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By Lisa Steiner, Robin Burgess-Limerick

In 2004, there were 646 underground coal mines in the USA employing 37,445 miners. These mines reported 3556 injuries to MSHA that year - 17% were associated with bolting machines (593 injuries), 8% with continuous miners (283 injuries), and 4% each with Scoop/LHD (1 51 injuries), shuttle cars (134 injuries), and personnel transport (145 injuries). The use of the frequency of reported injuries for the prioritization of risk control strategies has limitations because of the tendency to underestimate the importance of relatively rare but high-consequence events. Injury reports also underestimate the contribution of risk factors such as whole body vibration, which have a long-term cumulative contribution to an elevated risk of injury. However, taking these limitations into consideration, the results of the injury narrative analysis suggest the following hazards as the highest priority for elimination or control: • rock falling from supported roof • inadvertent or incorrect operation of bolting controls • handling continuous miner cable • collisions while driving LHD/Scoop, shuttle cars and personnel transport • rough road while driving or traveling in LHD/Scoop, SC & PT

By Frank E. Federspiel

In 1986 and 1987, at the request of the U.S. Forest Service, the U.S. Bureau of Mines examined the 47,000-acre Electric Peak study area (part of the formerly-designated RARE II Non-wilderness Recommended Area no. 1609) to evaluate its' identified mineral resources. The study area is in Powell and Jefferson Counties, YT, about 30 mi southwest of Helena and 30 mi north of Butte. Three lode localities within the study area contain an estimated 159,000 tons of identified subeconomic resources containing gold, silver, and accessory lead, copper, and zinc. Resources at those localities range from 10,000 to 134,000 tons with grades ranging from 0.04 to 0.32 oz/ton gold, 0.92 to 16.42 oz/ton silver, 0.14 to 79.65 percent lead, and as much as 0.41 percent copper and 0.68 percent zinc. One property also contains 0.15 percent antimony. Gold, silver, and base-metal content in samples of poorly exposed mineralized structures indicate that further exploration may identify resources on seven additional study area localities.

Jan 1, 1988

By H. N. Smith

IN 1944 the Congress passed the Synthetic Liquid Fuels Act that authorized the Secretary of the Interior, acting through the Federal Bureau of Mines, to conduct basic research and construct and operate demonstration plants to produce synthetic liquid fuels from coal, oil shale, and other substances. As a basis for the oil shale investigations to be undertaken in this country, the progress of foreign countries in developing and using oil shale as a source of liquid fuels was studied by the technical missions of the Federal Bureau of Mines. Oil shale mines, retorting plants, and refineries were visited; geological information on the nature and occurrence of the foreign oil shales was obtained; and samples of the oil shales were collected where possible. Samples collected by these missions or acquired by other means came from Australia, Brazil, Canada, France, Manchuria (China) , New Zealand, Scot-land, Spain, Sweden, Thailand, and Union of South Africa. These countries represent a large part of the locations where oil shale developments have taken place. The major omissions are the Estonian, German, and Russian developments.

Jan 1, 1959

By Lloyd A. Morley

This report details the continuation of mine power systems transient research under USBM Grant G0155003. The purpose of the work, which commenced under Grant G0133077, is the elimination of safety hazards created by transients" and the objective is to provide knowledge about transients existing in a-c and d-c coal mine power systems. The report chapters cover theoretical background, instrumentation, and experimental investigations. The instrumentation discussion scans measurement problems and considerations plus the development of a low-cast peak-detector. Transient data from in-mine measurements are presented and include high-voltage distribution and d-c trolley systems. Extremely unique field exercises are described involving actual power equipment connected on the surface to duplicate typical underground coal mine system arrangements. Here, transients on high-voltage distribution resulting from vacuum circuit breaker operations could be observed under controlled conditions, and work centered around how surge capacitors effect transients. Using the in-mine and staged transient data, specific conclusions and recommendations are made with emphasis on high-voltage distribution.

Jan 1, 1977

By Daniel W. H. Su, Gregory J. Hasenfus

This paper demonstrates that finite-element modeling can be used to predict in situ coal pillar strength, especially under non ideal conditions where interface friction and roof and floor deformation are the primary controlling factors. Despite their differences in approach, empirical, analytical, and numerical pillar design methods have apparently converged on fundamentally similar concepts of coal pillar mechanics. The finite-element model results, however, are not intended to suggest a new pillar design criterion. Rather, they illustrate the site-specific and complex nature of coal pillar design and the value of using modeling procedures to account for such complex site-specific conditions. Because of the site-specific nature of coal pillar design, no single pillar design formula or model can apply in all instances. Understanding and accounting for the site-specific parameters are very important for successful coal pillar design. More work remains before the century-old problems related to pillar design are finally solved. Future research should focus on the cross-linkage of empirical, analytical, and numerical pillar design methods.

Jan 5, 1999

By Steven J. Page, John A. Organiscak

Prolonged exposure to airborne respirable coal mine dust is responsible for coal workers' pneumoconi¬osis (CWP): Furthermore, miners who show evidence of higher radiographic categories of simple CWP are at increased risk of developing progressive massive fibro¬sis (PMF). As of 1990, there were nearly 130,000 coal miners in the United States. "' This excludes mines that produce less than 10,000 tons annually and the anthracite coal mines. Estimates indicate that at age 58, an average of 7/1000 U.S. workers and 89/1000 U.K workers will have developed PMF(2-1) Health research studies have iden¬tified that the risk of developing and the severity of CWP arc directly related to (1) the amount of respirable dust exposure and (2) the coal rank.,'- The rank of coal is its stage of formation in the series peat, lignite, sub-bituminous, bituminous, and anthra¬cite (in order of increasing rank). The rank of coal can also be represented by the com¬mercially important characteristics specified by its proximate analysis: fixed carbon, vol¬atile matter, mineral matter, and moisture content.

By David Hoadley, Kenneth R. Maser, Ashok B. Boghani, James E. Billar, D. Randolph Berry, Mackenzie Burnett, Robert H. Trent

APPENDIX C - HOISTING SYSTEMS - AVAILABLE EQUIPMENT C 1 - Introduction A survey has been made of available hoisting equipment which has applications for use in metal and non-metal mine emergency escape hoist systems. The information was gathered from a number of sources, including representatives in the USBM and MESA, mine operators, personal visits and telephone interviews with manufacturers, field visits to inspect equipment, advertisements, catalogues and indices of manufacturers. Wherever possible, technical specifications and prices were checked out with the manufacturer, or supplier. The sections on individual sub-systems and components, such as automatic control systems, winches and controls, are not intended to be all encompassing surveys. Rather a reasonable number of representative units in each category are discussed. The sample is large enough to provide a general picture of the kind of equipment available, including the abilities and limitations and a reasonable price range. The survey has been divided into six categories 1. Complete Hoisting Systems A Above ground installations B Below ground installations 2. Hoist Assemblies ^(Man-rated) 3. Hoists (not Man-rated)

Jan 1, 1976

By J. E. Chilton, C. R. Carpenter

The U.S. Bureau of Mines has developed an intrinsically safe carbon monoxide (CO) monitoring system for mines by coupling a fiber-optic data telemetry (FODT) system with a prototype electro- chemical CO monitor. The CO monitoring system can be used in a coal mine as one component of an early fire warning system. This system may be used in belt haulage entries when the entries are used for supplying ventilation air to working places. The FODT accepts a 0.1- to 1.1-V analog signal from the monitor and converts it to pulses (0 to 5 V) at frequencies from 1.1 to 11 kHz that drive a light- emitting diode (LED). An electrically nonconducting fiber-optic cable carries the LED signal to a remote receiver. The receiver analyzes the incoming light signal and displays the measured CO concentration in parts per million. This report discusses the performance of the FODT system and characteristics of the CO monitor such as response times, linearity, and temperature and pressure effects.

Jan 1, 1992

By A. T. Iannacchione

Underground stone mining represents an emerging sector for the U.S. mining industry. As this expansion takes mines under deeper cover and as more efficient mining methods are utilized, adequate stone pillar design methods will become more important. It is the purpose of this paper to examine current design practices and to discuss issues for safe mine layouts so that a rational first approach towards balancing the demands for increased production can be weighed against increased risk to worker safety from rib instabilities and pillar failures. Seventy-two stone mine pillar designs were examined. Pillars with width-to- height ratios below 1.5 and subjected to excessive stress levels appear more likely to fail. When width-to- height ratios fall below 1 .O, defects in the pillars, such as through-going discontinuities, can have a significant influence on stability. Discontinuity persistence, dip, material properties, and orientation are important factors controlling pillar strength. The influence of discontinuity dip, a characteristic easily identified in the field, was examined so that its presence could be accounted for in developing generalized guidelines for pillar design.

By David Hoadley, Kenneth R. Maser, Ashok B. Boghani, James E. Billar, D. Randolph Berry, Mackenzie Burnett, Robert H. Trent

C. 4 Hoist Assemblies (not man-rated) A large number of manufacturers supply materials handling winches. These units are predominately electric powered while a limited number of vendors supply air powered equipment. Air powered units are currently used extensively for underground materials handling purposes. Suppliers of materials handling equipment normally include a disclaimer statement in their published literature which clearly states that the equipment "is not designed or suitable for lifting or lowering persons " This category of commercially available equipment can be adequate for emergency man hoisting provided that its' capacity is suitably derated and provided also that the necessary safety features are incorporated. Section C. 5 details the equipment which could be added to a commercial materials hoist to meet these needs. Four commercially available hoist assemblies, two electric and two pneumatic are discussed in the following paragraphs. This equipment is typical of what is commercially available and three of the units are currently used extensively in mining applications. Each hoist description includes a remarks paragraph which identifies the additional equipment each hoist would require for emergency hoist use.

Jan 1, 1976

Until man was able to produce light, his working day was pretty much limited to daylight hours. Underground miners have a special problem because in a mine it is just as dark during daytime as it is at night. The first devices used for mine lighting were torches and open flame 011 lamps. Torches made from twisted grass and dipped in tallow or pine pitch would burn for a while, but they made a lot of smoke and probably went out when they were needed most. During the 15001s, miners lamps consisted of a small metal dish with a hook attached to hang it up. The saucer-shaped dish was filled with animal or fish oil and a wick made of twisted fibers was laid In the 011 and hung over one edge where it would burn. This lamp would burn longer than a torch, but the amount of light cast by the pale, flickering flame was probably only a little better than no light at all.

Jan 1, 1976

By Maria I. De Rosa

Table 19 and figure 7 show the number of fires and fire injuries for surface coal mines by state during 1990-1999. Table 19 also shows by state the risk rates, employees' working hours, lost workdays, and coal production. For surface coal mines, 215 fires occurred in 21 states during 1990-1999. Ninety-four of those fires caused 93 injuries and I fatality (the yearly average was 21.5 fires and 9.3 fire injuries). Fourteen fires and seven injuries involved contractors. The Ewhr value was 729 x 10° hr (In = 0.026), the CP value was 6,355 x 10° st (Fn = 0.034), and the LWD value was 8,141. Kentucky had the most fires and fire injuries (45 fires and 23 injuries), followed by Pennsylvania (33 fires and 14 injuries), West Virginia (25 fires and 14 injuries), and Indiana (20 fires and 8 injuries). Among these states, Pennsylvania had the highest fire risk rate value (Frr=0.145), while Kentucky had the highest injury risk rate value (In 0.041).

Jan 1, 2004

By Mark A. Ackerson, Kenneth E. Hjelmstad

An ideal fire warning alarm system for underground mines would be low cost, convenient, fast, reliable, and able to warn all underground workers. Present warning systems, such as phones, messengers, and stench, fail one or more of these criteria. The U.S. Bureau of Mines may have devised the ideal system. The one way communication system employs a large loop antenna and transmitter to create a 630 hertz (Hz) electromagnetic field to send information through-the-earth to cap lamp battery mounted micro- receivers worn by underground miners. Field tests of prototype equipment in 1986 resulted in through-the- rock signal transmission of over 762 m (2500 ft). Subsequent hardware upgrades for more recent tests resulted in transmissions of over one mile. Recently developed receiver circuitry employs phase- locked-loop detection circuitry responsive only to a specific series of pulses of given time duration, that eliminates false alarms from electromagnetic noise emitted by mine equipment, power lines, or lightning. A multichannel system can relay standard messages to miners

To rapidly and dependably locate shorts and opens in mining equipment power cables. Approach: The approximate locations of faults are found using a sound pulse echo, then the faults are exactly located with one of two probes. How It Works: To approximately locate u fault in shielded or unshielded cable, the cable is disconnected from the mine power center, and connected to the sound pulse generator. The generator is also connected to the ground conductor of the cable. When the generator is energized, electrical pulses are transmitted, and each moves along the conductor until it reaches a fault. When a pulse reaches the fault an echo returns to the instrument, either a positive pulse if the fault is an open, or a negative pulse if the fault is a short. See Figure 1. The further along the cable the first fault is from the instrument, the longer it takes for the echo to return. The instrument automatically measures the time and calculates the distance. The distance in feet is shown on an illuminated digital display.

Jan 1, 1976

To improve a miner's chance of survival during an emergency by providing immediately avail-able breathable air and protection from toxic gases until a longer-duration breathing apparatus, stored nearby, can be reached. Approach: A belt-carried apparatus which can provide a closed-circuit atmosphere for ten minutes breathing has been developed under a Bureau of Mines contract. How It Works: Water vapor and carbon dioxide in the user's exhaled breath are removed, and oxygen is supplied, by chemical reactions. When the user exhales into the mouthpiece, water vapor in his breath reacts with potassium superoxide (KO2) stored In the canister to produce oxygen. The other product of this reaction (KOH) reacts with carbon dioxide and removes it from the air. The oxygen-enriched air then flows from the canister into two breathing bags. When user inhales through the mouth, that air is drawn out of the bags, makes a second pass through the chemical-containing canister, and flows into the mouthpiece tube. A nose clip is worn to seal off the nasal passages.

Jan 1, 1975

By W. K. Overbey

Knowledge of fracture systems in oil or gas reservoirs is essential to the efficiency of both primary and secondary production operations. A relationship was established between structural features of the surface and both natural and induced fractures in oil and gas reservoirs, thus providing a method of predicting the direction of rock fracture prior to field development and well completion. Correlations between the surface features and under-ground fractures resulted from analysis of joint strike measurements, bottom-hole impression packer surveys, photographs of hydraulically fractured wells, fracture data from oriented cores, in situ strain measurements from formation outcrops, and lineament analyses from aerial photographs. The mean orientation of surface fractures, lineaments, and stress field directions ranged from N 53° E to N 73° E, compared with an average orientation of N 63° E for the hydraulically induced fractures. Tectonic stress field was shown to influence the direction of hydraulically induced fractures. This report presents the details and application of techniques to obtain the orientation of the principal horizontal compressive stress field component and thus the direction of induced fractures.

Jan 1, 1971

Develop a dry dust collector suitable for working faces and belt transfer paints. Approach A filter cartridge with a reverse-pulse, self-cleaning system has been mounted in-to a low profile unit requiring electric power only. How It Works Dust-laden air entering the in-let end of the collector passes through the two inline filter elements. When the elements load to a pre-selected pres-sure drop, they are automatically pulse-cleaned by a "backflush" method using compressed air. When the elements are pulse-cleaned, caked dust material on the filter surface is released, and falls away as lumps. Dust is removed from the collector by an auger mechanism. Features of the collector are: (1) unit is completely self-contained, (2) built-in air compressor for pulse-cleaning, (3) cleaning cycle initiates automatically at a preset restriction, (4) automatic auger discharge of collected dust, (5) detachable extension auger for transporting collected dust, (6) "dust leak" indicator light, and (7) "change filter element II warning light. The collector has been designed as permissible although approval has not yet been granted.

Jan 1, 1981

By Jack C. White

The Bureau of Mines, in its efforts to insure the continued viability of the domestic minerals economy, has been engaged for several years in research on the extraction of alumina from domestic, nonbauxitic resources. Hydrochloric acid leaching of kaolin is one of the more promising technologies being studied for recovering alumina for feedstock to existing aluminum smelting capacity; 93 pct of this feedstock is currently imported either as bauxite or alumina. Organics contamination of pregnant leach liquor, originating during solvent extraction for removal of iron from aluminum chloride solution formed during hydrochloric acid leaching, causes rapid deterioration of the semihard rubber lining of process equipment. These organics were removed by a skimming tank-coalescer-activated carbon adsorption system. Organic levels of less than 10 ppm from the coalescer and less than 0.5 ppm from carbon adsorption were achieved. Analytical methods employing CC14 extraction and infrared spectrophotometry were developed to determine the organic content of both the liquor and the carbon. Mass transfer zones delineated in the carbon columns provide adsorption data for the design of larger systems.

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

Provide reasonably priced, reliable fire protection for loading shovels. Approach An automatic fire, sensing and suppression system using both dry chemical and Halon 1301 was developed. It is more rugged than similar industrial-type fire protection systems. How It Works Temperature sensors detect heat from a fire, and trigger the system. These sensors are located inside the machinery house and under the house and shovel frame where it rotates around the crawler chassis ring gear. An alarm is sounded, and extinguishing agents are released either in the machinery house or in the ring gear area. The system can also be triggered by a manual control. If the fire Is detected in the machinery house, all power is shut down to the motor-generator sets, ventilation fan, and all electrical controls. Doors are automatically closed. After a delay to allow time for the ventilation fan to stop, Halon 1301, a gaseous fire extinguishing agent, is released inside the machinery house until it reaches a concentration of about 7 percent. This concentration is sufficient to extinguish a fire, but isn't toxic to personnel

Jan 1, 1980