Pittsburgh Mining Research Division Research Articles

Hot Surface Ignition of Liquid Fuels Under Ventilation.

Mine equipment fires remain as one of the most concerning safety issues in the mining industry, and most equipment fires were caused by hot surface ignitions. Detailed experimental investigations were conducted at the NIOSH Pittsburgh Mining Research Division on hot surface ignition of liquid fuels under ventilation in a mining environment. Three types of metal surface materials (stainless steel, cast iron, carbon steel), three types of liquids (diesel fuel, hydraulic fluid, engine oil), four air ventilation speeds (0, 0.5, 1.5, 3 m/s) were used to study the hot surface ignition probability under these conditions. Visual observation and thermocouples attached on the metal surface were used to indicate the hot surface ignition from the measured temperatures. Results show that the type of metal has a noticeable effect on the hot surface ignition, while ventilation speed has a mixed influence on ignition. Different types of liquid fuels also show different ranges of ignition temperatures. Results from this work can be used to help understand equipment mine fires and develop mitigation strategies.

Field Verification of an Improved Mine Fire Location Model

Underground mine fires remain a concern for mine operators, posing a health and safety risk to mineworkers. In the last decade, the number of mine fires has decreased significantly; however, dealing with an unknown fire in underground mines can be a challenging task, which could lead to a hazardous condition for miners during an evacuation and rescue operation. A timely detection of a mine fire and monitoring its characteristics, namely size and location, are of great importance in reducing the risk of mine fire injuries. A new improved fire location algorithm has been developed and integrated into an Atmospheric Monitoring System (AMS) program by researchers from the National Institute for Occupational Safety and Health (NIOSH). This paper describes the new fire location model and presents the results of verification fire tests conducted at the Safety Research Coal Mine (SRCM) facility of the Pittsburgh Mining Research Division (PMRD) using the collected AMS data. NIOSH is endeavoring to develop workplace solutions to improve detection of and reduce the risk of hazardous conditions in mines. The results demonstrate successful application of the improved fire location model and provide a useful tool for solving the problem of unknown fire location and reducing the risk of hazardous conditions.

An Improved Method to Calculate the Heat Release Rate of a Mine Fire in Underground Mines

Continuous monitoring of carbon monoxide and other fire-related parameters by means of an atmospheric monitoring system (AMS) has been used by the mining industry for early fire detection in underground mines. The National Institute for Occupational Safety and Health (NIOSH) initiated a project to integrate real-time AMS sensor data with NIOSH’s mine fire simulation program, MFIRE 3.0, to simulate and predict the spread of smoke that would provide assistance to mine fire emergency response personnel. Determining the heat release rate of a fire using the monitored sensor data was a critical component of the successful completion of this project. NIOSH researchers developed a direct method to calculate the heat release rate when a fire is within close range of sensors. However, this method is only applicable to the case where a fire occurs in AMS-monitored airways. This paper presents an improved method for determining the fire heat release rate for complicated scenarios where a fire is distant from sensors and airflow splits and merges are present. The method was validated using a full-scale diesel fuel fire test conducted in the Safety Research Coal Mine at the Pittsburgh Mining Research Division and can help mine operators and safety personnel make informed decisions during a fire emergency.

The Impact of Black Lung and a Methodology for Controlling Respirable Dust.

Coal workers' pneumoconiosis (CWP), commonly known as black lung, is caused by the inhalation of respirable coal mine dust and is a disabling and potentially fatal lung disease with no cure. Historically, CWP has taken a tremendous human and financial toll in the US coal mining industry. Recent health surveillance data indicates that CWP continues to occur at elevated levels. Respirable coal dust exposure must be controlled to prevent the development of CWP. The Pittsburgh Mining Research Division of the National Institute for Occupational Safety and Health (NIOSH) conducts laboratory and mine-site research to identify control technologies that can be used to successfully reduce respirable dust levels. Various technologies, using multiple methods of control, can be applied in order to reduce dust levels. An overview of CWP's impact and a general methodology for controlling respirable dust in underground coal mines are discussed in this paper.

Investigation of Machine-Mounted Area Lighting to Reduce Risk of Injury from Slips-Trips-Falls for Operators of Mobile Surface Mining Equipment.

Nonfatal injuries from slips, trips, and falls (STF) that occur at surface mines can result from inadequate lighting. Mobile equipment operators are among the occupations associated with the nonfatal incidents reported to the U.S. Mine Safety and Health Administration (MSHA). In addition, getting on/off the equipment (ingress/egress) frequently adds to the highest proportion of nonfatal incidents. Accordingly, researchers at the Pittsburgh Mining Research Division (PMRD), National Institute for Occupational Safety and Health (NIOSH) conducted a field study to investigate lighting on haul trucks and wheel loaders with regard to glare and illuminance levels recommended by the Illuminating Engineering Society (IES). The objective was to determine whether two light-emitting diode (LED) area luminaires-a Mr. Beams® (model MB390 Ultrabright) (area luminaire-1) and a NIOSH-developed Saturn (custom-designed for a mine roof bolter study) (area luminaire-2)-could complement a headlamp luminaire. Measured levels of visual tasks, with the headlamp alone and the area luminaires plus the headlamp, demonstrated that illuminance met or exceeded IES-recommended levels. Nevertheless, the area luminaires illuminated a much broader area, which is key to increasing hazard awareness. Discomfort and disability glare were lower with area luminaire-1 than with area luminaire-2. Differences in glare were more noticeable for newer models of haul trucks and loaders featuring updated ingress/egress system designs. This study demonstrates that commercially available luminaires, such as area luminaire-1, are capable of complementing headlamp lighting, and can thus improve a miner's ability to detect and avoid STF hazards.

Investigating the Impact of Caving on Longwall Mine Ventilation Using Scaled Physical Modeling.

In longwall mining, ventilation is considered one of the more effective means for controlling gases and dust. In order to study longwall ventilation in a controlled environment, researchers built a unique physical model called the Longwall Instrumented Aerodynamic Model (LIAM) in a laboratory at the National Institute for Occupational Safety and Health (NIOSH) Pittsburgh Mining Research Division (PMRD) campus. LIAM is a 1:30 scale physical model geometrically designed to simulate a single longwall panel with a three-entry headgate and tailgate configuration, along with three back bleeder entries. It consists of a two-part heterogeneous gob that simulates a less compacted unconsolidated zone and more compacted consolidated zone. It has a footprint of 8.94 m (29 ft.) by 4.88 m (16 ft.), with a simulated face length of 220 m (720 ft.) in full scale. LIAM is built with critical details of the face, gob, and mining machinery. It is instrumented with pressure gauges, flow anemometers, temperature probes, a fan, and a data acquisition system. Scaling relationships are derived on the basis of Reynolds and Richardson numbers to preserve the physical and dynamic similitude. This paper discusses the findings from a study conducted in the LIAM to investigate the gob-face interaction, airflow patterns within the gob, and airflow dynamics on the face for varying roof caving characteristics. Results are discussed to show the impact of caving behind the shields on longwall ventilation.

Evaluation of Post-blast Re-entry Times Based on Gas Monitoring of Return Air

Blasting is the main method of production in many non-coal underground mining operations and produces multiple toxic gases as a result. The Mine Safety and Health Administration (MSHA) requires mine operators to measure the level of toxic gases in mines as frequently as necessary to ensure they are below regulatory safety limits. The current practice uses portable gas monitors to check the concentrations of toxic gases after a fixed post-blast time. This paper studies the application of a gas monitoring system in the return entry of a limestone mine to determine a safe re-entry time. The National Institute for Occupational Safety and Health (NIOSH) conducted such a monitoring program in a limestone mine from September 2016 through May 2018. NIOSH/PMRD (Pittsburgh Mining Research Division) is endeavoring to develop workplace solutions to improve detection of and reduce the risk of hazardous conditions. This study showed that the use of gas monitoring in the return air can be a useful tool at the mine operator’s disposal to detect and reduce the risk of hazardous conditions and also to reliably estimate the re-entry time.

The potential use of a NIOSH sound level meter smart device application in mining operations.

Many mobile sound measurement applications (apps) have been developed to take advantage of the built-in or fit-in sensors of the smartphone. One of the concerns is the accuracy of these apps when compared to professional sound measurement instruments. Previously, a research team from the National Institute for Occupational Safety and Health (NIOSH) developed the NIOSH Sound Level Meter (SLM) app for iOS smart devices. The team found the average accuracy of this app to be within ±1 dBA when using calibrated external microphones with a type 1 reference device and measuring pink noise at levels from 65 to 95 dBA in 5-dBA increments. The studies were conducted in a reverberant noise chamber at the NIOSH Acoustics Laboratory in Cincinnati. However, it is still unknown how this app performs in measuring industrial/mining sound levels outside of a controlled laboratory environment. The current NIOSH study evaluates the NIOSH SLM app to measure sound levels from a jumbo drill (a large mining machine). The study was conducted in a hemi-anechoic chamber at the NIOSH Pittsburgh Mining Research Division and followed by a field evaluation in an underground metal mine. Six different iOS smart devices were used with two types of external microphones chosen from previous studies to measure sound levels during jumbo drill operations, and the results were compared with a reference device. Results show that the average sound levels measured by the NIOSH SLM app are within ±1 dBA of the reference device both in the laboratory and field. However, the type of operation being performed, the selection and use of external microphones, distance from a noise source, and environmental factors (e.g., air movement) may all influence the accuracy of the app's performance. Although additional validation is still needed, the results from this study suggest a potential for using the NIOSH SLM app, with calibrated external microphones, to measure sound levels in mining operations.

Effect of longwall-induced subsurface deformations on shale gas well casing stability under deep covers

This paper presents the results of a 2017 study conducted by the National Institute for Occupational Safety and Health (NIOSH), Pittsburgh Mining Research Division (PMRD), to evaluate the effects of longwall-induced subsurface deformations within a longwall abutment pillar under deep cover. The 2017 study was conducted in a southwestern Pennsylvania coal mine, which extracts 457 m-wide longwall panels under 361 m of cover. One 198 m-deep, in-place inclinometer monitoring well was drilled and installed over a 45 m by 84 m center abutment pillar. In addition to the monitoring well, surface subsidence measurements and underground coal pillar pressure measurements were conducted as the 457 m-wide longwall panel on the south side of the abutment pillar was being mined. Prior to the first longwall excavation, a number of simulations using FLAC3D™ were conducted to estimate surface subsidence, increases in underground coal pillar pressure, and subsurface horizontal displacements in the monitoring well. Comparisons of the pre-mining FLAC3D simulation results and the surface, subsurface, and underground instrumentation results show that the measured in-place inclinometer casing deformations are in reasonable agreement with those predicted by the 3D finite difference models. The measured surface subsidence and pillar pressure are in excellent agreement with those predicted by the 3D models. Results from this 2017 research clearly indicate that, under deep cover, the measured horizontal displacements within the abutment pillar are approximately one order of magnitude smaller than those measured in a 2014 study under medium cover.

Experimental methods to reduce noise generated by haul trucks and LHDs

The National Institute for Occupational Safety and Health (NIOSH) maintains the Pittsburgh Mining Research Division (PMRD) where a wide variety of mining-related health and safety research is conducted. Part of this research is devoted to reducing the incidence of noise-induced hearing loss (NIHL) among the nation's mining workforce. The need for this research is particularly important, as NIHL is the second most common occupational-related disease among miners. Many types of equipment operators are overexposed to noise, and NIOSH has worked to develop noise controls that reduce the sound level at the equipment operator's location and, thus, operator noise exposure. Examples of these include a urethane-coated flight bar chain for continuous mining machines and a drill bit isolator for roof bolting machines. This article discusses the development of a retrofitted noise control package for haul trucks and load-haul-dumps (LHDs) used in underground metal/nonmetal mines. Experimental methods under discussion include dosimetry and time motion studies, to determine when an operator accumulates the most noise dose. Noise source identification techniques are used to determine the primary noise contributors to the sound level at the operator's position. Proof-of-concept testing using rudimentary noise controls is undertaken to confirm that treating the suspected noise sources will actually reduce the sound level at the operator's location. Next, a description is given of the development of noise controls-an iterative process where noise controls are fabricated, evaluated in an acoustic laboratory, refined, and tested again. Those noise controls that show promise are then field tested under actual mine operating conditions.

Characterization of airborne float coal dust emitted during continuous mining, longwall mining and belt transport.

Float coal dust is produced by various mining methods, carried by ventilating air and deposited on the floor, roof and ribs of mine airways. If deposited, float dust is re-entrained during a methane explosion. Without sufficient inert rock dust quantities, this float coal dust can propagate an explosion throughout mining entries. Consequently, controlling float coal dust is of critical interest to mining operations. Rock dusting, which is the adding of inert material to airway surfaces, is the main control technique currently used by the coal mining industry to reduce the float coal dust explosion hazard. To assist the industry in reducing this hazard, the Pittsburgh Mining Research Division of the U.S. National Institute for Occupational Safety and Health initiated a project to investigate methods and technologies to reduce float coal dust in underground coal mines through prevention, capture and suppression prior to deposition. Field characterization studies were performed to determine quantitatively the sources, types and amounts of dust produced during various coal mining processes. The operations chosen for study were a continuous miner section, a longwall section and a coal-handling facility. For each of these operations, the primary dust sources were confirmed to be the continuous mining machine, longwall shearer and conveyor belt transfer points, respectively. Respirable and total airborne float dust samples were collected and analyzed for each operation, and the ratio of total airborne float coal dust to respirable dust was calculated. During the continuous mining process, the ratio of total airborne float coal dust to respirable dust ranged from 10.3 to 13.8. The ratios measured on the longwall face were between 18.5 and 21.5. The total airborne float coal dust to respirable dust ratio observed during belt transport ranged between 7.5 and 21.8.

Investigation of human body vibration exposures on haul trucks operating at U.S. surface mines/quarries relative to haul truck activity

Workers who operate mine haul trucks are exposed to whole-body vibration (WBV) on a routine basis. Researchers from the National Institute for Occupational Safety and Health (NIOSH) Pittsburgh Mining Research Division (PMRD) investigated WBV and hand-arm vibration (HAV) exposures for mine/quarry haul truck drivers in relation to the haul truck activities of dumping, loading, and traveling with and without a load. The findings show that WBV measures in weighted root-mean-square accelerations (aw) and vibration dose value (VDV), when compared to the ISO/ANSI and European Directive 2002/44/EC standards, were mostly below the Exposure Action Value (EAV) identified by the health guidance caution zone (HGCZ). Nevertheless, instances were recorded where the Exposure Limit Value (ELV) was exceeded by more than 500 to 600 percent for VDVx and awx, respectively. Researchers determined that these excessive levels occurred during the traveling empty activity, when the haul truck descended down grade into the pit loading area, sliding at times, on a wet and slippery road surface caused by rain and overwatering. WBV levels (not normalized to an 8-h shift) for the four haul truck activities showed mean awz levels for five of the seven drivers exceeding the ISO/ANSI EAV by 9–53 percent for the traveling empty activity. Mean awx and awz levels were generally higher for traveling empty and traveling loaded and lower for loading/dumping activities. HAV for measures taken on the steering wheel and shifter were all below the HGCZ which indicates that HAV is not an issue for these drivers/operators when handling steering and shifting control devices.

Characterization of a mine fire using atmospheric monitoring system sensor data.

Atmospheric monitoring systems (AMS) have been widely used in underground coal mines in the United States for the detection of fire in the belt entry and the monitoring of other ventilation-related parameters such as airflow velocity and methane concentration in specific mine locations. In addition to an AMS being able to detect a mine fire, the AMS data have the potential to provide fire characteristic information such as fire growth - in terms of heat release rate - and exact fire location. Such information is critical in making decisions regarding fire-fighting strategies, underground personnel evacuation and optimal escape routes. In this study, a methodology was developed to calculate the fire heat release rate using AMS sensor data for carbon monoxide concentration, carbon dioxide concentration and airflow velocity based on the theory of heat and species transfer in ventilation airflow. Full-scale mine fire experiments were then conducted in the Pittsburgh Mining Research Division's Safety Research Coal Mine using an AMS with different fire sources. Sensor data collected from the experiments were used to calculate the heat release rates of the fires using this methodology. The calculated heat release rate was compared with the value determined from the mass loss rate of the combustible material using a digital load cell. The experimental results show that the heat release rate of a mine fire can be calculated using AMS sensor data with reasonable accuracy.

Respirable dust measured downwind during rock dust application.

The Pittsburgh Mining Research Division of the U.S. National Institute for Occupational Safety and Health (NIOSH) conducted underground evaluations in an attempt to quantify respirable rock dust generation when using untreated rock dust and rock dust treated with an anticaking additive. Using personal dust monitors, these evaluations measured respirable rock dust levels arising from a flinger-type application of rock dust on rib and roof surfaces. Rock dust with a majority of the respirable component removed was also applied in NIOSH's Bruceton Experimental Mine using a bantam duster. The respirable dust measurements obtained downwind from both of these tests are presented and discussed. This testing did not measure miners' exposure to respirable coal mine dust under acceptable mining practices, but indicates the need for effective continuous administrative controls to be exercised when rock dusting to minimize the measured amount of rock dust in the sampling device.

CFD gas distribution analysis for different continuous-miner scrubber redirection configurations.

The U.S. National Institute for Occupational Safety and Health (NIOSH)'s Pittsburgh Mining Research Division (PMRD) recently developed a series of models using computational fluid dynamics (CFD) to study gas distribution around a continuous mining machine with various fan-powered flooded bed scrubber discharge configurations in an exhaust curtain working face. CFD models utilizing species transport model without reactions in FLUENT were constructed to evaluate the redirection of scrubber discharge toward the mining face rather than behind the return curtain. The study illustrates the gas distribution in the slab (second) cut. The following scenarios are considered in this study: 100 percent of the discharge redirected back toward the face on the off-curtain side; 100 percent of the discharge redirected back toward the face, but divided equally to both sides; and 15 percent of the discharge redirected toward the face on the off-curtain side, with 85 percent directed toward the return curtain. These models are compared against a model with a conventional scrubber discharge where air is directed away from the face into the return. The models were validated against experimental data, proving to accurately predict sulfur hexafluoride (SF6) gas levels at four gas monitoring locations. This study includes a predictive simulation examining a 45° scrubber angle compared with the 23° angle for the 100 percent redirected, equally divided case. This paper describes the validation of the CFD models based on experimental data of the gas distribution results.

Computational fluid dynamic modeling of a medium-sized surface mine blasthole drill shroud.

The Pittsburgh Mining Research Division of the U.S. National Institute for Occupational Safety and Health (NIOSH) recently developed a series of models using computational fluid dynamics (CFD) to study airflows and respirable dust distribution associated with a medium-sized surface blasthole drill shroud with a dry dust collector system. Previously run experiments conducted in NIOSH's full-scale drill shroud laboratory were used to validate the models. The setup values in the CFD models were calculated from experimental data obtained from the drill shroud laboratory and measurements of test material particle size. Subsequent simulation results were compared with the experimental data for several test scenarios, including 0.14 m3/s (300 cfm) and 0.24 m3/s (500 cfm) bailing airflow with 2:1, 3:1 and 4:1 dust collector-to-bailing airflow ratios. For the 2:1 and 3:1 ratios, the calculated dust concentrations from the CFD models were within the 95 percent confidence intervals of the experimental data. This paper describes the methodology used to develop the CFD models, to calculate the model input and to validate the models based on the experimental data. Problem regions were identified and revealed by the study. The simulation results could be used for future development of dust control methods for a surface mine blasthole drill shroud.

Using software to predict occupational hearing loss in the mining industry.

Powerful mining systems typically generate high-level noise that can damage the hearing ability of miners. Engineering noise controls are the most desirable and effective control for overexposure to noise. However, the effects of these noise controls on the actual hearing status of workers are not easily measured. A tool that can provide guidance in assigning workers to jobs based on the noise levels to which they will be exposed is highly desirable. Therefore, the Pittsburgh Mining Research Division (PMRD) of the U.S. National Institute for Occupational Safety and Health (NIOSH) developed a tool to estimate in a systematic way the hearing loss due to occupational noise exposure and to evaluate the effectiveness of developed engineering controls. This computer program is based on the ISO 1999 standard and can be used to estimate the loss of hearing ability caused by occupational noise exposures. In this paper, the functionalities of this software are discussed and several case studies related to mining machinery are presented to demonstrate the functionalities of this software.

Influence of continuous mining arrangements on respirable dust exposures.

In underground continuous mining operations, ventilation, water sprays and machine-mounted flooded-bed scrubbers are the primary means of controlling respirable dust exposures at the working face. Changes in mining arrangements - such as face ventilation configuration, orientation of crosscuts mined in relation to the section ventilation and equipment operator positioning - can have impacts on the ability of dust controls to reduce occupational respirable dust exposures. This study reports and analyzes dust concentrations measured by the Pittsburgh Mining Research Division for remote-controlled continuous mining machine operators as well as haulage operators at 10 U.S. underground mines. The results of these respirable dust surveys show that continuous miner exposures varied little with depth of cut but are significantly higher with exhaust ventilation. Haulage operators experienced elevated concentrations with blowing face ventilation. Elevated dust concentrations were observed for both continuous miner operators and haulage operators when working in crosscuts driven into or counter to the section airflow. Individual cuts are highlighted to demonstrate instances of minimal and excessive dust exposures attributable to particular mining configurations. These findings form the basis for recommendations for lowering face worker respirable dust exposures.