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Reduce shaft sinking costs and workers exposure to mechanical hazards, drill dust, blast dangers, and fumes. Approach Replace drilling and blasting by using a large, cab-mounted impact breaker suspended from the bottom work deck of the galloway. How It Works The pneumatically actuated impact breaker is positioned by an articulated boom con-trolled from an operators cab. The breaker delivers 2,000 ft-lb blows that fragment the rock at the shaft bottom. Mucking is accomplished by a backhoe bucket on an articulated boom mounted on the cab. See photograph. The mucked material can be removed either by dumping into a previously drilled borehole or by being lifted out in a muck bucket as shown in the drawing. Positioning of the breaker, rotating the cab around its vertical axis, and moving the cab support frame around the perimeter of the shaft are all controlled by one joystick. Separate controls position the mucker boom, which can be swung horizontally through a 180° degree arc towards either side of the cab. Because the cab can be rotated to any position around its vertical axis, and can also be moved in a horizontal circle around the shaft, virtually any position on the bottom of the shaft can be reached by the breaker and mucker.

Jan 1, 1981

Enable mine personnel to determine the effectiveness of and to optimize the mine fire stench warning system without resorting to costly trial and error fire drills. Approach The mine fire stench warning system is used by underground metal/nonmetal mines to warn mine workers of a fire or other emergency. Stench is released directly into the mine ventilation and/or compressed air lines, and its repulsive odor warns miners to evacuate the mine or to follow other established emergency procedures. Unfortunately, since most deep metal mines have complex ventilation systems, some areas of the mine may receive nauseatingly high concentrations of stench while other areas, in more remote locations, may receive no warning or greatly delayed warring at best. The Bureau of Mines, through research, endeavored to solve this problem with a computer modeling system designed to calculate the distribution of odorant by the stench warning system.

Jan 1, 1986

Reduce rockfall fatalities and injuries by using innovative blasting practices to reduce damage to the rock at the excavation limits with little or no increase in cost. The Problem Falls of highwall have been a leading cause of fatalities, injuries, and equipment damage in the surface mining industry. Although the number of highwall falls is not great, when such an incident does occur it is about 14 times more likely to be fatal or result in severe injury and damage to equipment than other types of surface mine accidents. Overbreak or damage to the rock from poor or improper blasting practices is a major factor contributing to rock falls. Presplitting or cushion blasting is the technique most often recommended for improved wall control. This type of blasting however, adds to drilling and blasting costs and is not universally accepted by the industry. Air gap presplitting techniques, also called air decks, are currently being used in some mines as a less costly alternative to conventional presplitting. Approach Blasting can cause highwall damage, but proper blasting techniques have been shown to reduce the magnitude of rockfall problems. In preventing rock falls, it is important to maintain the natural strength of the rock structure to the greatest extent possible. Improved blasting practices have three main advantages: 1) they are preventive rather than corrective in nature; 2) they are cost effective; and 3) they have a very low impact on the mining operation when properly implemented. New ways of evaluating highwall integrity, such as seismic refraction tomography, were investigated.

Jan 1, 1991

Provide longwall operators with practical information and guidelines concerning mine design to reduce problems associated with the interaction of adjacent workings in multiple-scam longwall mines. Background The high productivity achieved by longwall mining demonstrates its potential to provide a substantial segment of underground coal production. Longwall mines produce more than 30 pct of underground coal, up from pct just 15 years ago. However, the continued growth of this mining method without appropriate multiple-seam planning may increase the cost and risk of mining. Research by the U.S. Bureau of Mines (USBM) indicates that 25 longwall mines (32 pct of the total number in the United States) have mining in adjacent coalbeds either above or below. About half of these longwall mines report some type of interaction problem with the adjacent workings, such as caving due to subsidence. Optimization of mine design factors is the best means for controlling interactions between operations in adjacent scams. To avoid higher mining costs, operators should focus on adopting practices and procedures that prevent and control interactions in multiple scams. The USBM, in an effort to improve longwall mine planning, has been investigating multiple-seam longwall design and development.

Jan 1, 1994

By Wallace W. Roepke

The Bureau of Mines has a well-established health and safety research effort directed to fundamental studies of the mine cutting system. This report describes the ignition danger of using cutting bits with flat wear area on still-intact carbide inserts.

Jan 1, 1983

By T. G. Carnahan

The Bureau of Mines investigated a flotation-nitric acid leach procedure as part of the goal to maximize minerals and metals recovered from primary and secondary domestic resources. Studies were conducted on an ore that contained carbon-bearing and sulfide mineralization that rendered a portion of the ore refractory (resistant) to conventional leaching technology. The procedure investigated for treating the ore consisted of the following: (1) separation by flotation of the carbonaceous and sulfidic components from the ore, (2) leaching the flotation concentrate with nitric acid at 100° to 110° C, (3) leaching the flotation tailings with sulfuric acid, and (4) processing the combined leached slurries in a conventional manner to recover yellow cake. In step 2, HN03 is converted to gaseous products from which it is regenerated by reacting these products with air and water for further leaching. An overall uranium extraction of 96 pct was achieved by this procedure.

Jan 1, 1979

Determine the site specific flow behavior of leachants and groundwater during development, production, and restoration phases of an in situ leaching operation. Approach A computer program has been developed which simulates the hydrologic activity associated with in situ mining. Various user options enable modeling of many of the site specific geologic conditions and well field specifications that affect the hydrology of solution mining. How It Works In situ hydrology is modeled, using a closed-form solution to the three-dimensional, partial differential equation that describes changes in hydraulic head as a result of pumping from leachant Injection and recovery wells. Model capabilities include arbitrary well patterns and pumping schedules, partially penetrating well screens, directionally anisotropic permeability and natural groundwater flow, in either

Jan 1, 1981

By R. W. Stahl

Increasing use of continuous miners, especially the boring type, has focused attention on the inadequacy of face ventilation in coal mines. The bulk of the machine, the rapid advance of working faces, and the increased liberation of methane from the larger expanse of freshly exposed coal surfaces have created ventilation problems that were unknown with conventional mining equipment. Ignition of gas, especially that caused by machine bits striking hard rock or pyritic inclusions, have increased at an alarming rate. As the mines penetrate beds under thicker cover at an ever-increasing rate of face advance, this problem will probably increase unless face ventilation is improved. A previous survey, described in Bureau of Mines Report of Investigations 5414, Auxiliary Ventilation of Continuous Miner Places, disclosed that auxiliary fans with tubing generally improved circulation of air and removal of gas at the face. The study here reported attempts to examine, face ventilation at various mines and to note any plan or innovation of. air coursing that industry might adopt to reduce the danger of gas ignition. ACKNOWLEDGMENT The mines visited were very cooperative in the study-and-generously supplied any data requested.

Jan 1, 1960

By Edward Thomas

"HISTORYThe origin of roof bolting as a means of roof support is obscure. During the past 23 years a method was developed by the. St. Joseph Lead Co: at its mines in southeastern Missouri, ranging from occasional use of single bolts with small bearing plates to systematic networks of bolts utilizing continuous bearing plates. Officials of this company are not certain which of its employees suggested their use. Many instances of occasional use of roof bolts have come to light during the past few years in widely separated mining districts, such as in West Virginia, Alabama, Illinois, Colorado, and Wyoming bituminous coal mines, and in Pennsylvania anthracite, Lake Superior iron, and Colorado lead-zinc mines. A few of the known installations have boon in place as long as 40 years.These installations usually were made to supplement wooden timbering in mine openings whore space was constricted, although it had been reported that roof bolting was started as a systematic moans of roof support in at least three instances but was abandoned because the cost of installation was excessive. The extra expense above that of conventional timbering could not be recaptured through economies resulting from increased efficiency, such as would be gained through mechanized mining.Roof bolting was first mentioned in mining literature in an article by W. W. Weige 3/ in Engineering and Mining Journal of May 1943, in which he described the use of bolts with 4-inch channel bearing plates in mines of the St. Joseph Load Co."

Sep 1, 1950

Utilize innovative processing technology to prepare high-purity, ultrafine advanced ceramic powders with little or no contamination occurring during the milling process. Advanced ceramic materials made from these powders could substitute for high-temperature alloys containing critical materials such as chromium, cobalt, and nickel. Approach Modify and evaluate the Bureau's turbomill, developed earlier to grind a variety of ceramic raw materials (clay, mica, and talc), as a milling or size-reduction technique for hard and abrasive advanced ceramic powders, such as silicon carbide. Background Powders for producing ceramic materials, such as silicon carbide. silicon nitride, alumina, and zirconia, which arc being considered for use in severe applications requiring high-temperature and/or corrosion resistance, are very difficult to reduce to fine sizes for processing into finished parts. Traditional techniques of particle size reduction, such as ball milling and jet milling, are very energy intensive and/or slow. These traditional techniques often produce materials that have a nonuniform particle size distribution and are contaminated by the milling media or container.

Jan 1, 1989

By G. St. J. Perrott, N. A. Tolch

"PURPOSE OF TESTSThe propulsive strength4 developed by the Cardox blasting device depends on the thickness of disk, weight of heater element, and weight of carbon dioxide charge. It might be supposed that the maximum weight of carbon dioxide that can be charged into the shell should give the greatest strength. However, according to the ballistic pendulum, the maximum weight of carbon dioxide with certain conditions of heater and disk has less propulsive strength than a smaller charge; in one condition of test a loss of 39 per cent in propulsive strength was noted. It is therefore of interest to study the effect of the variables that determine the strength of Cardox.ACKNOWLEDGMENTGrateful acknowledgment is made to A. B. Coates, associate mechanical engineer who developed the testing method for measuring pressures in the Cardox shell.DESCRIPTION OF DEVICEThe Cardox blasting device as fully described by the bureau in Report of Investiga¬tions 2920 (1929), consists essentially of hollow—steel shell, cylindrical in shape, an electrode, valve assembly, shearing disk, and discharge cap. The shell is prepared for use by inserting a heater element, closing the open end with a shearing disk, and screwing in place the discharge cap. The charge of carbon dioxide enters the shell through the electrode.The heater element is fired by an electric igniter of the match—head type. The heat released by the heater element completely gasifies the carbon dioxide and raises the pressure of the gas until it is enough to shear the disk."

Apr 1, 1931

This Information Circular from the National Institute for Occupational Safety and Health (NIOSH) documents and supplements the information presented in a series of workshops held during 2002 and 2003. The primary intended audience consists of all who are involved in developing and conducting miners' training. According to the Mine Safety and Health Administration (MSHA), mine operators reported 240,000 full-time equivalent workers and independent contractors reported 42,000 full-time equivalent workers working on mine property during the year 2000. Unfortunately, these workers have a relatively high risk of suffering serious work-related injuries and illnesses. The mining industry has the highest rate of occupational fatalities among all U.S. industries. The fatality rate is 30 deaths per 100,000 workers compared to 4.6 for all private industry (Morbidity and Mortality Week Report, 2001; NIOSH, 2002). Compared to workers in other industries, miners also have a relatively high rate of nonfatal lost-time injuries, and their injuries tend to be more severe (Bureau of Labor Statistics, 1999). Many miners are also exposed to significant health hazards, including coal and silica dust, diesel exhaust, and noise. More than 1000 U.S. miners die of lung disease each year (NIOSH, 1999). Mine safety and health professionals have long recognized training as a critical element of an effective safety and health program. Federal regulations (30 CFR, Parts 46 and 48) require mine operators to provide initial safety and health training to all new miners, as well as a minimum of 8 hours of refresher training each year. The time and money being spent to train U.S. miners is substantial, and so there is a strong and steady demand for new and better mine training materials and methods. A growing concern among mine safety professionals regards the training of new workers. A major change in the mining workforce is anticipated within the next decade. In major segments of mining, especially coal, relatively few workers have been hired since the 1970's. Thus, as an entire cohort of miners in the current workforce nears retirement, the replacement of these employees will require an influx of new workers. New miners may be young people who lack the ability to recognize and respond to mining hazards in an appropriate manner. They may also have had different educational experiences than their older counterparts. Many safety professionals believe that these two cohorts require different approaches to training. The papers in this report should help prepare mine trainers for the changes about to occur in the workforce and acquaint them with strategies they can use to enhance the effectiveness of their training. The first three papers present basic principles for teaching adults. The five remaining papers are intended to illustrate how these principles can be applied to the development and imple¬mentation of effective training for miners. Below is an overview of these papers. 1. Kowalski and Vaught review the process and principles of adult learning. The learning model they present includes a discussion of goals, content, delivery, assessment, and remediation. Adults are viewed as active learners, experienced-based, expert in their own right in specific areas, independent, real-life centered, task-centered, problem-centered, solution-driven, skill-seeking, self-directing, and internally and externally motivated. Basic aspects of curriculum development are briefly reviewed. For further information about adult learning, see Camm and Cullen's paper. 2. Mallett and Reinke's first paper discusses issues related to training new miners who have recently or will soon be entering the mining workforce. These new generations of miners have different learning style preferences and training needs than Baby Boomers and other older miners. Even trainers who have been highly effective in the past should reassess their training styles and their classroom materials to determine if they are prepared to meet the needs of these young new workers. This paper provides information that will help mine trainers communicate across the generation gap. 3. Mallett and Reinke's second paper provide an overview of training evaluation. Trainers and decision-makers are given a framework for planning and assessing training evaluation strategies. The authors present Kirkpatrick's (2001) model of evaluation categories and discuss how to start an evaluation plan and various ways to collect data. They do not provide detailed instruction in evaluation methodologies, but give trainers a review of the things they need to consider when developing an evaluation plan. A good evaluation plan can inform revisions to a training course, assess trainee learning, and/or answer managers' questions about program effectiveness. 4. Brnich, Derick, Mallett, and Vaught discuss a technique for incorporating worker participation into fire prevention and safe equipment operation training. This technique involves development of short (5 to 7 minutes) videotapes coupled with toolbox talks that ground the content of the videos within the context of a miner's workplace. An example of one of these training modules is presented, along with the results of an evaluation performed on its effectiveness at improving miners' understanding of what types of information they should be sure to communicate during a mine emergency. 5. Wiehagen, Conrad, Friend, and Rethi discuss on-the-job training (OJT) as a method for teaching miners safety and production skills. Much of the training is done by experienced workers. This paper describes how small investments can help improve the effectiveness of on-the-job training. Effective on-the-job training involves some structure and planning in the transfer of responsibility for task performance from the trainer to the novice. Assisting the trainer could involve helping develop up-to-date job analyses and offering strategies for teaching and evaluating job skills. This paper addresses organizational considerations supporting structured on-the-job

Jan 1, 2002

Reduce workers' dust exposure by capturing airborne coal and quartz dust generated by a continuous mining machine. Approach Install a water-powered scrubber system operating at 1,000 psi on the boom of a continuous miner at the conveyor throat. Dusty air from the face area is drawn through the scrubber and cleaned air discharged into the return. How it Works Most coal mines use exhaust face ventilation to send fresh air over the miner operator and contaminated air behind the line curtain to the return. The problem with exhaust ventilation is that the line curtain should be within 10 ft of the face for maximum effectiveness. If the line curtain is not extended properly, or water sprays for dust control are poorly installed, dust rolls back towards the operator. An effective way of removing this dust is with a scrubber mounted on the mining machine.

Jan 1, 1988

By R. V. Ramani, R. Stefanko, G. W. Luxbacher

MINE VENTILATION NETWORK ANALYSIS

Jan 1, 1977

By Sabri Ergun

The method of constant compositions involves the determination of the time required for the attainment of a given conversion at various temperatures. Heretofore, it has been used in evaluating the energy of activation only. A development of the method, made in the present study, makes possible the evaluation of the functional dependence upon composition and the frequency factor in addition to the energy of activation. INTRODUCTION Kinetics of reactions are best analyzed in the light of the mechanism, energy requirements, and forces involved in the reaction. Such physico-chemical information is not often available in solid state phase transformations. The reaction rates are followed by changes in a physical property during the course of the reaction, and repeating the experiment at different temperatures permits the determination of activation energy only. The possibility of a complete kinetic analysis by such a purely "phenomenological" approach has been questioned.4/ In this report a method is developed making possible the evaluation of the functional dependence upon composition and frequency factor in addition to the energy of activation. The application of the method to a study of solid state order-disorder changes is demonstrated.

Jan 1, 1960

By R. V. Lundquist, H. Leitch

Sodium aluminate is the principal aluminum compound formed in the sinters prepared by the lime - soda sinter process for recovering aluminum from silicate source materials . The properties and characteristics of this compound were studied to improve the efficiency of the process . Crystalline sodium aluminate was prepared by sintering stoichiometric quantities of soda ash and calcined alumina for 1 hour at 1,250 ° C. The extent of aluminum extraction from sodium aluminate was determined in water and in solutions of NaOH and Na₂ CO3 . Nearly complete extraction of aluminum from sodium aluminate was achieved only in solutions containing free NaOH in excess of that supplied by the salt through hydrolysis . About 42.2 to 68.8 percent of the aluminum was extracted in water or in solutions of Na₂ CO . The precipitation of alumina trihydrate from sodium aluminate solutions was shown to be part of a continuous , reversible reaction according to the equation Al (OH ) A1 (OH )3 + OHThe reverse reaction dissolves alumina trihydrate in NaOH solutions to produce sodium aluminate . Approximate equilibrium concentrations were determined for the reaction at 30° , 50 ° , and 70 ° C. False apparent equilibrium conditions for the dissolution reaction appear when only a small excess of alumina trihydrate is present in the NaOH solutions . A large excess of alumina trihydrate must be present before the true equilibrium point is assured . The engineering significance of the data is summarized , showing controls that should be exercised for a successful and efficient process .

Jan 1, 1964

By J. H. Maysilles

The Bureau of Mines is examining a variety of low-grade uranium ores because projections indicate that an appreciable percentage of future U.S. uranium production will be derived from resources containing 0.01 to 0.1 percent U308. One possible source is represented by a granitic material from Wyoming; the available samples contained 0.06 and 0.12 percent U308. Tests were conducted to explore the general leaching characteristics of this potential resource. The material responded to both acidic and alkaline leaching techniques. Conventional acid leaching extracted 93 percent of the uranium in 18 hours; the required acid addition was 50 to 100 pounds of H2S04 per ton of ore, and the oxidant addition was 3 pounds of NaCl03 per ton of ore. The acid consumption continues after maximum uranium recovery has been reached; this effect may complicate heap or in situ leaching with acidic solutions. Some variation in reagent requirements was noted between the two ore samples. Conventional carbonate leaching with strong solutions at 85° C extracted 94 percent of the uranium in 24 hours. These granitic materials also showed some response to dilute carbonate solutions, and the results suggest that the material may be chemically amenable to heap or in situ leaching with dilute carbonate solutions.

Jan 1, 1977

By H. J. Sloman

"INTRODUCTION Industry, including coal mining, has come to realize that to prevent accidents the human element must be given more consideration than was customary in the past. In formulating safety rules and regulations and in the enactment of laws governing mining, too often enforcement is emphasized rather than the means of gaining willing compliance.' The purpose of this paper is to call attention to the human side of accident prevention, and the approach to this important and much-discussed subject will deviate somewhat from the usual discussions.The human being is a complex mechanism, both physically and mentally. It is difficult to establish a common denominator for the actions of humans, except in general. In establishing mining laws, rules, regulations, and standards, the ultimate objective should be to gain the best possible response of workmen, so that optimum results in accident prevention may be obtained. The complexity of human beings is apparent when the many ways 1n which they differ are considered. Some of these differences are manifested in emotional and phlegmatic types, degrees of intellect or native intelligence; and in hopes, desires, aspirations, and philosophies of life. How much simpler ac¬cident prevention would be if the response to laws, rules, regulations, or standards were equivalent to the definite movements of puppets responding to pulls on strings. Each time, the strings are pulled in exactly the same way, the puppets will respond in exactly the same manner. Human beings, although having many similar characteristics, do not respond uniformly to identical ""string-pulling""; therefore, much study is necessary before the desired re¬sponses can be obtained. To achieve the ultimate in accident prevention, it must be ""worked at"" constantly. Regardless of the adequacy of safety laws, rules, regulations, or standards, good accident records will not ""roll in"" if dude consideration is not given to the personal traits of those most likely to be involved in accidents."

May 1, 1948

Reduce the number of accidents caused by slips and falls from large mining equipment. Approach A powered lift was developed that provides operators with a safer way of getting on and off large machines. How It Works The powered step is designed to lift personnel and materials to working levels on large machines. It eliminates hazardous blind steps and makes it unnecessary to climb on irregular surfaces made slippery by mud, ice, snow, and accumulations of grease. The step is powered by a self-contained electric/hydraulic unit which is connected to a vehicle's auxiliary power supply. When in the "down" position, the step rests about 15 inches above ground level. When the power unit is activated with an electrical switch located on the step, a Single cylinder attached between two lifting arms smoothly lifts the step. In conjunction with the lifting motion, a linkage and bearing arrangement on the mounting end of the lift arms causes the step to rotate towards the machine, so that the step moves in an arc from ground to platform level. When the machine Is operating, the step is automatically locked in the "up" position, protecting it against any damaging contact with obstructions. The step is lowered by activating a pressure release solenoid. An in-line orifice controls downward speed and prevents free fall. On most machines, additional control switches are conveniently located at ground level and in the operator's cab. Visual alarms and machine interlocks are provided where necessary to prevent machine operation when the step is In the "down" position. The powered step can be easily adapted to any type or model of large machinery.

Jan 1, 1981

By Ronald D. Hill, Elmore C. Grim

Mining as an extractive process alone is outdated and unacceptable to today's environmentally concerned public. Multiple land use must be considered as well. Only through effective preplanning can the full potential of reclamation result in a lasting asset for future generations. The coal industry is now recognizing that reclamation of mined lands is part of the mining cycle that must be planned and carried out in a timely and orderly manner. It is also finding that planning reclamation in advance of mining is cheaper and more effective than waiting until mining is completed. The decision to open a strip mine must be based on the results of studies to determine if successful reclamation can be achieved and whether the economic benefits to the company will be justified(1). Information regarding the physical, chemical, hydrologic and biologic systems operative at the site must be under- stood or reclamation will be a failure. Working together, engineers, management and reclamation specialists should design the actual mining and reclamation plan before mining is begun.

Jan 1, 1974