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By David C. Oyler, Dennis R. Dolinar, Christopher Mark, Craig S. Compton

Fully-grouted roof bolts comprise more than 80% of the primary roof supports used in U.S. coal mines. However, nearly 1,500 MSHA reportable, non-injury roof falls occur each year, and most of these are attributable to failure of the roof bolt system. Anchorage failure is one failure mechanism for fully-grouted bolts. As roof deformation works its way upward, the bolts can become heavily loaded near their upper ends. If the applied load exceeds the anchorage, the bolts will simply pull out. Research dating back 30 yrs indicates that this type of anchorage failure is most likely when the roof rock is weak, just where roof support is most critical. In soft shale or coal roof, the small amount of data available in the literature indicates that 20-30 in of resin anchorage may be required to achieve the full capacity of the bolt. In other words, the “full resistance zone” of a 60 in bolt may actually be just 30-40 in. Despite its potential importance, there is no widely accepted anchorage test for fully grouted bolts. Standard pull tests have sometimes been employed, but they provide no information on the anchorage near the top of the bolt. An alternative, first described more than 25 yrs ago in the U.S., is the short-encapsulation pull test (SEPT). With this test, the bolt is installed with only a short (1 ft or less) tube of resin. In recent years variations of this test have become international standards. v

By D. R. Flinn

A newly developed chemical conditioning technique, which greatly simplifies the preparation of plating baths for the electrodeposition of titanium diboride (TiB2) coatings, is described in this report. The new plating technique was used to prepare samples of titanium diboride (TiB2) coatings on three types of substrate materials. These samples were then evaluated in both low- and high-speed wear-test programs to determine the wear resistance, microhardness, and adhesion of the coatings. In general, it was found that the wear resistance of the coatings is independent of substrate. Scanning electron micrographs have shown that the coating wear surfaces are very smooth, suggesting slow and continuous removal of the coating during the wear test (that is, adhesive wear). Adhesion between the coating and all substrates was excellent. Microhardness results show that the TiB2 coating is harder than alumina, with a hardness value exceeding 5,000 kg/mm2 measured in one test. The results of the wear tests show that TiB2 coatings have relatively poor wear resistance compared with alumina in low-speed unlubricated sliding environments, but exhibit wear properties comparable with alumina in high-speed unlubricated sliding environments.

Jan 1, 1981

By Sam S. Taylor

Subsurface disposal of oil-field brines was practiced in Oklahoma on a limited scale as early as 1925. The technique of subsurface injection has been improved immensely and has been applied with varying success in many oil-producing areas in Oklahoma, and elsewhere. This method of disposal, however, is only one of several methods available to operators of oil-producing properties, but, in contrast with usual methods of handling brines on the surface it eliminates the damaging effect of mineralized water on fresh-water supplies, vegetation, and aquatic and other animal life. Other methods of brine disposal approved by regulatory agencies in some States include (1) impounding in impervious ponds and solar evaporation, (2) controlled diversion into surface waters, and (3) recovery of the mineral salts of the brine. In most, States where oil is produced regulatory bodies authorize the use of one or more of these methods of brine disposal. In Oklahoma, for example, the Oklahoma Planning and Resources Board of the Conservation Commission has been authorized to adopt whatever methods or means may be necessary to prevent contamination by mineralization of all potable waters within the State.

Jan 1, 1942

The Bureau of Mines conducted large-scale laboratory copper ore leaching tests to enable improving copper recovery from large dump-leaching operations. This was done by comparing leaching progress when copper was recovered from recycled leach liquor either by cementation or by solvent extraction. Copper was leached from 7-ton ore samples at room temperature using pH 2 ferric sulfate solutions. With are samples containing 11 percent minus 0.5-inch fines, no marked advantage in using either of the copper recovery methods was evident after 416 days of leaching. With ore containing 32 percent minus 0.5-inch fines, solvent extraction of copper was advantageous in that 60 percent of the copper was extracted after 568 days, whereas only 48 percent of the copper was extracted when cementation was used. Less acid was consumed during leaching when solvent extraction, rather than cementation, was used for copper recovery. Iron, contributed by cementation with scrap iron, plugged the ore bed containing 32 percent fines.

Jan 1, 1981

By Kenneth H. Johnston

This publication describes a thermal-recovery project and two waterflood projects in Carter, Garvin, and Stephens Counties, Okla., that will be visited during the 1966 annual tour by the Bureau of Mines in cooperation with the Kansas-Oklahoma Waterflood Association. Among the unique features of the projects arc (1) the movement of heavy (15° to 28° API gravity) crude oil through the reservoir and into the well bore with energy furnished by burning a portion of the crude oil therein; (2) the use of an inverted nine-spot pattern with dually completed injection wells, to produce oil from deep (8,200 to 10,200 feet) reservoirs; and (3) the flooding of five sand lenses separately by using controlled water injections through multizone completed injection wells. Discussion of the individual projects includes information on their early history, method of completing and operating wells, source and treatment of injection fluids, oil production decline curves, and the results obtained from the development.

Jan 1, 1966

By S. Gallagher, A. G. Mayton

Back injuries account for a high proportion of lost workdays in the mining industry and are a leading cause of disability in mine workers. Two risk factors for low back injuries are manual lifting and whole-body vibration exposure when operating mobile equipment. Recent research has shed light on possible mechanisms through which low back injuries may occur, and the results of these studies can be used to improve the design of lifting tasks and seats to decrease injury risk. This article discusses recent research results and how this knowledge can be leveraged to reduce the risk of low back pain.

By Kenneth H. Johnston

This publication describes a thermal-recovery project and two waterflood projects in Carter, Garvin, and Stephens Counties, Okla., that will be visited during the 1966 annual tour by the Bureau of Mines in cooperation with the Kansas-Oklahoma Waterflood Association. Among the unique features of the projects arc (1) the movement of heavy (15° to 28° API gravity) crude oil through the reservoir and into the well bore with energy furnished by burning a portion of the crude oil therein; (2) the use of an inverted nine-spot pattern with dually completed injection wells, to produce oil from deep (8,200 to 10,200 feet) reservoirs; and (3) the flooding of five sand lenses separately by using controlled water injections through multizone completed injection wells. Discussion of the individual projects includes information on their early history, method of completing and operating wells, source and treatment of injection fluids, oil production decline curves, and the results obtained from the development.

Jan 1, 1966

By R. G. Gürtunca

Over the past century coal miner safety and health has seen tremendous improvements, the fatality and injury rates continue to decrease while productivity continues to increase. Many of the hazards that plagued miners in the past, such as coal bumps, methane and coal dust explosions, ground fall accidents and health issues have been significantly reduced. The contribution of NIOSH research includes products for prevention and survival of mine fires, methane control measures, design procedure for underground coal mines, methods for excavation surface controls, methods and procedures for blasting, laser usage in underground mines and prevention of electrocution from overhead power lines that have reduced accidents and injuries in underground coal mines. Health research has produced products such as the personal dust monitor, noise abating technologies and ergonomic solutions for equipment operators. Research priorities at NIOSH are set by considering surveillance statistics, stakeholder inputs and loss control principles. Future research in coal mining is directed towards respiratory diseases, noise induced hearing loss, repetitive musculoskeletal injuries, traumatic injuries, falls of ground and mine disasters. The recent spate of accidents in coal mines resulted in the Miner Act of 2006 which includes a specific role for NIOSH in future mine safety research and development. The mine safety achievements in the USA reflect the commitment of industry, labour, government and research organizations to improving the safety of the mine worker.

By M. R. Geer

Information on the performance of coal-cleaning equipment is necessary to provide a basis for evaluating the performance of existing plants and projecting that of new plants. Performance data can contribute greatly to the wise selection and effective use of coal-washing equipment. The Bureau of Mines has published information on the performance of several commercial plants, as well as of some laboratory-scale equipment, 5 (2-9, 11, 12, 17-12, 21-25) from time to time for a number of years. A more intensive program to provide such information for all the principal types of cleaning equipment is underway. The present evaluation of table performance is part of this program.

Jan 1, 1962

By R. H. Hiltz

The Coal Mine Health and Safety Act of 1969 legislated maximum dust levels for the working place. As the law was implemented, extensive efforts were undertaken to provide the technology necessary to control dust generation. One approach to dust control was the use of high expansion foam in place of the usual water sprays on coal cutting equipment. At the time of the act, high expansion foam had already seen considerable testing for the suppression of dust in underground coal mines. Work by MSA, several coal companies and the Bureau of Mines itself had provided data which showed foam to have some merit as a dust control mechanism. It suffered in a few areas, however, which limited its practical application. Its principal difficulty was persistence which hampered operations due to foam buildup, but problems were also encountered due to equipment size and form.

Jan 1, 1975

By M. L. Bowser

Pulse-forming circuitry is described for use in explosives research that requires precise synchronization and control of events in order to investigate detonation parameters. Included are pulse generators for oscilloscope sweep control, counterchronograph actuators, and a raster-type oscillographic method for the determination of velocities of detonation that are applicable to studies on solid, liquid, and gaseous detonations. INTRODUCTION Prom time to time, requests have been received for information on electronic circuitry used in explosives work at the Explosives Research Laboratory, Bruceton, Pa. The methods used are not entirely original;4 5 6 however, modifications of earlier techniques and some novel design aspects have resulted in time-tested methods that warrant a more detailed description.

Jan 1, 1962

By W. S. Sanner

Anthracite was used extensively as a fuel in iron metallurgy from 1840 to 1880. In 1874, 226 of the 680 blast furnaces in the United States were operating on anthracite and producing almost one-half of the Nation's pig iron. However, by 1890, railroad expansion, the development of western iron-ore reserves, and the growing use of coke decreased the importance of anthracite as a metallurgical fuel. As a result, the last blast furnace designed exclusively for anthracite use was built in 1891. Because of the increased energy requirements of our expanding national economy, the abnormally high demands during national emergencies, and the proximity of anthracite deposits to eastern steel-producing areas, interest has grown in again using anthracite in iron metallurgy. Estimates of anthracite reserves indicate a 300-yr. supply at a production rate of 30 million tons per year. These large reserves dictate the development of an adequate technology for the use of anthracite by the metallurgical industry.

Jan 1, 1961

By B. J. Moore

This Bureau of Mines publication estimates that U.S. helium resources as of January 1977 were 710 billion cubic feet. These resources are broken down into four classifications, as follows: Helium in measured natural gas resources and in storage, 201 billion cubic feet; helium in indicated natural gas resources, 150 billion cubic feet; helium in hypothetical natural gas resources, 175 billion cubic feet; and helium in speculative natural gas resources, 184 billion cubic feet.2 Most of the helium in natural gas is presently dissipated as natural gas is consumed as fuel and for other purposes. Helium resources of the United States may also be divided into three other categories: (1) Depleting and undiscovered natural gas resources, 589 billion cubic feet; (2) nondepleting natural gas, 83 billion cubic feet; and (3) storage, 38 billion cubic feet, of which 37 billion cubic feet is federally owned and 1 billion cubic feet is privately owned. The United States does not have any significant leasehold rights in the depleting fuel gas resources. However, through the Department of the Interior, it does have leasehold rights to about 70 percent of the helium found in nondepleting natural gas, and it owns over 90 percent of the helium in storage.

Jan 1, 1979

By E. F. Divers

This Bureau of Mines report describes the results of a program to develop small, rugged mechanical dust collectors (scrubbers) with high dust collection efficiency and low energy comsumption for controlling dust in coal mining operations. All of the scrubbers described are similar in configuration and are powered by 6-hp, 2,000-ft3/min vane axial fans. Air pressure differential is less than 6 inches water column. Height of the scrubbers? including fan is less than 14 inches, width is less than 16 inches, and length is less than 45 inches. The flooded fibrous-bed scrubber achieved respirable (less than approximatey 7 µm) dust collection efficiencies of 95 percent. The small-diameter-cyclone scrubbers showed about 92 percent efficiency and can be best where excess water is a problem. The wetted brush scrubber showed 88 percent efficiency at low cost, and the wetted fan scrubber showed a slightly lower efficiency (87 percent) but offered the smallest size and cost. A suitable water droplet eliminator is described.

Jan 1, 1978

By Charles Vaught, Kathleen M. Kowalski

Safety and health professionals from all sectors of industry recognize that training is a critical element of an effective safety and health program. A major concern in the mining industry is how to train both an aging workforce and the expected influx of new miners and mine managers as older workers retire. Thus, a review of some of the basic principles of adult learning may be helpful to mine trainers. This paper discusses the principles of adult learning based on research in education and psychology. It stresses the importance of taking a systems approach to training, focusing on the relationship between the environment and technology, and understanding how workers interact with both. The authors argue that the principles of adult learning and a systems approach are fundamental to the delivery of effective training in the mining industry. Examples of training programs developed by the Pittsburgh Research Laboratory of the National Institute for Occupational Safety and Health are presented within two broad performance domains: routine and nonroutine skills. Basics of curriculum development are also briefly presented to provide the mine trainer with a template for program development.

Jan 1, 2002

By P. C. McWilliams

Theoreticians in soil mechanics have been pursuing a probabilistic approach to the factor of safety of an embankment or darn for the past 10 years. The motivation for this work is in contrast to the current practice of deterministically computing a factor of safety and treating it as an absolute with no regard to its inherent statistical variability. Basic to the probabilistic approach is the selection of an appropriate statistical model to represent the histogram or probability density function (PDF) of the factor of safety values, Rather than simply assuming which PDF is appropriate, the Bureau of Mines collected data at two waste disposal embankments for consideration, This report addresses three candidate models, using the techniques of nonlinear curve fitting, and identifies the "best" model. A propagation of error formula for estimating the variability of Fellenius? factor of safety is also discussed.

Jan 1, 1983

In Bureau of Mines research on recycling chrome refractory wastes, used refractories from argon-oxygen decarburization and electric steelmaking furnaces were beneficiated, concentrates were reformed into briquets, and modulus of rupture tests were conducted at 1,350° C. The test results indicated that the beneficiated minus 6-mesh material could be used for producing magnesia-chrome refractories.

Jan 1, 1980

By M. B. Balachandra

A three-dimensional finite element analysis was performed of an instrumented section of a double-entry coal mine in order to provide a comparison between field measurements and existing analytic techniques. The BMINES computer code was used to perform the analysis. The sequence of excavation of the entries was considered, as well as the installation of rock bolts and cribbing during the mining cycle. The materials In the region under investigation were idealized into four rock types and coal. The rocks were assumed to be isotropically elastic, perfectly plastic. Coal was represented by an elastically anisotropic (transverse isotropy) and plastically isotropic model. A fracture yield criterion of the Coulomb form was used for all materials. The strength and stiffness of all materials were substantially reduced from available laboratory data to account for in-situ properties. Qualitative trends and stress distributions obtained from the calculation were found to be reasonable. However, computed displacements and closures were greatly exaggerated and an excessive degree of inelastic deformation was indicated in the coal, especially adjacent to the excavated faces. It was established that both these effects were the result of an excessive reduction in the strength and stiffness of the materials. The analysis underscores the need for three-dimensional calculations by identifying a number of important structural response parameters that would be either outside the scope of, or misrepresented by, two-dimensional analyses. The analysis also emphasizes the need for comprehensive and accurate measurement of material properties in order fully to exploit the power of the analytical techniques to generate reliable predictions.

Jan 1, 1976

By W. Reed

During the 20th century, the increased emphasis on worker health and safety and the advent of new mining equipment and methods led to many changes in mine face ventilation practices. Efforts by government and private industry to improve and modify ventilation practices resulted in better health and safety conditions for workers. This paper examines factors that had a significant influence on mine face ventilation design during the past century. Several “milestone” events are discussed along with the impact they had on worker health and safety. Significant ventilation research efforts by government and private industry are presented. This brief ventilation history highlights innovative ventilation designs and a consistent commitment to mining health and safety.

By Philip K. Hopke

A systematic study of the mechanism of interaction of 218Po(RaA) armed by the decay of 222Rn with airborne particulate matter has been made. The rate of attachment of RaA to particles in the diameter range of 0.1 µm to 10.0 µm has been measured as a function of particle size, concentration, and composition, radon concentration, time of interaction, relative humidity and temperature. It was found that under the conditions in these experiments the attachment rate was proportional to the square of the particle diameter and varied with temperature and relative humidity. The composition of the particles apparently has no effect on the attachment. The variation in attachment rate was related to a sticking probability coefficient of approximately 0.02 that varies systematically with temperature and humidity. In addition, the rate of deposition of RaA on the wall of the attachment kinetics system was measured and also found to change with temperature and relative humidity.

Jan 1, 1980