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By William H. Schiffbauer, William D. Mayercheck, August J. Kwitowski

This report summarizes work sponsored by the Bureau of Mines in the development of a remote operating system (ROS) for controllng a thin-seam continuous miner (TSCM) 500 feet or more distant from the extraction face. Detail s are provided on ROS subsystems including the continuous miner, video equipment, controls and displays, the electronic control system, and the operator station.

By Anthony W. Sparks

The Bureau of Mines conducted tests designed to compare its breathing metabolic simulator (BMS) with other methods that are currently used to evaluate the performance of respiratory protective equipment. The BMS is a commercially developed device that uses a piston cylinder to simulate breath movement. Using a propane furnace that consumes oxygen and forms CO2, the BMS also simulates the respiratory metabolism of humans. The breathing and metabolic subsystems of the BMS are described in detail in this report. Results are compared from tests that used the BMS to evaluate respiratory equipment and from tests that used human subjects for the same purpose. The BMS was also tested against a pulsatile breathing machine (PBM) previously designed by the Bureau. Both machines were used to test respiratory equipment, and the test results are compared in this report. To illustrate typical applications of the BMS, the report briefly describes how the BMS was used to test two different types of closed-circuit respiratory apparatus, and the test results are presented. This research showed that BMS test results compared more closely to the results of tests that used human subjects than did results obtained using the PBM.

Jan 1, 1980

By James H. Russell

The Bureau of Mines, U.S. Department of the Interior, in cooperation with the Department of Energy, has attempted to increase the activity of nickel catalysts for converting synthesis gas, derived from coal, to a substitute natural gas. This report describes the effects of low-level additions of B, Ca, Ce, Co, Mn, Mo, Pd, Re, Ti, Y, Zn, and Zr on the methanation activity of Raney nickel. The methanation rate at 320° C and the resistance to poisoning by 2 ppm H2S were used to compare catalysts. The effects of the additions were small, and the experimental variances were large, necessitating the use of statistical methods to identify significant effects. Co, Ti, Y, and Zn improved the resistance to H2S poisoning, but only Co improved the methanation rate In some individual catalysts containing Ca, Mo, or Mn, both the methanation rate and resistance to H2S poisoning were improved.

Jan 1, 1980

By Albert J. Rambosek

The results obtained in a study of the stress conditions existing in a drill bit-point area and in the underlying rock, when the bit was in full but nonpenetrative contact with the rock, are presented. This investigation by the Bureau of Mines was the preliminary exploratory phase of a long-range program of research on rock drilling to establish criteria for the maximum economically feasible rate of rock penetration. The photoelastic technique of experimental stress analysis was the principal method used to obtain the data. Transparent models and transmitted light were employed to investigate patterns in drill-bit models and isotropic materials under the bit when subjected to a concentrated static load. Comparative stress data for anisotropic rock were obtained by the reflective photoelastic technique. Brittle lacquer and an extensometer were used obtain supplementary information wherever substantiating data were desired to check photoelastic results. The zone of maximum shear occurs along an arc near the contact face of the bit. The stress distribution pattern in an isotropic model rock near the area contacted by the bit was nearly a mirror image of that exhibited within a similar areal zone of the bit. The stress pattern in granodiorite specimens was similar, though not symmetric, to the pattern in the isotropic model rock. The asymmetry of the stress pattern in the granodiorite was attributed to the anisotropic characteristics of the constituent minerals of various sizes.

Jan 1, 1963

By L. J. Douglas, A. G. Kim

Methane and other hydrocarbon gases, byproducts of coalification, are emitted from coal at widely varying rates and often present ventilation problems during mining. The air in some coal mines apparently contains no methane. To determine if coals from mines which had no history of detectable gas emission contained adsorbed methane, samples of coal at the shaft bottom and at an active face were obtained and placed in sealed metal cylinders. The atmosphere around the coal was sampled and analysed by gas chromatography. Methane, ethane, ethylene, propane, propylene, and butane were found to have been desorbed from these coals. Hydrogen and helium were also detected. An estimate of the amount of residual gas per ton of coal indicated that coal samples from the active face generally contained more adsorbed gas than coal samples obtained from the shaft bottom, although in both instances the total amount of gas was relatively small.

Jan 1, 1973

By Paul W. McGann

THE MINERAL INDUSTRIES had a near-record year in 1950, as rising industrial activity in general, greatly accentuated by the outbreak of hostilities in Korea in midyear, called forth increasing supplies of mineral fuels and raw materials. The aggregate value of mineral production was second only to that in 1948, and the aggregate physical volume was exceeded only in 1948 and 1947. Lower coal production accounted for the failure to surpass these earlier years. Growth of production was fairly constant throughout the year, especially for crude petroleum; its physical output for the year as a whole exceeded that of 1949 by 7 percent. According to Federal Reserve Board indexes, other relative gains were 16 percent for coal, 9 percent for fuels in general, and 17 percent for metals. The increase for mining in general was of the order of 10 percent. This was not quite as large as the general increase in industrial production but clearly reflected the total-industrial trend (see fig. 1).

Jan 1, 1953

1. A total of 14,413 mining operations reported employment to the Mine Safety and Health Administration (MSHA). Nearly half (48.9%) were sand and gravel operations, followed by stone (28.5%), coal (14.7%), nonmetal (5.7%), and metal mines (2.1%). 2. Mine operators reported 240,000 full-time equivalent workers1 (down 3.9% from 1999). Independent contractors reported 42,000 full-time equivalent workers working on mine property (up 8.6% from 1999). Coal operators accounted for 26.8% of reported employee hours, followed by stone operators (25.9%) and sand and gravel operators (12.1%). 3. Eighty-four (84) work-related mine fatalities occurred in 2000 compared to 90 the year before. •The mine fatality rate was 29.8 per 100,000 full-time equivalent workers compared to a fatality rate of4.6 per 100,000 employees for all private industry. •Thirty-one percent (31%) of the fatalities occurred in underground work areas, which account for only17% of total employment. •Although the largest number of fatalities (28) occurred among miners who work for coal operators, coal contractor employees had the highest fatality rate (61.1 per 100,000 full-time equivalent workers). 4.There were 10,839 nonfatal lost-time injuries reported to MSHA, occurring at a rate of 3.8 injuries per 100full-time equivalent workers, and resulting in a total of 417,918 lost workdays.2 •Among all employees,3 the highest injury rate occurred among coal operator employees (5.6 nonfatal injuries per 100 full-time equivalent workers). •The highest percentage (34.7%) of nonfatal lost-time injuries were due to handling materials (e.g., over-exertion in lifting, pulling, or pushing objects), which also accounted for the greatest percentage of lost workdays (29.3%). •Among the most frequently occurring injuries, the most severe (as measured by the median number of days lost) were associated with accidents involving falls of ground, the use of powered haulage, and slips or falls. •The most frequently reported part of the body injured was the back (22.9% of all injuries). Back injuries accounted for the highest percentage of lost workdays (21.6%). 5.Seven hundred sixty-seven (767) cases of occupational illness were reported to MSHA. •The most frequently reported illness was repetitive trauma, resulting in joint, tendon, or muscle inflammation or irritation (37.3%). •There were 155 (20.2%) illnesses reported as hearing loss. The majority (68.4%) of hearing loss cases occurred among surface workers. •Coal workers' pneumoconiosis accounted for 14.5% of reported illnesses.

May 15, 2002

By C. W. Davis

This is the first of a series of papers being; prepared as the work progresses in a study of the hydrometallurgy of manganese. The investigation is being made in an endeavor to make possible the utilization of lour-grade domestic manganese ores. The value of a hydrometallurgical process for manganese depends on the present and future uses for manganese products.

Jan 1, 1930

By P. E. Churchward

Rhenium sources and recovery methods were investigated by the Bureau of Mines to delineate potential resources of the metal. The only significant rhenium resource appears to be about 28,000 lb of rhenium contained in the domestic annual output of approximately 20,000 tons of byproduct molybdenite concentrates from porphyry copper operations. An estimated 70 to 80 pct of this rhenium is potentially recoverable by processing the rhenium-bearing fumes and dusts obtained during conventional roasting of molybdenite concentrate. At 70 pct recovery this would amount to 19,600 lb of rhenium. A more conservative estimate by the Committee on Refractory Metals of the National Research Council (1513 is that 12,000 lb of rhenium metal could be produced annually from current production of molybdenite from porphyry copper operations in the United States. A procedure was developed in the laboratory for recovering rhenium in the form of electrolytic flake by electrowinning the metal from a solvent extraction strip solution. The procedure included (1) water leaching of molybdenite roaster flue dust, (2) selective extraction of rhenium from the leach liquor by contacting it with a kerosine solution of a quaternary amine, (3) stripping of rhenium from the loaded organic solution by a perchloric acid solution, and (4) electrodeposition of rhenium from the loaded strip liquor. Raw material for the studies was flue dust containing 0.48 pct Re, 35 pct Mo, and 23 pct S in sulfide and sulfate form, and small amounts of numerous metallic impurities. Water leaching dissolved 85 pct of the Re and yielded a solution that was 13 in sulfuric acid and contained, 1 g/l Re and 16 g/l Mo. The solvent extraction strip solution that was electrolyzed for rhenium deposition was 1 molar in perchloric acid and 1 molar in ammonium sulfate and contained 13 g/l Re and 0.01 g/l Mo.

Jan 1, 1963

By T. L. Marchewka

As part of its program to conserve the Nation's natural resources by developing improved performance materials, the Bureau of Mines, U.S. Department of the Interior, in cooperation with the U.S. Department of Energy, has conducted an investigation of materials of construction able to withstand the high temperature and hostile environments encountered in coal gasification units. Refractory pipe liners are required when extremely hot gases or abrasive solids are transported between processing units in the gasification plants. One promising technique for producing refractory pipe (or refractory pipe liners) is centrifugal casting. For this study, the effect of processing variables such as workability, additives, reinforcement and spinning time, and centrifugal force were evaluated using four commercial refractory concretes. In addition, data on characteristics such as strength, density, abrasion, and spalling resistance of 5-inch-diam refractory pipe were developed. Techniques for forming large-diameter (19-inch) refractory pipe also were evaluated. The test results indicated that all four refractory concretes could be made into strong, homogeneous pipe, but that optimum casting parameters had to be determined for each specific composition. The investigation revealed that the major controlling factor in the production of the centrifugally cast pipe was the workability of the refractory concrete.

Jan 1, 1979

By F. Garcia, J. Cervik

Recent advances in the commercial separation of gases using membranes have renewed interest in the possibility of applying this technology to the recovery of methane ( CH4 ) from mining operations . This Bureau of Mines report briefly reviews the history of the development of membranes for gas separation , the theory of how they work , and their application to the separation of methane from air and associated problems . However , methane -air mixtures are difficult to separate with membranes because the pertinent gas couples , 02 - N2 , 02 - CH4 , and N2 -CH4 , have poor separation characteristics , as indicated by their separation factors of about 3 or less . Even if these separation factors were substantially higher , there is doubt that methane could be recovered economically from the low concentrations in mine ventilation exhaust ( 2 vol pct or less ) . The exhaust pressures are not sufficient for adequate separation . The power cost of compressing the methane recovered . these mixtures would far exceed the value of New discoveries could make separation of gob hole methane - air mixtures practical . These mixtures have much higher concentrations of methane (from 30 to 100 vol pct ) ; however , for safety reasons , be limited to gob gas with 60 vol pct CH4 or more .

Jan 1, 1988

Provide a rapid, reliable means of warning underground miners of a fire or other emergency. Approach An ultalow-frequency electromagnetic signaling system was designed, breadboarded, and tested at various under around mines. How It Works Current fire warning systems for underground mines, such as stench, audible alarms, and messengers, arc slow, unreliable, and seldom achieve total mine coverage. An ultralow-frequency electromagnetic fire warning alarm system with true through-the-earth signaling capabilities was developed to solve these problems. The system was originally designed for high-back room-and-pillar mines where stench systems are unusable due to the low velocity of mine air flow. However, the system has an application to all underground mines.

Jan 1, 1988

By Robert L. Crosby

The Bureau of Mines investigated the substitution of cement copper powder for commercial copper powder in an Fe-7 pct Cu-l pct C powder metallurgy alloy. Copper powders from six different commercial cementation operations were separately upgraded by screening and hydrogen reduction. They were then mixed with commercial iron and graphite powders to form the Fe-7 pct Cu-l pct C alloy. Various chemical and physical properties were determined on the upgraded cement copper and the alloy powders. Mechanical, physical, and chemical properties were determined on green and sintered specimens made from the alloy powders. Mean tensile and bending strength of sintered specimens were significantly lower than the means from specimens made from commercial metal powders. The lower strengths are apparently related to poor sinterability.

Jan 1, 1970

This volume summarizes the contract work performed over a nine-month period by Westinghouse Electric Corporation on a Cost Plus Fixed Fee Contract for the Department of Interior's Bureau of Mines. The contract has been extended primarily to carry out improvements recommended for equipment produced under the contract for communicating with and locating trapped miners. These improvements will enhance the performance and utility of this equipment for operational use in actual mine emergencies. An additional complete set of the equipment will also he furnished to the Bureau under this extension. The work of the basic contract was to design, produce and test hardware in accordance with the Westinghouse response to a Bureau of Mines Request for Proposal which was based technically on recommendations of a study performed for the Bureau by the National Academy of Engineering (NAE). The NAE study made suggestions for new equipment in three areas of need:

Jan 1, 1971

By Frank E. Chase, John Rusnak, David Newman

During the past quarter century, coal mine geologists have evolved from providing a qualitative description of drill core and coal reserves into quantitative geotechnical specialists who bridge the gap between geology and engineering. In the late 1970’s and early 1980’s, hazard prediction mapping was in its infancy. At best, hazard maps identified rudimentary structures and conditions such as stream valley locations, sandstone/shale transition zones, and lineaments. A “technical disconnect” had existed between geologists and mining engineers as each profession operated largely independent of each other. Engineers did not readily integrate geology and geologic conditions, with the exception of coal thickness, into mine planning. Geologists were relied upon for reserve estimates and did not participate in mine planning or design. The employment and market slump of the 1980’s and 1990’s combined with mining more challenging reserves mandated that this gap be bridged and forced geologists to learn to speak more “numerically” to engineers so they could be understood. The purpose of this paper is to describe the procedures and thought processes used by coal mine geologists when determining various mineability and reserve extraction feasibility issues. The paper will also address underground geologic hazard mapping and prediction techniques. To achieve these objectives, the opinions and experiences of leading coal mine geologists, geotechnical and strata control specialists across the United States were solicited.

By V. E. Erwin, W. W. Adams

"Production of explosives for industrial use in,the United States during 1934 continued the upward trend begun in 1933 from the low-level output of 1932, and the output in 1934 was only slightly less than in 1931.Reports to the United Stated Bureau of Mines from companies engaged in the manufacture of industrial explosives showed that the quantity of explosives manufactured in the United States and sold during 1934 for use within the various States was 314,767,922 pounds - 23 percent more than in 1931.Production during 1934 included 39,207,845 pounds of permissible explosives 5 206,625,027 pounds of high explosives other than permissibles, and,68,935,050 pounds of black blasting powder of which 37,192,700 pounds were in granular form and 31,742,350 pounds in pellet form. These figures represent an increase over 1933 of 15.6 percent for permissible explosives, 30.9 percent for other high explosive, and 7.4 percent for black powder.Coal-mining operations were the chief consumers of permissible explosives; 99 percent of the total output in 1934 was used, in coal mines. The proportion used by bituminous mines was 59 percent and by anthracite mines 40 percent. Coal mining was likewise the principal consumer of black blasting powder, taking 88 percent of the total sales during 1934; of this proportion, bituminous mines received 78 percent and anthracite mines between 9 and 10 percent. Consumers of high explosives other than permissibles were more varied; the reports showed that 11 percent of the total quantity sold was for coal mining, 22 percent for metal mining, 17 percent for quarrying and nonmetallic-mineral mining, 46 percent for railway and other construction work, and 4 percent for all other purposes."

Oct 1, 1935

By A. W. Henderson

The growing importance of halide metallurgy for preparing high-purity metals has stimulated research to extend halogenation reactions to the direct extraction of metals from low-grade sources. This Bureau of Mines investigation involves a pioneering study of chlorination reactions in the presence of a fluorine donor. Tin slags containing tantalum and columbium and a zircon concentrate containing a relatively high ratio of hafnium to zirconium were studied. Direct chlorination of these materials at 500° C. yields only a 5-percent conversion of tantalum and columbium or zirconium and hafnium to anhydrous chlorides. This investigation showed that small additions of calcium fluoride to the reaction increased the recovery of tantalum and columbium to 95 percent and the recovery of zirconium and hafnium to 27 percent. These results were achieved with ratios of calcium fluoride to mineral or slag of only 0.2. Silica, the major impurity in the materials studied, was found to be converted to silicon tetrafluoride during chlorination in direct proportion to the quantity calcium fluoride added to the charge. However, large additions of calcium fluoride decreased the volatility of the resulting halides of tantalum, zirconium, and hafnium. Smaller amounts of calcium fluoride also favored recovering minor metal constituents in the zircon concentrate (uranium, thorium, and rare earths).

Jan 1, 1962

By J. C. Meeks, C. L. Klingman

An instrument that is sensitive , portable , safe , and low in cost was developed by the Bureau of Mines for detecting helium leaks by comparing the thermal conductivity and flow rate of the atmosphere around the suspected leak against a reference of helium- free air . A vacuum pump pulls the sample gas through a restriction and over thermistor elements , the combined electrical output of which is affected by thermal conductivity and flow rate of the sample gas . Tests showed that the battery - operated Helium Leak Detector was effective and rugged instrument that could be operated safely in explosive atmospheres . The instrument could also detect , but not identify , other gases such as methane , hydrogen , argon , carbon dioxide , and Freon 12 .

Jan 1, 1964

By Albert E. Keller

This paper describing the timekeeping and pay-roll methods of the Britannia raining and Smelting Co. (Ltd.) is one of a series being prepared for and published by the United States Bureau of nines regarding office procedures in connection with mining operations. The general office of the Britannia Mining and Smelting Co. (Ltd.) is located at Britannia Beach, B. C., a town of about 600 inhabitants at tidewater on the east side of Howe Sound and about 30 miles from Vancouver, B. C. The Beach, as it is locally termed, is a company town consisting largely of about 250 employees of the company and their families. Here is the milling and concentrating plant of over 6,000 tons daily capacity- the main service units comprising the electrical, mechanical, blacksmith and woodworking shops and the local electric-furnace foundry; the central-heating steam plant; the air and electric generating units; the ball-manufacturing plant; the warehouses; and the general store, which serves this community and also acts as distributor for the general stores located elsewhere on the property.

Jan 1, 1932

By M. J. Ankeny

All bituminous-coal mines, by the nature of their product and inherent gassy tendencies, are subject to explosions or mine fires. The evolution from large, hand-loading sections employing numerous men and containing open-type equipment, lights, and nonpermissible explosives to small, concentrated mechanical sections with but few well-supervised men utilizing modern preventive equipment has not altered this premise. Mine catastrophes such as Centralia and New Orient No. 2, as well as recent disasters of less magnitude, have refuted the trend of thinking that modern equipment, will prevent or localize explosions and prevent widespread or loss of life.

Jan 1, 1952