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By Theodore Kootz

Manufacture of high-grade ferromanganese; as a rule; requires a low-phosphorus-manganese ore with 45 to 55 percent Mn, chiefly obtained in the Soviet Union, the British Dominions, and Brazil. Also, low-manganese ores have already been used for ferromanganese production, especially in North America .and Germany. During World War I, a process was developed in which a high-phosphorus ferromanganese or spiegeleisen was prepared in the blast furnace from law- or high-phosphorus manganiferous ores, then low-phosphorus manganese slag was prepared by refining under an acid slag, and this material was, worked into a low-phosphorus ferromanganese in the blast furnace.9/ Manufacture of useful manganese ores from a phosphorus-bearing spiegel with 12 to. 15 percent Mn, 4.5 percent C,, and 0.5 percent P by slagging in a refining furnace was reported by Joseph, Barrett, and Wood.10/ The spiegel was refined to 0.75 percent Mn, 3.4 percent C, and 0.45 percent P. Thereby, a slag with about 43 to 58 percent Mn and, about 10 percent Si02, was obtained. Hotter melts gave a smaller phosphorus content in the slag than cold melts. In addition, the phosphorus content of the slag varied with the manganese content of the intermediate metal.

Jan 1, 1952

By Eugene Frey

"INTRODUCTION The Blue Bell fluorite deposits were examined in August and November 1944 by an engineer 3/ of the Bureau of Mines, and an underground project was set up. The Bureau of Mines began development of fluorite here February 10, 1945, and completed its survey on June 21, 1946.ACKNOWLEDGMENTSIn its program of exploration of mineral deposits, the Bureau of Mines has as its primary objective more effective utilization of our mineral resources to the end that they make the greatest possible contribution to national security and economy. It is the policy of the Bureau to publish the facts developed by each exploratory project as soon as practicable after its conclusion. The Mining Branch, Lowell B. Moon, chief, conducts preliminary examinations, performs the actual exploratory work, and prepared the final report. The Metallurgical Branch, C. C. Ralston, chief, analyzes samples and perform beneficiaticn tests. The exploratory project was under the direction of Paul T. Allsman, chief, Salt Lake City Division, Mining Branch. Acknow¬ledgment is due R. Thurston of the Federal Geological Survey for mapping the topography of the area, and to F. H. Gunnell and W. A. Young of the divisional office for detailed mapping of the surface and underground development and interpretation of the results.The chemical analyses included in this report was performed under the direction of H. E. Peterson, analytical chemist; the petrographic studies on the ore were written by LaMar Evans, petrographer; and the beneficiaticn section was written by C. H. Schack, metallurgist, under the direction of S. R. Zimmerley, chief, Salt Lake City Division, Metallurgical Branch."

Jul 1, 1947

By Jalna R. Zatko

The Bureau of Mines, U.S. Department of the Interior, has developed a novel method of flocculation dewatering of phosphatic clay wastes using polyethylene oxide as the flocculant. Research was conducted to determine whether ethylene oxide gas was present in the air in the vicinity of disposed waste materials which had been flocculated with polyethylene oxide. Samples of clay waste materials containing polyethylene oxide were prepared in stoppered glass bottles in simulated disposal environments. Gaseous samples, removed over a 75-day period using an airtight syringe, were injected into a gas chromatograph that was capable of separating ethylene oxide from air. The presence of ethylene oxide gas was not detected in any sample. To determine possible degradation products of polyethylene oxide, the properties and reactions of ethylene oxide and its polymers were reviewed. Based upon the literature survey and experimental study, it was concluded that adverse environmental effects were not likely to result from the use of polyethylene oxide for flocculating phosphatic clay waste products.

Jan 1, 1980

By George H. Schnakenberg, Aleksandar D. Bugarski

This report reviews the performance and applicability of technology for the control of emissions from diesel-powered equipment used in underground coal and metal/nonmetal mines. The methods discussed include Mine Safety and Health Administration-approved low-emission engines, engine derating, fuels, fuel additives, diesel oxidation catalysts, and diesel particulate filters. The potential of each of these technologies is examined individually and in combination. The performance estimates are derived from the published literature and presented in narrative and Tabular form. The purpose of this report is to help the mining industry select the most appropriate method to reduce underground exposures of miners to diesel exhaust in the context of the recently developed diesel regulations. It is important to note that the control technologies discussed in this report have received limited evaluation in underground mines. Additional research is ongoing, and some engineering design changes may need to be implemented before all of these diesel emission control technologies can be safely and successfully used in underground mines.

Jan 1, 2002

A revolutionary development in blasting materials has occurred in recent years. Ammonium nitrate, sensitized by the addition of a small percentage of No. (class) 2 diesel fuel or other suitable petroleum product, has been adopted as a low-cost, efficient blasting agent2 in a wide variety of mining, quarrying, and heavy construction operations. Moreover, the ready availability of the component supplies throughout the Nation, together with the ease of formulating them into effective blasting agents, has made it possible for the blaster himself to prepare the mixes at the site of use. Recently, most established explosives manufacturers have begun supplying premixed AN-FO (ammonium nitrate-fuel oil) or a comparable product to various mining operations. However, many individuals and small business establishments are marketing premixed products prepared in facilities that are often poorly constructed and poorly located. Although these blasting agents have partly or wholly displaced explosives such as dynamites in many applications, there are some blasting operations in which the fuel-sensitized ammonium nitrate agents do not appear to be well adapted. As long as the hazards they present are clearly understood and respected, ammonium nitrate-based blasting agents have important safety characteristics when prepared under competent factory control or field-mixed under equivalent close control. This publication attempts to summarize the knowledge of those hazards and to incorporate practical ways to cope with them.

Jan 1, 1963

By J. A. Kosek

Work has been conducted under Bureau of Mines Contract Number HO 357078 to develop instruments for detecting CO, NO and NO2 in a mine atmosphere, using fuel cell technology. The approach has been to optimize the fuel cell sensor configuration for the specific detection of CO, NO and NO2 in the presence of other mine gases utilizing recent advances in catalyst, electrode and solid polymer electrolyte membrane technology. Para-metric testing has been conducted on three electrode sensor cells to define performance and life characteristics as a function of temperature, feed flow and applied sensor voltage. Extended life testing has been performed on sensor cell configurations exhibiting favorable characteristics. Reliable, efficient gas sampling and electronic control circuitry has been fabricated for use with the sensor cells, and integrated into devices to meet the performance and design specifications for portable, battery-powered, hand held direct indicating gas detectors for use underground. Twenty of the production-type, direct indicating CO detectors have been tested and delivered to the Bureau of Mines under the present contract. Three prototype diffusion head CO monitors have also been delivered for evaluation under the pre-sent contract. The gas sampling pump and related parts have been replaced by a diffusion tube assembly in which CO reaches the sensing electrode surface by diffusion alone. In addition, delivery will be made of ten direct-indicating nitric oxide detectors and ten direct-indicating nitrogen dioxide detectors. These instruments are very similar in design to the direct indicating CO detector.

Jan 1, 1979

By B. W. Jong

As part of the Bureau of Mines program to develop substitute or improved performance refractory materials for metallurgical applications, the Tuscaloosa Research Center has evaluated the effect of additives on sintering and strength properties of aialon (silicon aluminum oxynitride) compositions fabricated by a conventional powder metallurgy technique. Additions of Y203, Gd203, CeO2, MgO, ZrO2, ZrSiO4, and MgA12O4 to a sialon composition containing 70 pct ß-Si3N4 + 30 pct a-A1203 increased sintered densities by as much as 50 pct over densities of undoped material. The studies also indicated that sintered densities reached a maximum between 20 and 30 mole-pct a-A1203 when a series of sialon compositions of a-Si3N4, having 6.7 to 57.9 pet a-Al203, were doped with Y203, Gd2O3, and MgO. In studies to establish the effect of the crystalline phase of the silicon nitride and alumina used, tests were made using a- and ß-Si3N4 and a- and ?-A12 03 as starting materials. The tests indicated that when using an addition of 5 wt-pct Y203, best results were obtained with a sialon composed of 74.4 mole-pct a-Si304 and 25.6 mole-pct ?-A1203. In other tests made with this sialon composition MOR values of 28,120 and 29,500 psi at 25° C, and 23,520 and 16,850 psi at 1,400° C, were obtained when doping with 5 wt-pct ZrSiO4 and ZrO2, respectively.

Jan 1, 1980

By William M. Hinton

This report describes the approach, procedures, and results of a program to develop training materials for roof bolter operators. The objective of the program was to design and produce a training sequence which would prepare roof bolter trainees for job performance. Data was collected and analyzed using the general procedures of Instructional Systems Development (ISD). Input data came from a previous roof bolter training analysis program. This data was expanded and structured through a series of ISD steps: objectives hierarchies, media selection, syllabus, lesson specifications, and train¬ing materials development. The resulting program consisted of an ordered sequence of 15 lessons. The media mix for the 15 lessons included lectures, slide-tape lessons, and hands-on instruction using operational roof bolters. Contents of all lessons were reviewed and approved by the Bureau. The key recommendations were to (1) validate the materials and measure relative effectiveness of media formats; (2) survey mines for training resources and conditions - match materials to user capabilities, rather than selection state of the art technology/media; (3) develop job performance aids (JPAs) rather than simulators; (4) create a style/media/JPA development guide for use in future projects of this kind.

Jan 1, 1982

By D. E. Traut

A fluidized countercurrent ion-exchange system was developed, operated, and evaluated by the U.S. Department of the Interior, Bureau of Mines. The system consisted of integrated multiple-compartment absorption and elution columns in which the solution flows were continuous except for short periods when resin increments were withdrawn. The exchange of uranyl carbonate between a simulated in situ uranium leach liquor and a strong-base ion-exchange resin together with the subsequent elution with an ammonium chloride solution was studied. The effects of the number of sections, section height, amount of resin withdrawal, solution flow rate, and column diameter were investigated. The kinetic and equilibrium relationships for the absorption and elution steps were also examined. The experimental data indicate a strong interdependence between variables. Solution retention time appears to be a major limiting variable in the absorption process, while resin residence time is the determining factor in the elution process. The column was efficient over a range of conditions, but close control was needed for optimum operation.

Jan 1, 1978

By Roy E. Peterson

The Bureau of Mines conducted bench-scale research to evaluate materials which showed potential as low-cost reductants for use in the ironmaking industry. These materials were lignite, subbituminous coal, coal char, tree trimmings, refuse--derived paperboard, used crankcase oil, and peat. To compare their effectiveness, the materials were tested in the reduction roasting of nonmagnetic taconite and, except for oil and peat, in the reduction of iron oxide pellets to metallized pellets. Reduction was conducted in a 18-cm-diameter, rotary drum, which was externally heated in an electric furnace. Over 92 pct of the iron was magnetically recovered from a nonmagnetic taconite after roasting with any of the reductants, but greater quantities of reductant were required to achieve this when the waste materials were used. The fossil fuels were also more effective for metallizing pellets, although metallizations above 90 pct were also obtained with tree trimmings and refuse paperboard. However, refuse paperboard had to be frequently recharged to the furnace because it depleted rapidly.

Jan 1, 1983

By Robert J. Pokora

This report summarizes the work performed under USBM Contract No. J0100038, "Demonstration of Noise Control Techniques for the Crushing and Screening of Nonmetallic Minerals." The objectives of the program were to: a. Identify the prevalent sources of crushing and screening noise in portable and stationary plants b. Design retrofit noise control treatments for those sources c. Field test control treatments under actual operating conditions. A census of the nonmetallic industry was performed to determine the number and types of crushing and screening equipment. Based on the census, eight plants were selected and surveyed to assess the variety of noise sources, determine the worker noise exposure to those sources, and to identify possible constraints that had to be considered in designing and installing the retrofit controls. Three plants were selected from those surveyed and retrofit noise control treatments were designed, including: a. A primary crusher operator control booth b. Screen decks made of resilient cloth c. Screen feedbox impact pads d. Rubber feed plate for secondary crusher e. Rubber feed chute linings for secondary crusher f. Noise attenuating curtain for secondary crusher. A new primary crusher control booth was installed at one plant, and the operator noise levels were reduced from 97 dBA to 78 dBA. Screen noise at the two secondary crushing plants was reduced by 3 dBA to 7 dBA; crusher noise was reduced by 5 dBA at one of these two plants. Noise levels at normal outside operator and cleanup locations were reduced by 4 dBA to 7 dBA at one secondary plant, but operator/cleanup noise levels were not significantly reduced in the second plant due to rapid wear of installed materials. At one of the two secondary plants the retrofit noise control materials displayed excellent wear characteristics. The rapid wear of retrofit materials at the second plant was due to improper materials being supplied and changing circuit conditions.

Jan 1, 1982

By M. M. Wong

The Bureau of Mines, under a cooperative research program with four lead companies, has investigated a nonsmelting process for the production of lead metal. The process, which would eliminate sulfur dioxide generation and minimize particulate lead emissions, involves ferric chloride leaching of galena concentrate to produce lead chloride, followed by molten-salt electrolysis of the lead chloride to yield lead metal and chlorine. This chlorine is used to regenerate ferric chloride in the leaching solution. The process was tested in an experimental unit with a capacity of 500 lb of lead metal per day. The tests were performed in three 10-day and six 5-day campaigns, during a period spanning 28 mo. The study was carried out using a southeastern Missouri lead concentrate. Typical lead recovery was about 98 pct. Process problems related to impurity buildup and control were studied. When copper and silver impurities were removed from the leaching solution, a lead metal purity of 99.999 pct was obtained. Lead-in-air levels and lead-in-blood levels of operating personnel were monitored. The process has potential for producing lead with minimum pollution, but is not ready for commercial utilization. Operation of a prototype commercial electrolytic cell and a full-scale pilot-plant investigation by industry are needed to evaluate the commercial viability of the process.

Jan 1, 1983

By G. Huang, S. Vytla

Computational fluid dynamics (CFD) is a continually developing numerical technique by which complex fluid flow problems can be solved on computers. To be able to transfer CFD expertise to analyze and design a face-ventilation system, a comprehensive validation study of current CFD tools against mining-related benchmark experiments is required. In the last four years, such studies, funded by National In¬stitute for Occupational Safety and Health (NIOSH) under Grant #R01 CCR415822, were conducted in the Department of Mining Engineering at the University of Kentucky. A wide array of ventilation schemes and mining configurations were considered. Recently, an additional study was performed in cooperation with the NIOSH Pittsburgh Research Laboratory. This study was dedicated to the methane behavior in the empty (containing no equipment) face area with a blowing curtain and a 10. 7-m (35-ft) setback. In this paper, the authors present and discuss the computer-simulation data and compare them with data collected during the laboratory studies at the NIOSH lab.

By Clete R. Stephan, Mark J. Schultz, William A. Slivensky, Eric S. Weiss, Kenneth W. Jackson

he Pittsburgh Research Center (PRC)~ and the Mine Safety and Health Administration (MSHA) are participating in a research program to evaluate the strength characteristics and air leakage resistance of seals and water trap designs for use in underground coal mines. This program is being conducted at PRC's Lake Lynn Laboratory near Fairchance, Fayette County, PA. Seals designed with a 40-cm-thick polymer (polyurethane) and aggregate core between two dry-stacked (no mortar) concrete block walls (coated on out by sides) withstood a 138-kPa pressure pulse while maintaining acceptable air leakage rates. Similar seal designs utilizing a 97-cm-thick, 91-kg/m7-density, polymer-only core did not survive; however, a 5 1 -cm-thick, 203-kg/mi-density, polymer-only core seal successfully withstood the explosion pressures. Evaluations of cellular concrete seal designs have shown that a two-pour slurry injection technique did not adversely affect the strength of the 1.2-m-thick seals when subjected to a 138-kPa pressure pulse. Two seal designs utilizing low-density cementitious block have also been evaluated with successful results. In addition to seal strength tests, various 15- and 30-cm-diam U-shaped water trap pipes and a water trough design were evaluated under explosion conditions and were shown to be inadequate when evaluated under worst-case conditions. Simple modifications to the various water trap designs were successfu1 in preventing the passage of explosion flame through the trap.

Jan 4, 1996

By H. V. Makar

Laboratory tests were performed to obtain a quantitative description of the effectiveness of sodium sulfate (Na2SO4) for removing copper from molten iron and to determine the effectiveness of Na2SO4 on actual auto scrap. The tests were conducted on induction melted heats of iron averaging 0.58 and 1.50 percent initial copper and on cupola-melted auto scrap containing 0.45 percent initial copper. The Na2SO4 was added in powder form in amounts ranging from 2.9 to 43.8 percent of the weight of iron being treated. The data showed that copper removal for the various Na2SO4 treatments followed a similar trend, regardless of the iron composition that was tested. The equation Y = 1 - e-3.23x approximately reflects the relationship between copper removal and amount of Na2SO4 added, where Y is the fraction of copper removed and x is the ratio of the weight of Na2SO4 added to the weight of metal treated. Copper removals ranged from 3.3 to 74.5 percent and reductions down to less than 0.10 percent final copper were achieved in the auto scrap. Copper removals were generally accompanied by sulfur removal, and initial sulfur contents ranging from 0.10 to 0.20 percent were reduced to as low as 0.02 percent. High temperatures and long slag reaction times tended to induce copper and sulfur reversion from the slag, but, generally, the Na2SO4 treat¬ments were effective up to approximately 2,820° F with reaction times not exceeding 7 minutes.

Jan 1, 1968

By J. A. Herbst

During the last decade it has been established that conventional flotation control strategies based on classical control theory result in significant increases in grade, recovery, and operating-cost savings. In the current report a description of an advanced model-based control philosophy is presented. The derivation and verification of a simplified flotation model is described. The implementation of a Kalman filter for estimation of unmeasured variables for input to controllers is discussed. Several control strategies using the model-based approach are described, emphasizing the nonlinear nature of the flotation plant. Expected trends in the implementation of such model-based flotation control strategies in the future are discussed.

Jan 1, 1986

The small-scale surface mining operation in northern regions is typically located in a remote, ungaged basin. With the recent increase in the economic potential of mining, the number of small operations is increasing. The year-to-year variability in precipitation in this region under study is of great concern to mine operators. Some years may yield only 5 to 6 inches of precipitation, while others may yield in excess of 15 inches. Such variability makes placer mining operations difficult to plan, since low water years may result in too little run-off for gravel washing and high water years may result in flooding of mining developments. There are no official streamfloaw records in many watersheds in the northern region containing placer mining claims. However, information from other streams permits calculation of an estimated discharge for a watershed under consideration using average flows per square mile of drainage. It is to be emphasized that these are average or expected figures in reality, one water year may be significantly wetter or drier than another. This high variability of annual precipitation is significant in relation to placer operations because of the large quantities of water required for this type of mining. Some operations can not operate in low water years. In the larger watersheds, operations may continue in low water years but at a slower pace because of longer water collecting times. The high variability of available run-off rakes placer mining in many parts of Alaska difficult to plan on a long range because of the unpredictability of water supplies.

Jan 1, 1985

By C. J. Thompson

This Bureau of Mines study describes the preparation of sulfur compound concentrates boiling from 225° to 400° C, and reports the sulfur types detected in these concentrates by low-voltage mass spectrometry (LVMS). Existing LVMS methods were extended; the procedures described should be generally applicable to high-boiling petroleum distillates and concentrates as a preliminary means of narrowing the number of factions to be considered for more detailed separation and identification studies. The following major sulfur compound constituents of petroleum are indicated by the data: benzothiophenes, dibenzothiophenes, naphthanothiophenes, naphthenobenzothiophenes, and homologs and isomers of these. Cyclic and chain sulfides comprise a significant portion of the gas-oil range sulfur compound types. The presence of some classes of sulfur compounds containing two sulfur atoms per molecule was indicated.

Jan 1, 1966

By Peter P. Kopas

Study, analysis, fabrication and testing for canopies on Roof Bolters and Shuttle Cars in coal seams under 48?.

Jan 1, 1980

By Lon A. Williams

This appendix contains drawing lists and drawings of components and assemblies designed for the prototype portable and machine mounted lighting systems per Tasks II & IV of Contract No. H0220065.

Jan 1, 1976