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By J. P. Bennett

The Bureau of Mines investigated the dimensional changes of ceramic materials exposed to acid environments to evaluate construction materials for emerging technology in chemical and metallurgical processes. Six commercial ceramic materials (two red shale, two fireclay, one silica, and one silicon carbide (SiC» were exposed to H20, 20 and 30 wt pct HCl, 40 and 60 wt pct HN03, and 10 and 50 wt pct H2S04 at temperatures from 50° to 90° C for 300 days. Linear expansions ranged from a low of -0.02 pct for the silica to a high of 0.45 pct for the red shale. A general ranking of the volume expansion of the materials tested, (from high to low), is as follows: high-porosity red shale A and fireclay B » low-porosity red shale B and fireclay A > silicon carbide and silica. A general ranking (largest to smallest) of the effect of exposure environments is HCl > H2S04, HN03 > H20. An autoclave test method was evaluated. Data obtained from 8-to 24-h exposures were compared with data obtained from the 300-day exposures. The relative expansion trends were similar, indicating that this method could be used as an accelerated test.

Jan 1, 1988

By Welton J. Wenger

Apparatus for the analytical distillation of crude oils under an artificial pressure of 760 mm. of mercury has been designed and constructed. This apparatus enables laboratories at high altitudes to make Bureau of Mines routine analyses of crude oils with results similar to those obtained by laboratories at sea level. This is especially important for laboratories in the Rocky Mountain region, where barometric pressures of approximately 600 mm of mercury are encountered. During the past 30 years, the ?Bureau of Mines has made several thousand analyses of crude oils from various parts of the United States and from foreign countries. The first part (stage 1) of the distillation for the analysis is made at atmospheric pressure, and as most petroleum laboratories are near sea level, comparable results are obtained ordinarily. However, the increased use of the method by .laboratories at high altitudes has caused difficulty, as the analyses cannot be accurately compared with analyses from laboratories at sea level. For instance, laboratories at 7,200 feet generally report 2 to' 4 percent (based upon the crude oil) more gasoline than sea level laboratories. The use of the pressurized apparatus developed by the writers makes it possible for these high-altitude laboratories to duplicate analyses made at sea level.

Jan 1, 1949

By G. Nuñez, M. A. Pathak, A. A. Afshari, C. F. Stanley

"To help evaluate the vibration patterns of an excised lung, a method is developed to determine which parts of the surface of an excised lung are responding to acoustic excitation via the trachea. Holographic interferometry, a very' sensitive technique ·that can measure movements of a few microns, is used to detect the lung surface movements.The intact lung and heart are excised from Long· Evans male rats weighing 250 gm. A tube is inserted into the trachea and connected via a funnel to a 3 inch cone speaker. The assembly is positioned in the holographic unit and excited at frequencies up to 10,000 Hz. The holographic unit contains an acousto-optic shutter used with a 0.5 watt Argon laser.The resulting reconstructed holograms contain interference fringes that are indicated of lung surface vibration.INTRODUCTIONA 1986 report by the U.S. National Committee on Biomechanics [1] describes diseases of the lung as a major national health problem. One of the recommendations of the report is for continued study of the mechanical properties of lung tissue. As an example, the report cites at least three areas that would benefit from a better understanding of the vibratory patterns or the lung."

Jan 1, 1989

By David F. Gearhart, Thomas M. Barczak

This U.S. Bureau of Mines report examines the roof and floor contact pressure provided by the interaction of a shield with the surrounding strata. Controlled forces were applied to an 800-ton two-leg shield in the Bureau's mine roof simulator; the distribution of forces acting on the canopy and base of the shield were measured with 24 hydraulic pressure cells. Several influential factors that affect the load distribution were investigated: (1) the magnitude of loading (leg pressure); (2) the profile of the canopy, principally the upward-sloping tip; (3) the base-lifting device; (4) horizontal load acting on the shield; and (9 compliancy of the immediate roof and floor. It was concluded that the shield does not develop full canopy or base contact without deformation of the strata. Maximum contact pressures are developed at the rear of the canopy and on the toes of the base. Less than 10 pct of the available shield capacity is developed at the canopy tip despite the design intention to ensure tip contact. Horizontal loading reduced the toe pressure acting on the base by as much as 75 pct. The base-lifting device exaggerated the inherently high toe loading, increasing the contact pressure by more than 200 pct.

Jan 1, 1992

By C. Sunderman, J. Johnson, S. Signer

Researchers at the National Institute for Occupational Safety and Health have developed a miniature data acquisition system (MIDAS) that can measure resistance changes and temperature, store data for later retrieval, and illuminate LED lights. This instrument can be used with strain-gaged bolts, cable bolts, CSIRO stress-measuring gages, string pots, and any other instrument that uses single-ended, resistance-type gages. MIDAS has the capability to measure up to 16 gages at preset time intervals and store more than 2000 scans, yet is small enough to fit in a 35-mm hole. Because the MIDAS consumes little power, a 9-V alkaline battery will operate the system for 6 months. Data from the MIDAS can be sent to a PC via an RS232/RS485/IRdA port. A software program was written to set operation parameters, graph data, and store all information directly to a spreadsheet. Three LED lights change from green to yellow then red based on reading levels and/or rates of change. This feature can be used with different types of gages to warn miners of possible rock instabilities. The MIDAS has received MSHA experimental permissibility approval and is currently being tested at several mines.

Accurately measure time of detonation and explosive detonation velocity in a blasthole for analysis of explosive performance and delay intervals. Approach A blasthole-monitoring fiber optic probe was developed consisting of filer optic cable to carry the fight and a sensor to detect and convert the light signals into electrical signals. Events can then be recorded on an oscilloscope, tape recorder, digital computer, or start-and-stop timer. This method is simpler to use and more immune to electronic noise than existing resistance techniques. The fiber optic material,, are inexpensive and easy to obtain, and the recording devices, such as storage oscilloscopes, arc available or easy to obtain. The probe provides the mining industry, explosive manufacturers, and those studying blasting, with a practical alternative to complex and expensive coaxial cable reflectometry, resistor strings, or resistance wire methods for determining explosive and detonator performance. How It Works The fiber optic cable is a plastic light guide consisting of sixteen 0.01-inch-diameter optic strands having an overall outside diameter of 0.087 inch. The receiver module incorporates a photodiode to detect the signal and an integrated circuit receiver for signal amplification into one package about 1/2 by 5/8 by 7/8 inch.

Jan 1, 1989

Permit quicker, safer clearance of hang-ups in the ore passes and chutes of underground mines. Approach Develop a device that can be operated from a safe distance to explosively propel a projectile into the hang-up. How It Works The Hang-Up Clearance Module, consisting of a stand, steel disk, explosive charge, and aiming device, is placed at a location convenient for line of sight aiming at the hang-up. This placement can be more than 100 feet from the target. Once aimed, the charge is remotely detonated, and the disk is converted by explosive force into a slug and propelled to the hang-up, bringing it down. The steel disk and an explosive charge are contained by a plastic casing. A small booster which is placed at the rear center of the explosive makes up the last component of the charge. Initiation is accomplished by standard means such as detonating cord or a number 8 blasting cap. When Initiated, a detonation wave travels through the explosive, inverting and consolidating the steel disk into a large slug. This slug is propelled at high velocity to the hang-up, delivering more than 5 million foot-pounds of energy on impact.

Jan 1, 1981

Develop a down-hole replaceable diamond core bit that will reduce overall drilling costs and increase total available drilling time per hole. Approach A one-piece diamond core drill bit of unique geometric shape has been designed, fabricated and field tested. The bit can be withdrawn (or replaced) from the bottom of the well-bore without removing the drill rods from the hole, saving a significant amount of non-productive drilling time. How It Works The replaceable bit system consists of two basic subsystems: the removable core bit, and the equipment necessary to replace the wornout bit without pulling the drill rods out of the hole. The geometric configuration of the bit is that of a one-piece diamond studded cutting element created by "slicing off" two parallel sides of a conventional diamond cone bit. This geometric configuration, along with some minor modifications to the outer core barrel, allows the bit to be rotated in two planes and, with the retraction-insertion tools, raised or lowered through the interior of the drill rods using a conventional wire-line system. For example, to retrieve the bit, a retraction tool is lowered through the drill rods using a conventional wire-line system and at the hole bottom, the tool automatically orients itself within the outer core barrel.

Jan 1, 1981

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

By J. E. Emmerling

The Federal Bureau of Mines investigated dust suppression obtained with three different water-spray nozzle systems during underground continuous coal mining at the face. The nozzles were the "regular" nozzle normally used by the mine, and high-efficiency and low-efficiency nozzles selected on the basis of an airborne capture theory of respirable dust by spray drops. The high-efficiency nozzle used one-third less water than the others throughout the testing. Results depended on the type of cutting operation at the face. The sump-downshear operation appeared to involve a significant amount of capture of airborne respirable dust. The same amount of dust was measured when using the high-efficiency and regular nozzles. The dust levels when using the high-efficiency nozzle were about 20 pct less than those measured when using the low-efficiency nozzle. The sump-upshear operation seemed to involve a predominance of other aspects of dust suppression, such as impaction of spray drops onto the face. Compared with the downshear operation, there was a significant reduction in dust levels for a total face operation when using the regular nozzle; dust levels when using the regular nozzle were about 15 pct lower than those measured when using the high-efficiency nozzle.

Jan 1, 1975

Reduce costs of surface mine reclamation by improving scaper operating efficiency and reducing tire costs. Approach The Wheel Slip Monitor senses and compares the peripheral speed of a scraper's four tires 10 the true ground speed of the scraper, and alerts the operator if any of the tires exceeds a predetermined amount of slip. This system helps scraper operators reduce wheel slip during the loading cycle, thereby improving the loading efficiency of the scaper and reducing tire wear and damage. How It Works The system consists of five ultrasonic doppler velocity-sensing devices for measuring the speed of each wheel as well as the true ground velocity (see photograph). Each sensor produces an electrical output signal having a frequency proportional to the speed of the tire or terrain. The signals are conveyed through electrical cables to a control box in the operator's cab where they are converted to voltages proportional to individual wheel speeds (see photograph). The signals are further processed to activate a blinking red light, corresponding to any individual wheel which is slipping, and to sound a beeping tone that is audible to the scraper operator. The rate at which the light blinks and the tone beeps is proportional to the degree of slip. Alerted, the operator can take corrective action.

Jan 1, 1985

Provide the National Park Service (NPS) with guidelines for closing abandoned mine openings such as shafts and adits. Approach The NPS needed alternative methods of closing a variety of abandoned mine openings on National Park lands. Because the U.S. Bureau of Mines (USBM) has a long history of mining-related experience, the NPS requested that the Bureau provide them with technical mine closure information. USBM engineers compiled information on various types of mine closures and prepared technical illustrations of those closure techniques. Multiple closure options, by type of opening, were prepared as one-page field guides to assist NPS field personnel in determining the most appropriate closure method for a given situation and detailing the construction of the closure method. Results Guidelines provided to the NPS included a description of the method, use applications, construction techniques, technical illustrations, and technical support information. The following provides a brief description of 11 mine closure techniques identified for use by NPS personnel. Most of the closure methods, except the backfill methods, allow for construction that can provide access to the mine. However, providing access makes the closure susceptible to vandalism. Most closure methods require periodic monitoring for subsidence and corrosion or deterioration of construction materials.

Jan 1, 1994

By B. W. Jong

The U.S. Bureau of Mines investigated anhydrous chlorination and caustic-acid leaching processes to recover Ni, Co, Mo, and W from waste hydroprocessing catalysts. In batch laboratory-scale equipment, the chlorination process extracted 61 to 99 pet of the metals. Final recovery was 65 to 99 pct. The caustic-acid leaching process extracted 81 to 98 pct of the metals. Final recovery was 36 to 99 pct. Chlorination processing included roasting, chlorination, hydrolysis of metal chlorides for recovering Mo or W, water leaching of Ni or Co from the spent charge, purification, and solvent extraction or precipitation of Ni or Co from the purified solutions. Caustic-acid leach processing included NaOH leaching, solvent extraction of Mo or W from the NaOH leach liquor, H2S04 leaching of the NaOH leach residue, purification, and solvent extraction or precipitation of Ni or Co from the purified solution. The estimated fixed capital cost for a commercial-scale plant processing 39,000 Ibid of waste Ni-Mo-AI catalyst was $8 million for the chlorination process and $9.6 million for the caustic-acid leaching process. The estimated operating cost was about $0.20 and $0.40 per pound of the waste catalyst, respectively, for the two processes.

Jan 1, 1989

By H. William Zeller

The Bureau of Mines performed laboratory research to determine the effects of a barium-based fuel additive on diesel particulate emissions. The test engine was typical of types used to power underground coal min-ing equipment. Test parameters consisted of baseline measurements without additive, three fuel additive concentrations, and five steady-state engine loads, all at 1,200 r/min. Additive effects on soot mass concen-tration, opacity, particle size distribution, volatile fraction, and NOx emissions were determined. Important findings are as follows: Using the manufacturer's recom-mended additive concentration increased the gravimetrically measured mass of particulate by 30 to 80 pct at four of the five steady-state load conditions. Soot measurements by optical methods did not agree with those by gravimetric techniques, for additive-treated fuels. The additive reduced volatile hydrocarbons adsorbed on filter deposits by up to 50 pet. At most engine loads, carbon particulate was also reduced. About 40 pet of the barium added to the fuel was accounted for in the exhaust. The health implications for miners were considered, but no firm conclusions were drawn or recommendations made because the results are for steady-state conditions, which may not be representative of real-world operation of diesel-powered equipment underground.

Jan 1, 1987

By Douglas Pollock, John Organiscak

Water spray characteristics, including droplet size and velocity, airborne dust capture potential, and induced airflow quantity for various spray nozzle designs were evaluated to provide basic information for improving spray applications. Water droplet size and velocity characteristics were initially measured by a Phase Doppler Particle Analyzer (PDPA) for hollow cone, full cone, flat fan, and air atomized spray nozzles at similar operating parameters. Airflow inducement and dust capture experiments were also conducted under the same operating parameters to examine any salient features of the spray nozzle type, droplet characteristics, induced airflow, and airborne dust capture. Test results indicate that there are trade offs between airflow inducement and dust capture efficiency. A spray nozzle with a wider discharge angle was observed to induce more airflow, but at reduced dust capture efficiencies. Increasing spray nozzle fluid pressure(s) generally reduced water droplet sizes with concurrent increases in droplet velocity, airflow inducement, and airborne dust capture. Placing a three-sided barrier around the spray nozzles normally reduced spray air induction and increased dust capture efficiency. A direct relationship between airborne dust capture efficiency and spray input power normalized per unit of airflow induced was ob- served. This information can be utilized to improve the performance of water sprays for reducing airborne dust levels.

Introduction The NIOSH Office of Mining and Construction Safety and Health Research has redesigned its Mining Safety and Health Web topic page. The updated page incorporates a significant amount of new safety and health information, plus an improved layout to better serve stakeholder needs. It also provides back-ground information about the NIOSH Mining Research Program, including research awards, core competencies, unique labs, community and educational outreach, and a brief discussion of how the research program is structured. The new Web topic page can be found at www.cdc.gov/niosh/mining. "Search" Feature The redesigned Web topic page features improved search capabilities. The "Search Mining" feature on each page lets you search only the NIOSH Mining Safety and Health Web topic page. The user can still search the entire NIOSH Web page by using the "Search NIOSH" option. New Safety and Health Topics Developers expanded the "Safety and Health Topics" and reorganized the site to make it easier to find information. Each topic link now has a significant amount of new and updated information, as well as links to related topics of interest. Safety and health topics include dusts, diesel exhaust, hearing loss, contact with electric current, fires, explosives, ventilation, emergency management, new and older workers, and education and training. All topics can be accessed from the home page (Figure 1). Publications Although the Web topic page highlights many of the most requested publications on the safety and health topic links, you can find a complete list of downloadable publications as well. More than 600 mine safety and health publications are now downloadable from the page. Short summaries let the user quickly identify publications of interest. Products The updated Web topic page offers more than 120 NIOSH mine safety and health products, including training exercises, toolbox talks, videos, computer software, guides, and checklists, many of which are downloadable. If not, instructions are given on how to obtain copies. Some of our products include: • Software to analyze horizontal stress, design pillars for longwall mines, and select roof bolts for ground control. • Educational software including the Hearing Loss Simulator, which simulates the effects of noise and aging; and Coal Country, which teaches children about coal formation, mining techniques, and everyday uses of coal. • Utility software including the HazCom Helper software to assist individuals in writing a HazCOM plan, as required by the Mine Safety and Health Administration (MSHA), to track hazardous chemicals at their mine sites. • Guides for troubleshooting roof support systems, under-ground workstation design, and seating design. • Training exercises and videos that can be used for safety training. Data and Statistics General mining statistics are used by a wide variety of stakeholders. The NIOSH Mining Web topic page offers statistical graphs, tables, maps, fact sheets, and other publications that document the mining population, injuries, fatalities, diseases, and occupational exposures for all mining commodities. If users prefer to analyze data themselves, downloadable files of MSHA data are available. These cover employment, production, injuries, fatalities, and accident data from 1983 to the present and are available in both SPSS® and dBASE® formats.

Jan 11, 2005

By J. L. Holman

The Bureau of Mines is conducting research to recover strategic and critical metals such as Ni, Co, and Cr from mixed contaminated super-alloy scrap. One approach being studied involves melt refining of superalloy scrap to produce anodes for electrolytic deposition of Ni-Co alloy. This melt refining of superalloy turnings is described based on melt-oxidation and oxidation-carburization experiments, using roasted superalloy grinding sludge to supply the 0 needed to oxidize Cr and other readily oxidized elements to the slag. Controlled melt-carburization subsequent to oxidation improved the metal phase recovery of Ni and Co to well over 90 pct and decreased electrolytic solubility of Cr, Mo, and W by carbide formation. Electrolytic refining experiments were conducted using a controlled-potential mode (preset cathode potential). Data show effects of Fe and Cr impurities, cation concentration, electrolyte pH, S04-Cl electrolyte ratio, temperature, cathode potential, and cation-selective membrane use on current efficiency, current density, and deposit composition. Disposition of Ni, Co, Cr, MO, W, and Fe is compared for melt-oxidized versus oxidized-plus-carburized anodes. Deposits containing >97 pct Ni + Co (major impurity Fe) have been routinely obtained from scrap anodes. Research is continuing to improve deposit quality in sustained deposition and to recover Cr and other metals from refining slags and anode sludges.

Jan 1, 1986

By J. E. Pahlman

As part of its effort to reduce the need for strategic minerals through conservation and to reduce the capital and energy requirements of mineral processing, the Bureau of Mines has investigated a method for preparing ferrochromium alloys containing less than 2 percent carbon. This method will conserve chromium and should reduce the capital and energy requirements for chromite reduction. Reduced products containing less than 2 wt-pct C and as low as 0.01 wt-pct C were obtained by reacting pellets of chromite and carbonaceous reductant mixtures at pressures of 0.1 to 1 torr and temperatures of 1,230° to 1,320° C. The extent of reduction increased with increased temperature and decreased pressure; however, operating conditions were limited due to the onset of significant chromium vaporization at higher temperatures and lower pressures. Foundry coke, anthracite, and carbon black were found to be supe¬rior to graphite as reductants. The reduction of chromite to metallics was found to proceed via the carbide intermediates (Fe,Cr)7C3 and (Fe,Cr)23C6, No evidence of carbide intermediates Fe3C or Cr3C2 was found. Buttons of ferrochrome alloys were made by melting a mixture of reduced products with CaO and Si02 at 1,700° C for 20 minutes in an induction furnace,

Jan 1, 1980

By F. G. Horino

The Bureau of Mines conducted compressive strength tests on model pillars of selected rock types with each pillar containing a critically oriented plane of weakness. The objective of these tests was to determine if a significant increase in the strength of the model pillar could be obtained by either (1) installing tensioned rock bolts through the pillar and normal to the plane of weakness, or (2) wrapping tensioned steel wire ropes around the pillar at uniformly spaced intervals along the pillar. Equations based on Coulomb's failure criterion are developed to predict uniaxial compressive strength of model pillars that are either rock-bolted or wire-roped. Laboratory compressive strength tests on unbolted and bolted model pillars of sandstone, marble, Indiana limestone, and oil shale containing a plane of weakness oriented at 45° showed that the bolted pillars are stronger than the unbolted pillars by 84, 31, 52, and 28 pct, respectively. Laboratory compres-sive strength tests on nonroped and roped model pillars of Texas limestone, sandstone, and granite containing planes of weakness showed that the roped pillars were stronger than the nonroped pillars by factors ranging from 1.01 to 2.41, depending upon the angle of the plane of weakness and the rock type. Rocks with a low Young's modulus benefited most by the wire-roping technique.

Jan 1, 1971

By A. E. Raddatz

The Federal Bureau of Mines, as part of its goal to minimize undesirable environmental impacts associated with mineral processing, has investigated a soda-smelting technique for processing ilmenite into pig iron and a titanium slag that is suitable for a feed to a sulfate-process titania pigment plant. By this procedure, the generation of ferrous sulfate waste and its associated disposal problem is obviated. Molten titania slag was quenched, water leached, and filtered to yield a sodium titanate intermediate product containing about 70 wt-pct Ti02, 1 wt-pct Fe, and 20 wt-pct Na20. This intermediate product, high-soda titanate (HST), was mixed with H2S04, calcined, quenched, and water leached to produce a low-soda titanate (LST) product that contained only 2 wt-pct Na20. Both the HST and LST were evaluated as feed materials for preparing titania by the sulfate process. About 95 pct of the Ti02 was extracted from HST and LST by digestion in concentrated or 50-wt-pct-H2S204 solutions. About 95 pct of the solubilized Ti02 was subsequently recovered from the titanyl sulfate solutions by hydrolysis. Barren solutions from hydrolysis, containing about 26-wt-pct H2S04, were upgraded by vacuum-thermal evaporation or electrodialysis. The regenerated acid solutions were used to digest additional HST and LST.

Jan 1, 1979