Mining Incidents

Covol Fuels No. 2, LLC: 1 recorded fatality Coal

Controlled by Headwaters Inc
Greenville, Muhlenberg County, KY  ·  Abandoned
MSHA Mine ID: 1519205

Covol Fuels No. 2, LLC has $3K in proposed MSHA penalties and $0 outstanding across 1 contested dockets, plus health sampling and the full incident record.

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Fatalities
1
Total incidents
11
Years on record
2009–2011
Latest incident
Dec 2011
Compliance record
MSHA citations since 2009
19
citations
5
significant & substantial
$3,397
proposed penalties
$3,397
paid to date
100% of proposed penalties paid to date, a $0 gap.
Source: MSHA violations data, updated weekly.
Inspection activity
MSHA inspections since 2008
31
inspections on record
635
inspection hours
n/a
citations per 100 inspection hours
This rate is recorded citations divided by MSHA inspection hours, per 100 hours. It reflects inspection effort, not mine size or production.
Rate withheld: 635 inspection hours is too few for a stable rate. A minimum of 1,000 inspection hours is required.
Source: MSHA inspections data, updated weekly.

Covol Fuels No. 2, LLC has $3K in proposed MSHA penalties and $0 outstanding across 1 contested dockets.

Penalty disposition
Differences between proposed and paid penalties reflect both settlements and conference reductions and amounts still owed. Outstanding is the balance currently owed.
$3K
proposed penalties
$3K
current assessed
$3K
paid to date
$0
outstanding
18 assessments are final orders; 1 contested dockets.
Of $100 in penalties contested before the Commission, $0 was upheld in final decisions.
As of the most recent assessment on 2019-01-22.
Source: MSHA assessed-violations and conference/litigation data, updated weekly.
Violation severity profile
Shares are computed over citations that carry the MSHA gravity and negligence coding; a small share of records are uncoded.
27.8%
significant & substantial
0.0%
high negligence or reckless
27.8%
reasonably likely or greater
11.1%
permanently disabling or fatal if injury occurs
Negligence coding: 0.0% none, 16.7% low, 83.3% moderate, 0.0% high, 0.0% reckless.
Source: MSHA violations gravity and negligence coding, updated weekly.
When citations were contested
Contesting a citation before the Federal Mine Safety and Health Review Commission is a lawful right. These figures state the public outcomes of that process, from MSHA's Contested Violations file.
1 citations taken to the federal commission · 5% of citations on record
  • Vacated or withdrawn 1 · 100%
100%
Penalty reduction in decided contests
$100 proposed, $0 after decisions · industry: 39%
Source: MSHA Contested Violations file (public record), updated weekly. A dismissed or defaulted contest leaves the citation standing as issued; a vacated or withdrawn citation is removed from the violation record. Latest contest filed 2009-05-04.
Contested penalties
A reduction or dismissal at the Commission is a lawful outcome of contesting a proposed penalty. Figures are the proposed amount and the amount upheld in the docket's decision.
Largest penalties this mine contested before the Federal Mine Safety and Health Review Commission, with the outcome on record.
Docket Decision Judge Year Proposed / upheld
KENT 2009-994 Withdrawal Lesnick 2010 $100 → $0
Source: FMSHRC civil penalty dockets and decisions (public record), updated weekly.

MSHA sampling at Covol Fuels No. 2, LLC shows 100% of 32 respirable coal dust samples met the 1.5 mg/m3 standard.

Health sampling
A sample is a point in time compliance measurement, not an individual exposure history. These figures describe MSHA sampling records and do not establish causation or personal dose.

Respirable coal dust
Respirable coal dust and silica figures cover coal facilities. Dust compliance is measured against the current 1.5 mg/m3 standard; samples predating the 2014 standard are included, so compliance rates are a coarse historical signal.

Last sampled: 2011-06-14, 15 years ago
100%
within 1.5 mg/m3
32
samples
1.00
dust max (mg/m3)
32 samples taken by MSHA inspectors, 0 by the operator.
Most-sampled occupations
  • HIGHLIFT OPERATOR/FRONT END LOADER7
  • BULLDOZER OPERATOR3
  • CLEANING PLANT OPERATOR3

Noise
The share counts noise samples whose measured dose exceeded the 90 dBA permissible exposure limit. It describes the sampled workplace, not what reached the miner's ear: hearing conservation programs and the hearing protection worn during the shift are recorded separately and are not reflected here.

Last sampled: 2011-06-14, 15 years ago
0%
over PEL
15
samples
Most-sampled occupations
  • HIGHLIFT OPERATOR/FRONT END LOADER4
  • MECHANIC3
  • FINE COAL PLANT OPERATOR2
Source: MSHA respirable dust, quartz, and noise sampling records, updated weekly.
Health sampling trend
A sample is a point in time compliance measurement, not an individual exposure history. These figures describe MSHA sampling records and do not establish causation or personal dose.
Respirable coal dust by year
Respirable coal dust and silica figures cover coal facilities. Dust compliance is measured against the current 1.5 mg/m3 standard; samples predating the 2014 standard are included, so compliance rates are a coarse historical signal.
Year within 1.5 mg/m3 samples
2011 100% 10
2010 100% 6
2009 100% 16
Noise by year
Year over PEL samples
2011 0% 5
2009 0% 10
Source: MSHA respirable dust, quartz, and noise sampling records, updated weekly.

Covol Fuels No. 2, LLC recorded 0.00 reportable injury cases per 100 full-time workers in 2013.

Injury rate, 2013
This rate is reportable injury cases per 100 full-time-equivalent workers per year, computed as 200,000 times cases divided by MSHA operator-reported employee-hours. Cases are injuries MSHA graded degree 01 through 07; accident-only events that hurt no one are excluded, and so are contractor injuries, whose hours do not attach to a single mine. Rates begin in 2000, when quarterly employment reporting starts, and are withheld below 20,000 hours in a year.
0.00
total case rate
0.00
days-away rate
0.000
fatality rate
Below average. The US coal mining average was 3.94 and the all-US-mining average was 2.99 cases per 100 workers.
In Kentucky, coal mining averaged 4.63 cases per 100 workers that year.
Under 100,000 employee-hours were reported that year, so a single case moves the rate by two or more. Read the figure as approximate.
Year total case rate days-away fatal
2013 * 0.00 0.00 0.000
2012 * 0.00 0.00 0.000
2011 * 14.02 2.80 0.000
2010 * 5.75 2.87 0.000
2009 * 10.11 6.74 0.000
* Fewer than 100,000 employee-hours that year; the rate is less stable.
Source: injury cases from MSHA accident and injury records; employee-hours from MSHA quarterly employment reports. Rate is cases per 100 full-time-equivalent workers, operator employees only.
Ownership history
  1. Covol Fuels No 2 LLC 2008 to 2013
  2. BRC Minuteman LLC 2013 to 2015
  3. Covol Fuels No. 2, LLC 2015 to present
Source: MSHA controller and operator history, updated weekly.
Workforce and production
Coal production is reported quarterly and lags the current period; the most recent quarters may be incomplete.
Year Employees Coal produced (tons)
2020 4
2019 5
2018 4
2017 1
2016 1
2015 1
2014 5
2013 12
2012 12
2011 32 150,209
2010 30 361,880
2009 25 238,839
2008 6 2,588
Source: MSHA quarterly employment and production, updated weekly.

Covol Fuels No. 2, LLC sits in Muhlenberg County, Kentucky, where the Census mining category is 3.2% of county employment.

Local economic context
County figures come from the US Census Bureau's American Community Survey, 5-year pooled estimates, so the 2023 vintage covers 2019 through 2023. The Census category is 'mining, quarrying, and oil and gas extraction', which is broader than MSHA jurisdiction and includes oil and gas workers no mine employs. These figures describe the surrounding county, not this mine, and are not a factor in any specific incident.
Muhlenberg County, Kentucky · Population 30,712
3.2%
Mining share of county employment
$52,672
Median household income
Source: US Census Bureau, American Community Survey 2023 5-year estimates.
Quarterly safety rates
Citations per million reported employee-hours. Rates begin in 2000, when MSHA's quarterly employment data starts; earlier incidents are counted but cannot be rate-adjusted. Quarters under 100,000 reported hours are greyed: too few hours for a stable rate.
Citations per million employee-hours, as reported to MSHA
Quarter Hours worked Citations S&S Per 1M hrs
2020 Q3 1,440 0 0 0.0
2020 Q2 1,920 0 0 0.0
2020 Q1 1,800 0 0 0.0
2019 Q4 1,800 0 0 0.0
2019 Q3 1,800 0 0 0.0
2019 Q2 1,800 0 0 0.0
2019 Q1 2,120 1 0 471.7
2018 Q4 2,120 0 0 0.0
Show 43 earlier quarters
Quarter Hours worked Citations S&S Per 1M hrs
2018 Q3 660 0 0 0.0
2018 Q2 520 0 0 0.0
2018 Q1 520 0 0 0.0
2017 Q4 520 0 0 0.0
2017 Q3 520 0 0 0.0
2017 Q2 520 0 0 0.0
2017 Q1 520 0 0 0.0
2016 Q4 520 0 0 0.0
2016 Q3 520 0 0 0.0
2016 Q2 520 0 0 0.0
2016 Q1 520 0 0 0.0
2015 Q4 520 0 0 0.0
2015 Q3 520 0 0 0.0
2015 Q2 520 0 0 0.0
2015 Q1 480 0 0 0.0
2014 Q4 1,560 0 0 0.0
2014 Q3 1,560 1 0 641.0
2014 Q2 1,560 0 0 0.0
2014 Q1 5,280 0 0 0.0
2013 Q4 6,385 0 0 0.0
2013 Q3 5,999 0 0 0.0
2013 Q2 6,084 0 0 0.0
2013 Q1 6,280 0 0 0.0
2012 Q4 5,552 0 0 0.0
2012 Q3 5,559 0 0 0.0
2012 Q2 5,897 0 0 0.0
2012 Q1 6,683 0 0 0.0
2011 Q4 13,305 0 0 0.0
2011 Q3 22,569 1 0 44.3
2011 Q2 17,756 0 0 0.0
2011 Q1 17,683 1 0 56.6
2010 Q4 18,553 0 0 0.0
2010 Q3 18,178 3 0 165.0
2010 Q2 14,428 2 0 138.6
2010 Q1 18,413 0 0 0.0
2009 Q4 17,776 0 0 0.0
2009 Q3 11,600 0 0 0.0
2009 Q2 15,488 1 0 64.6
2009 Q1 14,475 7 4 483.6
2008 Q4 5,029 0 0 0.0
2008 Q3 0 0 0
2008 Q2 0 0 0
2008 Q1 0 0 0

Fatalities at this mine

1 recorded
February 26, 2009 KY · Coal laborer, blacksmith, bull gang, parts runner, roustabout, pick-up man, pitman Fatality · SLIP OR FALL OF PERSON
Covol Fuels No 2 LLC · Fall from ladders

Installing a rolling steel door, the victim was on a stepladder - Lost his balance and fell approximately 7 feet landing on a concrete floor. He died from his injuries. He was taken by helicopter to the hospital (St. Mary's in Evansville, IN.)

Reportable incidents

10 on file (excluding fatalities above)

2011 · 5 incidents

December 1, 2011 KY · Coal laborer, blacksmith, bull gang, parts runner, roustabout, pick-up man, pitman HANDLING OF MATERIALS
Covol Fuels No 2 LLC · Struck by falling object

Removing pipe from pump - the pipe wrap fell hitting right thumb.

November 12, 2011 KY · Coal laborer, blacksmith, bull gang, parts runner, roustabout, pick-up man, pitman HANDLING OF MATERIALS
Covol Fuels No 2 LLC · Over-exertion in lifting objects

Employee aligning large pipe (12" to 14") diameter to install a tee in the pipe line - was using a chain and Komatsu-wa2oo, put self in twisted postion to assist in the lift.

August 30, 2011 KY · Coal prep plant foreman, supervisor, mill plant supervisor, kiln supervisor DISORDERS (REPEATED TRAUMA)
Covol Fuels No 2 LLC · (Not Elsewhere Classified)

Employee is scheduled to see ear, nose & throat (ENT) doctor on 10/4/11 to determine if the hearing shift is work related if the hearing shift is work related ee exposure will be evaluated to determine the contributing conditions.

August 22, 2011 KY · Coal laborer, blacksmith, bull gang, parts runner, roustabout, pick-up man, pitman HANDTOOLS (NONPOWERED)
Covol Fuels No 2 LLC · Over-exertion (Not Elsewhere Classified)

Over exertion by employee.

January 25, 2011 KY · Coal prep plant foreman, supervisor, mill plant supervisor, kiln supervisor SLIP OR FALL OF PERSON
Covol Fuels No 2 LLC · Over-exertion (Not Elsewhere Classified)

Winter conditions/mud-snow, icy, worker had mud on his boots causing him to slip while going down the stairs.

2010 · 2 incidents

November 29, 2010 KY · Coal laborer, blacksmith, bull gang, parts runner, roustabout, pick-up man, pitman HANDTOOLS (NONPOWERED)
Covol Fuels No 2 LLC · Fall onto or against objects

Using a pry bar to clear rocks and wood from under a leaking 14" water line. Pushing back and forth on pry bar when it shifted sending employee forward into the catwalk sliding his little finger down the edge slicing his little finger open.

January 26, 2010 KY · Coal laborer, blacksmith, bull gang, parts runner, roustabout, pick-up man, pitman HANDLING OF MATERIALS
Covol Fuels No 2 LLC · Over-exertion in lifting objects

EE overloaded shovel, it was heavier than he expected due to the difference in material (coal,fines,rocks,clays). EE was cleaning material from the conveyor where it was clogged up.

2009 · 3 incidents

December 9, 2009 KY · Coal superintendent HANDTOOLS (NONPOWERED)
Covol Fuels No 2 LLC · Fall to the walkway or working surface

Weather was changing - becoming very windy w/gusts to 40 mph - trying to pull doors (large metal) closed on 2nd floor of plant using a large wooden arm with an eye bolt in it. Bolt came loose, lost grip & fell back catching self with left hand.

November 20, 2009 KY · Coal laborer, blacksmith, bull gang, parts runner, roustabout, pick-up man, pitman HANDTOOLS (NONPOWERED)
Covol Fuels No 2 LLC · Over-exertion in pulling or pushing objects

Using a garden rake to pull clay balls from vibrator screen, rake hung in clay pulling on employee as the clay fell into the gob chute.

November 4, 2009 KY · Coal laborer, blacksmith, bull gang, parts runner, roustabout, pick-up man, pitman HANDTOOLS (NONPOWERED)
Covol Fuels No 2 LLC · Over-exertion (Not Elsewhere Classified)

EE was working on dredge winch cable using a pry bar to loosen the cable by striking the cable. He lost control of the bar, causing him to strain his right arm and neck, also lost his footing. Using the wrong tool and poor positioning.