Search Documents

By Dana C. Reinke, David K. I Ingram

Researchers at the National Institute for Occupational Safety and Health partnered with the water well industry to develop engi­neering control technologies and training products to address noise exposure at the job site. Noise­induced hearing loss continues to be a problem in the well drilling industry. Research con­ducted by NIOSH found that air rotary drill rigs produce sound levels more than 90 dB(A) over the course of an eight­hour workday. Sounds levels above 90 dB(A), identified during hammer drilling and the hammering of casing, exposes workers to levels that can damage hearing. A typical air rotary drill rig provides no barrier, for noise and dust pro­tection, between the drill’s control panel and the drill stem. The development of a partial cab is the clearest example of NIOSH’s research partnership with the water well industry. NIOSH researchers determined that an engineering noise control to protect the oper­ator at the rig’s control panel would be effective, based on typical work site conditions. Many surface rigs do not have full cabs as a result of the original equipment manufacturer design or the high cost of aftermarket products. Developed as a partial cab, the NIOSH engineer­ing noise control design addressed stakeholders’ needs associated with cost, transport, and worker usage (Figure 1). Field tests found the partial cab effective in reducing sound levels at the rig’s control panel, a typical location for a drill rig operator. Sound levels at the control panel were reduced from 104 to 96 dB(A) (Figure 2). Coupled with continued use of personal protective equipment, such as hear­ing protection devices, the partial cab can help to reduce noise exposure. NIOSH researchers created a CD with informa­tion about noise exposure and the partial cab. Most important to well drilling companies is information on how to construct and attach the partial cab to drill rigs. The CD can be viewed on a standard computer and includes a video of the partial cab in use on a work site. Computer­aided design drawings are included on the CD and provide detail of the cab design as well as information on construction mate­rials and design details. Additionally, the CD provides background infor­mation on noise­induced hearing loss and hearing protection devices to increase knowledge about this occupational health concern. This information can be viewed by all company employees to help promote the partial cab’s importance to workers using the cab. More information on the partial cab noise control technology can be downloaded from www.cdc.gov/ niosh/mining NIOSH researchers also examined the health and safety training needs of workers in the ground water industry. It was quickly realized that most workers learn health and safety on the job and do not attend any sort of formal training. In addition, there is not a lot of time for daily “tailgate talks” or “shop talks” on health and safety issues. As a small business industry, the owner is often operating a drill rig along with his other employees. In general, new employees learn the job in an apprentice style sys­tem. As a result, workers and owners have few opportunities to access uniform health and safety information based upon the job — an outdoor work environment with daily change in work sites. With this information, NIOSH researchers devel­oped two products that deliver health and safety information to fit into the daily work of well drillers. Both are information circulars and are available through download at www.cdc.gov/niosh/mining and the NGWA Web site at www.ngwa.org/publication/ publications.cfm. These circulars are: Water Well Safety Bits. This booklet provides information in a “quick bites” style. It is pre­sented in a magazine format and can be left on

By R. A. Beall

Homogeneous zirconium-alloy ingots have been cast on a production basis by the consumable-electrode arc-melting process at the Northwest Electrodevelopment Experiment Station, Bureau of Mines, Albany, Oreg. This paper describes the various methods used to introduce alloying materials into the ingot and evaluates 1 each method by the degree of homogeneity of resulting ingots, as determined in tests on sections cut from the ingots. As many as 30 or more ingots, each 6 to 10 inches in diameter and weighing 300 to 500 pounds, were melted, using each method; and, as most of them subsequently were fabricated to strip 0.1 inch thick, the test results are considered to be representative of production practice. Ingot homogeneity has been considered more difficult to achieve in arc-melting practice than by methods where the molten metal is poured into molds and the addition can be stirred into the total mass of metal before casting. Owing to the unique requirements of consumable-electrode arc melting the addition can be made only to that part of the total mass of the ingot that is molten at one time. Observation of the flowlines in 500-pound ingots produced at Albany indicates that the molten pool has a maximum depth about equal to the ingot diameter. The weight of metal molten at one time is, therefore, not over 100 pounds. Characteristically, the arc-melting process is conducive to segregation, which can be overcome, at least partly, by adding the alloy constituents almost continuously during casting.

Jan 1, 1956

By Kihong Park, Matthews C. Habjan, Arthur L. Miller

New Mining Safety and Health Administration (MSHA) regulations limit the mass concentration of airborne diesel particulate matter (DPM) or, more specifically, the concentration of elemental carbon (EC), in underground mines. The mine operators are responding by introducing a variety of controls to reduce DPM in the mines, potentially including the evaluation of new maintenance procedures to reduce underground mine vehicle emissions. There is currently a lack of an inexpensive and dependable method to directly measure the DPM concentration emitted from the vehicle tailpipe. To that end, this work demonstrated a simple field portable method for estimating the mass concentration of elemental carbon exiting the tailpipe of a diesel engine using a direct reading photometer. Simultaneous measurements of tailpipe exhaust were made with a Thermo Electron Personal DataRAM 1200 photometer (particulate mass concentration based on light scattering) and by analyzing PM2.5 and PM1.0 samples collected on quartz fiber filters using the National Institute of Occupational Safety and Health (NIOSH) method 5040 (mass concentration of EC via thermal-optical method). Results indicate surprisingly good correlation (R2 ) 0.97) of the two methods when the data are adjusted for relative humidity (RH) and corrected using an empirically generated calibration factor. Although preliminary, it may be possible to implement this method in maintenance shops to monitor emission trends and to compare emissions of various vehicles in a fleet. Such data will be useful for fleet planning to meet new air quality standards.

By William R. Vogel

The Bureau of Mines Information and Analysis organization collects worldwide data on virtually every commercially important nonfuel mineral commodity. These data form the base for tracking and assessing the health of the minerals sector of the U.S. economy. This data collection activity was instituted by the 47th Congress in an appropriations act of August 7, 1882 (22 Stat. 3291, to place the collection of mineral statistics on an annual basis. The most recent authority for the Bureau of Mines Information and Analysis activity is the National Materials and Minerals Policy, Research and Development Act of 1980 (Public Law 96-479, 96th Congress), which strengthens protection for proprietary data provided to the U.S. Department of the Interior by persons or firms engaged in any phase of mineral or mineral- material production or consumption.

Jan 1, 1989

By Peter Swanson, John Rettkowski

As part of a research program to reduce injuries and fatalities in the U.S. mining workforce, NIOSH is investigating the potential use of noncontact vibration measurements to identify hazardous ground fall conditions. In the present study, the effectiveness of remote vibration sources in exciting resonant responses in damaged structures is examined. Initial experiments were performed on a damaged concrete slab in a controlled environment. Vibration response was measured with a laser Doppler vibrometer using both single-point and two-dimensional array recordings. Excitation sources included direct mechanical impacts to remote portions of the slab and a remotely located industrial demolition hammer. Surficial damage was effectively delineated with both sources through visualization of vibration response in spectral bands selected to discriminate wave propagation from large-scale slab resonance effects.

By J. Chilton

The fact that methane ignitions continue to occur at the mining face indicates that monitoring with machine-mounted methanometers does not always indicate the presence of high methane concentrations. Methane concentrations at the face change quickly due to changes in airflow. By measuring these changes in airflow, it may be possible to predict changes in face methane levels more quickly. Currently there are no techniques or instruments to accurately measure airflow in by the mouth of the ventilation curtain or tubing. Tests conducted in the NIOSH ventilation test gallery compare the data provided by one-, two-, and three-axis ultrasonic anemometers. The effects of changes in airflow direction and turbulence on instrument readings are discussed, and guidelines are given for selecting the type of instruments to be used for monitoring airflow near the mining face.

MFIRE is a computer simulation program that performs normal ventilation network planning calculations, and dynamic transient state simulation of ventilation networks under a variety of conditions. The program is useful for the analysis of ventilation networks under thermal and mechanical influence. MFIRE simulates a mine's ventilation system and its response to altered ventilation parameters, external influences such as temperatures, and internal influences such as fires. Extensive output enables detailed quantitative analysis of the effects of the proposed alteration to the ventilation system Network simulation using digital computers has become widespread throughout the mining industry in recent years. However, as the sophistication of the simulator increases (MFIRE, for example), the complexity of input data requirements and interpretations of results requires more skill and knowledge from the users. Perhaps the most difficult part of using MFIRE is to construct the data set describing the mine's physical layout and its ventilation properties. The initial attempts to get the data set running often reveal unknown or ignored aspects of the mine's ventilation. MFIRE was written in Fortran 77 and compiled with Microway1 Fortran for the Intel 80386 based computers with a 80387 math co-processor. The source code is portable and available for users who wish to modify the source code to operate on other computers. This user manual describes the development of MFIRE, the input format and requirements, the output, common errors, fire parameters, and examples MFIRE application. Valuable reference material is included in the appendices. Knowledgeable users may skip directly to the PROGRAM INSTALLATION AND OPERATION section to begin using MFIRE immediately.

Jan 1, 1995

By M. C. Chapman, P. L. Swanson, A. T. Iannacchione

The National Institute for Occupational Safety and Health (NIOSH) evaluated microseismic activity from three field sites to compare and contrast the characteristics of microseismic emissions from very different geologic, stress, and mining environments. Recently, NIOSH has embarked on a research program to evaluate the use of microseismic monitoring information to identify roof fall failure processes and to assess its potential to warn of unstable roof conditions. Large roof instabilities, such as roof falls and certain roof caving events, have proven difficult to anticipate representing an increased risk to miners working in these inherently hazardous areas. When local failure processes are better understood, appropriate control measures can be engineered to mitigate these hazards. This study used microseismic emissions to help identify three local rock failure processes. It was also shown that analysis of microseismic emissions can aid in assessing the degree of instability associated with these local rock failure processes.

By Irving Hartmann, F. P. Christofel, John Nagy, E. B. McGibbeny

"INTRODUCTION When permissible explosives are used in c procedure recommended by the Bureau of Mines 5/ they are relatively safe, and, no mine explosions are known to have resulted from this type of blasting. However, unsafe blasting practices - the use of nonpermissible explosives or the improper use of permissible explosives - have caused many serious disasters. In fact, such unsafe practices constitute the third most important cause (exceeded only by electricity and the use of open lights and smoking) of coal-mine explosions in the United States. During 1929-1947, inclusive, 81 explosions, resulting in 475 fatalities, were ascribed to unsafe blasting. 6/The hazards of black powder, dynamite, and other nonpermissible explosives in coal mines have been recognized for many years, and attention has been called to this in numerous Bureau of Mines publications. Not only can these explosives ignite flammable gas-air mixtures readily, but they can also ignite coal dust, as has been illustrated repeatedly in tests and at educational public demonstrations at Bruceton and elsewhere. 7/Research in the Experimental coal mine 8/ of the Bureau of Mines at Bruceton, Pa., and unfortunate experience in commercial mines have proved beyond doubt that improper use of explosives that have passed the official permissibility tests can cause as explosions. In limited tests with a fey American permissibles at Bruceton, and in more, extensive tests with permitted explosives at the Polish experiment station, 9/ explosive charges were fired from steel cannon and freely suspended in coal-dust clouds. In these experiments coal dust was ignited under some conditions. However, it has never been definitely established whether permissible explosives can initiate coal-dust explosions when fired in a coal seam. It is true that a few mine explosions were strongly suspected to have resulted from ignition of coal dust by misuse of permissibles, but in each case other complicating factors introduced some doubt in the minds of the investigators. Full knowledge of the problem is important, because coal dust is present in most blasting operations in coal."

Apr 1, 1952

By Thomas M. Barczak

Roof support technology for longwall tailgates has changed dramatically during the past decade. Filling tailgates with conventional wood cribs is becoming the exception rather than the rule. Modern engineered timber support systems and a host of other alternative support products provide far greater capacity as well as stiffer response, thereby allowing the supports to resist roof movement with much less displacement than the soft wood cribbing used in the past. For these reasons, these products can provide superior roof control. In addition, the material handling requirements for support installation have now become a major consideration in the support design and selection process. Products such as conventional wood cribbing that require piece-meal construction of bulky, heavy components have diminished, while prop-type supports and products that can be installed with machinery and pumpable support technologies have grown in use resulting in fewer injuries to mine workers. Now, the opportunity exists to provide the safest, most cost effective support system, through engineering design rather than by trial and error and to optimize the use of the support system chosen. Yet this is rarely done. The key to accomplishing this task is to understand the interaction of the support system with the ground conditions at the installation site. A major focus of the paper is to conceptualize the support and interaction through the use of a ground reaction curve which relates the support resistance to the convergence of the longwall tailgate. The goal of any roof support design is to control the ground deformations and maintain the structural integrity of damaged or broken ground to the extent possible to provide a stable mine opening. In general, deformations will be a function of the stress environment and inherent strength of the surrounding rock mass. However, if the deformations are intimately linked to the stress changes such that the deformation can be controlled by the load resistance or reinforcement provided by a roof support system, then the loading behavior can be described as load-controlled. Conversely, if the deformation occurs irrespective of the installed support (assuming practical limitations), then the loading behavior is described as displacement-controlled. In this case, the deformation can be considered irresistible from a practical standpoint. In this context, the nature of the loading has significant consequences on the support design requirements. Finally, examples using the NIOSH Support Technology Optimization Program (STOP) to develop design criteria using ground reaction data from underground studies and ways to include uncontrolled convergence as part of the design criteria for standing roof supports will also be discussed.

By Suresh K. Bhatt, Christopher Mark

Fatalities caused by highwall/spoil bank failure in the surface mines, coal and non-metal, increased to an alarming rate of seven during 1999. To determine the causes of slope failure and successful mining practices, the National Institute for Occupational Health and Safety undertook a study. The study included: 1.A review of accident statistics; 2.A review of Federal and state mining laws pertaining to surface mining; 3.A literature review, and; 4.Mine visits. The study emphasized surface mines in the states of West Virginia, Ohio, and Pennsylvania. The review of a decade’s accident statistics using the mine Safety and Health Administration’s (MSHA) database showed that approximately 40% of all ground control related incidents reported to MSHA occurred in just four eastern states: Kentucky, West Virginia, Pennsylvania, and Ohio. The comprehensive literature search provided a historical perspective of highwall stability issues. Eleven mines we visited to obtain data on their mining practice or design. Commodities included coal, sandstone, and limestone. Based on the visits, five case studies were developed to represent typical mining methods and effective ground control practices used in eastern surface mines. Benching was found to be a common technique to reduce the overall highwall slope angle. Decking in the softer zones, such as shale, proved useful in controlling damage due to blasting.

The Bureau of Mines Minerals Information organization collects worldwide data on virtually every commercially important non fuel mineral commodity. These data form the base for tracking and assessing the health of the minerals sector of the U.S. economy. This data collection activity was instituted by the 47th Congress in an appropriations act of August 7, 1882 (22 Stat. 829), to place the collection of mineral statistics on an annual basis. The most recent authority for the Bureau of Mines Minerals Information activity is the National Materials and Minerals Policy, Research and Development Act of 1980 (Public Law 96-479, 96th Congress), which strengthens protection for proprietary data provided to the U.S. Department of the Interior by persons or firms engaged in any phase of mineral or mineral-material production or consumption.

Jan 1, 1984

By Thomas O. Glover

Cameroon continued to enjoy sustained economic growth that began with its independence in 1960. Growth in the gross domestic product (GDP) averaged 2.8% per year during the 1960's and the first half of the 1970's. Starting in 1976 and for the succeeding 10 years, the GDP accelerated rapidly owing to the coming on-stream of Cameroon's small but domestically significant offshore oil industry. In 1985, the GDP grew by 7.8%, but in 1986, it was only up 5.5%. The country's sustained economic growth in dollar terms of gross national product (GNP) per capita reached $1,075 in 1986. The ranking in GNP per capita by the International Monetary Fund put Cameroon in the middle-income category for developing countries. The sustained economic growth rate up to 1986 was due to the injection of income from oil into the economy, but crude oil price reductions in 1986 brought a slowdown. In 1986, crude oil production grew to 200,000 barrels per day, an increase of 8.2% from that of 1985. Most of the oil came from the Société Nationale Elf Aquitaine (SNEA) wells in the multifield Rio del Rey complex. Additional output came from the Moudi Field operated by Compagnie Française des Pétroles S.A. Proven oil reserves in Cameroon were 540 million barrels. At 1986 production rates, and in the absence of further discoveries, Cameroon will have exhausted its recoverable oil reserves by the year 1995. Owing to worldwide crude price reductions, the country's oil income fell 60% between 1985 and 1986, from $1.82 billion2 to $0.72 billion. Cameroon's refinery operator commenced operating the Sonara refinery in 1981 at Point Limboh. Sonara's capacity of 43,000 barrels per day was small by most standards. In 1986, natural gas reserves, estimated at 100 billion cubic meters, were not produced commercially because there were no domestic users. Proposals for a multibillion-dollar liquefied natural gas plant at Kribi had been submitted; however, work on the plant had not commenced.

Jan 1, 1988

By J. M. Riley

The Bureau of Mines investigated a promising new technology for recovering A1203 from alunite to support the Bureau's alumina miniplant project. Results are presented for a study of the technical feasibility of treating alunite crushing and grinding reject fines for recovery of A1203. Alunite pellets having sufficient strength and resistance to degradation were produced by combining fines and coarse alunite with a KOH binder. The best pellets were prepared, in a laboratory pelletizer, by adding 1 pct KOH as a 5-pct solution to a mixture of 40 pct alunite dust (98 pct minus 65 mesh) and 60 pct coarse alunite (minus 20 plus 65 mesh). Calcines suitable for K2SO4 and A1203 recovery were produced by reducing dehydrated alunite pellets with sulfur in a laboratory shaft furnace for 4 h at 600° C, followed by air oxidation of the reduced calcine for 1 h at 600° C. This report presents design calculations, schematic diagrams, and discussions of the essential features of a proposed process research unit (PRU)--a continuous, 6-lb/h alunite shaft furnace--for studying the process.

Jan 1, 1983

By Stephen C. Tadolini, Thomas M. Barczak, Peter (Yunqing) Zhang

A cooperative study was conducted with Emerald Coal Resources, L.P., an affiliate of Foundation Coal Corporation, and the National Institute for Occupational Safety and Health (NIOSH) to evaluate the effectiveness of (partially) pre-driven longwall recovery rooms supported with pumpable roof supports. This paper evaluates the load transfer mechanics associated with the advancement of the longwall face into the pre-driven recovery room and the widening of the room to recover the longwall shields. The results show that the yielding of the panel fender produced uncontrollable convergence that caused yielding of the shields and stiff pumpable roof supports when the face was approximately 10 ft from the recovery room. The shields continued to yield until the face advanced into the recovery room. Convergence in the pre-driven recovery room typically reached 6-8 in once the pumpable supports yielded and shed load through a declining residual load capacity prior to being cut out by the longwall shearer. Roof deformations occurred beyond the 32-ft horizon with total deformation ranging from 2 to 4 in, indicating that standing support was necessary to help control the span as the longwall face advanced into the pre-driven recovery room. Stability improved as the pumpable supports were cut out, thereby reducing the span between the shields and the outby pillars. In the end, the shields were successfully recovered under stable ground conditions. However, a disconcerting discovery was the load shedding of the outby pillars as the recovery room was mined into. It is postulated that this may be due to the progression of the rear “abutment” moving toward the recovery room as the panel fender and standing support in the recovery room yield and shed load. This behavior was not expected with a relatively narrow room that is fully supported with standing support. If this mechanism is indeed occurring, the width of the room and performance of the standing support becomes even more critical. Premature failure of the support can lead to excessive convergence on the shield line that cannot be controlled even with modern shields, resulting in roof instabilities that can lead to catastrophic results.

By Gabriel Esterhuizen, Tom Goodwin, Scott Schilling, Anthony T. Iannacchione

The Roof Fall Risk Index (RFRI) is a new method introduced by the National Institute for Occupational Safety and Health (NIOSH) to assist the underground stone mine operator in 1) assessing defects the mine strata and 2) rating the relative roof fall risk these defects pose. The RFRI utilizes observational techniques to identify defects in the roof strata caused by local geologic, stress, and mining conditions. Assessment values for ten defined defect categories provides the foundation for estimating a range of risk conditions between 0 and 100 that define the potential for a roof fall. This paper examines how the defect information is collected using two field verification sites and proposes methods to analyze the RFRI data. These examples provide information on how well the method replicates observed conditions and how it might be applied in practice.

By Michael J. Sapko, Gregory M. Green, Kenneth L. Cashdollar

The National Institute for Occupational Safety and Health (NIOSH) and the Mine Safety and Health Administration (MSHA) conducted a joint survey to determine the range of coal particle sizes found in dust samples collected from intake airways of US coal mines. The last comprehensive survey of this type was performed in the 1920s. The size of the coal dust is relevant to the amount of rock dust required to inert the coal dust, with more rock dust needed to inert finer sizes of coal dust. Dust samples were collected by MSHA inspectors from several mines in each of MSHA's 10 bituminous Coal Mine Safety and Health Districts. Samples were normally collected in several intakes at each mine. The laboratory analysis procedures included acid leaching of the sample to remove the limestone rock dust, sonic sieving to determine the dust size, and low-temperature ashing of the sieved fractions to correct for any remaining incombustible matter. The results indicate that particle sizes of mine coal dust in intake airways are finer than those measured in the 1920s. This finer size coal dust in intake airways would require more incombustible matter to be effectively inerted than the 65% incombustible specified in current regulations.

By Avery H. Reed

RECORD production of cement, clays, salt, sand and gravel, and stone highlighted the mineral industry of the State in 1956. Coal and iron-ore production declined owing to increased imports of foreign iron ore and decreased demand for metallurgical coke. Alabama ranked second in production of bauxite and of native asphalt, and third in output of iron ore. New developments in the State included the Citronelle oilfield and its 97 wells, which more than doubled the total production of petroleum compared with 1955. There is no question about the impetus that field has given to the oil and gas industry in Alabama, now 13 years old. The State's 4 oilfields are in southwest Alabama and its 1 gasfield is in Marion County, in the Warrior coal basin.

Jan 1, 1958

By James R. Boyle

The value of Alabama's nonfuel mineral production in 1981 was $312.7 million, a decrease of $15.7 million from that of 1980. Output of most non fuel minerals declined; cement, crushed stone, lime, clays, and sand and gravel were the major commodities produced in the State. Alabama led the Nation in the production of crushed marble; was second in bauxite; third in native asphalt, kaolin, and oyster shell; fourth in bentonite, dimension marble, and fire clay; fifth in masonry cement; and sixth in common clay, ferroalloys, and lime.

Jan 1, 1983

By Elaine T. Cullen

Miners, like many skilled blue-collar workers, are not traditional learners. They have not always been successful in classroom-type settings, preferring to learn on the job in a hands-on environment. U.S. law requires that miners have a minimum of 8 hours of safety training annually, plus 40 hours for underground miners and 24 hours for surface miners when they enter the industry. However, miners rarely view this training time positively. In fact, it has been called “safety jail” by many, who regard it as a time to get a little extra sleep While mining has become far safer in the past 100 years, it is still a dangerous occupation. The Office for Mine Safety and Health Research, a part of the National Institute for Occupational Safety and Health (NIOSH), has funded a project for the past 4 years to address this challenge. The purpose of the research was to find a way to develop effective safety training for these people. Miners are born story tellers. They share “near miss” stories, stories about master miners they have known, and stories about how things used to be. These stories not only pass along information about what will happen if a miner fails to respect the mining environment, they also instruct listeners in the culture of mining and the values that it embraces. Stories, it seems, are a way to get safety messages across to miners, especially inexperienced ones, and using older, wiser miners in these stories is an obvious choice. This paper will discuss how a series of training videos was developed, how “master miners” and story lines were chosen, and how the resulting videos have been received in the mining industry.