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By Patrick R. Taylor

Sub-micron sized boron carbide powders have been synthesized in a non-transferred arc thermal plasma reactor. Precursors for this synthesis are boric acid or boron oxide powders and methane. The powders produced were characterized in terms of size, shape and purity. Methods to increase the purity of the product were evaluated and included hot water leaching to remove unreacted oxides and controlled temperature, air roasting to remove excess carbon. Theoretical results are also presented on the thermodynamics and mechanisms of the synthesis reactions.

Jan 1, 1994

By Jim Sundal

Primary steel manufacturers using electric arc furnaces generate one of the largest hazardous waste streams nationwide. The waste stream, known as electric arc furnace dust, is a listed hazardous waste with the designation K061. Oregon Steel Mills, Inc., (OSM) of Portland, Oregon, has implemented a process known as Glassificationn, which uses KO61 as an ingredient in an onsite recycling process. Because OSM was able to demonstrate that the Glassificationm recycling process beneficially uses all toxic constituents in the electric arc furnace dust and that the recycling process produces marketable products, the process is not subject to Resource Conservation and Recovery Act (RCRA) permit requirements. The marketable products manufactured using Glassificationn include roofing granules, ceramic glazes and colorants, abrasive blasting media and, more recently, synthetic slag fluidizers. The purpose of this paper is to identify the regulatory issues for recycling hazardous waste and demonstrate that OSM glass frit is effective as a slag fluidizer in primary steel manufacturing.

Jan 1, 1994

By Russell J. Foster

Public awareness of, and involvement in, recycling has increased significantly in recent years. Nevertheless, recycling is generally perceived as a new development, and is familiar only in the context of municipal solid waste management. The actual magnitude and scope of metals recycling in the United States have gone virtually unnoticed. Over time, both the quantitative and qualitative aspects of secondary metals recovery and reuse have changed substantially, while the attendant regulations have become increasingly stringent. This U.S. Bureau of Mines report examines trends and developments in major metal demand and recycling, and analyzes the possible impacts of regulations with regard to recycling activities.

Jan 1, 1994

By Yambu J, Titus K

Geotechnical investictations and monitoring have been integral to development of the Porgera Gold Mine. The steep, unstable terrain has required a program for monitoring of slopes and foundations which includes survey stations, borehole inclinometers and piezometers. Case studies of the Maip Pass landslide, Yakatabari land-slide, Anawe Plant Site CIP pond excavation and batter, and a load test study for mine waste dumps are presented.Monitoring is needed to ensure that geotechnical risk is kept to a minimum. A vigilant program will be required for the life of the mine.

Jan 1, 1994

By Dennis S. Kostick

Sodium is a silver-colored metal that is so unstable that it reacts violently in the presence of water, and chlorine is a greenish-colored gas that is dangerous and lethal. Yet the combination of these two elements forms sodium chloride, commonly known as salt, which is a white-colored compound essential to life itself. Salt is perhaps the only mineral in the world that is used virtually by every human being in every country. Although its importance has diminished over time, salt has had a profound influence on history. Sources of salt have determined the location of cities, such as Salzburg, Austria, Salzgitter, Germany, Salt Lake City, UT, and Saltville, VA. Populations have migrated in search of salt, and wars have been fought to obtain or to protect it. Although there is no written record of when prehistoric man first discovered salt, he probably instantly appreciated its unique and distinctive taste and sought more of it. He noticed animals were attracted to salt springs and salt licks, where they satisfied their innate cravings. Man used this knowledge to hunt for food; where he found the salt, he would find the animals. Because prehistoric man was not aware of his physiologic need for salt, he automatically received his salt requirements from the meat of the animals he ate. A Mesopotamian tale tells of a wounded pig that ran into the ocean and drowned. After being recovered from the ocean, where it was saturated in the salt brine, the pork was found to taste better than unsalted meat. It was not until man graduated from a nomadic to an agricultural society when he introduced vegetables and cereals into his diet that he realized he needed additional supplements of salt. The Sumerians ate salted meat and used salt to preserve food about 3500 BC. In approximately 1000 BC, the Trojans learned to use salt for preserving fish. The maritime civilizations, such as that of the Phoenicians, engaged in an extensive salt trade throughout the Mediterranean. Many superstitions, customs, and traditions surround the religious, social, economic, and political aspects of civilization. Although some commodities have provided the basis of some ageless metaphors and cliches (i.e., heart of gold, strong as steel, etc.), none are more commonly used than those pertaining to salt. Being "the salt of the earth" referred to a person's worthiness, as referenced in Matthew 5:13 of the Bible. Someone "not worth his salt" reportedly was used in ancient Greece in bartering salt for slaves. When a laborer was worth his salt, he was paid a salary (sal is Latin for salt), a term still in use today that dates back to Roman times when part of a soldier's pay was salt rations. Fearing those around him, the Roman leader Pompey was known to add a grain of salt to his drinks as a supposed antidote to poison. Hence, "taking it with a grain of salt'' is to regard something with suspicion. The earliest known record of salt production was in China about 2000 BC when Emperor Yu decreed that salt had to be supplied to the court as a tribute. Because salt was a commodity that had universal demand, governments often intervened to control salt production and distribution to generate revenue for major national projects. State-run salt monopolies were common in history, such as in Rome about 506 BC. Revenue was also derived from taxes levied on salt sales. The word gabelle refers to the direct salt tax used in France. This tax was so despised that it was a major cause of the French Revolution. Although the tax was repealed in 1790, it was reinstated in 1805 to raise revenue for war. France continued to used the gabelle until 1945. Salt making was an important economic activity in many areas of the world. Archaeological evidence indicates that salt was quarried from hills near the Dead Sea before the Bronze Age. At Hallstatt in the eastern Alps of Austria, rock salt was mined as early as 1400 BC. Solar salt was being produced in the northern Yucatan peninsula by the Mayan civilization from about 50 BC to AD 300. Other than the prehistoric use of salt in the southwestern part of the United States by the Native Americans, the first production of salt by American colonists began in June 1614 on Smith's Island, VA, seven years after the founding of the Jamestown colony. The short-lived activity was in response to the high price of salt being charged by ship's captains who brought salt over as ballast from England. Although Nathaniel Loomis is credited with starting the first commercial inland salt production in the United States at Onondaga Lake in New York in 1790, salt had been made by individuals for private use years earlier. Indians had long known of the salt springs in the Kanawha Valley of Virginia (now known as West Virginia). In 1755, Mary Ingles, a white settler, was kidnapped by Indians and was forced to make salt from the saline springs. After her escape, she told other settlers how to make salt. At Saltville, VA, Arthur Campbell began making salt in 1782 by boiling brine obtained from salt springs. In 1799, William King sank a shaft about 3 m in diameter down about 61 m to the underlying Saltville salt deposits. The shaft flooded before he could extract any rock salt; however, King has the distinction of digging the shaft of the first salt mine in the United States. Fig. 1 shows the King site as it appears today in Saltville, VA. Production of brine from the shaft continued until 1892. Settlers moved into the Kanawha Valley in 1785, but it wasn't until 1806 that Elisha Brooks established the first commercial salt works in Kanawha.

Jan 1, 1994

By A. B. Cecala

The Bureau of Mines has been performing research to lower the dust exposure of workers at mineral processing operations for a number of years. This research has mainly been directed at source control techniques in an effort to lower a worker's dust exposure at a particular job function. In some cases, this control technology provided a carryover effect in lowering the exposure of workers at other locations, but for the most part had very little effect in lowering dust levels throughout an entire mill building. Recently, the Bureau became aware of several mineral processing operations having problems with high over-all mill dust levels. These operations were all using baghouse-type collectors to address their most serious dust contamination areas. Although these major dust sources were being controlled, there were numerous minor dust sources that were not. These minor dust sources were causing dust levels in these operations to gradually increase as the day or shift progressed. The intent of this work was to determine general guidelines and design criteria for operations that may be interested in implementing a total mill ventilation system. Most mill buildings can be considered a closed system and thus any dust that is not being controlled within the structure, will cause dust levels to gradually increase over the shift. A total mill ventilation system should be designed to draw clean make-up air in near the base of the mill. This air provides general purging and may clear some dust laden areas throughout the mill structure. This air should be discharged at or near the top of the structure, where it is not a contaminant to plant personnel working outside. Without this exhaust system, dust can exit the building through open doors, windows, etc., and contaminate outside plant workers. This dust can also be recirculated back into the mill building causing additional contamination problems. A total mill ventilation system is not a stand-alone technique, but is a supplemental technique to assist other localized dust control systems.

Jan 1, 1994

By H. M. Breza

Recovery of phosphate concentrate has received increased attention as the existing mine and plant production capacity limitations of the Texasgulf Inc. Aurora, North Carolina Mine are reached. Improved mining techniques and mineral processing of waste streams offer a potential to increase overall phosphate production without major expansion of the Mining facility. Innovative processes have been or are being identified to maximize pit mining recovery and to minimize losses in waste streams, resulting in more effective use of the valuable phosphate natural resource. This paper will describe the various continuous recovery improvement programs being implemented to achieve this goal.

Jan 1, 1994

By M. Polat

Variations in flotation rate by particle size and specific gravity have been investigated for three different bituminous coals. The flotation rates for various components were determined by separating the products of bulk flotation into size-specific gravity fractions. The effects of feed size and reagent addition on the flotation response of individual size-specific gravity fractions were evaluated.

Jan 1, 1994

By Rena I. Geroyan

This U.S. Bureau of Mines report presents an evaluation of the coal mining industry's impact on the economy of Pike County, KY. A software package called IMPLAN was used to perform the analysis. The results of this study show that coal mining was the primary income producing industry in Pike County in 1990, accounting for about 46% of the county's Total Industry Output, and 21% of the total employment.. Coal production in that year amounted to 29.6 M mt (32.6 M st). Two alternate economic scenarios were developed to study the potential effects of changing coal market conditions on the county. Scenario A assumes market changes result in a coal production increase of 4.5 M mt/yr (5.0 M st/yr), and scenario B assumes a decrease of 4.5 M mt/yr (5.0 M st/yr). Scenario A would result in a 15.3% rise in the value of Pike County's Total Industry Output, adding a total of 1,663 jobs (+6.1%) in all sectors in the county. Scenario B would have the opposite effect, decreasing the Total Industry Output and employment by identical amounts. Such knowledge would allow local and regional officials to anticipate the economic and social impacts of shifts in coal production, and plan accordingly to mitigate impending changes.

Jan 1, 1994

The deep seafloor in Papua New Guinea's proposed Exclusive Economic Zone appears to be a gold-rich province in the same sense as the territory above sea level. Two significant sites with polymetallic massive sulphide deposits forming today are known on neovolcanic ridges in the Manus Basin. Their high precious metal contents have led to renewed interest in the issue of exploiting seafloor mineral deposits. The prospects of finding other, possibly larger deposits in the region appear substantial. This paper reviews current data on seafloor deposits in Papua New Guinea (PNG) and raises some issues relating to future commercial exploration and mining of the sea floor. One of the known PNG deposits could become a prime candidate for the trials needed to develop technology, establish costs, and minimise environmental impact.

Jan 1, 1994

By C. S. Thompson, P. A. Ciullo

Pyrophyllite is a naturally occurring hydrous aluminum silicate with the molecular formula SiO,,AI,,(OH), or, as more commonly expressed, the oxide formula A120,~4Si02~H20. Pyrophyllite is rarely found in deposits as the pure mineral and is often intimately associated with quartz, sericite, kaolinite, and diaspore. These associated minerals, to a large degree, help determine the most appropriate commercial application for a given pyrophyllite ore. Structural similarities plus the generally soft platy nature of pyrophyllite has in the past caused it to be included with talc in applications and production data. The Minerals Yearbook, published annually by the US Bureau of Mines (USBM), still reports on talc and pyrophyllite together, although admitting that they do not share the same uses. Pyrophyllite has also at times been considered a clay mineral because of its structure and chemistry. The refractory properties of pyrophyllite have been known for nearly 200 years, but it has only been in the past 60 to 70 years that a variety of applications have been developed to exploit the unique characteristics of this mineral. Worldwide, pyrophyllite is a component of refractories, whiteware, foundry mold dressings, pesticides, paint, plastics, rubber, cement, fiberglass, and soap. Historical Overview The most salient refractory features of pyrophyllite are its low coefficient of thermal expansion, high thermal conductivity, low moisture expansion, and good resistance to corrosion by molten metals and basic slags. One of the first recorded uses of this mineral was as firebrick in Japan in the early 1800s. This followed its discovery in 1797 on Mount Omotoyama at the site of the present Mitsuishi mine. In addition to firebrick, sawn blocks of ore were used for carvings and in the manufacture of slate pencils and signature seals. The Mitsuishi mine is still one of Japan's largest. By the mid-1800s, refractories were being made in Japan from roseki (a pyrophyllite-bearing ore) for the construction of metal melting furnaces. The mineral did not get its name until 1829 when R. Herman, testing a sample of supposed talc from the gold-quartz veins at the Berezovo deposit in the Urals, showed that it was actually an aluminum silicate and designated it pyrophyllite. This name was derived from the Greek pur for fue and phullon for leaf, in allusion to the effect of heat in causing separation of the laminae in foliated varieties (Mellor, 1927). The exact date of the discovery of pyrophyllite in the United States is uncertain, but it is believed that the talc and soapstone deposits noted in an 1827 report on the geology of the slate belt of North Carolina were actually pyrophyllite occurrences (Olmstead, 1827). Pyrophyllite was first used in North Carolina on a local basis in the early 1800s. Blocks were sawn and cut for use as stove linings, mantels, chimneys, fireplaces, and gravestones. This was the material of choice because it did not shrink when heated, but cut easily and hardened as it weathered. Pyrophyllite crayons were sold commercially by local gold miners for steel marking and as tailor's chalk from about 1800 until 1922. It was during this period that pyrophyllite was discovered near the town of Hemp (later renamed Robbins), NC. The large quantity of scrap resulting from the sawing of crayons at this deposit prompted the construction in 1921 of a grinding plant. The ore scrap was ground to fine granules and sold to asphalt producers to prevent shingles from sticking together. By the mid-1930s, milled pyrophyllite from North Carolina was also being successfully utilized by the ceramics industry in whiteware for its low cost and ability to shorten firing time. Also during the 1930s, pyrophyllite was first used in kilncar furniture in the United States. Canada was another early entrant in the pyrophyllite business. Mining at the Foxtrap deposit on the Avalon Peninsula of Newfoundland began in 1904, with ore shipped to the United States. Production from this deposit was mostly sporadic in the ensuing years until 1956 when mining began for shipment and captive use in US tile manufacture. This production has remained continuous and still essentially captive to the present. The Foxtrap deposit is currently the sole commercial source of pyrophyllite in Canada.

Jan 1, 1994

By William P. Diamond

Ventilation has long been the primary means of controlling methane emissions in underground coal mines. However, as mining has progressed into gassier areas of U.S. coal basins, supplemental means of methane control have become of interest, if not a necessity, for continued safe and productive mining operations. This paper describes the history and technology of methane drainage in the United States and other countries. The methane drainage technology developed in European countries is a valuable resource since their longer history of mining has already forced mine operators to deal with methane emission problems only now being experienced in the United States. Methods for assessing the need for methane drainage and the data required for planning and implementing an appropriate system are reviewed. The effectiveness of the various technologies for reducing methane emissions underground and/or the in-place gas content of individual coalbeds is illustrated with case studies. In addition to the safety and productivity gains to be realized from methane drainage systems, the potential for commercialization of coalbed methane is discussed.

Jan 1, 1994

By A. A. Campoli

A stress control design strategy was developed to minimize the explosive failure of highly stressed pillars, during room-and-pillar retreat mining conducted between stiff immediate roof-and-floor strata. A confined core coal pillar strength model was based on in-mine geotechnical evaluations of successful room-and-pillar and longwall bump control designs. Tributary area and linear shear angle approaches were used to estimate development and gob side abutment pillar loads for supercritical section widths. Subcritical width sections separated by barrier pillars to control stress within total extraction panels were optimized with the boundary element program MULSIM/NL.

Jan 1, 1994

By Francis D. Leathers

Four friction pile load test programs, including 23 tension tests and 9 compression tests, have been performed as part of the Central Artery/Tunnel Project in Boston, Massachusetts. The tests, performed on both precast, prestressed concrete (PPC) piles and steel piles, yielded the following adhesion values: [Soil Type Clay Clay Glacial Till Interbedded Sand and Clay Interbedded Sand and Clay Pile Type PPC Steel Steel Steel PPC Adhesion (psf) 610 to 1,200 230 to 900 220 to 550 680 1,280 ] The adhesion appears to be affected by differences in pile material type, with PPC piles having higher adhesion than steel piles. However, part of the apparent difference for the clay may be due to differences in time between driving and testing. The significant range of test data means that the need for site specific testing to determine or verify design values of adhesion should be considered during design. Creep rates at loads near failure ranged from about 0.02 to 0.18 inches per log cycle of time, with most values in the range of about 0.04 to 0.08 inches per log cycle of time.

Jan 1, 1994

By Thompson M

The humble gabion basket is to mine development what the light bulb and safety pin are to eir-ryday life. Gabions provide a flexible, easy to assemble and cost efficient solution for "101" mine and civil engineering development applications.In some instances gabion baskets are still efficiently in use after many years of faithful, maintenance-free service. In other situations, the baskets have been demolished or made redundant within days, either having served their temporary usefulness or negligently destroyed by the operator of heavy equipment. Either way, the gabion basket must surely rate among the top 10 cost efficient engineering construction materials.

Jan 1, 1994

By Mark A. Williams

"This paper was originally intended to be a presentation of a case study of two surface bituminouscoal mines in the southern Appalachian coal fields located within five miles of each other. These mines were nearly identical in every aspect from geologic setting to equipment application. Althoughrepresentatives from each mine desired to participate in the preparation of this paper through support in providing background information and in review and editing, it was later concluded that, due to the environmental sensitivity associated with each mine, it may not have been a good decision to present this case study in a public forum."

Jan 1, 1994

By Elliot Schwartz, Julian Szekely

"In this paper we describe an experiment that was recently performed on the IML-2 Space Shuttle mission in which the thermophysical properties of molten metals were measured using electromagnetic levitation. In the planning of these experiments calculations had to be performed to predict the levitation and stirring forces, heating rates, sample deformation, and internal flows within the sample. These predictive calculations were essential for both the planning of the experiments and for the re-planning of experimental runs during the actual Space Shuttle mission.Introduction""Materials Processing in the Computer Age"" involves the use of mathematical modeling to obtain a quantitative understanding of the phenomena that govern materials processing operations. Microgravity, or space shuttle experimentation represents a specific case in point here; the very high cost of the space shuttle flights, the very limited flight opportunities that are available, and the tight resources aboard a shuttle clearly mandate that these experiments be very precisely planned and that all possible opportunities for mathematical modeling be fully exploited.The purpose of this paper is to present the results of calculations performed for the planning of a space shuttle experiment involving electromagnetic levitation and wherever possible present a comparison of the computational predictions with both experimental measurements and asymptotic analyses. Finally we shall seek to discuss the practical implications of both the computational methodologies and the potential experimental findings."

Jan 1, 1994

By D T. Froedge

The latest development in vibration measurement equipment involves small microcomputer operated micro-sized seismographs. As the result of this there has been an explosion of the data generated by these systems. For example: ten micro-seismographs taking ten shots generate over 2.5 megabytes of data.

Jan 1, 1994

By Stig O. Olofsson

The problem of overbreak in underground construction and mining is normally approached by a variety of smooth blasting methods. Numerous small diameter, low velocity explosives have been developed specifically for blasting the contour line. Increased mechanization in rock excavation has led to the development of several methods of mechanical explosive loading. A new mechanically loaded smooth blasting explosive was developed in Sweden . However, several limitations were realised, which after several trials resulted in a hybrid smooth blasting method, The Suaer Cautious Contour Blasting Method which will be discussed in this paper.

Jan 1, 1994

In line with DML Resources continual forward management policies, the Roscommon Quarry operation has recently installed and commissioned a Nordberg 7 ft Symons cone crusher and a HP 300 cone crusher. Both machines have enhanced the production capabilities and quality control of the Roscommon comminuition circuit and they will provide efficient and reliable crushing well into the next century.

Jan 1, 1994