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By S. J. Hussey

A jig tailing with gold content ranging from 0.33 to 0.43 oz/ton was leached in weak cyanide solution with extractions of up to 97 pct in 24 hours. By countercurrent batch leaching studies and laboratory pilot plant operation, minus 10- plus 20-mesh and minus 6- plus 16-mesh coconut carbon were loaded to 700 oz/ton of Au. Minor silver in the ore reported in the carbon in amounts of up to 100 oz/ton. Gold adsorption rate data and an equilibrium adsorption curve for minus 10- plus 20-mesh carbon at ambient temperatures were developed and used in the successful application of a cascade design theory. The work was performed as a part of the overall Bureau of Mines research effort to help maintain an adequate domestic supply of metals by making improvements in mineral-processing technology.

Jan 1, 1979

The production of harmful pollutants from coal mines and/or from coal and associated strata has been a recognizable fact in the United States for over two hundred and seventy years. In 1698, Gabriel Thomas observed(l) that the colored water flowing from streams in this country was similar to that which flowed from the coal mines in Wales. Hence, water pollutants such as acid were being produced before any known coal mines were operating in this country. The coal mining industry has contributed to the increase of pollution by exposing large amounts of sulfide materials that enable the reaction of water, oxygen and sulfur containing materials to form acid. A map of the United States coal fields can be seen on Figure 1. The anthracite regions of Pennsylvania, although small when compared to the total reserves, have produced some of the country's major water problems. The map indicates the extent of bituminous reserves of the Appalachian and midwest regions. Also evident are the bituminous, subbituminous and lignite coal reserves in the west which have recently come into greater demand. Acid mine pollution is encountered in numerous states, but the major problem is found in the Ohio, Susquehanna, and Potomac River basins.(2) Most coal beds contain some sulfur which may be in the inorganic, sulfate, or sulfide form, and thus have the potential to produce sulfuric acid. However, much of the strata that overlays the coal beds also contains acid neutralizing materials. Therefore, the amount of acid produced depends upon the amount of both acid and alkali materials that dissolve in the water in any given mine. The common sources of sulfurous material in the seam or surrounding rock are generally called sulfur balls or "nigger heads" by the miners. Sulfur balls that have been observed(3) seem to be equally divided between those containing sulphuritic iron capable of producing sulfuric acid upon oxidation and those that are primarily calcium carbonate. It has been observed in many instances that two types of water, acid and alkaline, are being produced in the same mine. A study of the geological strata and a survey of subsidence, faults and sulfur balls will usually give some indication of why this happens. The reaction of pyrite (FeS2) with oxygen and water to form ferrous sulfate (FeSO4) and sulfuric acid (H2SO4) by a series of complex chemical interactions is well documented but not well understood.(4,5) However, it is well known that the reactions to form the acid cannot occur unless all three constituents are present. Since pyrite is inherent in most coal seams and air is needed to sustain the miner, the most logical answer is to eliminate water infiltration into the mine, or to remove it from the mine before acids can form.

Jan 1, 1970

By H. B. Humphrey, J. J. Forbes

"In accident prevention, a study of statistical data is necessary to determine primary causes of accidents to devise means to eliminate causes at the original sources. Explosions in coal mines of the United States during the 10 years ending December 31, 1931, ranked third in the causes of fatal accidents; they constituted 16.2 per cent of all fatal accidents in bituminous mines and 8.4 per cent of all fatal accidents in anthracite mines. A study of coal-mine explosions in Pennsylvania, with approximately 160,000 men employed in anthracite mines and about 145,000 in bituminous mines or about 205,000 out of -the approximately 525,000 men employed in all coal mines of the United States, should give information of value to all persons endeavoring to reduce or eliminate coal-mine explosions. This circular reviews explosions of gas or dust or of both in the coal mines of Pennsylvania to show the hazard of gas and dust, to point out the influence of certain factors in causing explosions, and to emphasize the efficacy of explosion-preventive measures.The data published annually by the State Department of Mines and of the United States Bureau of Mines were used in compiling the tables of explosions. Through the cooperation of W. H. Glasgow, secretary, Department of Mines of Pennsylvania, and his assistants, many doubtful cases were clarified, so that as far as recorded the history is comparatively complete. Figures used in compiling some of the tables were furnished by W. W. Adams, chief statistician, demographical division, United States Bureau of Mines.Anthracite in the Wyoming Basin of Pennsylvania was used locally by gunsmiths in 1755, by blacksmiths in 1769, and as domestic fuel in 1808.Mining and shipments developed slowly between 1806 and 1812, but more rapidly after that.Early mining along the outcrops gave essentially no trouble from gas, but by 1870, when State inspection was established, explosions were frequent; ventilation was crude and accumulations of gas were generally ""brushed"" or burned out.Table 1 lists 1,232 ignitions and explosions of gas in anthracite mines from 1870 to 1932, inclusive, every one of which was accompanied by loss of life. Some details are given of 110 representative cases in which five or more lives were lost or in which it appeared that some violence was present.During the period 1870 to 1932, inclusive, gas explosions caused 2,213 fatalities, or an average of about two deaths for each ignition or explosion. Records are not available as to the number injured in these and in other explosions where no deaths occurred, but from a study of explosion reports it appears probable that the number injured exceeds the number killed. In the 110 cases described, 599 were killed and 294 were injured. As shown in Table 2, fatalities from gas explosions averaged 8.3 percent of the total fatalities in Pennsylvania anthracite mines from 1870 to 1931, varying from 6.0 percent in 1931 to 13.1 percent in 1927."

May 1, 1933

Reduce costs of surface mine reclamation by improving scaper operating efficiency and reducing tire costs. Approach The Wheel Slip Monitor senses and compares the peripheral speed of a scraper's four tires 10 the true ground speed of the scraper, and alerts the operator if any of the tires exceeds a predetermined amount of slip. This system helps scraper operators reduce wheel slip during the loading cycle, thereby improving the loading efficiency of the scaper and reducing tire wear and damage. How It Works The system consists of five ultrasonic doppler velocity-sensing devices for measuring the speed of each wheel as well as the true ground velocity (see photograph). Each sensor produces an electrical output signal having a frequency proportional to the speed of the tire or terrain. The signals are conveyed through electrical cables to a control box in the operator's cab where they are converted to voltages proportional to individual wheel speeds (see photograph). The signals are further processed to activate a blinking red light, corresponding to any individual wheel which is slipping, and to sound a beeping tone that is audible to the scraper operator. The rate at which the light blinks and the tone beeps is proportional to the degree of slip. Alerted, the operator can take corrective action.

Jan 1, 1985

By Fred Turin, Kim Cornelius, Lisa Steiner

NIOSH researchers have been examining underground coal mining activities in order to evaluate work crew hazards. In 1994 a continuous mining machine operator was killed by falling roof during extended cut mining. Many aspects of the incident were used by NIOSH researchers to develop a scenario interview. The goal was to provide a realistic framework for acquiring frank and detailed insights. The interview consists of two sections. The first describes the underground mining conditions. The second recounts the fatal incident. Each section is supplemented by a diagram and a set of questions addressing relevant safety issues. The interview was administered at three mines that actively take extended cuts. Researchers found the scenario approach to be an effective interview tool as well as an effective hazard awareness and safe work practices training platform.

By D. H. Chambers

The Bureau of Mines developed a process for producing high-purity zinc and tin by electrorefining from liquid amalgams. Commercial grade metals were dissolved in mercury to produce saturated amalgams at room temperature. Amalgams were also prepared by electrolytic transfer from soluble anodes of the metals to a mercury cathode. Amalgams formed by both methods were used as anodes in electrorefining cells to produce high-purity cathodes. Metal impurities, excluding mercury, were at levels of less than 5 ppm in zinc and 9 ppm in tin. Mercury content was about 2 to 10 ppm in zinc products, and this was effectively removed by heating the cathodes in a vacuum. Mercury was excluded from tin cathodes by pumping the tin electrolyte through tin turnings and controlling the cell temperature.

Jan 1, 1969

By A. E. Raddatz

The Bureau of Mines has determined the electrochemical rate of anodic dissolution of vanadium metal in a VC12-VC13-NaC1 electrolyte at 860' C for the purpose of elucidating the reaction mechanism. Rate measurements were carried out with the help of specially designed equipment capable of continuously recording the weight loss experienced by a cylindrical vanadium anode immersed in the molten salt electrolyte while a constant current is maintained through it. The rate is expressed as a function of current density and VC13 concentration, and the reaction is interpreted in terms of an adsorption mechanism. Multiple regression analysis of the data gave the following rate equation: Rate x 104 (g.cm-2.sec-1) = -0.38 + 2.64 current density (amp-cm-2) + 0.69 log, (mole-percent VC13).

Jan 1, 1974

By L. H. Banning

The Bureau of Mines conducted pioneering batch and laboratory cyclic tests that simulated plant operation in developing a procedure for acidulating phosphate rock with fluosilicic acid. Both high-grade deslimed phosphate rock and low-grade phosphate rock samples were treated. The most promising results were obtained by acidulating des limed high-grade material. In a series of seven cyclic tests, 85.4 percent of the P20S was recovered in solutions. The average P2O5 content of the phosphoric acid-monocalcium phosphate solutions of the first step was 156 grams per liter, and the average fluorine content was 4.7 grams per liter. Residues had an average fluorine content of 30.7 percent and contained 83.9 percent of the total fluorine in the charge materials. Some fluorine was lost by volatilization.

Jan 1, 1975

By B. J. Scheiner

A ferrous chloride-oxygen leaching system was investigated by the Federal Bureau of Mines to determine its effectiveness for recovering copper and silver from a tetrahedrite concentrate that had been pretreated to remove a majority of the antimony. The pretreated concentrate contained coppers, silver, lead, zinc, antimony, and arsenic. Parameters affecting metal extraction (such as temperature, pressure, amount of ferrous chloride, and initial hydro-gen ion concentration) were studied. Copper extraction of 98 pct was achieved by leaching 4 hours at 40 pounds per square inch gage (psig) and 100° C. Copper was recovered from leach solutions by cementation with iron, and the resulting ferrous chloride was recycled. Leaching the residue with cyanide followed by electrowinning recovered 99.7 pct of the silver. Iron, antimony, arsenic, and sulfur reported to the tailings.

Jan 1, 1978

Reduce costs of surface mine reclamation by improving bulldozer operating efficiency. Approach A draft power indicating system helps bulldozer operators adjust blade height and other controls for maximum load movement, by continuously indicating the rate at which work is being done. How It Works This system continuously measures both the push of the blade against the overburden, and the true ground velocity of the bulldozer. It multiplies those quantities to determine the real work rate of the machine. The system consists of a velocity sensor, a blade load sensor, processing circuits, and a work-rate indicator. The processing circuits include an analog multiplier which has an output signal representing the draft power (velocity x load = power). The draft power, or pushing power is a measurement of the work rate at that moment.

Jan 1, 1979

By Eugene Baker, Joseph Cervik, Albert Sainato

In Europe, water infusion is used widely to reduce generation of respirable dust during mining. Its use in the United States is limited to a few plow operations in the Pocahontas No. 3 Coalbed. This Bureau of Mines report describes the technology for infusing water in to a longwall panel and reports the results of a recent demonstration in the Lower Sunnyside Coalbed that achieved dust reductions averaging 58 pct. Because water infusion increases moisture content of the coalbed, face air velocities in excess of 500 ft/min (2.5 m/s) are possible, further diluting dust levels before dust entrainment occurs. An economic analysis shows a 23-pct reduction in operating costs when coal production is increased by changing from unidirectional mining to bidirectional mining with water infusion.

Jan 1, 1983

By Joseph Cervik, Gerald L. Finfinger

The Bureau of Mines conducted an experimental degasification project in Island Creek Coal Co.'s Virginia Pocahontas No. 5 mine. Methane from the over- lying Pocahontas No. 4 coalbed was entering mine workings in the Pocahontas No. 3 coalbed through fractures in the roof rock. Small-diameter (1-5/8-inch) holes were drilled into the overlying coalbed to reduce the gas pressure and intercept methane flows, which were piped to the surface through an under- ground 6-inch-diam steel pipeline. The total methane flow rate from the vertical holes averaged 150,000 ft3/day for the first month. Methane flows into the mine were reduced by 47 pct, thereby demonstrating the effectiveness of this form of degasification in reducing ventilation requirements and providing a safer working environment.

Jan 1, 1979

By D. L. Paulson

The Bureau of Mines is investigating pyrometallurgica1 and" chemical methods to recover valuable constituents from metallurgical dusts and slags. Under this program a technique was developed to recover iron from molten copper smelting furnace slags by carbon injection. Slags from gas-fired reverberatory and electric copper smelting furnaces were treated in an 800-kva electric-arc furnace by injecting coke breeze into the bottom of the molten bath. Over 95 pct of the iron and over 90 pct of the copper contained in the smelting furnace slags were recovered, while up to 85 pct of the carbon injected into the system was utilized. It is anticipated that the metal product containing approximately 95 wt-pct iron and 2 wt-pct copper will be a satisfactory medium for recovering copper by cementation.

Jan 1, 1977

By Isaac A. Zlochower, Michael J. Sapko, Ronald S. Conti

This paper describes a U.S. Bureau of Mines investigation of large-scale coal dust explosions in an experimental mine using a high speed electro pneumatic mechanism for the rapid grab-sampling of gases and dusts. This technique enables the monitoring of pyrolysis and charring in fuel dust particles, and the collection of gaseous combustion products, in both large and small-scale explosions. Data obtained from full-scale dust explosion tests at the Bureau of Mines Lake Lynn Test facility show the following: Rapid sampling appears to "freeze" the burned gas compositions at the flame temperature values. Gas samples taken entirely in the flame zone consist of pyrolysis and combustion products with very low residual oxygen. The particles collected in the flame zone show signs of extensive pyrolysis and charring. Measurements of gas concentrations and particle flame temperatures suggest that char burning may have occurred in the flame zone.

By V. Rajaram, S. Bhattacharya, M. F. Dunn

During a mine fire or other emergency, it may be desirable to reverse the airflow in order to provide an escapeway or to isolate a fire. Also, (in colder areas, the airflow may be reversed to prevent ice buildup. When reversing main mine fans, the mine operator usually does not know what operating characteristics of flow and pressure to expect. Laboratory a field tests of vane axial main mine fans in the 7- to 9-ft diameter size range were conducted to establish forward and reverse performance characteristics under controlled conditions and at typical mine installations. The data obtained suggest that reverse performance characteristics are dependent upon the blade angle and the hub to tip ratio. There is also evidence that reverse performance can be predicted for a family of blade angles and a given hub to tip ratio. Generally, quantity of air is 30% to 65% less in reverse than when operating in the normal forward mode.

Jan 8, 1983

By Edmond Chin

Mineral production was of minor importance to the country's economy, and Bangladesh was not a ranking world producer of any mineral commodity in 1980. Natural gas was the most important mineral exploited, and reserves were sufficient to allow a significant increase in its use. A greater proportion of the domestic heat and electrical energy needs could be filled by increased production and distribution of natural gas. Also, the export of natural gas was feasible either by pipeline to India or in the form of liquefied natural gas (LNG). Some nonmetallic minerals could be developed, as well as coal and peat, given sufficient capital investment. Bangladesh's strongly agricultural economy made fair progress in 1979.80.1 The major harvest of November-December 1979 turned out to be better than had been anticipated after an early drought left poor planting conditions. Secondary crops (harvested in February-March 1980 and June- July 1980) were excellent. There were prospects for a record harvest in fiscal year

Jan 1, 1982

By M. M. Fine

A satisfactory mean: of beneficiating a Brazilian phosphate rock was developed in a mineral-dressing-research study by the Bureau of Mines. High-grade concentrates well ever the specified minimum grade of 70 percent tricalcium phosphate, were produced, with goad recoveries by agglomerate tabling and flotation. A lower gads but usable secondary product was recovered by sedimentation of the minus-200-mesh fraction of the ore. The ore wan representative of an extensive deposit recently discovered near Recife in the State of Pernambuco, Brazil, which will be exploited in a plant planned to eventually produce at the rate of 500,000 tons of concentrate annually. Although Brazil has been reported to Lave a substantial reserve of phosphate rock,3/ the country has never been more than a small producer of this commodity. From 1945 to 1950 the highest production of phosphate rock attained in Brazil amounted to 10,421 tons. Production in 1949, the most recent year for which figures are available, was 4,553 tons.4/

Jan 1, 1954

By D. H. Baker

This report, one of a series prepared by the Federal Bureau of Mines on the technology of titanium, describes the development of an electrorefining cell from which cathode deposits up to 30 inches long can be produced. Data show individual deposits to be homogeneous, comparable from top to bottom, and not varied in quantity or quality of metal over the entire length of the deposit. Investigations concerned with various diameter cathodes showed that cathode current efficiencies were materially reduced with cathodes less than 2 inches in diameter. Deposits produced on 1/2-inch-diameter cathodes showed cathode current efficiencies of 19 percent and on 1-inch cathodes, just over 22 percent, whereas deposits produced on 2- and 4-inch-diameter cathodes showed about 70-percent current efficiencies. A series of 20 deposits on 4-inch-diameter cathodes was produced under simulated production operation. The average current efficiency, based upon a divalent ion, was 72 percent with 11 1/2 pounds of metal produced per cycle of operation - 98.8 percent of which had a Brinell hardness number (B.h.n.) of 80 or less.

Jan 1, 1959

By Edward P. Barrett

[Iron oxides, when reduced at temperatures below 900° form a dark gray substance, very porous bait otherwise in almost the same form as the original particles. In the temperature ire range of 1,000 to 1,100° the product is pertly sintered but still shows the outlines of the original particles. Those products are known as "sponge iron." At temperatures of 1,100 to 1,2000 the metallic iron begins to flow together and to a semifused, pasty, porous mass called a "bloom," which can he worked under a hammer to form a product similar to wrought iron; it contains slag inclusions and is too low in carbon to make steel. If the temperature is 1,300 to 1,300°, part of the iron will fuse enough to absorb more carbon. The dissolved carbon lowers the melting point and still more carbon is absorbed. The melted portion acts a flux for the unmelted metallic particles until the entire mass becomes a high-carbon fluid known as "cast iron." Sponge iron was probably the form in which the first iron was recovered from the ores. As early as the eighth century the Catlan forge3 developed into a low-shaft furnace known as the "high bloomary," in which iron eras produced in the form of a pasty mass. In 1340 the first blast furnace was built in Belgium. The greater part of the iron was made into wrought-iron blooms by crude puddling processes. Charcoal was used as the fuel until tie latter part of the 17th century when coke was used in England. In 1865 Bessemer built his first converter in. England, and within a few years the Siemen's regenerative open-hearth furnace was developed, also in England. Enormous expansion in the metallurgy of iron followed. The idea of "direct processes" for the production of iron arid steel has persisted throughout all this time. The production of steel from sponge iron has theoretical advantages over the present-day standard methods, and handreds of so--called "direct processes" have been proposed or tried during the past century.4]

Jan 1, 1929

By W. E. Wallace, P. Bolsaltis, M. J. Keane, B. L. Rauaboni

Thermal treatment of respirable size silica dust samples results in marked changes in their hemolytic activity. These changes can be correlated with changes in the characteristics of the particle surface as measured by infrared spectra, zeta potentials, and specific surface area. Silica samples from various sources (Min-U-Sil, fumed silica, and a NIOSH standard sample) were heated or calcined at temperatures ranging from 100-1095C. The hemolytic activity of the crystalline materials decreased after thermal treatment. The behavior of the fumed material was found to be more complex. Material of very large surface area (small particle size) exhibits an initial increase in hemolytic activity upon calcination. This result confirms other experimental observations pointing to a particle size of maximum toxicity. Tre changes in hemolytic activity can be related to infrared spectra and zeta potentials of the materials. The absorption band in the 3200-4000 cm-1 frequency region of the fumed material disappears upon heat treatment while a sharp, characteristic band at 3750 cm-1 increases in intensity. Zeta potential measurements conducted in the pH range of 2.0-10.5 exhibit a unique change in zeta potential v.s. pH profile with heat treatment. These findings indicate that the removal of active surface silanol groups by calcination results in reduced cytotoxicity, as measured by a hemolysis test.

Jan 1, 1988