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By L. W. Brandt

As part of its objective to expand the body of mineral information as a basis for new technology, the Bureau of Mines conducted research on the fundamental behavior exhibited by phosphate clay waste in settling ponds. A semiempirical equation used to describe the compaction of ceramic powders in a single-acting die was applied to aqueous phosphatic clay waste and attapulgite slurries. This equation, [*V = a1 e ?k1/P + a2e ? k2/P] was found to describe the compaction of an attapulgite gel and a phosphate slime gel by a moving screen. [*V] is the ratio of the compaction achieved at a given pressure, P, to the compaction achieved at a pres-sure sufficient to remove all space between particles. The constant al represents the fraction of compaction achieved at low pressure by rearrangement of floes to higher packing density, and a2 represents the fraction of compaction achieved at higher pressure resulting from removal of voids within floes. K1 and K2 are constants determined from the experimental data. Both the low-pressure and high-pressure compaction mechanisms were observed in the compaction of the clays. These two compaction mechanisms offer an explanation for the observation that impounded slimes initially dewater rapidly and then dewater at a much slower rate.

Jan 1, 1982

By R. M. Gammell

"INTRODUCTION The Farmer prospect was examined by W. R. Green, an engineer of the Bureau of Mines, in June 1944. As a result, studies of this property were included in a general preliminary investigation of the Etevens County lead-zinc deposits by the Bureau in 1945. The exploratory work was designed chiefly to supplement the surface examination by determining the nature of the mineralization below the zone of oxidization. The results of the small-scale diamond-drilling program undertaken at the property are presented in the following report.ACKNOWLEDGMENTSIn its program of exploration of mineral deposits, the Bureau of Mines has as its primary objective the more effective utilization our resources to the end that they make the greatest possible contribution to 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 prepares the filial report. The Metallurgical Branch, R. G. Knickerbocker, chief, analyzes samples and performs beneficiation tests."

Mar 1, 1947

By R. C. Buehl

[Improvements in refractories for high-temperature service have made possible the use of higher temperature in many processes. Consequently, it sometimes is desirable to use gases heated above 1,600° F., and for moderate rates of gas flow, there gases can be heaters best with pebble heaters. Pebble heaters of the stationary-bed type in which the chanber was lined with mullite brick and pebbles of pure alumina served as the heat-exchange medium have been used recently to heat the air blown into an experimental blast furnace4/ These pebble heaters worked well and made it possible to use air temperature up to 2,500° F. at the tuyere of the furnace. Since little has been published on this type of gas heater, a review of the construction on employed and operating data should assist in selecting applications and designing units.]

Jan 1, 1953

By Bruce D. Hanson

The Bureau of Mines conducted a series of ignition tests with two types of conical bits (plumb bob and pencil) used on continuous mining machines, to determine their ignition potential at various bit speeds, cut depths, and wear conditions. The tests were conducted using single bits mounted on a 34-in-diam drum in a Bureau ignition test facility. The bits impacted blocks of Berea sandstone in a 6.5 pet methane atmosphere at various bit speeds and cut depths. In a new condition, the plumb bob bits were considerably more incendive than the pencil bits, causing ignitions in 32 of 35 tests at 60 rpm, compared with ignitiolls in 2 of 22 tests for the pencil bits. The results from new bit testing also show that reduction of bit tip velocity to 180 fpm does not eliminate ignition potential. When subjected to progressive wear, bits of both types were more incendive when they were locked in place, unable to rotate, than when they were free to rotate.

Jan 1, 1983

By R. C. Gabler

Effective recycling or disposal of flue dusts is a continuing problem, particularly for secondary smelters treating low-grade Cu scrap. The Bureau of Mines investigated a variety of flue dust treatment approaches and demonstrated the technical feasibility of a bench-scale alkaline method that includes leaching, cementation, precipitation, and roasting. Flue dust was leached at room temperature with an alkaline solution of (NH4)2C03 and NHpH to solubilize ZnO and Zn metal. Some copper, lead, tin, and most of the zinc were dissolved in the leach step. Copper, lead, and tin were recovered in the cement product. The Zn in the flltrate was precipitated by pH adjustment to neutral using CO2 injection. The Zn salt was flltered from solution and roasted to give high-purity ZnO. The leach residue, enriched from 4.3 to lOA pct Sn, could find a ready market; the metallic cement product can be recycled back to the copper converter; and the high-purity ZnO product can be sold in several markets, leaving no material for disposal. The possibility for recycling of reagents, lower energy demand, and low environmental impact make this method economically and environmentally attractive for recycling secondary copper smelter flue dusts.

Jan 1, 1988

By M. L. Skow

Large tonnages of the manganese ores found in Aroostook County, Maine, are refractory to conventional mineral-dressing techniques and to the common chemical- extraction procedures. The Maple Mountain-Hovey Mountain ores are typical of this type. Because the most promising method of recovering the manganese from these ores has been a chloridizing roast in which the ground ore is in contact with gaseous hydrogen chloride, preliminary batch tests were made with a fluidized bed. On the basis of these tests, it was concluded that fluidization, with careful control of operating conditions, could be employed for this cloridization and warrants further study. Selective volatilization of the iron at 600° C. was unsuccessful. An operating temperature of approximately 950° C. was necessary for a practicable rate of volatilization of manganese chloride. Hydrogen chloride contents of 10 to 100 percent of the fluidized gas gave essentially equivalent manganese recoveries with an 80- minute retention time, For shorter periods reaction was more complete with the higher hydrogen chloride concentrations. At the 80-minute retention period the lower hydrogen chloride concentrations volatilized somewhat less iron and also improved the physical operation of the process. Fluidization gave results superior to comparable tests on chloridization in a fixed bed.

Jan 1, 1956

By F. P. Haver

The Bureau of Mines has investigated the electrochemical reduction of lead chloride as a method for producing lead without the pollution problems associated with smelting. It was determined that high-purity metal (>99.9 pct Pb) could be obtained, using PbC12 prepared by ferric chloride leaching of galena concentrate: PbS + 2FeCl3?PbCl2 + 2FeC12 + S°. Optimum results in small-scale electrolytic tests were achieved with a bath consisting of 40 to 70 wt-pct PbCl2 dissolved in KC1-LiCl eutectic, an operating temperature of 450° C, a current density of 2.5 amp/in2, and an electrode spacing of 0.5 inch. In large-scale tests made to develop a cell design for commercial application, the optimum electrode arrangement proved to be a bipolar configuration with horizontal plates. This gave a current efficiency of 86 pct with an energy requirement of 0.52 kwhr/lb lead. To determine the effect of impurity buildup in the bath, 1,200 lb of PbC12 prepared by ferric chloride leaching of galena concentrate was electrolyzed over a period of 2 months. Little deterioration of the metal quality occurred in that time; all of the lead produced had a purity equal to or better than corroding grade (>99.94 pct Pb).

Jan 1, 1976

By Kenneth P. V. Lei

The Bureau of Mines investigated a silver-catalyzed oxidative procedure for leaching an arsenical copper sulfide concentrate containing 10 pct As and 32 pct Cu_ Currently, there are no environmentally safe means to treat arsenical copper concentrates in the United States. Leaching was conducted in a 2-L autoclave reactor. The effects of catalyst concentration, O2 pressure, temperature, and H2S04, Cu, As, and Fe concentrations in the leaching solution on extractions of metals from the concentrate were determined. The best leaching conditions for extracting 95 pet eu and As and less than 21 pct Fe were 260 g/L concentrate, 0.007 mol/L (1.0 g/L) AgCI, 3.0 mol/L (294 gIL) H2S04, 1000 C, 60 psig 02, and 6 h. Copper as CuS04-5H20 was recovered by crystallization from the pregnant solution. Arsenic, as AS203, was recovered from the copper mother liquor by solvent extraction, with tributyl phosphate, S02 reduction of As5+ to As3+ in the strip solution, and crystallization of the As3+. The silver catalyst was recovered by contacting the leached residue with a brine solution. A conceptual scheme is proposed for treating arsenical copper sulfide concentrates.

Jan 1, 1987

By H. M. Cooper, R. F. Abernethy

Determination of the fusibility of coal ash consists in melting a pyramid of the ash to fluid under prescribed conditions . The conditions of the test are specified by the American Society for Testing Materials4/ and must be adhered to strictly if comparable results are to be obtained . The Society formerly specified a particular type of furnace , but with improvements in design of both electric and gas furnaces , it was decided by the Society to specify only essential details of the test . The Chairman of Committee D - 5 , Coal and Coke , of the American Society for Testing Materials suggested that the Coal Analysis Section of the Bureau of Mines conduct a cooperative investigation on the effect of furnace type and atmosphere upon fusibility of coal ash . The Coal Analysis Section enlisted the aid of a number of laboratories using the more common furnaces to cooperate in the investigation . Four types of gas furnaces burning natural and manufactured gases and two types of electric furnaces with different methods of maintaining a reducing atmosphere were employed . The results from the survey are tabulated herein , and some comparisons are made . There were not enough data from any particular furnace and atmosphere to make a reliable statistical analysis . However , definite tendencies are evident , and attention is called to them by direct comparison. in tables .

Oct 1, 1943

By M. M. Fine

"Button" type ore from the Cason mine, Batesville, Ark., can be up-graded to plus-40-percent manganese by mineral-dressing procedures. A simple process including gravity concentration and. magnetic separation yielded more than 50-percent recovery of concentrates containing 38.1 to 40.6 percent manganese. These values in turn could be raised to 41.4 and 42.8 percent, respectively, upon sintering to conform to size specifications. The Bureau of Mines in the past has surveyed and tested many manganese ores and prospects in an endeavor to alleviate the shortage of manganese. The present period of emergency again emphasizes the strategic position of the metal, and manganese investigative work is being stressed to find new ore bodies and to apply newer beneficiation techniques to the known deposits.

Jan 1, 1953

By Davis E. Traut

TiC14, AIC13, and VC14 were coreduced simultaneously via a Kroll-type magnesium reduction to form an alloy sponge as part of a research effort by the Bureau of Mines to produce titanium alloy powder. Reduction tem-peratures of 750°, 850°, and 950° C, a range of chloride feed rates from 34 to 152 Ib/(ft2·h), and crucible diameters of 7-3/4 and 10-1/4 in were tested. Microprobe analyses using a 40-um-diam spot showed no effect on alloy microhomogeneity (distribution of Al and V in the Ti, considered critical as a powder property), due to changes in process variables within these ranges. Statistical analysis of these data for alloy sponge indicated greater variation in the chemical composition (AI and V) than that found in commercial Ti-6Al-4V plate or Plasma Rotating Electrode Process (PREP) powder. Therefore, a one-step approach to pow-der, such as grinding the Ti alloy sponge, would not produce a powder product of acceptable chemical homogeneity. An approach that homoge-nized the sponge, such as with a melting step, would produce an accept-able powder product with respect to chemical homogeneity.

Jan 1, 1987

By N. E. Hanna

Experience with the current version of gallery test 4, in use since 1913 to evaluate the incendivity of permissible explosives in the presence of coal dust, has shown the procedure to have inadequate discrimination. Consequently the Bureau of Mines used the up-and-down method of statistical design to investigate the incendivity of permissible explosives in the presence of coal dust and gas. A suitable device was developed to measure coal dust concentrations in the air-gas mixtures and to disperse the dust in the gallery atmosphere. A proposed testing method which uses suspended shots in a predispersed coal dust-gas-air mixture was evaluated. The new method can discriminate between different explosives with respect to their incendivity. Maximum ignitibility of the coal dust cloud by permissible explosives occurred in the vicinity of 0.3 oz/cu ft. About 10% sodium chloride in permissible explosive formulations had a very significant effect in reducing the probability of igniting coal dust. Bundled charges were more incendive than column charges.

Jan 1, 1966

By P. H. Floyd

This report presents the results of laboratory beneficiation tests on a sample of scheelite ore and a sample of low-grade scheelite flotation concentrate from the Sangdong mine, Korea. Sangdong was the foremost producer of tungsten concentrates on two occasions - during part of World War II and in 1953. It was also a significant producer of bismuth concentrates. Resources are very extensive and could support a 5,000-ton annual output of tungsten concentrates for many years. Located in the eastern part of South Korea near the 37° latitude, Sangdong has been a vital source of dollar income for the Republic of Korea in recent years. Its shutdown in March 1954 came about as a result of the great decline of tungsten prices and the fact that a sales contract with the United States Government had been terminated, In addition to establishing new markets, the problem of reopening Sangdong will be related to cost reductions and improving mill recoveries. Large quantities of offgrade scheelite concentrates were produced in the past and shipped to the United States for further beneficiation. Other low-grade concentrates and middlings have been stockpiled or discarded at the mine plant.

Jan 1, 1954

By J. C. Nigro

Hematite-to-magnetite reduction kinetics were investigated mainly in CO-CO2 atmospheres at temperatures ranging from 500° to 1,000° C. Reduction rates were measured with a thermobalance, which recorded the weight loss as the specimen was reduced. Reduction data on both synthetic and natural hematite spheres showed good linearity of ro [1-(1-R)1/3] with time, t, up to over 85 pct conversion to magnetite; the rate coefficient (k[L], cm/min) obtained from the linear portion of the plot was used to characterize the penetration rate of the hematite-magnetite interface. Gas composition, porosity, and silica content were major factors affecting the rate. Temperature dependency of the reaction rate was small, yielding a mean activation energy of about 3 kcal/mole. Silica additions increased the reaction rate, probably through an increase in the effective surface area and diffusion; however, above 900° C, silica can react to form fayalite. Experimental data showed that the linear thickening rate of the magnetite layer, normally evidence of a chemically controlled reaction, can also be indicative of a reaction controlled by both mass transfer and diffusion. Evidence from this study indicates that the dominant rate-controlling factor in the reduction of hematite to magnetite at high temperatures is transport in the gas phase.

Jan 1, 1973

By D. J. Bauer, V. E. Shaw

Bastnasite concentrate was processed to recover total rare - earth content and obtain high - purity ceric nitrate . Reaction of the concentrate with 45 percent caustic soda for 1 hour at 180 ° C in stainless steel vessels resulted in 99 - percent conversion to rare - earth hydroxides . A drying step followed by solution in nitric acid produced a tetravalent cerium fraction amenable to extraction with TBP . Single- stage separatory funnel experiments resulted in 90 -percent recovery of ceric nitrate at a purity of 99.9 percent . Fractional extraction in pressure - bubbler columns resulted in 98.5 - percent recovery of 99.5 -percent - pure ceric nitrate .

Jan 1, 1964

By Frank J.

The increased demand for aluminum for military purposes during World War II necessitated the development of domestic deposits of alumina-bearing ores. Kaolin, siliceous bauxites, anorthosite, and diaspore-containing clays have been investigated and studied in the laboratory and pilot plant. The Bureau of Mines is preparing a series of reports covering investigations of these ores. The tests contained in this report are restricted to sintering and leaching tests on kaolin from South Carolina, where extensive deposits were proved to exist. The leach liquors were found to have substantially the same composition as those produced from the diaspore-containing clays, and therefore it would be expected that no difficulty would be experienced in producing calcined alumina of relatively coarse particle size and with other properties conforming to the specifications for metallurgical-grade alumina.

May 1, 1947

By Fred C. Turin, Sean Gallagher, Kim M. Cornelius, William J. Wiehagen

An important part of initiating a site-wide ergonomics evaluation process is prioritizing jobs to be analyzed. While injury data is important, other factors such as worker discomfort and physical exertion requirements, should be considered. This paper describes the use of four sources of data (injury records, the Nordic Standardized Musculoskeletal Questionnaire, supervisor interviews, and management concerns) to prioritize jobs for ergonomic analysis. The approach described integrates the four sources using a decision matrix to prioritize jobs for ergonomics analysis.

By M. O. Renwick, Paul Zinner

"INTRODUCTION In September 1943, the Bureau of Mines conducted a limited program of churn drilling on the Winskell property in the Shullsburg area of Lafayette County, Wis. The work was undertaken as part of a general investigation by the Bureau of the zinc-producing area of southwestern Wisconsin at a time when special effort war being made to increase the production of metals necessary for the war program.Drilling described supplemented a previous drilling program conducted by the Vinegar Hill Zinc Co. The results of both programs encouraged subsequent investigation by the Cuba Mining Co. and eventual development of the Andrews mine.ACKNOWLEDGEMENTSIn its program of investigation of mineral deposits, the Bureau of Mines has as its primary objective the 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 such project as soon as praticable after its conclusion. The Mining Branch, Lowell B. Moon, chief, conducts preliminary examinations, performs the investigative work, and prepares the final report."

Aug 1, 1947

By John W. Walkiewicz

The U.S. Bureau of Mines has conducted studies to utilize rapid microwave heating to stress fracture ore samples. Iron ores containing hematite, magnetite, and goethite were subjected to microwave energy in batch operations at 3 kW and heated to average maximum temperatures between 840 and 940 °C. Standard Bond grindability tests showed that microwave heating reduced the work index of iron ores by 10 to 24 pct. In a microwave chamber designed to simulate a continuous throughput operation at 3 kW, the grindability of a taconite ore was improved by 13 pct at a bulk temperature of 197 °C. Because stress cracking occurred at a lower temperature, less energy was consumed. To further improve the economics of microwave fracturing, higher powers up to 16 kW were used to rapidly heat samples to relatively low temperatures in a continuous, belt-fed applicator. A significant improvement of grindability was obtained with a larger rod mill feed size in comparison to a minus 6-mesh Bond feed.

Jan 1, 2010

By Bruce Maxwell

The deformation modulus of coal mine pillars theoretically can be reduced by drilling holes in advance of the mining face. This reduction of modulus along the edge of the pillar has the effect of decreasing the stress concentration in the roof; control of roof caving is thereby predicted. Initial field work indicated that a high horizontal stress field existed at the field test site: Subsequent field work was undertaken to confirm the high horizontal stress field and to attempt to relieve the horizontal stress in the immediate roof. A method of softening pillars in conjunction with normal mining activity was developed. Instruments to measure horizontal roof strain, roof parting, roof tilt at the rib, and changes in vertical and horizontal stress in the roof and in the coal were used. These instruments were installed in both softened and unsoftened entries and in locations to indicate the effect of vertical slots in the roof. Significant stress reduction due to pillar softening was indicated, but the effect of this reduction on roof stability was not established. The vertical roof slots relieved the horizontal stress in the immediate roof very effectively, and observations of roof conditions indicated that the slots definitely improved roof stability.

Jan 1, 1977