Silicosis is an occupational respiratory disease that roof bolter operators are susceptible. It is caused by overexposure to respirable quartz dust (RCS) and has no cure and may ultimately be fatal. The only method of prevention of silicosis is by preventing exposure to RCS. The wet box collection system is a newly developed dust collection system for roof bolting machines, a modification of the existing dry box collection system utilizing water to saturate the material that is collected by the dust collection system. Testing was conducted for 3 days on a dual boom roof bolter with the wet box installed on the left side and the dry box installed on the right side. Sampling, using the coal mine dust personal sampling unit (CMDPSU), during cleaning of the collector boxes demonstrated that using the wet box dust collection system instead of the dry box dust collection system can reduce RCS exposures during cleaning of the collector boxes by 71% (day 1), 82% (day 2), and 88% (day 3). In addition, the quartz content of samples collected during cleaning of the wet box was 0.0%, while the quartz content of the samples collected when cleaning the dry box was 4.6%, 10.3%, and 7.4%. © 2022, This is a U.S. government work and not under copyright protection in the U.S.; foreign copyright protection may apply.

The canopy air curtain (CAC) has been proven to reduce the respirable dust exposure of roof bolter operators in underground coal mining. This technology is being adapted for use with shuttle cars and ramcars. The plenum is mounted on the underside of the shuttle car canopy over the operator’s position. The blower providing filtered air to the operator is plumbed into the shuttle car’s existing hydraulic system. After the system was installed on a ramcar, field testing of the CAC’s ability to provide respirable dust control was conducted on a section using blowing face ventilation. Results showed that overall respirable dust reductions during the total time the operator was underneath the canopy ranged from 11 to 34%, demonstrating adequate performance. However, further analysis demonstrated that the CAC performance was exceptional when the ramcar was being loaded by the continuous miner. At this location, a position where the shuttle car operator has their highest potential for respirable dust exposure, the CAC provided dust reductions ranging from 57 to 65%. These results, especially during ramcar loading at the CM, demonstrate that the CAC can be an important dust control device to reduce shuttle car and ramcar operators’ exposure to respirable coal mine dust. © 2022, This is a U.S. government work and not under copyright protection in the U.S.; foreign copyright protection may apply.

U.S. Code of Federal Regulations 30 CFR 75.402 and 75.403 require 80% total incombustible content to be maintained within 40 feet of the coal mine face via the liberal application of rock dust. Unfortunately, this application of rock dust limits miners' visibility downwind and can increase the miners' exposures to a respirable nuisance dust. Wet rock dust applied as a slurry is, at times, used to negate these negative effects. Although this aids in meeting the total incombustible limits, the slurry forms a hard cake when dried and no longer effectively disperses as needed to suppress a coal dust explosion. As a result, a dry rock dust must be reapplied to maintain a dispersible layer. Therefore, researchers from the National Institute for Occupational Safety and Health (NIOSH) have been working towards finding and testing a foamed rock dust formulation that can be applied wet on mine surfaces and remain dispersible once dried which minimizes the likelihood of mine disasters, including mine explosions. The initial tests were aimed at discerning dispersion characteristics of three different foamed rock dusts via the NIOSH-developed dispersion chamber and led to identification of a two-part foam with adequate dispersion characteristics. The current study was conducted to assess the robustness of the two-part foamed rock dust. Through a series of laboratory-scale experiments using the dispersibility chamber, the effects of testing conditions and product formulations on the foam's dispersibility was determined. Some of the tested variables include: exposing the foam to high humidity, varying the component levels of the foamed rock dust, altering the rock dust size distribution, and varying the rock dust types. Further pilot-scale tests examined the atmospheric concentrations of dust via personal dust monitors downwind of foamed rock dust production and application. Additionally, product consistency was recorded during pilot-scale testing at key points in the formulation and application. The results of these experiments will be discussed in this paper. © 2021

Researchers at the National Institute for Occupational Safety and Health (NIOSH) performed laboratory testing to improve longwall dust control by examining the use of underside shield sprays in conjunction with the longwall directional spray system. In a field survey of longwall operations, NIOSH researchers observed dust clouds created by the fracturing and spalling of coal immediately upwind of the headgate drum that migrated into the walkway, exposing mining personnel to respirable coal dust. The goal of this research was to create an effective traveling water curtain to prevent this dust from reaching the personnel walkway by redirecting it toward the longwall face. The location, orientation, and pressure of the water sprays were the primary testing parameters examined for minimizing dust exposure in the walkway. Laboratory testing indicates that the use of underside shield sprays on the longwall face may be beneficial toward reducing respirable dust exposure for mining personnel.

A 3rd generation roof bolter canopy air curtain (CAC) has been developed and constructed by J.H. Fletcher & Co., Inc. As with the previous generation of the CAC, this design uses the principle of providing uniform airflow across the canopy area as recommended by the National Institute for Occupational Safety and Health. The new modifications include a plenum that is constructed of a single flat aluminum plate, smaller-diameter airflow openings, and a single row of perimeter nozzles designed to prevent mine air contaminated by respirable dust from entering the CAC protection zone. Field testing was conducted on this new 3rd generation design showing reductions in coal mine respirable dust exposure for roof bolter operators. Dust control efficiencies for the CAC for the left bolter operator (intake side) ranged from approximately 26%-60%, while the efficiencies for the CAC for the right bolter operator (return side) ranged from 3% to 47%.

Testing was completed on an earlier roof bolter CAC that used slots to provide a perimeter airflow. NIOSH tested it due to its unique design that differed from canopies that provided uniform airflow. Based upon NIOSH recommendations from the earlier testing, a 3rd generation roof bolter CAC has been developed by J.H. Fletcher & Co. The changes to this CAC involve design modifications to the plenum outlets, using a single row of outlets on the perimeter and a different material for the plenum. This laboratory testing was a continuation of the original perimeter slotted CAC design. Using gravimetric and instantaneous sampling of respirable dust concentrations underneath and outside of the CAC, the laboratory testing was completed using three different blower fans that delivered differing airflows. The maximum plenum airflow velocities ranged from 2.34 to 3.64 m/s (460–716 fpm). Results showed plenum respirable dust concentrations ranging from 34.6% to 49.3% lower than respirable dust concentrations outside the plenum protection zone, thus showing an improvement in protection for the roof bolter operators.

A 2nd generation roof bolter canopy air curtain (CAC) design was tested by National Institute for Occupational Safety and Health (NIOSH) at a Midwestern underground coal mine. During the study, the roof bolter never operated downwind of the continuous miner. Using a combination of personal Data Rams (pDR) and gravimetric samplers, the dust control efficiency of the roof bolter CAC was ascertained. Performance evaluation was determined using three methods: (1) comparing roof bolter operator concentrations underneath the CAC to roof bolter concentrations outside the CAC, (2) comparing roof bolter operator concentrations underneath the CAC to the concentrations at the rear of the bolter, and finally, (3) using the gravimetric data directly underneath the CAC to correct roof bolter operator concentrations underneath the CAC and comparing them to the concentrations at the rear of the bolter. Method 1 dust control efficiencies ranged from −53.9% to 60.4%. Method 2 efficiencies ranged from −150.5% to 52.2%, and Method 3 efficiencies ranged from 40.7% to 91%. Reasons for negative and low dust control efficiencies are provided in this paper and include: incorrect sampling locations, large distance between CAC and operator, and contamination of intake air from line curtain. Low dust concentrations encountered during the testing made it difficult to discern whether differences in concentrations were due to the CAC or due to variances inherent in experimental dust measurement. However, the analyses, especially the Method 3 analysis, show that the CAC can be an effective dust control device.

Airborne respirable coal dust capture by water sprays or wet scrubbers has been studied and developed over many decades as an engineering control to reduce dust exposure in coal mines and combat coal worker pneumoconiosis. Empirical relationships and deterministic models for particular dust capture experiments have previously been devised to show the key parameters involved in airborne coal dust capture. Many of the results from these models show that the significant parameters related to airborne dust capture are water spray pressure, water quantity, water droplet size, relative water droplet-to-dust particle velocity, and total operating air pressure of the scrubber. However, many airborne dust capture efficiency relationships and models developed for particular experiments cannot be readily applied to forecast the dust collection efficiency of different spray and scrubber design configurations, which rely on several key dimensional engineering measures. This study examines engineering measures from previous water spray and wet scrubber experiments conducted by the U.S. National Institute for Occupational Safety and Health (NIOSH) and the U.S. Bureau of Mines (USBM) to develop empirical models for wet collection of airborne dusts. A dimensionless empirical model developed for predicting airborne dust capture efficiency of water sprays and wet scrubbers is presented.

Tests were conducted to determine properties of four foam agents for their potential use in longwall mining dust control. Foam has been tried in underground mining in the past for dust control and is currently being reconsidered for use in underground coal longwall operations in order to help those operations comply with the Mine Safety and Health Administration's lower coal mine respirable dust standard of 1.5 mg/m3. Foams were generated using two different methods. One method used compressed air and water pressure to generate foam, while the other method used low-pressure air generated by a blower and water pressure using a foam generator developed by the U.S. National Institute for Occupational Safety and Health. Foam property tests, consisting of a foam expansion ratio test and a water drainage test, were conducted to classify foams. Compressed-Air-generated foams tended to have low expansion ratios, from 10 to 19, with high water drainage. Blower-Air-generated foams had higher foam expansion ratios, from 30 to 60, with lower water drainage. Foams produced within these ranges of expansion ratios are stable and potentially suitable for dust control. The test results eliminated two foam agents for future testing because they had poor expansion ratios. The remaining two foam agents seem to have properties adequate for dust control. These material property tests can be used to classify foams for their potential use in longwall mining dust control.

Testing was conducted to determine the ability of foam to maintain roof coverage in a simulated longwall mining environment. Approximately 27 percent of respirable coal mine dust can be attributed to longwall shield movement, and developing controls for this dust source has been difficult. The application of foam is a possible dust control method for this source. Laboratory testing of two foam agents was conducted to determine the ability of the foam to adhere to a simulated longwall face roof surface. Two different foam generation methods were used: compressed air and blower air. Using a new imaging technology, image processing and analysis utilizing ImageJ software produced quantifiable results of foam roof coverage. For compressed air foam in 3.3 m/s (650 fpm) ventilation, 98 percent of agent A was intact while 95 percent of agent B was intact on the roof at three minutes after application. At 30 minutes after application, 94 percent of agent A was intact while only 20 percent of agent B remained. For blower air in 3.3 m/s (650 fpm) ventilation, the results were dependent upon nozzle type. Three different nozzles were tested. At 30 min after application, 74 to 92 percent of foam agent A remained, while 3 to 50 percent of foam agent B remained. Compressed air foam seems to remain intact for longer durations and is easier to apply than blower air foam. However, more water drained from the foam when using compressed air foam, which demonstrates that blower air foam retains more water at the roof surface. Agent A seemed to be the better performer as far as roof application is concerned. This testing demonstrates that roof application of foam is feasible and is able to withstand a typical face ventilation velocity, establishing this technique's potential for longwall shield dust control.

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.