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By R. Blickensderfer

An impact wear testing machine was devised by the Bureau of Mines that simulates the repeated impact conditions encountered in large milling and grinding operations where breakage and spalling are problems. The apparatus provides data on materials that may help in the design of alloys with improved resistance to deformation, spalling, and breakage. The test blocks are 2 in thick by 6 in by 8 in. Impacts are produced by dropping 3-in-diam balls weighing 4 lb from a height of 10 ft. Tests were run until breakage occurred or to a total of 100,000 impacts. Four types of failures of the test block were observed: (1) cold flow of the bulk material by plastic deformation, (2) flaking of the surface in the impact region, (3) spalling of the block to form a crater in the region of impact, and (4) breakage of the test block into two or more major pieces. The effects of composition, heat treatment, microstructure, and hardness on types of failure are discussed.

Jan 1, 1983

By S. S. Todd

[The purpose of this investigation was to obtain, heat-of-formation values a four Common titanates and, to conjunction with other requisite data, to derive free-energy-of-formation values In tem peratures in the range of 1,600°-1,800° K. T ht four titanites are tricalcium ?ditanite !['a¬spheremr?raritanar( rint-tir.rniurn rill( 1 This rc rr,rt sul,rlc?nu?nIs :r },r; vinu~ hul,lrc.irse,n3i n wlti h eht-rmnnIN-ti i n c {ar.a ai?rc? pu -,csseeri (or, 11 in(c-rnxiLIic co mrc+unrls conraininL~ rir:,niurrl. 'f Lac? !1~:)mc? c?xpcrirnc'ntnl n-ut rhod w,i. rna~loycul. lic?.ats of for rn:ltion of rlre comi?c,unr4~ it 29S.N. ut re mca,urc?,l by tioItl[ion e':iIorrr)utrv, using a ctrneaR }ryrlrc,fllanric-hY rir~chlorie- ,aci l mixttrrt .is rhr c-zle~rinrrrric- fluid and rc.actic~n rtu,liura}.]

Jan 1, 1956

By W. W. Agey

As a result of a field examination made during the Bureau of Mines intensive manganese program, three lots of ore were procured from the famous old Paymaster District, 7 miles from Midway Wells, Imperial County, Calif. This district is an old producer and shipped approximately 10,000 tons of 45-percent manganese ore during World War I. A 2-ton lot of ore was taken of a Bureau engineer from the exposure of a small fissure vein in conglomerate on the Turtle Group of claims; 1 mile east of the Pacific Coast Manganese Corp. claims. The vein material consisted of manganese oxides, calcite, and quartz in fairly coarse association.

Jan 1, 1949

By M. E. Tyrrell

Lightweight basic refractories suitable for use in some sections of the all-basic furnace were developed. Potential advantages of such refractories are lower weight, improved resistance to thermal shock, and less tendency to spall off the working face. Plant trials in positions not subject to heavy loading or severe erosion seem warranted. Forsterite (2MgO.SiO2), stabilized dolomite (2Ca0?SiO2 + MgO), and chrome-spinel [(Fe,Mg)0?(Cr,Al) 031 refractories were fabricated using bubbles as the principal component in the brick mixtures. Bubbles were blown from melts of the basic raw materials as they were tapped from a conducting-hearth arc-resistance furnace. The bubbles were graded, bonded with synthetic Forsterite plus mineralizers, dry-pressed, and fired to temperatures of 1,600° C. or over in a gas-fired kiln. Refractory properties of the bubble brick were compared with those of insulating refractories made by burning combustibles out or dense brick mixtures. Lightweight refractories fabricated of bubbles were one-third lighter in weight than dense bricks of like materials. Their mechanical strength was satisfactory, and their resistance to thermal shock was excellent. In tolerance to open-hearth slag and in resistance to thermal shock, the chrome-spinel bubble bricks wore the best of the refractories tested. Basic refractories of the insulating type were about 40 percent lighter in weight than dense commercial refractories, but they were mechanically weak and not suitable for superduty service.

Jan 1, 1962

By George McCaa, H. C. Howarth

"During recovery operations following a recent coal-mine explosion, 12 small fires were encountered near the break line of pillar extraction in a large panel. All of the fires except one were quickly extinguished by the rescue and recovery parties. This fire had found its way into a large quantity of loose material at a corner of the cut-through between two rooms, about 100 to 150 feet from the break line of an extensive goaf; had it been necessary to seal the fire, the inclusion of this break line not only would have made the work difficult but would have made the section hazardous as it probably would have given off gas. The fire covered a floor space of about 100 square feet and when discovered was burning briskly, with the flame extending to the roof at a height of 3 or 4 feet; it was the cause of much apprehension on the part of those in charge of the recovery operations and resulted in delaying the work considerablyThe object of this article is to describe in detail the method by which the fire was brought under control and finally extinguished, so that other persons encountering similar conditions may have the benefit of the experience.When the fire was discovered a request for rock-dust, fire extinguishers, and other fire fighting equipment was telephoned to headquarters on the surface. The promptness with which fire fighting equipment and material was provided was a big factor in finally extinguishing the fire and illustrates one of the many advantages of a good organization for fire-fighting. Material was transported in mine cars to a point on the main hauling road about 1,200 feet from the fire. It was then carried to the scene of activity by workmen. The first material to be delivered at the fire was a number of fire extinguishers of various types. The contents of 30 to 35 of these were discharged on the fire and with the aid of a small quantity of rock-dust were sufficient to smother the flame temporarily. It was the opinion of several persons who were present when the fire extinguishers were used that the acid-soda type of extinguisher gave more effective results than the two or three other types used.When the contents of all of the fire extinguishers had been exhausted the fire was temporarily smothered, but as there appeared to be danger that the flame would burst forth again, means for completely extinguishing the fire were"

Feb 1, 1929

By John Nagy

A study was made in the Bureau of Mines experimental coal mine of factors affecting gas ignition by a cutoff explosive charge. Experiments showed that, although gas could be ignited under some circumstances, the probability under normal mining conditions would be low. The use of permissible explosives, relatively short-delay intervals in firing adjacent holes, blasting to a 6-inch kerf, and reasonable care in the placement of the holes favor safe blasting and are current practice in mining. The experiments also showed that the weight of the charge is not a primary factor in the ignition of gas by a cutoff charge. The quenching action of a first charge on the igniting action of a second was verified in a supplementary study. Related experiments have shown that gas at the face may be ignited by a single charge of explosive when fired with a light coal burden. Permissible explosives were less hazardous under these conditions than nonpermissible explosives. The frequency of gas ignition in cutoff and single-charge experiments increased as the linear distance between the sheared face and the opposing mine rib increased.

Jan 1, 1960

By G. R. Hopkins

"A new record in fuel efficiency at petroleum refineries was achieved in 1935, when an average of only 615,000 B. t. u. was needed to refine a barrel of crude oil, compared with an average of 638,000 B. t. u. in 1934 and 829,000 B. t. u. In 1925. (See fig. 1.)Refiners have made almost uninterrupted progress in firing efficiency during the last decade although much of this gain was brought about by improved technique and greater use of heat exchangers and pipe stills, the determining factor was the trend in crude runs to stills. Most plants can increase their crude throughput materially with but small increase in fuel consumption. Consequently, in years in which crude runs have increased substantially, average requirements have declined; but in years in which crude runs have decreased, the average has tended upward. This conclusion is confirmed by figure 1, which shows that there has been but one minor exception to this rule in the last 10 years.Technical progress in fuel efficiency may be illustrated by comparing crude runs and total B. t, u. consumed. Between 1925 and 1935 crude runs to stills increased 31 percent, but the total quantity of heat required did not increase; in fact, it declined slightly.The trend of modern still construction is from shell stills, in which a large body of oil is heated, to tube stills, in which the heat comes into much closer contact with the oil. In 1935 the total capacity of operating pipe stills increased about 4 percent; this increase, though small, probably was related to the gain in average efficiency.The Increased use of heat exchangers and their role as fuel savers have been discussed in previous reports of this series. It is sufficient to say that refiners with insufficient exchange capacity added as much in 1935 as their budgets would permit."

Jan 1, 1937

By Seth C. Schaefer

As part of the Bureau of Mines, U.S. Department of the Interior, effort to provide thermodynamic data for the advancement of minerals technology, the Gibbs energy of formation of sphalerite (zinc sulfide) was investigated with a high-temperature galvanic cell employing stabilized zirconia as the electrolyte. In the temperature range 948 to 1,210 K, potential measurements were obtained for the cell Pt, ZnS + ZnO, S02 = 1 atm // Zr02 // Cu20 + Cu, Pt, with the overall cell reaction ZnS(c) + 3 Cu20(c) = ZnO(c) + 6 Cu(c) + S02(g). (1) These results, combined with the best available values of ?Gf° for ZnO, S02, and Cu20 from the literature, give the Gibbs energy of formation of zinc sulfide for the reaction Zn(l,v) + 1/2 S2(g) = ZnS© (2) ?Gf° = -64.223 + 24.02 X 10-3T ± 0.650 kcal/mole (3) (948-1,180 K; standard states - pure liquid zinc and S2 gas at 1 atm), and ?Gf° = -92.720 + 48.17 X 10-3 ± 0.650 kcal/mole (1,180-1,210 K; standard states - pure zinc vapor and S2 gas at 1 atm). A third law analysis yields for the formation reaction Zn(1) + 1/2 S2(g) = ZnS(c), (5) a standard enthalpy of formation as follows: ?Hf298.15 = -63.64 ± 0.700 kcal/mole.

Jan 1, 1978

The Bureau of Mines performed cratering experiments in a homogeneous granite to test scaling laws for charge weights of 0.00476, 0.0220, 0.0900, 0.304, and 1.03 lb. Agreement among the data was best when empirical scaling exponents greater than one-third were assumed. Although the analysis showed that the best empirical scaling exponents were 0.37 for crater volume, 0.38 for crater radius, and 0.39 scaling for crater depth, all three crater dimensions could be scaled with a 0.38 scaling exponent.

Jan 1, 1970

By E. G. King

Low-temperature heat capacity determinations of the minerals goethite and pyrophyllite were made in the temperature range from 510 to 298° K. The entropies at 298.15° K were evaluated as 14.43 ±0.15 cal/deg mole for goethite and 56.6 ±0.5 cal/deg mole for pyrophyllite. The entropies of formation from the constituent oxides are -4.4 ±0.2 cal/deg mole for goethite and -12.3 ±0.6 cal/deg mole for pyrophyllite. The standard free energy of formation of goethite from its oxides is ?G°298.15 = 0.16 ±0.20 kcal/mole.

Jan 1, 1970

By Thomas M. Barczak

Longwall operators are again pushing the envelope in terms of life expectancy for longwall shields. State-of-the-art shields are now expected to last more than 60,000 loading cycles, twice the life expectancy compared with those of a decade ago. A review of trends in shield design shows that shields continue to increase in both size and capacity. Some state-of-the-art shields now weigh over 30 tons and provide up to 1,200 tons of support capacity. Although life expectancy has increased and modern shields are structurally more reliable, premature failures do still occur. This paper provides an engineering and operational assessment of shield design and provides key points to observe in what causes premature shield failures. Design practices to improve structural margins of safety that will prevent premature failures from occurring are also examined. A survey of recent shield failures is provided, as well as trends in shield design and how they might impact the performance and longevity of a shield. Hydraulic failures are more common than structural failures. Although hydraulic failures occur on all aging longwall shields, they often go undetected for long periods, resulting in degraded support capacity that can lead to serious ground control problems. The fundamentals of shield hydraulics are described in order to evaluate hydraulic failures that plague all shields at some point in their service life, and practical methods to detect hydraulic failures are examined. The paper concludes with recommendations for inspecting damaged shields and safety precautions regarding their continued use.

Jan 10, 2000

By Edward P. Barrett

[Iron oxides, when reduced at temperatures below 900° form a dark gray substance, very porous bait otherwise in almost the same form as the original particles. In the temperature ire range of 1,000 to 1,100° the product is pertly sintered but still shows the outlines of the original particles. Those products are known as "sponge iron." At temperatures of 1,100 to 1,2000 the metallic iron begins to flow together and to a semifused, pasty, porous mass called a "bloom," which can he worked under a hammer to form a product similar to wrought iron; it contains slag inclusions and is too low in carbon to make steel. If the temperature is 1,300 to 1,300°, part of the iron will fuse enough to absorb more carbon. The dissolved carbon lowers the melting point and still more carbon is absorbed. The melted portion acts a flux for the unmelted metallic particles until the entire mass becomes a high-carbon fluid known as "cast iron." Sponge iron was probably the form in which the first iron was recovered from the ores. As early as the eighth century the Catlan forge3 developed into a low-shaft furnace known as the "high bloomary," in which iron eras produced in the form of a pasty mass. In 1340 the first blast furnace was built in Belgium. The greater part of the iron was made into wrought-iron blooms by crude puddling processes. Charcoal was used as the fuel until tie latter part of the 17th century when coke was used in England. In 1865 Bessemer built his first converter in. England, and within a few years the Siemen's regenerative open-hearth furnace was developed, also in England. Enormous expansion in the metallurgy of iron followed. The idea of "direct processes" for the production of iron arid steel has persisted throughout all this time. The production of steel from sponge iron has theoretical advantages over the present-day standard methods, and handreds of so--called "direct processes" have been proposed or tried during the past century.4]

Jan 1, 1929

By F. Fraas, H. H. Storch

"In the second paper 4 of this series, data were presented concerning the decomposi¬tion of polyhalite by saturated salt solutions. It was found that uncalcined polyhalite upon leaching with boiling saturated sodium chloride solutions yielded a brine in which the (K2 Mg) /304 ratio was considerably higher than that obtained from the calcined material, and for this reason appeared more suitable for the production of potassium chloride. It was found, in fact, that the leach liquors from uncalcined polyhalite deposited a mixture of KC1 and NaC1 upon evaporation and subsequent cooling, whereas those from calcined polyhalite yielded mixtures which contained not only potassium and sodium chlorides but also large quantities of glaserite, K3Na (S04)2. Hence it was decided to study the evaporation of the uncalcined poly—halite leach liquor and postpone experiments on the calcined polyhalite liquors until such time as a process for further removal of sulphate was developed.A considerable body of equilibrium data is available in the literature on thesystem K+ Mg++ — Na+ Cl—S04 =,— H20 for temperatures up to 83º C. Owing, however, tothe lack of data other than that corresponding to the invariant points and the complete absence of data for temperatures of 100 to 115°C., and owing to the fact that supersaturation phenomena render unsafe the prediction of the behavior of such a system upon evaporation, it was considered essential to obtain the necessary data by actual evaporation and analysis of the brines thus obtained."

Feb 1, 1931

To concentrate coarse mica particles using a dry beneficiation technique. Approach Concentrate coarse, II berated mica particles using a Bureau-designed system of crushers, screens, and a two-stage zigzag air classifier. How It Works Because mica has a flat plate-like crystalline structure, mica particles are significantly lighter than blocky gangue particles of the same size fraction. Thus an air classification technique can separate the flat, light mica particles from the heavier gangue particles. The ore, which Is first run through a standard jaw crusher, a roll crusher, and a hammer mill to liberate the mica, enters the rougher Zig-zag section through a rotating air lock. See photograph and diagram of a 2-stage air classifier. Airflow through the classifier can be varied according to the size of the particles being separated. The gangue material falls through the airstream of the rougher zigzag section and is discarded as tailings. The mica flakes are carried by the air-stream to the cyclone shown on the right side of the diagram, where they are collected. This rougher mica concentrate is fed to the cleaner zigzag section through another rotating air lock. The mica particles are again carried by the airstream but they are now collected In the cyclone on the left side. The cleaner concentrate leaves the left-side cyclone through a third rotating air lock and is rescreened to remove under-size material missed by the first screening. The final product of this pneumatic process is generally a high-grade mica concentrate. A generalized flow diagram for the pneumatic concentration method Is shown In the second diagram.

Jan 1, 1981

By Thomas H. Dubaniewicz

The National Institute for Occupational Safety and Health, Pittsburgh Research Laboratory conducted a study of laser safety in potentially flammable environments. Researchers measured threshold igniting powers as a function of beam diameter for butane and propane-air mixtures by laser-heating targets placed on optical fiber tips using a 1064 nm laser. The minimum igniting powers for propane-air and butane-air were about 250 and 300 mW, respectively. Threshold igniting powers for propane-air were approximately proportional to beam diameter for beam diameters from 0.1 to 2.0 mm. Results suggest that relatively powerful beams may be used in these atmospheres without causing ignition, provided the beam diameter is controlled. Threshold ignition delay times using 91125 and 62.51 125 pm fibers were approximately proportional to the inverse square of the laser power. Ignition delays were about 45 ms or longer for laser powers up to 800 mW. Preproduction samples of a commercial optical fuse prevented ignitions under selected test conditions. A self-healing effect was observed for one sample. Comparisons are made with the results of other researchers. O 2006 Laser Institute of America. Key words: propane ignition, butane ignition, laser ignition, nonbeam hazards, fiber optic fuse

May 3, 2006

By Jr. Dubaniewicz, Gregory M. Green, Kenneth L. Cashdollar

Laser-based instruments are used in areas where coal dust ignition presents a safety hazard. The National Institute for Occupational Safety and Health, Pittsburgh Research Laboratory ~NIOSH, PRL! is conducting a study to help determine when an optical beam may be considered a potential ignition source in underground coal mines or coal storage facilities. Researchers conducted experiments to determine threshold igniting powers for Pittsburgh seam bituminous coal dust clouds using an 803 nm continuous wave laser. For fine sized coal dust dispersed in air, concentrations ranging from 600 to 2000 g/m3 were the most easily ignited. A heated layer of coal dust that deposited on the fiber tip during dispersion ignited the dust clouds. Minimum observed igniting powers for laser beams delivered by 200, 400, and 800 mm core fiber optic cables and directed into coal dust clouds were 2.0, 3.0, and 5.0 W, respectively. Threshold igniting power was proportional to beam diameter, and threshold igniting power density decreased with larger fiber diameters. Ignition delay times averaged 0.6 s and did not vary significantly with laser power under initially turbulent test conditions and with flammable targets. Comparisons are made with the results of other researchers.

By A. L. Worthen

This is one of a series of pacers being published by the United States Bureau of Mines, describing mining and milling methods at crushed-stone plants throughout the United States. These pacers are designed to disseminate technical information regarding the methods used. The cost tabulations represent operating expenditures only and not total production costs. Although the publication of total production cost might not be advisable in some instances, yet a knowledge of operating costs is essential to the technical discussion and study of the methods employed. The attention of the reader is specifically called o this differentiation in order that there will be no misunderstanding of the scope of the cost tabulations. This paper deals with the quarrying and crushing methods used at the Plainville plant of the New Haven Trap Rock Co., which produces annually between 275,000 and 300,000 tons of trap rock, Although pct the largest quarry operated by the company, it typifies the standard methods used by all the quarries in producing crushed stone and has one or two rather unique operating features. The cost of production at this plant is close to the average cost at all quarries of the company.

Jan 1, 1936

By Thoms L. Chapman

The San Manuel is a deposit of low-grade disseminated copper ore. It was brought to the attention of the government in October 1942 through an application to the Reconstruction Finance Corporation for a development loan, supported by a report by Henry W. Nichols. Nichols’ sampling of two outcrops containing copper silicate and his geologic map indicated that a minable body of copper ore might be developed. The Federal Geological Survey was requested to examine the property. The Survey mapped the geology in March 1943 and cut a few check samples, which substantially confirmed Nichols’ sampling of the outcrops and a few shallow workings. The geologists of the Survey recommended some test drilling by the Bureau of Mines. The property was examined by the author and W. D. Hughes, associate engineer of the Bureau of Mines on March 22 and 26, 1943, and a preliminary drilling campaign was recommended. Five shallow churn-drill holes totaling 1,480 feet were put down under the supervision of Chas. A. Kumke, one of the Bureau’s engineers, from November 23, 1943 to January 15, 1944. This work indicated that the deposit extended deeper than the 350-foot depth attained in the deepest hole and might have very considerable areal extent. Additional funds were allotted, and the drilling contract was extended twice to a final maximum of 17,000 feet with 2,000 foot maximum depth of hole. Drilling was continued by the Bureau of Mines until February 2, 1945, when 15,844 feet of hole had been drilled. The Magma Copper Co. took options on this and adjoining property in September 1944 and commenced drilling with two machines. It also engaged the two contract drills used by the Bureau after it stopped drilling. It exercised its options in August 1945 and organized the San Manuel Copper Corp. to operate the property. That company is continuing to explore the ore body with six churn drills. Thomas Lyon took options early in 1945 on holdings adjoining the San Manuel property on the east and is operating two churn drills. Exploration up to the completion of the last holes started by the Bureau of Mines indicated a block of ore 5,100 feet long, 400 to 800 feet wide, and 500 to 900 feet thick, and averaging about 0.8 percent copper. Subsequent drilling showed that the ore body extends considerably beyond this block. The axis of the ore body strikes about N. 61º E. Copper minerals are disseminated in hydrothermally altered quartz monzonite and monzonite porphyry. Ore outcrops in two small areas over the northeast part of the block. Elsewhere the copper-bearing rocks are capped by Gila conglomerate, which thickens toward the west and south. Drilling showed that the ore is in a thick, tabular body with a steep dip to the south. The ore body lies near the surface in the northeastern part of the block. The south side of the block is much farther below the surface than the north side. There the upper part of the copper-bearing rocks is lightly mineralized, so that the hanging wall of minable ore lies deeper than the base of the conglomerate cap, which thickens southward.

Aug 1, 1947

By Peter G. Kovalchik, Lawrence W. Scott, Thomas H. Dubaniewicz, Frank T. Duda

Overheating of electric cables on shuttle cars has long been recognized as a cause of premature insulation failure leading to shock and electrocution. Use of cable reels on shuttle cars can cause excessive heat build up which, in turn, causes the cable insulation to soften and become easily damaged This heat-softened insulation reduces the life of the cable. Repeated cycling of a cable in this manner can cause premature aging of the insulation; it becomes bridle, cracks and allows electrical leakage paths to farm. These leakage paths provide the opportunity for shock and electrocution to occur if miners come in contact with the damaged section of cable. It is imperative that cable operating temperatures be maintained at safe thermal limits. This paper discusses a research project conducted by the National Institute for Occupational Safety and Health, Pittsburgh Research Center to determine dynamically the conductor temperature of reeled shuttle car cables using fiber optics technology. The research portrays typical shuttle car loading cycles (both current and time cycles). Root-mean-square current loading is calculated based on the results. The thrust of this effort is to provide the scientific basis for ampacity derating factors specifically for mine machinery using reeled cables This information will reduce the probability of electrical hazards from reeled cables

By A. B. Hooker

All State mining laws require that flame safety lamps be used in gassy mines; the laws of some States require that safety lamps be kept for emergencies at every coal mine, whether gassy or nongassy. The use of the flame safety lamp has been widespread because it is the only defice readily available for detecting both the presence of methane and deficiency of oxygen. This paper reports the results of an investigation by the Electrical Section, in cooperation with the Gas Section, of the Pittsburgh Experiment Sta¬tion relative to the behavior of permissible flame safety lamps in mine atmospheres deficient in oxygen and the effects of methane5 on the detection of Oxygen deficiency.

Jan 1, 1937