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By C. Daniel Kealy

Dissolved and suspended solids are present in the free water of tailings ponds. This Bureau of Mines study was designed to identify the influences of the slime zone in preventing these solids from reaching the environment outside the tailings pond. The finite-element method was used to determine the rate of discharge of subsurface water from the Van Stone tailings pond in northern Washington. The slime zone was sampled and tested for the first time, and results were interpreted and incorporated into the mathematical model. Computer results were verified by installing and monitoring piezometers in the field and by a simulated (16- by 1/2- by 3 foot) laboratory model. Output from the numerical model defined critical seepage zones and revealed that proper pond design and maintenance can reduce pond seepage losses to a minimum. Minimization of seepage requires maintaining the pond water level over the slime zone. Sufficient physical, chemical, and limnological data were collected and analyzed to conclude that the only realistic reflection of synergistic effects is obtained by study of the indigenous biota in combination with quantitative chemical and physical data. Proper planning and management of the milling and waste disposal operations are the key to minimal pollution.

Jan 1, 1974

By Z. J. Fink

Ultraviolet-visible and infrared emission spectra from propagating methane-coal-dust-inhibitor mixtures have been obtained in a 0.2-by 0.2¬by 5.3-m vertical duct over a range of flame speeds from 2 to 100 m/sec. Results serve as a basis for the design and evaluation of thermal radiation detectors for triggered barriers that suppress ongoing mine explosions. Of particular significance is the large continua superimposed on the methane-air spectra when small amounts of coal dust are present and the variation of emissivity with infrared (IR) wavelength in dust flames. In conjunction with the spectral measurements, studies of flame speed, particle size, gas sampling plus thermodynamics, and dust sampling are presented and discussed in order to gain insight into the more fundamental aspects of propagating explosions. Sampling results have shown that only a near-stoichiometric amount of dust is consumed in the flames studied even though initial concentrations are five times stoichiometric. Difficulty in propagating coal-dust inhibitor flames of realistic mine characteristics in a cold-walled laboratory duct has been encountered. A simplified analysis of the flame zone utilizing spectral and sampling results indicates that the stability of slowly propagating flames is more dependent upon thermal radiation than upon convection losses to the walls. It is predicted that thermal radiation losses will make any measurements of coal dust burning velocities, "quenching diameters," or flammability limits more apparatus dependent than those corresponding to gaseous fuels.

Jan 1, 1974

By Eugene H. Skinner

This Bureau of Mines report describes the fieldwork and subsequent analysis to determine physical properties, stress distribution, and several aspects of rock behavior as a necessary evaluation for a typical mine opening. All work was done at a test site on the 3300 level, Crescent mine, Coeur d'Alene mining district, Idaho. Free field stress beyond the influence of the opening was also determined. Conventional overcore technique with the three-component borehole deformation gage developed by the Bureau of Mines was used in three drill holes. Three field verification tests were performed using a gage newly developed by the Spokane Mining Research Center in an approach herein termed "initial deformation method." Use of this method validated that aspect of overcore theory which predicts that similar deformation effect occurs in the wall rock around the perimeter of an opening in rock under stress. Also described are all drilling procedures and performances. Physical property determinations were made on rock samples obtained from the three overcore drill holes. Twelve physical properties with a total of [532] values were obtained at various drill hole orientations and depths. Exhaustive statistical tests were utilized in the analysis of these physical properties. Further elaborated are statistical inferences based on these analyses. Extensive analysis and interpretation of Crescent mine geology are also described.

Jan 1, 1974

By Richard A. Busch

Inadequate engineering design criteria for coal refuse embankments has allowed hazardous impoundment structures in coal mining areas to be created. A necessary first step to develop adequate design criteria is the determina¬tion of basic, respresentative physical property data on the materials that constitute typical refuse embankments. An extensive field and laboratory program was undertaken by the Federal Bureau of Mines. Much physical property data was generated. Additonal petrographic analysis and large scale triaxial compression testing was performed by others. The data presented here should aid in establishing design parameters for coal refuse embankments

Jan 1, 1974

By E. S. Shedd

Amenability studies were conducted by the Federal Bureau of Mines on an electrooxidation technique for the extraction of mercury from cinnabar ores, particularly those that are too low in grade to be furnaced or retorted economically. Oxidation was accomplished by electrolysis of the ore while slurried with brine. Mercury was dissolved through the formation of the soluble tetrachloro mercury complex, HgC142-. Mercury extractions ranged from 90 to 98 percent in 4 to 6 hours of processing time when tests were made on eight different types of cinnabar ores containing from 0.7 to 18 pounds mercury per ton ore. Salt concentration was varied from 4 to 10 weight-percent depending on whether Pb02 anodes and iron cathodes were used or whether graphite was used for both electrodes. Power consumption ranged from 17 to 64 kilowatt-hours per ton of ore treated. Ninety-nine percent of the mercury was recovered from pregnant solutions by precipitation on an active metal such as zinc, followed by distillation of the resulting amalgam at 600° C.

Jan 1, 1975

By Michael L. Boucher

Copper and nickel sulfides occurring in the Duluth Complex of northern Minnesota were examined at the Bureau of Mines, A microscopic study was undertaken to determine the mineralogy and paragenesis of the ore minerals. Eighty-two samples were taken from one deep diamond drill core located near Babbitt, Minn. Modal analyses are presented for the Duluth Complex rocks and for the are minerals in the major mineralized zone. The major sulfide minerals are chalcopyrite, cubanite, pyrrhotite, troilite, and pentlandite. Results of this investigation suggest that the mineralization is related to the structural features of the enclosing rocks: pores, open fractures, and cavities. The pyrrhotite-troilite-pentlandite assemblage is believed to have formed from an immiscible sulfide melt, probably associated with the troctolitic rocks. Most of it settled to the very porous base of the Duluth Complex, and to the other porous zones near xenoliths; small portions were trapped higher in the section. A later introduction of a copper-rich sulfide melt replaced some of the pyrrhotite-troilite and oxides, and filled in the remaining open spaces and fractures in the Duluth Complex and those of the adjacent footwall rock.

Jan 1, 1975

By Joan T. May

The Bureau of Mines conducted laboratory tests to evaluate the production of high-purity H3P04 by HCl digestion and solvent extraction. Both batch and bench-scale continuous tests were made. Western phosphate rock concentrates were acidulated with HCI, and the digestion liquors were processed by solvent extraction. Phosphoric acid was extracted with isoamyl alcohol and recovered from the organic extract by contact with an NH4F solution. This solution was fractionally distilled to yield high-purity H3P04. The raffinate from solvent extraction was treated with lime to precipitate CaF2, which was subjected to steam pyrolysis to generate HF. This method was successful in recovering 95 pet of the phosphate and 80 pct of the fluoride contained in the concentrates.

Jan 1, 1976

By Michael J. Beus

This Bureau of Mines report describes a tunnel stress relaxation gage (TSR) developed to measure initial radial displacement around full-sized underground openings. The TSR technique was shown to be a valid concept in previous field verification tests. Sensitivity has been improved by employing a titanium alloy cantilever in the transducer head, which also permits a deeper sensor location. Use of improved fabrication methods such as stainless steel bellows and sputtering techniques and use of an environmental chamber for testing greatly increased overall reliability. A miniature data acquisition system (DAS) was interfaced directly to the transducer for increased versatility and containment entirely within a borehole. The present TSR system is suitable for use around full-size underground excavations, particularly machine-bored openings. Field evaluation of the improved instrumentation verified the design goals.

Jan 1, 1978

By Joan T. May

Federal Bureau of Mines studies showed that some organic amine hydrochlorides can be used as dehydrating agents for producing anhydrous magnesium chloride from hydrates and brines. Laboratory-scale tests showed that double salts are formed by reacting 35 percent magnesium chloride brine or spray-dried magnesium chloride with pyridine hydrochloride. Heating decomposed these double salts to anhydrous magnesium chloride and recycle pyridine hydrochloride. Pyridine hydrochloride also chlorinated any magnesium oxide in the spray-dried magnesium chloride. The anhydrous magnesium chloride obtained by the method described contained less than 0.8 percent oxygen. More than 98 percent of the organic amine hydrochloride was recovered.

Jan 1, 1978

By B. T. Brady

Recent theoretical, experimental, and field studies conducted by the Bureau of Mines suggest that rock failures may be predicted and, in some instances, controlled. Theoretical studies that were later corroborated by laboratory and field studies predict that a seismic anomaly will precede rock bursts and/or roof falls in mines. The seismic anomaly is predicted to consist of an increase in the number of seismic events occurring in the immediate vicinity where the failure 1s nucleated. This increase will then be followed by a dramatic decrease of seismicity in a broad region that surrounds the location of the impending failure. The dimensions of this region allow a preliminary estimate of the time to failure (measured from the time the seismicity increase began) as well as an estimate of the energy that will be released at the instant of failure. Field observations indicating that this predicted behavior does precede rock bursts and a roof fall are presented in this report. Implications of results to the problem of failure control in mines that experience massive rock failures are discussed.

Jan 1, 1978

By L. A. Neumeier

The Bureau of Mines investigated hot-rolling and forging characteristics of experimental ductile iron castings, both sand and permanent-mold, made with charges containing up to 70 pct foundry pig iron and 95 pct steelmaking pig iron. Between 1,550° and 1,950° F, most castings could be rolled to 90-pct reduction or forged to 70-pct reduction without serious cracking. Charge and composition have less bearing on workability than on subsequent properties. Permanent mold castings could be worked as readily as sand castings at 1,750° and 1,950° F. Plasticity improved with temperature. Small billets were also forged cold to 50-pct reduction without cracking. With equivalent nodularity, composition affects properties of wrought materials by altering matrix structure and strength. Properties vary with reduction and improve with increasing working temperature. Rolled material has high strength and anisotropy, and low ductility, particularly in the trans-verse direction. Annealing reduces strength and improves ductility, but anisotropy persists. At 70-pct reduction, impact resistance in the longitudinal direction is about twice that in the transverse. Annealing roughly doubles impact resistance. Deformation enhances damping capacity. The feasibility of die-forging and bar-rolling of ductile iron was evaluated in trial tests conducted under a Bureau contract. Although workability and ductility of ductile iron are inferior to those of steel, more advantage could be taken of ductile iron's plasticity to work rough shapes to final dimensions.

Jan 1, 1980

By S. D. Hill

To help insure the continued viability of the minerals and materials sector of the U.S. economy, the Bureau of Mines is conducting research and disseminating technology that will result in more efficient minerals extraction. As part of this effort, a process is being investigated that involves an aqueous chlorine-oxygen leaching procedure to treat complex sulfide concentrates to produce ZnCl2. Subsequent fused-salt electrolysis of the ZnCI2 produces high-purity zinc metal. Previous reports described preliminary, small-scale research on the chlorine-oxygen leaching system and fused-salt electrolysis of ZnCl2. This report discusses the details of design, construction, and longterm, continuous operation of both monopolar and bipolar fused-salt cells. The effects of temperature, electrode gap, current density, electrolyte composition, and electrode configuration on current efficiency and energy consumption were determined for a ZnCl2-KC1-NaCl electrolyte system. Zinc metal was produced at the rate of about 50 lb/day in a monopolar cell which was operated continuously for 60 days with current efficiencies from 85.8 to 98.6 pct and an average power consumption of 2.1 kwhr/lb. Bipolar cells with several different electrode configurations were operated for 90 days. A current efficiency of about 70 pct and power consumption of about 1.7 kwhr/lb of zinc were achieved using a three-electrode-pair, bipolar assembly with a chlorine gas lift pump to circulate electrolyte.

Jan 1, 1981

By B. W. Madsen

To help maintain an adequate supply of minerals to meet national economic and strategic needs, the Bureau of Mines developed a mathematical model that describes acidic ferric sulfate leaching of copper from sulfide ores. The leaching model can aid in maximizing minerals and metals recovery from primary sources by giving operators and management a better understanding of the copper leaching process. This will aid in improving dump leaching operations. The model is based on a steady-state approximation of the continuity equation for diffusion of ferric ions in the rock pores and the intrinsic leaching kinetics of the various sulfide mineral particles. Ore characteristics included in the model were ore particle-size distribution, particle shape, grade, mineral content, mineral particle size, porosity, and tortuosity. The continuity equation was used with ferric ion concentration gradients and a fixed value for the diffusion coefficient. Except for effective diffusivity, each of these factors was either measured experimentally or estimated from theoretical considerations. The effective diffusivities were determined by fitting calculated leaching curves with experimental leaching data. Vertical variations in leach solution composition and temperature within a dump are not considered in this model. The model accurately predicted copper extractions for several large-scale tests during nearly 500 days of leaching.

Jan 1, 1981

By John C. Nigro

This Bureau of Mines report summarizes the performance characteristics of a 30-day around-the-clock gasification-pelletizing test conducted in October and November of 1980 with North Dakota Indianhead lignite. Gasification was conducted in a commercial-size, 6.5-it-diam, Single-stage, fixed-bed, atmospheric pressure producer with a rated capacity of about 30 million Btu/hr. Iron oxide pellets made from a commercial hematite concentrate were fired with the low-Btu gas in a 2.8-ft-diam by 35-ft-long pilot plant rotary kiln at a rate of 900 lb of pellets per hour. Gasifier operations at fuel feed rates up to 3 tons of lignite per hour and hematite pellet induration with raw 160-Btu/std ft3 lignite gas are described.

Jan 1, 1982

By E. G. Baglin

As part of an effort to decrease U.S. dependence on imports of critical and strategic metals, the Bureau of Mines investigated three leaching methods for extracting the base metals and recovering platinum-group metals (PGM) from matte prepared from Stillwater Complex flotation concentrates. Because of a limited supply of natural material, synthetic matte of composition similar to matte prepared from natural concentrates was used to devise the extraction sequences. The validity of the sequences was verified with matte prepared from Stillwater concentrates. In two-stage matte leaching, first-stage H2S04 leaching extracted 99 pct of the nickel and iron from the matte but negligible amounts of copper and PGM. Second-stage oxidative leaching with Fe2(S04)3 or FeC13 solubilized more than 98 pct of the copper and no precious metals. Sequential leaching, in which acid and oxidizing lixiviants were added sequentially to the matte without an intervening filtration step, extracted 99 pct of the Fe, Ni, and Cu. A roasting-leaching technique, in which the residue from first-stage leaching was roasted between 360° and 500° C before a second leaching with H2S04, solubilized 98 pct of the copper. The three leaching methods yielded high-grade PGM residues containing more than 98 pct of the PGM in the matte.

Jan 1, 1982

By A. E. Raddatz

The Bureau of Mines is investigating methods for recovering tungsten from domestic resources. A calcine-quench-leach (CQL) technique was developed for the extraction of tungsten from the Golconda, Nev., hot springs ores. The deposit contains disseminated tungsten that cannot be beneficiated by conventional techniques and must be treated by hydro-metallurgical methods. The CQL procedure consists of calcining the ore at 900° C for 3 hours, quenching in a solution containing 1.5 parts of Na2C03 and 1.5 parts of NaOH per part of WO3 in the ore and at a solution-to-ore ratio of 3 to 1, leaching at 200° C and at 250 psig for 3 hours, and filtering and washing the residue. A series of closed-circuit batch tests showed that 92 pct of the tungsten was extracted from a sample containing 2.32 wt-pct W03. The pregnant solution contained 11 g/l W03.

Jan 1, 1982

By Slavoljub D. Maksimovic

The Bureau of Mines, through a memorandum of agreement with the State of Ohio, tested a method of constructing seals in abandoned mine openings in Ohio by means of pneumatic stowing of crushed limestone and gravel with sand. A total of five openings and one shaft were back-filled. Pneumatic stowing uses compressed air to convey material through a pipeline and into the mine opening. The stowing equipment consists of a power supply, a blower, a feeder to inject the material into the pipeline through an airlock, and a nozzle for directing the placement. Material is ejected from the nozzle at high velocity, creating a high-compaction fill upon impact. Well-graded aggregate up to 2 inches in diameter and having sufficient fines is used as fill. The stowing method is safer and faster than conventional methods, is cost competitive, prevents trespass into abandoned mine openings, and eliminates or reduces the exposure of workers to possible hazards since the discharge nozzle can be kept at the mouth of the opening. The equipment is mobile, and, with some modification, the technique could be widely used for sealing abandoned and active mine openings, even in remote locations and during severe weather conditions.

Jan 1, 1982

By Theodore L. Turner

This Bureau of Mines report describes calcination of kaolinitic clay in a direct-fired 2-1/2- by 24-ft rotary kiln at 750° and 775° C. Methods for preparing kaolin feed materials and characterization of calcined products are discussed. Approximately 99 pct of the alumina in a typical eastern Georgia kaolin was soluble in HC1 after calcination at either 750° or 775° C.

Jan 1, 1982

By David A. Larson

Preliminary laboratory experiments have been conducted by the Bureau of Mines to define the influence of bit geometry on methane ignitions as a step toward establishing safer mining-machine operating parameters. The experimental system was designed to simulate the operation of a continuous mining machine, using a drum-type cutterhead of normal diameter with a narrow cross section, permitting full-diameter drum cutting tests to be run on material representative of sandstone lenses (or inclusions) in coal seams. Two conical bit types were tested at shallow depths of cut with three drum speeds. Bits that rotated in the mounting block during testing did not produce ignitions. The ignition frequency for used bits was three to four times greater than for new bits at the same kerf depth.

Jan 1, 1983

By Dwight L. Sawyer

To provide technology that can help decrease the dependence of the U.S. aluminum industry on imported bauxite, the main ore of aluminum, the Bureau of Mines is investigating the extraction of aluminum from abundant domestic reserves of kaolinitic clay. Miniplant studies of the continuous leaching of calcined kaolin with boiling 25-pct HC1 acid resulted in a 93- to 99-pct extraction of the acid-soluble alumina in the calcined kaolin feed. Data are presented for an acid leaching study carried out in three or four continuously stirred tank reactors (CSTR) in series, feed rates of 100 to 250 lb/hr of calcined kaolin, and total nominal residence times of 0.7 to 2.3 hr. A material balance for a 176-lb/hr calcined kaolin feed rate in a circuit consisting of three reactors, four classifiers, and five thickeners is given. Data provide detailed compositional and physical information for calcined kaolin, process liquors, and acid-leached residue solids.

Jan 1, 1983