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In order to reduce waste and improve resource conservation, mine planning, and development, the U.S. Bureau of Mines is investigating the effects of multiple seam interactions associated with longwall coal mining. Field investigations were conducted at a mine located in Boone County, WV, where a longwall panel was operating subjacent to room-and-pillar workings in an overlying seam. To assess the effects of overlying workings on longwall headgate stability, the Bureau gathered various geotechnical information at this minesite. Headgate pillars and entries were instrumented and monitored to study their behavior during side-abutment loading as the longwall panel approached and passed beneath the overlying room-and-pillar developments. The two operations are separated by 800 ft of interburden, and although interactions between operations separated by this distance are uncommon, geomechanical measurements indicate the occurrence of an interaction. These measurements show that convergence on the headgate entries was most adverse subjacent to barrier pillars in the overlying mine. Pillar measurements indicate that side-abutment pressure increases were slightly greater than predicted values. Several factors related to both geology and mine design, believed responsible for this large interactive distance, are discussed.

Jan 1, 1990

By W. R. McDonald

Part of the U.S. Bureau of Mines mission is to supply the U.S. mineral industries with information that is useful in planning to meet the Nation's critical and strategic mineral needs if a national emergency occurs. The Bureau conducted laboratory research including operating a nominal 100 lblh pilot plant to demonstrate the recovery and concentration of chromite by gravity and flotation operations from three northern California mineral deposits. Gravity beneficiation test results show that concentrates contained as much as 52 pet chromic oxide (CrZ03) with recoveries of about 80 pet. Results from the bench-scale unit operations of mineral liberation, tabling, vanning, spiraling, pinch sluice, work index, and thickener area determination tests are presented in this report.

Jan 1, 1990

By S. P. Signer

The Bureau of Mines conducted a series of field tests to improve the understanding of the support interaction mechanics between fully grouted bolts and coal mine roofs and to help lay the foundation for improved design and evaluation techniques. Strain gauges were installed on 14 fully grouted bolts placed in shale roof rock at four mines in Colorado, Illinois, and Pennsylvania to determine how load was transferred between the bolts and the rock. The results of field tests on elastic bolt behavior compared well with previous laboratory work and numerical models. The field tests showed that the anchorage length of grouted bolts installed in shale was slightly longer than the anchorage length determined in laboratory tests conducted in concrete blocks. The field results produced more variability because of geological variations. Tests run past the yield point of the steel bolt indicate that the yield zone varies significantly and translates down the length of the bolt anywhere from 4 to 22 in.

Jan 1, 1990

By Thomas A. Davidson

The Bureau of Mines Helium Field Operations has developed a method for determining the helium-3 CHe) content of natural gas and mixtures eontaining 0.5% to 100% helium. The helium is preconcentrated by passing samples through anhydrone, a liquid-nitrogen-cooled chareoal trap, and a titanium absorption trap. The mass spectrometer used to analyze the samples is tuned to 3He at mle ::=; 3.016. Hydrogen deuteride (HD+) interference is minimized by the titanium absorption trap and high instrument resolution. Sample measurements are compared with identically made measurements of a gravimetrically prepared primary standard. The method has a limit of detection of 0.15 ppb with a relative deviation of 13% below the 1~ppb level. The relative deviation is less than 7% for gases eontaining over 100 ppb 3He. The helium isotope ratios of natural gases from the Bureau's Tuck-Trigg Dome Red Cave, the Bush Dome Red Cave, and the Bush Dome Brown Dolomite Formations are distinguishable from one another and from the isotope ratio of crude helium produced from the Panhandle-Hugoton Gasfield.

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 Keith G. Wallace

Coal mine ventilation systems are often subject to high leakage rates. As a result, changes in airflow resistance will strongly affect the efficiency with which air is delivered to the working place. One major source of airflow resistance is the line brattice used to direct air from the last open crosscut to the working face. Because it is a great distance from the fan, the resistance of the line brattice can result in more overall leakage than an equivalent resistance closer to the fan. Substituting auxiliary fans for brattice eliminates this source of resistance, with improvements in system efficiency and cost. Also, in some mines, the leakage that leads to spontaneous combustion can be reduced. The benefits obtained by several different brattice and fan substitutions have been studied by Mine Ventilation Services, Inc., Lafayette, CA, under contract to the U.S. Bureau of Mines. Changes in main fan duty were compared with additional costs associated with auxiliary fans. Results indicate that in some circumstances, considerable leakage reductions and cost savings are possible.

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 M. R. Peterson

The U.S. Bureau of Mines investigated column flotation for recovery of a high-grade fluorite (CaF2) concentrate and byproduct concentrates from the Fish Creek fluorite deposit in Eureka County, NY. The recovery scheme consisted of (1) grinding the ore to minus 48 mesh, (2) fluorite rougher and cleaner flotation, (3) desliming the rougher fluorite flotation tailings at 20 Jjm, (4) mica flotation, and (5) silicate rougher flotation. Acid-grade fluorspar, mica, free silica (Si02) sand, and low-grade beryl (Be3Al2S~018) concentrate were produced in a 100 lb/h continuous column flotation unit (CCFU). The highest results achieved were %.6-pct CaF2 recovery in a fIrst cleaner concentrate containing 99.7 pct CaF2. Beryl recovery was as high as 92 pct at a grade of 5.3 pct BeO. The silica sand, which assayed 98 pct Si02, was recovered as the rougher beryl flotation tailings. Collector reagent consumption was reduced 45 pct for fluorite and 58 pet for silicate flotation in comparison with bench-scale conventional flotation. All products were signillcantly improved in both grade and recovery over conventional flotation results, and the recovery scheme was simplifIed by removal of several stages of flotation in the fluorite and silicate flotation steps.

Jan 1, 1990

By S. P. Sandoval

Several researchers have shown that the surface of chalcopyrite becomes hydrophobic under oxidizing conditions. Because dissolution of copper from chalcopyrite in dump leaching occurs under oxidizing conditions, the U.S. Bureau of Mines studied the effect of surfactants on chalcopyrite leaching under dump chemical conditions. Surfactants were selected for study because they can lower interfacial tension. The tests were conducted in shaking water baths using 250-mL Erlenmeyer flasks in statistical experimental design formats. The addition of nonionic surfactants increased copper extraction in the fernc sulfate leaching of chalcopyrite when sufficient Fe3+ was present. A positive interaction between Fe3l+ concentration and surfactant concentration was demonstrated. Copper concentration in the leachhing solutions was increased by as much as 100 pct at 25° and 50° C by adding nonionic surfactants. ionic surfactants decreased leaching. The structure of the nonionic surfactants and their hydrophile-lipophile balance (HLB) influenced surfactant performance. The branched hydrophile of an ethoxypolyol was beneficial to surfactant performance. The ethoxypolyol was the superior surfactant at 25° C, but became unstable at 50° C. Four surfactants, an ethoxyalchohol and three block copolymers, performed best at 50° C.

Jan 1, 1990

By Nabil A. Bibawy

An improved method for preparing gravimetric standard gas mixtures of helium-4 in nitrogen has been developed by the U.S. Bureau of Mines. A single-pan 12-kg analytical balance that has a sensitivity of 3 mg is used to prepare the mixture. The balance will accommodate a cylinder having a volume of approximately 4 L that weighs approximately 5 kg. The method has been improved to a precision of ±O.04 pct by performing four successive dilutions, by improved handling of gases in the manifold, and by using an improved analytical method to select high-purity gases.

Jan 1, 1990

The U.S. Bureau of Mines conducted a series of laboratory tests in a full-scale model to determine the respirable quartz dust capture efficiency of an irrigated-filter collection system while testing different filter densities, different filter materials, preconditioning water sprays, and wetting additives in the spray water. Impactor samplers were operated upstream and downstream of the filter unit to determine overall dust collection efficiency. The impactor filters containing the 0.7-to 4.7-J.l-m size fractions were analyzed for quartz content, and these data were used to calculate quartz dust collection efficiency. The results of this testing indicated that (1) increased ftIter density improved quartz dust collection, but also resulted in a significant increase in pressure drop across the filter, (2) an alternate synthetic filter material improved dust collection without increasing pressure drop, (3) preconditioning sprays mounted in the system ductwork can have a beneficial effect on dust collection, and (4) additives to the spray water did not significantly increase dust collection.

Jan 1, 1990

By Agnes Y. Lee

As part of the U.S. Bureau of Mines program to improve base metal leach systems, pressure leaching of galena (PbS) concentrates in fluosilicic acid (H2SiF6) solution was investigated. Lead extraction was 93 pct when PbS was pressure leached in H2SiF6 at 95° C with 2OO-psig O2 pressure for 40 min, using ferric nitrate [Fe(N03)3] as a catalyst. The effects of several catalysts, O2 pressure, time, and acid concentration on leaching were determined. The purified leach solution was electrowon to recover high-purity Pb metal. The H2SiF6 used in leaching and electrowinning can be recycled continuously. A flow diagram was proposed based on this investigation. Elemental sulfur (SO) was recovered from the leach residue by solvent extraction. A method was also developed for treating the flnal residue to segregate the important byproduct elements such as Ag, Cu, and Zn and enable their recovery by standard commercial processes.

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 Jack E. Fraley

Poor lubrication reduces the life of wire hoist ropes when they are used in corrosive environments. Although lubricants are added to ropes during the manufacturing process, these lubricants can deteriorate during use, and it is often necessary to add more lubricant to both the interior and exterior of the rope while it is in service. The U.S. Bureau of Mines evaluated the effectiveness of synthetic lubricants, using electromagnetic nondestructive testing (NDT) to measure deterioration in ropes while they were in service. For nonpressurized lubricant applications, synthetic lubricants appear superior to petroleum-based lubricants in their ability to penetrate to the interior of a rope. Therefore, the synthetics offer better wear and corrosion protection.

Jan 1, 1990

By S. R. Droes

The U.S. Bureau of Mines investigated calcium fluoride (CaF2) assisted sulfuric acid (H2S04) leaching as an alternative to the melting-quenching procedure to obtain Mn from domestic manganese silicate resources. Pyroxmangite [(Mn, Fe) Si03] ore containing, in percent, 34.4 Mn, 22.8 Si, 2.6 Ca, and 1.3 Fe was leached in a 500-mL resin kettle. Ninety-six percent of the Mn was extracted under conditions of 330 g/L ore, 245 g/L H2S04, 35 g/L CaF2, 90' C, and 2 h. To incorporate electrowinning in recovering Mn, the ore was leached with a simulated spent anolyte solution containing, in grams per liter, 12 Mn, 140 H2S04, 130 (NH4)2S04 (ammonium sulfate), and 5 CaF2. Manganese extraction of 92 pct was achieved from 130 giL ore leached at 90° C in 3 h. The Fe, silica (SiOJ, and other impurities were precipitated from the pregnant solution by neutralization with ammonia (NH3). Manganese of greater than 99-pct purity was deposited at a cathode current density of 50 mA/ cm2 at 30° C, with a current efficiency of 65 pet in a two-compartment cell. A flowsheet was proposed for the leaching and electrowinning procedure.

Jan 1, 1990

By A. F. Jolly

As a part of ongoing research into the sulfidation partitioning of selected complex minerals, the U.S. Bureau of Mines conducted research designed to selectively recover Cu from sulfidized chalcopyrite (CuFeS2). Ferric chloride (FeCI3) solutions leached >90 pct of the Cu and <20 pct (sometimes < 10 pct) of the Fe in the sulfidized concentrates. Cupric chloride (CuCI2) leaches were even more selective, solubilizing essentially 100 pct of the Cu and < 5 pct of the Fe. In contrast, leaching non-sulfidized CuFeS2 with either FeCl3 or CuCl2 showed that somewhat more Fe than Cu dissolved. These studies demonstrate that Cu is substantially more leachable from sulfidized CuFeS2 than from nonsulfidized CuFeS2? The Cu-and Fe-bearing constituents generated as sulfidation products, CuS (covellite) and FeS2 (pyrite), respectively, are differentially dissolved. The solubility of Fe from pyrite in sulfidized CuFeS2 is much lower than the solubility of Fe from complex nonsulfidized sulfide where Fe and Cu are bound in the same crystal lattice. Thus, the Cu dissolves selectively, producing a high-Cu filtrate from which Cu can be recovered by cementation or by electrolysis. Flotation of CuS-FeS2 mixtures indicates partitioned phases can be physically separated if effective liberation can be achieved. Magnetic separation tests yielded less promising results.

Jan 1, 1991

By Donna L. Anderson

This U.S. Bureau of Mines report discusses the status of a laser-based guidance system to provide position and heading feedback and closed-loop control of tramming maneuvers for a continuous mining machine. The system has been developed and tested at the Bureau, and is now being prepared for underground experiments. The system hardware includes laser scanners, a sensor communication network, and host computer hardware. The system software includes a position and heading computation module and a tram control module. The description of the software includes discussions of laser data acquisition, error compensation methods, position and heading determination, safety checking for continuous miner tramming, and closed-loop tram control. The accuracy of the laser scanner&apos;s data, the reliability of the lasers in a dusty environment, and the system&apos;s accuracy on tracking the position and heading of the continuous mining machine are shown in the results of experiments performed at the Bureau. Conclusions are stated based on these experimental results, and further work to improve the system performance and prepare for underground testing is discussed.

Jan 1, 1990

By P. E. King

The U.S. Bureau of Mines is conducting an ongoing research project to better understand the phenomena involved within electric arcs utilized in electric furnace steelmaking. With a better understanding of the physical and electrical characteristics involved, dynamic or predictive control of electric arc furnaces may be possible. A mathematical model is presented, but not solved, and the system of coupled equations is analyzed. Characteristic parameters are used to determine relative importance. In this manner, significant quantities are dermed. The parameters found to contribute little to the system of equations of motion are ignored. A resultant simplified system is identified, and directions for further study are indicated toward control of electric arc furnaces.

Jan 1, 1990

By Frank J. Susko

The U.S. Bureau of Mines is developing a process for removing metals from mining and mineral processing waste streams by precipitation. The precipitation process is accelerated by flocculation when a high molecular weight polymer is added. Infrared (IR) studies were performed on zinc hydroxide [Zn(OH);J, copper hydroxide [Cu(OH);J, and zinc sulfide (ZnS) flocculated with both non ionic and anionic polyacrylamide (PAM) and polyethylene oxide (PEO). The IR data were compared with general trends in the performance of the polymers observed during flocculation. These studies will help to understand the bonding between the precipitate and polymer and indicate the effectiveness of a flocculant for dewatering. Two types of bands showed up on the IR spectra; one type described the interlayer water of the flocs, the other described the organic bonds of the polymers. A general decrease in the areas of the three water bands, hydroxyl (O-H) stretching (3,200-3,500 cm-1), water bending (1,610-1,630 cm-1), and torsional oscillations (600-700 cm-1), indicate interlayer water being driven off, which is a favorable condition in flocculation. Shifts in the O-H stretching band indicate water bridging between the precipitate and polymer. Shifts in the amine (N-H) deformation, carbon-nitrogen (C-N) stretch band (1,600-1,610 cm-1) indicate the amine group of the PAM is involved in the bonding. Evidence suggests that ether oxygen of PEO is also involved in the bonding process.

Jan 1, 1990