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By George H. Schnakenberg

Automation of coal mining activities at the face offers improvements in worker safety, health, and productivity. Introduction of integrated computer-sensor systems to current mining machines will enable these machines to perform some of the most hazardous tasks through supervised teleoperation. The U.S. Bureau of Mines is pursuing the development of the enabling technology necessary to achieve this goal. The research program consists of both basic and applied research, each focused on the fundamental issues of computer and sensor technologies. Short-term research is directed to providing computer-assisted, remote supervisory operation of present underground equipment; the long-term goal is the development of progressively more intelligent mining systems. The research program includes a review of robotic machine and autonomous vehicle technologies and of current mining technology, which provides a base for developing innovative mining methods; research in navigation and guidance technology, emphasizing control of a continuous mining machine; research on coal-rock interface sensing technology for horizon control, and rib thickness control in highwall mining; the development of computer systems and hierarchical architectures for real-time control; and development of expert systems for machine system fault diagnostics and predictive maintenance. This report presents a brief background and the current status for each of these research areas.

Jan 1, 1989

By Emory Smith

The Victorville cement plant of the Southwestern Portland Cement Co. is located about 1 mile from the city of Victorville, Calif. Two transcontinental railway systems, the Atchison, Topeka & Santa Fe, and the Southern Pacific Railroad, afford shipped facilities. The plant is modern and well kept, as the officials, especially the higher operating officials, take pride in the appearance of the place. Dust has been practically eliminated by the installation of dust collectors and wet grinding. The plant has a rated capacity of 5,000 barrels of cement daily.

Jan 1, 1929

By L. C. IlsLey

The last previous Bureau of Mines publication relative to details of permissible methane detectors (Bulletin 331, published in 1930) describes detectors of four different types, namely flame, combustion, catalytic, and a combination Weatstone-bridge and catalytic type in which catalytic action at the surface of a platinum filament when in methane causes a change in the temperature and resistance of the filament, thus unbalancing the bridge circuit and giving a reading proportional to the methane concentration. Three detractors of the latter type have been approved since 1930. A brief description of each follows: U. C. C. Detector Approval No. 902, covering the U. C. C. indicating detector, as described in Bulletin 331, was extended. January 27, 1930, to cover important changes in design that permit checking the calibration of the detector at any time whether in gas or fresh air. Essential features of the detector are shown in figure 1.

Jan 1, 1937

By James A. Browning

Following an unsuccessful attempt earlier in the program to develop and market a drill channelling machine, we have designed and tested a new continuous channelling method which reduces operating sound levels to below 100 db. This new method relies on a small diameter oxygen-enriched burner to produce narrow channels. Sound intensities are reduced substantially compared to conventional channel widths. They are further reduced by a water spray directed immediately above the flame. Baffles placed along the top of the channel will reduce sound levels to below 90 db. Cutting rates are greater than those of existing channelling burners with costs per unit of channel area substantially reduced for those cases where oxygen costs are reasonable.

Jan 1, 1981

By W. M. Myers

"The continued expansion of modern industry broadens the markets for minerals and their product. With these increasing demands new uses are being found for minerals that heretofore were considered as possessing no commercial possibilities. This tendency is reflected in the nonmetallic field in a constantly increasing demand for minerals formerly considered to be of scientific interest only, Furthermore, nonmetallic minerals of established commercial importance are used in new ways in various products, and this tends to expand the markets for these minerals. Some recent outstanding developments in applications of minerals are given in the following pages.The Andalusite GroupAmong the minerals that until recently were considered of scientific interest only, may be listed those of the andalusite group. This group is composed of the three minerals, andalusite, cyanite (or kyunite), and sillmanite, which are all forms of the compound Al2SiO5 (A1203, S1O2), and are therefore identical in chemical composition, but differ in physical properties,"

Mar 1, 1924

By L. L. NAUS, R. D. Currie

Hazards in connection with the use of compressed-air jets for ventilating gassy mines are given little consideration by most mine officials largely because compressed air is considered the safest means of transmitting power for operating various types of mining machinery, and the inherent dangers in its use for this purpose are virtually negligible . The installation of compressed-air lines in coal mines leads to the utilization of compressed air for ventilating working places , with the result that , although the primary ventilation systems may be adequate to meet existing needs , proper conduction of normal ventilation has been neglected , so the working faces receive only a small amount ofthe total air circulated through the mine . Reliance in part on compressed air or other auxiliary means for ventilation is always attended by danger that gas will accumulate , due to intermittent operation , and the tendency is to operate auxiliary schemes only. during the working shift ( or possibly only part of the shift ) and to dispense with them during off- shifts or at times during the working shift when gas may accumulate because of lack of ventilation . When the men come on shift the auxiliary ventilating device often may be started without a preliminary examination of the working place , or .. the examination may be made sometime before the oncoming shift arrives , the gas being allowed to accumulate in the meantime. This may result in uncontrolled movement of a body of gas if proper precautions are not taken . Several mine explosions have been caused by the movement of a known body of gas by compressed air into the haulageway, where it was ignited by an arc from a passing locomotive . This danger is more pronounced where supervision is lax .

Aug 1, 1937

By Jan M. Mutmansky

"When, in 1973, a limit was placed on the amount of dust in the coal mine atmosphere, restricting the average exposure of a coal miner to 2 milligrams of dust per cubic meter of air (mg/m'), skeptics in the United States and abroad Said the standard could never be achieved. They cited much more lenient standards already established in other countries and refused to believe that the United States could meet the world's most stringent requirements in mines where dust had never before been regulated. Yet 10 years later the goal had largely been achieved and miners were working underground in a cleaner atmosphere than ever before. It was a major achievement and a big stride in what had become a war on coal workers' pneumoconiosis (CWP), the black lung disease prevalent among miners in underground coal mines.Although the health hazards caused by working in a dust-filled mine atmosphere have long been recognized, the problem became particularly acute in this century with the mechanization and increased productivity of underground coal mining. The United States was much slower than some other countries to address the problem of respirable diseases among miners. While dust levels in South African gold mines were first regulated in 1912, in the United States it was only when 476 workers died of silicosis while blasting a tunnel through a mountain near Gauley Bridge, West Virginia in the 1930s that widespread public attention became focused on the plight of workers in dust-filled environments. Another 30 years passed before regulation of dust finally became law in the Coal Mine Health and Safety Act of 1969.With a stringent new standard imposed in all underground coal mines, the industry was faced With the daunting problem of reducing levels of airborne dust from perhaps 6.5 mg/m' to 2 mg/m', in an inherently dusty operation carried out in the close confines of underground passageways. Most of the coal dust is made by the cutting operation in which the continuous miner or longwall machine can produce several thousand milligrams of respirable dust for each ton of coal mined. Other dusty operations such as drilling holes for roofbolts, loading and unloading coal on shuttle cars, and the operation of conveyor belts contribute to the overall problem.Since the institution of the new dust control standards, a number of strategies have been adopted for reducing the coal dust in the mine atmosphere. These strategies involve engineering and design improvements that help lo prevent the generation of particles, keep particles of dust from becoming airborne, carry dust away from the working area, and isolate the dust from the workers in the mining operation. These procedures have been pursued vigorously by the Bureau of Mines, and many successful methods have been developed to reduce the mass concentration to which the workers are subjected. The mining companies were reluctant at first to confront the problems but after a period of trials and gradual improvement, they joined with others in the fight to reduce the dust concentrations in the working place."

Jan 1, 1990

By Alan G. Mayton

The Bureau of Mines conducted a study to (1) determine from laboratory tests the feasibility of a photographic method for determining reflec-tances that may be applied to measuring in-mine mineral reflectances and (2) formulate a procedure for collecting and analyzing the data. The method uses a 35-mm camera with automatic flash and a gray-scale re-flectance standard to collect on film the reflectivity data in under-ground mineral mines. After the film is processed, the data on the photographic prints are analyzed in the laboratory with a photometer. Test results show the photographic method can provide values of reflec-tance to within ±5 pet of full scale (full scale = 100 pet). The method's usefulness for determining reflectivity values, within similar limits of absolute percent error at the lower end of the scale, however, has not been completely resolved by the study and consequently warrants further investigation. The method offers an acceptable means for collecting and analyzing reflectivity data for reflectivities at the higher end of the scale, i.e., 50 pet or above; it should be used with caution when reflectivity values are below 50 pet. Four films were evaluated; all gave relatively satisfactory results.

Jan 1, 1987

By Alvin Schallis

Of all the uses for dolomite that depend on its magnesia content, perhaps the most important is its use in basic refractories. The quantities of dolomite (including both that used as crude and that calcined before use) sold or used for refractory purposes by producers in the United States for 1920-41, inclusive, are shown in figure 1. As can be seen from the chart, the utilization of dolomite as a basic refractory is far from new; it was, in fact, the first basic refractory used extensively in open-hearth steel furnaces. After large deposits of magnesite were opened in Austria-Hungary, the use of dolomite in the open hearth declined somewhat, only to be actively revived during the World War of 1914 to 1918, when supplies from Austria were shut off. The use of dolomite as a refractory in the steel industry again declined slightly for a brief period after the Armistice, but subsequently its use has tended steadily to increase, latest statistics indicating that more dead-burned dolomite is used per ton of open-hearth steel now than during the World War of 1914 to 1918. Despite fluctuations in consumption, dolomite has continued to be by far the most widely used basic refractory material. The following table, showing the quantities of basic refractories consumed in the manufacture of steel, the principal outlet, indicates the relative importance of dolomite. The chief reason for the widespread use of dolomite as a basic refractory is its relatively low cost. Its abundance and the proximity of the deposits to the steel industry (see fig. 2) afford every incentive to enhance the desirable physical properties of dolomite refractories and to ameliorate certain of their less desirable characteristics. The present emergency, with its huge demands upon the steel industry, has lent further impetus to the work of improving dolomite refractories.

Jan 1, 1942

By J. D. Spagnola

The Bureau of Mines conducted research to obtain comparative data on the extent of reduction of galena and sphalerite with molecular hydrogen and with hydrogen from the thermal cracking of ammonia and methane at various time intervals. Galena reductions of 95 to 99 percent were obtained with H2 and with decomposed NH3 while reductions of 70 to 80 percent were obtained with cracked CH4? Sphalerite reductions of 99 percent were obtained at 1,000° C with Hz and with decomposed NBs; however, complete volatilization of the free zinc from the remaining concentrate and the subsequent recombination of zinc and sulfur vapors resulted. A promoted iron catalyst brought about a decrease of 100° C in the temperature required for complete decomposition of ammonia. It was found that H2S retards NB3 decomposition and that nitrogen retards the reduction of galena by H2? A mixture of N2 and He in about the same ratio as that obtained by the thermal cracking of NBs gave about 15 percent less reduction of galena than was obtained with decomposed NB3; this indicates that a portion of the hydrogen obtained by NBs decomposition is in an active form.

Jan 1, 1965

The objectives of this research were to examine and to laboratory performance of several brands of rigid urethane een brands, produced by 13 manufacturers, were examined. was performed in a laboratory under controlled conditions. document the foam. Eight-All testing Preliminary laboratory tests included flame spread evaluations, flame penetration, ignition temperatures, air permeability, and adhesion. Having established arbitrary cutoff values, the original 18 candidates were narrowed to 8. More specialized tests followed. The effects of water immersion and dry aging on flame spread performance and other physical properties were then examined. This Bureau of Mines report was written to provide information for those concerned with using rigid urethane foam as a sealant. Its intent is to describe the various laboratory evaluations performed and to delineate the performance of each candidate. This report neither promotes nor discourages the use of rigid urethane foams. It presents results that will enable those responsible for using or enforcing the use of rigid urethane foams in underground mines to make informed decisions.

Jan 1, 1985

By S. J. Gerdemann

In support of its objective to improve mine safety, the Bureau of Mines has searched for better materials and systems to anchor roof bolts. TIlis report describes a study on the effects of mine waters upon accelerated gypsum, one of the materials under consideration. The accelerated gypsuw dissolved at an appreciable rate relative to an assumed 10-yr life span of a roof bolt. Surface orientation, initial ion concentration of a dissolving solution, and flow rate of the solu-tion had substantial effects on the dissolution rate. Factors such as water-cement ratio, accelerator content, wax capsule additions to the gypsum in cartridge-installed bolts, surface area, temperature, and curing duration had little effect. In an actual roof-bolt environment, dissolution will occur in static solutions to the solubility limit of gypsum (~2 giL) and cease, result-ing in minimal damage; but in flows of unsaturated solution as slow as 1 L per month, a loss of up to 10 pct will occur in 2 yr. Since miners cannot readily measure the flow or ion concentration of static-appearing water at every roof-bolt site, all such water must be assumed to be pure and flowing. It is recommended that gypsum-bonded roof bolts be confined to dry roofs only.

Jan 1, 1983

By John J. Sammarco

Computer-related accidents have caused injuries and fatalities in mining as well as other industries. Normal accident theory (NAT) explains that some accidents are inevitable because of system complexity. NAT is a classic argument in organizational sociology although it has been criticized as having imprecise definitions and lacking criteria for quantifying complexity. These limitations are addressed by a unique approach that recasts this organizational theory into an engineering-based methodology to quantify NAT complexities of computer-based systems. In this approach complexity is categorized as external or internal. External complexity is defined by the external behavior of a system, and is quantified by these dependent variables: system predictability, observability, and usability. Dependent variable data contain the perceptions of 32 subjects running simulations of a system. The system?s internal complexity is characterized by modeling system-level requirements with the software cost reduction (SCR) formal method. Model attributes are quantified using 15 graph-theoretical metrics?the independent variables. Five of 15 metrics are correlated with the dependent variables as evidenced by structure correlations exceeding 0.25, with standard errors <0.10 and a 95% confidence interval. The results also show that the system predictability, observability, and usability decreased as NAT complexities increased. This research takes a step forward in operationalizing NAT for computerized systems. The research benefits mining and other industries as well.

Jan 1, 2005

By E. R. Rodriguez

Improved practice resulting from recent changes in the method of supplying compressed air and in pneumatic drilling equipment used in secondary drilling and in development work at the Morenci mine of the Phelps Dodge Corp., has resulted in improved safety conditions, as well as in a reduced cost per foot of drilling. A large stationary compressor installed outside the mining area and the compressed-air pipelines in the mine were replaced by portable compressor units. A self-propelled, self-contained drilling unit was obtained for drilling large footages where short moves were involved. Large wagon-drill units were replaced by faster and lighter drill machines and conventional bits by carbide insert bits. The safe practices employed in air drilling and in the related blasting and scaling operations have contributed to an excellent safety record at this mine. The complete sets of instructions listed in the company codes of safe practice aid materially in training employees.

Jan 1, 1956

By C. W. Owning

"The Bureau of Mines has repeatedly emphasized the necessity of completely ""rock-dusting all coal mines, except anthracite mines, in every part whether in damp or dry condition."" Every open accessible part of, the, mine without exception should be thoroughly rock-dusted, including parallel entries, air courses, trackless entries, crosscuts, and rooms to within at least 40 feet of every coal face. Very few mines have followed this recommendation and warning, with the result that there have been explosions not only in mines which have not used rock dust but also in so-called rock-dusted mines. Following a number of mine explosions it has been reported that the mine was rock-dusted,"" whereas it is probable that only some of the haulage roads had been given a hurried application of rock dust and in most instances not as much as 5 per cent of the mine was really rock-dusted. That is not rock-dusting.Some conscientious, well-meaning mining men have felt that rock-dusting of haulage roads would effectively stop an explosion; however, when shown, through widespread explosions in mines ""well rock-dusted"" according to the above method, that leaving large areas undusted, furnishes paths through which a violent explosion may travel, these mining men have realized the necessity of thorough rock-dusting and have adopted this explosion-prevention method.The Mather Collieries mine, Pickands, Mather and Co., operators, at Mather, Pa., was the first mine in Pennsylvania to receive, full credit for rock-dusting under the new 'stringent ruling of the Pennsylvania Compensation Rating Bureau, the provisions of which require that:"

Feb 1, 1931

By J. V. Scalera

Because of U.S. dependency on imported critical metals, the Bureau of Mines has conducted research to evaluate the possible substitution of nitrided low-alloy steels for higher chromium-containing alloys. The corrosion data for nitrided steels are limited primarily to the Soviet literature. The objective of this study was to determine the corrosion properties of six commercially nitrided low-alloy steels in a 5-wt % NaCl solution at pH 4. Weight-loss tests indicated that, in deaerated test solutions, most of the nitrided steels were less corrosion resist-ant than nontreated steels. However, electrochemical tests indicated that under more oxidizing conditions, nitrided materials are converted to a passive state with a significantly reduced corrosion rate. Elec-trochemical tests performed in an aerated environment confirmed the passivity of the samples in an oxidizing environment.

Jan 1, 1984

By Maurice J. Peterson

THE VISUAL-ARC spectroscopic method of rapid qualitative analysis of complex inorganic compounds has been popularized in the past few years and is being employed by an increasing number of laboratories. The mineralogy and chemistry departments of several universities recently have added visual spectroscopy to their laboratory curricula. This revival of interest in a somewhat dormant analytical method has been stimulated through the publication of three papers 4 by members of the College Park staff of the Bureau of Mines. These virtually are the only recent sources of information on visual-arc spectroscopic analysis. They include data on the spectroscopic assembly, the analytical procedure, and the practical application of the method to determinative mineralogy and related fields. Requests for reprints of these papers continue to be received; at present only a limited number of copies are available for distribution. In order that these requests may be adequately answered, material from the three papers has been combined and, with some additional data, is presented in this bulletin. Numerous specific inquiries have been received regarding types of equipment available, problems in instrumentation, and information on the approximate sensitivity limits of the elements that can be detected by this method. Some of this material was not included in the original papers. Accordingly, the table of wavelengths has been revised to include the approximate visual-arc spectroscopic sensitivities, and a section on commercially available equipment has been added.

Jan 1, 1953

By Roger L. King

The Bureau of Mines has developed probes to be used in emergency mine rescue operations by being lowered through a borehole drilled into an underground mine. Various probes can provide two-way voice communication with trapped miners, continuous mine atmosphere monitoring, temperature indication, and television searching capability. At present, an infrared imaging probe is being developed for "seeing" through coal smoke.

Jan 1, 1976

By A. Bartkowiak

The lower flammability limit of methane at 0 p.s.i.g. and ambient temperatures is 5.6 volume percent in chlorine, 5.2 in oxygen, and 5.0 in air. The corresponding upper limit values are 70, 60.5, and 15 volume percent, respectively, so that the range of flammable mixtures is greater in chlorine than in oxygen or air. The lower flammability limit of ethane at 0 p.s.i.g. and ambient temperatures is 6.1 volume percent in chlorine, 3.0 in oxygen, and 2.9 in air. The corresponding upper limits are 58, 66, and 12.5 volume percent, respectively. In this instance the range of flammable mixtures is greater in oxygen than in chlorine or air. Generally, the limits of flammability for both methane-chlorine mixtures and ethane-chlorine mixtures widen with increases in temperature and pressure.

Jan 1, 1960

By Ellsworth R. Spencer

A lightweight fiberglass feed leg for hand-held pneumatic percussion rock drills has been fabricated and tested by the Bureau of Mines. Its lighter weight facilitates easier handling of the rock drill apparatus, thereby reducing the potential for back injury to the driller and in- creasing drilling productivity. Current hand-held feed leg drills of the same class are 50 pct heavier than the Bureau-devised feed leg drill, which is comprised of a reduced-noise drill and the fiberglass feed leg. In-mine tests of the fiberglass leg showed that its performance and cost are comparable to those of standard aluminum feed legs.

Jan 1, 1985