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Improve the dust control effectiveness of dry collection systems on surface coal mine drills. Approach Use a dust pelletizer to convert the respirable dust particles discharged by the dry collector into dust pellets that present no health hazard. Background Blasthole drills are well-known sources of respirable dust that can contain significant amounts of quartz. The drills frequently use a dry cyclone-filter type collector that can obtain dust reductions theoretically greater than 95 pct. However, surface mine drills using dry collectors typically have three major dust sources that significantly reduce the overall effectiveness of the collection system: (1) the dust collector dump cycle, (2) drill shroud leakage, and (3) leakage around the drill stem seal in the drill table.

Jan 1, 1989

By Timothy W. Beck

Roof bolter occupations in underground coal mines continue to experience overexposure to respirable dust. One potential source of dust in roof bolting operations is the exhaust from the roof bolter dust collection system. A wet exhaust conditioner (?water box?) has been developed to reduce dust emissions from the exhaust of the vacuum dust collection system on roof bolting machines. The exhaust conditioner consists of a muffler chamber and a water chamber with four internal partitions to direct airflow over the surface of the water. The National Institute for Occupational Safety and Health conducted a series of laboratory tests to assess the respirable dust capture ability of this device as compared to the standard exhaust muffler. To determine the dust collection efficiency, both devices were placed in the exhaust stream of a simulated roof bolter dust collection system. Gravimetric samplers were operated upstream and downstream of the exhaust conditioner and muffler to evaluate the ability to capture both respirable coal and limestone dust. Researchers observed a 41 percent reduction in dust concentrations for the water exhaust conditioner in the laboratory configuration. Significant levels of dust deposition in the sampling chambers may have contributed to this effective capture rate.

Jan 1, 2010

"There is considerable evidence that all mine dusts do not present the same health hazard. Rank of coal and composition, especially silica content of the mine dust, shape, and surface charge are risk factors that affect the incidence and severity of CWP. Current efforts of Center researchers involve characterization of:•,size/shape/composition•,surface and functional groups•,particle interactions.Work is underway to prepare and characterize respirable coal dust samples, and to develop and evaluate techniques and procedures for the characterization of respirable dust. A suite of standard samples including anthracite, medium volatile and high volatile bituminous coals, quartz, clay, and rock dust have been prepared and thoroughly characterized with respect to the distributions of particle size and compositions. A comparison of the morphology of the standard dust particles with similar particles collected in an underground coal mine is given in Figure 43. Samples of these characterized (Standard) dusts have been distributed among various research groups associated with the Center.The aerodynamic diameter of a particle is a particularly important characteristic since this parameter determines the point of deposition in the human respiratory tract. A 3-dimensional numerical model for theoretically determining the equivalent aerodynamic diameter of irregular shaped particles has been developed and used to analyze coal dust particles and a particle shadowing technique has been developed for .experimental 3-dimensional shape analysis (Figure 44). In the theoretical technique, the equivalent aerodynamic diameter of the particle is numerically determined from computation of the fluid drag on the particle. This allows the aerodynamic diameter of any regular or irregular shaped particle to be determined as a function of the particle's orientation or as an average over all particle orientations. The technique is quite accurate in that the aerodynamic diameter of several coal dust particles have been numerically determined to be within 5% of experimentally measured values."

Nov 1, 1988

Reduce worker exposure to respirable dust without interfering with bag-filling operations. Approach A dust control hood was developed which contains and captures dust close to its source and prevents it from entering the bag-filling operator's work place. How It Works A sheet metal hood is placed around the nozzle of the bag filling machine. The hood is connected through ducts to the plant exhaust ventilation system. Air pulled into the front of the hood and around the sides of the bag picks up dust generated inside the hood, and carries it to the dust collector. The size of the hood can be adapted to fit most fluidized valve-type bag-filling machines. The height of the hood depends on the bulk density of the product and weight of the bags being filled. The 14-inch-width of the hood allows it to be used on multi-nozzle baging machines spaced 16 inches on center. Only 2/3 of the bag is actually within the hood, and this allows easy operator access for placing the bags on the nozzle.

Jan 1, 1978

By Gregory J. Chekan

In This Chapter [Drilling, blasting, and crushers Diesel particulate Enclosed cabs Ventilation with jet fans Stopping construction methods Propeller fans as main fans] This chapter explains how to control dust in large-entry stone mines, including both silica dust and diesel particulate. Most stone mines are limestone mines, but a substantial minority are marble, sandstone, and granite mines. These mines differ from most others in that entry widths are 30 ft or more and entry heights are 25 ft or more. Such mines, developed with room-and-pillar methods, have large open areas that can make ventilation and dust control more difficult. Because of the difficulty of ventilating stone mines, improved ventilation is a major focal point of this chapter. However, the chapter also covers the control of dust from drills, blasting, and crushers. Another part of the chapter covers enclosed cabs, an effective dust control technique for some workers. BACKGROUND The major dust compliance problem in stone mines is caused by silica (quartz) in the rock. Mines in high-silica rock, 8% or more, are far more likely to have a dust problem than those where there is less silica. Geographically, the limestone in the Northeastern and South Central United States has higher silica than the rest of the country. Chekan and Colinet [2002] have analyzed Mine Safety and Health Administration (MSHA) dust sampling results [MSHA 2001] from the stone industry. They have concluded that, on average across the United States, the workers exposed to the highest dust concentrations are rotary drill operators, front-end loader operators, truck drivers, and crusher operators. However, there are many regional differences. Also, occupations that work outside of cabs, such as blasters, roof bolters, and laborers, can be exposed to high dust levels.

Jan 6, 2003

In This Chapter [Ventilation: dilution and displacement Water sprays: wetting and airborne capture Water additives: foam and wetting agents Dust collectors: filtration efficiency and inlet capture efficiency Reducing the generation of dust for cutting, drilling, blasting, crushing, and conveying] [This chapter will give you a general perspective on what works or doesn’t work. The chapter will also help if your dust control problem doesn’t fit any of the circumstances described in later chapters. ] This chapter describes the three major control methods used to reduce airborne dust in tunnels and underground mines: ventilation, water, and dust collectors. It also describes methods to reduce the generation of dust, so less has to be removed from the mine air. The ventilation methods provide the best use of air in the vicinity of workers and in the vicinity of dust sources. In this sense, the methods described are local ventilation methods. Most of the emphasis is on so-called displacement ventilation because it is the most effective dust control technique available. The section on water sprays outlines the dual role of sprays—wetting and airborne capture—and describes why wetting is more important. It also corrects some of the misconceptions about spray effectiveness and describes circumstances where sprays can actually increase the dust exposure of workers. The section on dust collectors outlines the circumstances under which dust collectors can be expected to function effectively. It also describes some common design and maintenance problems. The final section describes how to reduce the amount of dust that gets into the air in the first place, since once the dust is airborne it is always harder to control.

Jan 6, 2003

By J. P. Rider

Operating practices and resulting production from longwall faces are continually improving. Consequently, longwall operators are continually seeking to improve the dust control capabilities on longwalls. The National Institute for Occupational Safety and Health (NIOSH) has been conducting dust surveys at longwalls throughout the country in an effort to document the types of controls that are being used and to quantify the relative effectiveness of these controls. To date, surveys have been completed at longwalls in Alabama, Colorado, Pennsylvania, Utah, and West Virginia. In addition NIOSH has been reviewing longwall dust parameters provided by mine operators to MSHA to assess the status of dust control technology being used throughout the industry. Results from the underground dust surveys and information obtained from MSHA will be summarized in this paper to provide an update on longwall dust control technology and practices.

By Edward D. Thimons, Jay F. Colinet

Underground coal mining operations in the United States continue to increase productivity as mining equipment and practices are improved. Unfortunately, increased production also results in the potential for increased respirable dust generation and worker exposure. In response, US operations are applying basic controls at elevated levels and looking to emerging technologies in an effort to better control respirable dust levels. Ventilating air and water sprays remain the basis of dust control strategies for both longwall and continuous mining operations, and the level of application for these controls continues to increase. In addition, new technologies are emerging that have the potential to further reduce dust levels. The National Institute for Occupational Safety and Health (NIOSH) has been conducting research into methods to optimize existing control technologies and evaluate emerging control technologies. This paper will summarize control technologies routinely being used in underground coal mine operations, as well as provide a review of new controls that are being pursued.

By Welby G. Courtney

The Bureau of Mines conducted an exploratory field survey to determine the amount of airborne coal dust, the size distribution of the dust, and the rate of dust deposition in coal mine airways. The survey was taken at eight underground locations in operating coal mines. The rate of dust deposition in the airways depended upon the concentration of air-borne dust and decreased exponentially with distance from the dust source. The rate was seemingly independent of the size of the airborne dust particles. The rate of deposition, along a return, for the coal dust from a fade being mined with a continuous mining machine closely matched the rate for the rock dust from a trickle duster. A sample rock-dusting schedule for that return is presented; that is, the trickle duster should be operated for 3-112 hours after every five shifts to protect the average deposit of new float coal dust in the return, but operation after every three shifts is preferred, to protect an occasional heavier deposit.

Jan 1, 1982

Reduce respirable dust exposure of workmen operating auger-type continuous mining machines. Approach: An auger miner was fitted with an exhaust system which draws dust laden air through a [scruber] and discharges it behind the line curtain. How It Works: Dusty air is drawn into the space above the coal conveyor and through a scrubber, by two fans mounted side by side above the conveyor. Exhaust from the fans passes through a duct to the side of the auger miner, and into tubing that runs back and into the air return passage formed by the line curtain. See Figure 1. Of the 5,000 cubic feet per minute of air normally entering the working place, 4/5 is drawn out through the dust exhaust system. The system was installed on a Wilcox Mark 20 Miner and tested underground by personnel of the Bureau's Pittsburgh, Pa., Mining and Safety Research Center, under a cost sharing

Jan 1, 1976

By R. V. Ramani, R. Bhaskar

"The results .of an experimental and theoretical research study into the spatial and .temporal behavior of dust in mine airways is summarized in the paper. Experiments were performed in mine airways under both controlled and .normal operating conditions. The controlled experiments included the documentation of the concentration and deposition patterns for two types of dust under three different velocities. Real-time dust concentration data were obtained using Real-time Aerosol Monitors (RAM-1) to determine the dispersion coefficient in a mine airway. On the theoretical front, a convection diffusion model of the dust flow phenomenon in mine airways was developed considering dominant mechanisms affecting dust transport and deposition in mine airways. Mechanisms modeled include turbulent and gravitational deposition, coagulation, and dispersion.In this paper, comparative analyses of results of the controlled experiments with the predictions of the mathematical model are presented. In addition to the overall validity, the adequacy of the individual components of the model, such as deposition in the total and respirable range, and dispersion are examined in light of the experimental observations.The experimental data from controlled experiments compared more favorably with model predicted results for similar conditions as opposed to the ·comparative analysis results for in-mine experiments. Specifically, the model· predictions for an 800-meter stretch of a mine airway reveal some significant differences from the behavior noticed in the mine. The deposition was lower than that predicted by the model. Consequently, concentrations were higher than those predicted by the model. The implications of these and other findings for further investigations are discussed in the paper."

Aug 31, 1989

Provide respiratory protection and a clean work environment for stationary or semimobile workers at minerals processing plants. Approach An Overhead Air Supply Island (OASIS) was developed which filters, conditions, and evenly disperses an envelope of clean air over a worker's head, thereby insuring reduced dust levels and a clean work environment. How It Works The concept for the OASIS derives from an earlier Bureau development of a canopy air curtain for continuous mining machines (see Technology News #21). In this application, the benefits of a reliable, self-contained, self-cleaning industrial-duty air filtration and distribution system are extended to the minerals processing field. The OASIS draws dust-laden room air into a filtration system, removing the dust and delivering clean air to a specific 16-square-foot area. It consists of: ? a self-cleaning primary filter ? a heater (cooling coil optional) ? an airflow distributor and secondary filter (combined)

Jan 1, 1985

Rank the dust knockdown (airborne capture) ability of six different types of water spray nozzles, Approach A fixed quantity of dust is released into a large, closed chamber in a laboratory. Water sprays are turned on inside the chamber and their effectiveness on the dust cloud is evaluated from the rate at which the dust disappears. This method better simulates dust suppression underground than methods tried earlier. The results of the laboratory test were confirmed by conducting tests on a full-scale mod-el continuous miner face where dust levels were measured in the return airway. Results of the Closed Chamber Tests The graph indicates that atomizing nozzles provide the best use of water for dust scrubbing. However, use of these nozzles is limited by their susceptibility to damage and clogging. Hollow-cone nozzles perform almost as well as atomizing nozzles. Test results also indicate that full-cone, venturi-assisted, and flat-fan spray cones are about two-thirds as effective as hollow-cone nozzles. The least effective were venturi nozzles designed for moving air. The most significant advantage of hollow-cone nozzles over other nozzles tested is reduced clogging due to larger orifice size. The hollow-cone nozzle used in the test and depicted by the graph was type BD-3 manufactured by Spraying Systems Co., Wheaton, IL. This nozzle is already used on many continuous miners. Other hollow-cone nozzles of

Jan 1, 1982

By Jon C. Volkwein

Dust concentrations inside and outside enclosed cabs on several types of mining machinery were measured by the Bureau of Mines. Results indicated that properly enclosed cabs can offer significant dust protection for machine operators. Recommendations for improvements in cab technologies were discussed.

Jan 1, 1979

Bag stackers who use semi-automated palletizing machines and air slides may be exposed to high concentrations of dust. To reduce dust exposure, use an exhaust ventilation system in conjunction with an envelope of clean air over the bagstacker provided by an overhead air supply. Description of Hazard Mineral processing plants in the United States and throughout the world process material that is finely ground and placed into bags for shipping to the consumer. These bags normally range from 50 to 100 pounds in weight. Once the material is placed in these bags, a bag stacker loads the bags onto pallets. A bag stacker is exposed to a lot of dust that is mainly released by the force from loading the bag onto the pallet. The two main sources are the dust on the outside of the bag and the dust that escapes from inside the bag as it is loaded. The Mine Safety and Health Administration's (MSHA) records indicate the bag stacker's dust exposure is one of the highest of all workers at mineral processing operations. Ways to reduce the dust exposure and strain to the bag stacker are in constant development. Recently, automated systems have been built. These systems range from fully automated, which totally remove the worker from the bag-stacking process, to semiautomated systems, in which the bag stacker still performs some of the functions. This Hazard Control deals with controlling the bag stacker's dust exposure during use of a semi-automated palletizing machine. The worker slides the bags into position on the palletizing machine. Once an entire layer of bags is positioned, the bag stacker operates the controls on the palletizing machine to lower the layer of bags onto the pallet. An air slide is built into the semi-automated palletizing machine so the bags are easier to move. This slide uses a metal table with air jets that exit through small holes at high velocities, similar to an air hockey game. The dust problem occurs because the air slide causes dust to blow up onto the bag stacker, significantly increasing the dust exposure.

Jan 7, 2001

By William A. Hoffman

In This Chapter [MSHA regulations for coal mines MSHA regulations for metal/nonmetal mines OSHA regulations for tunnel construction Types of respirators used in mines and tunnels Filter materials and filter efficiencies Donning, seal checking, and maintenance Filter service life and Respirator information resources] In many cases, engineering controls are not adequate to achieve satisfactory dust levels, so respirators must be used. This chapter explains the Federal regulations governing the use of dust respirators in mines and tunnels and describes the most common dust respirators used. Filter materials and filter efficiencies for respirators are discussed. This chapter also gives some guide-lines for respirator use and recommends sources for more dust respirator information. Respirator effectiveness in reducing dust exposure usually exceeds the effectiveness of most engineering control methods. RESPIRATOR REGULATIONS [Different regulations govern respirator use in coal mines, metal/nonmetal mines, and tunnels under construction.] Coal mines under Mine Safety and Health Administration (MSHA) jurisdiction. Coal mine operators are required to meet dust standards using only engineering control methods. Typical engineering control methods include ventilation and water sprays. Respirators are not regarded as an engineering control method, so respirators cannot be used in lieu of engineering controls.

Jan 6, 2003

By R. V. Ramani, R. Bhaskar

"The National Academy of Sciences (1) recognized the importance of studying the spatial and temporal characteristics of respirable coal mine dust atmospheres. In this paper, the progress to date of a research project on dust transportation and deposition in mine airways is presented. A mathematical model is proposed for studying the transport of dust. A source representative of dust generation in underground coal mining is defined. The influence and applicability of surface roughness, dispersivities, coagulation and reentrainment to vine dust flow arc examined. A convective-diffusion model is proposed for the transport and deposition of dust in mine airways. Using the model, the spatial and temporal characteristics can be evaluated in terms of dust concentrations in the mine atmospheres.INTRODUCTIONThe prediction of the behavior of fine particles Is Important in many fields of science and engi¬neering including physics, chemistry, mining, mineral processing, and atmospheric science. In mining from the health point of view, fine coal dust is associated with the appearance of pneumoconiosis in miners exposed to the dust. Also, in addition to being a nuisance factor obscuring visibility and general mobility of miners, it can lead to sudden catastrophic incidences of explosions. This paper outlines the progress to date of a research project on dust transportation and deposition in mine airways. A mathematical model is proposed for studying the transport of dust for the various mechanisms. The dust dispersion is defined in terms of a dispersion term determined from experimental data by Skubunov (23). Coagulation is considered as one of the mechanisms that can lead to changes in the particle size distribution. Reentrainment as a possible secondary source of dust was examined during model development but was not included in the final model."

Jan 1, 1988

By Andrew Cecala, John Organiscak, William Heitbrink

Many types of heavy equipment used in the mining and construction industries use enclosed cabs to protect equipment operators from dust and noise exposure. Normally, when the equip- [ ] ment is new, manufacturers' deigned controls are effective at keeping the operator's exposure at acceptable level. However, as equipment becomes older and many components of the enclosure deteriorate, such as gaskets and seals, the effectiveness of the enclosed cab can be greatly reduced. This can cause excessive and dangerous exposures to respirable dust, especially when the ore or overburden contains crystalline silica.

"The dust/lung research of the Center has several long-range objectives:* better methods for the early diagnosis of coal workers' pneumoconiosis (CWP);* methods to modify the disease process;* tests to identify toxic products; and* tests to identify individuals with heightened susceptibility to pneumoconiosis.A major immediate objective is to define the mechanism of dust-induced lung disease. This means determining:* dust characteristics that are important in causing lung diseases;* important interactions between dust and lungs; and* earliest detectable stages of the disease.Several of the Center's projects involve exposing lung cells in culture (in vitro) or animal lungs (in vivo) to samples of the suite of characterized mineral dusts described earlier. The responses of the lung cells or tissues to the dusts are being studied in order to better understand how inhaled dusts cause lung disease.One project is studying the effect of dust exposure on the production of mucus by rat tracheal explants in vitro. Mucus is a major factor in clearing inorganic dusts from the lung. Results thus far have shown that exposure of tracheal cultures to coal dust caused a decrease in micin production in comparison to parallel cultures without dust. To examine the effect of in vivo coal dust exposure, rats were maintained in an inhalation chamber for two weeks, and control rats were in an identical, but dust-free chamber. Tracheal explants results indicate that the effect of in vivo dust exposure is similar to that noted in the in vitro experiments.Pulmonary alveolar macrophages (PAMs) are a key component of the lung's response to inhaled particulates, and they play several important roles in pulmonary inflammatory and repair processes. PAMs are the cells that actually ingest dust particles. Other studies have shown that they play a critical role in the development of silicosis and asbestosis. The Center is studying the effect of dust exposure on the release of oxygen free radicals (superoxide) by PAMs. Intercellular production of superoxide occurs when PAMs phagocytize particles, such as inhaled bacteria, and is an essential mechanism by which PAMs kill ingested, bacteria. A number of complex physiological events occur during this process which are not clearly understood. It is thought that PAMs containing indigestible materials, such as mineral dusts, overproduce superoxide, or inappropriately release it into the surrounding tissues. If true, this would cause toxicity to surrounding lung cells by peroxidation of the lipids in the cell membranes. In vitro exposure of PAMs to low or high doses of kaolin is inert. Preliminary studies indicate that coating the quartz particles with a surfactant reduces toxicity."

Nov 1, 1988

"As stated earlier the primary goal of the Generic Mineral Technology Center for Respirable Dust is to reduce the incidence and severity of respirable dust disease through advancing the fundamental understanding of all aspects of respirable dust associated with mining and milling and the interaction of dust and lungs. While initial work was directed to coal dust the charge to the dust center has been expanded to include diesel particulates and asbestosis, the latter of deep concern not just to workers in the mineral sector of the economy but also to the general populace.A major facet of Dust Center research has been the analysis and documentation of comprehensive research protocol and procedures that are appropriate state-of-the-art in the various areas of respirable dust. In addition to definition of standardized research protocols and procedures which would be utilized by center personnel for uniformity and reproducability there is a considerable need for utilizing standardized respirable dusts in experiments with consistent, reproducible characteristics which simulate those of actual mine dust. This respirable dust needs to be available in large quantities for a wide variety of research uses that include animal and medical experiments. The dust must be free of the lubricating oils and grinding wheel contaminants that are frequently encountered in laboratory generated dusts.The holistic approach to establishing standardized protocols and procedures applicable to the five major research areas of the center is presented in Figure 5.In one hypothesis, range in coal volatility is considered to be a major causal factor in the incidence and severity of pneumoconiosis. Therefore a suite of characterized standard respirable dust samples have been prepared for researchers from coals representing the western (high volitile A bituminous), central (medium volatile bituminous) and eastern (anthracite) mining areas of Pennsylvania. Quartz, limestone (rockdust) and kaolin clay samples, representing important mineral constituents of coal dust have also been prepared.A suite of medical investigations have been developed utilizing small and medium size animals as well as non-human primates in a variety of dust/lung interaction projects which will be discussed in the next section. A number of respirable dust sampling and dust generation methods have been investigated and selected techniques utilized for both in-mine and in-laboratory research investigations. These will also be discussed in more detail later. A wide range of respirable dust size, chemical and mineralogical analyses have been investigated, standardized and documented for use in various research investigations.This interaction and documentation of various respirable dust sample procedures, animal and medical tests, sampling and dust generation methods, plus size, chemical and minerological analysis applied in the five major areas of research investigation have served to create a very favorable synergism and rapid technology transfer in the respirable dust center."

Jan 1, 1988