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By Harry Dobroski, Larry G. Stolarczyk

Medium-frequency (MF) techniques have been successfully .[pplied] to the problem of radio voice communications in both coal and metal and nonmental mines. Long range is achieved by taking advantage of existing mine conductors that carry and propagate the signal over vast areas. It is very likely that in the near future such systems will become the referred method for general mine communications. MF techniques can also be applied to the areas of in-mine control and monitoring. Preliminary work in this area is described. In a western mine, locomotives are being operated under MF remote control in a loading operation. In several eastern mines, MF has been evaluated as a method for monitoring the status of devices in remote areas of the mines. All control and monitor information uses existing mine conductors.

To improve efficiency in producing clarified water from mineral and metallurgical processing streams containing suspended particles. Approach Particles suspended in mineral and metallurgical processing streams are filtered out by granular magnesium oxide (MgO) used as the medium in deep bed filters. How It Works MgO is substituted for the silica sand or garnet sand currently used in conventional deep bed filters. These filters presently consist of a 24- to-48-inch-deep layer of either silica sand or mixed media, consisting of a stratified combination of anthracite coal, silica sand, and garnet sand. As waste water containing fine solids is percolated through the granular bed, the suspended particles become attached to the filter grains. When MgO replaces sand as a filter medium, the overall filter capacity is generally increased 50 to 80 percent, and no equipment modifications are necessary for filter operation. MgO is unique because it has a positive surface charge in water while most suspended materials are negative. The attraction of these negatively charged suspended particles to MgO enhances filtering performance. As is necessary for all good media, MgO is insoluble and nontoxic.

Jan 1, 1983

By Stephen Gerard Sawyer

The Bureau of Mines developed a method for analyzing elastically certain types of protective cabs and canopies used on underground electric face equipment. The method is based on plane frame theory, and to be amenable to analysis by this method, cabs and canopies must contain symmetry about one plane. Additionally, protective structures with one or more top members in the long direction that do not frame into the columns should be approximately twice as long as they are wide and have two or more internal top members in the short direction. The assumptions and limitations of the plane frame method as regards analysis of three-dimensional cabs and canopies are discussed. A step-by-step procedure for application of the plane frame method is given, and three example canopies are analyzed following this procedure. Elastic strengths calculated for the three example canopies compare within 10 percent of those computed by the more complicated space frame analysis. Formulas employed in plane frame analysis of cabs and canopies are given in the appendixes.

Jan 1, 1973

By Donald A. Wilson

As part of a continuing effort to maximize metal recovery from domestic secondary resources, the Bureau of Mines investigated a process for recovering the metallic portion of scrap alkaline batteries. A pyrometallurgical method for recovering nickel and cadmium from Ni-Cd scrap batteries previously developed on a laboratory scale, was scaled up to 25-and 43-pound charges. The method employed reduction and/or decomposition in a retort using a minimum of 2.5 percent carbon as a reductant. Metallic cadmium was distilled at atmospheric pressure and a minimum of 900° C. Purity of the recovered cadmium was 99.8 percent minimum and the nickel-iron residue contained less than 0.02 percent cadmium.

Jan 1, 1981

By Jr. Flynn

"The Bureau of Mines receives and answers many requests for information on the qualities and properties of American coals, and also publishes many papers that deal with coal characteristics. Compilations of chemical analyses of coal from specific locations are contained in a series of technical papers,2/ by States, whereas typical analyses of coal seams, by States and counties, are given in data books, volumes 1 to 7,2/ by producing districts, as defined in the Bituminous Coal Act of 1937. Bulletin 446, ""Typical Analyses of Coals of the United States,"" condenses and supplements these data books, which do not apply to the Western States. Other coal properties are described in numerous publications listed in the Bureau of Mines Bibliography of Publications. However, no recent publication lists average B.t.u. values by rank on a Statewide and national scale. Averages have been estimated in the past, and some of them are included in this paper for comparison.The average and the ranges of as-received B.t.u. values of American coals on a Nation-wide basis, as found by the statistical method described in this paper, are given in table 2 and on a State-wide basis in table 3. The following is abstracted from table 2:In deriving average B.t.u. values for coals, the results depend on the type of data available and the methods of calculation. The data, or analyses, may represent any of three types of samples - mine, tipple, or delivered. In mine sampling, a channel cut is made of a vertical face of the coal bed, carefully excluding most of the impurities, and the material retained is the sample. It is readily seen that mine samples are selected samples and do not strictly represent the unmined coal bed, unless the coal contains no major impurities. Mine samples generally represent the best-quality coal that could be produced. In contrast to mine samples, tipple and delivered samples represent coal that actually has been mined, and their analyses may show either lower or higher values than mine samples of the same coal, depending on treatment and preparation after mining.Of the thousands of analyses accumulated by the Bureau of Mines, most are of either tipple or delivered samples and represent the coal after it has been mined. Any average calculated from this aggregate of data will, consequently, reflect coal that has been produced, and not unmined coal in situ.The method of calculating an average from the basic data also will have considerable influence. If there are three seams of coal in a county, the average analysis for the county is not necessarily the arithmetic mean of analyses of the three individual seams. For a probable average of unmined coal, the B.t.u. values of each seam should be weighted in proportion to the unmined reserves of each seam. In similar manner, an average for past pro¬duction should be weighed according to the past production for each seam. Figures for coal reserves are only estimates based upon geologic evidence and its interpretation. Production records are much more accurate than estimated reserves, although detailed production records for individual seams by counties are very few."

Dec 1, 1949

By R. W. Stahl

Increasing use of continuous miners, especially the boring type, has focused attention on the inadequacy of face ventilation in coal mines. The bulk of the machine, the rapid advance of working faces, and the increased liberation of methane from the larger expanse of freshly exposed coal surfaces have created ventilation problems that were unknown with conventional mining equipment. Ignition of gas, especially that caused by machine bits striking hard rock or pyritic inclusions, have increased at an alarming rate. As the mines penetrate beds under thicker cover at an ever-increasing rate of face advance, this problem will probably increase unless face ventilation is improved. A previous survey, described in Bureau of Mines Report of Investigations 5414, Auxiliary Ventilation of Continuous Miner Places, disclosed that auxiliary fans with tubing generally improved circulation of air and removal of gas at the face. The study here reported attempts to examine, face ventilation at various mines and to note any plan or innovation of. air coursing that industry might adopt to reduce the danger of gas ignition. ACKNOWLEDGMENT The mines visited were very cooperative in the study-and-generously supplied any data requested.

Jan 1, 1960

Develop a machine which can accurately simulate both the breathing and metabolic functions of a human being. The advantages of such a machine over a human being for testing of respiratory protective devices lie in its ability to quantify metabolic input, its repeatability, and the lack of a need to deal with the vagaries of human subjects. Breathing simulation has been widely achieved throughout the world but metabolic simulation has not. Approach Utilize the latest computer technology and place the complex portion of the system in software, leaving the mechanical portion as simple as possible. How It Works The concept for the automated breathing and metabolic simulator (ABMS) was developed through a research contract with the Pennsylvania State University. The ABMS utilizes a continuous removal/replacement concept to simulate metabolic functions, with breathing and metabolic functions being controlled by a computer. The mechanical portion of the machine is simple; the complexity of the system lies in its computer software which is not subject to maintenance problems.

Jan 1, 1987

By J. W. Walkiewicz

One of the objectives of the Bureau of Mines is to develop substitution technology for scarce materials. In accordance with this goal, alloys containing lanthanum, cobalt, copper, and magnesium were investigated for fabrication of rare-earth-cobalt (RE-Co) permanent magnets. A complete substitution of lanthanum for samarium and a partial substitution of copper for cobalt was accomplished. Magnets of La-Co and La-Co-Cu-Mg alloys were fabricated by powder metallurgy techniques and evaluated. A maximum intrinsic coercivity of 23.2 kOe was obtained with a La-Co-Cu-Mg alloy. In comparison, maximum values of 9.3 kOe and 11.6 kOe were obtained with La-Co and La-Co-Cu alloys, respectively. The substitution of copper and magnesium for part of the cobalt resulted in a large increase of intrinsic coercivity, similar to the results of Bureau research with mischmetal-Co-Cu-Mg alloys. Unlike the mischmetal-Co-Cu-Mg magnets, the La-Co-Cu-Mg magnets showed signs of physical deterioration on exposure to air. The effects of fabrication parameters on the magnetic properties of the La-Co-Cu-Mg alloys were also determined.

Jan 1, 1982

Aluminum alloys are used in two broad classifications: wrought and cast. Wrought alloy products, which are formed into final shape by rolling, forging, extruding. etc., contain low percentages of alloying elements; whereas cast aluminum products, which generally are not worked before use, may contain higher percentages and a somewhat different selection of alloying elements. For example, wrought aluminum alloys usually contain less than one percent silicon and cast alloys contain as much as 18 per-cent silicon. While there are good techniques available for separating aluminum alloys from mixed scrap, there are no efficient ways to separate wrought aluminum from cast aluminum. The high levels of silicon, iron) copper, and zinc from the cast alloys make wrought-cast mixtures unacceptable for wrought alloy production. Consequently, separated wrought aluminum scrap commands a premium price on the market. Since increasing amounts of mixed aluminum alloys are being recovered from automobile scrap, this separation is important for efficient recycling of these alloys. Approach The difference in thermo-mechanical properties between the two classes of aluminum alloys is used as the basis for the separation process. Casting alloys lose their ductility within a certain temperature range while wrought alloys remain ductile. As temperature increases, aluminum alloys gradually become weaker, and at a certain temperature, each alloy loses strength and ductility due to incipient melting in localized areas. For casting alloys that temperature generally lies between 520° to 560° C, but it is above 600° C for most wrought alloys. Mild crushing, therefore, in the proper temperature range will result in complete fragmentation of the casting alloys but only plastic deformation of the wrought alloys. A simple screening step then is used to separate the oversize wrought pieces from the fragmented cast alloys.

Jan 1, 1984

Develop a safe, efficient filter for removing diesel particulate matter (soot) from the exhaust of underground mining machines equipped with water scrubbers. Approach The Bureau of Mines and the Donaldson Company, Inc., jointly developed a low-cost, disposable, pleated-media filter (PMF) system. The system is intended for use on Part 36 permissible equipment or other machines equipped with water scrubbers. The PMF is installed downstream of the water scrubber to take advantage of the cool exhaust produced by the water bath. This demonstration system was tested on three Jeffrey 4114 Ramcars and a Wagner LST-5 scoop at Utah Fuel Company's Skyline mine near Scofield, Utah. Figure 1 illustrates a clean filter element being inserted into the canister on the Ramcar. How It Works The PMF system consists of a water trap, an optional over-pressure relief valve, filter canister, and PMF Under normal operations exhaust from a vehicle equipped with a water scrubber is heavily laden with water, especially on immediate startup of the engine. The water trap is designed to remove most of the water droplets from the exhaust before they enter the PMF, thus improving PMF performance. The over-pressure valve is designed to limit the exhaust backpressure by venting off some exhaust gas before the: filter. It is attached to the water trap upstream of the PMF. Figure 2 illustrates and shows a break out sectional view of the location of the PMF on the Ramcar.

Jan 1, 1991

By B. Dimitriades

The Bureau of Mines measured the reactivities of 19 hydrocarbons known to be prominently present in automotive exhaust and ambient air in a smog chamber. Results agreed well with those obtained using two other smog chambers. Reactivity scales were developed for hydrocarbons and aldehydes using the results of this work and those of a previous study. Application of the reactivity scales to automotive exhaust samples gave fair agreement between predicted and observed rate-of-N02-formation values; however, predicted and observed ozone yields were neither in agreement nor did they correlate well. This lack of correlation for ozone yield was attributed to the inappropriateness of (1) the individual component reactivity data, (2) the reactivity classification scheme used, and (3) the linear summation method. In seeking to understand this problem and to develop more appropriate reactivity scales, the data were examined from a reaction mechanism standpoint, and further studies were suggested.

Jan 1, 1975

By George M. Lucich

This report describes a sensitive, proportional temperature controller developed by the Bureau of Mines that is useful in the temperature range from 40 to 400° C with an accuracy of ±0.10 C. A temperature controller of this kind is potentially useful for regulating temperatures in air chambers, liquid baths, furnaces, and reaction vessels, and for other applications. This instrument was developed to control the duration and temperature of the heating cycle of a charcoal-filled adsorber that is part of a special helium analyzer used by the Bureau. The controller was made from commercially available parts, and can be easily modified to provide continuous temperature control. The circuit is solid state and employs no electromechanical devices. Over a 2-year period of use as a component of the special helium analyzer, this temperature controller performed successfully and required no maintenance.

Jan 1, 1979

By A. May

Florida has accumulated about 400 million tons of phosphogypsum, a mineral process waste generated in the production of fertilizer, and is adding 30 million tons to this annually. To minimize storage of this waste and reduce potential environmental effects, the Bureau of Mines conducted research into utilizing the phosphogypsum, by identifying and developing high-volume uses for this material. Admixtures of phosphogypsum, fly ash, and lime that could produce a coarse aggregate suitable for road construction were investigated. Using phosphogypsum with asphalt, cement, cement-kiln dust, silica, clays, and oxychlorides to pro-duce aggregate was also examined.

Jan 1, 1985

By S. H. Katz

Artisans and laborers in mineral industries where the air is dusty with particles of reel: are subject to a peculiar pulmonary disease known as miners' phthisis or stone cutters' consumption. In granite cutters the disease is specifically designated as granite pneumoconiosis. Very fine particles of the harder rocks are especially injurious when inhaled into the lungs. It is estimated particles about one micron (1/23000 part of an inch in diameter) are most injurious, because larger particles are more readily removed by the cilia and,wet surfaces of the respiratory passages before reaching the lungs, while smaller particles either do not readily lodge or are more easily eliminated. Silica, of which quartz and flint are composed, and which forms a large part of granite, is one of the hardest of the common rock-forming materials. It is also very insoluble when silica lodges in the lungs elimination is difficult. Rock constituents of granite other than silica are probably injurious but in a lesser degree, and this is also probably true of limestone and the softer rocks. Ultimately a worker who daily inhales much granite dust has considerable deposited in his lungs. If he continues at his trade the lung tissue becomes harder and less elastic, he finds himself short winded, and in extreme cases death may come either directly or indirectly as a result of lung failure.

Feb 1, 1921

By Robert C. Gabler

The extraction of metals from coal ash was investigated by the Bureau of Mines in an effort to produce a more environmentally acceptable waste and offset waste disposal costs with recovered metal values. The research was conducted in two steps: determination of the parameters that affect extraction of metals from coal ash and development of extraction-recovery procedures. Data obtained indicate that the major parameter affecting the extraction of metals from coal ash is the calcium content of the ash. Other parameters such as furnace type and operating temperature had much smaller effects on metal extraction. Two procedures were studied for metal extraction: an acid leach procedure for high-calcium ashes and a lime sinter-acid leach procedure for low-calcium ashes. An alumina product was recovered that, with sufficient washing, meets Hall cell specifications. The leach residues pass the EPA EP Toxicity Test and are thus nonhazardous wastes available for a variety of uses.

Jan 1, 1983

By H. E. Sanford

"INTRODUCTION Of the occupations in and about coal mines, those of the haulage crews are among the most hazardous. Statistics indicate that the second largest number of fatalities about coal mines occurs during haulage operations and through the use or misuse of haulage equipment. Despite the fact that relatively few coal-mine employees are engaged continuously at haulage operations, approximately 20 percent of all coal-mine fatalities are attributable to haulage.Most of the hazards in haulage operations could be very greatly reduced if more serious consideration were given to the problems of the haulage crews and if sincere efforts were made to reduce the hazards. Underground haulage is similar in many respects to railroading; yet, railroading is now considered one of the safest of occupations a distinction that has been attained only by honest effort and whole-hearted cooperation on the part of all concerned. Underground haulage is also similar to street and highway operation and has in it some of the difficulties encountered in the reduction of traffic accidents the seriousness of which has not by any means been con¬trolled as yet, notwithstanding the fact that much effort has been expended through a multiplicity of laws, ordinance regulation, etc., as well as by thousands of enforcement agencies and officers.The men working on the locomotives are among the most important members of a coal-mine organization; without skilled haulage employees, the production of coal would be greatly retarded. Their jobs, particularly the job as brakeman, require physical endurance, agility, and mental and physical alertness; in thin coal beds, especially where the roof is not brushed and the coal is loaded into mine cars by hand, the need for these qualifications is greatly increased."

May 1, 1948

By R. A. Guidotti

The Federal Bureau of Mines has studied the reaction of oxides of columbium, vanadium, and tantalum with ammonia in vertical, gas-solids reactors at temperatures ranging from 300° to 1,300° C with the goal of preparing nitride intermediates for subsequent preparation of the metals by a thermal-decomposition step. The best nitride conversions were obtained in nonmetal reactors. With Cb205, V2O3, and V205 , low-temperature maxima in reaction rates occurred at 800°,800°, and 450° C, respectively, during oxynitride formation (in A1203) at 1 atm of pure ammonia. Conversion of the oxynitride, in a second step, to the mononitride was optimum at 1,200° C for columbium and 1,050° C for vanadium. In the case of Ta205, the rate of reaction to form Ta3N5 (in a single step) was highest at 900° C, where the presence of up to 5 percent methane was found to be beneficial; improved results were obtained by conducting the nitriding in a rotary kiln. Optimum space velocities (in the vertical Al203 reactor) ranged from 5,280 hr-1 for Cba205 to 7,950 hr-1 for V203. Oxide particle size had little effect upon reaction rates. Under fully optimized conditions, products containing less than 1 percent oxygen were readily obtained in under 6 hours.

Jan 1, 1975

By A. L. Engel

This report describes laboratory-scale experimental treatment of six base-metal ore samples taken by engineers of the Bureau of Mines, Region II, while investigating ore deposits in California and Nevada. The information is of interest in developing the mining districts represented or when similar ores from other sources are being studied. Simple treatment methods were employed as far as possible. More complex treatments also were tried when necessary. The possibilities and limitations of the methods applied to the several ores are shown by the data herein reported.

Jan 1, 1960

By Lloyd A. Morley, Robert Stefanko

This report was prepared by The Pennsylvania State University, College of Earth and Mineral Sciences, ' Department of Mineral Engineering, University Park, Pennsylvania, under USBM Grant No. GO-133077. The grant was initiated under the Coal Mine Health and Safety Research Program. It was administered under the technical direction of the Pittsburgh Mining and Safety Research Center with Mr. G. J. Conroy acting as the technical project officer. Mr. J. A. Herickes was the grant administrator for the Bureau of Mines. This report is a summary of the work recently completed as part of this grant during the period 19 June, 1973 to 17 June, 1975. This report was submitted by the authors on 18 July, 1974. This technical report has been reviewed and approved.

Jan 1, 1974

Provide blasting-resistant, quickly reusable stoppings for large mine openings. Approach Stoppings are assembled using roof-to-bottom panels of brattice held together by Velcro seams that peel open when struck by a strong air blast. How It Works The Velcro seam is designed to open when exposed to forces lower than would normally damage the brattice. When the seams partially open, they relieve the blast air overpressure to prevent damage to the brattice panels and their anchoring devices. A stopping is returned to service by reclosing the Velcro seams. To hang a brattice panel, its top is stapled to a board, and wrapped once or twice around it. That assembly is then attached to the roof with bolts. The length of the board should be a foot less than the width of the panel to allow for the sealing seam on each side of the panel. The boards are installed end-to-end in an approximately straight line across the roof of the mine opening.

Jan 1, 1979