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By W. N. Cathey

Many materials including carbides, silicides, phosphides, borides, nitrides, oxides, and metals were studied by the Bureau of Mines as potential fuel cell catalysts for electroreduction of oxygen in a 1[N]H2S04 electrolyte. The objective of this study was to assess the potential of abundant, low-cost materials as substitutes for platinum or to increase the catalytic efficiency of platinum. Several compounds were rejected because of their reaction in the corrosive environment of the oxygen electrode. However, some of the remaining were the most active catalysts. Activity of carbides such as tungsten carbide could be improved by doping with platinum-group metals, by varying stoichiometry, or by sputtering on a layer of platinum. While no catalysts were found with activity as high as platinum, some compounds were shown to be deserving of further investigation.

Jan 1, 1979

Reliably detect fires by sensing sub-micrometer-sized particles released into the air by smoldering or burning materials. Approach An extremely sensitive, ionization-type fire detector has been built that continuously draws air samples through its ionizing field and collects the ionized smoke particles downstream, thereby generating a proportional electrical output signal. (An offshoot instrument measures the size distribution and number of sub-micrometer particles in air.) How It Works Mine air to be monitored is drawn through the instrument assembly by a small pump. A pre-filter and cyclone remove dust particles and other particles larger than 0.6 micrometer diameter. The air and remaining aerosol-sized particles flow through a gastight tube which contains the detector. See diagram. Smoke and other sub-micrometer-size particles moving Into the detector, pass through an Ionizing field, and are struck by alpha particles released from radioactive source located on the axis of the tube, The alpha particles move radially outward until they strike smoke particles or molecules of air or water. When struck, a smoke particle or molecule loses an electron and becomes positively ionized.

Jan 1, 1979

By A. Visnapuu

The Bureau of Mines, as a part of its goal to minimize occupational hazards associated with mining and mineral processing operations, has developed and field tested a compact exhaust air muffler for mechanized, jumbo-mounted pneumatic rock drills. The muffler is constructed of 1/8-inch sheet steel and has nominal dimensions of 1-3/4 by 9 by 13 inches. A directed air passage, flexible neoprene baffles, and an expandable slit-type outlet are incorporated to reduce drill exhaust air noise and eliminate muffler icing. Field tests in actual mining operations showed a l5-dbA reduction in exhaust noise and an 8-to 12-dbA reduction in overall drilling noise with no icing problems or decrease in drill performance. Data are presented on muffler construction, laboratory, and field test results.

Jan 1, 1979

By E. LaRocque

Denison Mines Limited has been processing uranium ore in the Elliot Lake area for the past 20 years. As the original concept of uranium processing has been modified somewhat over this period, the present paper will describe the current recovery practices at the Denison mill from crushing through concentrate drying and packing . Special emphasis will be placed on the leaching, ion exchange and precipitation sections of the process, with consideration being given to the entire circuit. Descriptions will be given of equipment now being used and control strategies will be discussed.

Jan 1, 1979

By T. V. Shockley

The Gulf Coast, from New Orleans, Louisiana to Brownsville, Texas, is one of the largest high energy consuming areas in the United States. This region has areas of very high industrial density. The lower Mississippi River from Baton Rouge past New Orleans has a high industrial density. Lake Charles, Louisiana, the Orange-Beaumont-Port Arthur area, Houston (4 separate areas) and Corpus Christi all have the same high industrial density. This situation developed due to good transportation, good labor conditions, good weather and the abundance of cheap energy-gas and electricity. Obviously the latter had the greatest impact. The availability of cheap natural gas made Gulf Coast sites very attractive to energy intensive industry such as metals and petro-chemicals. The area was also very attractive to refinery development due to the large supply (endless?) of crude oil available. As we all know, the energy situation has changed dramatically in the last five years. The cost of a MMBTU has risen from the 17¢ to 19¢ level to a price of $1.95 to $2.10. The price of interstate gas, as defined by the National Energy Plan recently passed by Congress, was approximately $1.98/MMBTU escalated to October, 1978. It goes without saying, that this has had a major impact on doing business in the Gulf Coast. As fuel prices soared, different companies responded in different ways; but overall, industrial energy consumption along the coast was reduced 20% to 25% from 1974 to 1975. Since 1975 production and energy use has been increasing, however, production at some plants is still significantly below plant capacity.

Jan 1, 1979

During an eight month period, January to August 1978, nine bore holes were drilled in the Mikonui River gravels. On account of two rebores required from near bottom, the number of bores is in effect 11. Just on 1300 feet were drilled with an average depth of 120 feet. Depth varied from 102 feet to 133 feet. Penetration on average per hole value, varied from 7.4 to 16.4 feet per day. Gold values were even more erratic. Drill rig used was the Keystone churn drill manufactured locally by the Dispatch Foundary. It is skid mounted and requires a crew of two persons.

Jan 1, 1979

By B. Ignasiak

Laboratory studies suggest that improvements of coke strength brought about by pre-heating caking coals before carbonization accrue from inadvertent oxidation rather than from other low-temperature changes in the coal mass. Controlled oxidation of highly caking coal, followed by laboratory carbonization, produces cokes which, in terms of a laboratory scale tumble test index, are equivalent to those obtained from prime metallurgical blends. Appropriately formulated blends of exhaustively oxidized and fresh caking coal similarly yield cokes with strength indices comparable to those of cokes made from the same coal after oxidation under optimum conditions.

Jan 1, 1979

Reduce the number of accidents in which large mining trucks crush objects that were not visible to the driver. Approach Improved rear view mirrors, light-bending plastic lenses, and a closed circuit TV, are combined in a rugged system that allows the driver to see almost all areas around a large raining truck. How It Works Improved mirrors, used in place of ordinary left and right rear view mirrors, give wider angle viewing. Fresnel lenses, two mounted on the front edge of the hood and another one mounted above the right front fender, show objects close to the front and right side of the truck. A rugged closed circuit TV camera mounted above the rear axle reveals objects behind the truck. See diagrams showing reduction of blind area around a 150-ton mining truck. The improved mirrors for rear viewing are approximately rectangular. The left rear view mirror has a flat reflecting surface 10 inches wide by 20 inches high. The right rear view mirror is curved to give wider viewing angles, both from left to right and up and down. This mirror is 12 inches wide by 16 inches high. Its convex reflecting surface has the same curve as the surface

Jan 1, 1979

By Albin E. Anderson

The PSM System has been available to the mining industry for nine years. During this time, many of the more than 160 Systems sold have been put to practical use and have provided the owners a handsome return on investment. In this paper, the author will briefly discuss how the System works and how it can be put to use in automatic grinding circuit control. Throughout, detailed consideration will be given to the many factors that can significantly influence how successful a specific application is.

Jan 1, 1979

This publication summarizes, for potential contractors and other interested parties, the research, development, and demonstration contract projects programed by the Bureau of Mines for fiscal year 1979 (October 1, 1978-September 30, 1979) under its Mine Health and Safety Research program. The objective of these projects is to provide an ordered and sequenced series of advances toward the Bureau's overall goal of providing the system technology required to create a healthier and safer working environment for the Nation's miners.

Jan 1, 1979

By Gerald G. Griswold, Allan G. Provost

INTRODUCTION The Norad Expansion Project was located 10 miles southwest of Colorado Springs, Colorado, within Cheyenne Mountain. The expansion areas to be excavated would be adjacent to the existing underground Norad complex, which would remain in operation during the work on the expansion. The original complex had been constructed approximately eight years earlier and had been in full operation for approximately five years. Phase I, Excavation was awarded the Tiro Construction Corporation, a subsidiary of Harrison Western Corporation, Denver, Colorado, in the fall of 1970. Notice to Proceed was given to Tiro on 28 December 1970. The project owner was the U. S. Air Force, design was performed by the U. S. Corps of Engineers, Omaha District, who would also serve as the construction agency. [ ]

Jan 1, 1979

By Louis A. Panek

Using an approach based on the theory of similitude, the author develops a general equation and related concepts that provide new insights to an old problem. The load-bearing capacity (strength) of a square, rectangular, or cylindrical prism of a brittle material such as rock, coal, or concrete is expressed as the mathematical product of a size effect, a shape effect, and a function of the mechanical properties (deformability, cleat/joint spacing, and friction) of the pillar, roof and floor materials. Through an application of multivariate statistical analysis, the results of assorted tests and observations of failed pillars can be combined into a fundamental scaling equation, which provides a unified, consistent approach to the estimation of mine pillar strength. The form of the equation is sufficiently general to be able to incorporate refinements in the characterization of the basis factors, as they become available through future experimentation and analysis.

Jan 1, 1979

By D. L. Madge

The text of this chapter was not received in time for printing.

Jan 1, 1979

By Michael J. Miller

In the design of a modem mill, a stockpile storage system for raw and/or semi-processed ore has become almost indispensable. This paper discusses the benefits of such stockpile storage as well as the various types of belt conveyor stockpiling units available. Particular attention is given to large radial stackers since they offer the greatest flexibility. Stacker control systems and accessory equipment are briefly discussed. Various alternative reclaiming arrangements for stockpiles are reviewed and a discussion of the advantages and drawbacks of each arrangement is included.

Jan 1, 1979

By D. K. Bose, C. K. Gupta, K. U. Nair

A new approach to processing an indigenously available low grade molysulfide concentrate by chlorination with elemental chlorine in presence of oxygen is reported. Recovery of nickel and copper values associated with the sulfide concentrate by suitably treating the residue obtained after chlorination is also reported. In the chlorination process, a gaseous mixture of chlorine and oxygen in the volume ratio bf 2:5 has been passed at 1.66 x 10- 5 m3/s for 1800 s over a 0.01 kg batch of molysulfide concentrate at a temperature of 573°K. Most of the molybdenum has been volatilized as molybdenum oxychloride which has subsequently been extracted in water. The molybdenum value from the aqueous solution has been recovered in the form of calcium molybdate (CaO.MoO3) by treatment with calcium chloride (CaCI2). In an alternative processing scheme, the molybdenum rich solution has been treated with an oxidizing agent (K2S20f.J) and allowed to boil to recover a major portion of the molybdenum value in the form of molybdic oxide (MOOS). The spent charge obtained after molysulfide chlorination has been mixed with about 1 wt % sodium chloride and heated at 773K under an oxygen atmosphere. The reacted mass has been water-leached to yield a nickel-copper bearing solution with limited iron. The process liquor appears to be well suited for further processing by known hydrometallurgical recovery processes for nickel and copper. In the conventional process of molybdenum extraction, the molysulfide concentrate (-59% Mo) is first subjected to roasting to produce molybdic oxide. The oxide is then further processed in sequential steps involving vacuum distillation, ammonia leaching, and calcination to higher purity prior to hydrogen reduction to metal. In India there is at present some small tonnage production of molysulfide concentrate from a byproduct recovery plant of the M/s. Uranium Corp. of India Ltd. (M/s UCIL), Bihar. Efforts are being made at this laboratory to process the low grade fraction of the concentrate which contains sulfides of copper, nickel, and iron; quartz; and chlorites. Here, the conventional routes involving roasting and vacuum distillation appear unsuitable to produce an acceptable quality of molybdic oxide at high recoveries. Formation during roasting molybdates of some of the impurities present in the sulfide concentrate make subsequent vacuum distillation less efficient. In view of these problems, in earlier work reported from this laboratory the low grade concentrate has been processed hydrometallurgically to P. produce calcium molybdate. Starting from this molybdenum intermediate, processes have also been developed for the production of molybdenum and ferromolybdenum. Chlorination as an alternative to roasting for metal sulfides has been drawing considerable interest. The high reactivity of chlorine, the relatively low temperature of operation, the suitability of application to low grade resources, the convenience of recovering sulfur in non-polluting form, and the purity of chlorides which are separated by distillation all favor chlorination. In recent years, considerable work has been reported on the chlorination of common metal sulfides. In the field of molybdenum extraction from its sulfide resource, use of chlorination technology has been rather limited. Senderoff and Labrie3 were the first to chlorinate molysulfide concentrate with elemental chlorine at about 823°K to molybdenum pentachloride for use in the electrolytic preparation of molybdenum. The only other reported work, by Haver, Uchida and Wong, involved reaction between molysulfide and chlorine at 673°K to recover sulfur. The reaction products were, however, identified as molybdenum pentachloride and sulfur monochloride.

Jan 1, 1979

By J. G. Cullain

In conjunction with the over-all goals of energy conservation at Inco Metals Company, a program of improvement in compressed air utilization was established. Air flows were monitored and compared to calculated requirements to establish efficiency by area. With the cooperation of area management, measures were implemented to reduce nonproductive usage. At the operation, annual savings in power consumption alone were 80,000 dollars. The program is being extended to other mine areas within the Division.

Jan 1, 1979

By David M. Hopstock

To help assure an adequate supply of minerals to meet the Nation's economic and strategic needs, the Bureau of Mines is conducting bench-and pilot-scale research using wet high-intensity magnetic (WHIM) separation to recover iron from oxidized taconites of the. Lake Superior region. The advantages and disadvantages of WHIM separation in relation to other separation methods, the most recent innovations in WHIM flowsheet design, and the role of mathematical models in process optimization are discussed.

Jan 1, 1979

By A. M. Hill

"This is an account of the expansion of Texasgulf's Timmins concentrator by the building of a fourth circuit.The original capacity of the mine and concentrator was 3.6 million tons per year of ore. In 1974, Texasgulf decided to increase that capacity by about one third to 4.8 million tons per year. It was planned that the increased capacity would be available by mid-1978.The expansion involved work at the rninesite, increased railroad capacity, and a new circuit in the concentrator, and it is the concentrator expansion which is described here.In 1974, the minesite drew its ore from the open pit. The pit was being phased out and was to be replaced by No. 1 mine. To allow for the expansion, a second mine was required. The railroad was capable of handling 18 car trains. Its capacity had to be increased to 27 cars per train and this, in turn, required two new locomotives. Each of these alone cost half a million dollars.The concentrator building in 1974 contained the concentrating equipment and miscellaneous services (such as machine shop, warehouse, analytical lab). The grinding and flotation sections were divided into three circuits ('A', 'B', & 'C'). 'A' and 'B' circuits treated copper-zinc ore and 'C' circuit treated the much more difficult copperzinc- lead ore. This 'C' circuit had been modified over the years to implement improvements in the metallurgy."

Jan 1, 1979

By Larry D. Patts

Section 317(e) of the Federal Coal Mine Health & Safety Act of 1969 directed the Secretary of the Interior to prepare standards under which all working places in a mine shall be illuminated by permissible lighting while persons are working in such places. Section 317(e) further provides that such working places shall be illuminated within 18 months after such standards are promulgated. In accordance with this section of the Act, there was published in the Federal Register for December 91, 1970, a notice of proposed rulemaking which prescribed the illumination to be provided in the working places of underground coal mines. In light of written comments, suggestions, and objections to this proposed rulemaking, the proposedstandards were withdrawn and reproposed in the Federal Register for Wednesday, October 27,-19h. In light of further comments, suggestions, and objections, a public hearing was held on April 4, 1974, and standards were again reproposed and published in the Federal Register for April 1, 1976. Promulgation of the final lighting standards took place on October 1, 1976, which means that the underground coal mining industry must comply with face illumination requirements by April 1, 1978. As mentioned previously, the first proposed rulemaking for illumination of underground coal mines was published in the Federal Register on October 27. 1971. In early 1972, Consolidation Coal Company (Consol) and the United States Bureau of Mines agreed to a cooperative study of underground face illumination: Consol felt that expertise is this field would become increasingly important. Consol's initial efforts in illumination were aimed at investigating practical lighting systems for underground face equipment. We were concerned with installing unobtrusive lights which provided sufficient face illumination for safety, but at the same time were readily maintainable, electrically reliable, and physically sheltered from damage. We believe that our initial lighting systems did provide sufficient face lighting for safety, but because only prototype components were available for field testing, the resultant poor system reliability and maintainability necessitated drastic improvement before face lighting could become practical. Final Lighting Standards Deem Early Lighting Installations Out Of Compliance On April 1, 1976, the Federal Register contained the final version of the illumination standards (as they were later promulgated in October). When these illumination regulations and measurement techniques were defined and measuring instruments were available, Consol checked their lighting systems underground and determined that the systems were not in compliance with these final illumination standards. More Lighting Hardware Added In An Attempt To Achieve Compliance. After determining that all of our face lighting systems were not in compliance, we began adding additional lighting hardware in order to meet compliance with published regulations. Unfortunately, to date, we have not been able to meet compliance with practical lighting systems. We have determined from our field installations that the required additional lighting hardware, (to meet compliance) with its increased vulnerability and decreased reliability, renders the lighting systems impractical, if not impossible, to reasonably maintain. Our attempts to provide 0.06 footlamberts have also produced adverse operator reaction to the glare and to illumination systems in general. BCOA Members Ask MESA To Demonstrate Practicability Of Compliance With Regulations Industry concern about meeting the impending lighting regulations was mounting, and in May of 1976 a meeting between MESA and BCOA members was held to discuss lighting compliance problems. At this meeting, BCOA offered to work cooperatively with MESA in testing the practicability of various lighting systems mounted on underground mining equipment. Field tests were to be conducted by United States Steel Corporation, American Electric Power Service Corporation, and Consolidation Coal Company. The purpose of this underground field testing was to develop capability to provide adequate face illumination in a safe, workable manner which would not detract from efficiency of operation. BCOA members involved in this cooperative study were to submit necessary machine drawings, sketches, etc. to MESA in order that MESA could perform a "black-box" study and specify the type and location of luminaires to be installed on the test machines. MESA was confident that they could specify lighting systems that would be in compliance and would be practical so as not to detract from efficiency of operation. Consol was first to install lighting hardware under the BCOA/MESA cooperative agreement. As per MESA specifications, Control Products HgV luminaires were installed on a Joy 2BT-2H boring machine at the Williams Mine of Northern West Virginia Region. As of mid-October, 1976, Consol had approximately eight weeks operating experience with the lighting system on this boring machine underground and had drawn the following conclusions: The lighting system installed at Williams Mine (1) does not meet compliance with lighting standards as originally proposed by MESA, (2) does not provide illumination in a safe workable manner, and (3) will detract from efficiency of the mining operation due to operational delays. Although Consol has rearranged lights on this boring machine in an attempt to reduce operator objections, a practical lighting system which is "in compliance" has not been arrived at as of this writing.

Jan 1, 1979

By Larry Snyder, Levent Ozdemir, Charles Fishman, Fun-Den Wang

Tunnel Boring Machine Instrumentation A 9.17 m. diameter tunnel boring machine presently in operation in Chicago, Illinois, has been instrumented to continuously monitor and record machine thrust, torque and penetration rate during boring. A micro-processor-based data logger capable of monitoring up to 60 channels of data digitizes and converts into appropriate engineering units the signals from various transducers mounted on the machine. The output from the data logger is sent to a teleprinter, providing a permanent record of measured data. The program control enables the data logger to scan all data channels at desired time intervals. Data obtained to date have been analyzed to determine the interrelationships of the parameters measured. Penetration rate was found to increase linearly with machine thrust with a unit increase in thrust causing more than a unit increase in penetration rate. For low thrust levels corresponding to the initial stages of a boring cycle, the penetration rate was observed to behave erratically until the thrust pressure was sufficiently high for the cutters to establish full contact with the tunnel face. Torque showed a curvilinear increase with machine thrust, reaching the design rating at about 70% of maximum available thrust. No-load torque was approximately 20% of the machine's rated torque capacity. Overall, the trends observed in measured machine parameters correlated closely with those predicted from experimental and theoretical boreability studies. In summary, the instrumentation system has mett two basic goals. First, it provided extensive and accurate boring data and secondly, it has proven that an automatic data acquisition system can be installed on a TBM and can function under adverse environment.

Jan 1, 1979