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By P. G. Barnard

Losses of alloying metals in furnace flue dusts, grinding swarfs, and mill scale produced during the manufacture of stainless steel are substantial. About 25 million lb Cr, 8.7 million lb Ni, and 150,000 lb Mo and other critical metals can be made available annually for recycling by a process developed by the Bureau of Mines. Stainless steel wastes pelletized with a portland cement binder were reduced in a small electric-arc furnace by a two-stage process to produce a recyclable alloy containing Cr, Ni, Mn, and Fe. The initial reduction was with carbon; the second, with ferrosilicon. Results are compared with previously reported laboratory induction melting tests. A 2,000-lb demonstration test of the process in a commercial electric-arc furnace is also described. Data are also presented on three 1,500-lb tests made using various slag conditions in the electric-arc furnace. Recoveries up to 99 pct of the Fe, Cr, and Ni contents of stainless steel wastes were obtained in using the process.

Jan 1, 1977

By Fred N. Kissell

Tracer gas decay curves were experimentally obtained in a full-scale model coal mine working face area. The concentration of tracer gas was found to decay in exponential fashion but with a change in slope. This change in slope is attributed to eddy zones in the face area. A simple theory was developed that allows one to calculate the approximate amount of gas in the eddy zones and thus estimate the size of the eddy zones.

Jan 1, 1974

By Donald M. Hausen

Diamond-bit performance and cost data accumulated by the Bureau of Mines in core-drilling schists reveal significant trends of economic interest. Low-quality, small-size drill bort were the most economical. The percentage of core recovery, type and size of bit, and bit matrix are also correlated with bit performance and costs. Detailed analyses of the factors affecting diamond-bit performances and costs are assessed in the tables, graphs, and discussion.

Jan 1, 1956

Reduce longwall intake contamination by controlling respirable dust generated by the stage loader. Approach Install a water-powered scrubber on the stage loader immediately outby the crusher. Dusty air from the crusher is drawn through the scrubber and a clean air discharge is delivered into the primary face airflow. How It Works The contamination of intake air is a significant dust control problem often overlooked on many longwall faces. This dust source contributes to the full shift dust exposure of all face personnel, and thus can significantly affect compliance with Federal regulations. Several sources contribute to contamination; however, dust generated by the stage loader crusher is the single largest source. The breaking action of the crusher generates a tremendous quantity of dust, which mixes with the primary ventilation airstream and is carried down the entire length of the longwall face. The installation of a water-powered scrubber (see diagram) has proven effective in controlling crusher-generated dust. The scrubber is mounted immediately outby the crusher. A duct is placed over the scrubber intake and attached to a flanged opening over the crusher discharge. In

Jan 1, 1982

To clean coal mine air by developing a low-cost scrubber suitable for belt transfer and similar applications. Approach Design a scrubber operated by water only, with no moving parts. Use conventional water spray nozzles located within a duct to both move and clean the air. Use a droplet eliminator to get the water droplets and mist back out of the airstream. How It Works Conventional scrubbers require a mechanical fan driven by either an electric or a hydraulic motor. They also require water sprays and some type of scrubbing mechanism. The water powered scrubber, however, offers higher reliability over conventional scrubbers since it utilizes the water sprays to both move the air and scrub the particulate from the air. Conventional water spray nozzles are placed near one end of a rectangular duct open at both ends. The sprays are directed towards the far end of the duct where a stationary wave blade water droplet eliminator is located. Movement of the water spray droplets coming from the nozzles generates (by momentum transfer) an air movement In the same direction as the sprays. The volume of air moved Is primarily a function of the duct cross-section size, water pressure and water

Jan 1, 1981

This section contains a summary of our investigation of the soil conditions (type, porosity, moisture content, etc.) at the two sites (Lanse and Kato, Pennsylvania) selected for field testing of latex as a soil sealant. Other natural conditions such as rainfall, frostline, depth of the water table, etc., were also measured and recorded for possible later use in assessing the effect of the latex seal on the total environment. The numbered sites referred to throughout this report are shown on the maps of the Lanse and Kato sites (Figures 1 and 2). KA, RB and KC are positions at the Kato site - all other numbered positions refer to the Lanse site. Two other terms used throughout the report which should be explained are “horizon” and "profile". These are synonymous terms for soil layer, A horizon (or A profile) referring to topsoil and B horizon (or B profile) referring to subsoil. The properties that control the flow of water through the soil are of special interest because these will also govern the passage of a sealant into and through the soil. Normally the particle size distribution is a good measure of soil permeability, which is directly proportional to sand content and inversely proportional to silt and/or clay content. Tables I1 and I11 show the percentages of gravel or stones, sand, silt and clay of Lanse and Kato soil samples. According to the United States Department of Agriculture classification, the gravel is ,ignored and the residue separated into sand, silt, and clay fractions. Figures 4 and 5 indicate by means of the USDk soil texture triangle that the variability of composition of Lanse soil ranges from sandy loam in the creekbed to clay loam. The variation is even greater among soil samples from Kato. Porosity of soil, also known as percent voids, is another indication of how readily water will travel through soils. Soil density usually increases and porosity decreases with depth, and as expected, the porosity of the top soil at Kato, a forest, is exceptionally porous and open (see Table IV) The pore diameter and length of soil capillaries is extremely variable, and its distribution in the field is impossible to determine. In addition to the capillaries, soil also contains many macro cracks, crevices, and passages around stones and roots. All these affect the flow rate of water through soil. Poiseuille's law states that the rate of flow of a liquid through a narrow tube is proportional to the 4th power of the radius of the tube. Pore size normally decreases with depth and in soil containing appreciable amounts of silt and clay this is especially true. Thus, deeper soils should be less permeable and such was the case at Lanse and Kato.

Jan 1, 1972

Provide a machine for economically drilling probe holes in coal mines (required where there's a possibility of unmapped, abandoned workings) to check for possible water flood or gas hazards ahead of the face. Approach A lightweight air-powered drill, that mounts on a light-weight frame anchored to the face with an expandable packer, is used to drill one or more probe holes. The anchor installs quickly and will lock the drill in any desired position. How It Works The drill is portable and can be broken down to small components for ease of transportation. One man can carry these sections through restricted access routes to the working place. Components that are separable are the anchor assembly, drill frame assembly, and drill motor assembly. The drilling sequence is as follows: A 2-inch-diameter anchor hole is drilled 2 feet deep. The fixed anchor tube is rubber packer is expanded. A second anchor hole is drilled through a bushing in the anchor frame. The removable anchor tube is inserted and its rubber packer expanded. (This anchoring system withstood pulls of up to 14,000 pounds.) Next, the frame is attached to the anchor with two screw knobs, and the motor is attached to inserted in the hole and the rubber packer is expanded. A second anchor hole is drilled through a bushing in the anchor frame. The removable anchor tube is inserted and its rubber packer expanded. (This anchoring system withstood pulls of up to 14,000 pounds.) Next, the frame is attached to the anchor with two screw knobs, and the motor is attached to the frame with a single locking pin. Installing the anchor and drill takes less than 12 minutes.

Jan 1, 1981

By Robert L. Chufo, H. Kenneth Sacks

Medium-frequency (MF) waves can propagate in a coal seam, bounded above and below by conducting rock, in an approximate transverse electro-magnetic (TEM) transmission-line mode with the electric field vertical and the magnetic field horizontal. The theory of this coal seam mode is applied to recent MF data for a number of mines in order to classify the propagation characteristic of the mines in a simple way. When conductors such as rails, trolleylines, or power cables are present in the vicinity of the measurement path, it is found that the magnetic field versus range plots have two distinct regions with very different slopes. This effect is attributed to coupling of the cylindrically spreading coal seam mode to a low-attenuation conductor guided mode. As a result, voice communications range between mobile transmitters can extend several thousand meters. The use of MF for mine communications is discussed.

By David L. Moffatt

Considerable current interest is evident[l,2] in the use of transient electromagnetic methods for subsurface remote sensing. A transient method is discussed which uses a periodic video-type pulse containing a wide frequency range. A video pulse is used as an interrogating signal both for "target" identification and detection for relatively short depth (c 20 meters) applications in soil and soft rock media. If the medium is favorable, e.g., hard rock, greater depth applications appear to be feasible. The same procedures would be applicable for deep geological exploration but would require a substantial reduction in frequency and increase in target size. It should be noted that video pulse generators with 35 kv peak voltage and nanoseconds base widths are now within the state-of-the-art, thus significant power over broad spectral ranges is possible. In the design of a video pulse sounding system, 5 main problem areas can be identified; 1 ) selection of the pulse shape or spectral content of the video pulse, 2) design of a radiating structure which effectively couples such a pulse into the medium, 3) isolation of the radiating and receiving mechanisms, 4) realistically accounting for the dispersion and attentuation of the medium and the air-medium interface, and 5) interpretation or processing of the received signal waveform. Each of these problem areas will be discussed and illustrated with experimental and/or theoretical results. The Video Pulse Selection of the proper video pulse signal is dictated by 3 considerations, the maximum desired depth of penetration, the attenuation of the medium and the required resolution and size of the target. For a lossy medium, penetration and resolution are clearly at cross purposes and a compromise is necessary. The exact nature of the compromise is dictated by the application, but the spectrum of the video pulse should not contain any frequencies higher than the predicted cut-off, i.e., that frequency which is attenuated to the threshold level of the receiver. As a practical matter, it may be necessary to select 1 or 2 video pulses reasonably suited

Jan 1, 1973

Decrease dust concentra¬tions of longwall face workers by keeping them up¬wind of the headgate stage loader and crusher. Approach Direct the face airflow from tailgate-to-headgate, the direction of coal transport. How It Works Ventilation is the primary method of dust control on longwall faces, and the most effective ventilation control is to put workers upwind of dust sources. Recent ad¬vances in longwall dust sampling by the Bureau have shown that on some faces, the headgate crusher and transfer points are signifi¬cant sources of dust -some¬times making up more than half of the total dust to which the face workers are exposed. Also, when the air is coursed from head-to-tail, the relative velocity between the air and moving coal on the face conveyor can cause dust entrainment from the conveyor, particularly if the coal is dry. On the faces where these dust sources are a signifi¬cant problem, they may be eliminated by coursing the air from tailgate-to-headgate, provided that the mine roof is stable enough to permit the necessary intake of the tailgate along with an aux¬iliary intake at the headgate.

Jan 1, 1982

By L. H. Banning

The Bureau of Mines conducted pioneering batch and laboratory cyclic tests that simulated plant operation in developing a procedure for acidulating phosphate rock with fluosilicic acid. Both high-grade deslimed phosphate rock and low-grade phosphate rock samples were treated. The most promising results were obtained by acidulating des limed high-grade material. In a series of seven cyclic tests, 85.4 percent of the P20S was recovered in solutions. The average P2O5 content of the phosphoric acid-monocalcium phosphate solutions of the first step was 156 grams per liter, and the average fluorine content was 4.7 grams per liter. Residues had an average fluorine content of 30.7 percent and contained 83.9 percent of the total fluorine in the charge materials. Some fluorine was lost by volatilization.

Jan 1, 1975

By John Durkin, Harry Dobroski

This paper presents a general overview of the Bureau of Mines' programs in the areas of operational and post-disaster communications. These programs encompass both hardware developments and system evaluations. Topics discussed include a new visual paging system compatible with existing pager phone lines, a means of modifying commercially avail able pager phones to permit selective paging and message leaving, a multiplexed telephone system that uses twisted shielded pair and requires no central control, medium frequency hardware developments, and a manual for mine communications. Research has continued in the area of post-disaster location and communications. This research is based on seismic and electro- magnetic techniques. Each has been extensively studied and field tested to better understand its ability to perform effectively. A brief description is given of the post-disaster program. Results are promising and provide insight into future areas of research.

To produce industrial-grade titanium castings by processes that are nonpolluting and lower cost than the currently used rammed-graphite process. Approach Foundry-grade zircon and olivine sands, bonded by waterglass or bentonite, are used to make shell or rammed molds which require relatively low-drying temperatures and do not generate noxious fumes during drying or casting. Procedures Three separate processes have been developed which meet the stated pollution and cost goals. These are: 1. Waterglass-bonded rammed zircon or olivine sand molds are dried at 480°F, zirconia washed, redried, and used in an inductoslag or skull-casting furnace. 2. Waterglass-bonded zircon or olivine sand shell molds are formed at 560°F, cured at 620°F, zirconia washed, dried at 480°F. and used in an inductoslag furnace. 3. Rammed zircon and olivine sand molds are bonded with western bentonite, zirconia washed, dried at 980°F, and used in an inductoslag or skull-casting furnace.

Jan 1, 1981

By H. Robert Ensminger

The Belizean economy had an estimated annual growth of about 3.4% over that of 1986. Economic growth during the 2 previous years was slower and was characterized by a negative trade balance. The gross domestic product (GDP) was an estimated $200 millioni2 in current dollars. Limited natural resources and scarce finances continued to make the Government's task a difficult one. Belize and China signed an economic cooperation agreement in April under which the Chinese Government is to provide technical assistance, a cash grant of $60.000, and a long-term, interest-free loan of approximately $1.5 million. In May, it was reported that gold was discovered in a remote area of the Maya Mountains in western Belize. An estimated unassayed value of $400 million has been placed on the deposit by one of its discoverers. However, the government in Belmopan has played down the discovery. Two U.S. oil companies. Seahawk Oil International of California and Alston Oil Co. of Texas, were granted licenses to explore for oil. Seahawk Oil will explore a large area of the Orange and Corozal Districts, while Alston Oil will prospect a 90,000-acre area of the western Cayo District. Another U.S. oil company, Pecten Oil Co., recently completed seismic studies off-shore of Belize City. Pecten Oil has made plans to start drilling in 1988.

Jan 1, 1989

By E. G. King

The work described in this Bureau of Mines report was undertaken to fill a need of industry for high-temperature heat-content data for uranium tetrafluoride. Without such data, heat balance evaluations of processes involving this substance are seriously hampered. Measurements of the heat content of uranium tetrafluoride were conducted at temperatures from 298° to 1,350° K. The melting point and heat of fusion were determined. The results are presented in suitable tabular form, and representative heat-content equations are included.

Jan 1, 1961

Provide a strategy for calculating optimum distribution of selected sensors for detecting underground mine fires. Approach The Bureau of Mines performed research to determine adequate distribution of product-of-combustion (POC) fire sensors within mine entries. This placement strategy would improve the miner's chances for escape by locating sensors where they would most effectively, quickly, and efficiently detect fires resulting from coal or wood combustion. Spacing of Sensors Placement strategy guidelines were based on the performance of 160 F heat sensors with ideal operating characteristics which were placed at intervals of ten feet in underground mine entries. Data obtained from full-scale mine fires were used to estimate fire sizes and alarm activation times for the heat sensors. Various equations were then developed to determine spacing requirements for any fire detection system installed in entries of varying heights, widths, and ventilation rates.

Jan 1, 1983

Lower the respirable dust exposure of longwall shearer operators by keeping the dust cloud confined to the face. Approach Change the location of face-side machine cooling, water sprays. How It Works The dust breathed by the longwall shearer operator is usually produced by the shearer itself. The dust cloud originates at the face, and the exposure of the operator depends largely on how quickly this cloud spreads into the walkway. Water sprays on the shearer body can have a large effect on dust cloud spreading. Results to date indicate that sprays can help confine the dust cloud to the face if they are carefully placed. Otherwise they can make dust levels far worse. The worst offenders are often face-side sprays used to discharge cooling water from the cooling jackets of the shearer motors. These face-side sprays set up an air circulation pattern as illustrated in the drawing. Air induced by the sprays to flow towards the face, raises the air pressure in front of the face, which causes the air flow to turn and then move back over the shearer, bringing dust with it into the walkway.

Jan 1, 1981

Reduce mine worker dust exposure by capturing airborne coal and quartz dust generated by a continuous mining machine. Approach Install a water-powered scrubber system operating at 1,000 psi on the side of a continuous miner boom. Dusty air under the boom is drawn through the scrubber, and cleaned air is discharged into the face return. How It Works Most coal mines use exhaust face ventilation to send fresh air over the miner operator, and contaminated air behind the line curtain to the section return. The difficulty with exhaust face ventilation is that the line curtain should be within 10 feet of the face for maximum effectiveness. If the line curtain is not extended properly, or water sprays for dust control are poorly installed, dust rolls back toward the operator. A scrubber mounted on the mining machine will effectively reduce this dust rollback and the dust in the return airstream.

Jan 1, 1989

Increase the safety of underground mine workers by minimizing hazards associated with rerailing mine cars after derailment. Background and Approach A serious operational problem in underground mines is the task of rerailing mine cars. Current rerailing practices are not only hazardous but are inefficient as well. Most methods involve pulling the derailed car back onto the track with a locomotive. This causes damage to the road bed and is not effective on curves or in situations where the car's wheels are too far from the rails. Jacks, wooden props, and pry bars are also used to raise or lower cars back onto their tracks but methods involving these tools require much strenous manual effort by mine workers, thus posing possible serious injuries. The problem is further compounded by the cramped, narrow confines of the underground mine environment which allows no space to permit use of cranes or other surface railroad rerailing techniques. The Bureau of Mines, aware of these problems, investigated improvements in current underground rerailing methods. Through a cooperative effort with Hoesch MFD, a system was designed and modified that can be easily carried into the mine by workers and quickly assembled at the derailment site. The system is hydraulically and pneumatically powered rather than reliant upon manual operation.

Jan 1, 1986

Reduce costs of surface mine reclamation by improving bulldozer operating efficiency. Approach A draft power indicating system helps bulldozer operators adjust blade height and other controls for maximum load movement, by continuously indicating the rate at which work is being done. How It Works This system continuously measures both the push of the blade against the overburden, and the true ground velocity of the bulldozer. It multiplies those quantities to determine the real work rate of the machine. The system consists of a velocity sensor, a blade load sensor, processing circuits, and a work-rate indicator. The processing circuits include an analog multiplier which has an output signal representing the draft power (velocity x load = power). The draft power, or pushing power is a measurement of the work rate at that moment.

Jan 1, 1979