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By Robert M. Cox

The U. S. Bureau of Mines (USBM) MULSIM/NL modeling technique has been used to analyze anticipated stress distributions for a proposed alternative longwall gate road design for a western Colorado coal mine. The model analyses indicated that the alternative gate road design would reduce stresses in the tailgate entry without increasing stresses in the headgate entry. To test the validity of the alternative gate road design under actual mining conditions, a test section of the alternative system was incorporated into a subsequent set of gate roads developed at the mine. The alternative gate road test section was instrumented with borehole pressure cells, as part of an ongoing USBM research project, to monitor ground pressure changes as longwall mining progressed. During the excavation of the adjacent longwall panels, the behavior of the alternative gate road system was monitored continuously using the USBM computer-assisted Ground Control Management System. During these field tests, the alternative gate road system was first monitored and evaluated as a headgate, and later monitored and evaluated as a tailgate. The results of the field tests confirmed the validity of using the MULSIM/NL modeling technique to evaluate mine designs.

Jan 1, 2010

By G. L. Anderson

The critical importance of wire rope integrity to the mining industry has led to the creation of standards for the retirement of wire rope as well as to the development of electromagnetic devices and procedures that would allow wire ropes to be tested against these standards without destroying them, The U.S. Bureau of Mines (USBM) conducted research to evaluate these devices by measuring loss of metallic cross-sectional area and the number of wire breaks, or local faults. The intent was to define the extent to which the technique can identify degradation within the rope, e.g., broken wires, corrosion, and wear. Experimental results showed that instrument sensitivity depended on a number of factors, including rope diameter, placement of sensors, location and characteristics of flaws, rope speed, and tension on the rope. The experiments also demonstrated the importance of having an elongated recorder trace and a properly trained and experienced operator to interpret overall results. A design of a rope and test procedures for use in laboratory evaluation of instruments have been recommended by the American Society for Testing and Materials Committee E07.07.10, Wire Rope Applications. The USBM is working through this committee to develop standards for an electro-magnetic method of wire rope inspection.

Jan 1, 2010

By P. D. Laverty

This report describes a processing method developed by the U.S. Bureau of Mines to produce high-quality flake graphite from the steelmaking waste known as kish. The kish produced by current steelmaking practices is a mixture of graphite, desulfurization slag, and iron that is skimmed from the molten iron feed to the basic oxygen furnace. It is estimated that the graphite content of kish discarded by U.S. steel plants is more than sufficient to meet the total U.S. demand for flake graphite. That need is now filled by natural graphite from foreign sources. Kish was treated by a combination of screening and hydraulic classification to produce a concentrate containing greater than 70 pct graphite. Leaching of the concentrate with hydrochloric acid solution gave a graphite product with 95-pct purity. An optional secondary leaching operation with hydrofluoric acid produced graphite with a purity of 98 pet or greater. The flake size of graphite from kish ranged from 10 mesh down. Evaluation of test samples by industrial graphite users indicated that kish graphite is a suitable substitute for the natural material for most uses. A process flowsheet and material balance for pilot plant design are presented.

Jan 1, 2010

By Alexander May

The U.S. Bureau of Mines investigated the application of oxidation-reduction potential (ORP) and pH measurements to environmental studies of mining and mineral processing wastes, and developed a computer program to estimate the concentrations of species of lead present in samples from a lead processing waste site. The methods and techniques for the ORP-pH measurements were investigated using known standard solutions made in the laboratory, samples from a ferric oxide waste disposal pond at a rutile production plant, and samples of well water and stream water from the lead processing waste site. ORP values were measured from 5 to 80 °C, from pH 1 to pH 12, and at various ratios of oxidant to reductant. The ORP-pH values can help identify valence values and species of ions present, including those of major, minor, and trace concentrations, and also indicate possible reactions at various pH values. The ORP measurements versus temperature yield data from which thermodynamic values can be calculated. The application and limitations of these measurements are discussed, and a brief discussion of the computational program to identify species of lead is presented.

Jan 1, 2010

By C. L. Karr

U.S. Bureau of Mines (USBM) research has shown that fuzzy logic and genetic algorithms (GA's) have great potential for industrial process control. A technique has been developed by the USBM in which GA's are used to substantially reduce the time needed to design fuzzy logic controllers (FLC's).This technique shows promise as an efficient, robust approach to developing control systems. The research described in this report is twofold. First, the basic approach to developing an FLC using GA's is presented. The GA-designed FLC is developed for a specific physical system, a pH titration system. Second, empirical results are presented in which variations in the FLC implementation are compared. Specifically, the effects of altering five aspects of the pH FLC are considered: (1) membership function form, (2) number of fuzzy classes, (3) the center-of-area method, (4) implication operator, and (5) fuzzy rule form. Results indicate that (1) the technique in which GA's are used to design FLC's is effective, and (2) when this technique is used, variations in FLC implementation have little effect on FLC performance in a chosen control problem.

Jan 1, 2010

By G. L. Anderson

The U.S. Bureau of Mines (USBM) has conducted research to improve the nondestructive testing (NDT) of wire hoist ropes. Losses in the diameter of a wire hoist rope are used as one criterion for judging when a rope should be replaced. Losses are determined by periodically measuring the rope diameter and comparing this measurement with the original measured diameter; when the diameter reaches a specified minimum at any point along its length, the rope must be retired. Generally, these measurements are made at randomly selected locations along the length of the rope, using a hand caliper. To provide more accurate measurements and to allow measurements to be taken continuously along the length of a hoist rope, an optical diameter-monitoring system was built for the USBM under contract. Continuous measurements are preferable because, when combined with continuous electro-magnetic NDT results, they can indicate whether losses in metallic cross-sectional area originate from external wear or internal wear and corrosion. Tests of the system showed that the instrument met specifications when measuring wire rope at low rope speeds but was inaccurate at speeds over about 30 m/min (100 ft/min). This report describes the prototype system, presents the results of the test program, and describes the capabilities of the system.

Jan 1, 2010

By G. F. Friel

A series of experiments in the U.S. Bureau of Mines Safety Research Coal Mine at the Pittsburgh Research Center evaluated the effects of crosscuts on the travel time of carbon monoxide (CO) along an entry to improve the accuracy of a mine-fire locator program. Three entries, ten single crosscuts, and three double crosscuts were instrumented with CO sensors. One-percent CO in nitrogen was released and monitored as it traveled the entries. In addition to dispersion of CO at the front of the CO wave, CO was entrained from the entry into the crosscuts. It was determined for an entry and single-crosscut configuration that the measured travel time for a concentration change of 5 ppm was 27% greater than the predicted time based upon entry volume only, but 13% less than the predicted time based upon entry and crosscut volumes. For an entry and double-crosscut configuration, the measured travel time for the same concentration change was 25% greater than the predicted time based upon entry volume only, but 10% less than the predicted time based upon entry and crosscut volumes. An effective dispersion coefficient for CO dispersion along one of the entries was estimated to be 1.5 m2/ s.

Jan 1, 2010

By S. L. McGill

The U.S. Bureau of Mines has determined the microwave heating rates for a suite of minerals and reagent-grade compounds. Maximum temperature achieved for the samples and the time required to reach temperature are reported. Heating rates of powdered samples are presented as a function of incident powers up to 3,000 W at 2,450 MHz. Descriptions of the microwave cavities, test cells, and a thermocouple assembly used to measure temperature in the microwave field are given. Many minerals of value heated in the microwave field, whereas host rock or gangue materials did not. In general, heating rates increased as incident power was increased. Exceptions to this were some very good (CuO, Fe304, and PbS) and very poor (CaC03 and SiO2) microwave-absorbing materials that showed negligible changes with increased power. Applications demonstrating the use of microwave energy in mineral processing that are described herewith include oxidation-reduction reactions, mineral liberation, and mercury retorting-vaporization. Microwave data on mineral heating rates will provide insight to possible chemical and mineral processing applications as well as assist in predictions of processing parameters.

Jan 1, 2010

By J. B. Salsman

As part of the research effort on investigating the effects of microwave energy on the chemical and physical properties of minerals and ores, the U.S. Bureau of Mines (USBM) Tuscaloosa Research Center has conducted research to measure the dielectric properties of these materials. The objective was to establish a reliable database for use in predicting the effects of microwave heating on a wide range of minerals. The dielectric constants and loss factors of minerals, commonly referred to as the dielectric properties, were determined utilizing the theory of microwave propagation through an open-ended, air-filled coaxial line that was terminated at its open end with the particular mineral under investigation. In this phase of microwave research, the USBM measured the dielectric properties of powdered minerals with medium to high electrical conductivities in the frequency range of 300 MHz to 3 GHz and as a function of temperature from 25 to 325 °C. Since the minerals were prepared as powders, techniques were used to relate the measured dielectric properties of the powdered minerals to the dielectric properties of the mineral at its theoretical or natural density.

Jan 1, 2010

By Maria I. De Rosa

The U.S. Bureau of Mines conducted a study to determine if correlations exist between the chlorine or nitrogen contents of materials and the hydrogen chloride (HCI) or hydrogen cyanide (HCN) concentrations evolved during the thermal decomposition of these materials. Hydrogen chloride, hydrogen cyanide, and carbon monoxide (CO) were found to be the primary toxic gases evolved during the combustion process. The experiments were carried out in a 20-L furnace with 1-g samples. The furnace temperature, rising from ambient, was set at 1,000 °C with an airflow of 10 L/min. The variables measured were the gas loads (milligrams per gram) of HCI, HCN, CO, and CO2 (carbon dioxide); CO and CO2 concentrations as a function of time were also measured. Other variables included the average concentrations of submicrometer smoke particles and particles' average diameter, mass of particulates, sample and furnace temperatures, and sample weight loss. The data indicate that there are significant correlations between the percentage of chlorine or nitrogen contained in the original samples and the HC1 or HCN concentrations evolved during the combustion of the materials. These correlations may be used to predict and evaluate a material's toxic hazard during combustion.

Jan 1, 2010

By D. K. Steele

The domestic primary copper industry generates in excess of 600 million t of mining and mineral-processing waste annually. Most of the waste poses negligible environmental threat, but a small fraction, because of toxic or corrosive characteristics, may be subject to regulation under Subtitle C of the Resource Conservation and Recovery Act (RCRA) or other pertinent regulations. Among the wastes generated by various copper producers are flue dusts, slags, refinery-bleed solutions, and. acid-plant wastes. The U.S. Bureau of Mines (USBM) has researched methods to mitigate the environmental threat posed by copper-processing wastes while recovering valuable metals from these materials. Acid-leach processing of flue dusts has been demonstrated feasible along with sulfide treatment of liquid refinery wastes and acid-plant-bleed and gas-cleaning solutions to precipitate dissolved metals. In, addition, the feasibility of removing copper and molybdenum from slag, as well as stabilization of precipitated sulfide wastes by vitrification, have been investigated.

Jan 1, 2010

By David E. Siskind

The U.S. Bureau of Mines and the State of Indiana cooperated with AMAX Coal Co. and its consultants to determine the effects of coal mine overburden blasting on nearby pipelines. Five pressurized 76-m pipeline sections were installed on the Minnehaha Mine highwall near Sullivan, IN, for testing to failure. Four 17-to 51-cm-diameter welded steel pipes and one 22-cm PVC pipe were monitored for vibration, strain, and pressure for a period of 6 months while production blasting advanced up to the test pipeline field. In contrast to previous studies of small-scale, close-in blasting for construction, these tests involved overburden blasts of up to 950 kg per delay in 31-cm blastholes. Analyses found low pipe responses, strains, and calculated stresses from even large blasts. Ground vibrations of 120 to 250 mm/s produced worst case strains that were about 25 pct of the strains resulting from normal pipeline operations and calculated stresses of only about 10 to 18 pct of the ultimate tensile strength. No pressurization failures or permanent strains occurred even at vibration amplitudes of 600 mm/s.

Jan 1, 2010

By Robert L. Kranz

The U.S. Bureau of Mines (USBM) has been monitoring and studying seismic activity associated with mining in the Coeur d'Alene silver district of northern Idaho. New statistical methods of studying the stope-scale (1-to l00-m) seismicity at one Idaho silver mine are used in this report (part 1) and its companion (part 2). This report deals with methodology and its limitations. The recent concept of fractals and their seismological use is discussed and applied to mining-induced seismicity. Three types of fractal studies are addressed: spatial analyses (including temporal changes of spatial patterns), temporal analyses, and size analyses. Other statistical measures of mine seismicity are also addressed: event mean location, inter-event distance distribution skewness, temporal coefficient of variation, nearest neighbor and next event statistics, and event location planarity patterns. Each of the methodologies discussed (fractal and nonfractal) is presented using sample data from two stopes in the mine. It is shown that stope-scale, mining-associated microseismicity has a fractal nature. The usefulness of demonstrating fractality (scale invariance) for predictive or descriptive purposes depends on recognition of the factors affecting the calculation of fractal dimensions. Several methodological traps are illustrated that can lead to an incorrect conclusion.

Jan 1, 2010

By J. C. Duchon

The use of extended workdays or compressed workweeks (regular shift lengths exceeding 8 h) is attracting growing interest in many industries using continuous operations. While extended workdays promise increased worker satisfaction due to more days off, including weekends and holidays, there are legitimate concerns about the potential effects on the health and safety of such a schedule. The U.S. Bureau of Mines (USBM) conducted a study at a Canadian underground copper, lead, and zinc mining operation that was designed to study the safety and performance implications of extended workdays. Measures were taken before and after a change from the old 8-h continuous schedule to the new 12-h continuous schedule, including behavioral performance measures to analyze perceptual-motor changes, continuous heart-rate monitoring and aerobic capacity to measure physical fatigue, a variety of self-report questionnaires to measure perceived adaption and satisfaction with the new schedule, and pulmonary-respiratory measures to examine air contaminant exposure. Based upon the overall acceptance of the new schedule by the workers and lack of change in fatigue-sensitive behavioral and physiological performance measures, this study recommends that the mine retain the 12-h schedule. However, certain precautionary measures are suggested to insure the safety of the workers.

Jan 1, 2010

By E. A. Barrett, K. M. Kowalski

The U.S. Bureau of Mines (USBM) conducted experiments to determine if training using a latent- image, three-dimensional (3-D) slide simulation exercise improved miners' ability to recognize roof and rib hazards. The effectiveness of this innovative type of classroom training was investigated by measuring workers' performance on a hazard recognition task. The study was unique in that hazard recognition skills were assessed in the workplace using actual coal mine roof and rib hazards. Results showed that training with a latent-image, 3- D slide simulation exercise significantly improved each subject's performance on the in-mine hazard recognition task. Further, the USBM researchers concluded that transfer of learning from the classroom to the workplace occurred.

Jan 1, 1995

By E. A. Barrett

The U.S. Bureau of Mines (USBM) conducted experiments to determine if training using a latent-image, three-dimensional (3-D) slide simulation exercise improved miners' ability to recognize roof and rib hazards. The effectiveness of this innovative type of classroom training was investigated by measuring workers' performance on a hazard recognition task. The study was unique in that hazard recognition skills were assessed in the workplace using actual coal mine roof and rib hazards. Results showed that training with a latent-image, 3-D slide simulation exercise significantly improved each subject's performance on the in-mine hazard recognition task. Further, the USBM researchers concluded that transfer of learning from the classroom to the workplace occurred.

Jan 1, 2010

By L. L. Oden

The U.S. Bureau of Mines and the Department of Energy (DOE), through its contractor EG&G Idaho Inc., are collaborating on a multiyear research project to evaluate the applicability of three-phase, electric arc furnace melting technology to vitrify materials simulating low-level radioactive and mixed wastes buried or stored at the Idaho National Engineering Laboratory and other DOE sites. The melter is a sealed, 1-t (1.1-st), three-phase, 800-kV?A electric arc melting furnace with 10.2-cm-(4-in?) diameter graphite electrodes, water-cooled roof and sidewalls, and four water-cooled feed tubes. A water-cooled copper fixture provides for continuous tapping of slag. An instrumented air pollution control system (APCS) with access ports for analysis and a feeder based on screw conveyors and a bucket elevator are dedicated to the facility. Test data are provided by an arc furnace analyzer and by sensors indicating feed rate; slag temperature; and temperature, pressure, and velocity in the APCS. These data are received by a data logger, digitized, and transmitted to a personal computer for storage and display. This unique waste treatment facility is available for public and private use on a cost-sharing basis.

Jan 1, 2010

By Thomas L. Vandergrift

To significantly increase the stability of underground excavations while exploiting the full advantages of confined rock strength, methods must be developed to actively control the distribution of stresses near the excavation. This U.S. Bureau of Mines study examines theoretical and practical aspects of rock pres¬surization, an active stress control concept that induces compressive stress in the wall rock through repeated hydraulic fracturing with a settable fluid. Numerical analyses performed by incorporating the rock pressurization concept into a variety of boundary-element models indicate that rock pressurization has the potential to improve underground excavation stability in three ways: (1) by relocating stress concentrations away from the weak opening surface to stronger, confined wall rock; (2) by inducing additional stresses in a biaxial stress field to reduce the difference between the principal stress components near the surface of the opening; and (3) by counteracting the tensile stresses induced in the rock around internally loaded openings. Practical aspects of the rock pressurization concept were investigated through a series of hydraulic fracturing experiments. The use of sulfur as a settable fluid for hydraulic fracturing was demonstrated, although problems related to sulfur viscosity suggest that other molten materials, such as wax, may be better suited to practical field application of the rock pressurization concept.

Jan 1, 2010

By M. J. Beus

The U.S. Bureau of Mines is conducting investigations to improve design methods for mining volcano-genic massive-sulfide (VMS) type deposits in environmentally sensitive regions. This study was conducted at the Greens Creek Mine, which is typical of many VMS-type deposits throughout southeast Alaska, and served as a case history for computer modeling and structural analysis. Results indicated that the finite-element design method provided reasonable comparisons with both the anticipated regional stress regime and the measured deformational response of the underground accessways. Investigators concluded that reasonable accuracy can be expected for stability analyses of proposed mine design scenarios at this mine using the results of this preliminary study.

Jan 1, 2010

By W. G. Pariseau

A U.S. Bureau of Mines case study of pillar recovery in high-grade ore near the Ross shaft at, the Homestake Mine, Lead, SD, has demonstrated the usefulness of the finite-clement method for the evaluation of shaft pillar mining plans and shaft stability. This report, one of three in a series describing the Ross shaft pillar case study, focuses on the premining stability analysis. The two-dimensional computer program UTAH2 was used in advance of pillar mining; results suggested that the shaft would remain stable. Subsequent reports describe parts 2 and 3 of the study. In part 2, borehole extensometers and other instruments were installed to provide data for model verification and shaft monitoring. Results of the recalibrated two-dimensional model confirmed the premining stability evaluation. However, after mining began, great concern developed because of the appearance of cracks and other signs of ground movement over considerable distances from the area of active pillar miping. In part 3, an intense three-dimensional modeling effort using UTAH3 was initiated. The results again showed that the shaft would remain safe. Three-dimensional analyses of alternative pillar mining scenarios indicated that more of the shaft pillar ore reserve could be recovered than previously thought.

Jan 1, 2010