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By Rudolf Kudlich

"The realization that fuel costs, high as compared with those enjoyed prior to the war, are apparently permanent, has caused steam power plant operators to apply their best efforts towards improving the fuel economy of their plants.Though they have given much attention to the reduction in combustion losses by improving methods of firing and improved equipment, and to diminishing the heat losses by more care in maintaining clean heating surfaces and tight and adequate baffling, they have almost universally neglected the waste that occurs from discarding unconsumed combustible with the boiler refuse.This loss varies between extremely wide limits, depending on the quality of the coal, the type of plant and the firing practice in general, the higher the ash content of the coal the greater will be the amount of combustible appearing in the refuse, and the losses will be greater as the boilers are driven at higher ratings. The refuse from stoker fired boilers is apt to have a lower aver-eve percentage of combustible than that from hand fired boilers if operated at the same rating, but stoker fired boilers are usually pushed to higher ratings and the combustible in the refuse will run higher.In actual operating practice the amount of unconsumed combustible in the boiler refuse may range from a few percent to as high as forty or fifty percent. In an informal statement one well known combustion engineer estimates that the average amount of combustible in the refuse from a large stoker fired central station boiler plant is about 15 or 20%. Assuming that the coal burned contains 12% of ash, and allowing for flue dust losses, approximately two percent of the coal will be lost through this channel. The operating engineer of one large modern central power plant reports that when burning coal of about the same ash content, the average amount of combustible in the refuse was in the neighborhood of 33%, en tailing a loss of approximately 4% of the heating value of the fuel fired. Where the coal used daily runs up into hundreds of tons, an appreciable economy could be effected by recovering this percentage."

Sep 1, 1924

By R. G. Nelson

This report covers investigations of the Bureau of Mines for the period of June 15, 1952, to June 15, 1953, on a research project for the Materials Laboratory, Wright Patterson Air Force Base, Dayton, Ohio. The primary purpose of this investigation was to make high-purity chromium-base alloys having room-temperature ductility and high-temperature strength. The Nonferrous Metals Branch of the Bureau of Mines, Albany, Oreg., has, during the past 7 years, developed on a laboratory scale a hydrogen treatment method for making high-purity chromium that can be fabricated into thin sheet and wire. This material can be bent at room temperature. The object of this investigation was to use this material to develop improved chromium-rich alloys for high-temperature uses.

Jan 1, 1955

By Jack I. Paige

The Bureau of Mines conducted studies to provide data on the room temperature mechanical properties of Ti-6Al-4V alloy cast in waterglass-bonded zircon sand and to determine the effect of hot iso-static pressing (HIP) on these properties. Data on the cast and annealed Ti-6Al-4V alloy were compared with published data for forged and investment-cast Ti-6Al-4V alloy. The average Charpy V-notch impact strength compared favorably with the typical values of 17 ft?lbf for wrought material and 19.2 ft?lbf for investment-cast material. The room temperature mechanical proper-ties of cast and annealed material compared favorably with published values for investment-cast Ti-6Al-4V alloy and exceeded the specifications for (1) titanium and titanium alloy castings, grade C-5 according to ASTM B367-69, and (2) titanium alloy bars and forgings as specified in AMS4928H, except for the AMS4928H minimum requirement for reduction in area (25 pct). The minimum requirements are: tensile strength, 130 ksi; yield strength, 120 ksi (0.2 pct); and elongation, 6 pct. None of the specimens tested met the AMS4928H minimum requirement for reduction in area. The HIP process healed the internal casting porosity in the test specimens, but the fatigue strength was not significantly improved. The fatigue properties of both the cast and cast plus hot isostatically pressed castings were significantly lower than those of wrought products.

Jan 1, 1984

By G. T. Lineberry, W. J. Wiehagen

A Paradigm Shift As market economists, mine managers are interested in "staying in business" and even "prospering." Bottom-line results are the "order of the day." Concern for bottom-line results invokes questions such as: How much was produced? At what cost? And, was anyone injured? While these questions will always carry everyday emphasis at the mine, they are fundamentally lacking in that they often appear, especially to lower levels of management and to the production worker, as preeminent concerns. Driven by market economics, many organizations have decentralized, outsourced, downsized, restructured, and formed new coalitions. Investments in new technology and concentration on productivity have been part and parcel with these changes, contributing to improvements in both safety and efficiency. A reason for (and, perhaps a result of) these improvements has been the development of a highly experienced and flexible work force. These changes in mining present an interesting opportunity to modify a few paradigms about work life in general, and perhaps a few paradigms about how we invest in the miner, in particular. Studying these issues now might offer some interesting opportunities for the future, as the foundations for the next generation of mine workers are laid. With the average "experienced" U.S. miner five to fifteen years from retirement, perhaps a key determinant of future success in the world market might be how well we make the transition from today's work force to the work force of tomorrow. We can ill afford to wait a few more years to tap into the special knowledge residing within a veteran mining work force. The WCPM work Crew Performance Model, see pp. ) is one approach to defining, capturing, and transferring this expertise.

By N. S. Petersen

As part of the Demand Evaluation Program of the Bureau of Mines to determine future needs for minerals, a study was instituted to develop and describe a methodology for approaching the problem of substitution between mineral commodities and between mineral commodities and other materials. The report comprises three sections: A review of general factors relative to substitution, a case study of the effect of substitution on zinc die-casting markets in recent years, and a general methodology for reviewing materials substitution with specific emphasis derived from reviewing substitution in the domestic zinc die-casting markets.

Jan 1, 1971

This publication summarizes the research (in-house and contract projects) programmed by the Bureau of Mines for fiscal year 1985 (October 1, 1984-September 30, 1985) under its Health and Safety Technology Program. The objective of these projects is to provide an ordered and sequenced advance toward the Bureau's overall goal of providing the system technology required to create a more healthful and safer working environment for the Nation?s mining and minerals processing workers.

Jan 1, 1985

By F. S. Kendorski

This report presents the results of a program to improve, using existing and proven technology, unstable highwall conditions through better blasting practices in Appalachian strip coal mines. Better borehole blasting agent distribution and optimization of burden, spacing, and delay periods allowing satisfactory breakage with minimal backbreak were the objectives. At a selected field site, geologic conditions were closely examined with regard to joint orientation and spacing, and resulting slope stability considerations. A test series of eight blasts was completed and the resultant highwall monitored by repetitive photography. The study of drilling and blasting economics along with equipment performance led to an economic model of blast parameters and the identification of blast design cost benefits. The work demonstrated that small strip mining companies' are able to achieve a more stable highwall excavation utilizing presently available technology, equipment, and explosive products at improved operational cost and safety.

Jan 1, 1981

By A. N. Baldwin

This report documents the work performed under Bureau of Mines Contract J0265029 to study and develop two innovative mining systems: ? An underground auger capable of augering into the right and left ribs without repositioning the machine ? A conventional mining system employing recently developed innovative machinery. The report is separated into two volumes to document the two studies separately. Volume I describes work performed and the recommended concept for a bidirectional auger. Volume II describes the studies of mining equipment performance and mining plans developed to determine a conventional mining plan offering improved productivity.

Jan 1, 1977

By Guy A. Johnson

This Bureau of Mines report summarizes the results of efforts to develop reasonably priced, reliable mine shaft fire and smoke protection hardware for metal and nonmetal mines. The hardware was incorporated into a viable prototype system that would minimize fire and smoke hazards. The design of the system had to be sufficiently flexible to be utilized in a wide variety of metal and nonmetal mine shaft and shaft station configurations. As a result of long-term, rugged field tests, an improved (second generation) system was developed. The hardware is now commercially available.

Jan 1, 1978

Miners, like everyone else, must be able to see well in order to work well. But simply hauling bigger and brighter lights into the mines does not necessarily produce better mine illumination. This chapter tells why. Increasing the power of the light source can create problems of portability, glare, adaptation and contrast. This chapter also discusses some ways to increase illumination by Improving the reflectability of walls, roofs and other exposed surfaces. In Chapter IV you learned that the "brightness" of a room or work area was really a matter of how much light was reflected from the walls, roof, and other surfaces. Therefore, if you want to Improve visibility you should increase the amount of reflected illumination. O HOW DOES ONE DO THAT? One way of Increasing reflected illumination would be to increase the power of the light source.

Jan 1, 1976

By A. N. Baldwin

This report documents work performed under Bureau of Mines Contract J0265029 to study and develop two innovative mining systems: ? An underground auger capable of augering into the right and left ribs without repositioning the machine ? A conventional mining system employing recently developed innovative machinery. The report is separated into two volumes to document the two studies separately. Volume I describes work performed and the recommended concept for a bidirectional auger. Volume II describes the studies of mining equipment performance and mining plane developed to determine a conventional mining plan offering improved productivity.

Jan 1, 1977

By J. W. Town

As part of the Federal Bureau of Mines titanium resources examination program, samples from seven deposits in the Pacific Northwest were tested for amenability to various beneficiation techniques. The samples obtained by the Bureau's Office of Mineral Resources at Spokane, Washington represent a large potential source of titanium. This report summarizes the results of tests at the Bureau's Metallurgy Research Center, Albany, Oregon. Recoveries from tabling placer samples were about 50 percent at grades of 30 percent titanium dioxide. Flotation was the most effective method for concentrating the fine ilmenite in clay samples; recoveries of approximately 50 30 percent titanium dioxide. Flotation was the most effective method for concentrating the fine ilmenite in clay samples; recoveries of approximately 50

Jan 1, 1961

By L. E. Dalverny

This Bureau of Mines report describes the deployment, 5-month operation, and lessons gained from a continuous gas monitoring system using sampling-tube bundles at an underground mine fire in West Virginia. Research information gained indicates the utility of relating certain gas concentration ratios to events during fire development, mine reventilation, and mine recovery. In addition to monitoring the quality of remote fly ash seals, the system provided timely warning of dangerous gas concentrations which developed during surface and underground recovery activities. An evaluation of system components is supplemented by recommendations for improvements.

Jan 1, 1975

By R. B. Schluter

Magnetite pellets were simultaneously reduced and indurated on a laboratory scale in order to determine the effects of temperature, induration time, degree of metallization, and sulfur content upon the physical and chemical properties of prereduced pellets. The reductants were commercially-pure tank gases. Among the findings were these: 1,100° C is the minimum temperature that will produce acceptably hard pellets using carbon monoxide as the reduc-ing gas. Prolonged treatment time improves the pellets' crushing strength, but the rate of improvement falls off sharply after 2 hours' induration. At 1,120° C, 75-percent metallization produces the maximum crushing strength; there was no corresponding peak at 900° or 1,050° C. Sulfur in the furnace atmosphere lowers the required induration temperature. A few tenths of 1 percent sulfur in the pellet increases the sintering rate of metallic iron in pellets by forming a liquid FeS phase that facilitates iron transfer.

Jan 1, 1968

By T. L. Joseph

"IntroductionThe efficiency of ore reduction in the blast furnace and fuel requirements depend upon the degree of uniformity with which reducing gases can be distributed through the stock column and upon the permeability of individual pieces of ore and sinter. If the ore is fine, the major problem in reduction is to get the ascending gas stream to the surface of the ore-Hard, dense ores of low permeability, mined in coarse sizes, tend to improve the permeability of the bed, but unless they are crushed to the proper size they reach the hearth unreduced.Surveys by the Bureau of Mines have shown conclusively that the gas distribution in the upper three fourths of the furnace is far from ideal. Furnace lines, top design, and methods of charging are important, but more thorough size preparation of the ore is necessary to eliminate size segregation at the stock line, which inevitably leads to non-uniformities in gas distribution.Because of the quantity of sinter now produced close study of the characteristics which determine its behavior in smelting is warranted. As the use of concentrates increases agglomeration will become more of a necessity. Improvements in the physical character of the ore burden are particularly important to plants using coke of poor physical quality. In addition to aiding reduction, improved physical properties of the ore burden will permit the use of higher blast heats, which is equally important.Reduction Tests on Fine Sizes of SinterPrevious reduction tests on minus 0.742— plus 0.525--inch pieces of commercial sinters revealed large differences in porosity and reducibility. The results have been published in a former report. 3 Although the physical properties of the sinter, particularly porosity, were found to be of major importance in determining the rate of deoxidization, it appeared that certain chemical properties of the sinter appreciably retarded the reduction of sinters high in silica. This was attributed to the presence of fayalite, which has been identified by Schwartz and by Luyken and Kraeber4 as an important constituent of sinter. Although furnace operators and metallurgists have assumed that iron silicate is more difficult to reduce than hematite or magnetite, definite data on the reduction characteristics of this material were not available. Tests were undertaken, therefore, to develop a method for de-termining the amount of iron silicate present in sinters so that its effect upon reduction could be observed."

Jun 1, 1934

By Raymond F. Farrell

A goal of the U.S. Department of the Interior, Bureau of Mines, is the advancement of minerals technology through the development of improved metals and minerals processing. In support of this goal, the Albany Metallurgy Research Center has developed atomic absorption spectrographic methods for the rapid analysis of A1203, CaO, Fe203, MgO, MnO, and Si02 in steelmaking slags. The application of these methods is discussed using an inexpensive pressure dissolution system. The overall coefficient of variation is 5 pct. The accuracy is the same as the reproducibility.

Jan 1, 1979

This publication summarizes, for potential contractors and other interested parties, the proposed research, development, and demonstration contract projects programed by the Bureau of Mines for fiscal year 1977 (October 1, 1976-September 30, 1977) under its Advancing Coal Mining Technology program. The objective of these projects is to provide an ordered and sequenced series of advances toward the overall goal of providing the system technology required to increase the productivity of the coal mining process.

Jan 1, 1977

By A. C. Fieldner

All technical facilities of the Bureau of Mines have been geared for more efficient use and conservation of mining equipment, developing plans for safety, improving the quality of coal through better methods of preparation, studying the problems of coal storage and utilization, and extending the uses of coal5/ for the war and postwar economy. The Bureau is now analyzing all of the coal purchased by the Army and much of that required by the Navy. Work on boiler feed water was doubled over last year to meet the increased demand made by the War Department for protecting vital boiler plants in many new camps and defense plants. Progress has been made in safely storing coal to reduce dangers of spontaneous ignition to a minimum and to preserve coking power. Mixtures of oil and coal to be used as a substitute fuel have been investigated. Technical service on the conversion of plants to other fuels has been given to government agencies and private consumers. The possibilities of making motor fuel,

Jan 1, 1944

By M. A. Reyes

This experiment investigated the effects of different machine mounted area lighting technologies on visual performance. The primary objective was to conduct a comparative evaluation of the lighting technologies based on the visual performance of thirty-six human subjects in a simulated underground mine environment. Incandescent (Incand), fluorescent (Fluor), and light-emitting diode (LED) technologies were used to create four lighting combinations. Visual performance was quantified for the detection of movement in the peripheral field of view and the identification of ground hazards. Measurements were made of the speed [response time measured in milliseconds (ms)], the accuracy (the number of targets and objects missed), and the subjective discomfort rating of the glare experienced for each lighting combination. A secondary objective explored the effects of aging on visual performance. The results indicate that lighting combinations which consisted of LED area lights significantly improved visual performance for the detection of hazards found in the peripheral field of view, as well as those found on the ground. They furthermore, indicate that age plays a significant role in visual performance.

Jan 1, 2009

By Albert L. Brautigam, Michael C. Leigh, August J. Kwitowski

The U.S. Bureau of Mines developed and tested a teleoperating system to control a new highwall mining system. A remote operator was provided out-of-sight sensory information and control of coal extraction and haulage equipment. Surface and production testing proved that the teleoperating system supplied the operator with sufficient sensory information to operate the mining system. Details on the teleoperating system provided in this report include (1) sensor selection, (2) a description of the electronic control system, (3) equipment selection and modifications, (4) the positive test results, and (5) recommendations for system improvements.

Jan 1, 1992