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By S. Harteis, D. Dolinar

Many mining operations rely on bulkheads to provide a barrier between impounded water or slurry and active mine workings. However, bulkhead failures could cause and have caused catastrophic flooding that puts the underground workforce at risk. The National Institute for Occupational Safety and Health1 (NIOSH) in collaboration with the Mine Safety and Health Administration (MSHA) is conducting research to evaluate the adequacy of existing design practices for water and slurry bulkheads. A key component of this research effort is documentation of the performance history and design parameters for bulkheads installed in underground coal mines during the last 20+ years. This research is part of a larger effort to develop general design guidelines and procedures for constructing and maintaining bulkheads that will help to ensure their long-term structural integrity, while significantly reducing the inundation risk for miners. This paper presents the results of NIOSH’s research to identify state-of-the-art bulkhead designs, including design criteria, leakage monitoring systems, and emergency warning systems. Underground observations and evaluations of existing bulkheads suggest that the most important design factors influencing their performance are the interface of the bulkhead with the surrounding strata and the potential magnitude of the hydraulic pressure to which they may be subjected. When a bulkhead has failed, leakage has generally been through the surrounding strata or along the bulkhead/strata interface, with the failure potential along the interface increasing with hydraulic head. It was also determined that development of a monitoring program to ensure the long term structural integrity of bulkheads is an important safety consideration. Current monitoring procedures range from weekly visual inspections to constant monitoring via pressure transducers and fluid level indicators. Where possible, these devices are used in conjunction with a computer based mine monitoring system to alert mine personnel when an emergency condition exists at the bulkhead installation.

By E. Chin

The only economically significant mineral exploited in Banglades - during 1981 was natural gas. Nitrogenous fertilizer production was important to the agricultural sector and was totally dependent on the natural gas for fuel and raw material. Domestic cement plants were also fu pled by natural gas. The flat river-delta terrain for most of Bangladesh makes the potential for discovering major mineral deposits poor. No large deposits of metal ores have been found and only in the small hilly southeastern section of the country is there even much chance of finding any. Heavy mineral sand deposits may eventually be exploited along the Chittagong coastline. There is a good potential for crude oil discoveries. The Bangladesh economy has been heavi¬ly subsidized by billions of dollars of foreign aid since the country's inception. A World Bank report recommended total aid needs of over $2.6 billion in fiscal year (FY) 1980-81. It received commitments for barely over one-half that amount.

Jan 1, 1983

By E. R. Bauer

Prolonged exposure to noise can cause permanent damage to the auditory nerve and/or its sensory components, known as noise induced hearing loss (NIHL). It is the most common occupational disease in the United States today. The Pittsburgh Research Laboratory (PRL) of the National Institute for Occupational Safety and Health (NIOSH) is addressing NIHL in the mining industry through several research efforts. This paper presents a general review of NIHL, the status of NIHL in mining, the results of the longwall noise surveys, and a review of the longwall engineering controls research efforts.

Jan 1, 2008

By W. W. Adams

With production of coal per man-hour of work at a higher level than ever before, the coal-mining industry of the United States established a near-record in lowering the accident rate of nonfatal injuries per million man-hours of exposure in 1940, the injury rate being lower, except for 1939, than in any year since 1930, the first year for which comparable figures for nonfatal accidents were collected by the. Bureau of Mines, United States Department of the Interior. The rate for fatal accidents, on the other hand, was not as low or favorable as in 1939, nor was it as low as in many years since 1910, the earliest year for which fatality rates were complete for all coal-mining States. Accident and employment reports received from mine operators and fatal-accident reports from State mining departments and inspectors showed that 533,267 men were employed at coal mules in 1940, exclusive of the number employed at coke ovens, Although this number represented 6,108 fewer employees than in 1939, a large increase was made in the volume of work performed and in the quan¬tity of coal produced. In 1940 the amount of labor performed at coal mines was 748 million man-hours, a gain of more than 10 percent over the previous year. The average employee worked 199 days, an increase of 20 workdays per man. Production of coal was nearly 513 million tons, an increase of 14 percent, of which more than 461 million tons was bituminous coal and more than 51 million tons was Pennsylvania anthracite. Accidents to mine workers caused the death of 1,388 employees; in addition, 59,781 employees were injured, and each injury resulted in disability of the employee for more than the remainder of the day on which the accident occurred.

Jan 1, 1942

By J. E. Rourke, O&apos

A wide variety of techniques and equipment are available for coring soft or poorly consolidated geological material. This report presents a comprehensive literature review and evaluation of these techniques and equipment. A potential user will find guidelines in this report to assist him in selecting sampling equipment. A bar chart shows what samplers have been used under what geological conditions, and gives the specific literature references. Two matrices rate the present techniques and equipment with respect to reported success for sampling specific materials, and with respect to several performance characteristics including complexity of use and core quality. These matrices are supplemented with tables of typical sampling equipment. and program costs. Near-term future developments are seen primarily in improved training of drillers, and in instrumenting the drilling operation to provide objective data on drilling characteristics. An extensive annotated bibliography, a catalogue of equipment suppliers including specifications and cost ranges, and a list of manufacturers and distributors are appended to the report.

Jan 1, 1978

By L. J. Kane

Conventional methods for determining the size of dust suspended in a gas require that agglomerates (clusters of particles) first be broken into particles, but in evaluating industrial dust-removing equipment the size of the agglomerates as they actually exist in the gas stream is far more important. This paper presents results of an investigation by the Federal Bureau of Mines to develop methods for determining the size of dust agglomerates suspended in a gas stream. The studies are part of the Bureau's continuing research on synthetic liquid fuels. The size and size-distribution of agglomerates as they exist when the gas reaches the filter was determined by using a membrane filter in conjunction with a dust count under a microscope. A membrane filter is a cellulosic sheet about 150 microns thick containing millions of holes per square centimeter--holes of uniform diameter that run directly through the sheet without interconnection.

Jan 1, 1960

By T. M. Barczak, S. C. Tadolini

Reduction in the recovery time required and improvements in safety during a longwall face move have compelled coal mine operators to examine and use pre-driven longwall recovery rooms. The recovery entry is developed at the longwall stop position and supported ahead of time so that the required combinations of standing and internal supports can be installed before the longwall face approaches. A calibrated three-dimensional finite element model, developed in conjunction with an underground test area, provided the critical components and design principals for a comprehensive parametric study. The study indicates that vertical, horizontal, and shear stresses concentrated on the outby abutment pillar corner of the recovery room resulting in deformations in the immediate roof above the primary roof support anchorage level. The results of the numerical model and field site observations indicated that the combination of the internal bolting system and the standing concrete supports are critical for the successful and safe extraction of the longwall equipment. Cable supports installed at and angle over the pillars can help stabilize the disturbed zone above the adjacent fender and outby pillars, however; standing supports are required in most sedimentary roof conditions to increase stability and assure a safe longwall extraction.

By A. B. Hooker, L. C. IlsLey

"Observation of the use of trailing cables in ""mines shows that the chief limiting factor in the life of the cables and their safe use is the smashing or crushing of the cables in service, together with the effects of consequent splicing.Trailing cables are crushed when run over by cars, mining machines; and locomotives or when hit by falls of roof. Crushing damages the insulation and may cause failure at once or in later use. Failure may be either by short circuit between the conductors or by grounding to the track. The failure of a live cable causes electric arcs capable of igniting explosive mixtures of methane and air. Every cable failure in a gassy or dusty mine is, therefore, a real or potential hazard.Some mine operators do not allow the splicing of trailing cables for use in gassy mines, bet require that a damaged cable be immediately replaced and if repaired that it be used only in nongassy mines. Other operators allow the making of temporary splices to permit completion of the shift but require that such splices be remade and vulcanized before the cable is used again.Still other operators allow the continued use of temporary splices, which in general means that a cable is used until the splices give trouble in reeling, or overheat, or pull apart. Then the spliced sections are either cut out or the whole cable is replaced.Splices often determine the useful life of a cable. A splice poorly made may pull apart ueder mechanical strain and cause arcing that burn* the surrounding cable or ignites as or coal-dust. If it has lower conductivity a splice is the first part of the cable to heat; it may become so hot under load that it will burn apart and damage other parts of the cable, or, if it be a soldered splice, the solder may melt and allow parting of the cable. A poorly made splice often has insufficient insulation which may alloy short-circuiting between conductors or permit external contacts capable of giving an electric shock to one handling the cable. The splice is sometimes bulky from too much insulation and takes up too much room on the reel, causing uneven reeling; also by catching on the spooling device the oversized splice may receive expressive pulls and wear. Splicing is therefore a very important factor in the use of trailing cables."

Mar 1, 1932

By Pramod C. Thakur

In This Chapter [Origins of coalbed methane Reservoir properties of coal seams Thresholds for coal seam degasification Methane emissions in mines Methane drainage techniques How to transport gas safely in mine pipelines and Economics of coal seam degasification Recommended publications on coal seam degasification are Gas Control in Underground Coal Mining [Creedy et al. 1997], Coalbed Methane Extraction [Davidson et al. 1995], and Methane Control for Underground Coal Mines [Diamond 1994].] ORIGINS OF COALBED METHANE AND RESERVOIR PROPERTIES OF COAL SEAMS Origins of coalbed methane. Coal seams form over millions of years by the biochemical decay and metamorphic transformation of plant materials. This coalification process produces large quantities of byproduct gases, such as methane and carbon dioxide. The amount of these byproducts increases with the rank of coal. It is the highest for anthracite, where for every ton of coal nearly 1,900 lb of water, 2,420 lb (20,000 ft3) of carbon dioxide, and 1,186 lb (27,000 ft3) of methane are produced [Hargraves 1973]. Most of these gases escape to the atmosphere during the coalification process, but a small fraction is retained in the coal. The amount of gas retained in the coal depends on a number of factors, such as the rank of coal, the depth of burial, the type of rock in the immediate roof and floor, local geologic anomalies, and the tectonic pressures and temperatures prevalent at that time. The gases are contained under pressure and mainly adsorbed on the surface of the coal matrix, but a small fraction of gases is also present in the fracture net-work of the coal. Methane is the major component of gases in coal, comprising 80%–90% or more of the total gas volume. The balance is made up of ethane, propane, butane, carbon dioxide, hydrogen, oxygen, and argon.

Jan 6, 2006

By John J. Sammarco

The U.S. Bureau of Mines seeks to increase safety and efficiency in U.S. coal mines. One approach is to develop technology for automation of a continuous mining machine. Realization of an autonomous mining machine requires development of subsystems for machine intelligence, navigation-positioning, and computer control. This report focuses on investigation of one subsystem, an onboard heading system, which would be responsible for determining and controlling machine heading. The onboard heading system investigated is a multisensor system to determine machine heading, pitch, and roll. A directional gyroscope provides heading (yaw), fluxgate sensors provide a compass heading, and gravity-referenced clinometers give machine pitch and roll. The system utilizes a dedicated microcontroller networked to an external system of computers. Tram commands, supplied to the network from external computers, are executed by the onboard system. Sensor feedback is employed for closed-loop control of machine heading by controlling pivots and turns. The report discusses operating limitations and error sources of system sensors and presents test results of closed-loop control of machine heading. Results of tests with a mining machine are used to exhibit various sensor shortcomings and to evaluate control of pivots and turns.

Jan 1, 1990

By Kermit G. Davis, Sean Gallagher, William S. Marras, Kimberly Kovacs

This study evaluated spinal loads associated with lifting and hanging heavy mining cable in a variety of postures. This electrical cable can weigh up to 10 kg per metre and is often lifted in restricted spaces in underground coal mines. Seven male subjects performed eight cable lifting and hanging tasks, while trunk kinematic data and trunk muscle electromyograms (EMGs) were obtained. The eight tasks were combinations of four postures (standing, stooping kneeling on one knee, or kneeling on both knees) and two levels of cable load (0 N or 100 N load added to the existing cable weight). An EMG-assisted model was used to calculate forces and moments acting on the lumbar spine. A two-way split-plot ANOVA showed that increased load (p<0.05) and changes in lifting posture (p<0.05) independently affected trunk muscle recruitment and spinal loading. The increase in cable load resulted in higher EMG activity of all trunk muscles and increased axial and lateral bending moments on the spine (p < 0.05). Changes in posture caused more selective adjustments in muscle recruitment and affected the sagittal plane moment (p < 0.05). Despite the more selective nature of trunk EMG changes due to posture, the magnitude of changes in spinal loading was often quite dramatic. However, average compression values exceeded 3400 N for all cable lifting tasks.

By W. P. Yant

A previous report of the Bureau of Mines dealt with the toxicity of dichlorodifluoromethane5, a new refrigerant that has a remarkably low toxicity. Continued research by the Prigidaire Corporation6 and toxicological experiments performed in the Laboratory of Applied Physiology of the University of Cincinnati7 revealed another organic fluoride, dichlorotetrafluoroethane, whose toxicity also appeared to be of a very low order and whose physical-and chemical properties make it suitable for refrigeration purposes. In addition to low toxicity, safety in its use is further enhanced by its physical properties, which permit the design of equipment that operates at comparatively low pressures and hence mitigates the dangers and problems of leakage. The investigation described in this report was performed by the Bureau of Mines at the request and with the cooperation of the Frigidaire Corporation.

Jan 1, 1932

By Frank Chase, M. Terry Hoch, George Karabin, Joseph C. Zelanko, Christopher Mark

Pillar recovery continues to be a significant ground control hazard. During the past decade, 10 miners were killed during pillar extraction operations in southern West Virginia. Studies conducted during the past decade have identified a number of “risk factors” that can be used to evaluate pillar extraction plans: •Cut sequence •Final stump •Timber or Mobile Roof Supports •Roof bolting •Intersection span •Depth of cover •Roof quality •Age of workings For each of these factors, rock mechanics science suggests which alternative would be expected to be more risky. For example, numerical models were used to evaluate different cut sequences, and indicated that less roof convergence occurred with the outside lift method than with the Christmas tree in the particular environment simulated. For many of the risk factors, accident statistics confirm the science. One finding was that currently almost 70% of the retreat coal in southern WV is being mined with MRS. In contrast, timber supports were used in 70% of the past decade’s pillaring fatalities. This paper discusses each of the risk factors in turn, presents the relevant accident statistics, and shows how the risk factors can be combined to estimate the overall hazard. It also addresses the use of pillar design to minimize the risk of global stability hazards including squeezes, massive collapses, and bumps.

By W. L. Hunter

The research on this report was conducted to obtain information on the feasibility of producing ferro chromium of varying silicon and carbon contents from domestic chromite. Concentrates from the Mouat deposit were chosen because they typify the chromite found in the Stillwater complex, the largest domestic reserve, and are similar in composition to other extensive North American and foreign deposits. Batch-smelting tests designed to produce high-, medium-, and low-carbon ferrochromium were made in single phase and three-phase, electric-arc, steelmaking furnaces. Agglomeration studies were made in a rotary kiln. Continuous smelting tests were made to yield data on the production of high-carbon ferro chromium and low-carbon ferrochromium-silicon. The carbon content of high-carbon ferrochromium was lowered to the medium-carbon range by oxygen injection. Mouat stockpile concentrates were nodulized in a gas-fired rotary kiln using quartz, limestone, and fluorspar additions in the proportion necessary to flux the slag. The nodules were smelted in a continuous test using coal, coal char, and mixtures of the two consecutively as reductants.

Jan 1, 1961

This publication is the fourth in a series of miners? circulars covering various phases of accident prevention in bituminous-coal mines; these circulars constitute a text hook for courses of instruction on accident prevention in bituminous-coal minim. To these may be added material of particular interest in the field where the course is presented. Other circulars in the series are: Accident Statistics as an Aid to Prevention of Accidents in Bituminous-Coal Mines (Miners? Circular 47). Accidents from Falls of Roof and Coal in Bituminous-Coal Mines (Miners&apos; Circular 48). Accidents from Hoisting and Haulage in Bituminous-Coal Mines (Miners&apos; Circular 49).

Jan 1, 1946

By Neldon L. Jensen

Although ASARCO Incorporated, the only domestic producer, had terminated copper smelting operations and associated recovery of byproduct arsenic trioxide at Tacoma, WA, in 1985, it shipped small quantities of both trioxide and metal from its remaining stocks in 1986. Imports for consumption of arsenic trioxide increased significantly, owing to increased demand for arsenical wood preservatives and the decrease in domestic shipments of trioxide. Prices remained unchanged throughout the year. Development of gallium arsenide integrated circuits, important in advanced military and commercial electronics circuitry, continued to gain momentum during 1986. Domestic Data Coverage.-Shipments of small amounts of arsenic trioxide and metal from remaining stocks by Asarco were reported voluntarily to the Bureau of Mines.

Jan 1, 1988

The National Institute for Occupational Safety and Health (NIOSH), in partnership with stakeholders in the mining and surface drilling industries, con-ducted research to develop engineering control technologies that reduce workplace noise exposure. The result of this research partnership is the development of a partial cab.

Jan 8, 2007

By J. L. Howell, D. E. Pollock, A. B. Cecala, A. D. O’Brien

Dust from worker,s clothes has been shown to be a problematic source of personal dust exposure. A recently completed effort between NIOSH and the Unimin Corporation has resulted in a quick and effective way to clean worker clothing. The process involves a booth under negative pressure with an air spray manifold to supply compressed air to blow off the dust from the clothing. The overall system is designed to meet MSHA and OSHA requirements. Results of field testing indicated that the manifold cleaned the clothes 10 times faster and removed 50% more dust than cleaning methods used by workers today.

By William S. Sanner

A demonstrated reserve base (DRB) of bituminous coal suitable for cokemaking has been estimated based on the latest published information on U.S. coal reserves. Bureau of Mines analyses of raw coalbed samples were used to classify the coals as low-, medium-, and high-volatile bituminous and grade them as premium, marginal, and latent coking coals. Coal rank was used as the basis for identifying coking coals, and ash and sulfur content were used to determine coking coal grade. The demonstrated reserve base of coking coal for the entire United States is 162.67 billion tons. However, only 18.96 billion tons are premium (metallurgical) grade, and between 80 and 99 percent occurs in the Eastern States. The demonstrated reserve base of marginal-grade coking coal is 31.3 billion tons; more than half the marginal reserve base is in the Eastern States, and most of the medium- and low-volatile marginal coals are in the Eastern States. The Eastern and Midwestern States contain most of the latent-grade DRB of 112.4 billion tons; most (106.6 billion tons) is high-volatile coal, and 98 percent of the medium- and low-volatile latent coals occur in the Eastern States. Based on the worst assumption, which assumes that only premium-grade coals are used for cokemaking, the DRB for high-volatile coal would suffice for 127 years, the medium-volatile coal for 80 years, and the low-volatile coal for 83 years.

Jan 1, 1979

By Vance G. Leak

A technique for recovering copper and steel from metallic scrap has been developed by the Bureau of Mines based on preferential melting in molten salt baths at 1,150° to 1,250° C, The molten salt, preferably barium chloride or calcium chloride, both minimizes oxidation of the metals and promotes heat transfer. Cleanest separations (0.01 percent copper remaining in iron) have been achieved by pretreatment (dipping or spraying) with sodium sulphate or sodium silicate, which alters and coats the surface of the iron to inhibit the alloying or brazing with copper. An economic evaluation of the process was carried out on six combinations of sweating media and inhibiting reagents. On the basis of the postulated model, a cost of about $0.20 per pound of copper recovered has been determined for the sweating treatment operation.

Jan 1, 1973