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By Winton Gale, David Oyler, Jinsheng Chen, Christopher Mark

The National Institute for Occupational Safety and Health’s (NIOSH) Pittsburgh Research Laboratory (PRL), RAG Pennsylvania and Strata Control Technologies of Australia have collaborated to conduct an extensive study of roof bolt strata interaction at the Emerald mine in Southwestern Pennsylvania. The primary goal of the project was to obtain detailed data on the interaction between the mine roof and the support elements for use in modeling studies. The study site was a longwall tailgate subjected to high horizontal stress. Three arrays of instruments were installed at the site, one in the tailgate entry and two in an adjacent crosscut. Pumpable concrete cribs were present in the tailgate array, and cable bolts were installed in one of the crosscut arrays. The instruments included mechanical and sonic extensometers for measuring roof movement, instrumented roof bolts, and three-dimensional roof stress cells. The study was ultimately successful in determining the magnitude of the horizontal stress concentration, the height of roof failure and the roof failure sequence, and the loading history of the primary roof supports.

By G. H. Bennett

A field experiment was performed in a production unit of an operating copper room and pillar mine to compare the support capabilities provided by resin and mechanical roof bolts. Resin and mechanical roof bolts were alternately installed in eight intersections in a single entry. Rock mechanics instrumentation was installed to measure roof sag, bed separation, convergence, bolt pullout, torque, and strain. Bolt cost and installation time are included. Two analyses of the test were made. The analysis of the rock mechanics data showed there was no definite difference between the two bolting systems. From a broader analysis on a mine-wide basis it was concluded that resin bolts gave better support. A critical view of the experiment is given in the appendix.

Jan 1, 1974

By Charlie Wyche

The British Solomon Islands Protectorate continued developmental work on bauxite deposits on the Islands of Rennell and Vaghena. A feasibility study was completed by Mitsui Mining & Smelting Co., Ltd., and Pacific Aluminum Ltd. (a subsidiary of Conzinc Riotinto of Australia Ltd,), and negotiations with the Government were in progress. The Government will receive a 25% share if the project is realized. It was estimated that the Islands contain 60 million tons of bauxite with an alumina content of 45% to 50%.

Jan 1, 1980

By Harold M. Smith

This report presents a complete qualitative picture of knowledge of the composition of petroleum as of April 1965. The material is presented in detai 1 on two imaginative maps--one, the Hydrocarbon Hemisphere, depicts the hydrocarbons that have been identified in petroleum; the other, the Heterogeneous Hemisphere, shows the sulfur, nitrogen, and oxygen compounds that have been found. All compounds are placed on the maps according to boiling point. The accompanying text illustrates by structural formulas the several types of hydrocarbon and nonhydrocarbon compounds identified, presents some quantitative data, and points out the possible geochemical significance of a number of the compounds. The possibilities of the Petroleum World of the future are discussed as a function of needed research.

May 1, 1965

By C. L. Brown

"INTRODUCTION The heavy loss of life from mine fires in some coal mines recently has focused attention on the importance of maintaining reliable communication systems between the active working sections of mines and the surface. A study of conditions following disasters in mines indicates that in several instances lives could have been saved if telephone communication had been available. Communication systems were not installed in some of these mines where disasters occurred, and in other mines they were installed in such a manner as to be rendered useless following a mine explosion or fire. Lives have been lost because of the inability of the rescue crews or persons di-recting the rescue to communicate with trapped men. Cases are known where many lives might have been saved had it been possible to give instructions for escaping or for location of barricades.More than 500 major disasters in which 5 or more lives have been lost have occurred in mines in the United States. The total number of lives lost in these disasters has exceeded 13,000. Some of the victims died instantly; but for many it was hours and in some instances days before death occurred. Evidence found in recovery operations following some of the disasters indi¬cates that many died needlessly because of the lack of suitable means of communication between the underground working areas and the surface.A localized gas and dust explosion in a coal mine in 1930 resulted in the death of 82 men; 2 were killed outright by the force of the explosion, 6 by a combination of burns and afterdamp, and 74 by afterdamp. About 140 men escaped or were rescued following the explosion, Of these, 119 escaped with little or no assistance, 2 were rescued promptly following the explosion, and 19 were rescued from behind a barricade. Seven bodies were re-covered from behind an ineffective barricade in another place; subsequent investigation proved that these men might have been guided to a safe location had an effective communication system been available."

Oct 1, 1946

By J. L. Holman

The Bureau of Mines is conducting research to improve technology for the recovery of strategic and critical metals, such as cobalt, nickel, and chromium, that are lost in bulk and particulate superalloy-type scrap because it has not been possible to process mixed contaminated scrap efficiently. The research approach involves melting and casting mixed superalloy scrap into soluble anodes for electrodeposition of Ni-Co alloys by controlled-potential electrolysis. The initial experimental results described in this report are from electrolytic tests us-ing alloy anodes cast from elemental nickel, cobalt, and chromium, the main constituent metals of superalloys. Baseline data and operating parameters are necessary for Ni-Co and Ni-Co-Cr alloys before detailed experiments can be conducted on the more complex superalloy scrap. This basic research assessed the effects of cathode potential, S04:CI electrolyte ratio, electrolyte pH, stirring rate, deposition time, cathode current density, and chromium concentration on cathode current efficiency, alloy deposit composition, and deposition potential at a cell temperature of 55° C.

Jan 1, 1985

By Forrest T. Moyer

The safety record of the coal-mining industry, both anthracite and bituminous, in 1966 was improved over that of 1965 in all general measures of injury experience. The improvement was more pronounced in the anthracite industry. The total of 10,679 disabling work injuries comprised 233 fatal and 10,466 nonfatal injuries, 26 and 692 fewer, respectively, than in 1965. The number of fatalities in 1966 was the lowest annual total since complete records were started in 1910. Similarly, the number of nonfatal injuries in 1966 was lower than in any year since 1930 when such data were first collected.

Jan 1, 1969

By W. A. McKinney

The segregation process consists of heating crushed oxidized or mixed oxide-sulfide copper are with a copper-volatilizing salt and carbonaceous material at about 750° C. to produce metallic copper which is recovered from the furnace calcines by conventional sulfide flotation. The Bureau of Mines made a number of bench-scale laboratory tests on two copper ores to determine the relative merits of using halogen salts, potassium chlorate, or various salt mixtures as volatilizing agents in segregation of the copper. Laboratory investigation of typical siliceous and calcareous oxidized ores revealed that sodium chloride was a better segregating agent than the other salts. Calcium chloride, magnesium chloride, sodium fluoride, or potassium chlorate gave nearly as good segregation as the sodium chloride on the siliceous ore. Segregation of the calcareous ore with calcium chloride was nearly as good as that obtained with sodium chloride, but inferior segregation resulted when magnesium chloride, sodium bromide, or potassium chlorate was employed. The use of sodium bromide or sodium iodide on the siliceous ore, and of sodium fluoride or sodium iodide on the calcareous are, gave appreciably poorer segregation than sodium chloride or the other salts. Other tests of the ores, using mixtures of sodium chloride and the other halogen salts or potassium chlorate, gave segregation approaching that obtained with sodium chloride.

Jan 1, 1962

By A. Visnapuu

Excessive noise and high vibration are inherently associated with equipment used in the mining, extraction, and processing of mineral resources. High vibration degrades structural components, often leading to catastrophic failure and loss of productivity, and excessive noise can result in permanent hearing loss. In order to foster efficient utilization of the Nation's mineral resources and minimize occupational hazards associated with mineral processing, the Bureau of Mines investigated the relationship between the microstructures of carbon and alloy steels and cast irons and their damping capacities (ability to absorb vibration). Researchers measured damping capacity and other properties and investigated the effects of carburizing, spheroidizing, and annealing. The investigators found that in carbon and alloy steels, rounded colonies of fine-grained pearlite in a ferrite matrix correlate well with low damping capacity. Steel microstructures that exhibit sharp-faceted pearlite in ferrite matrix and partially or fully spheroidized cementite in ferrite show considerably higher damping. In cast irons, the lowest damping capacity is associated with nodular graphite microstructure, and the specific damping capacity (SDC) increases as the graphite micro-structure progresses from nodular to compacted to flake. Predominant ferrite in cast irons is also associated with good damping. SDC data are presented for selected carbon and alloy steels and cast irons.

Jan 1, 1987

By H. M. Smith

The production of oil during the early development of new oil fields is usually accompanied by large quantities of natural gas. Since in most fields gas under pressure is the main source of the energy causing the oil to move through the sands into the wells and thence to the surface, coincident production of natural gas will continue as long as present-day producing methods are used. Generally the use of this gas is restricted, since markets are not readily available. Consequently, a large portion of the gas produced is often wasted by being blown into the air. The magnitude of gas waste is well brought out in the following statement by Miller: Only a few outstanding examples need be cited to show the enormous production of gas that accompanies the discovery of new sources. In April, 1927, the Ventura field produced approximately 210,000,000 cubic feet of gas a day; and during the summer of 1927 Alamitos Heights reached a peak gas production of 102,000,000 cubic feet a day; on December 1, 1928, as a result of the summer's deeper drilling in the Long Beach field, surplus gas production amounted to 125,000,000 cubic feet a day. It is estimated that in January, 1929, the Santa Fe Springs field will have a daily gas production of 387,000,000 cubic feet from the recently discovered Buckbee oil zone. Of this amount 274,000,000 cubic feet a day will be the surplus above the amount required for field and plant fuel, taken out by utility corporations, and that used in repressuring the Meyer sand which lies above the Buckbee zone. Another example of the waste of large volumes of gas is in the Turner Valley field of Canada, 6 where 250,000,000 cubic feet of gas is being burned daily in flambeaus, as there is no present outlet except at prohibitive cost.

Jan 1, 1931

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 T. A. Sullivan

The processing of sweated aluminum electronic scrap was investigated to develop methods for recovering the aluminum and concentrating the other metals, including copper, lead, gold, and silver, into a product that can be separated by known methods. Two molten-salt electrorefining processes were developed and tested. The first process utilized a three-layer refining cell with a BaCI2-NaF-AIF3 electrolyte, which operated at 750° to 850° C. The second process used an all-chloride electrolyte of NaCI-KCI-AICI3 at 750° to 800° C, with separate anode and cathode compartments. High-quality aluminum was recovered that averaged 99.8-percent pure in the three-layer cell and 99.6-percent pure in the compartment cell. Over 94 percent of the aluminum was recovered with cathode current efficiencies of approximately 90 percent in both methods. The copper, lead, tin, silver, gold, and other metals were concentrated threefold in an anode product. Separation of lead and part of the tin by liquation from this product seemed feasible. The anode product was smelted to prepare a 96-percent copper bullion that contained 690 ounces of silver and 65 ounces of gold per ton, with 98 percent recovery of these values.

Jan 1, 1972

By J. H. East

"INTRODUCTION Diesel locomotives have been used successfully in underground mines of Europe for 18 years, and much has been written on the technical details of the design of these machines and the safeguards provided by the manufacturers. The actual conditions under which' the Diesel locomotives are used have not been publicized as well and consequently are not well-known. In 1945 the writer observed numerous Diesel locomotives working underground in coal and metal mines of several European countries and was favorably impressed with the practical approach to the safe use of this- type of equipment.Recent statistics showing the number of Diesel locomotives in use are not available now because of the World War, but the extent to which this type of mine locomotive was used immediately before the war is indicated by table 1, which classifies the number of locomotives used in several countries according to the type of power, such as compressed air, Diesel, and electric.Mining conditions observed by the writer in the European countries are very different from those in most coal-mining districts of the United States. The surface plants are larger and are permanently constructed of brick or concrete; numerous coal beds are worked through one shaft; the crosscut rock tunnels or levels, driven to intersect the coal beds, are lined with brick or concrete blocks where needed instead of timber; the coal beds dip more steeply and are not as thick as in most fields of the United States."

Sep 1, 1946

By B. K. Shibler

During a research program to develop improved methods for recovering elemental sulfur and useful sulfur compounds from secondary source materials, the technical literature was searched for pertinent articles on processing methods. This report summarizes results of the literature survey and describes the more important processes that have been used or suggested for recovering sulfur and sulfur compounds from all non-Frasch sources. The bibliography presented represents a survey of the available English language literature on the subject through 1958, with particular attention focused on the period 1950 through 1958. Engineering Index and Industrial Arts Index were the principal guides used in the survey of this period. Chemical Abstracts was used to a limited extent to identify a few key foreign articles and patents. The Sulfur Symposium (4)4 published in November 1950 by Industrial and Engineering Chemistry includes a broadly representative selection of the literature up to 1949. Therefore, this reference was used extensively to locate and list pertinent articles on processing methods reported in the period prior to 1950.

Jan 1, 1962

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 Joseph A. DeCarlo

For the first time the Bureau of Mines is combining, in one report, comprehensive tabulations on both beehive and slot-type ovens. This publication presents statistical data on the number and capacity of all such coke ovens in the United States on December 31, 1957. Combining data on both types of ovens should prove helpful to those interested in keeping abreast of the latest changes in carbonizing capacity, particularly since the coke has similar properties and uses. Annual reports furnished to the Bureau of Mines by coke-oven operators shared that 78 oven-coke plants were operating in 22 States on December 31, 1957. This was a decline of one plant from December 31, 1956, as the Republic Steel Corp. took the ovens at Canton, Ohio, out of production on December 17, 1957, for dismantling and rebuilding in 1958. Total oven-coke capacity was 80,299,400 tons in 1957.

Jan 1, 1958

Combine the MSHA and OSHA versions of the HazCom Helper into one easy-to-use software tool.

Jan 6, 2007

1. Domestic Production and Use: In 1982, 13 companies operated 30 primary aluminum reduction plants, with 3 firms accounting for 55% of production. Washington, Oregon, and Montana accounted for 34% of the production; Texas, Louisiana, Missouri, and Arkansas 18%; Tennessee, Alabama, South Carolina, and North Carolina 14%; other central and eastern States 34%. Based on published producer prices, output of primary metal in 1982 was valued at over $5.5 billion. Aluminum consumption by 25,000 firms was centered in the East Central United States. Packaging accounted for an estimated 39% of domestic consumption in 1982, transportation 20%, building 14%, electrical 8%, consumer durables 8%, and other uses 11%.

Jan 1, 1983

By E. Don Dilling, W. F. Holbrook, Lloyd R. Michels, James W. Pennington, Dwight L. Harris, Wm. F. Hergert, Cyrus L. Blogett, H. A. Doerner, Ernest A. Reige

"IntroductionA process for production of magnesium by carbothermal reduction was developed at Padentheirm, Austria, by the Austro Americanische Magnesit Corporation& an independent investigation of this and other processes was started in 1937 by the Bureau of Mines at Pullman, Wash., with the cooperation of Washington State College. 10/ A preliminary study of the Radentheirm pro¬cess, as revealed by the meager information then available, demonstrated the following two major disadvantages,The use of hydrogen for shock cooling requires an enormous volume of gas - about 1,000 cubic feet for condensing each pound of metal as a pyrophoric dust which must be completely separated from this gas. Then if the gas is to be recycled for repeated use, the CO produced by the reduction reaction must be separated from the hydrogen. These separations are costly from the standpoint of equipment and operation. 11/The condensate is an impure, pyrophoric metal powder that must be purified and converted to coherent form. This is accomplished by distillation or sublimation of the metal. Distillation on a large scale involves difficulties inherent in the high boiling point (1,107° C.) and the chemical activity of the metal. To avoid these difficulties, the metal is sublimed at 600° C. and of very low pressure. This is quite easily carried out as a batch operation but is a costly procedure. A continuous sublimation process has not been accompli shed."

May 1, 1945

By John D. Sullivan, Alfred P. Towne

"In copper percolation-leaching plants the ore is usually crushed to a maximum size of about three-eighths inch. Ordinarily an ore is crushed as finely as feasible since the rate of extraction of copper is increased with decreasing size of particles owing to the greater surface exposed and. the shorter path required for solutions to come into contact with the minerals to be dissolved. However, greater degree of crushing also increases the amount of fines. When ores are charged into leaching vats the coarse and fine material tend to segregate, resulting in channeling of solutions and leaving the areas where fines predominate only partly leached. An improvement in the method of charging the ore into vats that would minimize the deleterious effects of the segregations of fines would increase the percentage extraction of copper.The Inspiration Consolidated Copper Co.4 recently installed classifiers to remove the primary slimes from the ore, before charging it into the leaching vats. This necessitates a separate agitation treatment for the slimes.Recent publications5 of the bureau have shown the advantages of agglomeration followed by trickle leaching to extract copper from concentrator tailings. It was shown that when equal parts of ore crushed to about 1/4-inch size and concentrator tailings were agglomerated with approximately 10 per cent of moisture, either in the form of water or leaching solution, and the mass was charred into a leaching vat the ore could be treated successfully by open-drainage trickle leaching. Even with 30 or 35 per cent of minus 200-mesh material present the ore could be leached, if it was not flooded with solution.The results obtained in agglomerating ores and slimes suggested the possible advantages to be gained by wetting the crushed ore for standard percolation-leaching plants before charging it into the vats. Wetting the ore whould make the fine material and slime cohere to the larger pieces of ore thus tend to prevent segregation when the ore is charged into the vats. The bureau, at its southwest Experiment Station and in cooperation with the Department of Mining and University of Arizona, Tucson Ariz., therefore made a study to work: out A way in which slimes could be handled in percolation leaching. The study showed that the method of charging ore into the leaching vats governed the distribution the fines and consequently the rate extraction of copper. The results of the study reported in this paper."

Feb 1, 1931