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By Eugene H. Skinner

The U.S. Bureau of Mines conducted experiments on the use of lightweight concrete in the density range of 100 Ib/ft3 for liners in underground mines. Three test sections were completed: a monolithic, portal-type structure with integral walls and arch constructed aboveground; an underground test section constructed in a mine drift using plywood forms; and a second section constructed in a drift using an air-supported formwork. The lightweight concrete in the two underground test sections was placed using piston pumps and a slickline. Fiber reinforcement was added to the concrete in the mine sections without any apparent problems with either pumping or placement of the concrete. In another experiment, the Bureau and Hecla Mining Co., Mullan, rD, used lightweight concrete in the density range of 25 Iblfe to replace timber blocking in a raise preparation structure. Other experiments are described in which low-density, lightweight concrete blocks were produced for mine ventilation doors, stoppings, and barricades. Other mine uses reviewed include pillars and collapsing beams. An advantage of low-density concrete is that it will display up to 50% deformation at a constant yield stress. These hlllovative concepts in deformable concrete lining systems will aid mine operators by decreasing capital and maintenance costs, increasing the available space in underground haulageways, and providing productivity gains and improved resource recovery in the soft, caving, squeezing, or bursting grollnu conditions often found in deep mines.

Jan 1, 1989

By Gary P. Sames

This U.S. Bureau of Mines study was conducted in eastern Kentucky drift mines as part of an ongoing research program to characterize the outcrop barrier zone. "Hillseams" were identified as the dominant geologic cause of roof instability unique to the outcrop barrier zone, with many roof fall injuries and fatalities attributed to them. Hillseam is the eastern Kentucky miners term for weather-enlarged tension joints that occur in shallow mine overburden where surface slopes are steep. Hillseams are most conspicuous within 200 ft laterally of a coalbed outcrop and under 300 ft or less of overburden. Hillseams form by stress relief, and therefore tend to parallel topographic contours and ridges. They can intersect at various angles, especially under the nose of a ridge, and create massive blocks or wedges of roof prone to failure. Examples of hillseams are described in both outcrop and in coal mine roof to establish their geologic character and contribution to roof failure.

Jan 1, 1989

By S. A. N. Sheya

The U.S. Bureau of Mines performed batch equilibrium contact experiments to examine the ability of activated coconut-shell carbon to adsorb various metal cyanide complexes. Tests were also conducted to determine the effect these cyanide complex impurities might have on the adsorption of gold by the activated carbon. Metal cyanide species included in the investigation were antimony, arsenic, cadmium, calcium, cobalt, gold, iron, mercury, nickel, silver, thallium, and zinc. Tests were made over a pH range of 6.4 to 12.5. The carbon exhibited a preference for gold adsorption over other metals present in solution. In the absence of gold, the metal cyanide complexes were adsorbed; adsorption generally decreased with increasing pH. However, calcium and thallium adsorptions increased with increasing pH, while arsenic and iron were not adsorbed at any pH.

Jan 1, 1989

By Robert R. Stein

Using an automated drill test fooure, the U.S. Bureau of Mines measured the sound power levels produced by a small, pneumatic, rotary roof drill. A series of tests was conducted to determine (1) the relative effectiveness of several drill muffling schemes and (2) the relationship between drill sound power and pneumatic power supplied to the drill. The influence of rotation rate (i.e., airflow) and feed thrust on the penetration rate of the drill was also noted.

Jan 1, 1989

The U.S. Bureau of Mines evaluated water-jet-assisted longwall shearers in full-scale laboratory tests and underground. Both test programs showed that use of high-pressure water did little to reduce the shearer motor energy required to maintain a given cutting rate. However, three other major benefits were achieved with the use of water-jet-assisted cutting. At a pressure of 1,800 psi, respirable dust levels were reduced about 80 pct compared with the dust levels of the conventional water spray system operating at 340 psi. Operating at higher pressures required for water-jet assist also resulted in an increase in the average size of coal cut, which translates into a decrease in product fines. Finally, although no controlled measurements of bit wear as a function of water pressure were made, mine personnel reported that the shearer bits lasted longer when water-jet-assisted cutting was used.

Jan 1, 1989

By Maria I. De Rosa

Combustible materials, when burned, produce toxic gases and smoke, which may vary dramatically from one material to another, with resultant different total toxicity and smoke obscuration levels. This U.S. Bureau of Mines report presents smoke property data acquired for a variety of mine combustibles and shows that there exists a correlation between the smoke properties, the relative toxicity, and the smoke obscuration levels of those combustibles tested. These correlations can be used to devise simple, standard tests for determining the toxic and smoke obscuration hazards of mine materials during fire.

Jan 1, 1989

By J. P. Dunford

This U.S. Bureau of Mines report describes the development of a yielding steel post for underground mine support. The report covers concept development, laboratory tests, modifications, and field evaluations. The objective of this work was to develop a stiff support member capable both of supporting high loads and yielding when excessive amounts of mine entry closure were present. The 6-to 7-ft steel post was designed to yield nearly 2 ft while maintaining a 45-ton (force) load. The post is a three-piece unit consisting of top and bottom telescoping legs and a separate foot bracket. It develops its load-carrying characteristics when the lower pipe, with an attached interference ring, is forced into the larger top pipe. Laboratory tests were used to determine critical loads and post performance for various post lengths. Field tests showed that the posts could perform in actual mining conditions. The post has the ability to provide support in highly yielding ground and also, because of its slender profile, enhance ventilation and provide more area for travelways and escapeways. The design is simple enough to allow for fabrication at most mine shop facilities.

Jan 1, 1989

By Timothy M. Barton

The U.S. Bureau of Mines is conducting research to assess the effectiveness of different chain pillar designs in maintaining gate entry stability. A particular concern is ground control for deep-cover 1ongwalls located at depths in excess of 1,000 ft. The study described in this report was performed in two experimental sections in one longwall headgate section which contained three different pillar designs. Two of the designs used conventional abutment pillars, while the third was a total-yielding pillar system. Both of the test areas were located under 1,800 ft of cover. The purpose of this study was to evaluate the effectiveness of these three pillar designs for gate road stability. As the longwall mined passed the test areas, Bureau engineers monitored entry convergence, roof sag, and changes in roof quality. The study indicated that the all-yield system performed nearly as well as the better of the two abutment pillar systems; but all of the three designs would have failed to provide acceptable stability for second panel mining without considerable artificial support.

Jan 1, 1989

By Gregory M. Molinda

Large structural faults create serious ground control hazards, as well as adversely affect coal mineproduction. Two faults related to the Pine Mountain overthrust sheet in Buchanan County, VA, were investigated by the U.S. Bureau of Mines to determine their effect on ground control and to develop recognition criteria for prediction. Five underground mines encountering these faults were visited and mapped for structural information. This information, along with surface mapping, indicated that Pistol Gap and Keen Mountain Faults show right-lateral, strike-slip faulting and bedding planes slippage, which can be projected linearly and vertically. These fault zones are up to 200 ft wide, with coalbed offsets up to 18 ft vertically, coalbed swags (depressions) up to 15 ft, and roof falls up to 20 ft high. Recognition criteria include bedding plane slips, coalbed offsets, fault gouge, coalbed swag (depressions or synclines), and disturbed bedding. These recognition criteria will help an informed operator realize that many sudden coalbed discontinuities are related to larger geologic events (in this case thrust faulting) and can be projected linearly and vertically. Ground control strategies include mine designs that minimize fault exposure. Mining plans can be adjusted based on type and extent of fault movement.

Jan 1, 1989

By Howard W. Kilau

The U.S. Bureau of Mines is investigating surfactants added to water sprays to enhance the control of dust during coal mining operations. The objective of the present work was to establish the general applicability of adding sulfate ion to anionic surfactant solutions in order to improve wetting action. This was pursued through laboratory wettability testing of four anionic surfactants and one nonionic surfactant in combination with various concentrations of sulfate ion. The experimental results demonstrated that the addition of sulfate ion enhanced the wetting characteristics of all the anionic surfactants when applied to hard-to-wet coals, while easy-to-wet coal showed more complex wetting behavior. Sulfate ion in the presence of nonionic surfactant enhanced wetting only slightly or not at all. Surface tension measurements of the dilute aqueous surfactant-sulfate anion solutions indicated this property was not important in coal-wetting phenomena, as long as the value was below the critical value for coal. Sulfate ion helps surfactant reduce surface tension but primarily appears to affect wetting action by altering the adsorption characteristics of surfactant on the coal surface.

Jan 1, 1990

By Bernard J. Steblay

The U.S. Bureau of Mines has attempted to use ultrasonic signal travel-time measurements to measure loaded roof bolt strains. The strain measurements are then related to roof bolt loads through equations or empirical calibrations. Such techniques offer the potential of accurate, rapid bolt load measurement that does not disturb the anchotage. This report presents 6e research findings for a specific type of ultrasonic measurement instrument using a pulsed-phase-Iock-Ioop technique. This technique measures signal travel time indirectly by measuring frequency changes. A complete development of the applicable theory and detailed derivations of key equations is presented along with empirical laboratory and field results. The differences between anticipated and measured behaviors are analyzed and discussed. The report identifies problems encountered in applying pulsed-phase-Iock-Ioop technology to roof bolt load measurement and provides potential solutions to many of them. A key assumption of pulsed-phase-lock-loop theory is that driving and reflected signal frequencies will always be equal. Findings showed that not only were actual frequencies not equal but they were not stable or simply related. Reflection wave shape also was not stable. The ramification of these findings and ways to minimize their adverse effects are presented.

Jan 1, 1990

By D. A. Rice

As part of a cooperative effort between the Bureau of Mines and the Florida Institute of Phosphate Research (FIPR), with input from the phosphate industry, the conversion of phosphogypsum to sulfur is being investigated. The proposed process incorporates the thermal reduction of phosphogypsum to calcium sulfide (CaS) and a hydrometallurgical treatment to convert calcium sulfide to sulfur (S°). The research described herein is focused on the latter half of the process. It was demonstrated that calcium sulfide could be converted to ammonium bisulfide (NH4SH), and that ammonium bisulfide could be oxidized by air in the presence of a catalyst, to elemental sulfur, which was adsorbed on the catalyst. Two methods for recovering sulfur from the catalyst were developed: (1) thermal treatment to volatilize sulfur, and (2) leaching the sulfur from the catalyst with liquid anhydrous ammonia. Over 90 pct of the sulfur adsorbed on activated carbon (the catalyst) was recovered by both methods. Based upon the encouraging laboratory investigations, a hydrometallurgical scheme was proposed for the overall conversion of calcium sulfide to elemental sulfur.

Jan 1, 1990

By Michael J. Friedel

As part of an investigation aimed at mitigating the hazards caused by abandoned mine openings, the Bureau of Mines conducted a series of electromagnetic surveys in the Galena, KS, area of the Tri-State mining district. The application of monostatic ground-penetrating radar (OPR) and inductive electromagnetic methods for detecting and delineating hazardous mine openings and attendant features was demonstrated to be feasible for shallow mine workings (i.e., less than 35 ft) occurring below flat-lying areas. Accurate determinations of depth to a mine roof appeared to be limited to roughly 20 ft using the GPR method. Features such as mine voids, fractures, and zones of subsidence were located beneath the Mainstreet (State Highway 26) site using the GPR system. Both the GPR and inductive electromagnetic techniques satisfactorily located mine openings and pillars at the Hell's Half Acre site. Geophysical interpretations were supported by exploratory drilling and mine maps.

Jan 1, 1990

By W. H. Pomroy

This report describes research by the U.S. Bureau of Mines to design and in-mine test a rapid response pneumatic fire detection system for multilevel metal mines. The relative merits of pneumatic detection are discussed in the context of typical multilevel mine layouts and environments. The Bureau's prototype system is described, with emphasis on design features that counter commonly experienced and/or perceived operating problems with pneumatic detection systems. Finally, the results of a 3-year in-mine performance evaluation of the prototype system are discussed.

Jan 1, 1990

By J. M. Goris

The U.S. Bureau of Mines is conducting research on cable bolt ground supports to assess their material and support properties, to provide design criteria for using cable bolt supports as roof control systems under various types of underground mining conditions, and to provide a mathematical model of cable bolt support systems. Part 1 describes laboratory studies of the support properties of cable bolts made of conventional steel cables and provides recommendations on such topics as the use of thick grouts, selection of breather tubes, and reduction of water bleeding in cement-based grouts. The studies evaluated both single and double cables; effects of different embedment lengths, water-cement ratios, and grout curing temperatures on support strength; effects of use or nonuse of breather tubes; pumpability and water-bleeding properties of grouts; and the strength properties of sand-cement grouts. Part 2 will cover the strength characteristics of birdcage cable bolt supports, epoxy-coated cables, and cables with steel buttons attached.

Jan 1, 1990

By J. J. Lukasko

The U.S. Bureau of Mines developed an alternative electrochemical process for the production of calcium metal. The current industrial practice is costly, complex, and inefficient. The Bureau method involved electrowinning of a calcium-tin alloy followed by electrorefining to produce calcium metal. In the electrowinning cell, CaCI2 was fed to a KCI2-CaCI2 electrolyte. The calcium was electrowon at 6500 C into the pure molten tin cathode until the cathode contained 7.5 wt pct Ca. Current efficiency for electrowinning averaged over 90 pct. The resulting calcium-tin alloy served as the anode for the electrorefming cell, which employed a [CaC~-CaF2] fused salt as the electrolyte. Calcium metal was electrorefmed at 8500 C with a current efficiency of 85 pct based on calcium metal recovered. The calcium metal analyzed 99.2 pct, which is purer than commercially produced calcium.

Jan 1, 1990

By Paul W. Jeran

Subsidence was monitored by the U.S. Bureau of Mines over the ends of longwall panels operating in the Pittsburgh, Kittanning, and No. 2 Gas Coalbeds of the northern Appalachian Coal Basin. The final subsidence over the finishing ends of three panels in the Pittsburgh Coalbed are compared with the subsidence measured over the rib at these panels. The characteristics of subsidence are different. At Mine A, data over the start of a longwall panel shows similar characteristics to the subsidence measured over the rib. Subsidence over the fmishing ends of panels in the Kittanning and No.2 Gas Coalbeds are also different from the subsidence over the rib. The use of a subsidence prediction model based on data gathered over the rib of a panel will not yield accurate results if it is applied to the finishing end of a longwall panel. Acceptable results may be obtained along the centerline over the starting end of a panel.

Jan 1, 1991

By Ann G. Kim

The U.S. Bureau of Mines mine fIre diagnostic methodology to locate and monitor fIres in abandoned mines and waste banks is based on the controlled sampling of the mine atmosphere to determine changes in the concentration of hydrocarbons desorbed from heated coal. To provide background data for this methodology, a laboratory study was conducted in which samples of coal and coal waste were heated under controlled conditions. Gas samples from the combustion furnace were analyzed for standard gases CO2 and CO and for the C1 to Cs hydrocarbons. In all tests, the concentration of desorbed hydrocarbons increased during heating and decreased during cooling. A dimensionless hydrocarbon ratio, Rl, was developed as the signature for heated coal. For bituminous coals, the value of Rl increases during heating of coal samples and decreases during cooling of the same samples. Generally, Rl values of 100 or more indicate coal sample temperatures of at least 100° C. The emission of higher molecular weight hydrocarbons from anthracite samples was very low, resulting in relatively low Rl values at all temperatures. Data from fIeld projects confIrmed these results.

Jan 1, 1991

By D. L. Hollis

An arc plasma reactor, constructed and used for studying extractive metallurgical processing, was adapted by the U.S. Bureau of Mines to separate gases of different masses by using the high rate of plasma rotation. With argon and helium as input gases, peripheral reactor outlet ports had a measured average increase of about 10 pet in argon concentration relative to helium with the plasma on compared with plasma off for the same gas inlet concentrations in both cases. Approximately the same average increase in argon concentration occurred from the peripheral outlet port compared with a central outlet probe with the plasma on. There was no difference with the plasma off.

Jan 1, 2010

By Larry A. Haas

The U.S. Bureau of Mines is investigating ways of enhancing the high-temperature softening-melting (HTSM) properties of domestic taconite pellets. These properties, which are important for determining the performance of pellets in blast furnaces, include pellet bed contraction, pressure drop, S-value (area under the pressure-temperature curve), and softening and metal-slag drainout temperatures. Experiments showed that HTSM properties were related to the physiochemical properties (fired strengths and reducibilities) of pellets containing different levels of limestone and dolomite flux. Flux additions resulted in slightly lower green and fired pellet strengths, but improved metallurgical properties, such as reducibility. The influence of reduction conditions on HTSM properties was evaluated by varying the pellet metallization starting temperature and the carbon monoxide content of the CO-N2 gas mixture. HTSM property change was more sensitive to flux addition levels when metallization was initiated at 1,100° C with 20 pct CO in the gas stream. The S-value and the metal-slag drainout temperature were found to be the best criteria for characterizing HTSM properties. The optimum flux addition level was about 8 pct (4 pct dolomite, 4 pct limestone) or a basicity of about 1. At higher flux levels, a higher metal-slag drainout temperature was obtained.

Jan 1, 2010