (2) treatment with CO2 to precipitate alumina as the trihydrate (A1203.3H20). Figure 1 is schematic flow sheet of this process.As the process is cyclic, it is necessary that nearly all of the soda and alumina remaining in the plant liquors after carbonation be recovered. Upon passing through one cycle, these liquors contain 14 to 15 percent NaCO3 2 to 5 percent NaOH, 1 to 3 percent A1203, minor amounts of silica, and, with certain materials such as Pennsylvania diasporic clays, 0.5 to 1.0 percent Na2S04. Approximately 50 percent of the Na20 in these liquors must be returned, as soda ash, to the dry-grinding and raw-materials blending operations. Previous work (6)5/ on sulfate-free solutions demonstrated that two methods for recovering Na20 were feasible, namely: (1) Salting out Na2C03.H20 by evaporation of the carbonated solutions and (2) crystallizing Na2C03.10H20 by cooling the concentrated carbonated solutions."

Sep 1, 1947

By J. S. Hansen

To advance technology that can conserve critical materials, the Bureau of Mines investigated a cast-on hard-surfacing that wear resistance and confines alloy additions to wear-prone surfaces. Wear-resistant material in form is on a polystyrene , the is embedded in a mold of unbonded s and the wear-resistant material is transferred to a cas surface at the time of For low-stress abrasion, derived from high-carbon ferro-chrome had higher wear resistance than did commercially available weld-hard. The microstructure of the was typi-white iron carbides. Free carbon added to the ferrochrome powder produced more M7C3 carbides than did material contained in surfacings made from ferrochrome alone, and improved the wear resistance. Several white iron powders with greatly reduced chromium contents also white iron contain-M7C3 carbides. One derived from white iron powder had wear resistance to that of weld-deposited hard facings. Among the parameters investigated, surfacing thickness was found to have a or influence on diffusion of elements out of the , microstructure, and wear resistance. The results of field tests on bucket-wheel excavator teeth and plowshares with cast-on hard surfacing are given.

Jan 1, 1985

The London Metal Exchange began its first official session of aluminum trading on Monday, October 2, LME prices based on 3-month forward contracts opened Monday at 52.4 cents per pound, fell midway through the week to 52.3 cents and ended Friday at a high of 52.7 cents. For the week, LME metal averaged 52.5 cents. Although Reynolds Metals Co. and Aluminum Co. of American continued in September to value unalloyed 99.5 percent aluminum ingot at 53 cents per pound, other producers were at higher positions of 55-57 cents. Alcan Aluminum Corp. of Alcan Aluminum, Ltd., a Canadian producer, increased prices for its U.S.-marketed ingot by 2 cents to 55 cents per pound, effective September 21. New York merchants increased ingot quotes by approximately 0.5 cents to 52.8-53.5 cents per pound.

Jan 1, 1978

1. Domestic Production and Use: Twelve companies operated 31 primary aluminum reduction plants, three firms accounting for 66% of production. Washington, Oregon, and Montana accounted for 32% of the total production; Gulf Coast States, 25%; Northern States, 29%; and other Southern States, 14%. Output of primary metal in 1973 was valued at $2.2 billion. About 80% of the secondary recovery was from new aluminum base scrap and 20% was from old scrap. Aluminum consumption by 25,000 firms was centered in the East Central United States. Of aluminum consuming industries in 1972, building accounted for 28%; transportation 19%; electrical, 13%; packaging, 16%; and consumer durab1es, 10%.

Jan 1, 1974