Search Documents

By W. F. Watts

This report describes a statistical analysis of 41,502 respirable quartz dust samples collected from 1974 through 1981 in metal and nonmetal mines and mills. The goal of this Bureau of Mines study was to identify commodities and occupations associated with high quartz dust exposure so that future enforcement and research activity can be focused on the high-exposure areas. For this analysis, the Bureau used its computerized Mine Inspection Data Analysis System (MIDAS), which contains data on nearly 350,000 air samples, including data for 61 contaminants in 45 commodities. The samples analyzed were collected by inspectors of the Mine Safety and Health Administration (MS HA). The data were entered into the MIDAS computer and coded according to commodity, occupation, location, and other categorical information. Occupations an. commodities with high quartz dust exposure were identified by grouping the data by code categories. Workers at sandstone, clay and shale, and miscellaneous nonmetallic mineral mills had the highest quartz dust exposures. Within these mills, occupations with high exposures were baggers, general laborers, and persons involved in crushing, grinding, and sizing operations. Dust concentrations in these mills were not necessarily the highest, but because the dust contained a high percentage of quartz, the health risk from dust exposure was the greatest.

Jan 1, 1984

By K. L. Williams

The Bureau of Mines laboratory tested the response of a commercially available real-time aerosol monitor (GCA RAM-1) to various dusts. Monitor measurements were recorded, averaged, and compared with simultaneous gravimtric measurements of each test dust. Tests usually lasted several hours. The test dusts of various particle size distributions used included coal, limestone, and a commercially available test dust. For each particular dust, the monitor response was linear and correlated well with mass concentration over the range of about 0.5 to 10 mg/m3. The monitor can estimate a 2.0-/m3 respirable coal dust concentration within as little as 26 pct with 95 pct confidence. The monitor must, however, be calibrated with the dust to be measured because the instrument response is affected by the type of dust particle. The average monitor response to same mass concentration of coal dust was approximately twice the average monitor response to the same mass concentration of limestone dust.

Jan 1, 1984

By Peter G. Chamberlain

The surge in gold and silver prices during the 1970's attracted many new mining operators and has rekindled interest among experienced ones. With its low capital investment requirements and fast payout, leaching has attracted many operators--particularly those with small or low- grade deposits. Although in certain situations leaching offers many advantages over conventional mining methods, many operators are uncertain how these relatively new techniques should be implemented. Consequently the Bureau of Mines has prepared this circular to disseminate information on gold and silver leaching practices, techniques, and problem. Engineering data gathered from 26 operations indicate that most ores are leached in heaps following crushing and distribution on pads. Metal values are recovered from cyanide leach solutions using either zinc precipitation or charcoal adsorption. Potential problems that my hamper on block development of a leaching operation are poor percolation characteristics of the ore, calcium salt buildup, low temperatures, and solution losses. An extensive bibliography on gold and silver leaching is appended.

Jan 1, 1984

By Mark R. Pettitt

After a long series of laboratory and in-mine tests, a cost- effective, mineworthy, reduced-noise auger miner cutting head was de signed, fabricated, and field-tested by Wyle Laboratories under contract to the Bureau of Mines. Compared with standard auger cutting heads, the new heads reduced noise by 10 dBA at the jacksetter's position and by 6 dBA at the operator's position. This report contains detailed fabrication instructions, including engineering drawings, that show how a standard auger cutting head can be modified to produce a reduced-noise auger.

Jan 1, 1984

By Christopher H. Roe

This Bureau of Mines report reviews the various methods of removing the liquid from tailings slurries that contain very fine grained solids. Gravitational settlement, centrifugation, filtration, and thermal drying methods are discussed in detail. Chemical additives, electrokinetic dewatering, and the rotary trommel screen are also mentioned. Lists of dewatering equipment and suppliers are given in the appendixes to assist the planner who must choose the most efficient, economic, and practical method of dewatering very fine grained mill tailings.

Jan 1, 1984

These proceedings consist of papers presented at Bureau of Mines Technology Transfer Seminars in December 1983 for the purpose of disseminating recent advances in mining technology in the area of mine ground control. The Bureau of Mines conducts several of these seminars each year in order to bring the latest results of Bureau research to the attention of the mining industry as quickly as possible.

Jan 1, 1984

By Richard P. Walters

This Bureau of Mines report reviews and assesses the technology for preparing electrodeposited coatings of the platinum-group metals from molten alkali metal cyanide baths. Methods are described for the preparation and purification of the cyanide electrolyte. Vacuum drying, fusion, and purity of the cyanide salts are discussed. Use of a sodium borosilicate test tube as a sodium-ion-conducting membrane for the addition of the desired platinum-group metal is described. The optimum plating parameters of potential and current density for Pt, Pd, Rh, Ru, and Ir coatings that result in the best deposits are given. A method for producing platinum-rhodium alloy coatings of predetermined composition is also described. The importance of careful substrate surface preparation is illustrated. While problems still remain with respect to coating porosity, careful application of the methods described permits the preparation of adherent, coherent electrodeposited coatings of the platinum-group metals.

Jan 1, 1984

By R. J. Pokora

This Bureau of Mines report is an applications manual that can be used by the nonmetallic mining industry for guidance in installing noise control materials into crushing and screening plants. These noise control modifications were installed and successfully tested at three operating quarries. This report identifies the major noise sources that can be encountered in crushing and screening plants, and discusses the applicable noise control materials and techniques that a plant operator can utilize on a retrofit basis to reduce equipment noise.

Jan 1, 1984

By Noel N. Moebs

This report summarizes 10 selected Bureau of Mines research contract reports produced from 1970 to 1980 which consist largely of geologic studies of coal mine roof support problems. Significant highlights from the contract final reports are discussed and presented in practical terms. The selected reports focus on the Appalachian and Illinois coal mining regions. In the Appalachian coal region, two geologic structures, roof rolls and slickensides, predominate over all structures as features that directly contribute to roof falls. Studies of these and other structures are reviewed, and improved methods of utilizing drill core and core logs to prepare hazard maps are presented. Among the reports described are several on the weakening effects of moisture on shale roof, as determined from both laboratory and underground measurements, and an assessment of air tempering as a humidity-control method. Also summarized are findings concerning the time lapse between roof exposure and permanent support installation as a factor in the effectiveness of roof bolting.

Jan 1, 1984

By P. R. Thomas

The Bureau of Mines determined the costs associated with the production of chromium, in the form of chromite and high-carbon ferrochomium, from the demonstated resources of 10 market economy nations. The analyses evaluated the relative geologic and economic position of these chromite resources contained within 80 producing or potential mining operations. This report presents cost evaluations of a demonstrated resource of chromite, contained within the nations studied, of appoximately 1.2 billion metric tons (t). Of this total, 70 pct is contained within the southern African nations of Zimbabwe and the Republic of South Africa. The majority of current chromium mining and smelting capacity is contained within these two countries as well. India and the Philippines have recently demonstrated greatly increased chromite resources and hold the most promise for expanding both chomite and ferrochromium production outside southern Africa. Their demonstrated resources represent approximately 7 and 16 pet, respectively, of the cost evaluated total tonnage. Chromite resources, on an identified or hypothetical basis worldwide, are highly concentrated within Zimbabwe and South Africa, with these two nations containing in excess of 95 pet of the total. Given the present market structure, a majority of chromium contained within the demonstrated chromite resources of the nations studied is economically recoverable; but from a long-term resource and economic perspective, South Africa should inceasingly dominate the markets for both chromite and high-carbon ferrochromium. In addition, it is anticipated that an increasing percentage of chromium traded on the world market in the future will be in the form of high-carbon ferrochromium as opposed to chromite, as this additional processing stage continues to relocate from the industrial nations that account for a majority of chromium consumption to those nations that mine chromite.

Jan 1, 1984

By Joseph S. Coffman

To determine the availability of manganese for metallurgical purposes from selected world resources, the Bureau of Mines evaluated the potential production of contained manganese in concentrates based on the demonstrated resources of 23 foreign and 8 domestic mines and deposits in 9 market economy countries. All but 2 of the 23 foreign deposits are operating mines; none of the domestic deposits are in operation. The demonstrated resources of the mines and deposits used in this study represent an in situ ore resource of approximately 2.2 billion tons," containing 780 million tons of manganese with a total recoverable production potential of 514 million tons of contained manganese in concentrates. The analyses of mines and deposits in this study indicate that about 213 million tons of the contained manganese (41 pct) is potentially available at a January 1981 constant dollar long-run total cost of up to $1.50 per long ton unit (22.4 lb, or 10.15 kg contained Mn), approximately 428 million tons (83 pet) is potentially available at a cost of about $1.75 or less, and 491 million tons (95 pet) is available at less than $3.30. The remaining 23 million tons, which is potentially available at much higher costs (about $8 to $35 per unit), represents the U.S. deposits. On an annual basis, with a cost range of up to $1.75 per long ton unit, the availability from currently operating mines would last at least 80 years based on 1980 world production data. Total manganese production costs are estimated to comprise mining-8 pet, beneficiation-3 pet, transportation-26 pet, and smelting-63 pet.

Jan 1, 1984

By James S. Grichar

Interest in mergers in the nonfuel mineral industry developed when 5 were listed among the 50 highest valued mergers in the United States in 1981. This report presents a Bureau of Mines study of trends in merger activity from 1960 to 1979 and explores motives for mergers in the nonfuel mining and mineral industry. The objective was to determine precedent for or a trend toward the 1981 acceleration in merger activity and to examine certain financial motives for non fuel mineral mergers. Data indicate that the relative value of non fuel mineral mergers has grown since 1972 although the number of mergers has remained proportionate to historical trends for all mergers. Since 1974, the assets acquired in "large," nonfuel mineral firm mergers, those of $10 million or more, have comprised at least 93 pct of assets acquired. More nonfuel mineral firm mergers involved mineral companies as the acquiring firm than vice versa but mining and minerals firms acquired were of higher value than nonmining firms. A major motivation for mergers involving large mineral firms was the acquisition of assets at less than replacement costs. Univariate statistical testing, a methodology chosen for its applicability to the data, confirms this hypothesis while rejecting other financial motives. The remainder of the work is devoted to a discussion of suggested areas for future study.

Jan 1, 1984

By C. T. Sheeran

The Bureau of Mines investigated a microprocessor-based real-time control and monitoring system for uranium mining applications. The system is capable of controlling and monitoring up to 768 stations within 3 km of the central processor on a common four-wire cable. It can be used in conjunction with detectors to continuously monitor and display radiation working levels at points throughout the mine. Surface alarms are sounded for critical situations such as rapid radiation buildup, loss of power to monitors or fans, and changes in air door position. Permanent records of all changes are automatically printed out with their time of occurrence. Printouts can also be obtained for shift reports or trend logs. The system can be used to remotely control fan startup and shut-down, and also can alert miners of underground conditions by blowing horns or turning on lights. Battery backup keeps the system operative for up to 4 h in case of a mine power outage. A special software feature permits automatic, time-delayed, sequential restart of fans.

Jan 1, 1984

This publication summarizes the in-house and contract research projects programmed for fiscal year 1984 by the Bureau of Mines under its Conservation and Development activity. The document provides a mechanism for interested parties to gain insight into projects of the Bureau's Conservation and Development research program. The objective of the Conservation and Development Program is to provide the technological advances needed to stimulate the mining of domestic deposits containing critical, strategic, and other essential minerals in compliance with existing regulations and at costs sufficiently low to be competitive in world markets. Research efforts are directed toward improving the fundamental understanding of processes and procedures involved in the production of minerals. The overall goals will be accomplished by investigating alternative mining methods to increase domestic production of critical and strategic minerals from low-grade deposits; expanding the technology for the economic and efficient extraction of minerals consistent with cost-effective compliance with environmental regulations; and advancing the technologies needed to insure an adequate supply of coal.

Jan 1, 1984

By Gary W. Krantz

Fibered, portland-cement-based gunite products were applied in the Bureau of Mines Lake Lynn Laboratory Experimental Mine using a variety of pneumatic guns and gunning crews, The demonstrated wet-mix (with silica fume), dry-mix, and surface bonding products were sampled by the Bureau and subjected to a suite of engineering analyses. Gunite flexural and compressive strength, rebound, permeability, porosity, dust loading, shooting rate, crew requirements, and cost factors were evaluated. Steel, fiberglass, or polypropylene fibers were contained in all but two of the gunires tested. Both Bureau and private testing laboratory analyses are provided for some products. Electron probe micro-analysis and X-ray diffraction analysis were performed on the silica fume fraction of the wet-mix gunite to characterize the dust. Aggregate size fraction distribution analyses were performed to provide strength relationships. Results indicate that all of the commercially available fibered-gunite materials tested can provide beneficial sealant, spall prevention, or roof stability control attributes for underground mining environments when applied by an experienced crew using a well-maintained gun, in accordance with product manufacturers' recommendations and when used for the designated purpose.

Jan 1, 1984

By Bernard S. Covino

The Bureau of Mines is conducting a study of methods to improve the efficiency of the process used to pickle stainless steels. A review of the literature on pickling of stainless steels showed that the chemistry of several process operations involved in the pickling of stainless steels is not fully understood, and that further research could improve the pickling efficiency. The benefits of this research would be a reduction in the annual loss of several thousands of tons of critical minerals such as nickel and chromium, and a reduction in the amount of solids and spent acid solution that are currently discarded. The conclusion from this review is that further research is needed in four operations that either directly or indirectly influence the pickling process: hot working, annealing, conditioning, and the actual operation of pickling, Laboratory studies of the pickling operation are presently in progress.

Jan 1, 1984

Overexposure to noise is a widespread, serious health hazard in the mining industry, and causes hearing losses to a large percentage of the mining population. Recognizing this fact, the Bureau has a major on-going research effort to address this problem area. These proceedings include an overview of the Bureau noise control program and summarize nine selected noise control research programs.

Jan 1, 1984

By D. A. Buckingham

The Bureau of Mines evaluated potential availability of domestic nickel from 23 deposits, Evaluations included an estimation of in situ and recoverable resources, applicable mining and processing technologies, and capital and operating costs. Discounted cash flow analysis with a 15-pct rate of return was used to determine the average total cost of production of each operation, Identified in situ resources contain 9.0 million metric tons (t) of nickel; 5.5 million t is recoverable as nickel metal or ferronickel. Demonstrated in situ resources contain 8.2 million t of nickel; 4.8 million t is recoverable as nickel metal or ferronickel. No nickel is available at a total cost of production equal to the January 1983 market price of $3.24 per pound. Analyses indicate that potential annual production can only meet current consumption levels at a total cost of production of $7.60 per pound of nickel, Nickel's availability is contingent on (1) successful adaptability of nickel processing methods to domestic resources, (2) location of a smelting facility, and (3) marketability of byproducts and coproducts. Analyses were performed on the effects of byproduct and coproduct revenues, energy, labor, and transportation costs, and metallurgical recoveries on nickel's availability.

Jan 1, 1984

By R. J. Fantel

The Bureau of Mines investigated the resource potential of 201 mines and deposits in 28 market economy countries and 17 mines and deposits in the U.S.S.R. and China. The 201 mines and deposits evaluated from market economy countries contain an estimated 34.2 billion metric tons of recoverable phosphate rock (at the demonstrated resource level), with Morocco and Western Sahara accounting for 61% (21 billion tons), followed by the United States with 19% (6.4 billion tons). The 17 mines and deposits evaluated in the U.S.S.R. and China contain approximately 1.5 billion tons of potentially recoverable phosphate rock. Potential annual capacity from low-cost, high-grade producing mines in the United States is estimated to decline significantly during the latter half of the next decade, and the United States will have to develop new, higher cost, lower grade mines in order to satisfy demand into the next century. Of the world's new production capacity which could likely be developed over the next decade, slightly over one-third could be produced at an estimated 1981 cost of $40 per ton or less, and about two-thirds would cost in the $40 to $50 range (including a 15% rate of return). In comparison, moot of the competing phosphate rock from producing mines in Morocco could be produced for under $40 per ton. The United States has sufficient demonstrated resources of phosphate rock (plus huge quantities at the identified and hypothetical resource levels) to satisfy domestic consumption for many years to come, but its future ability to compete in the major export markets against low-cost competitors is much more uncertain.

Jan 1, 1984

By Jeffrey Y. Foley

Chromite deposits along the Border Ranges Fault in southern Alaska were investigated by the Bureau of Mines. This report, part 1 of a two- part series, describes the deposits. Part 2 describes the mineralogy and the results of metallurgical tests. Fieldwork began in 1981 and continued through 1983. Ninety-four subeconomic podifom chromite deposits in eight mafic-ultramafic complexes were investigated. Previously unreported chromite deposits at Red Mountain on Kenai Peninsula, on Kodiak Island, and near Tonsina are described. Deposits range in size from less than a thousand tons to over 1.25 million tons of contained chromic oxide (Cr203). Grades range from about 5 to 10 pct chromite. Excluding all deposits more than 10 miles from tidewater or existing roads and all deposits containing only chemical- or refractory-grade chromite, about 2,200,000 tons of Cr203 are contained in 41 hard-rock deposits. A placer deposit contains an additional 556,000 tons. These 42 deposits constitute a subeconomic indicated and inferred reserve sufficient to meet the Nation's chromite demands for about 4 yr, or the metallurgical industry's demands for over 5 yr, at 1981 consumption rates.

Jan 1, 1985