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By Thomas M. Barczak

State-of-the-art longwall roof supports provide effective strata control, but failures of these support systems still occur. To identify failure mechanisms and the impact these failures have on the safety of the support system, the U.S. Bureau of Mines has been conducting research on shield mechanics in the Bureau's unique mine roof simulator, as well as field studies of in situ support loading and investigations of longwall failures, Three types of failures are discussed: (1) inadequate support capacity, (2) structural failure, and (3) instability. Hypothetical situations with proposed courses of action and case studies of actual longwall failures are described. This information is intended to assist the Mine Safety and Health Administration (MSEIA) and industry mining personnel in safety evaluations of longwall roof support systems.

Jan 1, 1989

By Donna L. Anderson

This U.S. Bureau of Mines report describes a system to determine the position and heading of a continuous mining machine during the maneuvers required at the face area of a mine. The system consists of commercially available angular position sensors and a computer interface developed and tested at the Bureau. The sensors employed are laser-based scanning devices that report the angular location of retroreflective targets within their 90° field-of-view. The targets are mounted on the continuous mining machine; the laser scanners are mounted on an external reference structure. The computer interface consists of a single-board computer-controller programmed to gather and process the angular position information, and to calculate the machine's position and heading relative to the reference structure. A sensor fusion algorithm will be incorporated into the computer interface programming to increase the accuracy and reliability of the system.

Jan 1, 1989

By John J. Sammarco

The U.S. Bureau of Mines has developed a regulated, intrinsically safe, rechargeable power supply for portable electronic equipment for underground use. The regulated output is ideal for microprocessor power requirements and is suited for operation in hazardous environments. Two rechargeable, sealed batteries are contained within the power supply. Provisions are made to use an external source of power if these batteries fail. Provisions are also made to charge these internal batteries when needed. The circuit is composed of three main circuits: the main regulator circuit, the input protection circuit, and the output protection circuit. The main regulator circuit provides remote voltage sensing, current sensing, fault monitoring, and internal thermal protection. The input protection circuit checks for excessive input current and low battery conditions. The output protection circuit contains two overvoltage detection devices. Schematics, a parts list, and a calibration procedure are provided in this report to enable readers to fabricate the power supply.

Jan 1, 1989

By J. C. Duchon

The U.S. Bureau of Mines is conducting human factors research for the purpose of reducing accidents and improving the person-machine interface found in surface and underground mining operations. Miners are exposed to a variety of environmental stressors, e.g., extreme heat, noise, vibration, and adverse illumination, throughout the workday. Exposure to these environmental stressors has been noted in the literature to affect performance on vigilance tasks. Since impaired performance at vigilance tasks can lead to industrial accidents, further investigation of the effects of environmental stressors on human performance is warranted. A brief description of the environmental conditions present in the mining workplace is followed by a review of experiments dealing with the effects of environmental stressors on vigilance task performance. The applicability of past research to actual mining operations is considered.

Jan 1, 1989

By Frank T. Duda

A U.S. Bureau of Mines interactive FORTRAN computer program can screen explosion-proof enclosures intended for underground service. The program incorporates important information and criteria to assist enclosure manufacturers and Mine Safety and Health Administration (MSHA) personnel by providing a first-order approximation of rectangular explosion-proof enclosure characteristics prior to actual certification testing. The program uses information and data that can be retrieved automatically during program execution. The program also performs the calculations for a series solution algorithm and various equations to evaluate the enclosure for both a static internal pressure and an internal explosion. The program writes the intermediate and final calculations and information concerning the status of the screening process to a summary file on a floppy disk. One data base contains MSHA certification requirements given in the Code of Federal Regulations (30 CFR 18). A second data base contains material properties of acceptable construction materials and weld joint efficiencies. A series algorithm determines bolt and cover stresses for a simply supported rectangular cover with arbitrary bolt locations. Limit and yield line analysis is used to calculate the strength of body panels.

Jan 1, 1989

By Xintan Chang

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 the influence of natural ventilation, fans, fires, or any combination of these. MFIRE simulates a mine's ventilation system and its response to altered ventilation parameters such as the development of new mine workings or changes in ventilation control structures, external influences (varying outside temperatures), and internal influences (fires). Extensive output enables detailed, quantitative analysis of the effects that the alteration will cause to the ventilation system. The program was developed at Michigan Technological University (MTU), Houghton, MI, with support from the Bureau of Mines. A personal computer (PC) version of the program was completed under contract for the Bureau by MTU. The purpose of this report is to document the installation and use of the PC version of the program MFIRE.

Jan 1, 1990

By Thomas J. Albin

U.S. Bureau of Mines research has found that maintenance of surface mining equipment is involved in slightly more than one-third (34.1 pct) of all surface mining accidents. Two groups of machines, haulage trucks and power shovels, accounted for over one-half of all surface mining mobile equipment maintenance accidents in 1978-84. Maintenance work-time histories for these machines were compared with accident records to identify the most hazardous-to-maintain systems within the machines. Recommendations to reduce the accident risk associated with maintenance of these hazardous systems are presented.

Jan 1, 1990

By Lloyd A. Morley

This Bureau of Mines publication presents a comprehensive review of mine electrical power-system theory and practice. It discusses fundamental theory and the vital aspects to be considered in planning and designing mine electrical power systems. The report is divided into three major sections. The first presents the history of electricity in mining and the fundamentals of electrical phenomena and components. The second focuses on power-system components: motors, grounding systems, cables, and protective equipment and devices. The final section includes mine power-center equipment, switchhouses and substations, batteries, and mine maintenance.

Jan 1, 2003

By Lloyd A. Morley

This Bureau of Mines publication presents a comprehensive review of mine electrical power-system theory and practice. It discusses fundamental theory and the vital aspects to be considered in planning and designing mine electrical power systems. The report is divided into three major sections. The first presents the history of electricity in mining and the fundamentals of electrical phenomena and components. The second focuses on power-system components: motors, grounding systems, cables, and protective equipment and devices. The final section includes mine power-center equipment, switchhouses and substations, batteries, and mine maintenance.

Jan 1, 2003

By Donna L. Anderson

This information circular documents the status of a laser-based guidance system to track and control the tramming maneuvers of a continuous mining machine. The work is part of a multiple project effort at the U.S. Bureau of Mines to develop technology for computer-assisted mining systems. The system includes stationary offboard laser-scanning sensors that report the angular coordinates of retroreflective targets on the mining machine. A microcomputer system processes the angular coordinates, determines position and heading, handles requests for data, and controls tram maneuvers of a continuous mining machine. This report describes the hardware for the sensor and computer systems and the software algorithms for continuous miner position and heading determination, closed-loop tramming, and data request handling. Improvements made to the system since previous documentation include the rewriting of the software on a stand-alone real-time microcomputer system, the implementation of real-time programming techniques, the use of a new version of the laser sensor, and the design and development of explosion-proof enclosures for the lasers and corresponding power supply.

Jan 1, 1991

By Slavoljub Makslmovic

One important element of the U.S. Bureau of Mines computer-assisted mining research program is the development of a reliable coal interface detection (CID) system. Several candidate CID concepts currently being investigated by the Bureau include use of natural gamma radiation (NGR), vibration, passive infrared, video, and radar. To help establish which CID sensor technologies need to be developed for a given seam, the Bureau has collected geological and mining practices data from over 460 underground and surface mines in the United States. Also, over 500 coal and rock samples have been obtained for laboratory analyses of ash content, sulfur content, heating value, and NGR. The Bureau's findings indicate that the immediate roof strata in 81% of the underground mines and 93% of the surface mines are made up of shale, draw slate, or claystone. The immediate floor strata in 88% of both the underground and surface mines consist of fireclay, shale, draw slate, or claystone. The results of the NGR testing indicate that the NGR method appears to be a potentially useful CID tool, provided that the immediate roof and floor are both composed of a high percentage of shale-type material.

Jan 1, 1993

By W. M. McKewan

This U.S. Bureau of Mines report discusses wire ropes used for hoisting in U.S. mines. The in-formation presented was extracted from a large body of data compiled by the U.S. Mine Safety and Health Administration (MSHA) using a data base management system (DMS). Further, these extracted data were then manipulated to provide tables of data that show the types and amount of wire rope used for hoisting. This report describes the different types of wire ropes and how a DMS can be used to manipulate MSHA's wire rope inventory data. The data indicate that more 1-1/4-in-diam ropes, 6x27 construction ropes, and right lang lay ropes are used in U.S. mines than ropes of any other diameter, construction, or lay type.

Jan 1, 1991

By Jay C. Hanson

Various electrical and electromagnetic (EM) geophysical techniques are currently being evaluated by the U.S. Bureau of Mines for their effectiveness in the detection and monitoring of electrically conductive (1 to 5 S/m) lixiviant (leach solution) to depths of 600 m, either above or below the water table. These techniques include magnetotellurics (MT) , controlled source audiofrequency magnetotellurics (CSAMT), resistivity and focused resistivity, ground-penetrating radar (GPR), frequency-domain electromagnetics (FEM), and time-domain electromagnetics (TEM). Of these techniques, TEM may be the most effective, but CSAMT and focused resistivity also hold promise. Geophysical computer modeling of the borehole TEM technique was conducted based on an idealized geoelectric section (layered earth) with characteristics based on the Santa Cruz porphyry copper deposit near Cas a Grande, AZ. Layer resistivities and thicknesses were obtained from geophysical data and geologic logs available from the site. Modeling of borehole TEM in both preleach and during leach situations was conducted. Simulating the TEM method using computer modeling proved to be encouraging since there were substantial differences between leached and nonleached responses. The modeling does not prove the effectiveness of TEM in the field, but does indicate that detection of deep lixiviant zones is theoretically possible.

Jan 1, 1992

By Staff

The goal of the U.S. Bureau of Mines diesel engine research program is to reduce exhaust emissions from diesel-powered equipment used in underground mines. This research has led to significant advances in aerosol measurement and to the development of more effective emission controls. This Information Circular contains reports of some of the presentations made at the Bureau's Information and Technology Transfer Seminar on Diesels in Underground Mines given in Minneapolis, MN, on September 29-30, 1992. The seminar emphasized the measurement and control of diesel particulate matter emissions. Topics covered include a discussion of the health issues associated with the use of diesel equipment underground, an overview of regulations, measurement techniques for diesel exhaust aerosol, levels of diesel exhaust pollutants found in mines, and modern emission controls. An appendix is included that contains a report describing the capabilities of the Bureau's diesel emissions research laboratory, two papers describing the effects of engine maintenance or: emissions, a paper describing the monitoring of carbon dioxide in mine air as an indicator of air quality, a glossary, and a list of abbreviations and acronyms.

Jan 1, 1992

By Christopher C. Jobes

Computer-assisted control of a mining machine can place the operator in a safe, remote location. A guidance system aids remote positioning of a mining machine by determining its position and heading. The mechanical position and heading system (MPHS) is one of several guidance systems being developed at the U.S. Bureau of Mines. The MPHS uses linear position transducers (LPT's) to provide navigation information during face maneuvers. This report presents an overview of the MPHS theory and implementation, including recent design modifications made for more successful underground testing. This report also presents the experimental setup and procedure for the underground test. The test showed that the MPHS provides reliable and accurate results and can, therefore, provide useful guidance information for face navigation.

Jan 1, 1992

By Jr. Boyle

This report analyzes the availability of chromium in the form of ferroalloy products (high-carbon and low-carbon ferrochromium and ferrochromium-silicon) and chromite products (metallurgical, chemical, refractory, and foundry sands) in market economy countries (MEC's). A total of 873.5 Mmt of in situ material, containing 202.5 Mmt of chromium, in 10 MEC countries was analyzed for availability as of the January 1989 study date. Extraction and beneficiation of this in situ material would result in 475.4 Mmt of marketable chromite products. As analyzed, 288.5 Mmt of these chromite products would be available for export or for internal chemical and refractory use and 186.9 Mmt would be smelted in-country to produce 74.3 Mmt of high-carbon ferrochromium, 3.9 Mmt of low-carbon ferrochromium, and 2.0 Mmt of ferrochromium-silicon, all available for export. A network flow model, which includes centrally planned economy countries (CPEC's), was also constructed to analyze world chromium supply and demand interactions for the period 1986 through 1994 and to address a hypothetical North American embargo on direct imports of all South African chromium products beginning in mid-1990. The model shows capacity constraints developing in the MEC high-carbon ferro chromium industry in 1987 and a possible subsequent overreaction by the industry in terms of new capacity additions. The results suggest that sufficient chromium is available to North America should an embargo on direct imports from South Africa be imposed by its governments. However, the effect on export revenues in South Africa is relatively small, and timely increases to world ferrochromium, chemical chromite, and foundry sand chromite capacities would be required.

Jan 1, 1993

By Ann G. Kim

Fires that occur in abandoned coal mines, waste banks, and in coal outcrops constitute a serious health, safety, and environmental hazard. Toxic fumes, the deterioration of air quality, and subsidence constitute the greatest hazards from these fires. Although tires on abandoned mined land (AML) occur in every coal-producing state, the severity of the problem varies. Methods to extinguish or control AML fires, including excavation, fire barriers, and sealing, are generally expensive and have a relatively low probability of success This U.S. Bureau of Mines report includes information from a variety of sources, i.e., agencies of the Federal Government, State agencies, research reports, conference proceedings, product information, and technical literature. This information has been collated into a comprehensive discussion of AML fire problems. Data on past fire control projects and on the estimated extent of the current problem have been compiled. Factors affecting the occurrence, propagation, and extinguishment of AML fires are discussed. Conventional fire control methods are described, and their probable effectiveness is evaluated. Information on the hazards of AML fires and safety considerations is included. The status of current technology, recent improvements in fire control methods, and areas of current research are discussed.

Jan 1, 1993

By William H. Schiffbauer

This report details a microcomputer-based control and monitoring network that was developed in-house by the U.S. Bureau of Mines and installed on a continuous mining machine. The network consists of microcomputers that are connected together via a single twisted-pair cable. Each microcomputer was developed to provide a particular function in the control process. Machine-mounted microcomputers, in conjunction with the appropriate sensors, provide closed-loop control of the machine, navigation, and environmental monitoring. Off-the-machine microcomputers provide remote control of the machine, sensor status, and a connection to the network so that external computers can access network data and control the continuous mining machine. Because of the network's generic structure, it can be installed on most mining machines.

Jan 1, 1993

By J. D. Lane

The U.S. Bureau of Mines is conducting research on guidance systems for computerized haulage in underground mines. This report describes the process of component selection, installation and testing, perception algorithm development, and steering control algorithm development, to produce a real-time steering control system for an articulated haul truck for underground mining. Ultrasonic transducers were mounted on the truck to provide perception data by measuring the distance to the ribs. Linear potentiometers mounted inside the steering cylinders measured the steering angles. Algorithms, implemented on an inexpensive, robust onboard computer system, analyzed the data and controlled the steering via an electro-hydraulic proportional valve. The steering algorithm presented follows a zone defined by the relative position between the truck and a rib. Experimental verification of the ability to follow the zone in a test corridor on the Colorado School of Mines campus is presented. The automatic steering system successfully negotiated straight sections, curves, and the transition zones between straight and curves with the truck in first and second gears. The resulting real-time automatic-steering system can be applied to many underground articulated machines.

Jan 1, 1994

By Jennifer A. Slatnick

Chlorofluorocarbons (CFC's), once universally accepted as ideal compounds for use in cooling and refrigeration, in foam production, and in cleaning electronic components, are being phased out and eventually banned under extensive international agreements because the chlorine in CFC's is thought to deplete the Earth's ozone layer. The industry has responded with the introduction of alternatives in the form of hydrofluorocarbons (HFC's), which contain no chlorine, and with hydrochlorofluorocarbons (HCFC's), which fill an intermediate gap in the replacement of CFC's. As a result of the elimination of chlorine in the HFC's and the reduction of it in the HCFC's, these alternatives contain more fluorine than the CFC's do. Other nonfluorocarbon substitutes, known as not-in-kind alternatives, contain no fluorine at all. As a result, the fluorspar mining industry, which is the source of fluorine in fluorocarbons through intermediate hydrofluoric acid, is being affected. Concern for this impact has led the U.S. Bureau of Mines to employ its capabilities to analyze various scenarios in the evolution of CFC replacements and substitutes to determine their effect on fluorspar mining. This report utilizes a network flow model to examine the effects of proposed replacements for CFC's, in terms of fluorine content, on fluorspar operations worldwide and on hydrofluoric acid plants in North America and Europe.

Jan 1, 1994