issues in u.s. mining › romania › presentations › romania...2003/08/25 · 22 22 coal...

1

11

Issues In U.S. Issues In U.S. MiningMining

2

22

Topics For TodayTopics For Today

!!A brief overview of the National Institute for A brief overview of the National Institute for Occupational Safety and Health/ Pittsburgh Occupational Safety and Health/ Pittsburgh Research LaboratoryResearch Laboratory

!!A brief overview of US minerals miningA brief overview of US minerals mining!!A review of the NIOSH/DOE sponsored A review of the NIOSH/DOE sponsored

RAND Critical Issues in Mining ReportRAND Critical Issues in Mining Report

3

33

Pittsburgh Research LaboratoryPittsburgh Research Laboratory

""Providing practical solutions Providing practical solutions to real world occupational to real world occupational safety and heath challengessafety and heath challenges

4

44

Pittsburgh Research LabPittsburgh Research Lab

"" Pittsburgh, PaPittsburgh, Pa"" Over 200 Over 200

EmployeesEmployees"" 180 Acres180 Acres"" Unique FacilitiesUnique Facilities

5

55

We are a unique combination of over 200 employees, representing wide range of disciplines, including engineering, epidemiology, industrial hygiene, chemistry, physics, geology, psychology and sociology, and world class facilities that enable it to address complex safety and health problems.

Pittsburgh Research LabPittsburgh Research Lab

6

66

PRL: Safer PRL: Safer -- Healthier Healthier -- WorkersWorkers

"" ProvenProven ��History ofHistory ofAccomplishmentsAccomplishments

"" PresencePresence ��Strong & LifesavingStrong & Lifesaving

"" PotentialPotential ��Prepared toPrepared to Address Address Future Safety and Future Safety and Health ThreatsHealth Threats

Idea Concept by Laroche College graphics students

7

77

0

2,000

4,000

6,000

8,000

10,000

12,000

14,000

1911-1915

1916-1920

1921-1925

1926-1930

1931-1935

1936-1940

1941-1945

1946-1950

1951-1955

1956-1960

1961-1965

1966-1970

1971-1975

1976-1980

1981-1985

1986-1990

1991-1995

1996-2000

Num

ber o

f Fat

aliti

es (5

-Yea

r Agg

rega

tes)

0

50

100

150

200

250

300

350

400

Ann

ual A

vera

ge F

atal

ity R

ate

(per

100

,000

wor

kers

)Coal M/NM

Rate Coal Rate M/NM

Great Depression1930s

World War II1939-1945

Federal Coal MineHealth and Safety

Act of 1969

Federal MineSafety and Health

Act of 1977

Source: USBM, MSHA

Number of Fatalities and Annual Average Fatality Rates in the MiNumber of Fatalities and Annual Average Fatality Rates in the Mining ning Industry, 1911Industry, 1911--20002000

Shows the total number of fatalities (summed over 5-year periods) and the average annual fatality rate within each 5-year period from 1911-2000.

8

88

PRESENCE:PRESENCE: The Research The Research ProgramProgram

" Diesel Monitoring and Control

" Dust Monitoring and Control

" Ergonomics & Machine Safety

" Fire Fighting & Prevention

" Hearing Loss Prevention & Engineering Noise Controls

" Emergency Response & Rescue

" Electrical Safety

" Explosives

" Ground Control

" Mine Ventilation

" Surveillance

" Training Research

9

99

World Class FacilitiesWorld Class Facilities

10

1010

Potential: Potential: Prepared to Address Future Prepared to Address Future Safety and Health ThreatsSafety and Health Threats

"" World Class ExpertiseWorld Class Expertise"" World Class FacilitiesWorld Class Facilities"" Strong ConstituenciesStrong Constituencies"" Close Customer Close Customer

CommunicationsCommunications"" Detailed SurveillanceDetailed Surveillance

11

1111

Mining in the United StatesMining in the United States

12

1212

Mining Operations, 2001Mining Operations, 2001

14,623 Mining OperationsSpotted randomly within counties

Not shown: Puerto Rico, 106 mines;U.S. Virgin Islands, 4 minesData source: MSHA

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Data source: MSHA

14

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Metal Mining Operations, 2001Metal Mining Operations, 2001

281 Mining OperationsSpotted randomly within counties

Not shown: U.S. Virgin Islands, 1 mine

Data source: MSHA

15

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Nonmetal Mining Operations, 2001Nonmetal Mining Operations, 2001

785 Mining OperationsSpotted randomly within counties

Data source: MSHA

16

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Sand & Gravel Mining Operations, 2001Sand & Gravel Mining Operations, 2001


Not shown: Puerto Rico, 45 mines

Data source: MSHA

17

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Stone Mining Operations, 2001Stone Mining Operations, 2001


Not shown: Puerto Rico, 61 mines;U.S. Virgin Islands, 3 minesData source: MSHA

18

1818

Number of Full-time Equivalent Workers* atSurface Work Locations by Employer Type and Commodity

1991 versus 2000

Data source: MSHA* Excludes office workers

14.3

20.4

24.4

30.0

34.0

40.2

71.1

10.6

23.9

14.6

40.5

27.7

64.1

61.5

0 10 20 30 40 50 60 70 80

Coal independent contractor

Nonmetal operator

Metal/nonmetal independent contractor

Metal operator

Sand & gravel operator

Coal operator

Stone operator

Full-time equivalent workers (thousands)

19912000

19

1919

Number of Full-time Equivalent Workers* atUnderground Work Locations by Employer Type and Commodity

1991 versus 2000

Data source: MSHA * Excludes office workers

1.3

2.0

2.1

2.5

4.4

0.5

1.5

1.0

3.7

6.6

61.235.2

0 10 20 30 40 50 60 70

Metal/nonmetal independent contractor

Stone operator

Coal independent contractor

Nonmetal operator

Metal operator

Coal operator

Full-time equivalent workers (thousands)

19912000

20

2020

Fatality Rate in Coal Mining, Metal/NonmetalFatality Rate in Coal Mining, Metal/NonmetalMining, and All Industry (Private), 2001Mining, and All Industry (Private), 2001

Data source: BLS

47.7

24.0

4.5

0

10

20

30

40

50

60Fa

talit

ies

per

100,

000

wor

ker

Coal Mining Metal/NonmetalMining

All Industry(Private)

21

2121

Nonfatal LostNonfatal Lost--time Injury Rate intime Injury Rate inCoal Mining, Metal/Nonmetal Mining, andCoal Mining, Metal/Nonmetal Mining, and

All Industry (Private), 2001All Industry (Private), 2001

Data sources: MSHA; BLS

4.4

2.6 2.6

0

1

2

3

4

5In

jurie

s pe

r 100

full-

time

equi

vale

nt w

orke

rs

Coal Mining Metal/NonmetalMining

All Industry(Private)

22

2222

Coal Workers' Pneumoconiosis: Number of Deaths,Coal Workers' Pneumoconiosis: Number of Deaths,Crude and AgeCrude and Age--adjusted Mortality Rates, United States Residentsadjusted Mortality Rates, United States Residents

Age 15 and over, 1968Age 15 and over, 1968--19991999

Data source: NCHS

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

1968 1971 1974 1977 1980 1983 1986 1989 1992 1995 1998

Num

ber o

f Dea

ths

(thou

sand

s)

0

5

10

15

20

25

Rate

per

mill

ion

popu

latio

n

DeathsCrude Mortality Rate

Age-Adjusted Mortality Rate*

* standardized to the year 2000 standard population

23

2323

New Forces at Work in Mining: Industry Views of

Critical Technologies

New Forces at Work in New Forces at Work in Mining: Industry Views of Mining: Industry Views of

Critical TechnologiesCritical Technologies

DJ PetersonTom LaTourretteJames T. Bartis

DJ PetersonDJ PetersonTomTom LaTourretteLaTourretteJames T.James T. BartisBartis

24

2424

About the StudyAbout the Study"" RANDRAND

�� An independent, nonAn independent, non--profit research institutionprofit research institution

"" The TaskThe Task�� Conduct inConduct in--depth discussions with key members depth discussions with key members

(�statesmen�) of the mining community(�statesmen�) of the mining community

"" The GoalThe Goal�� To identify those technologies critical to the success To identify those technologies critical to the success

of their operations now and over the coming decadeof their operations now and over the coming decade

25

2525

Who Requested the Study?Who Requested the Study?

"" NIOSH: National Occupational Research NIOSH: National Occupational Research AgendaAgenda�� Identified �emerging technologies� as a Identified �emerging technologies� as a

priority topic for researchpriority topic for research�� Proactive effort to anticipate hazards rather Proactive effort to anticipate hazards rather

than respond to accidentsthan respond to accidents

"" DOE Mining Industry of the FutureDOE Mining Industry of the Future�� Identifying technology needs & research Identifying technology needs & research

priorities for government and industrypriorities for government and industry�� ConsensusConsensus--building processbuilding process

26

26

A Range of Organizations Participated

COAL (8)

American Co alCompany

American ElectricPowe r

Arch Co al

A.T. Mas sey

CONS OL

Interwes t Mining

Peabody

Jim W alt erResources

METAL S (11 )

AS ARC O

Barrick

Canyo nResources

Clevela nd Cliffs

Echo B ay Mines

Hec la

Homestake

Inco

Kennecott U tahCopper

New mont

Phel ps-Do dge

MAT ERIAL S (4)

US Borax

HansonAggregates

Martin MariettaMaterials

Vulc an Mate rial s

TECHN OLG IES &SERV ICE S (29 )

Atlas CopcoWagnerAustin Powde rBucyrusCaterpilla rDyno NobelExxonM obilLubrica ntsFosrocGoodyearP& HJoyKomatsuMaste r B uilde rsModular MiningSys tem sOricaSandvik Ta mrockTrimbleNav igation

RE SEARC H &OTHER (7)

Carnegie-Mell onRoboticsInsti tute

Colorado Schoolof Mines

MIRARC O /LaurentianUniversity

Pennsyl vani aDE P

University ofArizon a

University ofUtah

Virgini aPoly technicInsti tute

Others...

58 organizations90+ individuals

27

2727

Industry Industry Views ofViews ofImportant Important TrendsTrends

28

28

GoldCopperCoalCrushed stone

1.5

0.6

0.5

0.7

0.8

0.9

1.0

1.1

1.2

1.3

1.4

U.S

. out

put (

inde

x, 1

990

= 1)

MR1324 Fig 2.3

RAND MR1324-2.3

1990 2000199919981997199619951994199319921991

SOURCE: U.S. Geological Survey, U.S. Bureau of Mines.

The Mining Industry, 1990s

GoldCopperCoalCrushed stone

1.5

0.6

0.5

0.7

0.8

0.9

1.0

1.1

1.2

1.3

1.4

Mar

ket p

rice

(inde

x, 1

990

= 1)

MR1324 Fig 2.2

RAND MR1324-2.2

1990 2000199919981997199619951994199319921991

SOURCE: U.S. Geological Survey, U.S. Bureau of Mines.

Production went up,

most prices went down

Production went up,

most prices went down

29

2929

Mining is a RiskMining is a Risk--Averse SectorAverse Sector"" Little spending on R&DLittle spending on R&D

�� InIn--house R&D programs have been shut downhouse R&D programs have been shut down

�� R&D� targeted to site�R&D� targeted to site--specific problemspecific problem--solvingsolving

"" Wariness of unknown technologies & those Wariness of unknown technologies & those requiring large capital commitmentsrequiring large capital commitments

"" Breakthrough innovations require sustained Breakthrough innovations require sustained and collaborative R&D effortsand collaborative R&D efforts

"" Result: Current innovations are incrementalResult: Current innovations are incremental

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Regulation is not CriticalRegulation is not Critical"" NotNot mentioned as a leading technology drivermentioned as a leading technology driver"" Main concerns when askedMain concerns when asked

�� Diesel emissionsDiesel emissions�� Dust (ambient & occupational) Dust (ambient & occupational) �� NoiseNoise

"" Two views on complianceTwo views on compliance�� Technology solutions will be available (diesel)Technology solutions will be available (diesel)�� See no technology solutions (dust, noise)See no technology solutions (dust, noise)

"" Entitlement Entitlement isis the issuethe issue�� Realm of politics, not technologyRealm of politics, not technology

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Few New Facilities are being Few New Facilities are being DevelopedDeveloped

"" Mining entitlement process in the US is complex, Mining entitlement process in the US is complex, lengthy, and costly (~10 years)lengthy, and costly (~10 years)

"" Existing facilities are being reengineeredExisting facilities are being reengineered

�� Going deeperGoing deeper

�� Going undergroundGoing underground

�� More thorough extractionMore thorough extraction

�� Reducing footprint to access to new reservesReducing footprint to access to new reserves

"" Result: Newer mines abroad are often seen as Result: Newer mines abroad are often seen as technology leaderstechnology leaders

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Stone & Aggregates is an Stone & Aggregates is an ExceptionException

"" Strong demand scenarioStrong demand scenario

"" Permitting issues are pushing the number of Permitting issues are pushing the number of quarries down and their average size upquarries down and their average size up

"" New product specifications call for better crushing New product specifications call for better crushing and screening technologiesand screening technologies

"" Result: Quarries may see some of the greatest Result: Quarries may see some of the greatest technology advances in the futuretechnology advances in the future

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3333

Industry Views ofIndustry Views ofCritical Critical

TechnologiesTechnologies

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Bigger, Stronger, Faster Bigger, Stronger, Faster EquipmentEquipment

" Larger capacity machinery� 340-400 ton trucks now; 1000 tons < 20 years � 50 yard3 shovels now; 150 yard3 < 20 years � Faster, more powerful conveyors, crushers

" Implications � Health & Safety (noise, visibility)� Facility scale-up (roads, other equipment)� Maintenance (larger sheds, mechanical assists)

" Question: Is bigger better? Trade-offs on reliability, shipping costs, and field assembly

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Emerging UnitEmerging Unit--Ops InnovationsOps Innovations"" BlastingBlasting

�� Trend from packaged to bulk productsTrend from packaged to bulk products�� HighHigh--precision delivery vehiclesprecision delivery vehicles�� Electronic detonationElectronic detonation

"" Mechanical cutting of hard rockMechanical cutting of hard rock�� Alternative to blasting in narrowAlternative to blasting in narrow--vein operationsvein operations�� May increase noise and dust problemsMay increase noise and dust problems

"" Ground controlGround control�� Bolter minersBolter miners�� Cable boltsCable bolts�� AdvancedAdvanced shotcreteshotcrete mixturesmixtures

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The Bottom Line on UnitThe Bottom Line on Unit--OpsOps

"" Changes in basic unitChanges in basic unit--ops equipment at ops equipment at mine sites will be fairly incremental, linear, mine sites will be fairly incremental, linear, and predictableand predictable

" What will change:�How you run it, control it, monitor it, and utilize it.

"" What will change:What will change:�How you run it, control it, monitor it, and utilize it.

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Information Technologies Information Technologies are Criticalare Critical

"" SensorsSensors�� Equipment status (tire pressure/temp)Equipment status (tire pressure/temp)�� Duty cycle (excessive speed/revs)Duty cycle (excessive speed/revs)�� Hazards (proximity)Hazards (proximity)�� Geological (rock anomaly/deformation)Geological (rock anomaly/deformation)

"" ComputersComputers�� Cheaper & more powerfulCheaper & more powerful�� RuggedizedRuggedized

"" Result: RealResult: Real--time decision makingtime decision making"" Concern: Knowledge managementConcern: Knowledge management��

�Data is not as interesting as insight.

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Communications is CriticalCommunications is Critical"" Wired and wireless systemsWired and wireless systems"" HighHigh--resolution GPSresolution GPS"" Results:Results:

�� RealReal--time & remote decision makingtime & remote decision making"" Automated dispatch, surveying, Automated dispatch, surveying,

placementplacement"" Faster breakFaster break--down & emergency down & emergency

responseresponse"" Remote controlsRemote controls

�� Process integration (tying unitProcess integration (tying unit--ops together)ops together)�� Process intervention (layeringProcess intervention (layering--in support)in support)

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Autonomous Equipment Looks Autonomous Equipment Looks PromisingPromising

"" Viewed by leaders as �the next big step�Viewed by leaders as �the next big step�� Reducing operatorReducing operator--induced wearinduced wear--andand--teartear�� Increasing equipment utilizationIncreasing equipment utilization�� Reducing labor costsReducing labor costs

"" Expected availabilityExpected availability�� Surface haul trucks: 2002Surface haul trucks: 2002--20052005�� Drills: 2003Drills: 2003�� LHDsLHDs: 2005: 2005�� Shovels: 2005Shovels: 2005

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Uncertainty about Autonomous Uncertainty about Autonomous EquipmentEquipment

"" Slowed by the complex mine environmentSlowed by the complex mine environment�The technologies for driving machines have

been around for a long time. But to do this with high reliability 24/7 is very hard.

"" Questions:Questions:�� Where will it be adopted first?Where will it be adopted first?�� Is ventilation needed?Is ventilation needed?�� Role of mine personnelRole of mine personnel�� Is it worth the cost?Is it worth the cost?

"" Result: SemiResult: Semi--autonomous systems are an autonomous systems are an intermediate step (drilling, U.G. haulage)intermediate step (drilling, U.G. haulage)

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Maintenance is CriticalMaintenance is Critical"" Better engineering (robust systems, easy access Better engineering (robust systems, easy access

ports, modular components)ports, modular components)"" Better facilities and practicesBetter facilities and practices

�� OnOn--site: cleaner, more carefulsite: cleaner, more careful�� OffOff--site: specialized facilities, diagnosticssite: specialized facilities, diagnostics

"" Trend towards predictive maintenanceTrend towards predictive maintenance"" Results:Results:

�� Maintenance done only when necessaryMaintenance done only when necessary�� Problems predictable and detected earlierProblems predictable and detected earlier�� Can better control the �terms of engagement�Can better control the �terms of engagement�

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Human Resources is CriticalHuman Resources is Critical

"" DecisionDecision--making is being pushed downwardsmaking is being pushed downwards

"" Roles are changing from following rules to solving Roles are changing from following rules to solving problemsproblems

"" Hard to compete for and retain qualified personnel Hard to compete for and retain qualified personnel in a �bricks and mortar� industryin a �bricks and mortar� industry

"" A safe and enjoyable workplace helps attract, A safe and enjoyable workplace helps attract, retain, and motivate employeesretain, and motivate employees

"" Result: People are Result: People are moremore criticalcritical

"" Challenge: Challenge: Getting people to think.Getting people to think.

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Management MattersManagement Matters"" On predictive maintenanceOn predictive maintenance��

�Changing the way we�ve done it for the last 40 �Changing the way we�ve done it for the last 40 years� requires �selling the program to the years� requires �selling the program to the people.�people.�

"" On boosting productivityOn boosting productivity��We did it not by buying new equipment, but by �We did it not by buying new equipment, but by motivating the workforce.�motivating the workforce.�

"" On mission successOn mission success��Technology won�t solve problems. It�s a �Technology won�t solve problems. It�s a combination of technology and people.�combination of technology and people.�

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Many Questions Remain OpenMany Questions Remain Open"" Tech views in the industry are very diverseTech views in the industry are very diverse

"" Where to invest in productivity enhancements?Where to invest in productivity enhancements?��Improvements on the back end have a big Improvements on the back end have a big impact on the front end.impact on the front end.

"" How do you measure benefits of new techs?How do you measure benefits of new techs?��It�s surprising to find an operation that It�s surprising to find an operation that understands their costs from beginning to end.understands their costs from beginning to end.

"" Who is responsible for new technologies?Who is responsible for new technologies?��You need everyone at the table to work things You need everyone at the table to work things outout..

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ContactsContacts

DJ PetersonDJ PetersonThe RAND CorporationThe RAND CorporationSanta Monica, CA 90407Santa Monica, CA 90407--21382138(310) 393(310) 393--0411x76110411x7611Fax: (310) 451Fax: (310) [email protected]@rand.org

Access the entire report:Access the entire report:www.rand.org/publications/

MR/MR1324/

George BockoshNational Institute for Occupational Safety and Health626 Cochrans Mill RoadPittsburgh, Pa 15241(412) 386-6465Fax (412) [email protected]

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