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By G. W. Eiger

Bureau of Mines laboratory tests show that ilmenite concentrates with titanium dioxide contents as low as 33 wt--pct can be beneficiated to produce a crystalline substitute for natural rutile suitable for direct chlorination. The synthesized product prepared by a three-step procedure was comparable with natural rutile in titanium content. Reduction smelting of ilmenite removes iron as a pig iron byproduct, and the remaining slag phase is greatly enriched in titanium. Oxidation of the slag in the presence of phosphorus¬bearing slag additive converts the titanium-bearing phases to discrete rutile crystals and a glass phase containing most of the associated impurities. Rutile is separated from the glassy impurities by attrition scrubbing ground slag in dilute phosphoric or sulfuric acid solutions. Tests made in a laboratory fluid-bed reactor show that synthetic rutile responds to chlorination at the same rate as natural rutile and that more than 95 pct of the titanium contained in the feedstock was extracted as titanium tetrachloride.

Jan 1, 1974

By A. E. Raddatz

The Bureau of Mines has determined the electrochemical rate of anodic dissolution of vanadium metal in a VC12-VC13-NaC1 electrolyte at 860' C for the purpose of elucidating the reaction mechanism. Rate measurements were carried out with the help of specially designed equipment capable of continuously recording the weight loss experienced by a cylindrical vanadium anode immersed in the molten salt electrolyte while a constant current is maintained through it. The rate is expressed as a function of current density and VC13 concentration, and the reaction is interpreted in terms of an adsorption mechanism. Multiple regression analysis of the data gave the following rate equation: Rate x 104 (g.cm-2.sec-1) = -0.38 + 2.64 current density (amp-cm-2) + 0.69 log, (mole-percent VC13).

Jan 1, 1974

By Richard J. Bielicki

Poor mixing of methane and air at coal mine working faces causes fluctuating methane concentrations. If these fluctuations are large enough, methane levels can periodically exceed safe limits, even though the time average methane concentration may be satisfactory. Concentration fluctuations measured underground can result both from variations in methane emission rate and poor mixing. The present paper reports on a statistical analysis of fluctuations at a constant methane emission rate, that is, on fluctuations due only to poor mixing. A full-scale model of a working face was used. Both peak heights and elapsed times between peaks were evaluated. Good mixing was indicated by normal, Poisson, and exponential distributions while poor or incomplete mixing was indicated by log-normal or gamma distributions.

Jan 1, 1974

By J. R. Allsup

In cooperation with the Division of Advanced Automotive Power Systems Development, Environmental Protection Agency, the Bureau of Mines studied a conventional spark-ignition engine as a prime mover for use in a hybrid system. The study involved both steady-state and transient engine operation with ignition timing, air-fuel ratio, exhaust gas recirculation, oxidizing type catalytic converters, engine speed, and power output as variables. Data were obtained from two 1971 model 350-cubic-inch-displacement engines mounted on engine dynamometer stands. When the hybrid engine was operated with an oxidizing catalyst at power output levels required for a 4,000-lb curb weight hybrid vehicle, carbon monoxide and hydrocarbon emissions could be reduced to approximately 2.0 grams and 0.3 gram per brake horsepower-hour, respectively. With exhaust gas recirculation, oxides of nitrogen emission levels could be reduced to approximately 1.2 grams per brake horsepower-hour.

Jan 1, 1974

By George S. Koch

A mathematical simulation model has been devised to guide the layout of underground mine workings, drill stations, and drill holes that are established in order to search for tabular ore bodies. Developed and tested for elliptical ore shoots in fissure veins in the Galena mine, Coeur d'Alene district, Idaho, the model can also be applied to ore bodies contained within sedimentary beds (for instance, many types of uranium, copper, and gold ore bodies) or other tabular structures. Programed for a time-shared digital computer, the model contains both stochastic and deterministic variables. Stochastic or natural variables include the number of ore shoots and their sizes, orientations, locations, and values. Deterministic or controllable variables include (1) locations and costs of workings; (2) drill-station locations and costs; and (3) drill hole azimuths, inclinations, lengths, and deflections, if any. For various assumptions about the stochastic variables, the model is run while the controllable variables are changed deliberately. Thus, layouts are devised to determine the percentages of the total number of assumed ore shoots found at different costs. In order to choose among the various layouts, cost-effectiveness measures are calculated.

Jan 1, 1974

By J. A. Eisele

The Bureau of Hines conducted a bench-scale investigation of a concentrated H2S04 reaction for recovering and separating rare-earth elements, barium, and strontium from a bastnasite ore and byproduct. Barium and strontium were dissolved in the concentrated acid and precipitated as a mixed product by water dilution. Separation of strontium from barium was effected by reaction with Na2C03 solution, followed by a dilute acid leach of the SrC03 formed. After removing the barium and strontium from bastnäsite are, the rare-earth elements were roasted to water-soluble sulfates. The rare-earth sulfate solution was subsequently processed by solvent extraction to produce rare-earth oxides low in lead and magnesium.

Jan 1, 1974

By Fred N. Kissell

Tracer gas decay curves were experimentally obtained in a full-scale model coal mine working face area. The concentration of tracer gas was found to decay in exponential fashion but with a change in slope. This change in slope is attributed to eddy zones in the face area. A simple theory was developed that allows one to calculate the approximate amount of gas in the eddy zones and thus estimate the size of the eddy zones.

Jan 1, 1974

By T. C. Wesson

The need for elemental-analysis information on coal mine dust for use in health and safety research prompted this study by the Bureau of Mines. Neutron-activation and X-ray fluorescent techniques were used to obtain five-element analysis (silicon, aluminum, iron, calcium, and magnesium) on 444 samples from 68 coal mines in 10 States. From these analyses, the average composition of the dust in coal mines was determined. The contribution of the primary dusting material (limestone dust) to the makeup of coal mines was shown. Regional differences in mine-dust composition were indicated.

Jan 1, 1974

By Seth C. Schaefer

The Bureau of Mines studied thermodynamic properties of Al-Ni alloys con¬taining 0.54 to 30.04 atomic percent nickel with the aid of the high-temperature galvanic cell Al(1) // Al+3 (AlCl3 in NaCI.KC1) // Al-Ni alloy (1 or s). Activities of aluminum and nickel (compared with pure liquid metals as the standard state) show pronounced negative deviation from Raoult's law at 1,273 K. The properties [?G, ?Gxs, ?G ideal, ?GA1, AGxs1, ?Gni , and ?GNixs] have been derived from the experimental data and are summarized in tables and illustrations. At 1,127 K, the thermodynamic stability for the invariant three-phase equilibrium consisting of a saturated liquid, A13Ni, and A13Ni2 has been uniquely defined by an activity for aluminum of 0.751. A free energy of formation at 1,127 K of -7,940 cal/g-atom was derived for the compound A13Ni.

Jan 1, 1975

By R. L. Schmidt

Research conducted over the past 20 years in France, Great Britain, and the United States on the use of the large-hole burn cut has established cer¬tain advantages for this system. Advantages include longer pull and more complete fragmentation from blast rounds. However, research is needed to establish a set of parameters for optimum performance. As part of the Bureau of Mines Advancing Mining Technology for Marginal Resources program, the Twin Cities Mining Research Center, Twin Cities, Minn., acquired a horizontal rotary drill capable of boring holes up to 24 in. in diameter. This was used for a series of underground experiments at White Pine mine, White Pine, Mich., during 1973. Exceptional results were obtained with a 12-1/4-in void hole that yielded up to 18 ft of pull in a 10- by 20-ft drift, Fragmentation was excellent, and the compactness of the muck pile facilitated loading.

Jan 1, 1975

By A. E. Harak

To determine the retorting characteristics of a column of mine-run, ungraded oil shale ranging in size from fines to 5-ton pieces, a 150-ton batch-type retort was designed and constructed at the Bureau of Mines Laramie Energy Research Center, Laramie, Wyo. The retort vessel is 45 feet high by 11 ½ feet inside diameter, and is supported in a 95-foot-high steel superstructure. Mine-run shale from the Bureau of Mines facility near Rifle, Colo., assaying about 25 gallons of oil per ton, was used as the test shale. To date, 11 runs have been completed, and the results of the last 10 of these are reported. The effects of oxygen content of the retorting gas and the superficial gas velocity of the retorting gas on oil recovery from a column of mine-run oil shale were studied. In one run, the average particle size of the shale was substantially increased to determine its effect on oil yield. Oil recoveries ranged from a low of 39.3 to a high of 65.8 volume-percent of Fischer assay.

Jan 1, 1974

By M. B. Shirts

Numerous alternative processes have been proposed as being potentially more economical or less polluting than the traditional smelting of copper sulfide concentrates. One such process as recently developed in the laboratory by the Bureau of Mines is composed of a two-stage fluid-bed, oxidation-reduction roasting followed by ammoniacal leaching, solvent extraction, and electrowinning. A copper-leaching recovery of 97.4 percent was obtained, and electrolysis of the acid strip solution deposited metal assaying 99.99 percent copper. The roaster gases contain over 95 percent of the sulfur at a concentration of 12 percent which is better suited for acid making or elemental sulfur production than conventional smelter gas. When considering byproduct recovery, a preliminary estimate indicates copper production costs are com-parable to the conventional smelters.

Jan 1, 1975

By J. B. Janus

This report continues a series of analyses of coal samples made by the Bureau of Mines in connection with the yearly purchase of several million tons of coal for various Government agencies. Listed are the analytical data on the composition and quality of tipple and de livered samples of coal collected during fiscal year 1974.

Jan 1, 1975

By C. R. Summers, J. N. Murphy

In response to the Coal Mine Health and Safety Act of 1969, mandatory noise standards have been developed that specify time-noise limits of mine personnel exposure. Most affected by elevated noise levels is the pneumatic roof bolter operator, both in terms of levels near or in excess of 115 dbA and in terms of length of exposure. Therefore, the principal emphasis of this Bureau of Mines report is on pneumatic drill noise control. It is not the intent of this report to suggest any drill redesign; instead, methods are suggested to reduce the noise level by complementing existing machines. An integral muffler system and a separate muffler system were tested in an attempt to lower pneurnaric drill noise levels. Pneumatic drills, when new, operate at about 115 dbA when drilling in sandstone. Using the drill muffler systems, it was possible to decrease the noise level of a 115 -dbA s rope drill to approximately 100 dbA.

Jan 1, 1974

By C. R. Summers

In response to the Coal Mine Health and Safety Act of 1969, mandatory noise standards have been developed that specify time-noise limits of mine personnel exposure. Most affected by elevated noise levels is the pneumatic roof bolter operator, both in terms of levels near or in excess of 115 dbA and in terms of length of exposure. Therefore, the principal emphasis of this Bureau of Mines report is on pneumatic drill noise control. It is not the intent of this report to suggest any drill redesign; instead, methods are suggested to reduce the noise level by complementing existing machines. An integral muffler system and a separate muffler system were tested in an attempt to lower pneumatic drill noise levels. Pneumatic drills, when new, operate at about 115 dbA when drilling in sandstone. Using the drill muffler systems, it was possible to decrease the noise level of a 115-dbA stope drill to approximately 100 dbA.

Jan 1, 1974

By Robert W. Freedman, Robert L. Craft, William G. Humphrey

As part of a continuing effort to reduce the weight and bulk of equipment that mining personnel must carry underground, the Bureau of Mines and the Mining Enforcement and Safety Administration (MESA) investigated accurate and convenient gas samplers for use by mine inspectors in sampling mine atmospheres. The samplers are septum-stoppered glass vials commonly used for routine blood sampling. These lightweight, compact samplers yield results comparable with those obtained with conventional bottle samplers of 250-ml nominal capacity.

Jan 1, 1975

By Robert W. Freedman

As part of a continuing effort to reduce the weight and bulk of equipment that mining personnel must carry underground, the Bureau of Mines and the Mining Enforcement and Safety Administration (MESA) investigated accurate and convenient gas samplers for use by mine inspectors in sampling mine atmospheres. The samplers are septum-stoppered glass vials commonly used for routine blood sampling. These lightweight, compact samplers yield results comparable with those obtained with conventional bottle samplers of 250-ml nominal capacity.

Jan 1, 1975

By E. G. Valdez

Iron foundries that melt automobile scrap produce flue dusts averaging about 32 percent zinc and 6 percent lead. Some is sold to smelters, but because of the meager return and difficulty in handling, most of the dust is discarded. As part of the Bureau of Mines program to find uses for mineral wastes, research was initiated to develop an economical process to recover zinc and lead from the flue dust. Research encompassed the extraction of zinc and lead by fuming, leaching, and agglomeration. Controlled vacuum fuming of zinc to produce Prime Western zinc and a lead-rich residue was the most effective method for treating the dust. This process involved two distillations, or fumings, with carbon and methane as reductants, and resulted in recovery of 91.4 percent of the zinc in a Prime Western grade product, and 98 percent of the lead. Hydrometallurgical techniques involved several leaching methods, but the simultaneous extraction of iron, manganese, and copper resulted in contamination of the solution and made the zinc recovery processes too complicated. Agglomeration was done by pelletizing or briquetting the dust for possible use as feed to a zinc smelter.

Jan 1, 1975

By M. E. Poad

Structural properties of steel-fiber-reinforced shotcrete and polymer-impregnated shotcrete, both plain and fiber-reinforced, were investigated by the Federal Bureau of Mines, Spokane Mining Research Center. The research center has found that flexural strengths can be increased by as much as 106 percent, and splitting-tensile strength by 50 percent, by introducing randomly oriented steel fibers. A slight decrease of compressive strength was found in the fiber-reinforced shotcrete. Polymer-impregnated shotcrete exhibited a threefold to fourfold increase in compressive and splitting-tensile strength. The techniques of preparing shotcrete with the dry process, using both fast-set agents and regulated-set cement, are described, along with the results of physical-property testing. Physical properties include compressive and splitting-tensile strengths, tangent and secant moduli, and stress-strain curves for plain shotcrete, fiber-reinforced shotcrete, and polymer-impregnated plain and fiber-reinforced shotcrete. Flexural strengths for plain and fiber-reinforced shotcrete are also reported. Steel-fiber shotcrete is the more promising of the new structural materials for ground support, and additional research is recommended.

Jan 1, 1975

By A. Landsberg

Chlorination of sulfide minerals and several prepared metal sulfides was studied. The resulting data were analyzed with respect to kinetics of the reactions and application to nonpolluting methods of winning metals from sulfide ores. Sulfides of iron, copper-iron, nickel, lead, zinc, silver, bismuth, arsenic, rhenium, molybdenum, and tungsten were investigated at temperatures up to 600° C. Copper-iron, lead, and zinc sulfides showed at least some product-controlled (parabolic) kinetics at the lower temperatures within the temperature ranges studied, but only nickel and silver sulfides had chlorination rates controlled by parabolic reaction kinetics in the commercially important temperature range of 450° to 600° C.

Jan 1, 1975