The Influence of Conical Pick Cutter Wear Conditions on Physical Characteristics and Particle Size Distribution of Coal: Health and Safety Considerations with a Focus on Silica

This study investigates the correlations between the wear conditions of conical pick cutters and key variables such as the physical properties (shape, aspect ratio, roughness), explosive potential, health and safety implications, and particle size distribution of coal dust and larger fragments using the linear cutting machine (LCM). This research was conducted within the framework of recent regulatory developments, notably implementing the new silica rule in the mining and construction sectors and climate change consideration. This study reveals critical insights into optimizing operational processes while adhering to stringent health and safety regulations. The findings indicate that as cutting tools wear, there is a significant increase in generated fine particles, including respirable crystalline silica (RCS), which elevates the risk of respiratory diseases and, in the case of coal dust, a higher potential for explosions. The results show that the silica content in respirable dust is a function of rock mineralogy; however, the results showed that the absolute amount of silica-containing dust increased with bit wear in rocks containing pertinent minerals. For the larger fragments, the new bit produced a 1699 fragment count, while the completely worn-out bit produced a 5608 count. The results of the dust concentration show that the new bit produces 89.2 mg/m3 (17.84%); the moderate bit produces 165.1 mg/m3 (33.03%), and the worn-out bit produces 245.6 mg/m3 (49.13%). Moreover, this study highlights the impact of bit wear on the production of larger fragments, which decreases with tool degradation, further contributing to dust generation. These results suggest the necessity for proactive equipment maintenance, enhanced dust control measures, and continuous monitoring of cutting tool wear to ensure compliance with regulatory standards and to protect workers’ health and safety.