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By Forrest T. Moyer

Injury experience at coal mines and mechanical-cleaning plants (excluding officeworkers ) in 1967 was 222 fatal and 10,115 nonfatal disabling work injuries during an exposure time of 241.8 million man-hours. These injuries occurred at a frequency rate of 42-75 per million man-hours worked; the severity rate was 7,699 days lost or charged per million man-hours. Each of these general measures of injury experience was lower than similar data recorded for 1966. Employment at 6,885 coal mines and 569 mechanical-cleaning plants, excluding officeworkers, averaged 139,312 men in 1967. The average number of days worked was 220. Coal production totaled 560.8 million short tons, at rates of 2.32 tons per man-hour and 18.32 tons per man-day. A total of 2,779 onsite officeworkers at coal mines and mechanical- cleaning plants worked 5.2 million man-hours in 1967 without a disabling work injury.

Jan 1, 1972

By Russel Bohn

The purpose of this study was to evaluate the various techniques far mine roadway dust control. This evaluation included (a) the types of dust suppressants available, (b) the interaction of these products with the properties of the roadway surface, and (c) the costs and performance measures of the predominantly used dust suppressants. Over 30 products were identified having a wide range of effectiveness depending largely on the properties of the road base, subsurface, and wearing surface. The effectiveness of a dust suppressant was also found to depend on the application and maintenance procedures employed. As a result of this investigation five dust suppressants were identified s being predominant in the surface mining industry: Coherex, wetting agents, lignin sulfonate, water, and calcium chloride: An approximate cost-effectiveness analysis, limited by the lack of quantitative field performance data, showed that the five suppressants ranked in the order given above, with water being one of the least cost effective. This report also presents an analysis of applicable federal and state regulations.

Jan 1, 1981

By Harry R. Nicholls

The objectives of this investigation were to determine the strain propagation laws for a strain pulse in salt and to compare the seismic effects from the detonation of different explosives in salt. The investigation showed that a strain propagation law of the type, e = K(R/W 1/3 ) n, and a strain energy propagation law of the type, Ea/W 1/3 = K(R/WI/3)b , are valid in salt. A change in the regression law coefficient, n , was noted with strain level. A similar change in b was inferred because strain energy is proportional to the square of strain amplitude. Particle velocity data may be used interchangeably with strain data under the test conditions.

Jan 1, 1962

By P. L. Woolf

Blast furnace coal injection tests conducted by the Bureau of Mines in cooperation with a consortium of 22 steel companies in 1963-1964 are described. These tests were part of a program of extensive investigation of auxiliary fuel injection in the Bureau's experimental blast furnace located at Bruceton, PA. Seventeen coal tests are described on various coals ranging from anthracite to subbituminous. Factors affecting maximum rates of injection were studied. These included coal size, coal type, and oxygen enrichment. The effect of high sulfur content coal and the means to control metal sulfur were investigated. An epilogue briefly describing the commercial experience with coal injection from 1960 to the present has been included.

Jan 1, 1985

By D. S. Burgess

About 100 tests of flammability were carried out with H2, CH4, and CO in mixtures with air using the Federal Bureau of Mines 12-ft-diameter spherical pressure vessel as an explosion test chamber. The LeChatelier approximation gave slightly conservative estimates of the limits of downward flame propagation (onset of significant pressure rise) using the following measured values for the individual gases, in percent: H2, 8.5; CH4, 5.25; CO, 13.0. No justification could be offered for using the LeChatelier law for upward flame propagation limits and indeed reported data suggest that calculated values would not be conservative. The observed upward limit for methane-air mixtures (4.85 pct) was less than the widely accepted lean limit for this fuel; those for lean hydrogen-air mixtures and carbon monoxide-air mixtures did not differ from the lowest accepted values. Diffusional effects on the propagation of single, binary, and ternary fuel mixtures are discussed.

Jan 1, 1982

By L. B. Berger

The Haldane gas-analysis apparatus used by the Bureau of Mines is patterned after the device developed by Haldane 4/ and differs from it only in structural modifications that have been added to facilitate operation and simplify construction. The apparatus was developed to permit determination of carbon dioxide, combustible gases, and oxygen with a degree of accuracy not attainable with apparatus of the types ordinarily used for the analysis of fuel gases, flue gases, and similar mixtures. The Haldane apparatus is used by the Bureau of Mines chiefly in the analysis of air samples collected in coal and metal mines and other underground workings and is applied also in the analysis of many other types of gas mixtures when accurate determination of certain constituents is desired.

Jan 1, 1938

By Verne E. Hooker

This Bureau of Mines report summarizes the results of modifications in the borehole deformation gage design and subsequent changes in the overcoring techniques. Modifications in the borehole deformation gage have greatly improved the creep characteristics and enhanced the versatility of the gage. In situ field tests in competent rock near St. Cloud, Minn., provided sufficient data to compare the reliability between gages and new techniques in obtaining good engineering estimates of stresses. Near-surface horizontal stresses at the test sites are compressive and biaxial in nature.

Jan 1, 1974

By Russell E. Griffin

The current state-of-the-art of fire and smoke detection technology is reviewed from the standpoint of suitability for use in underground metal and nonmetal mines. Detection modes, fire signatures, and environmental considerations are included. Preliminary results of long-term in-mine tests are presented.

Jan 1, 1979

By M. M. Wong

The Bureau of Mines, under a cooperative research program with four lead companies, has investigated a nonsmelting process for the production of lead metal. The process, which would eliminate sulfur dioxide generation and minimize particulate lead emissions, involves ferric chloride leaching of galena concentrate to produce lead chloride, followed by molten-salt electrolysis of the lead chloride to yield lead metal and chlorine. This chlorine is used to regenerate ferric chloride in the leaching solution. The process was tested in an experimental unit with a capacity of 500 lb of lead metal per day. The tests were performed in three 10-day and six 5-day campaigns, during a period spanning 28 mo. The study was carried out using a southeastern Missouri lead concentrate. Typical lead recovery was about 98 pct. Process problems related to impurity buildup and control were studied. When copper and silver impurities were removed from the leaching solution, a lead metal purity of 99.999 pct was obtained. Lead-in-air levels and lead-in-blood levels of operating personnel were monitored. The process has potential for producing lead with minimum pollution, but is not ready for commercial utilization. Operation of a prototype commercial electrolytic cell and a full-scale pilot-plant investigation by industry are needed to evaluate the commercial viability of the process.

Jan 1, 1983

By Ivor Hawkes

This report describes the results of a study to evaluate new design concepts for percussive rock drills that will result in quieter machines. It is shown that by incorporating such features as an efficient muffler, a plenum chamber integral with the machine body, and shroud tubes around the drill rods, etc., noise levels are reduced from about 114 dBA to about 95 dBA with very little change in drilling performance.

Jan 1, 1977

By Steve C. Albrecht

The objective of this study is "to assess the impact of surface mining on soil compaction in the Midwest". The study revolves around a unique field sampling program targeted at four mine sites utilizing four distinct types of soil movement of midwestern prime land. Through the preparation of a final report for use as a guidebook, an assessment is made of the degree to which surface mining operations contribute to the soil compaction problem. The final report is formulated through the use of field study data as well as information gathered in an intense literature review. The final report centers on applying collected data to practical field applications. Soil sampling on the four mine sites centers on a comparison of natural and replaced soils for moist bulk density. This characterization evaluates changes in density and texture throughout the soil profile to a depth of 48 inches. Fertility of the topsoil is also assessed for natural and replaced soils. During field sampling and observations, a base of information has been gathered to compile a case study on each mine site. The report accesses the regulations in the prime farmland areas through the use of a matrix. The regulatory matrix allows easy access of mining personnel to State and Federal regulations.

Jan 1, 1982

By Dipak Sengupta

This study analyzes the safety, technology, and economic impact of eliminating safety fuse from metal/nonmetal mines, based on operation and manufacturer experience over the past five to ten years. If safety fuse is eliminated, blasting accidents will decrease with no technical impact except for some limited, specific applications. The economic impact will be minor for large operations, but will be significant enough for small operations that some small operations will likely close rather than change. The majority of the mines would probably change over, with the extra cost absorbed by the market. Elimination of safety fuse would have obvious impact on the two manufacturers of safety fuse; one manufacturer already produces an alternative system, and will remain unaffected; the other will be affected if they do not change their production strategy. There will be a very minor effect on the mining industry as a whole due to abolishment of safety fuse from the standpoint of employment or production.

Jan 1, 1980

By Kenneth L. Whitehead

After many years of research, the occurrence of pneumoconiosis, black lung disease, among miners has been related to the mass of respirable coal dust to which mining personnel have been exposed. Congress passed Public Law No. 91-173 in 1969, which limited the dust concentration of respirable dust allowed in the mine working areas to 2.0 mg /M3 as of December 31, 1972. As a result of these restrictions, much work has been done in determining methods of either eliminating or suppressing respirable dust. The purpose of this project is to determine the state-of-the-art in continuous mining machine bit technology, particularly with regard to dust production.

Jan 1, 1973

By F. S. Kendorski

This report presents the results of a search for viable-self-drilling roof bolt concepts, detailed development, design, and manufacture of such bolts that drill their own holes, and testing in the laboratory and in the field in two different coal mines of three self-drilling roof bolts. Three new types of bolts were designed and tested, which drill their own holes and then anchor in continuous operation. These were a spring-actuated mechanical expansion shell, a slot and wedge, and a self-contained resin anchor bolt. Such bolts when fully developed for mine use would allow safer and remote installation of ground support and increase productivity. Recommendations are given for further work to improve drilling and anchorage performance.

Jan 1, 1979

By Martin Smirlock

A novel instrumentation system has been developed which enables simple, quick, and accurate measurement of vehicular dynamics within low speed ranges. The system, consisting of a microwave transceiver and microprocessor data acquisition and reduction system, measures the deceleration dynamics of low-speed mining and construction equipment. It makes the basic measurement, calculates key parameters such as average deceleration, initial velocity, stopping distance, and brake system delay time, and produces autoscaled graphs of velocity, acceleration, and displacement versus time.

Jan 1, 1981

By R. J. Gunderman

A conventional trailing cable connection box on a continuous mining machine was modified by the addition of two innovative devices. These are a pressure vent to preclude buildup of high pressure due to an explosion in-side the enclosure, and a grommet-type cable entry to simplify and speedup cable entering procedures. The innovative devices were evaluated for eight and one-half months in a working section of an underground coal mine. Laboratory tests before and after the in-mine exposure show no measurable change in the devices. Following the favorable in-mine evaluation, technical performance criteria were defined to serve as the basis of approval for the use of the innovative devices. Additional tests to measure comparable gripping of the cable by asbestos rope, substitution rope materials and by the urethane grommet-type entry were included in this effort. Also, literature for the last 80 years was searched. Comments are provided as to how the innovative devices comply with 30 CFR Part 18.

Jan 1, 1982

By R. J. Leary

The technologies of contemporary iron and steel production and of direct reduction processes have been studied to identify and estimate the potential effects of direct reduction on mineral consumption and the problems raised thereby for the Nation's mineral supply to the iron and steel industry. Contemporary patterns of mineral raw material and energy consumption were determined from a study of the 1964-70 period. Major changes were observed in requirements for 14 of 20 principal commodities. Average practice in 1970 was compared to best practice to estimate the potential effects of implementing existing technology without recourse to direct reduction. Potential effects of direct reduction were estimated by comparing the mineral requirements for 95 percent reduced pellets with 1970 best practice technology for two cases of use: (I) complete substitution for hematite pellets in blast furnace burdens, and (11) partial substitution (40 percent) for scrap in electric furnace steel charges. Effects upon mineral supplies are described; important collateral factors are analyzed, and the principal metallurgical, industrial, and environmental consequences of implementing direct reduction are discussed. Major effects of direct reduction on the domestic steel industry and its mineral supply system are foreseeable. Direct reduction will (1) create a large demand for low-gangue iron ore; (2) relieve the dependence of the steel industry on coking coal, and (3) permit great increases in furnace productivity, both in blast furnace ironmaking and electric arc furnace steelmaking.

Jan 1, 1973

By G. Andrews

This case study details the process that was used for project planning and permitting for the Greens Creek Mine, located near Juneau Alaska, as seen through the eyes of one of the primary environmental consultants. This case shows how a Company could involve the public and the agencies in the early 1980's and develop a project sensitive to concerns expressed with a high level of environmental protection. Comparisons are made to the current environmental permitting situation. Initial baseline studies performed during the exploration phase provided helpful information for more detailed environmental work in 1980-1981 as planning and permitting formally got underway. Since the mine was in a National Monument and abuts up to a designated wilderness, the Monument Manager administered the project for the lead agency, the USDA Forest Service. Planning and permitting progressed smoothly to a Final Environmental Impact Statement (FEIS) in 1983. Metal prices were depressed when the FEIS was completed and the project permitting proceeded slowly. Ownership changed several times in the mid-1980's. New owners re-evaluated the project and suggested five changes that required a supplemental EA prior to development. The project was fully permitted and started construction in 1988. Operation began in 1989. Today the environmental process in southeast Alaska is now much more complex, detailed, expensive, and time consuming than in the early 1980's. Significant issues discussed that may impede development and operation include overlapping agency jurisdictions, personal agendas of agency staff, conflicts between agencies that impede project progress, changing regulations, and a well organized environmental opposition.

Jan 1, 1993

By R. R. Faddick

Properties of coal-water slurries were studied in two separate phases: a rheological phase and a pipeline phase. The purpose of the study was to investigate the rheology of fine coal slurries to determine the effect of fine particles in a coal-water mixture on the economic and operational aspects of a slurry pipeline. The slurries consisted of 6x10, 100x200, and 200x0 mesh coal in water. A fourth slurry consisted of a mixture of the 6x10 and 200x0 mesh coal. Brookfield and Stormer rotational viscometers were used to obtain or simulate rheograms for a range of fine coal concentrations, temperatures, and particle sizes. All the slurries were pumped through a 1-inch diameter acrylic pipe. The fine coal slurries were found to encompass four distinct rheological models. The narrow size distribution of the coal slurries was apparently responsible for the high pipewall friction losses, more so than the particle size. A scale-up method applicable to Bingham plastics was found satisfactory for predicting pipeline headlosses of fine coal slurries from rheology data.

Jan 1, 1974

By Albert L. Toenges

The purpose of this paper is to describe some of the methods and practices of mining coal mechanically where more than one shift is worked, with the view of determining the advantages and disadvantages of various types of equipment and mining systems now in use. This paper is in the nature of a progress report, and, as the number of mines discussed in it is limited, the conclusions drawn in the comparison of various systems are not final but may be revised after subsequent investigations. Physical conditions vary in different and in the same mining districts and determine, more

Jan 1, 1938