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By W. C. Smith

The U.S. Bureau of Mines examined previous research on rib stability in an effort to develop a practical approach to understanding, characterizing, and controlling weak rib conditions in underground coal mines. Because success in stabilizing ribs depends on a basic knowledge of how weak ribs behave, the report reviews the mechanics of rib failure and the relationship of coal mine geology and pillar constraint to rib instability. Strategies for choosing an effective method of rib support are considered, and various rib support methods are discussed. Finally, the report documents techniques for monitoring ribs and use of models to assess rib stability; such monitoring and modeling can also help determine the most effective method for roof support.

Jan 1, 1992

By F. N. Kissell, H. K. Sacks

This study examines the accuracy of area sampling for measuring the dust exposure of mining machine operators in coal mines. The specific objective of this research was to find locations where an area sampler might work better than earlier studies have indicated. The results show that fixed-location area sampling cannot accurately predict the dust exposure of a machine operator, even when the best fixed location is sought, the fixed location is quite close to the operator and the bias due to the dust concentration gradient is corrected. Industrial hygienists have known for many years that area sampling is unsuitable for measuring air contaminant exposures in the workplace. Near contaminant sources, the dilution air and the contaminants are not evenly mixed. Therefore, when workers are near contaminant sources, exposure measurements must be taken from the worker's breathing zone to be accurate

By Christopher Mark

Australia and the United States both have large, modern underground coal mining industries. Many companies have invested in both countries, and there is growing awareness that technological developments in one country can rapidly affect the other. Yet the ability of technology to pass between the countries depends on comparability of ground conditions. Many Australian observers believe that their ground conditions are significantly poorer than typical U.S. conditions, but some U.S. professionals are not convinced. The author recently visited 10 Australian longwall mines and two room-and-pillar mines. Each mine visit included determination of the Coal Mine Roof Rating, roof support installed, pillar design, and an in-depth discussion of ground control experience. The Australian conditions observed are compared with an extensive data base from U.S. mines. The paper also offers observations on geotechnical data collection, monitoring, and the roles of the mine inspectorate and research community.

By Thomas J. Fisher, Thomas Novak

Strong circumstantial evidence suggests that lightning has initiated methane explosions in abandoned and sealed areas of underground coal mines. The Mine Safety and Health Administration (MSHA) investigated several of these occurrences within recent years. The investigated explosions occurred at significant depths, ranging from 500 ft to 1200 ft. Data from the National Lightning Detection Network indicate a definite correlation between the times and locations of the explosions with those of specific lightning strikes. This paper addresses the question, "Can lightning cause potential differences capable of igniting methane-and-air mixtures at overburden depths at which underground coal mining occurs?" A mine depth of 600 ft was selected for this initial study. Computer simulations were performed, with and without the presence of a metal- cased borehole extending from the surface to the mine level. CDEGSTU software from Safe Engineering Services & Technologies, Ltd (SES) was used for the simulation.

By Thomas H. Dubaniewicz, Gerald R. Cucci, Gregory M. Green, Kenneth L. Cashdollar

New types of industrial instruments use fiber-coupled law energy to power remote serum. Fiber-optic based instruments are useful in classified (hazardous) locations found in many industrial plants because the fiber provides a natural barrier against accidental electrical discharge into potentially explosive atmospheres. However, current safety standards do not cover the use of laser-powered fiber-optic instruments in potentially explosive environments such as found in coal mines. The U. S. Bureau of Mines began an investigation of laser-powered fiber-optic instruments in explosive atmospheres in support of the standards-making process. A commercial fiber-optic interface system, modified to sin relate several worst-case operating conditions, ignited explosive hydrogen-air mixtures. Worst-am simulations consisted of disabling a safety shutoff feature, operating the laser at significantly higher powers than intended for normal operations, and cleaving fiber-optic connections to direct laser energy onto selected absorptive materials. At the highest power level available, the fiber-optic interface system did not ignite selected methane-air mixtures. The obtained data should prove useful in establishing appropriate safety standards.

By Chelesa C. Woodward, Gregory G. Miller, Walter K. Utt, Wayne L. Howie

The process of drilling and bolting the roof is currently one of the most dangerous jobs in underground mining, resulting in about 1,000 accidents with injuries each year in the United States. Researchers from the Spokane Research Laboratory of the National Institute for Occupational Safety and Health are studying the use of a drill monitoring system to estimate the strength of successive layers of rock and assess the integrity of a mine roof so that roof drill operators can be warned when a weak layer is being drilled. Measurements taken during drilling can be converted to suitably scaled features so that a neural network can classify mine roof strata in terms of relative strength. The feasibility of this concept has been demonstrated in the laboratory. The research project was undertaken in order to increase the safety of underground miners, especially those involved in roof bolting. The system should be applicable to the mobile drills used in underground mining and would likely find wider application as well.

Jan 1, 2002

By T. M. Barton

This paper presents several case studies in which a mechanics-based boundary-element program is used to back-calculate the surface subsidence associated with various panels at several northern Appalachian coal mines. The program used in this case study is called LAMODEL, which incorporates a frictionless, laminated overburden into a general-purpose displacement-discontinuity code primarily designed for calculating the stresses and displacements in coal mines or other thin-seam or vein-type deposits. In this paper, the program is used to calculate both the underground convergence and the resulting surface subsidence at five longwall panels and a room-and-pillar section. The fitted subsidence from the model is compared with the field measurements and analyzed. The results from this work show that the LAMODEL program is not as accurate as available empirical subsidence-predictive methods: the expected correlation between the geology and the optimum input parameters is not evident. However, for a mechanics-based program, LAMODEL does provide moderately accurate subsidence calculations, and it is one of a few programs that can even attempt to practically calculate both underground stress and convergence and the resulting surface subsidence.

By J. P. Rider

Health surveillance efforts indicate that the development of lung disease and overexposure to respirable dust in underground coal mires continues to afflict mine worker. Results from the most recent round (1992 - 1996) of the Coal Worker's X-ray Surveillance Programs indicate that approximately 8% of the examined miners who had at least 25 years of mining experience were diagnosed with Coal Worker Pneumoconiosis (CWP) (category 1/0+). During the period between 1995-1999, mine operators and MSHA inspectors collected 9968 and 1365 dust samples respectively, from longwall designated occupation (DO) personnel. Analysis of these samples showed that 1970 (20%) of the mine operator samples and 25.8 (19%) of the MSHA samples5 exceeded the 2 mg/m3 dust standard. The continued development of CWP in coal mine workers and the magnitude of respirable dust over-exposures in longwall mining occupations illustrate the need for improved dust control technology on longwalls. Figure 1 illustrates the major longwall dust sources as determined in the early 1990's.4 This article describes the ongoing research to find ways to minimise shearer dust levels as a function of changes in dust control parameters, and research to determine the impact of high air velocities on shield dust entrainment.

By Andrew Cecala

During a recent National Institute for Occupational Safety and Health field evaluation of a newly designed filtration and pressurization system for an enclosed cab of a surface drill, it was determined that the drill operator's respirable-dust exposure was significantly increased during time periods when the cab door was opened to manually guide another section of drill steel into place to achieve additional cutting depth. Although no dust cloud was visible when the door was opened to perform this task, the drill operator's exposure was documented (over a three-day test period) to be nine times higher than when the cab door was closed. Even at this higher respirable-dust concentration, the drill operator's exposure remained well below the permissible exposure limit governed by the federal dust standard; however, an alternative method is being investigated to guide the drill steel in place in order to eliminate this increased exposure. .

Jan 1, 2008

By Thomas M. Barczak

The success of longwall mining can largely be traced to the development of powered roof support systems. The most significant improvement in powered support design has been the shield support, which improved kinematic stability and promoted the application of longwall mining in difficult-to- control caving conditions where chock and frame supports were inadequate. The most obvious trend in shield design has been an increase in shield size and capacity. This U.S. Bureau of Mines report examines shield design and operation practices and their consequences for the utilization of high-capacity shield support systems. An optimization goal is to minimize support loading by selecting an active shield setting force that is compatible with strata behavior and shield loading characteristics. Shield stiffness is an important design parameter that is often overlooked. A consequence of increasing shield capacity by incorporating larger diameter leg cylinders is a proportional increase in shield stiffness. Setting forces have also increased in direct proportion to the increase in shield capacity. The increased stiffness and higher setting force cause the available capacity to be consumed more quickly, severely limiting the ability of high-capacity supports to last longer and provide reserve capacity for difficult mining conditions.

Jan 1, 1992

By R. Karl Zipf

MULSIM/NL (multiple seams, nonlinear) is a new U.S. Bureau of Mines boundary-element-method (BEM) program for calculating stresses and displacements (is., convergence) in coal mines or thin, tabular rnetalliferous veins. This manual gives detailed operating instructions for MULSIM/NL and illustrates its use with several practical examples. While this manual concentrates on the practical aspects of actually running and using MULSIM/NL, another companion report titled "MULSIM/NL- Theoretical and Programmer's Manual" provides mathematical and programming details to those engineers and programmers who need to fully understand the FORTRAN program or desire to alter and enhance it. MULSIMINL analyzes one to four parallel seams that have any orientation with respect to the Earth's surface. Three main features distinguish MULSIM/NL from its predecessors: (1) nonlinear material models, (2) multiple mining steps, and (3) comprehensive energy release and strain energy computations. MULSIM/NL has six material models for the in-seam material including (1) linear elastic for coal, (2) strain softening, (3) elastic plastic, (4) bilinear hardening, (5) strain hardening, and (6) linear elastic for gob. The multiple mining step capability enables the user to simulate a changing mine geometry. Finally, MULSIM/NL performs comprehensive energy release rate calculations.

Jan 1, 1992

In the last few decades, a considerable amount of effort was directed at accurately determining the coal pillar strength to use for safely designing coal mines. The outcome of this early work was the well known Obert-Duvall, Holland-Gaddy, Bieniawski, and Salamon-Munro equations for coal pillar strength. All of these equations were developed for, and were calibrated with, pillars in a large room-and-pillar area such that the loading could be determined using the "tributary-area" theory. In order to account for the abutment loads associated with full-extraction mining, the empirical methods have typically adopted a simple conceptualization of the abutment load through use of an "abutment angle." Short of a complete numerical or analytical analysis of the coal seam and surrounding strata, very little work has been Fretted toward refining the empirical analysis of pillar loading. It appears that the vast majority of the research has been directed at determining the pillar strength, the numerator of the safety factor equation, when the denominator of the safety factor equation, the pillar loading, plays an equally important role in pillar design. This paper will address the deficit of pillar loading research by exploring the accuracy of the empirical abutment load calculations using insight provided by an elastic overburden model, a laminated overburden model and field observations. Ultimately, it is determined that a constant abutment angle probably over-predicts the abutment load as the mining depth increases.

By Lloyd A. Morley, Robert Stefanko

This report has presented a literature review of explosion proof¬ing of coal mine electrical equipment. The international "state-of¬the-art" is an extremely difficult definition to quantify but, from the preceding paragraphs, it is evident the international community be¬lieves that it is represented by the International Electrotechnical Commission's Publications. Five questions were set forth during the beginning of this report. Each will be evaluated in light of the preceding discussion. 1. Can Schedule 2G specifications on explosion-proof containers be substantiated? Literature was found in the three main problem areas, surface temperature, mechanical strength, and explosion transmission, to determine this. Surface temperature requirements are adequate except for equipment that can normally overload, and the required intern¬al pressure does afford some margin of safety. However, in terms of safety, gap dimensions are about ten times smaller than that needed. 2. Is it possible to replace the Schedule's design requirements with performance specifications? Two primary areas were determined as mechanical strength and explosion transmission. As was mentioned, for present flange and gap standards, the 150 psig requirement is adequate. Furthermore, it is the authors' opinion that the level cannot be re¬duced if the present gap requirements are retained. The Schedule now requires that 16 tests be run, but the literature suggests that only from three to six examinations are necessary. Then by using the abso¬lute maximum pressure from these measurements or 150 psig, whichever is

Jan 1, 1974

By Bruce K. Cantrell, Stephen W. Stein, David Hassel, Harvey Patashnick

The Mine Safety and Health Administration. Department of Labor, requires coal mine operators to measure compliance with federal re¬spirable dust exposure standards periodically using approved gravi¬metric samplers. However, the gravimetric approach, with its inher¬ent delays, cannot provide dust concentration data quickly enough to allow on-site correction of inadequate dust control strategies or re¬moval of personnel from harmful environments. Furthermore, alleged tampering with dust samples collected to determine compliance with standards prompted the Secretary of Labor to appoint a special Respirable Dust Task Group to study options to improve monitoring and control of respirable coal mine dust. The Mine Safety and Health Administration's Task Group recommended that the U.S. Bureau of Mines develop a fixed-site monitor that would provide continuous information to the mine worker and mine operator regarding dust levels and the status of compliance with the applicable respirable dust standard. In response to the Mine Safety and Health Administration's request, the U.S. Bureau of Mines is investigating several sensor tech¬nologies for continuously monitoring respirable coal mine dust. One of these technologies is the Rupprecht and Patashnick Co. tapered element, oscillating microbalance. The bureau is in the process of investigating the suitability of using this sensor in the high humidity and vibration environment of underground coal mines. Laboratory tests have indicated that, with modification, the sensor can meet the humidity and vibration requirements for underground coal mine use. Currently, the bureau is developing

By Mark Larson, Doug Tesarik, Joe Shoemaker, Brad Seymour

In cooperation with Cyprus Twentymile Coal Co., researchers from the National Institute for Occupational Safety and Health (NIOSH), Spokane Research Laboratory, conducted a study at the Foidel Creek Mine, an underground coal mine near Oak Creek, CO, to evaluate the stability of underground working conditions as a longwall advanced through a series of backfilled cross-panel entries. Instruments installed in the cross-panel entry pillars, backfill, longwall panel, and adjacent headgate entry were continuously monitored by a computerized data acquisition system as the longwall approached and advanced through the backfilled section of the panel. Data collected from these instruments were analyzed to determine the magnitude and direction of the secondary principal stress changes ahead of the longwall face, deformation and closure of the headgate entry, and stability of the cross-panel entry pillars and backfill. A three-dimensional, boundary element model was calibrated to accurately predict mining-induced stress changes and the distance they occurred ahead of the longwall face. As the longwall advanced through the backfilled entries, most of the mining-induced load was supported by the cross-panel entry pillars. The backfill provided stability for the roof and floor of the in-panel entries and also confined the entry pillars significantly improving their load-carrying capacity. Comprehensive information derived from backfill material property tests, instrument data, underground observations, and numeric modeling results document the safety and stability of the 8-Right mine through and should provide beneficial case study information for other longwall backfilling applications in the future.

By G. R. Peterson, K. E. Porter

The U.S. Bureau of Mines has estimated the potential availability of copper from 204 mines and deposits in market economy countries (MEC's). The evaluated properties have demonstrated resources totaling 436.4 million metric tons of contained copper and account for 90% of the Bureau of Mimes reserve base for copper in market economy countries. Total recoverable MEC copper resources are 340.8 million metric tons, 69% of which is from producing mines and 31% from nonproducing mines and deposits. Chile had the lowest estimated average total cost from producing mines of W.48 per pound of recoverable copper at a 0% discounted cash-flow rate of return (DCFROR), with estimated average total costs ranging from $0.40 to $0.81 per pound. The estimated average total cost of production, per pound of copper, for producing mines in the United States amounts to $0.57 in January 1988 dollars at a Wo DCFROR, with estimated total costs ranging from $0.36 to $0.85 per pound. In both real and nominal terms, the United States has, on average, significantly lowered its copper production costs since 1981. Rationalization of the industry and significant increases in productivity have made a strong improvement in the competitiveness of the U.S. copper industry to the extent that the United States should no longer be considered as a marginal producer of copper.

Jan 1, 1992

By Richard J. Mainiero, Eric S. Weiss

This project investigates the behavior of blast waves from the detonation of high explosives in an underground mine. A series of explosive tests was conducted in the underground and surface facilities at the Bureau of Mines' Lake Lynn Laboratory to evaluate the potentially dangerous effects of blast waves produced by open shooting, blown out holes, or accidental detonations of explosives. Shots of C4 and TNT were fired at the dead end of a 6 ft high by 20 ft wide entry, at the intersection of two entries, and on the surface. C4 and TNT were chosen for this research because they exhibit very consistent performance. Behavior of the blast wave was evaluated through recording of the pressure as a function of distance from the explosive detonation. For both explosives, C4 and TNT, peak pressure decay with travel down the entry was inversely proportional to distance to the 0.9 power. When comparing pressure measurements at 200 versus 100 feet from the detonation; at 200 feet the pressure would be 1/2 0.9 or 54 percent of that measured at 100 feet. By comparison, peak pressure for a surface shot exhibits a decay with distance to the -1.6 power, yielding a pressure at 200 feet 1/2 16 or 33 percent of that measured at 100 feet. This result confirms that the blast wave from detonation of an explosive in an underground mine maintains its force for a greater distance than would be the case on the surface. Table and figures follow the text.

By Richard J. Mainiero

The Bureau of Mines investigated coal-mine-type short-delay electric detonators marketed by three domestic manufacturers to determine the accuracy of delays and the probability of overlap between adjacent de- lay periods. The Winzer index was computed and compared with the probability of overlap. A close agreement between the Winzer criterion and overlap probability was demonstrated. A permissible blasting unit capable of delivering a maximum firing energy of 4.0 J and a digital oscilloscope were used to measure the delay time with an accuracy of 20.25 ms. Another oscilloscope and a pulse transformer were used to record firing current. Experimental data indicated negligible overlap probability in detonators of shorter delay periods: periods 1 to 4, which correspond to 25 to 250 ms. However, a significant probability of overlap was detected in some detonators of longer delay periods: periods 5 to 9, which cor- respond to 300 to 500 ms.

Jan 1, 1985

By M. J. Brnich

The purpose of this US. Bureau of Mines study was to assess the ability of trainees to don an unfamiliar self-contained self-rescuer (SCSR) after having become familiar with how to put on a different type of apparatus. Prepractice instruction was the same for all individuals learning to put on a device: a step-by-step, hands-on talk-through using the "3+3" method. Subjects were assigned to groups that had their initial donning instruction derivered on either the Draeger QXY-SR60B or the CSE SR-100. Trainees' performances were then evaluated using the other model. Donning trials were analyzed using a number of measures. It was found that SCSR design had a moderate influence upon how well the doming task transferred.

Jan 1, 1992

By S. McGinn, G. Schnakenberg, D. Petrie, A. Bugarski, M. Grenier

As part of the Diesel Emissions Evaluation Program (DEEP) consortium, Noranda Inc. has undertaken a field project to evaluate the overall performance of the latest diesel particulate filter technology (DPF) at its Brunswick Mine in Bathurst, New Brunswick. Performance of the filtration systems is evaluated with respect to their ability to reduce tailpipe emissions and concentrations of diesel particulate matter (DPM) and noxious gases in mine air, efficiency of filter regeneration process, maintenance requirements, reliability, and acceptance. Four different particulate filter systems deployed on heavy production vehicles are subjected to an 18-month field evaluation. Over the evaluation period the vehicles will have accumulated approximately 4000 operating hours in production. This paper presents the results of testing conducted mid way through the 18-month field trials. The 400- meter section of the mine drift at 525-5 sub level, hereinafter referred to as the "isolated zone" was isolated between intake and exhaust fan systems and sealed with bulkheads against leakage. The isolated zone was ventilated at the rate required per CSA Standards and issued by CANMET for the engines tested. Four vehicles, two load-haul-dumps (LHDs) and two trucks, retrofitted with particulate filter systems were tested along with a new identical model LHD and truck equipped with exhaust systems consisting of a catalytic converter (DOC) and muffler. The test vehicles were operated individually inside the isolated zone for approximately 4 hours over simulated production duty cycles. Measurements of ambient concentrations of particulate matter, tailpipe emissions, and engine parameters were performed for each of the tested vehicles. The DPM samples for carbon were collected at the most up- stream end of the isolated zone, at the vehicle next to the operator, and at the most downstream or exhaust end of the isolated zone. The DPM samples were analyzed for total (organic and elemental) carbon using NIOSH Analytical Method 5040. Ambient concentrations of particulate matter at the exhaust end of the zone were also measured using Scanning Mobility Particle Sizer (SMPS), and real time PAH monitor (PAS 2000). Efficiency of the filters was also evaluated on a basis of tailpipe measurements performed using raw exhaust instruments the NanoMet and the UGAS. In addition, relevant engine parameters were obtained using Detroit Diesel Diagnostic Link (DDDL) and from exhaust backpressure and temperature measurements. Results from the tests proved conclusively that diesel particulate filters can significantly reduce the concentrations of air- borne DPM, but not without careful monitoring of both ambient and tailpipe emissions and not without careful attention with respect to maintaining the integrity of the DPF systems.