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This Bureau of Mines report and its companion report (Information Circular 9142) have been prepared to assist in the preparation of prefeasibility type estimates for capital and operating costs of beneficiation of various types of mineral occurrences using current technology. The handbook provides a convenient costing procedure based on the summation of the costs for the unit processes required in any particular mining or mineral processing operation. The costing handbook consists of a series of costing sections, each corresponding to a specific mineral processing unit process. Contained within each section is the methodology to estimate either the capital or operating cost for that unit process. The unit process sections may be used to generate, in January 1984 dollars, costs through the use of either costing curves or formulae representing the prevailing technology. The mineral processing handbook includes individual cost estimation sections for unit operations associated with comminution, beneficiation, solid-liquid separation, hydrometallurgy, and special applications as well as infrastructure and plant general and administrative costs. When using this system for estimating cost data for a mineral processing facility or for checking or verifying processing costs from an existing facility, a minimum amount of background information is necessary.

Jan 1, 1987

By William H. Pomroy

Spontaneous combustion fires involving high-sulfide-content ores are a relatively infrequent yet serious safety hazard in mining. They are also the cause of lengthy mine shutdowns because they typically occur in areas of a mine where abundant fuel material is present but which are inaccessible for fire fighting. This Bureau of Mines report describes research to design, fabricate, and test in the laboratory and field a system that warns of spontaneous combustion fires in metal mines. Overall performance of the detection system was found to be satisfactory, in that the system was capable of reliably detecting low levels of combustion products believed to indicate the preflaming stage of spontaneous combustion in metal mines. Installation of similar systems in mines with a high risk of spontaneous combustion is recommended. Principal operating problems and recommended corrective actions are also discussed.

Jan 1, 1987

The Bureau of Mines human factors research program is directed toward reducing accidents and improving the overall efficiency of the person-machine environment interface found in surface and underground mines. The focus of the hum factors program therefore, is to insure that sound knowledge is available concerning human capabilities and limitations, and that this knowledge is applied to the design, of mining equipment, work tasks, and management procedures. The papers presented in these proceedings summarize some of the recent Bureau research in hum factors. The papers focus on two broad areas, human resource issues and human engineering of equipment, tools, and work procedures found in mines.

Jan 1, 1987

By Robert J. Evans

The monorail bridge conveyor (MBC) is a prototype continuous face haulage system that was surface tested and evaluated by the Bureau of Mines. The MBC consists of a series of cascading belt bridge conveyors suspended from roof-supported monorail track. Tests were conducted to determine MBC haulage capability, maneuverability, power consumption, and reliability using rigid and chain-suspended monorail track installations. Subsequent modifications to improve operation and reliability made during surface testing are described. Mining plans were devised to show potential MBC installations for room-and-pillar, longwall development, and shortwall mining sections. Compatibility tests were conducted with the Bureau's prototype hopper-feeder, to provide additional surge capacity and lump-breaking capability. Results from the surface test program, along with modifications to improve system operation and reliability, indicate that the MBC has the potential to perform success- fully in an in-mine trial.

Jan 1, 1987

By J. H. Welsh

This Bureau of Mines report presents guidelines to be considered in the design, installation, and operation of environmental mine monitoring systems in underground coal mines so as to enhance safety in the U.S. mining industry. A review of the current status of mine monitoring in the United States is also provided.

Jan 1, 1987

By D. E. Sullivan

The Minerals Availability Program of the Bureau of Mines conducts cost evaluations of current and potential mineral operations in the United States and foreign countries. The International Mining Cost Indexation System (IMCI) allows data of different time periods within a country to be updated to a common base year for analytical purposes. The IMCI comprises 12 factor cost indexes and an exchange rate series for 96 market economy countries, denominated in both local and U.S. currency. The IMCI for each country contains 12 time series indexes that measure the average annual rate of change in the cost of factor inputs to the mining industry within that country. Mining industry factor cost indexes include wages, plant and equipment, construction and mining materials, power and transportation, and other measures considered to comprise the majority of capital and operating costs. Cost data or proxies are collected in local currency. Index series within each country are constructed separately and indexed on a 1975 base year. The local currency index is converted to a U.S.-dollar-based currency index using an exchange ratio.

Jan 1, 1987

By A. F. Jolly

In an effort to better predict the useful service life of friction rock stabilizer mine roof bolts in coal mine environments, the Bureau of Mines has evaluated the corrosion resistance of stabilizer steels in air-saturated and deaerated waters from seven Eastern and Midwestern underground coal mines. Accelerated electrochemical corrosion tests were used to estimate corrosion rates for the two high-strength, low-alloy (HSLA) steels used to fabricate Split Set stabilizers and for galvanized steel. Long-term static-immersion weight-loss tests were also conducted with the HSLA steels. Corrosion rates developed from the weight-loss tests (steady-state air dissolution) were roughly comparable to rates determined from electro-chemical testing in aerated waters. Although the highest rates occurred in waters with the highest chloride contents, rates in the other waters were low (<2.0 mpy) and exhibited little correlation to the widely varied chloride contents of the waters. The generally low corrosion rates are attributed in part to the tendency to deposit a protective CaC03 film, reflecting susceptibility to carbonate precipitation as indicated by positive Langelier (saturation) index values for the waters. With one exception, corrosion rates for the galvanized steel were (2.0 mpy. Rates with aerated waters were higher than those with deaerated waters. Pitting tendencies of the steels were also estimated.

Jan 1, 1987

By Richard D. Smith

The Bureau of Mines evaluated the emission control methods, including the capital investments and operating cost, necessary for further reducing lead levels in ambient air at the Glover, Herculaneum, and Buick smelter-refineries in Missouri and the East Helena, MT, smelter. The U.S. Environmental Protection Agency (EPA) has proposed more stringent lead in ambient air standards than those currently in effect. This report presents theoretically achievable lead emission reductions and estimated capital and operating costs. Lead emission inventories theoretically can be reduced from 1985 levels by 2,421 lb/d at the three Missouri operations by containing and filtering fugitive emissions within structural enclosures and baghouses. The aggregated capital and operating costs in 1986 dollars using conventional environmental and workplace technologies are estimated to be $250,014,100 and $18,507,800, respectively. Estimated total incremental cost is $0.063/lb as refined lead. Additional regulatory costs attributable to Occupational Safety and Health Administration (OSKA), U.S. Department of Labor, workplace standards are included since proposed environmental controls may otherwise degrade workplace conditions. Continuous drossing is evaluated as an alternative to conventional OSHA controls. Substituting continuous drossing for conventional work- place technology results in an estimated aggregated capital and operating costs of $258,344,800 and $15,719,600, respectively. Estimated total incremental cost is $0.062/1b as refined lead. For comparison, the average open market price of refined lead during the first quarter of 1986 was $0.184/lb.

Jan 1, 1987

By Robert H. Peters

This Bureau of Mines report describes several significant problems associated with absenteeism among underground coal miners. The vast empirical literature on employee absenteeism is reviewed, and a conceptual model of the factors that cause absenteeism among miners is presented. Portions of this model were empirically tested by performing correlational and multiple regression analyses on data collected from a group of 64 underground coal miners. The results of these tests are presented and discussed.

Jan 1, 1987

By R. P. Vinson

The Bureau of Mines evaluated two real-time light-scattering dust monitors by measuring their response to Pittsburgh Seam coal dust and Arizona road dust (ARD). Both monitors, the model PDS-l, a personal dust sensor, and the model PCD-l, a digital dust indicator, are made in Japan by Sibata Scientific Ltd. Tests were conducted inside a laboratory aerosol chamber designed to maintain a uniform spatial distribution of the test dust. PDS-l and PCD-l measurements of concentrations for each test dust were averaged over 4-h test periods and compared with simultaneous gravimetric measurements. Both dust monitors responded linearly with mass concentration with both coal dust and ARD. However, the linear response of the PDS-l differed from that of the PCD-l for both dusts.

Jan 1, 1987

By J. E. Chilton

The Bureau of Mines has developed a portable flammable gas detecting system for estimating the flammable gas concentrations in a mine containing one or more combustible gases at concentrations up to 100 vol pct. With this portable detecting system, mine rescue or recovery personnel can quickly determine if they are working in a potentially explosive gas atmosphere and either leave the area or make appropriate changes in the fresh air ventilation of the mine to render the area safe. The detecting system uses a commercial, intrinsically safe, flammable gas detector with a range from 0 to 5 vol pct methane (CH4). The flammable gas detector has a catalytic heat-of-combustion sensor that can detect all flammable gases that would be encountered in a mine including methane (CH4), ethane (C2H6), carbon monoxide (CO), and hydrogen (H2). To determine the mine gas concentration, the rescue worker dilutes a sample with fresh air carried within the detecting system. The concentration of the diluted sample is then measured with the permissable flammable gas detector. The actual mine gas concentration is calculated from the product of the indicated diluted gas concentration and the system dilution ratio using a pocket calculator or the nomograph on the side of the unit.

Jan 1, 1987

By J. E. Geier

This Bureau of Mines report reviews hypotheses for the mechanism by which water jets reduce the specific energy of cutting for drag bits. Several of these hypotheses are shown to be inconsistent with published evidence and new observations. The notion of a limiting cutting speed, above which water jets would be incapable of rendering assistance, is shown to be improbable. The hypothesis that seems most plausible is that specific energy reductions are mainly due to the erosion of crushed materials from in front of the bit. This hypothesis leads to a prediction that, for a given rock type and jet-bit configuration at a constant depth of cut, the reduction in bit forces should be a function of dM/dx, the jet energy spent per unit length of cut. This dependence upon dW/dx is shown to be consistent with other workers? results.

Jan 1, 1987

By Kenneth L. Bickel

During an underground mine fire, the importance of controlling the spread of smoke and toxic gases with suitable ventilation structures has been proven. However, under certain conditions, control of the propagation of the fire itself may be even more critical in insuring a safe mine evacuation. Fire doors offer the means for accomplishing both objectives. In 1978, the Bureau of Mines initiated research to evaluate the state of fire-door technology and develop and test a fire door suitable for large openings (10 by 12 ft or larger) in noncoal underground mines. This report discusses current fire-door technology in the context of the underground mine environment and the design, fabrication, lab testing, and in-mine field testing of a mineworthy fire door. This door has a 1.5-h fire resistance rating and limits temperature rise across the door to 2500 F during the first 30 min of fire exposure.

Jan 1, 1987

By B. J. Moore

This publication contains analyses arid related source data for 274 natural gas samples from 20 States. Of the total samples, 269 were collected during calendar year 1985; the reminder were collected earlier, but releases granting permission to publish were not received before 1986, All samples were obtained and analyzed as part of Bureau of Mines investigations of the occurrences of helium in natural gases of countries with free market economies. This survey has been conducted since 1917. The analyses published herein were made by mass spectrometer and chromatograph.

Jan 1, 1987

By Les A. Beckett

The Bureau of Mines has developed MULSIM/BM, an improved computer program using the boundary-element approach for geomechanical analysis of mine plans in single or multiple coal seams. This Information Circular presents the improved features of the MULSIN/BM program. The four major improvements are the following: (1) Ability to specify up to 26 material property sets. (2) A new material model capability for gob and inserted materials such as packwalls or cribs. (3) Ability to model a large area with a grid of undivided blocks and to subdivide only a specified fine-mesh portion of these blocks into elements. (4) Specification of extraction ratios for the undivided blocks. In addition, an interactive graphics mesh generator program was written to accompany MULSIM/BM. A complete user&apos;s guide and program listings are included within the appendixes. The MULSIM/BM and mesh generator programs are available on tape from the National Technical Information Service.3

Jan 1, 1988

By Margaret R. Egan

The Bureau of Mines experimentally burned Pittsburgh Seam coal and other combustible materials found in mines in order to obtain a better knowledge of their emission products. These experiments were conducted in the Bureau&apos;s intermediate-scale fire tunnel, which simulates environ-mental conditions in underground mines. Smoke characteristics, gas concentrations, mass loss, and ventilation were measured. From these values, heat-release rates, particle sizes, obscuration rates, combustion yields, and production constants were calculated. This information was sought as part of a comprehensive study of combustible materials that will ultimately advance the design of more efficient fire detection and suppression systems. The coal combustion measurements presented in this report, together with previous analyses of wood and transformer fluid fires form a data base by which future studies of other mine combustibles can be compared.

Jan 1, 1987

By Scott A. Stebbins

This Bureau of Mines publication presents a method for estimating capital and operating costs associated with the exploration, mining, and processing of placer deposits. To ensure representative cost estimates, operational parameters for placering equipment and basic principles of placer mining techniques are detailed.

Jan 1, 1987

By Robert J. Evans

The Hopper-Feeder-Bolter (HFB) is a prototype multifunctional machine designed to improve productivity by minimizing continuous miner place changes. It is designed primarily to work beside a two-pass continuous miner, bolting on one side and then place changing to bolt the other side while simultaneously providing a surge car and lump breaker located directly behind the continuous miner. Surface testing was conducted at the Bureau of Mines Mine Equipment Test Facility (METF) to evaluate overall system performance and reliability. Tests were conducted to evaluate place changing, tramming, lump breaking, roof bolting, drawbar pull, conveying, temporary roof-support (TRS) capacity, lighting, and noise. Surface test results indicate the HFB is ready to be tested and evaluated underground in a production mode.

Jan 1, 1988

By Gary P. Sames

The Bureau of Mines recently initiated a study of geologic features that contribute to roof instability in western U.S. underground coal mines. The purpose of the study is to provide information for use in ground control planning and safety hazard reduction in that region, where mining activity has been increasing. Hazardous geologic conditions were surveyed in selected underground coal mines in Utah and Colorado, and both depositional and structural features were identified as potential ground hazards. Although the conditions found do not differ in kind from hazardous geologic conditions in the Eastern United States, they do differ in intensity of occurrence and relative importance. Three depositional features dominate where unstable roof occurs in western underground coal mines: paleochannel deposits, crevasse splay deposits, and flood basin deposits. Three structural features identified as hazardous, but not so widespread or common as the depositional hazards, are faulting, jointing, and igneous intrusions. This survey establishes a foundation for future studies aimed at reducing and preventing ground control accidents in western coal mines.

Jan 1, 1988

By F. Garcia, J. Cervik

Recent advances in the commercial separation of gases using membranes have renewed interest in the possibility of applying this technology to the recovery of methane ( CH4 ) from mining operations . This Bureau of Mines report briefly reviews the history of the development of membranes for gas separation , the theory of how they work , and their application to the separation of methane from air and associated problems . However , methane -air mixtures are difficult to separate with membranes because the pertinent gas couples , 02 - N2 , 02 - CH4 , and N2 -CH4 , have poor separation characteristics , as indicated by their separation factors of about 3 or less . Even if these separation factors were substantially higher , there is doubt that methane could be recovered economically from the low concentrations in mine ventilation exhaust ( 2 vol pct or less ) . The exhaust pressures are not sufficient for adequate separation . The power cost of compressing the methane recovered . these mixtures would far exceed the value of New discoveries could make separation of gob hole methane - air mixtures practical . These mixtures have much higher concentrations of methane (from 30 to 100 vol pct ) ; however , for safety reasons , be limited to gob gas with 60 vol pct CH4 or more .

Jan 1, 1988