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By Tuncel M. Yegulalp

This final report contains the results of all work performed under BOM Grant J0333905. A preliminary systems analysis of coarse-particle coal slurry pipelines as a haulage method for longwall mining systems was performed. Two exhaustive literature surveys on state-of-the-art longwall mining and slurry transport technologies were prepared. Two representative longwall systems were designed, one with conventional haulage and one with slurry haulage. These two systems were then compared on the bases of cost, safety, and reliability. The conclusions were that for the case of a two-face longwall mine, a coarse slurry transport system does not have a clear-cut cost advantage over a conventional (conveyor-hoist) system. However, indications were that a cost advantage could occur under different analytical conditions such as: (1) a larger scale mine, (2) if intangible benefits were quantified, and (3) if new generation technology rather than currently available technology were applied to the study. Budget and time constraints prevented exploration of these conditions.

Jan 1, 1982

By James H. McCutchan

The small and remote mine operators must comply with the Federal Mine Safety and Health Administration regulation requiring them to train and maintain mine rescue teams. The alternative is for the operators to contract with established teams within two hours travel time of their mine. Many of these remote operations are too far away from established teams and have too few employees to make up the necessary teams. Many cannot comply with the regulation either from a manpower or economic standpoint. The Office of Arizona State Mine Inspector, under the direction of the Honorable James H. McCutchan, State Mine Inspector, entered into a contract with the Bureau of Mines to develop the concept of a volunteer mine rescue program. This program with the assistance of the mining industry and volunteer rescue organizations, has planned and instituted a statewide volunteer mine rescue organization. The trained and equipped volunteers are stationed throughout the state and can respond to a mine emergency within the time constraints.

Jan 1, 1984

By Fun-Den Wang

Rock bolting has become a major method of coal mine roof support because of its effectiveness, economy, and convenience. The polymeric-resin-bonded bolt has generally proved to be more effective than the mechanically anchored bolt, but the higher cost of the resin bolt limits it to applications where the increased support is essential. The low-cost high-early-strength cement grout developed during this project will encourage more widespread use of fully grouted roof bolts provided practical installation techniques can be developed. Laboratory tests of four types were performed on various rapid-set and accelerated cement products to find a material with properties suitable for replacing resins. A proprietary gypsum cement was ultimately used with good success. A field test of the cement grout was made in an operating coal mine. An intersection was bolted in the standard pattern with cement-grouted bolts and instrumented. A nearby resin-grouted intersection was also instrumented and observations were carried out in both intersections for 2 months. No substantial difference was found between the support provided by the cement and the resin.

Jan 1, 1976

By A. L. Foote

This is the final report of work accomplished during 1973-75 under U. S. Bureau of Mines Contract No. H0242015, "System for Handling Underground Mine Supplies and Materials." The purpose of the contract was to develop a mechanical device which could safely perform handling tasks that are normally done manually in underground bituminous coal mines. The report discusses studies leading to construct-ion of a battery-operated, three-wheel vehicle with a six-degree-of-freedom manipulator. Supportive design studies included collection and analysis of production, manual functions, and injury data on the underground bituminous coal mining industry. Transfer tasks in section storage and working places were the prime candidates for mechanical handling. Functional specifications were developed for two handling devices (one to handle existing unit loads and one to handle repackaged unit loads) and for a vehicle to mount the handling device. Design concepts for nine different handling devices were developed and a cost/benefit evaluation made for each. Detail design, capital and operating costs, and method improvement savings data were developed for two battery-operated vehicles and for two different manipulators. The three-wheel vehicle with anthropomorphic manipulator was chosen for development.

Jan 1, 1978

By Clayton J. Bossart

The design and fabrication of an engineering model and three prototypes of a portable gas analyzer and sapling system is herein described. This design effort has provided a battery operated system which will indicate the degree of explosivity of return air and in the air beyond the seal during the course of fighting, sealing and quenching a mine fire. Performance tests, design criticisms and recommendations for designs are also included. The system is based on two analyzers: the MSA Catalytic Combustible Gas Analyzer for indication of total combustible gas concentration and a modified, totally automated version of an Analytical Instrument Development Corporation Model 622 gas chromatograph (CC) for analysis of individual gases. The system provides continuous monitoring of combustible gas level in the range of 0 to 100% LEL. The GC automatic analysis requires a 5 minute cycle time to update the concentration indications for: hydrogen @ 0 to 10% oxygen @ 0 to 25% nitrogen @ 0 to 100%, methane @ 0 to 10 or 0 to 50%, carbon monoxide @ 0 to 5% and carbon dioxide @ 0 to 10%. CC peak heights are translated into concentration units which are memorized and continuously displayed on Integral meter readouts. The underground analyzer system design was reviewed and tested by the MESA Approval and Certification Group and found to meet intrinsic safety requirements. The three underground packages consists of: a gas chromatograph with dimensions of 11" X 12" X 16" and weighing 25 lbs. , an electronics unit 10" X 14" X 19" in size and weighing 30 lbs., and a power pack 6" X 14" X 16" in size and weighing 45 lbs. Two AC/DC power supplies are provided for aboveground battery charging and system operation in the laboratory. The underground system is entirely automatic and self-contained, including sources for electrical and pneumatic power and for CC carrier gas via a rechargeable Gel Call battery and two lecture bottles of gas in the power pack-

Jan 1, 1978

By N. Seidle

Numerous studies conducted in the 1960's and 1970's concluded or implied (1) that a high accident rate in terms of severity and frequency exists among new (first year) operators of mine machinery equipment, and (2) that lack of experience and training is a major cause of this high accident rate. Further studies refined this premise to show that the major causes of accidents among first year operators are: (1) lack of manipulative skills; (2) failure to follow/adhere to routine procedures; and (3) failure to recognize and respond properly to hazards. This report describes the design, development, and manufacture of a shuttle car operator training system, including a program of instruction which: ? Is economically feasible. ? Addresses accident data and specific causes of accidents. ? Includes an aerospace quality simulator of sufficient fidelity to teach and develop manipulative skills, recognition of and response to hazards, and routine and emergency procedures. ? Is designed to significantly reduce the severity and frequency of accidents especially during the operator's first year. ? Is designed to significantly improve the performance of the trainee as compared to the standard learning curve. Development of the simulator produced several valuable by-products including a major state-of-the-art technological advance in visual systems for simulators, and a first-time application of (certain) advanced filming techniques to underground filming.

Jan 1, 1984

By Donald R. Alvic

For electric utilities serving the aluminum smelter industry in the United States, sulfur oxide (SOx) abatement legislation could bring about increases in the costs of generating electricity. This paper documents the method and assumptions used in estimating these increases, and the contains the results of the estimation. 1.2 SMELTER INFORMATION The smelters used in this study were identified by the Bureau of Mines (BOM) and are listed in Table 1.1. Also included in Table 1.1 are the electric utilities that serve these smelters. Compliance costs were estimated for these utilities. Some of the utilities are unique in the way that the information is handled or in the way the utility is operated; these are discussed below. 1.2.1 Big Rivers and Associated Co-ops, Data for Big Rivers and Associated Co-ops were gathered by George Mason University (GMU) students for BON and are included in this study.

Jan 1, 1988

By John F. Elliott

Because of the importance of the steel industry in the economy, a program of study was undertaken to develop a computer model by which it would be possible to predict the need of the industry for raw materials and energy in the next several decades. This report gives the results obtained it a preliminary 6-month program.

Jan 1, 1973

By John F. Elliott

Six major trends that have had and are continuing to have major effects on the use and supplies of pig iron and scrap in the United States are (a) gradual replacement of the basic open hearth furnace (OH) by the basic oxygen furnace(BOF); (b) use of the electric furnaces for the production of plain-carbon steels, a trend which is closely related to the first; (c) United States changing from being a net exporter to a net importer of steel; (d) replacement of ingot casting by strand casting; (e) increased exportation of scrap; and (f) the lack of growth of the capacity of the U. S. steel industry to produce pig iron in the last 5 to 8 years. This report gives an analysis of the relationships between these trends and the use of processes for the production of raw steel in solidified form.

Jan 1, 1975

By E. E. Buban

A self-contained breathing apparatus has been developed to provide complete respiratory protection for a miner in an irrespirable atmosphere. The apparatus has the desired features of comfort, reliability, maintainability, and quick-donning capability. The apparatus is packaged in a moistureproof envelope and is protected in a shock absorbing, fiberglass resin carrying case. The apparatus is a small, lightweight, one-time-use device that can be readily worn on a miner's belt, requires no maintenance and is designed to have a shelf life of five years and a carrying life of three years. It is deployed to the use position in a period of 15 to 30 seconds. Man tests conducted in-house and at the National Institute of Occupational Safety and Health (NIOSH) testing laboratories established that this unit meets all performance requirements listed in the Code of Federal Regulations, Title 30, Part 11, Subchapter B, Subpart H (CFR 30, Part 11) for respiratory protective devices. The unit, which has received joint approval (TC-13F-37) on a prototype basis from the Mining Enforcement and Safety Administration (MESA) and NIOSH has: (1) Ten-minute service life under escape conditions. (2) Thirty-minute service life when the wearer is at rest. (3) Peak-to-peak breathing resistance of less than our inches water column height. (4) Inspired gas temperature of less than 135°F. (5) Breathing gas contents greater than 19.5 volume per cent of oxygen and less than 2.5 per cent carbon dioxin. (6) A weight (complete in carrying case) of 2.75 lbs. (7) A carrying case size of 6-1/2"x 5-1/8"x 3-1/8".

Jan 1, 1974

By Walter W. Kaufman

This report summarizes a study conducted to establish the nature and impact of regulations governing disposal of refuse from underground coal mines. The regulations affecting refuse disposal in eight major coal producing states are collected, summarized and reviewed. Federal regulations applicable to refuse generated by underground coal mines are also included. Common refuse disposal practices are discussed as are the refuse quantities generated annually in each study state. Technical requirements of regulations are discussed acid presented in appended tables. Economic implications are also assessed through cost analyses of three major types of disposal processes. The report also includes an assessment of future trends in regulation and refuse generation plus a series of recommendations concerning potential improvements in both the regulatory and refuse disposal processes.

Jan 1, 1978

By Kenneth C. Ko

An engineering investigation was carried out on the technical and economic feasibility of implementing flexible liner/backpacking support systems In an advancing tailgate longwall mine. The system for a model mine consists of a circular tube constructed of liner plates and flyash backpacking. Flyash is pneumatically stowed into the tailgate. Small amounts of cement may be mixed to improve the support capability of the fill In difficult local ground conditions. Water is added inside the nozzle immediately prior to spraying. Results of theoretical analyses and a field test show that the designed system is technically feasible, can be cost-competitive, provides more stable ground conditions, and can Increase productivity and coal recovery, when compared with existing retreat longwall systems. In certain mine layouts, the new system can reduce the direct mining costs by a significant amount. The system would be particularly applicable to deeper coal beds with bad ground conditions.

Jan 1, 1980

By Bryan R. Carmenati

This report documents the need for formal health and safety, and equipment operations training in the mine construction industry. The outlines, objectives, and training texts were developed based on the recommendation of needs of mine construction personnel, and those of Dames and Moore (Safety Analysis of Shaft Sinking operations, 1977) and Kinton, Inc. (A Training Program for Conventional and Raise Drill Construction Personnel; Phase I, 1979). The training material samples contained herein (and under separate cover in its entirety) are designed to improve the safety and production of those in mine construction. An instructor-directed presentation is recommended. The results of the study are presented in the Findings and Recommendations section of this report.

Jan 1, 1982

By Louis Schaffer

The objectives of the research were to determine whether a model health and safety program could be defined in terms which would enable its application to mines of all types, and, if such a model program could be defined, to determine through evaluations in two mining companies whether it would achieve measurable improvements. Volume 1 describes the model, how it was applied in the field and how it was evaluated. This, Volume 2, describes the literature and field research that preceded the model definition.

Jan 1, 1983

By C. Richard Groves

As the level of technology applied in the electrical measurement, control, and display portions of mine hoist systems continues to advance, the issues and concerns associated with the ramifications of the application of microprocessor technology on the safety-related aspects of these systems become paramount. This report, in part tutorial, addresses several aspects of these concerns. Beginning with discussions of microprocessor-based system architectures, the report addresses some existing and anticipated uses of this technology in mine hoist systems and discusses safety related considerations associated with the areas of data derivation; control and display panels; and system reliability issues. The report concludes with electrical maintenance and inspection considerations associated with the safety assurance of microprocessor based mine hoist systems.

Jan 1, 1986

By J. L. Schwendeman

This is the final report of work done under contract H0210060 for the U. S. Department of the Interior, Bureau of Mines. This program was to show the feasibility of using plastic liners containing sand and other fillers as a means of roof support in coal and other mines. This laboratory study was conducted in two phases, namely: Phase I, directed toward determining which state-of-the-art resin systems might have utility as a means of roof support in a coal mine, consisted of a canvass of resin manufacturers to learn which resins were available commercially that might have utility for this application. The resins submitted by the manufacturers were evaluated in a number of simple tests to define which of them would be most suitable for roof support use.

Jan 1, 1972

The following report summarizes the results of engineering feasibility studies whose purpose was to assess the probable efficiency, reliability, safety and cost of a number of possible methods for removal of radon gas from the ambient air in underground mines. Fourteen candidate techniques were evaluated. Seven of these were based on specific individual principles, and seven were based on combinations of these principles. The individual principles were as follows: 1. Activated charcoal 2. Organic fluids 3. Semipermeable membranes 4. Molecular sieves 4. Cryogenics 6. Chemical reaction 7. Centrifuge The combinations were: 8. Cryogenics and activated charcoal 9. Cryogenics and molecular sieves 10. Cryogenics and chemical reactions 11. Membrane filters and organic fluids 12. Membrane filters, cryogenics and activated charcoal 13. Membrane filters and chemical reactions 14. Silica and an Organic Fluid

Jan 1, 1975

By S. Atallah

A survey was conducted relating to the current practices for the classification of hazardous locations in coal preparation plants. Several plants processing bituminous, anthracite and lignite coal in Pennsylvania, West Virginia, North Dakota, Colorado, Montana and Wyoming were visited. Coal preparation plant operations and designers as well as MESA inspectors were interviewed. The National Electrical Code was discussed with selected members of the NFPA committee and electrical equipment manufacturers. Data provided by MESA on fire and explosion accidents in coal preparation plants were examined. The requirements of the pertinent Federal Regulations, National Electrical Code, National Electrical Manufacturers Association and Underwriters' Laboratories were compared and evaluated. This report consists of two parts. Part I: "Analysis and Review" provides a summary of the findings. Part II: "Recommended Guidelines" consists of recommended uniform guidelines that may be used for interpreting the National Electrical Code as it applies to the classification of hazardous areas in coal preparation plants.

Jan 1, 1977

By Frederick C. Trutt

A guide to the utilization and development of extensions and modifications to the APL Mine-electrical-system Load-flow Program is presented. These modifications include the development of algorithms to minimize computational operations within the iterative-solution techniques, as well as minimization of the number of required iterations. Extensions to the load-flow program include the development of algorithms for the calculation of balanced faults, simplified specification of fault parameters, optional inclusion of pre-fault currents, and an alternate-solution technique.

Jan 1, 1978

By Tuncel M. Yegulalp

The objective of this study was to categorize mining operations in the stone, and sand and gravel industries into areas of similar ground control functions and define initial factors affecting operational safety in each area, by means of utilizing publicly available data, telephone interviews and on site observations. The findings and recommendations presented in this report are based on the information collected during the two phases of the project. They also contain, in part, the collective qualitative opinion of the operators with respect to government rules and regulations on ground control safety and the implementation of these rules and regulations by government inspectors.

Jan 1, 1981