Search Documents

By P. G. Clites

This bulletin summarizes the results of Bureau of Mines research on the development of the inductoslag melting process. Inductoslag melting is an induction melting technique using a segmented, water-cooled, copper crucible. The process was developed as part of the Bureau's work on effective utilization of reactive metal scrap, and the process has been applied to melting Ti, Zr, Cr, Co, Fe, Ni, and V. Construction details are given for the segmented crucibles and for both an ingot furnace and a casting furnace. The melting process is described, and results of tests conducted with a variety of reactive metals are given.

Jan 1, 1982

By J. Handin, S. J. Bauer, M. Friedman

Deformation mechanisms in room-dry and water-saturated specimens of Charcoal Granodiorite, shortened at 10-4s-1, at effective pressures (Pe) to 100 MPa and temperatures to partial melting (?1050°C) are documented with a view toward providing criteria to recognize and characterize the deformation for geological and engineering applications. Above 800°C strength decreases dramatically at effective pressures ? 50 MPa and water-weakening reduces strength an additional 30 to 40% at Pe = 100 MPa. Strains at failure are only 0.1 to 2.2 percent with macroscopic ductility (within this range) increasing as the effective pressures are increased and in wet versus dry tests. Shattering (multiple faulting) gives way to faulting along a single zone to failure without macroscopic faulting as ductility increases. Microscopically, cataclasis (extension microfracturing and thermal cracking with rigid-body motions) predominates at all conditions. Dislocation gliding contributes little to the strain. Precursive extension microfractures coalesce to produce the throughgoing faults with gouge zones exhibiting possible Riedel shears. Incipient melting, particularly in wet tests, produces a distinctive texture along feldspar grain boundaries that suggests a grain-boundary-softening effect contributes to the weakening. In addition, it is demonstrated that the presence of water does not lead to more microfractures, but to a reduction in the stresses required to initiate and propagate them.

Jan 1, 1982

By Steven J. Page

Longwall double-drum shearers frequently have difficulty complying with the 2.0 mg/m3 dust standard and, therefore, require the use of effective dust controls. However, before dust controls can be implemented effectively, the major individual dust sources must be determined and their relative severity evaluated. The Bureau of Mines has recently developed a sampling strategy, based upon short-term gravimetric sampling, that can identify the major dust sources contributing to the shearer operator's exposure. This technique utilizes approved gravimetric sampling equipment already available to all mine operators and can be performed by two people in 2 days. Five examples, including data analysis, are discussed with respect to various cutting sequences. In addition, typical dust source contributions obtained from studies of double-drum shearer operations regularly in compliance are included. Mine operators can thereby compare their dust source evaluation results with those from these longwalls.

Jan 1, 1982

By Peter J. Huck, Yoginder P. Chugh, M. Jennings

INTRODUCTION Large areas of the United States coal reserves have been undermined by room-and-pillar mining over the past century. These abandoned mines generally cause subsidence of the ground surface many decades after mining. Reports from England (1) where there is a longer history of room-and-pillar mining indicate that mines abandoned two centuries ago may still be causing subsidence, and causing surface destruction to urban areas or farm lands that have been developed in the interim. The devastation wrought by subsidence, both in terms of property loss and societal disruption is enormous. The authors discuss here the methods by which subsidence in abandoned mines may be controlled. Two distinctly different subsidence control technologies have been developed in the U.S. for abandoned coal mines. These are referred to as (1) Point Sup- port methods, and (2) Areal Backfilling. As the names imply, point support methods are used to protect individual structures, or even individual foundation elements of structures, whereas areas backfilling techniques may be applied to protect entire neighborhoods or urban districts hundreds of acres in extent. Both point support methods and areal backfilling have specific sub-categories of techniques that may be applied under different conditions as appropriate. POINT SUPPORT METHODS Point support methods are characteristically employed by civil engineers chartered with the design of a new structure or the protection of an existing structure. The subsidence control measures are only a part of a larger project, the safety of which must be assured to a degree of near certainty. The costs of point support methods involve a large number of bore-holes and the use of expensive materials in relatively small quantities. There exist several dozen point support methods, which operate either to support the underground cavities, controlling subsidence, or to isolate the structure from the effects of subsidence if it should occur. The latter methods usually involve deep foundations through the mine opening supporting the structure on the underlying strata. Our concern will be with the former method to support underground cavities to prevent subsidence. Gravel Columns and Associated Methods Gravel columns may be placed in the mine opening using the methods shown in [Figure 1]. Boreholes are drilled through the mine strata, and gravel poured down the borehole to form a pile on the mine floor. When the tip of the pile contacts the mine roof, it is rodded down to spread the pile, and permit additional gravel to be placed. The objective is to place as much gravel as possible in the mine opening, and to achieve firm contact with the mine roof. The gravel pile acts to reduce subsidence by three mechanisms. The filling of a significant fraction of the open mine volume reduces the amount of potential subsidence simply by killing open volume within the mine. In effect, the extraction ratio has been reduced by introducing the volume of gravel. The toe of the gravel pile abuts against nearby pillars, providing lateral support and protection against pillar deterioration. In effect, the height of the pillars has been slightly reduced by burying their lower portions. Finally, some direct support is provided to the roof strata, reducing the roof span and enhancing stability. The gravel column method may be used in a variety of applications, and with materials other than gravel. For example, gravel columns may be placed in a close line around the perimeter of the building to form a continuous gravel wall. The interior of the site may then be completely filled with sand, slurry or other material. Alternatively, a lean concrete may be used in place of gravel, so that the piles achieve significant structural capacity. The grout column, shown in [Figure 2], begins with the installation of a conventional gravel column which is placed around a grout pipe that extends through the borehole into the mine opening. When the gravel column is in place, portland cement grout is injected in stages. At each stage, sufficient grout is injected to fill the interstices in the gravel to build a column perhaps two meters in diameter and a meter tall. The group pipe is then raised one meter, and after the previously injected grout has set, the next stage of grout is injected. The process builds a column of grouted gravel to the

Jan 1, 1982

By David W. Kennedy, Stephen P. Harrison

In the past few years, a new system has been developed for ventilating longwall panels in some gassy coal mines in the Northern West Virginia area. This system utilizes a five or six foot diameter air shaft to ventilate a group of three or more longwall panels dependent on conditions. This shaft exhausts all the air needed to, ventilate the active longwall and adjacent gob areas. By law, this bleeder fan can handle double the maximum methane concentration allowed in a normal return air course. As a result, the methane that must be diluted by the primary ventilation circuits is reduced. This new ventilation system was first conceived by mine management as a means of coping with a sudden shift in production mode that occurred a few years ago. Formerly, production often consisted of room and pillar mining with continuous miners. The high methane liberation rate was handled by driving entries around a large block of coal prior to mining. This isolated the future mining area from the adjacent coal seam and allowed a major portion of the trapped in situ methane to bleed off. Also, these bleeders served to exhaust return air from the mining area. Once the bleeders were established, productive mining could start. When the decision was made to shift production mode from continuous miners to longwall mining, some of the bleeders did not encompass large enough unmined areas under the old ventilation system to initiate longwall production. Also, many other established continuous miner section bleeders were either improperly positioned or too restricted for longwall ventilation. Unfortunately, standard bleeder development can take up to two years' time. In order to eliminate the old style bleeder system and maintain or increase the margin of safety for ventilation, the bleeder shaft system was conceived. With this system, the only entries developed are those necessary for the longwall, significantly reducing the production delay. In this area, the Pittsburgh #8 coal seam dips to the northwest. As a result of this dip, the bleeder shaft is constructed in the northernmost set of tailgate entries. In this manner, groundwater accumulations can be pumped to the surface and bleeder entries kept dry. During the initial longwall entry development, the bleeder fan can be used to ventilate entries adjacent to virgin coal where significant methane liberation often occurs. Once longwall production starts, the bleeder shaft exhausts the entire air quantity necessary to safely ventilate the longwall. As the bleeder entries deteriorate, the air quantity and pressure characteristics must be increased. The extreme flexibility of the centrifugal fan used at the surface allows the air quantity and pressure to be adjusted without stopping the fan. This improves safety by decreasing the possibility of a methane buildup resulting from the fan being out of service. The bleeder shaft system of ventilation, developed by mine management in Northern West Virginia, can provide a safe means for effectively ventilating longwall panels in excessively gassy mines. This system should be considered where mining conditions are comparable.

Jan 1, 1982

By D. A. Trotter

"Low-pressure sodium light sources have been available for several years, but have not received wide acceptance in underground mining. This is because they are difficult to operate using DC power, they are not an intrinsically safe light where explosive gases may be encountered and they give poor colour rendition.With the need for energy conservation, several Canadian hard-rock metal mines are now changing their lighting to low pressure sodium, as it has the highest efficacy of any light source in terms of lumens per watt. Studies have pointed out several other advantages as well. Glare can be controlled, they penetrate fog well, they are easily maintained, they have a long life and they give the highest visual acuity when compared to other types of lighting. As well, in an underground mine, contrast is much more important than colour for task identification. For close work, the colour problem is alleviated with the use of cap lamps.Case studies are presented from Canadian practice. These show how the lights are modified for underground use, calculations preceding light installation, and how and where the lights are installed in the underground environment. Mention is made of worker reaction to the lights and possible physiological effects.IntroductionThe importance of good underground lighting to the total environment of mining cannot be overemphasized. In addition to the obvious benefits of improved worker morale, available studies show that good lighting practices reduce accident severity and frequency as well as increase production."

Jan 1, 1982

By R. T. Rometti, C. A. Bossard

INTRODUCTION Whenever a new mining property is developed or a new concentrator is built, considerable time, money, and planning are invested for the exploration, engineering, and construction of the required facilities. Yet, when these facilities are ready for startup, all too often insufficient time, money, and planning are invested in this critical phase of the project. Failure to plan for this phase results in untimely personnel mobilization, insufficient operator training, and inadequately prepared budget estimates, which combine to create excessive costs, lack of communication, unclear responsibility divisions, unnecessary delays, and poor production levels. Insufficient or excessive leadership, due to unclear assignment of responsibility, results in irrevocable problems within the startup team. A carefully planned and budgeted startup phase can avoid many of these problems. SCHEDULING A key element in properly planning the startup phase lies within the area of scheduling. Once the schedule has been established, planning can be greatly simplified through the expansion of each specified item. The overall project schedule should specify the date when the startup and initial operating management team will be brought onto the project. This team should be mobilized at least two years prior to the anticipated startup date, to allow sufficient time to begin to plan, assemble the startup groups for the various areas of the plant, initiate a workable communications system, and implement the development of the training program. This team is responsible for the preparation of a startup schedule, which would detail the dates for all key items associated with this phase of the project. These key items would include training program development, personnel hiring dates, prestartup plant checkout, etc.

Jan 1, 1982

By Mark S. Sanders

Based on laboratory tests and preliminary field tests of off-the-shelf steel toed rubber boots, a molded sole design was developed to provide increased traction over conventional calendared sole miners' boots. The pattern provided sharp edges perpendicular to both lateral and fore-aft slip vectors. The sole was designed to reduce mud caking. An instep lace-up capability was added to better secure the foot inside the boot. A five month field evaluation compared the prototype boots to the boots the participants usually wear. Although objective slip and fall data showed no significant advantage for the prototype, subjective evaluations made by the participants indicated increased traction for the prototype boots. Approximately 75 percent preferred the prototype to their own boot. Approximately one-third used the lace-up capability. It was concluded that molded soles provide better traction than calendared soles for the underground mining environment.

Jan 1, 1982

By M. Paczkowski

The use of inert gas systems to extinguish mine fires has been the subject of research for some time in the United States. In some European countries, it is an established practice. Tests were conducted with the CMI Inert Gas System (CMI), which is being used by the Polish mining industry. This system utilizes a modified jet aircraft engine and afterburner as a compact source of combustion products with a very low (less than one percent) oxygen content. Water injected into the combustion products stream provides evaporative cooling and forms a mist with a high cooling capacity. The CMI system was used under controlled conditions to extinguish coal pile fires at the U. S. Bureau of Mines Experimental Mine in Bruceton, Pennsylvania. The test results show that the CMI system can be used conveniently to extinguish fires quickly and to maintain an inert atmosphere in the fire zone to prevent re-ignition.

Jan 1, 1982

To evaluate the potential for dust reduction, during blasthole drilling, of water or foam applied directly into the drill hole. Approach The Bureau of Mines tested a through-the-drill-steel water and foam injection technique in two noncoal mines to evaluate the method's potential for greater dust reduction. The tests were performed by drilling a series of blastholes for an entire face (a 90 minute time-period). For the first 45 minutes of drilling, foam or water was applied through the drill steel. Blowing ventilation was supplied to the entry about 50 feet from the face. The dust concentration measurements were made by a Real-Time Aerosol Monitor (RAM-I), and the data were read out on a strip chart recorder. The evaluation test results showed that the water or foam injection technique, when used on localized dust sources, can be an extremely effective dust control method. Small amounts of water used in this method have also allowed it flexibility to be used in water-soluble ores such as salt, gypsum, anhydrite, and trona. How The System Works Water or foam is mixed with compressed air (approximately 100-120 psi) with suitable metering systems and forced through the drill steel into the blast hole at the point of dust generation. Because the water or foam is applied at the source, minimal quantities of liquid are needed (0.2 to 0.6 gpm). These low flowrates are sufficient to just moisten the dust emerging from the blast hole, thus eliminating a major source of airborne dust. The wet drilling procedure also eliminates a second source of dust. With dry drilling, the dust from the blast hole falls to the floor. Since this can be a 15-ft drop or more, the impact can send the dust billowing up from the floor, adding to the airborne dust. With wet drilling, the moistened dust merely dribbles down the face.

Jan 1, 1982

By A. D. S. Gillies

Loss of visibility due to the occurrence of atmospheric fogging in underground mine airways can lead to a reduction in travel times and loss of production efficiency, an increase in the frequency of vehicular and foot traffic accidents and difficulty in checking rock surfaces for instability and loose material. Where hot and humid surface air meets colder underground air, conditions for fog formation nay be present. Further, suspended particulate matter from diesel exhausts or stoping operations together with slow movement of air along passageways nay contribute to formation. The study describes an investigation being undertaken with the cooperation of Kennecott's Ozark Lead Company to identify causes of the problem.

Jan 1, 1982

By Rustu S. Kalyoncu

A major goal of the Bureau of Mines is to conserve the Nation's mineral resources by developing improved performance materials. In support of this mission, a survey of the state of the art of chemically bonded refractories has been made, covering the scientific literature, government reports, and patents. This review includes research and development results for phosphate, silicate, oxychloride, oxysulfate, and other bonding agents used in refractories manufacture. A significant finding of the review was that references on bonding mechanisms, bond formation kinetics, and other important process parameters and conditions were few and universally vague. As a result, recommendations are made to expand research efforts to investigate the kinetics and mechanisms of reactions in chemically bonded refractories.

Jan 1, 1982

By Patzen Wu

Taiwan is located in the orogenic belt of island arcs on the western rim of the Pacific Ocean. The structure of the Taiwan coal fields is much complicated as a result of active Cenozoic orogenic disturbance in Plio-Pleistocene time. The abundant faults and folds have created poor structural conditions of the coal seams and some peculiar safety problems in mining however, the domestic coal still played an important role in the economic development of Taiwan for the years before 1968. Because of increasing mining depth and a decreasing number of miners, the coal production dropped from nearly 5.1 million metric tons in 1968 to 2.45 million metric tons in 1981. There were 173 small active coal mines and about 22 thousand miners in 1981. The coal mining in Taiwan has a history of more than one century. Specific efforts have been undertaken in solving major coal mine safety problems such as gas outbursts, bad roofs and weak floors, difficulty in ventilation due to deep underground mining, spontaneous combustion etc. We have thus acquired much helpful experience which, we deem, is worth reporting at this meaningful meeting.

Jan 1, 1982

By Kiran B. Chaudhuri

The Kivcet process is technologically the most advanced of the new lead smelting processes which have been developed over the past decade construction of the first commercial scale Kivcet lead smelter which has been designed by KHD Humboldt Wedag for Sociedad Complejo Metalurgico de Karachipampa is at present nearing completion in Bolivia. Some of the measures taken to minimise emission of harmful elements as well as methods employed to minimise energy consumption in the design of the smelter, are presented. Results of recent testwork which have added to the flexibility of the process are summarised.

Jan 1, 1982

By Kim B. Shedd

The U.S. Bureau of Mines Particulate Mineralogy Unit examined the habits of six zeolite minerals commonly occurring in domestic zeolite deposits. Mineral habit is of interest because current theory on the potential for sarcoma production in test animals emphasizes the size and shape of mineral particles, without regard to composition or structure. A scanning electron microscopic study revealed that, of these six minerals, only mordenite and erionite crystallized in acicular to fibrous habits, The fibrous varieties of these two minerals were characterized by size and shape on the transmission electron microscope, and their dimensions were compared with those of asbestos and amphibole cleavage fragments. When comminuted, these two minerals possess "fibrosity indices" similar to those of amphibole cleavage fragments. One sample, a rare woolly erionite, has uniform widths, large aspect ratios, and a "fibrosity index" similar to those of asbestos.

Jan 1, 1982

By Jim F. Lemons

The Bureau of Mines Minerals Availability System collected and analyzed data for 34 nonlaterite and 9 nickeliferous laterite domestic chromite deposits in order to assess their viability as sources of chromium under present technologic and economic conditions. These 43 deposits, none currently in production, contain approximately 6.3 and 22.3 million metric tons of Cr203 at the demonstrated and identified resource levels, respectively. Approximately 4.6 and 15.6 million metric tons of Cr203 are recoverable at the demonstrated and identified levels, respectively, for the 34 nonlaterite deposits. None of these resources are economically recoverable at January 1981 market prices. Production of metallurgical-grade chromite (market price $128 to $144) would require a minimum chromite market price of $237 per metric ton. Chemical-grade chromite production (market price $74 to $85) would require a chromite market price in excess of $188 per metric ton. From the 34 nonlaterite deposits, roughly 5.4 and 17.6 million metric tons of ferrochrome could be produced at the demonstrated and identified resource levels, respectively; however, a minimum market price of $770 per metric ton of ferrochrome would be required to stimulate production. The nine nickeliferous laterite deposits were not evaluated through production stages because of uncertainties in process technology and cost.

Jan 1, 1982

By Ann G. Kim

Acid drainage from underground coal mines and coal refuse piles is one of the most persistent industrial pollution problems in the United States: This Bureau of Mines report reviews the acid mine drainage problem generally and describes research currently underway to combat it.

Jan 1, 1982

By K. H. Nimerick

Froth flotation of coal is growing in importance and complexity. Some of the reasons for these changes follow. 1) A need exists for energy resource conservation. 2) Preparation plants are processing widely varying coal -- deep seam, strip and stockpiled either separately or as blends. 3) More fines are being generated because more mines are using automatic mining equipment. 4) It is more practical and economical to remove ash and sulfur at the preparation plant than during utilization.

Jan 1, 1982

By Alten F. Grandt

What is prime farmland? Can such land, once it has been surface mined for coal, be restored so that it will produce corn, soybeans, wheat, and alfalfa? What methods or practices are necessary to bring about restoration within a reasonable time so that crop yields will be equivalent to or higher than those of unmined prime farmland under high levels of management? These questions concerned land use researchers in Illinois as early as 1948 when the Illinois Agricultural Experiment Station experimented with growing cultivated crops on surface mined land in St. Clair County (Grandt, 1949). This research was done almost thirty years before requirements of Public Law 95-87 were passed by the US Congress and signed August 3, 1977.

Jan 1, 1982

By M. R. Moharam

The well-known formulae of screening efficiency and circulating load calculations in closed crushing circuits were exploited to achieve graphical estimation of these parameters. Three basic charts were proposed and constructed. The first one is for the regular closed circuits where the new feed goes to the crusher. The second is for the reverse closed circuits in which the new feed reported to the screen is free of screen undersize particles. The third chart controls the reverse circuits when they are receiving new incoming feeds containing undersize material. Compound circuits were also reanalyzed and a concept of equivalent simple circuit was introduced to enable graphical manipulation of these complex circuits with the help of the aforementioned charts

Jan 1, 1982