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By M. K. Larson, B. G. White

Researchers at the National Institute for Occupational Safety and Health (NIOSH) are investigating the causes and mechanisms of roof failure in underground mines. It is expected that a better understanding of these causes and mechanisms will lead to better layout and support designs that will help prevent accidents and fatalities associated with fall of ground. Two numerical experiments were conducted by NIOSH researchers using the Fast Lagrangian Analysis of Continua (FLAC) computer modeling program with a strain-softening continuum to simulate fracture zones. Two models, one of a round hole in a plate and one of a rectangular opening, were constructed and boundary conditions were applied to simulate far-field shear. The Particle Flow Code in Two Dimensions (PFC2D) computer program was used to look at the effects of far-field shear in generating fractures around an underground opening, but these models are preliminary until boundary conditions, strengths, and stiffnesses are matched to the FLAC models. Results showed that shear zones propagated from the opposite corners of openings in directions that appeared to be determined by opening shape and far-field stress. Tensile failures also formed and extended away from these shear zones. The consistent direction of shear deformation with respect to far-field shear provides a plausible explanation for preferred directions of shear as seen in geologic environments.

By N. N. Moebs

The Bureau of Mines air-sealed a 77-acre) above-drainage coal mine to evaluate sealing as a means of reducing the acid and metallic salt contents in drainage from abandoned mines. An approximate reduction in acidity of 150 ppm (equivalent to 193 pounds per day) and in iron of 98 ppm were directly attributed to sealing. The topographical, hydrological, and other factors involved in air-sealing are discussed, and the construction used to seal the mine is described.

Jan 1, 1970

By Hylton R. Brown

Advertisements and articles in technical and trade journals announce the approach of a new age, in which plastics, light metals, laminated wood, and numerous other products or byproducts will be used in the construction of automobiles, airplanes, and furniture and equipment used in our factories, offices, and homes. Undoubtedly, after the war there will be many such developments which will introduce new manufacturing methods and new hazards to challenge the safety engineer. Already we know, from experience in laboratories and pilot plants where these new products are being tested, that there will be many fire and explosion hazards to be overcome. The danger of dust explosions may be one of the principal hazards, because thetic resins and other materials used in the plastics industry, as well as metal powders, wood dust, and other finely divided substances, are capable of forming explosive mixtures in air. Heavy losses of life and property have been caused by dust explosions in flour and feed mills, starch factories, and grain elevators, and it will be well to consider the possibilities that such losses may occur in any new industry and to provide all possible safeguards against hazards. Fortunately, we have learned something about the behavior of dust explosions and know something about the ease of ignition, limits of Explosive concentration, end pressure developed. Our efforts should now be directed toward the application of this knowledge in the development of safe operating practices.

Jan 1, 1945

By David S. Yantek, Paul Jurovcik, Eric R. Bauer

Workers in coal preparation plants, where vibrating screens are significant noise sources, are often exposed to sound levels exceeding 90 dB(A). The National Institute for Occupational Safety and Health, a major coal company, and a vibrating screen manufacturer conducted a cooperative study of vibrating screen noise. Rubber isolators reduced sound levels by 1 dB. Urethane screen panels did not reduce sound levels in this case. Drive noise was determined to be the dominant noise source on the screen. Damped side plates reduced vibration levels on the screen sides by 1 to 7 dB(A). Detailed results of the study are presented.

By Phyllip Worley, Frank E. Chase, Christopher Mark

The Harris No. 1 Mine, located in Boone County, WV, has been longwalling the Eagle Coalbed for over 30 years. Harris has experienced numerous interactions associated with the extensive room-and-pillar and longwall mining operations which have been conducted in the overlying No. 2 Gas Coalbed. The problems have included roof falls, excessive rib sloughage, and gateroad and bleeder entry closure. A detailed evaluation of the multiple seam experiences at Harris No. 1 Mine was conducted as part of the National Institute for Occupational Safety and Health (NIOSH) nation-wide multiple seam mining case history data base. One observation from the Harris gateroad case histories was that smaller, critically loaded, upper seam pillars seemed to cause more severe ground conditions than did wider pillars. The LaModel program was used to investigate this supposition, and the results confirmed that “critical” sized pillars do transmit the highest amounts of stress to adjacent seams. In addition, the data suggest that the probability of a major multiple seam mining interaction increases when the depth of cover is 1,000 ft or greater and when the Eagle seam pillars have a Analysis of Longwall Pillar stability factor less than 1.50.

By R. V. Thurston, Edmund S. Leaver

"During the development of the sulphur dioxide leaching process for the treatment of ""mixed"" copper ores at the Southwest experiment station of the Bureau of Mines*** the pulp from treatment of roasted cupriferous pyrite with sulphur dioxide gases and water showed an unexpected amount of sulphuric acid. After following out several false premises it was found that this was due to iron in the solution, and also that this iron tended to oxidize to the ferric state if the concentration of sulphur dioxide in the roaster gases used did not rise above a certain figure. While the percentage of iron present was email it was enough to cause an entirely different set of conditions from those of the original sulphur dioxide leaching process and to promise a much wider application of the general idea. Sulphurous acid dissolves only certain copper minerals, sulphuric acid solutions certain additional minerals and ferric sulphate solutions certain further additional copper minerals, so this observation was of importance in connection with possibilities in the hydrometallurgy of the so-called ""mixed"" or partly oxidized copper ores.The work has been carried along by a number of experimenters. L. R. Eckman, junior chemist of the Southwest station, contributed largely to the early developments. L. Roberts, W. D. Bonner and C. G. Maier each in turn physical chemists at the Pacific Experiment station, (Berkeley, Calif.) have studied the reactions involved. A complete report of all the work on this process will be prepared later under the direction of O. C. Rolston. The purpose of the present paper is to place a summary of the more practical phases of this seemingly important piece of work before those interested."

Dec 1, 1923

By Thomas M. Barczak

he stiffness characteristics of longwall shields were investigated in this Bureau of Mines study. Since longwall strata activity is characterized by roof-to-floor and face-to-waste displacements, a model with two degrees of freedom was used to describe the load-displacement relationship of the shield structure. The model considers the support as an elastic body and relates horizontal and vertical resultant forces acting on the support to associated displacements as a function of the stiffness of the support structure. Stiffness coefficients under full canopy and base contact configurations were determined by controlled displacement loading of longwall shields in the Bureau's Mine Roof Simulator (MRS). Three two-legged longwall shields of different manufacture were investigated. The stiffness characteristics of these shields were evaluated relative to two parameters, namely, shield height and setting pressure. The test results indicate a reduction in shield stiffness for increasing height. Setting pressure was found to have less of an effect on shield stiffness, producing only a slight increase in stiffness as setting pressure increased. Similar trends were observed for all three shields, indicating a similarity in stiffness characteristics for shields of the same basic configuration.

Jan 1, 1988

By J. Shawn Peterson, David S. Yantek, Adam K. Smith

Exposure to excessive noise over time can cause permanent hearing loss. Workers in the mining industry are frequently exposed to A-weighted sound levels in excess of 90 dB. The A-weighted sound level at the roof bolter operator’s location can exceed 100 dB while drilling. The National Institute for Occupational Safety and Health (NIOSH) measured the sound pressure at the roof bolter operator’s position and utilized a phased array of microphones with beamforming software to identify noise sources on a roof bolting machine while drilling. The test data indicates the sound level at the operator’s position is dominated by the 2000 Hz through 5000 Hz one-third­octave-band sound levels. The beamforming results indicate that the drilling noise is primarily from two areas: the portion of the drill steel just below the rock and the drill steel-chuck interface. This paper will discuss the methods used to identify the primary noise sources.

By G. M. Molinda, J. P. Ulery

Since 1970, abnormally high methane emissions have been observed in eastern sections of the Federal No. 2 Mine operating in the Pittsburgh Coalbed in northern West Virginia. The nature and volume of these emissions indicate a source other than the coalbed. An investigation was undertaken to delineate probable methane sources. Gas well information and stratigraphic correlation of corehole data indicates that a sandstone directly above the main coalbed is an additional source of methane emissions. The sandstone body appears to be an ancient stream channel, infilled with fine-grained sand and organic matter. Coalification of the organic matter produced methane as a byproduct. Additional methane presumably migrated into the sandstone unit from the subjacent coalbeds. The methane became trapped in the porous clasticunit by the surrounding impermeable strata. Mine development near this unit creates a significant pressure gradient, triggering abnormal methane emissions into the mine along naturally occurring fractures. Pre-development methane drainage of the sandstone could be accomplished by completing vertical boreholes along its trend.

Jan 1, 1984

By Parviz F. Rad

The Bureau of Mines conducted rock-cutting experiments under constant normal force and constant penetration in an effort to correlate laboratory data with those obtained in the field. Both independent and interacting groove spacing regions were studied, and optimum and critical cutter spacings were determined. For the laboratory work, the effects of specific energy, muck weight, groove depth, cutting coefficient, and size distribution of the muck for both independent and interacting grooves were studied. For field operations, forward thrust, torque, advance rate, and muck size distribution were the parameters studied. Satisfactory correlation is obtained between laboratory cutting results and field performance data.

Jan 1, 1974

By D. R. Douslin

This report describes an inclined-piston pressure gage that operates from a zero-pressure datum level. The gage is adaptable to accurate vapor-pressure measurements in the low and intermediate pressure range, 0.01 to 40 mm (mercury). Residual friction in the oil-lubricated piston-cylinder combination is eliminated by a unique oscillatory method that is free of end thrust on the piston and allows the full sensitivity of the gage to be realized. The axial component of the weight-to-area ratio of the piston is determined by measuring the angle of inclination with a goniometer that can be read to 1 sec. Accuracy of the gage proper is estimated to range from 0.001 to 0.012 mm from lower to upper pressure limits. Its highest practical sensitivity is about 0.0005 mm. As a test, the vapor pressures of ice and water were measured in the range -30° to +20° C.

Jan 1, 1963

By Verne E. Hooker

Stress relief measurements were made at three underground test sites associated with the Henderson project, American Metal Climax, located in the rugged, mountainous region between Loveland Pass and Berthoud Pass on the Continental Divide in Colorado. Sufficient data were obtained to determine the three-dimensional stress ellipsoid for each site. The measurements were made at hole depths greater than one diameter of the mined opening; thus, calculated stresses are representative of premining in situ conditions. The vertical components of stress are in good agreement with overburden depth including the influence of mountain topography. Horizontal components of stress substantially increase with depth. These components are believed to be influenced by stresses presumably of tectonic origin. The largest measured principal stress was 5,900 psi at a depth of 3.708 feet. The predominant orientation of maximum principal stress for the determinations at greatest depth is in the NW-SE quadrants.

Jan 1, 1972

By Charles F. Weber

Premature blasts of charges of explosives have caused many deaths in anthracite mines, and the causes of many of the blasts were not determined satisfactorily. Investigators often found fairly high potential differences between such metallic objects as rails, pipes, conveyor lines, or sheet-iron chutes in the working place where an accident had occurred. At one mine where a premature blast occurred in a rock tunnel, one workman was killed and two others were injured, and several days later a potential difference large enough to explode an electric squib was detected between the compressed-air pipe and the track rail; the voltage fluctuated and appeared to change with the movement of a locomotive. At another mine, a. workman was killed when a primed cartridge that he was about to load in a blast hole exploded in his hand. During the investigation, a potential difference was found between the conveyor line and the sheet-iron chute. During a 5-year Period, 61 fatalities and 771 nonfatal injuries were caused by explosives accidents in anthracite mines, and one of the chief causes of these accidents was premature blasts.

Jan 1, 1950

By Francis R. Redfern

Newton's method of solving a nonlinear equation is employed to develop a least-squares acoustic emission source location method in which the spatial residuals of the location equations are minimized. These residuals, related to the distances from the least-squares source location perpendicular to the surfaces described by the location equations, permit location error to be estimated to first order along the spatial axes. The solutions obtained by this method are the best spatial solutions to the location equations in the least-squares sense. Also presented is a procedure by which the geometrical control of a transducer array can be evaluated using the rate of change of source location with fractional velocity change.

Jan 1, 1982

By J. E. Dooley

An analytical procedure developed by the Bureau of Mines was applied to the separation and characterization of a 370° to 535° C distillate from Swan Hills (south field), Alberta, Canada, crude oil. Investigators determined the general characteristics of the crude oil by the Bureau's routine method for crude oil analysis. Suitable fractions were prepared for instrumental analyses by utilizing such techniques as isothermal and molecular distillations, chemical treatment, silica-alumina gel chromatography, and gel permeation chromatography (GK). A detailed characterization of the 370° to 535° C distillate was possible by the application of GPC-mass spectrometry correlations and nuclear magnetic resonance spectrometry. Semiquantitative data based on mass Z series distributions were determined and are shown. The data will be valuable in developing future processing techniques and in calculating yields for converting high-boiling distillates into more useful energy forms.

Jan 1, 1973

By Wilbur I. Duvall

This report presents experimental data on the propagation of explosion- generated strain pulses in rock. Tests were performed in 5 different rock types, employing 10 different types of explosives. Charge sizes ranged from 0.5 to 50 pounds, and travel distances ranged from 2.5 to 70 feet. Analysis of the data shows that the experimental peak strain data satisfy an exponential decay propagation law of the form: ?R/W1/3 = Ke ?aR/W1/3. For a particular rock, parameter K is a linear function of the calculated detonation pressure or the calculated energy density of the explosive. For a particular explosive, K is a linear function of the elastic parameter of the rock, p2, a result, which is at variance with elastic theory. The absorption constant, a, is independent of type of explosive but dependent upon rock type. However, no definite relation between a and the physical properties of the rock could be established.

Jan 1, 1959

By R. E. Perry

In connection with a program of coal research at the Southern Experiment Station the Bureau of Mines, in cooperation with the University of Alabama and the various coal operators, conducts washability studies of coal from beds in Alabama and other Southern States in which commercially important deposits occur. One of the main objectives of a washability study is to obtain technically and commercially important data necessary for determining the best methods for preparing and utilizing the Nation's limited reserves of coking coal. Such information is important to conservation because it facilitates selection of preparation methods that will provide maximum yields of coal with low ash and sulfur contents.

Jan 1, 1958

By G. E. McElroy

[During the period July, 1923, to April, 1924, we made a large number of careful determinations of the resistance to the passage of air in selected sections of airways in the metal mines of Butte, Mont. The experiments were conducted with the cooperation of the Anaconda Copper Mining Co., Frank D. Cannon, mining engineer of that company, and Fred P. Gaethke, mining engineer of the bureau, assisted in carrying out this work. This paper summarizes the, main group of data obtained in the form of a table, of friction factors, or coefficients of friction that is, values of K in the generally accented formula or air flow of [P = KSV or H = KSV2 ] where, in units customary to mining practice;]

Jan 1, 1925

By J. C. Kerkering

The Bureau of Mines used mathematical reliability theory to define, for use in the mining industry, the concepts of risk, safety, reliability, hazard, and mean time between accidents. In this report, the definitions are explained theoretically and illustrated by application to actual underground mine accident data extending over a 9-1/2-year period. The theoretical development proceeds along two parallel analytical paths. For each line of reasoning, the data are presumed to be independent. If they are not, the analysis stops, although there are interesting implications when dependency is demonstrated. The first method uses the elapsed times between accidents as the basic data. These elapsed times are fitted to a negative exponential distribution function using least squares and yielding the function parameter, P1 The P1 is used to form the Poisson distribution function for the data, which is then used to define the safety-related concepts. The second method uses the maximum likelihood estimator to formulate a Poisson distribution function for the data. The function is tested for adequacy by a goodness-of-fit test; if the fit is acceptable, the Poison function is used to define the concepts. Both methods were applied to the data base, yielding nearly identical results.

Jan 1, 1987

Aluminum alloys are used in two broad classifications: wrought and cast. Wrought alloy products, which are formed into final shape by rolling, forging, extruding. etc., contain low percentages of alloying elements; whereas cast aluminum products, which generally are not worked before use, may contain higher percentages and a somewhat different selection of alloying elements. For example, wrought aluminum alloys usually contain less than one percent silicon and cast alloys contain as much as 18 per-cent silicon. While there are good techniques available for separating aluminum alloys from mixed scrap, there are no efficient ways to separate wrought aluminum from cast aluminum. The high levels of silicon, iron) copper, and zinc from the cast alloys make wrought-cast mixtures unacceptable for wrought alloy production. Consequently, separated wrought aluminum scrap commands a premium price on the market. Since increasing amounts of mixed aluminum alloys are being recovered from automobile scrap, this separation is important for efficient recycling of these alloys. Approach The difference in thermo-mechanical properties between the two classes of aluminum alloys is used as the basis for the separation process. Casting alloys lose their ductility within a certain temperature range while wrought alloys remain ductile. As temperature increases, aluminum alloys gradually become weaker, and at a certain temperature, each alloy loses strength and ductility due to incipient melting in localized areas. For casting alloys that temperature generally lies between 520° to 560° C, but it is above 600° C for most wrought alloys. Mild crushing, therefore, in the proper temperature range will result in complete fragmentation of the casting alloys but only plastic deformation of the wrought alloys. A simple screening step then is used to separate the oversize wrought pieces from the fragmented cast alloys.

Jan 1, 1984