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By B. W. Madsen

As part of a program to maintain an adequate supply of minerals and metals to meet national economic and strategic needs, the Bureau of Mines conducted research to determine the diffusion coefficients for ferric ions in synthetic copper leach solutions. Determination of ferric ion diffusion coefficients in typical dump leach solutions is necessary for predicting leaching rates of copper from large-scale leaching operations and for optimizing concentrations of ferric iron in solutions to maximize leaching efficiency. Derivative chronopotentiometry, an electroanalytical technique, was used to determine ferric ion diffusion coefficients. The diffusion coefficient decreased dramatically with increasing concentration of iron in solution. An empirical model was used to relate the ferric ion diffusion coefficient to the total amount of sulfate in solution. Measuring the diffusion coefficient dependence on temperature yielded an activation energy of 5.5 kcal/mole of ferric ion. Activity coefficients of ferric ions as a function of concentration were calculated from diffusion coefficient data.

Jan 1, 1981

Provide an effective method for "soft" soldering aluminum and aluminum alloys using conventional tin-lead solder alloys and flukes. The Problem In the past, it was virtually impossible to solder aluminum and aluminum alloys using standard tin-lead soldering systems (solder and flux) due to the presence of an aluminum oxide surface film which forms instantly on aluminum and aluminum alloys when these are exposed to air. The tenacious and stable oxide film enables aluminum-base materials to maintain their bright luster. But the film also prevents the required wetting and spreading of solder on the substrate, causing the loss of adhesion between the solder and the substrate. In addition, the heat produced during soldering increases

Jan 1, 1983

Studies on coal mine drainage sludge densification have led to the following conclusions: 1. Coal mine waters containing iron principally in the ferrous (Fea+) state can be treated by a modification of the commonly practiced lime neutralization process to yield a ferromagnetic sludge. The sludge, presumably composed in large part of a hydrated ferrosoferric oxide (Fe304.xH20), is much denser and faster settling than the ordinary "yellowboy" sludge obtained by lime neutralization and aeration at ambient temperatures. 2. The magnetic sludge preparation technique involves (quantitative) precipitation of iron (largely as Fe(OH)2) by the addition of hydrated lime to a pH of 8.5, separation of the resulting sludge from the aqueous phase, and heating of the sludge concentrate to at least 80 C (176 F), preferably higher, followed by mild aeration. 3. Magnesium, present as Mg2 in most coal mine drainage waters, inhibits the formation of the magnetic sludge. This inhibition can be adequately minimized by keeping the pH below 9.6 during lime addition (thus avoiding the coprecipitation of Mg(OH)2) and by separating the sludge from the bulk of the aqueous phase before the heating step, as indicated in (2) above. 4. Aluminum, commonly present in coal mine drainage waters, also inhibits the formation of the magnetic sludge. This inhibition is of practical significance when the molar ratio of aluminum/total iron is greater than 0.18. Below this value, sludges are still appreciably magnetic, but are bulkier and slower settling than those obtained when aluminum is absent. Unlike magnesium inhibition, aluminum inhibition cannot be minimized by the scheme indicated above, since aluminum precipitates as Al(OH)3 near pH 4 and remains dispersed within the sludge. 5. The limitation on aluminum content is probably the most serious restriction affecting the feasibility of the magnetic sludge process as presently conceived. Nevertheless, a limited review of available water quality data has indicated that, in terms of relative acid and iron loadings, a significant number of major coal mine discharges in the eastern Ohio River basin may be amenable to treatment by a magnetic sludge process. 6. Data from tests on the use of magnetic seeding materials indicate that seeding did not enhance the formation of a magnetic sludge under the experimental conditions employed.

Jan 1, 1971

By Linda L. Chasko, Larry D. Stowinsky, Ronald S. Conti

Mine operators often rely on mine rescue teams to save lives during an underground emergency such as an underground fire, explosion or roof fall. It is extremely important that team members are provided with adequate exploration equipment and that training simulations are conducted in a realistic manner. A series of mine rescue training exercises was developed, conducted and evaluated by the National Institute for Occupational Safety and Health (NIOSH) in cooperation with the Pennsylvania Department of Environmental Protection, Bureau of Deep Mine Safety. The exercises were conducted at NIOSH’s Lake Lynn Laboratory during 1995 to 1998 and resulted in improved technology and training for mine rescue teams. For example, existing technologies were identified to help rescue teams during exploration. These included chemical light sticks to identify team members and mark crosscuts and mine materials, strobe lights for mapping out escape ways, and a helmet mounted thermal imaging system to see through smoke. A hands-free communication system showed potential for enhanced communications between team members and the fresh air base. A new high-visibility team lifeline that allows for flexibility of movement between team members was developed. A positive-pressure inflatable escape device (IED) was used to isolate the “hazardous” environment from fresh air and allow rescue team members to traverse through. An inflatable feed-tube partition that can rapidly block large openings such as underground passageways and simultaneously provide a feed-tube for high-expansion foam generators was also deployed for several simulations. During the simulations, mine rescue team members donned self-contained breathing apparatuses (SCBA) and traversed more than 305-m of mine passageways filled with nontoxic smoke. Visibility ranged from 0.3 to 0.9-m. In one area of the mine, a kerosene heater was used to simulate a fire and reduce the oxygen concentration. In another area, a 1.5 pct methane zone was established. The team members searched for "victims,” mapped the passageways, built temporary stoppings and ventilated the smoke-filled entries. The teams indicated that the simulations were challenging and very informative.

To improve a miner's chance of survival during an emergency by providing immediately avail-able breathable air and protection from toxic gases until a longer-duration breathing apparatus, stored nearby, can be reached. Approach: A belt-carried apparatus which can provide a closed-circuit atmosphere for ten minutes breathing has been developed under a Bureau of Mines contract. How It Works: Water vapor and carbon dioxide in the user's exhaled breath are removed, and oxygen is supplied, by chemical reactions. When the user exhales into the mouthpiece, water vapor in his breath reacts with potassium superoxide (KO2) stored In the canister to produce oxygen. The other product of this reaction (KOH) reacts with carbon dioxide and removes it from the air. The oxygen-enriched air then flows from the canister into two breathing bags. When user inhales through the mouth, that air is drawn out of the bags, makes a second pass through the chemical-containing canister, and flows into the mouthpiece tube. A nose clip is worn to seal off the nasal passages.

Jan 1, 1975

To increase awareness of float coal dust explosion hazards in the mining industry.

Jan 4, 2006

Objective Develop field measurement and computer modeling methods to predict the potential for hang-ups and structural failures in underground mine ore paws. Background Analysis of Mine Safety and Health Administration (MSHA) accident statistics has identified ore pass hazards as a significant safety problem in underground metal mines in the United Stales. Recent ore pass failures have underlined the lack or ore pass design methods ant1 standards available to both MSHA and mine engineers. Injury and fatality data for the 20-ycar period between 1975 and 1095 show that nearly 75% of the injuries were directly or indirectly related to pulling or freeing ore pass chutes, the use of hand tools, falls or broken rock, and structural failures or chutes or gates and ore pass walls.

Feb 1, 1998

Crosson and Peters treat the errors that result in miner location due to errors in the overburden earth model used for computing location. A parallel effort by J. Powell of PMSRC is discussed here, where the location method used is that of the Westinghouse location program - "Miner". This location program was tested by Powell by using arrival times generated from the overburden earth model of Table l* rounded to the nearest millisecond. Location computations were then made using 3 geophones at a time. The average location is tabulated for all geophone triplets except when 3 geophones are in line. Geophone arrays were as shown in Tables 2 and 3. The manner in which the test was done is illustrated in Figure 1. I. SUMMARY OF RESULTS The arrival time differences, based on the Table 1 earth model, together with geophone locations based on the array geometries of Tables 2 and 3, were entered into the computer, together with a stated depth of 700 feet and an estimated overburden seismic velocity of 10,000 feet per second. These parameter values were processed by the location program - "Miner". Figure 2 illustrates the interpretation of the plots and data. The tabular data and plots of Table 4 and Figures 3, 4, and 5 illustrate the location error results obtained. These plots indicate that for sources within the array, the errors are considerably less than the measured errors obtained during field tests of the present location system. The possible reasons for this discrepancy are noted in Part Eight (Earth Models).

Jan 1, 1974

Improve transmission of data from an underground mine monitoring system to a remote, mass-data storage system. Background Instrumentation systems in underground mines must operate under environmental extremes of dust and humidity, local electromagnetic/radio frequency (EM/RF) interference fields, and potentially explosive atmospheres. During a recent roof-bolt study performed by the Bureau of Mines, it was necessary to transmit a large quantity of data to a data storage system. Conventional wire cable transmission presented several limitations which often required special electrical isolation or physical protection. Because conventional wire cable presented certain problems, the Bureau of Mines investigated alternative means of data transmission. The research investigation led to the selection of fiber optic cable for data transmission applications. The fiber optic method of data transmission offers several advantages: ? Since the transmission medium consists of light waves, it is safe to use in gassy mines. Where applicable, MSHA permissibility standards for peripheral devices must be met. ? It is lightweight and rugged. ? It can operate up to 131000 feet (4km) without repeaters and without EM/RF field interference.

Jan 1, 1986

By Edward Thomas

"HISTORYThe origin of roof bolting as a means of roof support is obscure. During the past 23 years a method was developed by the. St. Joseph Lead Co: at its mines in southeastern Missouri, ranging from occasional use of single bolts with small bearing plates to systematic networks of bolts utilizing continuous bearing plates. Officials of this company are not certain which of its employees suggested their use. Many instances of occasional use of roof bolts have come to light during the past few years in widely separated mining districts, such as in West Virginia, Alabama, Illinois, Colorado, and Wyoming bituminous coal mines, and in Pennsylvania anthracite, Lake Superior iron, and Colorado lead-zinc mines. A few of the known installations have boon in place as long as 40 years.These installations usually were made to supplement wooden timbering in mine openings whore space was constricted, although it had been reported that roof bolting was started as a systematic moans of roof support in at least three instances but was abandoned because the cost of installation was excessive. The extra expense above that of conventional timbering could not be recaptured through economies resulting from increased efficiency, such as would be gained through mechanized mining.Roof bolting was first mentioned in mining literature in an article by W. W. Weige 3/ in Engineering and Mining Journal of May 1943, in which he described the use of bolts with 4-inch channel bearing plates in mines of the St. Joseph Load Co."

Sep 1, 1950

Increase the safety of underground mine workers by minimizing hazards associated with rerailing mine cars after derailment. Background and Approach A serious operational problem in underground mines is the task of rerailing mine cars. Current rerailing practices are not only hazardous but are inefficient as well. Most methods involve pulling the derailed car back onto the track with a locomotive. This causes damage to the road bed and is not effective on curves or in situations where the car's wheels are too far from the rails. Jacks, wooden props, and pry bars are also used to raise or lower cars back onto their tracks but methods involving these tools require much strenous manual effort by mine workers, thus posing possible serious injuries. The problem is further compounded by the cramped, narrow confines of the underground mine environment which allows no space to permit use of cranes or other surface railroad rerailing techniques. The Bureau of Mines, aware of these problems, investigated improvements in current underground rerailing methods. Through a cooperative effort with Hoesch MFD, a system was designed and modified that can be easily carried into the mine by workers and quickly assembled at the derailment site. The system is hydraulically and pneumatically powered rather than reliant upon manual operation.

Jan 1, 1986

By R. Hogg

"Agglomeration processes and agglomerate characteristics are largely controlled by the forces of interaction between particles. The nature and typical magnitude of these interaction forces are evaluated relative to the external forces commonly present in agglomeration systems. The specific roles of the interaction forces in the various stages of agglomerate formation and growth and their effects on the integrity and mechanical strength of agglomerates are briefly reviewed. Because the interaction forces affect different aspects of agglomerate development in different ways, conflicting requirements can arise. Examples of such conflicts are given and used to demonstrate the importance of evaluating the effects of interaction forces etc., in the context of the overall agglomeration process and its ultimate objectives.INTRODUCTIONThe term agglomeration is generally used to refer to processes whereby discrete particles are caused, or allowed, to associate into clumps in which the individual particles retain their identity but are held together by relatively weak, usually physical forces. Various other designations are given to these processes, depending on the specific circumstances under which agglomeration occurs. The terms balling and pelletizing are often used to describe agglomeration in dry or semi-dry powders; coagulation and flocculation are used to refer to agglomeration of particles dispersed in fluids. Common to all of these cases is the fact that the formation, growth and integrity of the agglomerates depend primarily on the forces acting on and between particles. The same forces are, of course, responsible for manyaspects of the behavior of colloidal systems and their study and evaluation constitute the,basis for colloid and interface science.FORCES ACTING ON FINE PARTICLES AND AGGLOMERATES It is convenient to classify the forces acting on and between particles into two general types: external forces and interaction forces. It should he recognized, however, that a sharp distinction is not always possible.External Forces Gravity and inertial forces act on all particles and their magnitude is proportional to particle mass, i.e. they vary with the cube of particle size. Such forces are oftensignificant for large agglomerates but may be negligible for individual, fine particles.Hydrodynamic (""drag"") forces are important, for particles suspended in fluids. For very small particles, the drag force is directly proportional to size (Stokes' Law) while for very large particles or agglomerates it varies with approximately the square of size (Newton's Law). A useful procedure for estimating drag forces over a broad range of particle sizes and physical conditions has been given by Concha (1)."

Jan 1, 1989

By William A. Hoffman

In This Chapter [MSHA regulations for coal mines MSHA regulations for metal/nonmetal mines OSHA regulations for tunnel construction Types of respirators used in mines and tunnels Filter materials and filter efficiencies Donning, seal checking, and maintenance Filter service life and Respirator information resources] In many cases, engineering controls are not adequate to achieve satisfactory dust levels, so respirators must be used. This chapter explains the Federal regulations governing the use of dust respirators in mines and tunnels and describes the most common dust respirators used. Filter materials and filter efficiencies for respirators are discussed. This chapter also gives some guide-lines for respirator use and recommends sources for more dust respirator information. Respirator effectiveness in reducing dust exposure usually exceeds the effectiveness of most engineering control methods. RESPIRATOR REGULATIONS [Different regulations govern respirator use in coal mines, metal/nonmetal mines, and tunnels under construction.] Coal mines under Mine Safety and Health Administration (MSHA) jurisdiction. Coal mine operators are required to meet dust standards using only engineering control methods. Typical engineering control methods include ventilation and water sprays. Respirators are not regarded as an engineering control method, so respirators cannot be used in lieu of engineering controls.

Jan 6, 2003

By Bruce T. Olenchuk, Wils L. Cooley

Electrical grounding is essential for the safe operation of power systems. A low-impedance path to ground is necessary to prevent the possibility of dangerously high potentials in human work areas. If for any reason this ground connection becomes faulty, a serious hazard may exist. One reason for faulty ground connections is ground bed corrosion. Corrosion of electrical ground rods has plagued the power industry and appeared in coal mine power systems. This paper will investigate ground rod corrosion, its cause, and possible solutions. Included is an evaluation of various ground rods for their ability to resist corrosion under stray current conditions. -The first known study of X-it3 Rod Corrosion is also presented.

Jan 1, 1979

By Dean H. Ambrose

This paper presents an approach for representing and analyzing random motions and hazardous events in a simulated three-dimensional workplace, providing designers and analysts with a new technique for evaluating operator-machine interaction hazards in virtual environments. Technical data in this paper is based upon a project striving to reduce workers' risks from being hit by underground mining machinery in a confined space. The project's methodology includes human factors design considerations, ergonomic modeling and simulation tools, laboratory validation, and collaboration with a mining equipment manufacturer. Hazardous conditions can be analyzed in virtual environments using collision detection. By simulating an operator's random behavior and machine's appendage velocity, researchers can accurately identify hazards, and use that information to form safe design parameters for mining equipment. Analysts must be discerning with the model and not read more from the databases than what the simulation model was designed to deliver. Simulations provided an interesting approach to data gathering in that there was no need for live subjects and logistics - test sites and costs associated with experiments-became insignificant. Collisions versus speed, operators' size, and risk behaviors proved the versatility found in the data obtained from the model. Preliminary results show that response time significantly affects the number of collisions experienced by the virtual subject. Also simulation data suggests that more mishaps occur with hand-on-boom-arm risk behavior.

By M. MacLaughlin, J. Whyatt

A case study is presented that relates statistical descriptions of joint sets to the distribution of local wedge failures along the crest of a catch bench at the Yellowstone Talc Mine. The fracture sets and bench width were mapped by teams of geological engineering students from Montana Tech under the direction of Dr. Mary MacLaughlin. The students analyzed the fracture data, conducted physical property tests, and used a beta version of a NIOSH program “Bwedge” to predict the distribution of surviving bench widths. In the course of this analysis the students developed evidence of software performance issues that, unfortunately, frustrated their analysis. These have now been addressed and a full analysis completed. The analysis confirms the validity of the student mapping program and provides insight into the effects of blasting and excavation practices on the bench. It also provides a tool for exploring the pattern of bench crest failure that would result from variations in both bench geometry and blasting practices.

By Richard V. Ageton

"Everyone admits that there are more accidents in metal mines than there should be but there is much difference of opinion as to the causes of accidents, whether avoidable or unavoidable, and the amount of responsibility attaching to the miner and the mine operator, respectively. However, it seems that one of the main reasons why there are so many accidents, is that there is so little general knowledge regarding their causes and costs. Some information regarding the costs and causes of metal-mine accidents is presented in this paper.The data contained were obtained from a study of the complete accident and medical reports of two large metal-mining companies, which carry their own insurance. Path maintain hospitals with competent medical attendants. One of these companies also maintains a very efficient safety bureau, consisting of a safety engineer, with two assistants who work in connection with the medical department, and with the safety committee made up from among the miners themselves.Daring the year of 1920, ""A"" Company employed approximately 900 men, and these men worked more than 270,000 shifts. There were 373 minor and major injuries, among these 900 men, hence assuming that each injured man was hurt cut once, 41 per cent of the men who worked in this mine received some kind of time-losing injury during the year. On account of these injuries the injured men lost 3731 shifts, and thus the time lost due to injuries amounted to approximately 1.4 per cent of the total number of shifts worked,"

Oct 1, 1923

Impermeable geologic faults in the coal seam can cause intermittent production problems or can cause unexpected amounts of water or gas to issue from degasification boreholes. These faults also can impact methane emissions into the mine workings, especially if they hinder proper and effective degasification of the coal bed. They may also act as barriers for methane flow in the coal seam. Although this might seem beneficial for advancing mine workings, faulting may also cause gas pressure buildups and result in compartmentalization of the gassy regions from which large quantities of water and methane may rush into mine workings. This study uses reservoir simulations to illustrate the effects of impermeable faults, with and without throws, on the production performance of vertical and horizontal degasification boreholes. These boreholes were drilled from the surface to intercept the coal layer and fault and were assumed to produce methane two years prior to mining of the coal seam. Longwall advances and face position related emissions and reservoir properties were characterized using sector definitions along the path of the panel grids. This work numerically evaluates water and gas productions of each borehole and presents the effects and the impacts of impermeable faults on methane emissions due to an advancing coal face. The results can be used to understand the effects of impermeable faults on borehole productions and face emissions due to these coal seam anomalies.

Jan 1, 2008

Develop an environmentally feasible method of mining shallow oil sands without removing overburden. Approach Oil sands are extracted through a single borehole by cutting into the sands around the borehole with a high pressure water jet, and pumping the resulting slurry to the surface. Although oil can be extracted from shallow fields by open-pit mining methods, this type of mining may create significant environmental impacts, including; (1) disruption of the surface, (2) accumulation of waste rock piles, (3) accumulation of tailings, (4) damage to the ground water quality, and (5) surface water pollution. The borehole mining system developed and successfully field tested by the Bureau of Mines offers a method for extracting oil from oil sand with minimal disturbance to environmental quality. (For examples of other applications of borehole mining, see Technology News Nos. 95, 63 56, and 48.) How It Works Prior to the start of mining operations, baseline conditions for ground subsidence and ground water quality are established at the test site so that the degree of subsidence and changes in ground water quality can later be determined. Oil sands mining is conducted using the Bureau of Mines borehole mining system. The borehole mining tool consists of a 12-inch-diameter pipe string and accessories capped with a three passage swivel terminated with a mining section. The mining section has an auger at the bottom. Four slurry inlet holes and an eductor are located above the auger, and a single cutting nozzle is located near the top of the mining section. The tool generates a high velocity water jet that erodes and slurrifies ores. The slurry is drawn into the inlet of the eductor which lifts the slurry to the surface where it is deposited into a slurry discharge sump. To detect evidence of subsidence, surveys of the land surface are made at regular intervals during, and until 30 days after, the termination of the mining operations. Samples of ground water from the borehole and two adjacent monitor holes are taken on alternate days during the mining operations, and are later analyzed to determine if any ground water contamination has occurred.

Jan 1, 1981

By M. A. Trevits, S. W. Lambert

In this Bureau of Mines investigation, production was monitored for 1 year at over 30 coalbed gas-drainage boreholes located in Alabama, Pennsylvania, and West Virginia. Results indicate that the quality of data gathered from such wells can be improved greatly if potential problems are anticipated and prevented in the early stages of well production. Major water-monitoring problems include solids buildup, freezing, the presence of gas in surface waterlines, and improper pumping interval settings. Such problems may be avoided by incorporating in the original well design waterline filters, sand screens, separator tanks, and systems to automatically control pumping intervals. Problems related to measurement of coalbed gas flow include large quantities of water vapor contained in the gas, especially during winter months; freezing and subsequent obstruction of flow; sudden, uncontrolled release of gas pressure; and solids buildup in metering equipment. The installation of commercially available items, such as filters, separators, and insulation, and the thoughtful application of a basic knowledge of coalbed gas reservoir characteristics will prevent most production-monitoring problems.

Jan 1, 1978