Search Documents

By Glenn A. Shirey

The objective of this contract as to prepare a detailed, readily usable handbook on dust control techniques for longwall mining operations. Information was gathered from available literature, and through contacts with industry and government personnel. The handbook describes those methods of dust control applicable to today's longwall mining systems, and contains sufficient design elements to assist operators with problems in testing or implementing new control procedures. Complete reference lists are presented at the end of each chapter to direct the reader to additional information.

Jan 1, 1985

By Robert S. Schechter

A minitest of the new potassium chloride-potassium carbonate two-stage in-situ uranium leach process has been carried out at the Intercontinental Energy Corporation (IEC) Zamzow project site in South Texas. Substantial quantities of high concentration uranium were produced indicating the viability of the leach solution. The test results yield information regarding the reservoir dispersivity, the average cation-exchange capacity of the formation, and the distribution coefficients describing cation-exchange reactions. The test also indicates permeability anisotropy and the existence of disturbed flow fields.

Jan 1, 1985

By T. F. Anstett

The Bureau of Mines estimated the potential availability of tungsten from 57 mines and deposits in 19 market economy countries. The tungsten resources of China and the U.S.S.R. were also estimated. This resulted from an evaluation of tonnage-cost relationships indicating the quantity of tungsten available as ammonium paratungstate (APT), artificial and natural scheelite, and ferrotungsten at various average total costs of production including 0- and 15-pct rates of return on invested capital. The evaluated deposits contain 1.2 million metric tons (t) of recoverable WO3, of which approximately 52,000 t of AEYT can be produced at the January 1983 market price of $5.37/lb, 89,000 t of natural and artificial scheelite at a market price of $3.63/lb, and 1,700 t of ferrotungsten at $5.61/lb of tungsten. An annual availability analysis indicates that by the early 1990's new deposit discoveries, development of known prospects, or expansions of producing mines will be necessary to meet projected tungsten demand.

Jan 1, 1985

By F. A. Penning

Improved skips, with lightweight cylindrical bodies, have made a significant contribution to advancing mine hoisting technology. New concept skips of aluminum bodies with rubber lining; fiberglas bodies with polyurethane liners have been designed and fabricated for field testing at an operating mine. New design, adjustable guide rollers have shown improved ride characteristics with noticeably less wear. Major reductions have been made in stress levels and stress concentrations. Field experience has shown the practicality of the approach. Guide alignment has been measured using the Guide Alignment Measuring System (GAMS). Analysis has been applied to interpret the data. Field measurements in an operating shaft and a test tower have shown the agreement in data from GAMS and plumb wires. Reproducibility has been demonstrated. The data are useful to realign shafts, to use as s maintenance tool, and to evaluate the maximum safe hoisting speeds. The surveys are made at several hundred feet per minute and the system is self-contained. Dynamics of skip-guide interaction has been analyzed using the computer program SKIP II. The effects of speed, weight, type of guides, kind of misalignment have been studied. Resonance has been demonstrated and factors that eliminate resonance have been identified. Data from the GAMS surveys are applicable to the SKIP II program. Interaction between the hoist rope and the mine conveyance has also been studied. Computer programs and closed-form solutions are presented. Economic impact of lightweight skips is presented for an existing mine and for a new mine. Reduction in rope size has a profound effect when using a lightweight skip for the same capacity. Increased productivity can be realized by keeping maximum rope pull the same while increasing skip capacity. Examples and charts project the significant savings in capital expenditure for new installations.

Jan 1, 1985

By R. V. Ramani

This volume is the second of a four-volume final report on research carried out under a contract from the U.S. Bureau of Mines on the development of a computer simulation model for surface mine reclamation planning. The other volumes are titled as follows: Volume I: Ore Reserve Estimation, Volume III: Mine Coordinate Generator System, and Volume IV: User's Manual for OPMHS/2. The dragline model described in this report simulates the movement of the dragline bucket across the digging face, the swing load, the dump, and swing back. It is programmed to handle chopdown, key cut, main cut, and rehandling operations. Provisions have been made for simulating equipment and mining delays. Any mining method can be specified in terms of numbered blocks, the dragline positions for the mining block and the dumping location for the block. Accounting procedures permit the calculation of production rates, rehandle volume, dig and delay times. The model can be used to study the effects of varying mining conditions, cut width, and spoiling sequence with special reference to toxic spoil, overburden and bench removal procedures. The basic input data for the model include machine parameters, the geology and material characteristics, the mining parameter, and the delay characteristics of the equipment.

Jan 1, 1985

By Michael E. Henderson

Presented in this report are the experimental results of coarse coal slurry degradation data obtained from the Hydraulic Transport Research Facility (HTRF) at the Pittsburgh Research Center (PRC), Bruceton, PA. The facility is operated by Boeing Services International, under Bureau of Mines Contract No. J0333956. Presented in this report are the experimental results of coarse coal slurry degradation data obtained from the Hydraulic Transport Research Facility (HTRF) at the Pittsburgh Research Center (PRC), Bruceton, PA. The facility is operated by Boeing Services International, under Bureau of Mines Contract No. J0333956. This particle degradation report is a summary of the particle distribution data obtained at the HTRF for the period 26 November 1982 to 1 October 1983. The testing covered herein is for coarse Pittsburgh Seam coal in the 6-in (150 mm) and 12-in (300 mm) pipelines, at velocities ranging from 5 to 18 ft/s (1.5 to 5.5 m/s), and at concentrations by weight ranging from 15 to 55 pet. Particle size distribution samples were taken systematically throughout the testing.

Jan 1, 1985

By James W. Reil

A test series of small, precisely-controlled and thoroughly-monitored production blasts was conducted at two quarries. In each series, all variables except delay were kept constant, as much as practically possible. The first aim of the study was to determine the effect of local geology on ground vibration. The second aim was to test several hypotheses relating the effect of millisecond delay intervals to fragmentation and ground vibration. A resonant frequency of ground vibration was shown to be related to the thickness of the overburden, in accord with a model proposed by Gupta (1961). Since the overburden geology creating this resonant vibration cannot usually be changed, two methods were tested to choose delays such that blast vibrations would destructively interfere. These were shown to be effective in modifying both the peak particle velocity and response spectra of ground vibration. The delay interval chosen also affects fragmentation, primarily in massive rock, with an optimum relief between holes of 2 ms/ft. Strain gage records indicate a possible mechanism consistent with this information.

Jan 1, 1985

Greater mining productivity requires a more efficient cutting process. The cutting force available from today?s mining machines has been optimized with respect to machine size and weight. Researchers have shown that when employing water-jet-assisted cutting, bit forces and drum torques can be reduced significantly, which may allow mining machines to become lighter and more efficient. The Bureau of Mines has initiated a program to develop a water- jet-assisted rotary cutting system using the conventional bit assisted by a directed water jet operating at moderate pressures (3,000 to 10,000 psi). This water-jet-assisted cutting system has the potential to improve cutting efficiency without increasing machine horsepower or water usage (beyond what is presently used for dust control) or requiring fundamental changes in mining practice. IR addition to improvements in productivity, other anticipated benefits of water-jet cutting include reduced generation of respirable dust, elimination of frictional ignitions, increased bit life, reduced fines, and fewer machine vibrations. The papers presented at this open industry meeting discuss the development of water-jet-assisted cutting technology and future application of this technology to a variety of mining techniques including roof drilling and longwall mining.

Jan 1, 1985

By Catherine C. Kilgore

The Bureau of Mines investigated the availability of fluorspar (CaF2) from 36 U.S. and 50 foreign mires and deposits in 13 countries. Only 6 U.S. properties are considered to be economic, as 29 domestic deposits were found to have an average total cost of production that was uneconomical at a breakeven (0-pct) discounted-cash-flow rate of return (DCFROR). The 50 foreign properties evaluated represent at least 55 pot of demonstrated fluorspar resources located in market economy countries and China. Al I evaluated foreign operations were found to be economic to marginally economic in January 1984 dollars when compared against published prices for each country. Reserves for 56 properties totaled 97 million metric tons (mt) (recoverable Ca F,) from demonstrated ore resources of 344 million mt that contained 123 million mt CaF2. The average total cost needed to cover all costs over the life of each operation was determined for all recoverable fluorspar products. Comparisons of ruining, beneficiation, and transportation costs per metric ton of fluorspar concentrate illustrate advantages between countries. Of the three countries with the greatest fluorspar production, China, with its high-grade, low-cost operations had the lowest weighted-average total cost of production ($38/mt concentrate), Mexico was next, at $54/mt concentrate, and benefited in U. S. dollar terms from the devaluation of the peso. The Republic of South Africa needed an average of $90/mt of concentrate to cover all costs of production at its large low-grade deposits.

Jan 1, 1985

This publication contains eight papers presented at a Bureau of Mines Technology Transfer Symposium in Charleston, W, on June 22, 1983, Five of the papers describe the results of Bureau-sponsored research on cabs and canopies for low-coal underground mining equipment. The other papers describe the efforts of three underground coal mining equipment manufacturers (FMC, Joy, and Lee-Norse) in the area of cab and canopy design.

Jan 1, 1985

By Charles L. Kimbell

Although virtually every available indicator of world mineral industry activity demonstrated a gain in 1983 relative to the 2 very poor years of 1981 and 1982, the overall prospects for future years seemed far from bright. There were significant upturns in the quantity and value of mineral commodities produced, traded, and consumed in 1983, and many nonfuel mineral prices advanced, although the price advances in current dollars in most instances barely compensated for inflation. The pattern of investment in exploration and development of new mining ventures and new plant construction reflected virtual industry-wide concern that substantial upturns in demand for mineral commodities in the near future were unlikely, at least for most large volume products. The world oil glut continued despite cutbacks in production, and substantial stocks of many other mineral commodities mitigated against growth in total productive capacity, at least among market economy nations. In these countries, development activity at both mines and plants was confined largely to programs aimed at substituting new, more efficient installations for old, uneconomic or marginally economic plants. Among the centrally planned economy countries, the pattern was somewhat different on the whole, but even there, growth in total productive capacity was evidently somewhat restrained, although it seemed questionable whether the restraint was a function of intentional planning or simply an inability to accomplish planned programs on schedule. International political events, particularly the Iran-Iraq war and the unstable situation in the eastern Mediterranean countries (Lebanon, Israel, and Syria), continued to adversely affect mineral industry activities in those areas. Similarly, the internal and international conflicts in Central America negatively influenced mineral industry operations there. In Afghanistan, it appeared that there was some upturn in the very modest mineral industry operations, but industry activities there undoubtedly continued to be affected by confrontations between the Soviets and the local citizenry.

Jan 1, 1985

By W. I. Nissen

As part of its program to provide technology for reducing undesirable environmental impacts of mineral processing operations, the Bureau of Mines developed the citrate process for desulfurizing industrial stack gases that contain from 0.1 to 2 vol pet S02. In this regenerable flue gas desulfurization (FGD) process, S02 is absorbed from cleaned and cooled industrial flue gas with a citric acid-sodium citrate solution. The absorbed S02 is subsequently reacted with H2S to precipitate marketable elemental sulfur and regenerate the solution for recycle. Laboratory investigations of process parameters provided information for designing larger scale continuous operations. Information gathered from operation of two pilot plants, one at a copper smelter and one at a lead smelter, confirmed the laboratory results. Data were obtained for design and construction of a commercial-sized demonstration plant at the George F. Weaton Power Station, Monaca, PA. A preliminary operation of the plant was demonstrated, under a cost-sharing Bureau-industry contract. This bulletin describes the citrate process and gives results of the laboratory, pilot plant, and demonstration plant studies, as well as corrosion investigations.

Jan 1, 1985

By Joseph M. Kuchta

This Bureau of Mines manual is oriented to the technical needs of an investigation of fire or explosion accidents and includes various practical and theoretical information that is needed in analyzing accidents or evaluating conditions that might lead to an accident. It is applicable to accidents in the chemical, mining, transportation, and other fuel-related industries. Specific procedures for conducting an accident investigation are outlined, and various guidelines are given for developing the fire or explosion evidence. Ignitability, flammability, and physicochemical data are presented for over 500 combustible gases, liquids, and solids; empirical and theoretical expressions are also given for extrapolating the behavior of combustible-oxidant-diluent systems to various environmental conditions. In addition, various data pertinent to damage analysis are summarized to facilitate the task of the investigator in developing plausible accident scenarios.

Jan 1, 1985

By J. A. Kost

The contract objective was to evaluate the effectiveness of available dust-control technology for double-drum shearers. Eight underground surveys were conducted to evaluate drum design, drum spray nozzle locations, ranging-arm sprays, water quantity, wetting agents, and cutting techniques. The final report is made up of eight dust-control technique reports, each discussing, details of the individual mine surveys.

Jan 1, 1985

By K. R. Price, M. Gauna

A high seam geologic condition exists at Jim Walter Resources No. 4 mine that requires immediate rib support after a continuous miner cuts a place. High seam mining heights are typically 2.4 to 2.6 m (8 to 9 ft) and a thick rock layer is present in the upper portion of the coal rib side. The 610-m (2000 ft) mining depth at No. 4 mine induces horizontal rib line movement after excavating an entry. Horizontal rib movement greater than 305 mm (12 in.) have been noted. When lateral movement occurs in the high seam areas, the thick rock layer, and the coal above the rock layer, become fractured and tend to roll into the entry. If not adequately supported, large rib rolls develop in the place being bolted as well as in previously mined areas that endanger men and equipment. To control this, rib support must be installed in the roof bolting operation as the bolting crew works toward the face. A rib control system has been developed for this high seam mining condition using a mechanical anchor bolt placed at an angle in the rib and installed with a modified Fletcher DDM-15 bolting machine. More than 120 km (75 miles) of entry have been supported with angle rib bolts. These angle bolts constitute 43% to 60% of the total roof and rib bolt footage in the high seam portions of No. 4 mine. The angle rib bolting system has proven safer, more effective, and more efficient than the earlier support method using bolts installed horizontally into the rib. No rib roll accidents have occurred since the angle drill bolting machines were placed in service in 1981. By securing the broken rib material with an angle bolt anchored above the coal pillar, a more effective means of rib control is achieved. Angle rib bolting does not interfere with continuous miner productivity. In addition, bolting crews are now reduced from three to two people. Total drilling supply costs are about 60% the previous cost, when compared to the previous support method using horizontal rib bolts:

Jan 1, 1985

By Z. Rogovin

In order to develop more accurate procedures for scale-up and design of semi-autogenous-grinding mills through detailed mathematical models, a better understanding of the charge motion and rock/ball segregation is needed. To achieve this a 0.61 m (2.0 ft) diameter x 0.305 m (1.0 ft) length plexiglas mill was constructed as a scale model of a commercial SAG mill. Rock motion in the rotating mill was simulated using various sizes of ceramic balls. Quantitative measurements of dynamic angle of repose, water and slurry motion, holdup and size segregation of the charge were taken. In addition, a video-presentaiton (available to the public) was prepared to elucidate charge and water motion at various mill speeds, charge volumes, rock size distribution and flow rates.

Jan 1, 1985

By N. W. Johnson

Two analysis tools which have been applied to problems in industrial Flotation processses are the application of kinetics and detailed mineralogical or liberation data, both on a size-by-size basis. The paper describes practical examples of the application of kinetics to examination of the entrainment recovery mechanism, the retardation of valuable minerals at the commencement of flotation sections and the resolution of problems related to valuable species with reduced rate constants at the end of sections. Examples of the usefulness of size-by-size liberation data for monthly composite samples of products from a concentrator are also described.

Jan 1, 1985

By Boyd Wise

A jet pump injector was developed and successfully tested, thereby demonstrating the feasibility of a jet injector for introducing coarse coal into an operating slurry face haulage system: In Phase I a variety of injection concepts were evaluated, and the jet pump was identified as best, due to its simplicity, compactness and performance potential. In Phase IIA subscale jet pump injector tests were conducted, and a computer model of a jet pump injector was developed whose performance predictions correlated well with subscale test results. In Phase IIB various system configurations were defined for integrating a jet pump injector into a fully operational underground coarse slurry face haulage system, further highlighting the feasibility and practicality of such a system. In Phase III a full-scale mobile haulage vehicle embodying a jet pump injector and coal sizing equipment was detail designed into a practical vehicle with attractive performance characteristics. More importantly, fully operational full scale jet pump injector -and feeder/breaker subassemblies were tested and proven successful in their ability to down-size coal to 3" in all 3 dimensions and to consistantly provide slurry of 4217 weight concentration at 6.4 TPM throughput under a wide range of operating conditions including zero to maximum feed rate within 5 seconds.

Jan 1, 1985

By G. Styles, K. Lye, R. Tenbergen, M. Mayhew

Requirements to produce a higher bulk concentrate grade have necessitated extensive use of on-stream analyser data and computer programming to obtain the targets set for Frood Stobie Mill as required by overall milling considerations.A brief history of milling process changes associated with the changes from a low grade (3% Ni) bulk concentrate in the sixties to a high (6 to 8.5%). Nil bulk concentrate currently will be presented.The heart of the presentation will be the computer control schemes for ""self optimisation"" of the distinct flotation sections in the plant within certain restraints to achieve targets set by the mill metallurgist.

Jan 1, 1985

By Robert S. Schechter

This report describes the development and application of PHASEQ/FLOW, a geochemical flow simulator capable of describing the dynamic changes in chemical composition of an aqueous solution during flow in a permeable medium. The solution components can react through intraaqueous reactions, redox, precipitation, or dissolution. The assumption of local thermodynamic equilibrium ensures maximum generality with respect to the number of species and components possible; however, the fluid flow itself is limited to one-dimension. The report describes several applications: generic batch equilibria, flowing equilibria, uranium roll-front deposition, and roll-front leaching.

Jan 1, 1985