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By Donald R. Irving

THIS CHAPTER is new to the Minerals Yearbook and will appear regularly hereafter. Its purpose is to present statistics that reflect technologic trends in the minerals and metals industries (except fuels). Much useful information has been collected annually through the Bureau of Mines mineral commodity and employment and injuries canvasses. However, these data must be supplemented by further data to permit evaluation of the type, direction, and rate of technologic change, which are vitally important in long-term mineral planning. In addition to, and fully as important as, expanding the available data is the need to ascertain that the various items collected are obtained from identical reporting units, to enable direct comparisons to be made.

Jan 1, 1960

By Peter F. Strong, Robert L. Lagace, Alfred G. Emslie

This paper is concerned with the theoretical study of UHF radio communication in coal mines, with particular reference to the rate of loss of signal strength along a tunnel, and from one tunnel to another around a comer. Of prime interest are the nature of the propagation mechanism and the prediction of the radio frequency that propagates with the smallest loss. Our theoretical results are compared with measurements made by Collins Radio Co. This work was conducted as part of the Pittsburgh Mining and Safety Research Center's investigation of new ways to reach and extend two-way communications to the key individuals that are highly mobile within the sections and haulage ways of coal mines.

Jan 1, 1973

By F. W. Wood

Ingots of zirconium and other highly reactive metals such as titanium and hafnium produced by the consumable-electrode arc-melting process require conditioning before forging or rolling. A nondestructive, arc-conditioning technique has been developed as a substitute for lathe conditioning. The technique employs en electric arc under an inert atmosphere to fuse surface metal on the sidewalls of ingots without seriously affecting the general quality of the ingots. Advantages of the practice are Increased yields, lower accumulation of inferior scrap, and actual cost savings. The work cited in this report was done on zirconium. INTRODUCTION The consumable-electrode arc-melting process as practiced at the Bureau of Mines3 4/ has proved to be a technique for producing sound, homogeneous, commercial-size ingots of zirconium and its alloys. Ingots produced by this process, however, have as a characteristic a layer of partly fused metal on the sidewall to a depth of 3/16 to 3/8 inch. To prevent extension of surface imperfections during forging, the ingots are ordinarily conditioned by removing defective material in a lathe. If the metal were less reactive or the requirements less severe, the machine chips could be recycled and remelted. However, zirconium, being so oxygen sensitive, is contaminated by merely being machined despite extensive cooling of the tool bit. Further, being contaminated with oxygen, the chip metal upon remelting is 10 to 25 Brinell-hardnese numbers harder than the ingot from which it was machined. For this reason, the ingot specifications for naval reactor use have prohibited remelting machine chips, except as required for starting pads. Again, were zirconium less costly or less in demand this ever-increasing pile could be burned to oxide and recycled through the Kroll sponge process. Economics do not favor this, as melting feed stock has an estimated increase In value over oxide of about $8.80 per pound of contained zirconium. The efforts of the Bureau to solve the problem have been directed along two lines: To reduce the contamination of the machine chips produced and to reduce the quantity of the chips produced. This paper presents the technique developed to reduce the quantity of chips produced by arc-conditioning the remelted ingot.

Jan 1, 1955

By C. Travis Anderson

"A recent critical study by Ralston3 of the iron system points out the importance of and necessity for work upon the preparation of ferrous oxide. Not only are ferrous oxide samples desired for determination of the important physical and chemical properties, such as specific heats and heats of formation, bat also information on the stability and behavior of this material is of considerable technical importance. Related. problems where the properties of Fe0 are important have to do with desulphurization of iron, the formation and occurrence of magnetite in copper smelter slags, and sulphur elimination in copperFerrous oxide also has valuable catalytic properties, as is demonstrated in nitrogen fixation.Pure ferrous oxide has never been prepared in quantities large enough to furnish adequate physical and chemical data on its properties. Only two or three experiments4 have produced a fraction of a gram in a state approximating purity and have collected evidence that has been sufficient proof of their having done so. Ferrous oxide is stable only above about 570°C., and below that splits into magnetite and iron according to the reactionUp to about 1920, those who had endeavored to prepare FeO made no provision for rapid chilling, so that although their product. may have had the proper iron oxygen ratio for FeO, in reality it-probably did not consist of pure FeO. The above reaction is reversible; above 570oC. magnetite and iron are supposed to recombine almost completely, and if so, should constitute a direct and easy method of preparation. The data, however, were somewhat conflicting, and the extent to which the reaction goes in either direction needed checking. Preliminary experiments on the interaction of molten Fe304 with solid Fe gave Fe0 of about 85 per cent purity, corresponding to. the approximate purity obtained by some previous investigators. The present work is concerned chiefly with the results cf repeated interaction between partly reduced magnetite and iron, and the calculations which may be made from such results. Repeated treatments are necessary, because molten impure ferrous oxide and iron can not be kept in contact for more than short periods of time."

Oct 1, 1928

By Dana Reinke, Launa Mallett, Michael J. Brnich

Some segments of the mining industry, especially underground coal, have seen a large influx of inexperienced miners in recent years. It is anticipated that this trend will reach other mining segments over the next 10 years. This paper discusses the training needs of the younger generation of inexperienced workers who have just entered or are soon to enter the mines. Currently, many trainers are of the so-called Baby Boom generation. Can these different age groups learn to communicate across the generation gap? Even trainers who have been highly effective in the past should reassess their training styles and their classroom materials to determine if they are prepared to meet the needs of these new trainees.

Jan 1, 2002

By Christopher C. Jobes, Alan G. Mayton, Farid Amirouche

Based on prior mine vehicle studies of operators’ exposure to whole-body vibration, researchers from the National Institute for Occupational Safety and Health (NIOSH) evaluated four seat designs on mine haulage vehicles, with regard to roadway-induced jarring/jolting and operator comfort. Investigators collected objective and subjective data from vehicle operators on two existing and two NIOSH seat designs. This study included time and frequency response data using accelerometers and a data recorder, operator perceptions of jarring/jolting and discomfort levels using a linear visual analogue scale, and data from a questionnaire developed for this study. Results from the analysis of subjective data show that operators generally favoured the NIOSH-designed seats over the existing seats. The results of analyses from the absorbed power method and the threshold limit method, based on ISO 2631-1 (ISO, 1985), support the premise that NIOSH seat designs are superior to the existing vehicle seat designs on both models of mine shuttle cars used in the study. The NIOSH seat designs, featuring viscoelastic foam padding, were more effective in reducing vibration energy for operators exposed to vehicle jarring/jolting. In this paper, the performances of the NIOSH and existing seat designs are compared relative to the operator’s exposure to vehicle vibration (mainly jarring/jolting).

By David Hoadley, Kenneth R. Maser, Ashok B. Boghani, James E. Billar, D. Randolph Berry, Mackenzie Burnett, Robert H. Trent

APPENDIX G TABLE IX MINE A 1 General Total Employees 3000 Maximum No, of Men Underground/Shift 800 Shifts/Day 3 Type of Ore Copper Daily Production (TPD) 25,000 Mining Method Room and Pillar Vein Dip/Thickness l0°/l5 ft Number of Levels/Max Depth 1/0 to 1800 ft 2 Haulage, Conveyances and Travelway Main Haulage Rubber Tire/10 miles belts Man-Ways - Typical Route of Travel to most Remote Sites Rubber Tired Vehicles Hoists - Capacity/Speed/Depth Depth under construction 3 Ventilation 2,500,000 cfm - 5 surface fans 4 Compressed Air N/A cfm 10" and 12" lines 5 Incendiary Storage 2 day powder 1000 gal fuel oil 6 Communications 1 complete system - all shops, dinner areas, and feeder/breaker stations 2 partial systems 7 Escapeway- Systems Man Check System Section boss log and punch cards Alarm System Mine phones with paging system Posting of Escape Route Maps No Escape Signs Every intersection, fluorescent paint Evacuation Drills 2/yr/shift Refuge Chambers - 1 cinder block - No longer required

Jan 1, 1976

By Harold J. Bennett

This report deals with the processing and marketing of iron and steal scrap in the intermountain States of Arizona, Colorado, New Mexico, Utah, and Wyoming and the northwestern Plains States of Nebraska, North Dakota, and South Dakota. The quantity and quality of iron and steel scrap consumed in both the steel mills and iron foundries in these States in 1964 were decided by (1) the type of facilities used to produce an end product; (2) the availability of a dependable source of iron and steel scrap at competitive prices; and (3) the, ratio of the cost of iron in iron ore to iron in scrap. In recent years the quantity of scrap used per ton of steel ingot produced has decreased. The major individual. consumers of iron and steel scrap were the steel mills in Arizona, Colorado, and Utah, foundries in Utah and Arizona, and copper leaching, operations in Arizona, New Mexico, and Utah. About 2 million tons of iron and steel scrap was used by the iron and steel industry in 1964. Although there has been a decline in the amount of scrap used per ton of steel ingot produced because of changes in steelmaking methods, there has been a slight increase in the overall quantity of scrap used because of the increase in ingot production. It is estimated that the scrap consumption in the steel industry will increase by 19 percent by 1980. In addition to the scrap consumed by the steel industry, 273,000 tons of ferrous scrap were used by copper-leaching operations. Thirty-one percent of the ferrous scrap used by the steel industry in 1964 was purchased from dealers and other sources. The CF&I Steel Corp. (formerly The Colorado Fuel and Iron Corp.) at Pueblo, Colo., complemented its blast- and open-hearth-furnace operations with basic-oxygen converters in 1962. The basic-oxygen and open-hearth furnaces were charged with 30 and 90 percent scrap, respectively. Future use of the open-hearths would probably be used to supplement ingot production requirements. Because it was more economical to use less scrap and a high molten-metal charge, the United States Steel Corp. at Geneva, Utah, which uses the open-hearth process to make steel, charges the furnaces with 25 to 35 percent scrap. The Allison Steel Manufacturing Co. at Tempe, Ariz., uses a 100 percent scrap charge in its electric furnace. Although it was estimated that there were 327,000 tons of various grades of motor vehicle scrap generated in 1963, no estimates were made concerning the total quantity and grade of scrap available in the area. Most of the scrap used in the steelmaking industry originated within the area. It was advantageous to sell scrap generated in eastern Nebraska, North Dakota, and South Dakota to markets in the Midwest because of freight costs.

Jan 1, 1967

By C. E. Hennig

On January 1, 1960 there were 310 petroleum refineries in the United States, with a crude-oil capacity of 9,901,424 barrels daily, according to the Bureau of Mines' annual survey. Compared with a year ago, this represents a net decrease of three in the number of refineries and an increase of 81,578, barrels per day in crude-oil throughput capacity. Continuing the trend to fewer units with greater individual throughput, the capacity of the average refinery in the United states increased during 1959 from 31,373 barrels per day to 31,740 barrels per day. Compared with the previous year, total crude-oil capacity of refineries on January 1, 1960 was lower in the Appalachian No. 1, Other Rocky Mountain, and Texas Gulf refinery districts. All other districts showed slight increases in capacity. At the beginning of 1960 the industry had under construction facilities that would increase the crude-oil capacity in the United States by 70,947 barrels per day. This was the smallest capacity increase under construction at the beginning of the year since 19460 Included in this construction of additional capacity were two new refineries, one in Michigan and another in Hawaii. In addition, the industry was constructing facilities to replace 50,250 barrels per day of existing crude-oil capacity.

Jan 1, 1960

By Robert P. Vinson, Kissell. Fred N., Edward D. Thimons

"The Bureau of Mines investigated the presence and extent of methane accumulations in mine roof cavities using a full-scale mine model. Methane was released at a constant rate into the roof of a cavity built onto a 700-ft wind tunnel. Two box-shaped roof cavities were used in the study: one had a volume of 114.7 cu ft; and the other had a volume of 57.3 cu ft. Methane concentration was measured at 28 sampling points in the cavities using 21 different combinations of gas emission rates and air velocities. Brattice hung in the cavity helped reduce methane concentrations without auxiliary ventilation. It was also found that the effective ventilation rate increased by a factor of 40 in the large cavity and by a factor of 20 in the small cavity when air velocity was increased from 100 to 600 fpm.INTRODUCTIONAny location in a coal mine where 5 pct or more of methane is present constitutes a potential site for an explosion and roof cavities are likely locations. Unfortunately, little is known about the buildup of methane in roof cavities. Some research has been done using scale models where no air flows past the cavity so that methane disperses only by diffusion (5) 4 a rare situation in mines.No known cavity-model investigations have been made that simulate air and methane flow conditions normally encountered underground. These Bureau of Mines studies were undertaken to determine the extent and manner of methane buildups in coal mine roof cavities with air velocities in the range normally found in coal mines and with various methane emission rates."

Jan 1, 1978

By D. C. Fleck

The Bureau of Mines, in a cooperative research program with four lead companies, has investigated ferric chloride leaching of galena to prepare lead chloride for molten-salt electrowinning to produce lead metal. The hydrometallurgical-electrolytic process is an alternative to the sintering-smelting-refining process currently used to produce lead metal and avoids the environmental problems associated with a conventional smelter. During investigations on the electrowinning aspects of the work, it was noted that certain cations, moisture, and sulfate in the electrolyte affect lead metal purity, cell voltage, current efficiency, and viscosity of the electrolyte. Results of bench-scale tests are re-ported on the effects of CaCI2, CuCI2, FeCI2, MgCI2, NaCI, ZnCI2, PbS04, and moisture on electrolysis. As impurities increased in the electrolyte, current efficiency decreased. CaCI2, CuCI2, and FeC12 decreased current efficiency by 12 to 47 pct. ZnCl2 gave a small voltage increase, while CaCI2 addition equivalent to 4.9 pct Ca caused a 50-pet increase in voltage. The lead metal was contaminated in direct proportion to the CuCI2 buildup in the electrolyte, Anode corrosion was observed with MgCI2 and MgC12?6H20. Viscosity increased appreciably with the buildup of NaCI, CaCI2, and sulfate. Electrolyte foaming occurred with ZnC12, MgC12?6H20, MgC12, FeC12?2H20, and FeCI2. Moisture inhibited the coalescence of the lead metal.

Jan 1, 1983

By M. M. Fine

This report describes a Bureau of Mines technical feasibility study of simultaneous reduction and induration of pelletized iron ore to make a product with superior qualities as blast-furnace feed. Highly reduced, physically competent pellets can be made from magnetite and specularite concentrates that contain small additions of bentonite as binder. In batch tests, pellets were dried, surrounded with solid fuel in crucibles, and heated to the reducing temperature. Total iron content of the best products was higher than 80 percent and crushing strength of 1/2-inch metallized pellets ranged up to 600 pounds or more. Comparative tests of several commercial oxide pellets showed a wide range in crushing strengths, but most values were less than 350 pounds. Continuous tests in a rotary kiln resulted in the same degree of reduction, but the pellets had lower crushing strengths because of the limitations in the maximum operating temperature of the small kiln.

Jan 1, 1962

By Thomas M. Garland

Reports that set forth the pertinent facts of existing secondary-recovery operations are an integral part of the work of the Bureau of Mines in promoting conservation and efficient utilization of the petroleum resources of the Nation. Knowledge of the success or failure of waterflood projects in an area is very useful to other operators. Although projects will not have identical results, information concerning the flood performance, method of operation, and difficulties encountered on one project will help operators to determine the feasibility of flooding a similar sand and to select the methods of operation most likely to prove successful. The increasing cost of discovering and developing new oil reserves, as well as the unending effort to reduce operating costs and increase ultimate oil recovery from known petroleum reservoirs, has required the petroleum industry to evaluate continuously the performances of various secondary-recovery methods. Waterflooding was recognized early by the petroleum industry as a possible means of increasing oil recovery. From the early accidental floods in Pennsylvania and through many haphazard attempts to inject eater into oil-bearing formations, waterflooding emerged as one of the more important methods of oil recovery. Waterflooding is important not only to the oil industry but also to the economy of the area concerned.

Jan 1, 1962

By David J. Ellis

The mineral industry of Benin continued to be confined to the production of cement, crude oil, salt, and sand and gravel. Only crude oil and cement were exported, with the value of crude oil exports and cement exports constituting about 20% and 2% of export revenue, respectively. The value of crude oil exports was less than the cost of imports of refined petroleum products. Production of crude oil was unchanged from 1986, averaging 5,500 barrels per day (bbl/d). The Government managed the facilities at the Semé Oilfield while actively seeking a new manager to replace Pan Ocean Oil Co. of Switzerland, whose contract was canceled in 1986. Recoverable reserves of crude oil were estimated to be between 18 and 30 million barrels.

Jan 1, 1989

By J. E. Dooley

An analytical procedure developed by the Bureau of Mines was applied to the separation and characterization of a 370° to 535° C distillate from Swan Hills (south field), Alberta, Canada, crude oil. Investigators determined the general characteristics of the crude oil by the Bureau's routine method for crude oil analysis. Suitable fractions were prepared for instrumental analyses by utilizing such techniques as isothermal and molecular distillations, chemical treatment, silica-alumina gel chromatography, and gel permeation chromatography (GK). A detailed characterization of the 370° to 535° C distillate was possible by the application of GPC-mass spectrometry correlations and nuclear magnetic resonance spectrometry. Semiquantitative data based on mass Z series distributions were determined and are shown. The data will be valuable in developing future processing techniques and in calculating yields for converting high-boiling distillates into more useful energy forms.

Jan 1, 1973

By I. L. Nichols

Laboratory characterization studies have investigated the processing variability of carbonaceous uranium-bearing materials found in-sandstone deposits. This work was conducted by the Federal Bureau of Mines in support of its goal to maintain an adequate supply of minerals to meet national economic and strategic needs. Conventional processing produces only partial uranium recovery from these ore materials. Ore samples from New Mexico, Texas, and Wyoming were examined, and each responded differently. Using direct acid leaching techniques, some of the ores required acid additions of only 50 pounds per ton, while others required 300 pounds per ton of material. Maximum extractions ranged from 83 to 94 percent in the six ores tested. Roasting those ores prior to leaching improved extraction of the uranium to the 90 to 99 percent range. An oxidative autoclave treatment used with five of these ores resulted in extraction of 78 to 97 percent of the uranium. The experimental studies also showed that some carbonaceous materials can be concentrated by froth flotation. The flotation tailings were amenable to acid leaching, and up to 98 percent of the uranium was extracted from this type of material.

Jan 1, 1979

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Jan 1, 2012

By C. R. Kindall

Recently 30 men wore viewing the demonstration of a now portable electric arc-welding outfit. A few hours later 17 of the 30 men reported to the doctor for treatment. They were suffering from traumatic conjunctivitis. In two cases the gain was very severe and the symptoms were similar to those of iritis. orphine had to be administered to afford relief from pain. Only two men of the 30 wera not affected in some way from this exposure. These two men were thick-lensed orange-colored glasses. Several of the men wore orange-colored glasses with thin lenses, but the latter were not heavy enough to afford protection.against an exposure as long as took place. The distance of the eye from the are also in- fluences the possibility of injury. Conjunctivitis is an inflammation of the con- junctiva; the conjunctiva is the mucous membrane covering the inside of the eye- lids and part of the eyeball. Traumatic conjunctivitis is caused by foreign bodies in the eye, exposure of the eyes to high winds, dust, smoke, intense light from electric arc lamps, and from electric welding apparatus. In the instance mentioned above, the inflammation was due to the ultra-violet rays. The ultra-violet rays lie beyond the violet rays in the spectrum and are invisible to the eye. In some cases the effect is so severe that, in addition to conjunctivitis, an inflammation of the skin similar to sunburn is produced. The symptons of conjunctivitis caused by intense light or by the ultra- violet rays are marked photophobia (abnormal intolerance to light), excessive secretion of tears, intense starting of the lid, contraction of the pupil, some- times swelling of the lid, and small ulcers developing on the eyeball or cornea. Unless properly treated by a physician immediately, chronic inflammation of the conjunctiva, cornea, iris, or retina, and possibly blindness, may result. Under proper treatment most cases get wall in a few days. All treatments should be under the direction of a physician. That usually advised is to place ice packs on the patient's eyes three or four times daily. The pack should be left on from 15 minutes to an hour. The eyes should be irrigated with normal salt solution (a teaspoonful to a quart of sterile vater) or a saturated solution of boric acid several times daily. If there is a discharge of pus, a few drops of a 25 per cent solution of argyrol or a 5 per cent solution of protargol should bo placed in the eyes three to six times daily. The patient should be confined to a darkened room until his condition improves in order to avoid complications. These treatments will reduce the swelling, give the patient confort, and prevent the development of chronic conjunctivitis. In severe cases it may be necessary to administer morphine to relieve the pain.

Oct 1, 1920

By D. J. Parker

Since the introduction of electricity into the mines of the United States , the hazards incident to the industry have increased materially in both coal and metal mines . For economic reasons the tendency at present , particularly in coal mining , is decidedly toward the adoption of electrical mine machinery , including alternating current machinery , on a more extensive scale than ever before . Obviously, the growing use of such equipment will result in an ever -increasing number of underground transformer stations . The principal electrical hazards in mines are threefold ; fire , explosion, and contact . Of these , fire is the greatest hazard involved in the use of electricity underground , and several fires have originated in underground transformer and motor generator set stations . The fire hazard due to improperly installed and poorly maintained underground transformer stations is an ever-present one , and failure to take the necessariman remedial action is likely to result , sooner or later, in the destruction of life and property . Upon suggesting the necessary corrective measures with respect to such installations , one is often confronted with the statement to the effect that even though this particular hazard has existed over a period of years , there have been no unfavorable results therefrom thus far . Frequently , the desirability for action is not apparent to the mine management until it is too late . Because a mine has a record free from fires , explosions , etc. , over a number of years of operation during which these hazards existed , such good fortune should not be taken as a guarantee that this or any other mine is immune from these common dangers . When the elements of an existing hazard are properly balanced or in the right proportion, the unfortunate combination must of necessity culminate in misfortune of one kind or another. The fire hazard due to underground transformer installations can be very definitely minimized by proper installation and maintenance . In coal mines the transformer banks , connected to 2,300 and occasionally to 4,400 volt circuits , are often found located in open- ended crosscuts , mounted on concrete or timber foundations , and in nonfireproof surroundings .

Jul 1, 1930

By Launa G. Mallett, Charles Vaught, Michael J. Brnich

Beginning in 1991, scientists at the Pittsburgh Research Laboratory recorded interviews with individuals who are recognized as experts in mine emergency response. These 30 veterans related stories and observations from events experienced during as many as 47 years of response activities. Overall, the response veterans averaged 29 years of mine emergency response experience and 35 years of mining experience. Interviewees included representatives from mining companies, the United Mine Workers of America, and State and Federal agencies. Most of their comments dealt not so much with technical aspects of particular mine emergency responses, but rather the human side of more general topics, including preparedness, experience, people on-site, mine rescue teams, and decision-making. An analysis of their interviews provides an overview of lessons learned on-site at some of the largest mine disasters since the mid-1940s. This knowledge was gathered so that it could be provided to today's miners and to tomorrow's emergency response personnel. It is expected that the collective wisdom obtained can be used to help train new responders and guide those decisions that will have to be made on the scenes of future events.

Jan 4, 2004