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By David A. Monaghan, Kenneth R. Maser, Adi R. Gurdar, D. Randolph Berry

SUMMARY The objective of this program was to develop a system to extinguish coal mine fires by remote sealing of the underground passageways. The system developed had to be versatile enough to function under a wide range of operating conditions, including large variations in passageway geometry, depth of mine, water conditions, both in the mine and at the surface, and rubble in the mine passage. The system developed had to include instrumentation for the remote probing of the passageway prior to sealing, a system for sealing the mine passages, and instrumentation for remote monitoring of the quality of the seal during and after construction. These objectives were successfully achieved during this program. The remote mine sealing capability of the system was satisfactc rely demonstrated in a field test conducted at the Eastern Associated Coal Corporation Federal No. 1 Mine in Grant Town, West Virginia. The remote sealing consists of: (1) A sonar initial probing system which can operate satisfactorily even in the presence of dense smoke. The system is capable of determining both the local passageway geometry, identifying the presence of cribs and other obstructions, and the position of the borehole in the mine passage. (2) A mine sealing material system which utilizes fly ash for making the complete seal or as a bulk filler in conjunction with a urethane, froth foam, seal topping system. The choice of using fly ash alone or fly ash with foam topping depends on a number of factors, such as quality of seal desired, time available per seal, depth of borehole, passageway geometry, and water holding require¬ment. The fly ash-foam seal is a better seal, capable of sealing against a higher water head than fly ash alone. The fly ash sealing

Jan 1, 1973

By M. Viswanathan, M. J. Jorgensen, N. K. Kittusamy

Operating heavy construction equipment is often associated with elevated rates of low back discomfort (LBD). However, there have been few formal studies that dealt with evaluating controls that can reduce the LBD among these workers. The objective of this study was to determine the effectiveness of using a continuous passive lumbar motion system (CPLMS) in reducing low back discomfort among operators of heavy earthmoving equipment. The CPLMS is an additional seat support that has a lumbar support bladder and a pump to provide cyclic inflation and deflation. Two groups of operators were identified as potential subjects for this intervention study, the intervention group with a mean age of 41.2 years and experience of 9.7 years used the CPLMS, and the control group with a mean age of 37.5 years and experience of 7.6 years did not use the CPLMS. Body part discomfort surveys were collected from both groups. In addition, the intervention group completed a CPLMS preference survey. The body part discomfort survey was collected up to eight days at three different times of the day. Results from the body part discomfort survey showed a decreasing trend the longer the CPLMS was used, for both the upper and low back region. A decreasing trend for the low back was also found comparing morning to evening discomfort scores across the days when using the CPLMS. When compared to their regular seat, 54% of the operators felt very comfortable in using the CPLMS, 36% of them wanted one for their equipment, and 54% showed interest in experimenting with the CPLMS for a longer time period. Results from this study indicate that the use of a CPLMS can effectively reduce the low back discomfort experienced by operators of heavy construction equipment.

To facilitate compliance with title 30 CFR 75.1001-1(b), which requires testing and calibrating of trolley line automatic circuit interrupting devices at intervals not to exceed six months. Approach Calibration of a circuit breaker ideally implies the passage of the expected fault current through the sensing circuit, and observing a successful circuit interruption at the preset level within a specified time. On trolley lines, the required current may be a few thousand amperes, with maximum duration well exceeding one-tenth of a second. Any method of obtaining this calibration current Involving the trolley wire can contribute to wire sagging and other permanent damage to the haul-age system due to the high energy dissipated during the test. Also, control to assure that exactly the required level and duration of current flow is obtained implies the use of equipment which is simply not available In the ordinary mine. Under a Bureau of Mines contract, a circuit to achieve the necessary calibration pulse was conceived and built. How It Works Two prototype units were fabricated and have been field tested by MSHA technical support engineers in under-ground mines. The equipment consists of an electronics Package 20 x 24 x 8 inches and weighing 93 pounds, including a side-mounted circuit breaker, with a set of 8 foot long detachable, AWG #4/0 leads with plier-type clamps. The total lead assembly weighs 21 pounds.

Jan 1, 1981

By W. A. Calhoun

A method for concentration of the nickel-cobalt-bearing mineral, siegenite, from a table middling has been developed by the Bureau of Mines at Rolla, Mo. The table middling is composed of a complex series of sulfide minerals, occurring in mill operations in the southeast Missouri "lead belt." In these operations the siegenite is lost as a separate concentrate, being diverted to other products. The procedure also includes recovering commercial-grade concentrates of copper and lead. A low-grade zinc concentrate, a potential coproduct, was also made.

Jan 1, 1962

Reduce the dust exposure of workers in large processing buildings at mineral processing operations, using a total mill ventilation system.

Jan 1, 1994

By C. Stephan, E. Weiss, J. Trackemas, M. Sapko

The National Institute for Occupational Safety and Health (NIOSH), Pittsburgh Research Laboratory (PRL), in collaboration with the Mine Safety and Health Administration (MSHA), the mining industry and seal manufacturers, conducted a series of full-scale experiments within the underground experimental mine at PRL's Lake Lynn Laboratory. The purpose of the experiments was to evaluate the explosion-resistant characteristics of several new seal designs for rapid deployment during mine emergencies. These seals can be deployed in less than 12 hours and are capable of withstanding explosion overpressures in excess of 140 kPa (20psi). These novel seal designs use available mine materials, do not require conventional rib hitching and, most importantly, can substantially reduce exposure time for coal miners during sealing and mine recovery operations.

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

1 14 THIS IS A DIGITAL COMPUTER SIMULATION OF THE VENTILATION SYSTEM OF A MINE LOCATED IN WASHINGTON COUNTY, PENNSYLVANIA. THE VENTILATION SURVEY ON WHICH THIS SIMULATION IS BASED WAS RUN FROM OCT. 27-30 AND ON NOV. 2, 1976 IN THE ACTIVE PORTION OF THE MINE INBY COMBS SHAFT AND THE INACTIVE PORTION AFOUND AND INBY DONAHOO SHAFT. FOLLOW-UP SURVEYS WERE THEN RUN ON FEB. 18 AND FROM MARCH 7-11, 1977 TO INCLUDE THE MAIN HAULAGE SYSTEM OUTBY THE ACTIVE AREAS OF THE MINE. ALL SURVEY DATA WAS NORMALIZED TO A STANDARD DENSITY OF 0.075 POUNDS/CU.FT. PRIOR TO THE CALCULATION OF INPUT PARAMETERS FOR THIS SIMULATION. IN THIS RUN, THE ORIGINAL VENTILATION NETWORK HAS BEEN MODIFIED TO INCLUDE NEW INTAKE AND RETURN AIRSHAFTS AT THE WEST MAINS. IN ADDITION A CONNECTION HAS BEEN MADE BETWEEN THE MINE UNDER STUDY AND A SHAFT IN A WORKED OUT MINE IN THE 1 FACE AREA. THIS SHAFT IS CONSIDERED AN INTAKE SHAFT FOR THIS RUN.

Jan 1, 1977

By Oliver C. Ralston

OUTSTANDING TRENDS of the year included the following: 1. Concentration and beneficiation of iron ores to provide improved blast-furnace feed and extend ore reserves. 2. Successful development of pelletizing and sintering procedures for fine iron ores. 3. The realization that cyclone separation could replace existing classifiers in many grinding circuits. 4. The rapidly blossoming metallurgy of ultrapure silicon and improvements in zone melting. 5. The rapid increase in the use of liquid-liquid extraction and ion exchange in hydrometallurgy. 6. The industrial application of vacuum melting on the 100-ton scale. 7. The hope for developing a columbium (noibium) base alloy for high-temperature use. The technologic advancement in metallurgy that had the greatest effect on the American economy was the beneficiation of iron ores to give improved feed for blast furnaces and indirectly extend our ore reserves. This was not a sudden development but rather culmination of a decade of intensive effort.

Jan 1, 1958

By A. B. Hooker, L. C. IlsLey

In lare-scal e blasting, it is customary to fire me.l'\Y shot.!:l simu1. taneously. The electric !atonators ara usually conneced in seies, ard are fired either from a power circuit or :from a blasting ma.chine with large capacity, operated by hand. "!hen :'::ri111; with a blasting ca.chine, trouble with missed shots has been freqi.,.ently e>:pert0nced.. Unit1:i:' thes ,:::rcu:ns tances, the shots that fail to fire are often a gr"up in the t.:E"nter r,f t>e series, Various explaz,.a.tions hs.ve been given as to the cause of the failurs. Tis paper covers a few tests made cy the electrical section of tl:.e Dti..'t'cau. cf Mines, wh;.r.;h may be helpful in understanding the -probable cuse of tl1e misfiring of c.:anter shots, Wh3tever th9 source ot the firir. current generator, magneto, or batter, the CUl"rent delivered th:·01.1.gh a shot-f:?·ing circu.it is determined by t.ae total resistance of ,;he clrcili +.; c:1nd all cure:it leaving th9 p,si tive terminal must return to tre negative te1-minal. If a. metallic circuit is well i1,.sul.:tted, praeti­ccl. l;1 a.ll of the t.'Urrent keepo within the circu.it; but in a. shot-!11·.irig ci.rc1li t, Nhere the ·.vires f:ll·e often 1n c.c,i.cact with the eru:"!ih as i11 wet holer., end whero the ins".lla.tion of the leg wires :i. inadecpa.te to prc·,ent lea.l.tage, the current ma.v tu.e v a.r ious pa the: thro-.. .. gh the nr r. earth.

Aug 1, 1922

By Lon D. Santis

This paper presents data and theorem to calculate the risk of experiencing undesirable lightning related events while blasting or while engaged in other lightning sensitive activities. The paper provides an overview of lightning hazards in blasting operations and a brief history of lightning related blasting accidents. Lightning continues to be the primary cause of premature initiations of explosives in mining, on average, over two such incidents are reported to the Mine Safety and Health Administration (MSHA) each year. The energy contained in lightning discharges and how this energy sets off explosives in mining is presented. Three categories of lightning warning methods: public media, lightning detectors, and atmospheric electrostatic field measurement are discussed. The remainder of the paper presents recently acquired data on the spatial characteristics of lightning development. This data is used to estimate the risk assumed by blasters under certain conditions. Risk estimations are made for electric and nonelectric blasting if persons are evacuated when cloud-to-ground (c-g) lightning approaches within a certain distance. For example, about 0.6% of all c-g lightning strikes have no other c-g lightning strikes within 25 miles in the previous 30 minutes. The paper shows that a typical blaster using nonelectric initiation in a high lightning density area with a 100% accurate lightning detector set to alarm at 25 miles would have a lightning caused unplanned detonation every 14,000 years

Provide an inexpensive, simple means of supporting highly yielding ground In underground mines. Approach The Bureau of Mines developed a high capacity support post made from standard steel pipe which, when using a 60-inch post configuration, has a 45-ton capacity and a yield length of 24 inches. How It Works The post mechanism is a three-piece unit consisting of a top and bottom leg (made from standard steel pipe) and a separate foot bracket. During installation in the mine, the bottom leg is placed on a relatively flat surface on the mine floor and the top leg is placed over it until its flared end contacts an expansion ring attached to the bottom leg. As the roof and floor converge, the flared end of the top leg is forced into the expansion ring, causing the walls of the top leg to be deformed radially and along the axis. The mechanism will yield until the unit bottoms out after about 24 inches of yield.

Jan 1, 1987

Measure the leakage through individual crosscut stoppings quickly and economically so that the worst ones can be identified and repaired. (Typically 60 to 80% of the air supplied to a mine short circuits before reaching a working face.) Approach Most of the leakage through a permanent stop-ping is channeled through two windows in a temporary stopping, and air velocities through the windows are measured; leakage is determined from a formula. How It Works A temporary stopping made of plastic brattice is erected in the same cross cut as the permanent stopping, either upstream or downstream. The brattice is fastened to the roof, bottom, and ribs of the entry with spads. Normal leakage of brattice was allowed for in deriving formula, and does not effect results. For best accuracy the brattice and the stopping should be separated by a distance of one hydraulic diameter.

Jan 1, 1979

Improve the field-of-view into the front-right blind spot for drivers of large haulage trucks, thereby reducing the growing collision hazard in surface mines. Approach Reduce the glare problem found in the first generation fresnel lens blind area viewer design by eliminating the upward-looking section of the fresnel lens and adding a rear hood to reduce backlighting. How It Works The first generation blind area viewer was developed and in-mine tested as an aid to improved visibility for large haulage trucks. Other aids were improved left-and right-hand mirrors. Evaluations showed that a blind area viewer mounted on the right-front of the radiator deck was effective and was readily accepted by drivers. Nevertheless, because glare was a problem under certain conditions, a low-profile viewer was developed. Glare control louvers from the earlier design were kept and a backlighting glare control hood was added. The height of the hardware was reduced by eliminating the top three inches of the fresnel lens. This portion of the lens contained an upward-looking segment which originally was thought to be needed so the driver could see the horizon when he looked through the viewer and be better

Jan 1, 1982

By John R. M. Hill

The Bureau of Mines performed elastic-plastic, finite-element analyses to investigate the support performance of hydraulic backfill. A mathematical model was developed for two vertically adjacent stopes separated by a sill pillar. An exact duplicate of a working stope was not intended; however, the model did simulate a working stope to the extent that field measurements from an active stope could be used for comparative purposes. Using a predetermined mining sequence, the computer analysis simulated the mining operation as a series of incremental cut-and-fill steps. Computer results included a complete history of stope closure and pillar stresses throughout the mining sequence. With the mining sequence and rock properties held constant, three separate analyses were made using varying backfill properties. These cases included no fill,-low-to-medium-quality fill, and medium-to-high-quality fill. Results of these analyses show decreases in stope closure and pillar stresses as the backfill quality increases, thus reducing the possible occurrence of rock bursts. Predicted stresses within the backfill compare favorably with field measurements. A relationship between maximum stress normal to the stope wall and the ratio of relative fill stiffness to relative rock stiffness was also indicated.

Jan 1, 1974

To clean coal mine air by developing a low-cost scrubber suitable for belt transfer and similar applications. Approach Design a scrubber operated by water only, with no moving parts. Use conventional water spray nozzles located within a duct to both move and clean the air. Use a droplet eliminator to get the water droplets and mist back out of the airstream. How It Works Conventional scrubbers require a mechanical fan driven by either an electric or a hydraulic motor. They also require water sprays and some type of scrubbing mechanism. The water powered scrubber, however, offers higher reliability over conventional scrubbers since it utilizes the water sprays to both move the air and scrub the particulate from the air. Conventional water spray nozzles are placed near one end of a rectangular duct open at both ends. The sprays are directed towards the far end of the duct where a stationary wave blade water droplet eliminator is located. Movement of the water spray droplets coming from the nozzles generates (by momentum transfer) an air movement In the same direction as the sprays. The volume of air moved Is primarily a function of the duct cross-section size, water pressure and water

Jan 1, 1981

Provide a more efficient method of cooling hot working environments in deep mines than is possible with single stage spray coolers or cooling coil heat exchangers. Approach Pass warm mine air through several stages of horizontally oriented water sprays fed by the chilled water supply of the mine. How It Works This concept extends the capabilities and potential applications of the coolers described in Technology News nos. 71 and 93. In this multi-stage design, hot ventilation air is cooled while passing through horizontal water sprays. Air enters the cooler through a diffuser section which slows the airflow and distributes it evenly across the cooler with a minimum of pressure drop. This ensures uniform exposure of the warm air to the cool water and consequent high thermal efficiencies. In the three-stage cooler shown, cold mine service water is sprayed from the first water stage manifold on the downwind end of the cooler. Slightly warmed water from this spray stage is collected in a sump, pumped and then resprayed through the second stage manifold. The process is repeated again for the third-stage. An overall counterflow heat exchange effect is thus achieved by exposing the hottest incoming air to the warmer, third-stage water spray first and to the coldest, first-stage water spray last. Wave plate eliminators can be employed between stages of water sprays to increase thermal efficiency or at the outlet to minimize the water discharged into the mine ventilation air. Cooled air can then be ducted to hot work spaces or simply released

Jan 1, 1985

By Richard Hammer

Various alternating current (ac) methods can localize faults in mining power cables. Several methods considered by the Bureau of Mines in this report are the Murray loop for short circuits, wherein a bridge provides proportional distance to the fault; capacitance measurements for open conductors; inductance measurements for shorted conductors; phase comparison, high speed recordings of voltage and current in the faulted state are compared with normal voltage and current with the difference being a function of impedance change and impedance change being a function of fault location; and standing wave measurements, detecting the resonance of the length of cable to a fault (either short or open). Portable capacitance bridges are presently available for the second method, and the fourth method is well developed for use on large power distribution systems. Because it utilizes pulses rather than ac, the time domain reflectometer (TDR) method of fault locating was not included in this investigation. However, a comparative evaluation between this versatile method and the Murray loop might prove advantageous in locating high resistance faults.

Jan 1, 1977

By S. E. Khalafalla

The ability of potentiometric, gas-sensing electrodes to reliably monitor free gaseous molecules in solution has been recently demonstrated. A gas such as sulfur dioxide from a dilute sample solution diffuses through a hydrophobic, gas-permeable membrane to an internal filling solution. The latter solution contains a sufficiently large excess of sodium bisulfite, the concentration of which can be considered constant regardless of the quantity of sulfur dioxide entering by diffusion. The electrode response is essentially due to the liberated hydrogen ions from the bisulfite-sulfur dioxide equilibrium. This Bureau of Mines report describes a new technique used to detect the formation, and to estimate the stability constant, of gas-molecule and gas-ion complexes in solution, as part of an effort to minimize the undesirable environmental impacts associated with mining and mineral processing. Although the unknown activity coefficients of the neutral and ionic species in the external solution complicate the quantitation of results, methods to circumvent these difficulties are presented. The technique is based on the isometric shift of the Nernst diagram of ion-selective electrodes to higher concentrations relative to the standard aqueous calibration curve. The method is applied to detect and estimate the formation constant of a sulfitocitrate complex, and agrees well with an independently determined stability constant of the disulfitomercu-rate complex.

Jan 1, 1978

By David A. Monaghan, Kenneth R. Maser, Adi R. Gurdar, D. Randolph Berry

APPENDIX B - DEVELOPMENT OF FOAM-CONCRETE SLURRY MINE SEALANT 1. Introduction This appendix describes the results of an experimental development and laboratory evaluation of foam-concrete as a rapid setting, lightweight, self-supporting mine sealant material. Foam concrete, otherwise known as Aerated Concrete, is a form of lightweight concrete whose structure consists of air bubbles held together by a hardened cement mortar. Its principal applications are found in roofing, insulation, shock absorbing, and backfill. The air bubbles in foam concrete are formed either by chemical reaction in the wet, placed mortar, or by introducing a stable foam into the mortar during mixing. The mortar is usually a cement slurry with fine sand or fly ash as filler. Our attention focused on preformed foam concrete, since this is most adaptable to field applications. Equipment is available,* which simultaneously mixes and pumps a slurry of foam concrete. Such a slurry can be produced at a rate of up to 50 yards/hr and has been pumped in a 2-inch-diameter hose 1000-feet horizontally and 250 feet vertically up without significant bubble deterioration. One very attractive feature associated with the use of foam concrete concerns site logistics. Foam concrete can be generated with densities as low as 20 lbs/ft3, and hence the total number of

Jan 1, 1973

Reduce or prevent acid mine drainage from coal refuse piles and surface mines by inhibiting the growth of acid-causing bacteria. Approach A dilute surfactant or deter? gent solution is applied directly to coal refuse piles or overburden using a hydro-seeder or road watering truck. The surfactant treatment can be used either as a preventive measure to avoid a potential acid drainage problem or to reduce water treatment costs by controlling acid drainage at its source. How It Works Acid drainage is prevented or reduced by inhibiting the growth of Thiobacillus ferrooxidans, a type of bacteria which obtains most of the energy it needs to survive by oxidizing ferrous iron in water. The oxidized iron in turn attacks pyrite, which forms an acid and additional ferrous iron for the bacteria to oxidize. T. ferrooxidans is protected by an outer membrane which enables it to survive in its acid environment. Anionic surfactants, or surfactants containing negatively charged ions, can be used to destroy this membrane, thus killing the bacteria and slowing down the oxidation of acid-forming pyrite. Of the anionic surfactants tested to date, sodium lauryl sulfate (SLS) appears to be the most effective as a bactericide. Alpha olefin sulfonate and alkyl benzene sulfonate are acceptable alternatives. These surfactants are major components of common household products, such as laundry detergent, shampoo and toothpaste. They are, therefore, readily available, inexpensive, biodegradable and present no environmental problems at low concentrations.

Jan 1, 1983