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By Erica E. Hall, Robert H. Peters, Charles Vaught, Jon C. Volkwein

Coal Workers Pneumoconiosis is the leading cause of death due to occupational illness among coal miners. This disease is caused by miners’ exposure to respirable coal mine dust. A Personal Dust Monitor has recently been developed to provide near real time feedback to miners regarding the number of milligrams of respirable coal mine dust in the air they breathe. This paper was prepared by the National Institute for Occupational Safety and Health to document coal miners’ reactions to this new device, and how they make use of the information it provides. Structured interviews were conducted with 30 coal miners at four mines. A four-stage conceptual model of miners’ decision processes with respect to how they interpret and respond to the dust exposure numbers from their personal dust monitor is proposed. The stages are: Diagnosis, Action Planning and Intervention, Evaluation, and Institutionalization. The interview responses provide considerable support for the model. Most miners paid attention to Personal Dust Monitor feedback and made efforts to reduce their dust exposure. Their efforts included: changing where they positioned themselves, making ventilation system improvements, and using respirators more often. The 29 miners who reported having experience wearing both the old and new type of dust monitors were asked which dust sampling system they preferred. Eighteen (62%) preferred the new monitors, 7 (24%) preferred existing monitors, and 4 (14%) had no preference. The most frequently cited advantage of the new monitor is its ability to provide relatively quick feedback on dust exposure. Miners provided several suggestions for improving the design of the instrument.

By Wesley A. Grosh

The Sutherland copper prospect is situated in Floyd County, Va. The immediate area was prospected around 1850, and one of the adits possibly dates from that time. Little or no ore has been mined from the deposit. The deposit is a mineralized sulfide zone occurring in mica schist and consisting mostly of pyrrhotite with minor amount of copper. A magnetometer survey of the deposit by the American Metal Co. in 1939 showed an anomaly that was thought to indicate a zone: of secondary enrichment. The Bureau of Mines diamond-drilled 14 holes, totaling 913 feet, and opened an adit during February and March 1943. No appreciable copper values or indications of secondary enrichment were found.

Jan 1, 1948

By G. R. Hopkins

One of the largest items in the expense of operating a refinery is the cost of the fuel used in distillation and for miscellaneous purposes such as in the heating of buildings and in the generation of electricity. On a B. t. u. basis, the average refinery consumes approximately one-tenth as much fuel as it produces. Theoretically, the fuel consumption at refineries should be much smaller than this, but furnaces can not be designed to be 100 per cent efficient and, in addition, a large part of the waste heat is low-temperature heat which would not pay for the expense of recovering it. Annual surveys of fuel consumption at refineries have been made by the United States Bureau of Mines, beginning with 1925. During the 5-year period, 1925-1929, the refineries made steady progress in fuel economy. This is evidenced by the computed figures of heat requirement per carrel of crude oil refined, which show a decline from 829,000 B. t. u. in 1925 to 639,000 B. t. u. in 1929 (see fig. 1). In 1930, however, 'the trend in fuel economy was reversed and the quantity of heat utilized in refining the average barrel of crude oil rose to 672,000 B. t. u. There were undoubtedly a number of reasons for the apparent decrease in fuel economy at refineries in 1930, chief of which were the tendency to carry the distillation farther instead of merely topping the crude and a gain in the consumption of waste oils, such as acid sludge, which in actual practice yield less heat per unit consumed than has been theoretically assigned to oil.

Jan 1, 1931

To concentrate coarse mica particles using a dry beneficiation technique. Approach Concentrate coarse, II berated mica particles using a Bureau-designed system of crushers, screens, and a two-stage zigzag air classifier. How It Works Because mica has a flat plate-like crystalline structure, mica particles are significantly lighter than blocky gangue particles of the same size fraction. Thus an air classification technique can separate the flat, light mica particles from the heavier gangue particles. The ore, which Is first run through a standard jaw crusher, a roll crusher, and a hammer mill to liberate the mica, enters the rougher Zig-zag section through a rotating air lock. See photograph and diagram of a 2-stage air classifier. Airflow through the classifier can be varied according to the size of the particles being separated. The gangue material falls through the airstream of the rougher zigzag section and is discarded as tailings. The mica flakes are carried by the air-stream to the cyclone shown on the right side of the diagram, where they are collected. This rougher mica concentrate is fed to the cleaner zigzag section through another rotating air lock. The mica particles are again carried by the airstream but they are now collected In the cyclone on the left side. The cleaner concentrate leaves the left-side cyclone through a third rotating air lock and is rescreened to remove under-size material missed by the first screening. The final product of this pneumatic process is generally a high-grade mica concentrate. A generalized flow diagram for the pneumatic concentration method Is shown In the second diagram.

Jan 1, 1981

To provide coal operators with an easy-to-use stress control design procedure to minimize coal mine bumps during room-and-pillar retreat mining conducted with available continuous mining machine technology. Approach The goal of this U.S. Bureau of Mines (USBM) re¬search was to facilitate safe and efficient room-and-pillar retreat mining of bump-prone coalbeds by limiting coalbed stress adjacent to expanding gob areas through variation of section layouts. The first step was design of total-extraction pillars and their associated pillar-extraction plans. The second step was development of a coalbed strength model. The third step was development of stress limit design criteria. The fourth and final step was development of a methodology to estimate the magnitude and distribution of development and abutment loads apllied to the pillar line. The linear geometry of unlimited-width sections allowed for the accomplishment of step four with the tributary-area and linear shear-angle concepts. Increasing overburden depths required limited-width sections separated by barrier pillars to control stress within total-extraction panels. The accomplishment of step four with limited-width section designs required prediction of abutment load distributions for rectangular gobs and apportionment of these loads over mixed pillar sizes. A parametric study of the complicated interaction of various combinations of overburden depths, total-extraction panel widths, and abutment pillar widths was conducted with the USBM-developed boundary-element program MULSIM/NL.

Jan 1, 1995

By F. F. Hintze

In the group of minerals used in making this study, the cyanite is associated with quartz, mica, and feldspar in the schist. The amount of quartz is variable, but it is always an abundant mineral. Both large and small crystals of quartz occur in irregular masses, rarely ever showing crystal outline. Mica is of the clear and dark varieties, the larger crystals being dark as a rule, and the finer crystals of light color. The present mineralogical composition of the mina is rather variable, as most of the original biotite and muscovite have suffered alteration, and much secondary mioa is present as a result of alteration of the original mica and other minerals present, especially the larger cyanite crystals. A large part of the mica now found in the ore is chlorite, with varying amounts of Jefferisite and others, especially sericite. These are in the form of aggregates, or felt-like intergrowths filling the spaces between the quartz, cyanite, and feldspar.

Jan 1, 1931

By Kenneth M. Earl

In its program of investigation of deposits of strategic minerals, the Bureau of Mines did some development drilling at the Tapley deposit in an endeavor to find an additional source of copper. There are accounts that many years ago the property had some production; there are several old, inaccessible shafts apparently sunk on a vein in rhyolite or diabase. The waste dumps of these shafts contain considerable sulfides, chiefly pyrite and chalcopyrite. To cut the vein below the old mine workings, the Bureau of Mines? diamond-drilled five holes aggregating 1,204 feet. No significant copper mineralization was found.

Jan 1, 1950

By A. J. Kraemer

[A great deal of interest has been manifested in the question of sulphur in fuels for automobile engines. Many different opinions have been expressed with respect to the effect of sulphur in gasoline on engine wear and engine performance. A wide difference of opinion exists as to the permissible limit of sulphur content for satisfactory operation.]

Jan 1, 1927

By Deno M. Pappas, Christopher Mark, Eric R. Bauer

During 1998-99, groundfall incidents resulted in 27 fatalities and were responsible for over 70% of all deaths in U.S. underground coal mines. To obtain a better understanding of where and why these incidents occurred, a comprehensive analysis of ground fall injuries and fatalities was conducted. The first portion of the study examined various factors associated with roof and rib fall injuries and reportable roof fall noninjuries that occurred during 1995-98. The study found that the room-and-pillar mining method has twice the groundfall incident rate than the longwall method. Mine locations with high groundfall rates seem to correlate to regions where there is a higher concentration of problematic coalbeds. For example, the Illinois Basin has very high groundfall rates, which can be traced back to several key coalbeds-Kentucky No. 13, Herrin/No. 6/Kentucky No. 11, and Springfield No. 5/Kentucky No. 9. High rib fall rates were found in mines located in thick seams. Groundfall rates were found to be 30% to 40% higher during the months of July through September, possibly due to high humidity that may cause the shale mine roof to deteriorate. The second part of the study examined the root causes of failure by reviewing all groundfall fatality reports for 1996-99. Primary and secondary hazard factors were assigned to each groundfall incident. The primaryf actors resulting in these groundfall fatalities were pillar extraction, traveling under unsupported roof, skin failure, construction, longwall faces, intersections, and geologic discontinuities. Defining prominent ground control incident trends and hazards will identify areas where additional study is needed and where innovative solutions need to be developed to reduce these severe occupational hazards.

Jan 10, 2000

1. In 2003, 14,391 mining operations reported employment statistics to the Mine Safety and Health Administration (MSHA). Almost half (49%) were sand and gravel mines, followed by stone mines (30%), coal mines (14%), nonmetal mines (5%), and metal mines (2%).

Feb 1, 2005

1. In 2003, a total of 1,972 coal mining operations reported employment to the Mine Safety and Health Administration (MSHA). Coal mines comprised 13.7% of all mining operations. • Bituminous mines comprised 92.5% (n = 1,825) and anthracite mines 7.5% (n = 147) of coal mining operations. • More than 70% of all coal mines were located in three states: Kentucky (29.0%), West Virginia (20.9%), and Pennsylvania (20.2%). • Bituminous coal mines reported the production of over 1 billion coal tons.

Feb 1, 2005

By G. R. Hopkins

One of the largest items in the expense of operating a refinery is the cost of the fuel used in distillation and for miscellaneous purposes such as in the heating of buildings and in the generation of electricity, On a B. t. u. basis, the average refinery consumes approximately one-tenth as much fuel as it produces. Theoretically, the fuel consumption at refineries should be much smaller than this, but furnaces can riot be designed to be 100 per cent efficient' and, in addition, a large part of the waste heat is low-temperature heat which would not pay for the expense of recovering it. Annual surveys of fuel consumption at refineries have been made by the United States Bureau of Mines, beginning with 1925. During the 5-year period, 1925-1929, the refineries made steady progress in fuel economy. This is evidenced by the Computed figures of heat requirement Per barrel of crude oil refined, which show a decline from 829,000 B. t. u. in 1925 to 639,000 B. t. u. in 1929 (see fig. 1). In 1930, however, the trend in fuel economy was reversed and the quantity of heat utilized in refining the average barrel of crude oil rose to 672,000 B. t. u. There were undoubtedly a number of reasons for the apparent decrease in fuel economy at refineries in 1930, chief of which were the tendency to carry the distillation farther instead of merely topping the crude and a gain in the consumption of waste oils, such as acid sludge, which in actual practice yield less heat per unit consumed than has been theoretically assigned to oil. The consumption of natural as fuel at refineries has declined since 1927, but this has been more than compensated by a rapid increase in the use of refinery or still gas. The total consumption of oil as refinery fuel in 1930 was not much below the 1925 total, but the consumption of coal has declined rapidly, so that in 1930 liquid and solid fuels contributed only 56 per cent of the total heat units- utilized at refineries as compared with 77 per cent in 1925 (see fig. 2).

Jan 1, 1931

By Greenwald, H. P

The Bureau of Mines has been conducting experiments on the explosibility of coal-dust in the experimental mine for more than 17 years. The results have been published from time to time3, and a forthcoming technical paper4 will summarize the results and discuss them in some detail. The present paper will be limited to a statement of the more important facts that these researches have discovered.

Apr 1, 1929

Develop a means for estimating vertical stress conditions in or around an underground mine so that appropriate measures for ground control can be taken before hazardous conditions arise. Background High vertical stress in an underground mine could cause or enhance hazardous ground control conditions which might lead to accidents, fatalities, and loss of reserves. An understanding of the vertical stress conditions at the mining level would allow a mine operator to take precautions that will minimize the occurrence of ground control problems. A knowledge of the underground stress conditions prior to mining could be used as an aid in future mine plan development to avoid or minimize ground control problems. Approach The Bureau of Mines developed a computer program for calculating the vertical stress resulting from the pressure of overlying rock masses on a mine or geologic surface at various depths.

Jan 1, 1990

By T. M. Garland

A nomographical approach is proposed as a fast, easy-to-use, and reason- ably accurate method for estimating expected discounted cash flow (DCF) rate of return and payout time for onshore development drilling and oil production. All costs pertaining to drilling, completing, and equipping development wells, annual expenses of operation, maintenance, and taxes incurred in producing properties, and crude oil prices were considered in developing the nomographs. This report briefly outlines the origin, derivation, and use of the nomographs.

Jan 1, 1973

By G. R. Hopkins

"Summary An apparent decline in fuel efficiency at refineries, which first became came evident in 1930 and continued through 1933, was checked in 1933 when the average amount of heat needed to refine a barrel of crude oil amounted to 660,000 B.t.u. This compares with an average requirement of 692,000 B.t.u. In 1932 and with a low of 639,000 B.t.u. in 1929. (See fig. 1.) The improvement in fuel economy in 1933 probably was closely related to the increase of 5 per cent in crude runs to stills. As much of the fuel burned at refineries is utilized for purposes other than under crude-oil stills and in relatively stable amounts, it is evident that a material increase in crude runs will usually reflected in a decrease in average fuel requirements. Another factor which has influences fuel economy at refineries in the past is the trend in cracking, a refining process requiring more than the average expenditure of heat. In 1933 production of gasoline by cracking increased slightly, but no appreciable rise in heat requirements resulted as an equivalent amount of fuel was saved in improved technique, particularly in the field of heat exchange.Since the beginning of the refining industry, the transition in fuels has been from solid to liquid to gaseous; in other words, the leadership was first held by coal, then passed to oil, and is now held by gas. In 1933, 54.7 percent of the total heat units generated came from gas, 39.0 percent from oil (including acid sludge), and 6.3 percent from coal and coke. The principal change in the relative importance of the various refinery fuels in recent years has been the rapid growth in consumption of refinery or still gas at the expense of all the other common fuels. Still gas owes its ascendency to its cheapness and availability, and probably it would have become the primary refinery fuel years ago if recovery methods had been perfected. The relative importance of coal showed a small increase in 1933, the first gain recorded since these surveys were inaugurated in 1925. The increase in use of coal was undoubtedly due to increased operations at plants using it,"

Feb 1, 1935

1. In 2002, a total of 2,820 contracting companies reported employment at coal mines to MSHA.

Jan 1, 2004

By D. N. Nilsen

The Bureau of Mines is developing a method to recover Ni, Co, and Cu from laterites containing less than 1.2 pct Ni and 0.25 pct Co. The method consists of the following basic unit operations: (1) reduction roasting, (2) leaching, (3) solvent extraction, and (4) electrowinning. The method reflects three Bureau of Mines objectives: (1) recovery of critical minerals that are domestically in short supply from low-grade domestic laterites, (2) lower processing energy requirements, and (3) solution recycling. This report deals with the extraction of cobalt and the preparation of a suitable cobalt electrolyte by solvent extraction from liquor produced by this method. Nickel and copper are coextracted with LIX64N from an ammoniacal ammonium sulfate leach liquor containing about 1.00 g/l Ni, 0.30 g/l Co, 0.03 g/l Cu, and 0.02 g/l Zn. Cobalt (III) in the nickel-copper barren raffinate is reduced to cobalt (II) with cobalt metal. Reduction of cobalt (III) to cobalt (II) greatly aids subsequent extraction. Commercially available XI-51 extracts about 94 pct of the cobalt from the treated raffinate in one stage in a laboratory mixer-settler continuous circuit. Ammonia loaded on the solvent is removed in two washing steps. About 94 pct of the cobalt then is stripped from the XI-51 in one stage with spent cobalt electrolyte containing about 77 g/l Co and 18 g/l sulfuric acid (H2S04), Electrolytes containing less H2S04 also may be used. Preliminary data indicate that coextracted zinc may be removed from pregnant cobalt eletrolyte containing 3 g/l or less H2S04 with di-(2 ethylhexyl) phosphoric acid (D2EHPA).

Jan 1, 1980

By Marc T. Filigenzi

Two of the major ground control safety issues confronting underground mine operations today are shaft pillar stability and the failure of rock around active mine openings. Failure of a mine shaft can lead to the entrapment of workers. Failure of rock around active underground mine openings can lead to roof falls, which in turn can result in worker injuries and fatalities. Finite-element analysis has proven to be a reliable method for predicting stresses and displacements around underground mine openings. However, this is a complex and time-consuming technique and is not used as often as it could be in mine planning. The purpose of this paper is to demonstrate one technique developed at the Spokane Research Center that allows the user to create a finite-element model of a two-dimensional section of an underground mine in a relatively straightforward manner. This model is then used to calculate stresses, displacements, and safety factors around mine openings. With this information, mine planers can evaluate the stability of mine openings as well as the stability of pillars and mine shafts. This analysis will help develop mining sequences and layouts that minimize stresses in that section of the mine. This, in turn, should minimize the occurrence of shaft failure, roof falls, and other hazards associated with underground mining.

By W. E. Wallace, V. Robinson, M. F. Keane, V. Vallyathan

"An in vitro study of the biologic responses of surface-modified and native silica and kaolin was made to provide comparative information on the supression of cytotoxicity by pulmonary surfactant. The release of alveolar macrophage cytoplasmic enzyme, lactate dehydrogenase (IDH), and lysosomal enzymes B-N-acetylglocosaminidase (B-NAG) and B-ghucuronidase (B-GLUC) and sheep blood-cell hemolysis were moni¬tored as indicators of cell membrane damage and cytutoxicity. Surface modification of silica and kaolin with dipalmitoyl lecithin (UPI) resulted in complete abrogation of cytotoxicity of both minerals. These findings indicate that surface modification of minerals with different adsorption properties by pulmonary surfactant generally lessens their prompt adverse effects.INTRODUCTIONAcute and chronic silicosis are well-characterized clinical and pathologic entities resulting from the inhalation of crystalline silica (Morgan and Seaton, 1984). Kaolin, a layered aluminosilicate clay frequently mined and used in manufacturing, contains tetrahedral silica alternately layered with alumina octahedra. Kaolin is relatively .inert biologically, and distinctly greater pulmonary burdens are seen in patients with kaolinosis than are seen in patients with silicosis. Crystalline siliea (quartz) induces a significantly greater degree of fibrosis in exposed animals in vivo than does kaolin (Hamilton and Hardy, 1974; Parkes, 1982; Hunter, 1976; Sheers, 1964; Warraki and t-lerant, 1963; Lynch and Mciver, 1954; Lapenas et al., 1984).This difference in pulmonary disease associated with the two types of dust is not reflected by in vitro cytotoxicity as Jetermined by pulmonary macrophage bioassays or erythrocyte hemolysis. Cytotoxicity studies using crystalline silica and kaolin of similar size fractions show comparable bioassay response on a mass basis. These cellular bioassays, therefore, do not correlate with the relative in vivo pathogenicity of silicates."

Jun 1, 1988