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By F. J. Cservenyak

The Bureau of Mines Solid Waste Program is directed toward three main areas of research: (1) Extraction of mineral, metal, and energy values from urban refuse; (2) recovery of mineral and metal values from wastes generated in the industrial extraction, processing, and utilization of raw materials and mineral-base products; and (3) upgrading and utilization of automotive scrap. The Bureau also has a contract and grant program which supplements the in-house research and aids in the training of personnel in the proper management of mineral- and metal-based solid wastes.

Jan 1, 1970

By S. L. Weber, D. E. Banks

"Silicosis was first reported by the ancient Greeks and is apparently as old as human history. The prevalence of this illness peaked in the last half of the 19th century and the early part of this century, when mechanized industry was developing and the relationship between dust exposure and disease was less well understood. Yet, even today in devel-oped countries, sporadic outbreaks of silicosis occur when workers are consistently exposed to silica particles of respir-able size (0.5 to 5.0 µm in diameter) at levels exceeding those recognized to be safe.Silicon dioxide or silica. is the earth's most abundant mineral. Silica is considered to be either free (i.e.. unbound to other minerals) or combined. Minerals with high amounts of free silica include quartz (including granite) flint. Chert, opal, chalcedony, and diatomite. Combined forms of silica are called silicates and include, among others, asbestos talc and kaolin.In the crystalline form, silica exists as quartz, cristobalite, and tridymite (Fig. 28). Of these quartz is ubiquitous in the environment and occurs as sand and as a part of many rocks. Cristobalite and tridymite occur naturally in lava and can be formed by the heating of quartz or amorphous silica. Cristo-balite is more tibrogenic than quartz. Amorphous silica is noncrystalline and, therefore, is relatively nontoxic and does not cause silicosis. It occurs as diatomite (skeletons of pre-historic marine organisms) or as vitreous silica (glass), the result of carefully melting and then quickly cooling free crystalline silica. Heating diatomite with or without alkali (a process known as calcining), forms cristobalite and adds the respiratory toxicity of free crystalline silica.There are many opportunities for occupational exposure to respirable crystalline free silica. Some of the commonly en-countered occupations in which the risk of silicosis exists are reported in Table 20.Silicosis. the pulmonary disease caused by the inhalation of silica particles of respirable size, is most commonly cate-gorized by findings on the chest radiograph. The most typical presentations simple silicosis and progressive massive fibrosis appear different radiologically but are grouped under the category of classic silicosis because they are a part of the radiographic spectrum of this illness. Radiographically, simple silicosis appears as small (less than 10 mm in diameter), rounded opacities, typically predominant in the upper lung zones. Progressive massive fibrosis is the result of the coalescence of these small nodular opacities and appears as larger opacities (more than 10 mm in diameter), again typicallydistributed in the upper lung zones."

Dec 1, 1995

By Bernard S. Covino

The Bureau of Mines is conducting a study of methods to improve the efficiency of the process used to pickle stainless steels. A review of the literature on pickling of stainless steels showed that the chemistry of several process operations involved in the pickling of stainless steels is not fully understood, and that further research could improve the pickling efficiency. The benefits of this research would be a reduction in the annual loss of several thousands of tons of critical minerals such as nickel and chromium, and a reduction in the amount of solids and spent acid solution that are currently discarded. The conclusion from this review is that further research is needed in four operations that either directly or indirectly influence the pickling process: hot working, annealing, conditioning, and the actual operation of pickling, Laboratory studies of the pickling operation are presently in progress.

Jan 1, 1984

By D Stepanenko, G Stovpchenko, L Lisova, D Togobitskaya, L Medovar

Classical electroslag remelting of consumable electrodes is a drop-by-drop melt feeding through a slag layer into a renewing molten metal bath, slowly solidifying into a homogeneous, dense, defectfree ingot in a copper water-cooled mould. The new look at the additive nature of the electroslag remelting (ESR) process in a protective atmosphere allowed us to formulate the principles of a comprehensive thermodynamic-based model that can predict dynamic changes in slag and metal composition at certain ingot remelting. The model considers drastically different slag-to-metal mass ratios at the beginning and end of remelting and predicts gas, slag and metal composition in a chain of thermodynamic subsystems. Despite consisting of calcium fluoride and stable oxides, the ESR slag can oxidise main and active elements from steel and alloys (primarily aluminium, titanium and silicon) due to chemical reactions between slag and metal. ESR is not an electrochemical process in its nature. However, slags are ionic melts and deviation in their composition causes a change in their properties, affecting both operation mode and ingot quality. Another important understanding derived from the modern metallurgy technological route is that the ability to refine metal from impurities is not a priority for the ESR because consumable electrode has already passed all stages of refining and deep degassing at ladle treatment that changes ESR slags engineering principles. The critical importance became slag’s ability to generate process heat and keep the melting composition in the metal bath unchanged (except for non-metallic inclusions assimilation). Slag engineering for ESR required a compromise between chemical inertness to a metal composition and desired physical properties deriving from technological reasons. The Directed Chemical Bonds Concept (DCBC) in a multicomponent oxide system was used to build predictive models of electric conductivity and the melting temperature of fluoride-oxide slag based on their chemical composition. Both models help to design a customised composition of effective slags for steel and alloy groups or individual grades, and they are significant steps in the development of a comprehensive model of electroslag remelting.

Aug 21, 2024

By William G. Pariseau, Mark K. Larson, Heather E. Lawson

Rational design based on engineering fundamentals is essential for the layout of safe, stable shafts and tunnels. Shafts and tunnels including winzes, raises, adits, and crosscuts are lifelines to the underground and must be secure. The contribution of this paper describes a significant extension in existing software previously developed for five important design problems in strata-bound mines such as coal, trona, salt, potash, and some large, lead-zinc mines. This extension in software allows analysis to proceed in three easy steps: (1) preparation of a strata properties file, (2) generation of the finite element model, a mesh, and (3) finite element program execution. Circular, elliptical, and rectangular shaft sections are available for a single shaft, twin shafts, and shafts in a row. Spacing of twin shafts and shafts in a row is a free parameter (pillar width). Tunnel shapes are the same as shafts but include the conventional arched back section. Dipping strata of variable thickness, depth and orientation relative to the excavation of choice are allowed. The analyses are three-dimensional. An elastic-plastic material model based on associated rules of flow and an N-type yield condition for isotropic, transversely isotropic, or orthotropic rock are used for all strata. Example analyses from several hardrock mines are provided to illustrate the three-step process including mesh plotting and plotting of selected results. The goal of this software is to advance mine design technology for improved miner health and safety.

By J. S. Miller

The Bureau of Mines conducted surface tests to determine the feasibility of using liquid explosives for underground rock fracturing. The effects of configuration, confinement, length, critical layer thickness, and fracture-propping sand on detonation and explosive propagation velocity of desensitized nitroglycerin were studied, using polymethyl methacrylate and glass-plate reservoirs through lengths from 3 to 12 ft, with explosive-layer thicknesses from 0.1875 to 0.0312 in and in aluminum tubes 8 ft long with diameters from 2.000 to 0.125 in. Interval and continuous detonation velocity data were obtained. Under the test conditions detonation velocity was dependent upon explosive confinement and fracture-propping sand. The detonation velocity of a confined nitroglycerin explosion in aluminum tubes can be reduced by as much as 85 percent, when the tube contains fracture-propping sand. The shape of the reservoir, whether triangular or rectangular, has little effect on the detonation velocity or explosive propagation. The critical or minimum explosive-layer thickness between glass plates, capable of supporting propagation, was 0.0312 in. The presence of a fracture-propping sand in the sheetlike layers increased the critical explosive layer thickness to 0.0625 in. In nitroglycerin-filled and nitroglycerin-sand filled tubes, the minimum tube diameters successfully tested were 0.125 in and 0.375 in, respectively.

Jan 1, 1969

By E Amini, N Beaton

Application of ore pre-treatment technologies such as Grade Engineering and in-pit ore treatment require comprehensive analysis to show proven value is being generated by switching away from the current practices. Considering most mining operations last several decades; the pre-treatment technologies must be investigated over life of mine (LOM) to truly show value was generated or lost. Therefore, a value chain flowsheet model has been usually developed to run those analysis/simulations over LOM using a set of defined ore characteristics and the operating equipment capacities. The Integrated Extraction Simulator (IES) has been used for this type of LOM simulations as it has the necessary flexibility to accommodate the whole mining value chain flowsheet in one platform and provide essential computation power to run mass simulations for the given scenarios using the resource block model. This allows to forecast the value chain response over the LOM for all given scenarios in a feasible amount of time. The traditionally developed flowsheets for the analysis/simulations are usually limited to the mineral processing plant and were developed based on a single audit conducted on the plant in a very short time, e.g. several hours. The process plant is being operated with a certain ore at a certain condition during the short audits which would not reveal the true capacity of the operation equipment when ore characteristics changes. Therefore, it would be impossible to define the true capacity of the equipment and identify the constraints along the value chain. In this study, a methodology was developed to identify the constraints along the value chain and implement those in the IES flowsheet using process information. Also, the equipment models were fine-tuned to represent the true capacity of the equipment in the flowsheet using the same data set. The methodology was tested over five process plant in two operations and showed the performance forecast was significantly improved over the traditional methods being used so far. Then those high-fidelity flowsheets were used to evaluate the ore pre-treatment technologies proposed by the relevant resource company experts.

Nov 10, 2020

By H. M. Harris

The Bureau of Mines investigated chlorination of domestic ilmenites in a fluidized coke bed at temperatures of 950° to 1,150° C. Objectives were to develop an effective process for producing TiC14 suitable for TiO2 pigment and to reduce pollution by collecting and treating waste byproduct chlorides. The reactor for these tests was a 10.2-cm-diam quartz tube heated externally by electrical resistance heaters. It contained coke beds of from 35.6 to 82.5 cm in depth that were fluidized by 13 to 25 l/min of chlorine. Ilmenite concentrate powders were introduced at the bottom of the fluid-bed reactor, using the chlorine gas stream as a carrier. Test results showed that greater than 90 pct of the ilmenite reacted at optimum conditions and recovery of TiC14 ranged from 95 to 99 pct of stoichiometric. A temperature-controlled cyclone was used to remove high-boiling-point chlorides such as MnCl2, MgCl2, and FeCl2, and also collected fine unreacted ilmenite and coke dust. Impure TiC14 and FeC13 were separated by collecting the, iron chloride in a condenser con-trolled at 200° C. Titanium tetrachloride vapor was cleaned by passage-through a salt-column filter followed by condensation in water-cooled and refrigerated condensers. Liquid TiC14 was purified further by well-known industrial methods to meet specifications for pigment-grade chloride. Integrated tests were conducted in which chlorine, produced by dechlorination of FeC13 with oxygen, was recycled and used directly in a fluidized-bed chlorinator.

Jan 1, 1976

By Kafui Nyavor

Acid mine drainage (AMD) is presently the biggest single environmental problem facing the mining industry. New and expanding metal mines in most parts of the world have to demonstrate their ability to contain this problem to obtain operating permits. Conventional methods of controlling acid mine drainage have primarily been limited to collecting the drainage and neutralizing with alkaline materials which do not provide a permanent solution to the AMD problem. Since acid mine drainage results from the oxidation of sulfides in the presence of oxygen, water and iron-oxidizing bacteria, controlling any of these three factors contributing to pyrite oxidation provides a potential at-source remedy for reducing or preventing acid mine drainage formation. Physical properties such as hydrophobicity also play an important role in the attachment of bacteria, adsorption of oxygen, water, and other ions that subsequently lead to the oxidation of pyrite. In this communication, the suppression of pyrite oxidation by treatment with fatty acid amines (FAA) was investigated. The FAA treated pyrite samples were tested at various conditions of temperature and pressure. At an elevated oxygen pressure of 500 psi and a temperature of 600 C, less than 0.2% oxidation was obtained for the FAA treated pyrite samples, while over 1.2% oxidation was obtained for the untreated samples in 10 hours of oxidation time. Accelerated column oxidation tests at ambient condition showed that FAA mated samples reduced pyrite oxidation by at least 75% in 81 days.

Jan 1, 1994

By Clarence O. Babcock

This report describes the results of Bureau of Mines laboratory and preliminary field tests on a rock bolt of helical shape. The flexible construction allows the bolt to maintain a more stable load level than is possible with a straight bolt. Bolt load changes resulting from anchor slippage, blasting shock, or changes in mine geometry with mining advance are minimized. Preliminary field tests were performed at the Kaiser Steel York Canyon mine where the load changes of straight and helical bolts were measured using a vibrating-wire load gage. The field tests were performed to establish the viability of the concept of a helical bolt. The practical usefulness in terms of performance and economics remains to be shown. The change in bolt load for the flexible bolts was one-third that for the straight bolts. There were no malfunctions of the gage, and the bolts maintained a more uniform load than the straight bolts used as controls.

Jan 1, 1978

By M. K. McCarter

In 1963, a major expansion program at Kennecott's Bingham Canyon mine converted rail operation in the upper portion of the pit to truck haulage. Since that time truck-haulage capacity has increased to about 272 000 Mg (300,000 tons) per day. The majority of this production is waste material which is deposited in monolithic dumps located on the eastern slopes of the Oquirrh Mountains. The largest of these dumps, referred to as Copper Notch and Keystone, measures approximately 1830 m (6000 ft) in length, from 180 to 300 m (600 to 1000 ft) in height, and contains some 430 Tg (470 mil lion tons) of waste. The height, structure, rapid rate of growth, and anticipated leaching suggested the possibility of dump failure. In order to evaluate this possibility, an outside consulting firm was retained in 1966 to investigate the stability of the growing dumps. Their investigation indicated that, other than superficial movement, the waste dumps would be stable under static loading, and that soil distribution was not continuous enough to sustain massive foundation failure. Since this investigation, however, several failure processes have been observed. Crest settlement occurs frequently in response to compaction and over-steepening in the upper portion of the dump surface. Over-steepening results from accumulation of fines near the crest caused by natural segregation. Normally, coarse material, near the base of the dump, exhibits an angle of repose near 0.65 rad (37"). The fine material, however, stands as steep as 0.75 rad (40"). Periodic equilibrium adjustments cause stepwise settlement (Figure 1) of the dump surface and occasional sloughing of the protective berm. Routine surface preparation by dozers and graders and frequent inspections by supervisory personnel have proven adequate in preventing problems associated with this form of crest instability.

Jan 1, 1976

By M. Westerstrand

It is known that the water chemistry of the process water during ore refinement can affect product quality, such as iron pellet strength. The main objective of this study was to quantify the amounts of major elements, such as Ca, Mg, Na, S and Cl carried by process water and by magnetite grain surfaces to the end product, iron ore pellets made from magnetite ore from the Kiirunavaara Mine in northern Sweden. In addition, the amount of colloids (0.22µm ? 1kD) in the process water was examined by ultrafiltration. The amounts of various elements sorbed to the magnetite surfaces were estimated by leaching with Milli-Q water, MgCl2, NH4-acetate and Na-acetate. Total dissolved solids were between 1,446 and 1,775 mg/l, dominated by Ca, S, Na and Cl (89%). The colloidal fraction was less than 3% for major ions. For Ca and Mg, sorption to magnetite surfaces was a much more important transport mechanism for the pelletizing process than evaporated process water, but for Na, Cl and S process water was an important carrier.

Jan 1, 2010

By A. O. Sfriso

"Numerical modelling is becoming universal in rock engineering practice. Most applications focus on the prediction of failure loads of 2D problems, where the numerical models are useful extensions to analytical methods and experience-based design criteria. For 3D problems and problems where the assessment of serviceability indicators – displacements, ground-structure response, etc. – are of importance, the selection of the constitutive models themselves and the implications of the selection of material parameters may have a very heavy impact on the reliability of the model outcome and its predictive capability.This paper overviews basic common aspects of constitutive equations used in practical rock engineering and summarizes some challenges that are frequently observed when reviewing numerical models performed for routine problems in rock engineering. INTRODUCTIONNumerical methodsFrom a philosophical perspective models, either analytical or numerical, are idealizations of a perceived reality. For us engineers, models are just tools we use to guide our judgement and understanding of the problem in hand. When dealing with problems in rock engineering, we resort to a wide range of techniques:1. Closed form solutions like confinement-convergence methods for circular tunnels: these methods satisfy equilibrium and compatibility requirements at the cost of a crude simplification of the material behavior and geometry;2. Limit analysis methods, like bearing capacity formulas: lower bound methods satisfy equilibrium but sacrifice compatibility, and upper bound methods do the opposite. Material behavior must be simple, geometry admits limited freedom;3. Limit equilibrium methods, like method of slices for slope stability: they satisfy restricted forms of equilibrium, do not satisfy compatibility requirements, require simple material behavior but have a much greater flexibility on geometry;4. Numerical methods, where a mesh is employed to discretize the problem geometry: when properly formulated, these methods satisfy equilibrium and compatibility requirements and give reasonable approximations to the behavior of very complex geometries and construction sequences. Very little restrictions remain on geometry and material behavior, but the cost of calibrating the material parameters can be very high."

Jan 1, 2015

By R. L. Rough

Photoelastic, wire resistance, and borehole-deformation gages were used to measure the in situ strains when an outcropping Black Hand Sandstone Formation in Hocking State Forest, Hocking County, Ohio, was overcored to stress-relieve the surrounding sandstone. Strains transmitted to the photo-elastic gage did not produce isochromatic patterns suitable for quantitative analysis. Strain readings from the wire resistance gage indicated tensile-strain loading during overcoring; readings from the strain-gage bridges in the borehole-deformation gage indicated compressive-strain relaxation during overcoring. The magnitude and orientation of the computed stress fields obtained from both gages were comparable when the corresponding tensile and compressive elastic moduli were applied. Stresses computed from deformation and resistance gages at depths to 5 feet showed the maximum stresses to range from 1.042 to 2.121 times greater than the minimum stresses. The bearings of principal stresses calculated from the deformation gage readings varied between N 61° E and N 83° E; the wire resistance strain gage bearing computations varied between N 68° E and N 82° E. Measurements of in situ strain in sandstone were shown to have promise but to require further development in field technique that could likely be achieved through experience.

Jan 1, 1971

By W. T. Robson

LAKE Shore Mines, Limited, with property at Kirkland. Lake, Ontario, was incorporated m 1914 and commenced product10n m March, 1918, with an initial capacity of about 60 tons per day. Since that time a gradual expansion has taken place until a present capacity of approximately 2,300 tons per day has been reached, giving a total annual gold production valued at approximately $16,000,000. At the time of incorporation of the Company, the Lake Shore property consisted of four mineral claims and four fractions, totalling 171.05 acres. In 1934, four claims belonging to the Minaker Kirkland Gold Mines, Limited, were acquired and a controlling interest purchased in the Kirkland Hudson Bay Gold Mines, Limited. Both these properties adjoin the Lake Shore claims on the south. From the accompanying compilation of the world's largest gold mines for 1934 (1), it will be seen that, while Lake Shore holds sixth position in respect to the number of ounces produced, there are twenty-five gold mines which treat a greater tonnage of ore. This is an indication of probably the most unusual feature of the Kirkland Lake deposits, namely, the high aver-age tenor of the ores. coupled with the comparatively large tonnages available.

Jan 1, 1936

By G. L. Neumann

In October 1949 the College Park Branch of the Mining Division instituted a survey of the New England pegmatites. Many of the New England pegmatite deposits were superficially examined, and the Bumpus quarry in Albany, Oxford County, Maine (see fig. 1), was selected for a diamond-drill exploratory-development project to supply information for developing more economical mining methods and no increasing production of beryl and other scarce minerals associated with pegmatitic intrusives. The Bumpus quarry has been mined intermittently by three operators since it was opened in 1927. At the time of drilling, the vein or dike (see figs. 2 and 3) had been mined to a depth of 60 feet for a strike length of 280 feet. The dike averages 40 feet in thickness and dips 50 degrees southeast. The Bureau of Mines drilled seven diamond-drill holes between September 27 and November 27, 1950. These holes showed that the dike persists for at least 350 feet to the east and probably 200 foot to the west of the present excavation. The drilling also indicated that the dip, as exposed at the surface, continued unchanged at 500 to a depth of at least 50 foot below the pit. The dike was not delineated, although it fingered out as pegmatite interbanded with Granite, diorite, and gneiss in diamond-drill hole B-4, approximately 250 feet west of the pit. Further drilling will be necessary to find the extent of this pegmatite dike and to determine the safest and most economic mining system.

Jan 1, 1952

By M. J. Dailey

This paper is one of a series being prepared by the United States Bureau of Mines on mining practices, methods, and costs in the various mining districts of the United States. The property of the Silver King Coalition Mines Co. is situated in the western past of the Park City mining district, Utah, about 1 ½ miles southwest of the town of Park City, The elevation at the collar of the main shaft is 8,137 feet above sea-level.

Jan 1, 1930

By S. A. N. Sheya

Many gold-bearing ores in the Western United States also contain small amounts of mercury. The presence of mercury creates potential pollution and health hazards during several steps in gold processing. An investigation was undertaken by the Bureau of Mines to develop techniques for removing mercury from cyanide mill solutions by selective electrowinning to reduce the potential hazards. Sixty-five percent of the mercury was selectively electrowon from synthetic carbon strip solution at applied potentials of 1.00 to 1.50 V when using a mercury-coated platinum or copper plate cathode. Increasing the active surface area by using mercury-coated copper wool resulted in up to % pct of the mercury being electrowon from mill carbon strip solutions that contained 1.9 to 20 ppm Hg, 20 to 345 ppm Au, and 0.35 to 39.5 ppm Ag. About 98 pct of the silver was electrowon with the mercury onto the mercury cathode. Gold extraction ranged between 0 and 20 pet. Results of the investigation showed that choice of cathode material was critical to the success of the process. Selectivity was not achieved using uncoated steel wool cathodes.

Jan 1, 1988

By John W. Cole

The Butte district has been the principal producer of metallurgical-grade manganese in the United States since World War I. Manganese dioxide nodules are produced from rhodochrosite ore by concentrating the rhodochrosite and roasting the concentrate in rotary "cement-type" kilns. The Anaconda Copper Mining Co. is the only producer at present. Under the stimulus of a purchasing program administered by Metals Reserve Company during World War II, however, several independently owned or operated mines (including the Norwich) produced manganese carbonate ore. These mines were examined in Juno 1949 by John W. Taber, mining engineer, Bureau of Mines. A core-drilling program to develop ore in the Norwich mine was recommended and approved. drilling was completed early in 1950. This report gives factual data obtained.

Jan 1, 1951

The dissolution behavior of gold and copper from their elemental states and from Au/Cu alloys in cyanide solutions has been investigated using a rotating disc electrode. The anodic and cathodic reactions were studied separately and the resulting polarization curves were combined to examine the overall dissolution reactions. The dissolution rate of pure gold in the aerated cyanide solutions was inhibited by the anodic passivation on the gold surface, while the dissolution rate of pure copper was found to be mass-transfer-controlled. On the other hand, the dissolution of gold and copper from the alloys was partially controlled by electrochemical reaction and largely by mass transfer.

Jan 1, 1994