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By Robert R. Perron

The U.S. Bureau of Mines is engaged in many diverse programs for improving mine safety. Of particular interest to the Bureau are new and improved means for minimizing the hazard of fire which can be initiated by prolonged low energy electrical faults on trolley line systems. When a high energy fault occurs on a trolley line, wherein the current exceeds the magnitude normally drawn by legitimate loads, such as locomotives, then the circuit breakers at close-by power rectifier sets trip. Tripping of the breakers not only protects the equipment at the rectifier sets, but also disconnects the energy source from the fault and thereby minimizes the fire risk. However, the fault current is frequently of a level substantially below that required to trip the overload breakers. When the fault is a substantial percentage of the set level of the breakers, the energy dissipated by the fault is frequently sufficient to clear the system by rapidly burning itself clear. Such a fault is often short-lived and does not present as serious a fire risk hazard as a prolonged, much lower energy fault, wherein the energy level is too low to clear the system. The breakdown of a trolley line insulator, in which there was a 20 or 30 ampere leak, would represent such a fault or illegitimate load and a substantial fire risk.

Jan 1, 1974

By Sidney Katell

This study estimates capital investment, operating costs, and selling prices for four underground bituminous mines producing coal with annual production ranging from 1.06 to 4.99 million tons. It is assumed that the mines have a 20-year life. Wages and union welfare payments are considered as of November 12, 1973, under the Bituminous Wage Agreement of 1971, and costs for material and equipment are based on 1973 indexes. Initial capital investment ranges from $12,540,700 for the 1.06-million-ton-per-year (MM tpy) mine to $44,720,500 for the 4.99 MM tpy mine. Total capital investment ranges from $21,850,700 to $75,693,500 for the same mines. Corresponding selling prices for the coal range from $8.76 to $7.53 per ton, assuming a 12-percent discounted cash flow rate of return after Federal income taxes.

Jan 1, 1974

Gunpowder Copper Limited processes 1,000 tonne/day of Mammoth ore in a conventional flot- ation concentrator. Run of mine ore is prepared for flotation by three stages of crushing and two stages of ball milling. The concentrate, in which the primary copper mineral is chalcocite, is solar dried and exported to Japan. The history of operation is summarised, and plant practice and metallurgical problems are discussed.

Jan 1, 1974

By Michael J. Beus

This Bureau of Mines report describes the development of load cells for measuring compressive loads in timber and lock-bolt support systems commonly used in. coal; metal, and nonmetal mines Design and evaluation is covered in detail to insure a reliable, accurate, and practical instrumentation scheme. The load cells are relatively inexpensive and adaptable to various size support systems. User-oriented procedures are emphasized, and design equations were reduced to a series of nomographs. Laboratory evaluation, destructive testing, environmental testing, and tests to determine the effect of extraneous loads were conducted. Field performance was evaluated in conjunction with ongoing Bureau projects at a metal mine in North Idaho and a coal mine in Utah. Load cells utilizing a titanium alloy as the cell body and weldable strain gages as the strain-sensing components satisfied the basic design and performance criteria, and with minor design modifications, the load cells can be adapted to many mining applications.

Jan 1, 1974

By F. E. Armstrong

An instrument using a gamma-ray backscatter technique for determining the weight-percent incombustibles content of coal dust and rock dust mixtures in coal mines has been built and tested. The unit gives a direct readout in per-cent incombustibles for coal mine dust mixtures containing between 50 and 100 percent incombustibles; calibration of the device requires using a sample of the rock dust employed; this is usually limestone but occasionally dolomite or gypsum. A small americium-24l source is used with a scintillation detector whose output feeds a rate meter. The source-detector geometry used was chosen to reduce the effects of variation in bulk density. Accuracy of the system is within ±3 percent for most mixtures. The instrument is portable and completely self-contained; the rechargeable batteries supply power for 300 to 400 determinations.

Jan 1, 1974

By M. L. Whisman

Three samples of waste lubricating oil were re-refined by processes developed by the Bureau of Mines and reformulated with additives to meet designated requirements for viscosity and service. Quality-defining bench-scale tests were used to compare and evaluate the quality of these three motor oils, eight commercially re-refined lubricating oils, and three new lubricating oils. Most of the re-refined oils studied could not be distinguished from new oils by the bench tests used to define quality. There was some evidence, however, that one and perhaps more of the re-refined products investigated might not meet all of the quality standards of new lubricating oil, suggesting the need for better quality controls by re-refiners.

Jan 1, 1974

By Jack L. Henry

The Bureau of Mines conducted seven pioneering experiments in a 12-inch-diameter Kroll reduction reactor to examine the feasibility of coreducing the chlorides of Ti, AI, and V to produce a homogeneous titanium alloy sponge. The coreduction studies proceeded in a normal manner, and the yields of sponge were comparable with those of pure titanium sponge made in the same reactor. Vanadium concentration was very uniform throughout the sponge cake when VC14 in solution in TiCl4 was fed into the molten magnesium. More difficulty was encountered in feeding solid VCl2 and AIC13. Vanadium and aluminum concentration in the sponge was not uniform, and mechanical difficulties were experienced with the small-scale screw feeder. Although the sponge varied in composition from region to region, the ingots prepared from it were uniform in composition.

Jan 1, 1974

By E. C. Foster

The project objective of this contract is to design, develop, and demonstrate a dust collecting system for auger head miners, used in coal seams 40 inches or less in height, which will reduce respirable dust below the limits established by the Federal Coal Mine Health and Safety Act of 1969. This system was to be incorporated into 3 Wilcox Mark 20 continuous miner. In order to accomplish this, the objective was divided in three main areas. First: To develop a dust control system which would remove by isolation, respirable dust from the face area and areas where miners work. Second: To develop a dust scrubbing system to remove and collect float dust before the air reaches the return airway. Third: To reduce the overall noise levels to which the miners are exposed.

Jan 1, 1974

By Parks T. C

A low-grade disseminated nickel sulphide serpentinite ore from W.A. had a relatively high permeability after drying. Various techniques indicated that the permeability resided within a fine network of fibrous vein- lets and especially within coarse cracks along which the sulphides lay. The ore minerals were therefore open to selective extraction by chemical leaching. A IM ammonia-7.8 wt.o "ammonium carbonate" solution, oxygenated at 1 bar oxygen pressure and about 23¦C, released nickel, copper and cobalt from the sulphides, leaving a permeable residue of goethite, while calcium, magnesium and iron concentrations remained negligible in the leachant. The nickel and copper was electrodeposited directly from the pregnant liquor in a deposit which included 16.5 wt.% sulphur. Enhanced copper/ nickel ratios early in the extraction suggested that valleriite (not amenable to flotation) was leached preferentially. Th$ controlling influence of the pore structure was demonstrated by the dependence of leaching rates on the size of the ore particles used, and on the measured porosity of different ore samples. A 2mm size was probably the optimum for exposing sulphides to the leachant. Leaching was accelerated by increasing the temperature and oxygen pressure.

Jan 1, 1974

By John T. Kuo

The miner's seismic source strength can be approximately estimated on the basis of a single force acting in an infinite medium. Because of the uncertain- ty involved in estimating the amount of conversion from mechanical energy to seismic energy, the source strength thus estimated may be in error by as much as a half-order of magnitude. Calculations of wave transmission must take into account geometrical spreading, dissipation of energy by internal friction, and energy partition due to reflection and refraction of waves impinging on inter- faces in the layered earth. Theoretically derived peak-to-peak particle velocities in microinches per second (PIPS) are given for two models ; viz: (i) 50-feet thick and (ii) 100- feet thick 4000 ft/sec layers with Q = 20, overlying a half-space of 10,000 ft/sec material with Q = 5O;for the cases .of a hammer blow and a timber impact, at the frequencies of 50 Hz and 100 Hz. Comparison of the theoretically derived peak-to-peak particle velocity with experimental data taken at the Copper Queen Mine indicates that the theoretical particle velocity may be overestimated. A discussion of the distortion of seismic wavefronts by mine tunnels indicates that it is unfavorable to use a seismic source impact on the floor of the tunnel, since deceptive delays in arrival time are liable to occur at the surface. A program of parallel theoretical and experimental work is required to clarify uncertainties still associated with the nature and strength of the miner's seismic source signal which cannot be resolved within the approximations of this work. Its major components include theoretical investigations of the (1) Wave diffraction and scattering of an impact source on a face of a cylindrical cavity. (2) Impact of an elastic object on an elastic medium.

Jan 1, 1974

By Manuel Gomez

A computerized moving average technique was developed to interpolate coal seam characteristics between sample points. The interpolative method coupled with multivariate regression analysis and simulation procedures was used to forecast coal properties not readily obtained from an analysis of drill core samples. Coal property forecasts were of two kinds: (1) specific mine property forecasts that are suitable for mine product control and yield a good approximation of the local variation along both the vertical and horizontal axes of the seam, and (2) regional estimates where much of the local seam variation is smoothed out, but the general trends are maintained. Forecasts of the volatile matter, ash, total sulfur, and the heating value for part of the Pittsburgh seam located in Ohio, Pennsylvania, and West Virginia were in good agreement with independent evaluation data. Spatial configuration for preparation characteristics, particularly, the effect of crushing on sulfur release, low-and high-temperature carbonization properties, the Hardgrove grindability index, the coal hardness index, gasification variables, and hydrogenation factors were constructed for the same area of the Pittsburgh seam. These forecasts may be developed from drill core data collected in the exploration phase of mining. The results, which may take the form of a series of maps, are useful to mining, chemical, and combustion engineers, to economists and mine managers, as well as to coal users for mine design, economic analyses, energy forecasts, utilization studies, mine product control, and environmental control and programming.

Jan 1, 1974

By F. G. Pickard

"The Strathcona Concentrator is one of three concentrators presently operated in the Sudbury District by the Nickel Division of Falconbridge Nickel Mines Limited. Production commenced in 1968 at a milling rate of 6,300 tons per operating day. Milling capacity was increased in 1970 to 7,200 tons per operating day. 7he ore contains iron, nickel and copper primarily in the form of pyrrhotite, pentlandite and chalcopyrite, while the common gangue minerals are feldspar, quartz, mica, talc and chlorite. The primary function of the concentrators is not only to liberate sulphides from silicate gangue minerals but also to separate pyrrhotite from the more valuable minerals pentlandite and chalcopyrite.SummaryExcessive wear on steel liners and blinding of grates in a regrind pebble mill of the Hardy Concentrator was corrected by the use of rubber liners and grates. The success of these resulted in their installation as original linings In all grinding units except the rod mills at the Strathcona Concentrator. The operation of rubber liners and grates when sized mine ore was used as the grinding medium was satisfactory confirming the Hardy Concentrator experience. Problems developed when the grinding medium was changed from sized mine ore to steel balls in that blinding of the grates occurred. This resulted in conversion of the units to overflow type mills through removal of the grates. The lifter bar life was significantly increased by using higher lifter bars.Grinding PracticeOperation of a regrind pebble mill commenced in 1961 in the Hardy Concentrator. This operation demonstrated the economic feasibility of using sized mine ore as grinding medium. Problems caused by excessive wear of metal liners and grates combined with blinding of the grates were corrected in 1964 through installation of rubber liners and grates."

Jan 1, 1974

By Pedro Lilienfeld

This Final Report describes a program whose objective was to design, develop, fabricate, and test an airborne mass monitor for unattended and recording measurements of the concentration of dust in mining environments. Sensing collection are performed by beta-radiation attenuation and inertial implementation respectively. The instrument is portable, battery or line operated provides a digital printout of the mass concentration during each selection sampling period, as well as the accumulated mass of dust, and the elapsed sampling time.

Jan 1, 1974

By J. Donovan Jacobs

Many improvements in the art of underground excavation have appeared during the past two decades. These improvements have been both in methods and in machinery and have resulted in more economical construction of today's tunnels. In the realm of machines, the developments of continuous boring heads for either soft ground or rock, random arm excavators and the sliding tunnel floor (Magic Carpet) have each made contributions toward more rapid tunneling. CONTINUITY OF ADVANCE Tunnel boring machines are often referred to as "continuous excavators". Continuous advance (without cyclical interruptions) has not been achieved, however, in any of the machines now in use. In most rotary-head tunnelers the thrust needed to make the cutters bite into the face is obtained from hydraulic cylinders reacting against anchoring devices held stationary by pads which grip against the sides of the tunnel. With this system the forward motion of the cutting head is continuous only until the propelling cylinders have reached their limit of extension. At this point the grippers must be released, moved forward and reset before a new cycle of advance can be begun. Some machines are built to obtain their propelling thrust from hydraulic cylinders pushing backward against newly-installed rings of tunnel support. This is the customary method for propulsion of shields. With it, each cyclical advance or "shove" must await the erection of a new ring of supports. Faster tunnel driving

Jan 1, 1974

By Charles H. Jacoby

The economic importance of salt domes has been recognized throughout the world primarily because of oil and gas accumulations on their flanks and, to a lesser degree, for the value of their salt and potash. Recently they have become of value as hosts for cavities used to store hydrocarbons. In the near future we believe that their main value will be as a source of geothermal energy. Although tremendous effort has been expended on the understanding of the geology and physical characteristics of the strata intruded by salt domes, relatively little energy has been exerted in the comprehension of the salt dome itself. Salt domes have long been recognized as a geological heat anomaly. With respect to other sedimentary rocks, salt is a good conductor of heat. Expressing values in 10-3 cgs units, sedimentary rocks vary from 1.0 to 8.0; metamorphic rocks from 5.2 to 8.4 and igneous rocks from 3.1 to 9.8. Rock salt in its pure form has a thermal conductivity of 17. (Gussow, 1970). Thus a salt dome (Fig. Ml) can be expected to act as a conduit bringing heat vertically from deep within the Earth's crust. This was, in part, substantiated when in 1958 a horizontal core hole was drilled from within the Avery Island Mine at the 500 foot level. The horizontal hole was started where the ambient temperature of the salt was 74° F. and drilled toward the center of the dome. At the end of this 2,000 foot hole the temperature was 90° F. thus depicting a horizontal temperature gradient of 7° F./1,000 feet. Because this core hole penetrated a shear zone connate water that appeared as a "cold spot" on the temperature gradient, the foregoing data can only be regarded as indicative.

Jan 1, 1974

By H. O. Poppleton

This Bureau of Mines study was made to investigate a possible method for selectively removing the Si02 component of silicate minerals and ores. Of specific interest were aluminum ores and zircon. Methods are described for removing Si02 from these ores as volatile silicon sulfides by treating the ore with sulfur and carbon; with sulfur, carbon, and a reducing gas; or with sulfur compounds and carbon. Comparative results are also given for the desilication of some of the ores with carbon alone to form volatile silicon monoxide. The silica component can be removed partially from bauxites at temperatures above the sublimation temperature of SiS (940° C) by treatment with carbon, sulfur, and methane; however, it is more difficult to remove the silicon from kyanite, manganese silicate, red muds from aluminum processing, kaolinite, lateritic nickel ores, and zircon. Complete desilication requires temperatures ranging from 1,100° C for bauxite to 1,450° C for zircon. Although the high temperatures required and the undesirable metal sulfides produced eliminate practical application of this method using present technology, the Bureau is reporting this data so that they will be available to future investigators.

Jan 1, 1974

By de Lassar de Pressigny Y

IRSID has in its laboratories two experi mental counter-current reduction furnaces allo- wing the simulation of the physico-chemical conditions of reduction in any gas-solid coun- ter-current process, including the blast furnace and direct-reduction shaft-furnaces. The counter current is realized by an electric furnace mo- ving along a laboratory tube filled with the material to be tested. The reducing gas stream in the tube travels in the same direction as the furnace After reduction, twenty samples, with dif- ferent degrees of reduction and which can be related to different levels of an industrial furnace, are taken from the tube and subjected to various quality tests. Experiments were realized to determine the behaviour of various types of industrial pellets when reduced under either blast furnace or shaft furnace conditions. The results show the large influence of the reducing conditions on any pa- rameter characteristic of the quality of the pellets : reduction efficiency, swelling, cru- shing strength and disintegration.

Jan 1, 1974

By Sidney Katell

This Bureau of Mines study estimates capital investment, operating costs, and selling prices for three underground bituminous mines producing coal with annual production ranging from 1.03 to 3.09 million tons. It is assumed that the mines have a 20-year life. Wages and union welfare payments are considered as of November 12, 1973, under the Bituminous Wage Agreement of 1971, and costs for material and equipment are based on 1973 indexes. Initial capital investment ranges from $12,938,200 for the 1.03-million-ton-per-year (MJ.Vl tpy) mine to $31,435,500 for the 3.09 MM tpy mine. Total capital investment ranges from $21,607,200 to $51,982,000 for the same mines. Corresponding selling prices for the coal range from $9.11 to $8.06 per ton, assuming a 12-percent discounted cash flow rate of return after Federal income taxes.

Jan 1, 1974

By Raymond M. Stateham

The Bureau of Mines used portable infrared scanners to examine the surface of pillars and faces in the Somerset mine near Somerset, Colo. Zones of temperature buildup, indicative of potential combustion, were detected with the scanners; their existence was verified by temperature measurements with conventional instrumentation. Temperatures of 32° to 6° C were measured on surfaces with normal temperatures of 26° to 35° C. The infrared instruments and techniques appeared to offer a rapid and efficient method for locating potential trouble spots in mines susceptible to fires caused by spontaneous combustion.

Jan 1, 1974

By Eliezer Kamon

To finalize the three years granted for the study of miners physiological responses to emergency situations, all the data obtained, were summarized into the following relevant sections; A.. Information on elements of the Man Test required under Subpart 4, Part 2, Title 30 in the Code of Federal Regulation (see Table M-T and Ref. I., Section A). B. Investigation on possible emergency activities, its simulation in the laboratory and the physiologic data obtained on miners performing them This included some studies under cool ambient conditions, expected to prevail in coal mines. C. While in section B the steady state responses have been obtained, time was devoted to establish a unit that will allow data gathering for non-steady state, i.e., transient responses to rapidly changing activities. Section B and C contained elements that were relevant to section A; the Man Test. Therefore some of the information described under section A Man Test, were actually measured during the battery of tests in either section B or in section C.

Jan 1, 1974