Mining vehicle manufacturers are developing lithium-ion (Li-ion) battery electric vehicles as an alternative to diesel-powered vehicles. In gassy underground mines, explosion-proof (XP) enclosures are commonly used to enclose electrical ignition sources to prevent propagation of an internal methane-air explosion to a surrounding explosive atmosphere. Li-ion batteries can create pressurized explosions within sealed enclosures due to thermal runaway (TR). NIOSH researchers measured TR pressures of nickel manganese cobalt (NMC) cathode type 18650 Li-ion cells, model MH1, as a function of free space within sealed enclosures and observed an inverse power relationship. TR pressure-rise rates, gas quantities, and temperatures were also measured. A confined NMC cell with 92.5 mL of free space produced 232 bar of pressure, far exceeding minimum pressure containment specifications for conventional XP enclosures. Approximately 287 times the cell volume of free space would be needed to reduce the TR pressure of these cells to 8.62 barg (125 psig) per U.S. Code of Federal Regulations, Title 30, Part 18. The NMC cell TR pressures were significantly higher than those measured previously for iron phosphate cathode Li-ion cells under comparable confinement conditions. 2022

Aerosols emitted by the explosion of lithium-ion batteries were characterized to assess potential exposures. The explosions were initiated by activating thermal runaway in three commercial batteries: (1) lithium nickel manganese cobalt oxide (NMC), (2) lithium iron phosphate (LFP), and (3) lithium titanate oxide (LTO). Post-explosion aerosols were collected on anodisc filters and analyzed by scanning electron microscopy (SEM) and energy-dispersive x-ray spectroscopy (EDS). The SEM and EDS analyses showed that aerosol morphologies and compositions were comparable to individual grains within the original battery materials for the NMC cell, which points to the fracture and ejection of the original battery components during the explosion. In contrast, the LFP cell emitted carbonaceous cenospheres, which suggests aerosol formation by the decomposition of organics within molten microspheres. LTO explosion aerosols showed characteristics of both types of emissions. The abundance of elements from the anode, cathode, and separator in respirable aerosols underscored the need for the selection of low-toxicity battery materials due to potential exposures in the event of battery thermal runaway. Copyright © This work was authored as part of the Contributor's official duties as an Employee of the United States Government and is therefore a work of the United States Government. In accordance with 17 USC. 105, no copyright protection is available for such works under US Law.

Researchers from the National Institute for Occupational Safety and Health (NIOSH) conducted a study in an isolated zone of an underground mine to characterize aerosols generated by: (1) a diesel-powered personnel carrier vehicle operated over a simulated light-duty cycle and (2) the simulated repair of existing equipment using manual metal arc welding (MMAW). Both the diesel-powered vehicle and MMAW process contributed to concentrations of nano and ultrafine aerosols in the mine air. The welding process also contributed to aerosols with electrical mobility and aerodynamic mobility count median diameters of approximately 140 and 480 nm, respectively. The welding particles collected on the filters contained carbon, iron, manganese, calcium, and aluminum.

Respirable dust can pass beyond ciliated airways of the respiratory tract and influence adverse health effects. Health effects can be studied using samples generated from bulk dust segregation. Because previous segregation methods diverge from size-selection criteria of the international convention for respirable particles (ICRP), a method was developed to approximate the ICRP. The method was compared to an ideal sampler by measuring the sample collection bias. The comparison shows that the uncertainty due to the bias was 0.10 based on European Standard EN13205:2014 criteria, which indicates that the segregator effectively follows the ICRP. Respirable particle size distributions were confirmed by an aerodynamic particle sizer and by computer-controlled scanning electron microscopy. Consequently, a systematic way to generate respirable powders for health effects studies and chemical analyses was developed.

The cloud and aerosol spectrometer (CAS) was calibrated to enable CAS sizing of coal dust for studies on flammable dust control. Coal dust sizes were determined by light-scattering theories for irregular particles that account for particle composition and morphology in computing coal dust diameters. Coal dust size computations were compared with test dust that was generated by cyclone separation and air-jet sieving and characterized by aerodynamic particle sizer (APS) and computer-controlled scanning electron microscopy (CCSEM) measurements. For test dust in the range of 0.5–32 μm, coal dust size distributions were consistent with cyclone-separated and sieve-segregated sizes. For the 3–20 μm size range, the coal dust size distribution had a mass median diameter that was 14% larger than that of the APS. This difference was reasonable considering that the basic calibration for glass spheres had 13% uncertainty. For the 20–32 μm and 32–45 μm test dusts, mass median diameters differed from CCSEM measurements by only 4% and 5%, respectively. Overall, the results suggest agreement between test dust sizes and computations for coal dust. Alternatively, using conventional Mie theory computations for spheres, coal dust mass median diameters were 35% and 40% larger than APS and CCSEM measurements, respectively.

Low-temperature compression ignition combustion can result in nearly smokeless combustion, as indicated by a smoke meter or other forms of soot measurement that rely on absorbance due to elemental carbon content. Highly premixed low-temperature combustion modes do not form particulate matter in the traditional pathways seen with conventional diesel combustion. Previous research into reactivity controlled compression ignition particulate matter has shown, despite a near zero smoke number, significant mass can be collected on filter media used for particulate matter certification measurement. In addition, particulate matter size distributions reveal that a fraction of the particles survive heated double-dilution conditions. This study summarizes research completed at Oak Ridge National Laboratory to date on characterizing the nature, chemistry and aftertreatment considerations of reactivity controlled compression ignition particulate matter and presents new research highlighting the importance of injection strategy and fuel composition on reactivity controlled compression ignition particulate matter formation. Particle size measurements and the transmission electron microscopy results do show the presence of soot particles; however, the elemental carbon fraction was, in many cases, within the uncertainty of the thermal-optical measurement. Particulate matter emitted during reactivity controlled compression ignition operation was also collected with a novel sampling technique and analyzed by thermal desorption or pyrolysis gas chromatography mass spectroscopy. Particulate matter speciation results indicated that the high boiling range of diesel hydrocarbons was likely responsible for the particulate matter mass captured on the filter media. To investigate potential fuel chemistry effects, either ethanol or biodiesel were incorporated to assess whether oxygenated fuels may enhance particle emission reduction. © 2016 IMechE.

Controlling float coal dust in underground coal mines before dispersal into the general airstream can reduce the risk of mine explosions while potentially achieving a more effective and efficient use of rock dust. A prototype flooded-bed scrubber was evaluated for float coal dust control in the return of a continuous miner section. The scrubber was installed inline between the face ventilation tubing and an exhausting auxiliary fan. Airborne and deposited dust mass measurements were collected over three days at set distances from the fan exhaust to assess changes in float coal dust levels in the return due to operation of the scrubber. Mass-based measurements were collected on a per-cut basis and normalized on the basis of per ton mined by the continuous miner. The results show that average float coal dust levels measured under baseline conditions were reduced by more than 90 percent when operating the scrubber.

Airborne coal dust generated during mining can deposit and accumulate on mine surfaces, presenting a dust explosion hazard. When assessing dust hazard mitigation strategies for airborne dust reduction, sampling is done in high-velocity ventilation air, which is used to purge the mining face and gallery tunnel. In this environment, the sampler inlet velocity should be matched to the air stream velocity (isokinetic sampling) to prevent oversampling of coarse dust at low sampler-to-air velocity ratios. Low velocity ratios are often encountered when using low flow rate, personal sampling pumps approved for use in underground mines. In this study, with a goal of employing mine-ready equipment, a personal sampler was adapted for area sampling of coarse coal dust in high-velocity ventilation air. This was done by adapting an isokinetic nozzle to the inlet of an Institute of Occupational Medicine (Edinburgh, Scotland) sampling cassette (IOM). Collected dust masses were compared for the modified IOM isokinetic sampler (IOM-MOD), the IOM without the isokinetic nozzle, and a conventional dust sampling cassette without the cyclone on the inlet. All samplers were operated at a flow rate typical of personal sampling pumps, 2 L/min. To ensure differences between collected masses could be attributed to sampler design and were not influenced by artifacts from dust concentration gradients, relatively uniform and repeatable dust concentrations were demonstrated in the sampling zone of the National Institute for Occupational Safety and Health experimental mine gallery. Consistent with isokinetic theory, greater differences between isokinetic and non-isokinetic sampled masses were found for larger dust volume-size distributions and higher ventilation air velocities. Since isokinetic sampling is conventionally used to determine total dust concentration, and isokinetic sampling made a difference in collected masses, the results suggest when sampling for coarse coal dust the IOM-MOD may improve airborne coarse dust assessments over "off-the-shelf" sampling cassettes.

Airborne coal dust mass measurements in underground bituminous coal mines can be challenged by the presence of airborne limestone dust, which is an incombustible dust applied to prevent the propagation of dust explosions. To accurately measure the coal portion of this mixed airborne dust, the National Institute for Occupational Safety and Health (NIOSH) developed a sampling and analysis protocol that used a stainless steel cassette adapted with an isokinetic inlet and the low temperature ashing (LTA) analytical method. The Mine Safety and Health Administration (MSHA) routinely utilizes this LTA method to quantify the incombustible content of bulk dust samples collected from the roof, floor, and ribs of mining entries. The use of the stainless steel cassette with isokinetic inlet allowed NIOSH to adopt the LTA method for the analysis of airborne dust samples. Mixtures of known coal and limestone dust masses were prepared in the laboratory, loaded into the stainless steel cassettes, and analyzed to assess the accuracy of this method. Coal dust mass measurements differed from predicted values by an average of 0.5%, 0.2%, and 0.1% for samples containing 20%, 91%, and 95% limestone dust, respectively. The ability of this method to accurately quantify the laboratory samples confirmed the validity of this method and allowed NIOSH to successfully measure the coal fraction of airborne dust samples collected in an underground coal mine.

The extensive use of diesel-powered equipment in mines makes the exposure to diesel aerosols a serious occupational issue. The exposure metric currently used in U.S. underground noncoal mines is based on the measurement of total carbon (TC) and elemental carbon (EC) mass concentration in the air. Recent toxicological evidence suggests that the measurement of mass concentration is not sufficient to correlate ultrafine aerosol exposure with health effects. This urges the evaluation of alternative measurements. In this study, the current exposure metric and two additional metrics, the surface area and the total number concentration, were evaluated by conducting simultaneous measurements of diesel ultrafine aerosols in a laboratory setting. The results showed that the surface area and total number concentration of the particles per unit of mass varied substantially with the engine operating condition. The specific surface area (SSA) and specific number concentration (SNC) normalized with TC varied two and five times, respectively. This implies that miners, whose exposure is measured only as TC, might be exposed to an unknown variable number concentration of diesel particles and commensurate particle surface area. Taken separately, mass, surface area, and number concentration did not completely characterize the aerosols. A comprehensive assessment of diesel aerosol exposure should include all of these elements, but the use of laboratory instruments in underground mines is generally impracticable. The article proposes a new approach to solve this problem. Using SSA and SNC calculated from field-type measurements, the evaluation of additional physical properties can be obtained by using the proposed approach. (Copyright 2012 American Association for Aerosol Research.)