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By W. E. Webb

This report describes a method the Bureau of Mines devised for measuring the dielectric constant and loss tangent of low-loss minerals at microwave frequencies. Determina-tion of these properties makes it possible to predict the effects of using microwave heating in potential mineral processing applications. The method uses a test cell and radio-frequency (RF) impedance analyzer with automated data acquisition and analysis. In this initial phase of microwave heating research, the Bureau measured dielectric constants and loss tangents at frequencies between 100 MHz and 1 GHz. The objective was to establish a reliable data base for use in predicting the effects of microwave heating on minerals. Comparison with previously measured data showed the Bureau's measurement method to be accurate to within ± 3 pct. This report describes the method and discusses the preliminary results of the Bureau's investigations. Typical comparative data are included.

Jan 1, 1986

By Steve W. Webb

The Bureau of Mines is researching a new technology for dewatering clay suspensions that consists of flocculation by high-molecular-weight poly-ethylene oxide (PEO) polymer and subsequent removal of water from the floes via a trommel. The minimum amount of PEO required to dewater the clays depends on the ions adsorbed on the surface of the elay particles. Infrared studies were performed on clays with Li+, NH4+, K+, Mg2+, Ca2+, Ba2+, or 8r2+ adsorbed, with and without adsorbed PEO, to develop data to aid in understanding the dewatering mechanism. Hydroxyl stretching modes between 3,400 and 3,250 em-I, associated with water adsorbed on the clay, showed changes in intensity proportional to the ionic eharge-to-radius ratio; that is, the ionic potential. In addition. a water-bending vibration of adsorbed water at 1,630 cm-1 showed variations associated with water desorption. The data are consistent with changes in adsorption of PEO resulting from variation of the acidity of water coordinated with the exchange ions, induced by the variation in field strength of the ions with the ionic potential.

Jan 1, 1986

By Robert A. Jankowski

Through laboratory and underground studies, the Bureau of Mines has evaluated the use of passive barriers (dust shields) to help confine dust generated by longwall shearers to the face area. Laboratory studies focused first on selection of the optimum barrier design, which proved to be a simple, gobside barrier (made of conveyor belting), coupled with a headgate splitter arm, which was found necessary to prevent the dust cloud from entering the walkway at the headgate end of the shearer when cutting tail to head. Further laboratory testing was done to determine whether using passive barriers in combination with different water-spray dust-reduction methods, including the shearer-clearer system developed by the Bureau, would improve dust reduction over that from using the water sprays alone. It was found that the combination of gobs ide passive barriers plus the full shearer-clearer system was most effective, and surmised that this would be especially useful in thicker seams. However, underground testing revealed that the shearer-clearer system alone was 35 pct more effective in reducing dust contamination than when used with the gobside passive barriers, and far more effective than using passive barriers with a conventional water spray system. For such an effective system as the shearer-clearer; the reduction in avail-able space over the top of the machine actually impeded system performance; this was shom1 in both eastern and western mines. But when used with comparatively inefficient water spray systems, the passive barriers, used in combination with a headgate splitter arm, provide consider-able help in reducing dust levels in the walkway.

Jan 1, 1986

By Kenneth E. Hay

The Bureau of Mines collected coal and coal waste aggregate material from two different mine sites to determine their strength characteristics for use in concrete. The concrete would be placed underground as support walls for ground control in adverse conditions or unique mining applications. A standard mix design was established for a "wet" mix using a water-to-cement (w/c) ratio of 1.0 to facilitate pumping into place. Later, material was collected from four more mine sites and used to make 2-by 2-by 2-ft test blocks with the same w/c ratio. A pull-out cone device and borehole shear tester were used to determine the in situ material strength of the test blocks. These techniques will provide a simple and quick way of determining support wall strength in an underground environment. Test results from the pullout cone de-vice showed a good correlation of 0.98 to test cylinder compressive strengths of the same mix. Results of the borehole shear tester were inconclusive.

Jan 1, 1986

By Jeffrey M. Listak

The Bureau of Mines has conducted a rock mechanics study to monitor deformation of near-seam strata above a longwall panel in the Pittsburgh Coalbed. The primary goal was to determine the height of caving immediately behind advancing longwall face supports. This study, although site specific, provides information on the caving mechanism associated with longwall extractions so that strata behavior and its interaction with longwall face supports can be better understood. Two holes were drilled, approximately 550 ft apart along the center line of a longwall panel, from the surface to the coalbed approximately 650 ft below. Various downhole geotechnical instruments were used to monitor strata deformation. In addition, surface elevation surveys were conducted to differentiate between surface and subsurface activity. This report discusses the caving characteristics of the strata as the longwall panel approached and passed beneath the boreholes. Physical property data are also presented to demonstrate the relationship between caving behavior and local geology. Data show that immediate caving of strata above the longwall face occurred at a height less than 23.5 ft and that strata behavior above longwall extractions is highly dependent upon lithology, with major disturbances occurring at weak lithologic zones.

Jan 1, 1986

By Welby Courtney

Because of the inherent safety problem associated with the deposition of airborne respirable dust onto the floor and other airway surfaces, the Bureau of Mines investigated the rate of reduction of airborne respirable dust in an airway due to deposition of the particles onto the surfaces of the airway. The effects of relative humidity and air velocity on the deposition rate were examined. It was found that the deposition rate was comparable in magnitude with the Stokes sedimentation rate and that it was independent of relative humidity. However, near the dust source the deposition rate depended significantly upon the air velocity, with such dependence decreasing with increasing distance from the dust source. In addition, the size distribution of the airborne particles was approximately constant along the first 300 ft of the airway, indicating that it was not merely the larger (heavier) particles that were being deposited. These results suggest that deposition, though comparable with the Stokes sedimentation rate in magnitude, does not follow a simple Stokes-type process, and that the process of deposition remains to be explained.

Jan 1, 1986

By W. W. Simpson

During cyanidation of mercury-bearing gold-silver ores, significant amounts of mercury are extracted. The presence of mercury decreases. gold loading and increases mercury stripping time on activated carbon, complicates fire refining of the gold cathodes, and creates a potential health hazard. Addition of calcium sulfide (CaS) to the cyanide leach slurry precipitates the solubilized mercury but also some silver. The Bureau of Mines investigated silver loss during CaS precipitation of mercury. Addition of 0.1 lb CaS per short ton ore to a mercury-bearing gold-silver ore precipitated both mercury and silver. However, if copper was added with CaS, or if the ore contained copper, much of the sil-ver loss was prevented. Addition of 235 ppm Cu with 0.1 lb/st CaS, prior to carbon-in-pulp adsorption, resulted in 89-to 97-pct, 80-to 91-pct, and O-pct adsorption of the solubilized gold, silver, and mer-cury, respectively, on the activated carbon.

Jan 1, 1986

By Stephen C. Tadolini

The Bureau of Mines conducted field investigations in two underground mines to determine the actual loads to which bearing plates were subjected when installed in conjunction with full-column resin-grouted bolts and the roof movements generated by the applied loads. Measured loads indicate that the bearing plate is an integral part of the support system. Vertical displacement gauges installed to monitor roof displacements in the test sites show that the highest degrees of loading occur in conjunction with the largest amounts of movement.

Jan 1, 1986

By Margaret R. Egan

This Bureau of Mines report presents results from experimental studies on wood crib fires in an intermediate-scale fire tunnel. Gas concentrations, smoke particle characteristics, heat release rates, and ventilation rates were determined. These measurements form a data base for wood, which can be used with previous analyses for coal and future studies of other mine combustibles, to comprehend the potential hazards of these materials in underground mine fires. A knowledge of the combustion products emitted from these materials will benefit fire detection and control. Results show the changes in burning rate and heat release rate produced by different crib configurations and ventilation rates. Also included are the effects that the burning rate has on smoke characteristics and gas production.

Jan 1, 1986

By P. D. Kovscek

The Bureau of Mines equipped a longwall shearer with a water-jet-assisted mechanical cutting system to determine the effect of the high-pressure sprays on machine performance, airborne dust levels generated, and size of particles formed. Testing was conducted on a simu-lated coal block (coalcrete) while cutting at a water pressure of 190 psi and at water-jet-assisted pressures ranging from 1,000 to 6,000 psi. The shearer motor energy used by the shearer while cutting coalcrete was determined for each cutting condition. Results indicate that the motor energy required by the shearer for each ton of material cut did not vary significantly as the water pressure was increased. Results of dust measurements recorded near the cutting drum indicate that at water pressures above 3,000 psi, dust reductions up to 85 pct were achieved com-pared with cutting with conventional sprays. Analysis of the particle size distribution during cutting showed that increasing the water pres-sure resulted in increased median particle size. In light of these results, various mechanisms for water-jet-assisted cutting are discussed.

Jan 1, 1986

By Je M. Oh

The Bureau of Mines is conducting research to determine the high temperature oxidation resistance of substitute stainless steels (SS) containing two less strategic elements, Al and Si, instead of Cr. Chromium is considered to be a critical and strategic metal. Although the Cr content was reduced to 8 wt pct, the alloys showed better oxidation resistance than did 304 SS containing 18 wt pct Cr. Specifically, the alloys that contained Fe-8Cr-16Ni with combinations of Al and Si showed excellent oxidation resistance even at temperatures up to 1,000° C. In this study, the effects of the alloying elements on oxidation kinetics and morphology of oxides were investigated using a Cahn Rg electrobalance, scanning electron microscopy, an energy-dispersive X-ray analyzer, X-ray diffraction, and an electron microprobe. Aluminum and silicon additions in combinatin were more effective in providing oxidation resistance than either element was alone.

Jan 1, 1986

By James C. Cawley

The Bureau of Mines conducted an investigation to statistically determine the mean current or voltage for resistive, inductive, and capaci-tive circuits that would cause spark ignitions in 8.3% methane-air, 5.3% propane-air, and 7.8% ethylene-air mixtures. Each mean ignition current or voltage was determined on the basis of 100 trials. Each trial consisted of 400 revolutions, 200 in each polarity, at 80 rpm of the standard breakf1ash apparatus. In general, spark ignition curves published in UL 913 for resistive and inductive circuits represent approximately the mean current values determined in this study, while published capacitive circuit values in methane are considerably less than the mean voltage values from this study, especially for a capacitance of less than 100 ~F. For resistive and inductive circuits, spark ignitions were obtained at currents con-siderably below those in the published curves, but this study was not optimized to find minimum ignition values. This report defines "safety factor" as applied to intrinsic safety testing as the energy ratio of the mean values of ignition current or voltage for two test gases. The safety factors presented in this report are not constant with voltage or current and, therefore, are not recommended for use.

Jan 1, 1986

By R. G. Burdick

The problems presented by old mine workings affect both present day mining and land development. An automated method of locating these old mines from the surface using electrical resistivity techniques was de-veloped earlier under a Bureau of Mines contract. Subsequent Bureau research has refined the techniques and expanded the area of study to a variety of geologic provinces. During this research, six mining areas in the United States were in-vestigated with the Bureau's automated resistivity method. This report describes the mining areas involved and the results of the resistivity investigations, which showed a high rate of success in detecting old mines. It also describes the field measurement techniques and data analysis procedures.

Jan 1, 1986

By N. Kyriazi, W. Duerr, J. Shubilla, J. G. Kovac, J. Kravitz

A joint effort by the Bureau of Mines and the Mine Safety and Health Administration (MSHA), U.S. Department of Labor, was undertaken to determine how well self-contained self-rescuers, deployed in accordance with Federal Regulations (30 CFK 75.1714), held up in the underground environment. This report presents findings regarding laboratory-tested breathing apparatus from the first year of a 5-yr program as well as other related findings. The SCSR's were tested on human subjects and on a breathing and metabolic simulator. These results indicate that the apparatus, if well-treated, perform as expected except for manufacturing defects or quality control problems, which are identified. However, when the apparatus are carried in and out of the mine every day and stored at the working section, they may suffer abuse that can be extreme. Physical signs of abuse, unless extremely obvious, frequently are not detected by the miners or the mine operators; this poses a danger to a potential user in case of emergency. Recommendations include improved training in inspection procedures.

Jan 1, 1986

By L. Y. Sadler

The Bureau of Mines conducted a study Lo determine the loss in weight of silica (Si02) volatilization from low-alumina (A1203) refractories used as hot face liner materials in such process equipment as coal gasifiers, synthesis gas transfer lines, and ammonia plant secondary re-formers. Small specimens of 80-and 40-pct-A1203 brick and 95-pct-SiO2 brick were exposed to steam in high-pressure furnaces at pressures of up to 1,000 psig and temperatures up to 1,400° C for periods ranging up to 120 h. Weight losses from the 40-pct-A1203 brick after 40 h of exposure were highest, 2.75 pet at 1,400° C and 1,000 psig. The rate of weight loss had dropped to near zero after 80 h of exposure at all temperatures. No relationship between total silica content of the specimen and weight loss could be established nor did scanning electron microscopic examination of the specimens before and after exposure identify specific regions (e.g., surface) suffering a disproportionate share of the silica loss. It was concluded that minor silica volatilization is likely to occur, if at all, at temperatures of less than 1,000° C and pressures below 1,000 psig, and that low-alumina refractories should be used as dry-ash coal gasifier hot face linings.

Jan 1, 1986

By C. W. Huggins

The primary objective of this Bureau of Mines research was to measure the size distribution of respirable quartz collected at metal mines, nonmetal mines, and processing plants to select the best reference standard for use in quantifying quartz in mine and plant dust samples. The secondary objective was to size all the nonquartz particles collected at the same sites. Particle size measurements were made on 29 samples using a scanning electron microscope in the backscatter mode of operation, interfaced with an image analysis system. The Mine Safety and Health Administration, Denver, CO, provided the 29 samples, which were collected at mines and processing plants in 19 states. The accumulated particle size measurements indicate that NBS 1878, minus 5-f.lm Hin-U-Sil, and minus 5-f.lm Supersil would be preferred over Silver Bond B as reference standards for most quantitative determinations by X-ray diffraction and infrared spectrometry. The respirable dust samples collected at sand plants, however, would be better served by a new reference standard having a quartz particle size distribution of approximately 2.2 um, as none of the four existing reference standards matched closely with them. Commercially available NBS 1878 and minus 5-um Hin-U-Sil CQuid be used as reference standards for 28 of the 29 samples studied in this investigation.

Jan 1, 1986

By Agnes Y. Lee

The Bureau of Mines has developed an effective hydrometallurgical method to recover high-purity Pb metal and elemental S from concentrates. This low-temperature process eliminates S gases and Pb emissions, in contrast to the current high-temperature smelting technology. The method consists of (1) oxidative leaching with H202, Pb02, and waste fluosilicic acid at 95° C to produce a solution of PbSiF6 and a residue containing elemental S, (2) electrowinning the PbSiF6 solution at 35° C to produce 99.99 pct Pb metal and H2SiF6, and (3) solvent extraction to recover S, leaving a residue containing Cu, Ag, and other metal values. Spent electrolyte was recycled repeatedly, with impurity buildup controlled by controlling the leach parameters.

Jan 1, 1986

By Gregory J. Chekan

The Bureau of Mines, in an effort to improve planning and development in coal mining, is investigating strata interactions associated with mining of multiple coalbeds. Two common interactions that occur between adjacent coalbeds are subsidence and pillar load transfer. The study described involves underground observations and measurements conducted at two Pennsylvania mines, each affected by one of these interactions. At the mine affected by subsidence, measurements show that undermining had little effect on upper mine pillar stability, but had a more severe effect on the development and maintenance of entries. Roof-to-floor measurements recorded over four times more convergence in entries developed over gob as compared with entries developed over support pillars in the lower mine. At the mine affected by pillar load transfer, Initial in situ measurements have shown the existence of a pressure arch in the lower workings. Prior research has shown that arch interaction between two adjacent openings can create stress concentrations in the in-nerburden. Underground measurements and results obtained from both mine sites correlate with theoretical and photoelastic multiple-seam models, and eventually these field data will serve to refine model accuracy. Further study of multiple-seam interaction mechanisms will lead to improved mine planning, increased resource conservation, and a safer working environment.

Jan 1, 1986

By Bill M. Stewart

To decrease the potential for fine coal waste slurry impoundment failures, the Bureau of Mines investigated a new disposal technique. The fine coal waste slurry is rapidly thickened (i.e., dewatered) and deposited on a slightly sloping surface. To accomplish rapid dewatering, a chemical flocculation system using polymers was developed to treat the fine coal waste slurry stream. The fine solids formed flocs, settled from suspension, and rapidly released excess water. During the last 5 days of the field test, slurry flowing at rates from 498 to 675 gal/min with a specific gravity range of 1.15 to 1.33 was successfully treated and dewatered. During this period, untreated slurry had an average moisture content of 227.4 pct (30.7 wt pct solids). The effectiveness of the dewatering system was determined by monitoring the moisture content of the deposited waste with respect to time. Sixty-five hours after ending the field test the average moisture content was 54.9 pct (64.5 wt pct solids); 68 days after the field test the average moisture content was 28.8 pct (78.0 wt pct solids).

Jan 1, 1986

By Maria I. De Rosa

The Bureau of Mines performed experiments to determine concentrations of toxic gases and liquids, and smoke-particle diameters and diameter-concentrations evolved during degradation of PVC-derived brattice with and without nylon-woven fabrics, fiberglass, cotton, and jute brattices, and other mine materials. The samples were exposed in a 20-L chamber at temperatures of 1500 to 4500 C, with a chamber airflow of 10 L/min; 27.3 cm3/s of which was directed into a submicrometer-particle detector-analyzer. During the degradation of PVC-derived brattice, large concentrations of hydrogen chloride (TLV, 5 ppm; STEL, 100 ppm) evolved at a temperature as low as 2000 C. The minimum toxic load of 3.1 mg or 40 ppm in 50 L of dilution air, with O.l~g weight loss, may be reached at a mine face with 314,000 L of dilution air, at the 5th min, during which less than 1 kg of brattice undergoes combustion. Fiberglass, cotton, and jute brattices, pine wood dust, and coal dust showed small concentrations of carbon monoxide evolving during early stages of combustion. Hydrogen cyanide gas evolved from the PVC-derived, nylon-reinforced brattice; at a later stage of combustion, large concentrations pf carbon monoxide and dense smoke evolved from all PVC-derived brattices. Experiments to characterize smoke particles showed that marked differences exist in particle diameter-concentrations among the materials.

Jan 1, 1986