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By Patrick E. Connell

During the ABM Conference of 2015 the latest design and process features of the new 3-roll RSB® generation were presented together with a unique Size Control System SCS® for a real time closed loop control to produce an extraordinary quality SBQ – day in, day out. In the past two years, Kocks has focused on improving the repeatability of the rolling process and developed technology to enhance the performance of its equipment. These developments include Fast Remote Control (FRC), Stands Adjustable Under Load (AUL) implementation of closed loop Size Control System (SCS), and finally a state of the art laser Gauge (4D Eagle) that pulls all of these developments into a complete package of quality. Gauges used in the past generally operated with the “shadow” measuring system. The latest gauge developments are based on the “light section” method. This method is more suitable to provide real time measurement parameters of the rolled bar. Placed close to the last rolling stand, the “light section” gauge is capable of measuring around the complete diameter with a clear definition of the bar stage in relation to the axes of the rolls. It is also capable of making these measurements using a very high measurement frequency. Following requirements of the market, requiring the highest gauge measuring frequencies which display the bar in the most accurate way even at the highest rolling speeds, the “4D Eagle” gauge was developed. This paper describes all the process features and parameters of this impressive and unique newly developed gauge as well as the other described technical improvements.

Oct 30, 2017

By R. C. Nkhoma, K. A. Annan, S. Ngomane

The effects of welding current, electrode force, and welding time in a resistance spot weld were studied to investigate the effectiveness of welded joints between a thin EN10130: DC04 material and a thicker 817M40 part, through analysis of the microstructural and mechanical properties. All welded specimens were subjected to tensile testing at room temperature (25°C) and sub-zero temperature (–46°C) to test the strength of the welded joints. No full button failure was observed at either room temperature or sub-zero temperature after optimization of the weldng parameters. The fusion zone was observed to consist mainly of martensitic phase, due to rapid quenching, while the HAZ was composed of clusters of martensite in a ferrite and bainite matrix. The base 817M40 metal remained fully ferritic after welding. The hardness was found to increase with increasing welding current. An increase in nugget size, indicating good fusion of the weld, was observed with an increase in the welding current.

Oct 1, 2021

By Wolfgang Oberaigner

Primetals Technologies has always been a driver of innovation in steelmaking, especially by providing sophisticated process expert models for continuous casting machines. This capability is demonstrated by recent advancements in automation solutions that include: DynaPhase, Dynacs 3D, and DynaGap. This state-of-the-art suite of dynamic secondary cooling and soft-reduction packages take into account thermodynamic effects such as shrinkage and phase transitions, and thereby significantly contribute to direct quality improvements during the solidification phase in the continuous casting process. Speed Expert calculates an optimum casting speed for every casting situation, and additionally recommends a strand speed so that the point of final solidification is positioned at the end of a segment for optimum soft reduction. In the case of steel grade changes, the Intermix Expert precisely calculates the chemical properties of the mixed steel, thereby minimizing losses due to deviations from required specifications. The Nozzle Expert is a new model that detects clogged nozzles and broken hoses in secondary cooling systems. The first installations were highly successful and customers are pleased with impressive reductions in maintenance costs and improved steel quality. This paper describes these innovative process automation solutions and gives an overview about the successful results achieved within the first installations.

Aug 16, 2017

By Ke Yang, Kai Zhang, Xiaolou Chi, Xiangyang Zhang, Yingming Li

Based on the research background of 1303 working face return air roadway in Jinyuan Zhaoxian Mine, Shaanxi Province, a method of determining the reasonable spacing of boreholes is proposed based on the stress transfer degree of coal above and between boreholes, combined with the law of plastic zone and energy evolution by theoretical analysis and numerical simulation. After drilling pressure relief, the average daily energy of microseismic events decreased by 70%, and those with microseismic energy greater than 104 J decreased by 99.2%. The research has a strong guiding significance and research value for determining the reasonable distance of borehole pressure relief.

Jun 25, 2024

By Konstantinos Salonitis, Joanna Mielnicka, Mark Jolly, Arun Prabhakar

Lead sheets are widely used for roofing applications, radiation protection and sound proofing. Most of the sheets are either produced by rolling cast slabs of lead sheets or via the direct method (DM) of casting of the sheet continuously. The DM method comprises of a rotating water-cooled drum that is partly immersed in a bath of molten lead and sheets are cast out continuously. The direct method of casting lead is more energy efficient compared to the rolling process which requires a casting process before rolling to achieve the required thickness. This work investigates the energy consumption in different stages of the DM process and suggests pointers for improvement. An energy audit of the process is conducted and the consumption is analysed at different stages and compared with rolled lead.

Mar 1, 2018

By G K. Robinson, M D. Sinnott

Three-dimensional granular flow models have been run to simulate three types of sample cutters: a cross-stream cutter, a vezin, and a cross-belt cutter. This type of modelling involves solving the equations of motion for large numbers of individual particles as they travel along a conveyor belt and interact with a sample cutter. It allows flows of bulk materials to be visualised and understood. Here we have used spherical particles. These results illustrate some advantages that modelling has compared to physical bias testing: By taking reference samples which are very close to the actual samples, the estimation of bias can be achieve quite precisely with very few runs. (Many Standards about bias testing recommend a minimum of 20 runs, but we have found that five runs generally provide adequate precision.) Potential bias can be divided into two components: the particles which are missed but should have been sampled and the particles which are extra but which should not have been sampled. This more detailed information can provide useful insight. Exactly the same material can be sampled using different sample cutters, thereby avoiding a source of variation that complicates physical testing. Much more detailed visualisation is possible, allowing better understanding of the bulk material flow in various circumstances.

Jan 1, 2005

By Kenneth P. Katen

Though the use of continuous mining machines consolidated the operations of cutting, drilling, blasting, and loading in one machine that would theoretically provide uninterrupted production, it was soon realized that the face haulage and roof support operations remained as major impediments to continuous production. The ability to provide not only continuous cutting and loading, but also continuous haulage and roof support (see Fig. I), was the basis for the introduction of mechanized longwall systems in this country from Europe in 1951. The early systems employed friction props for roof support, but were to become obsolete shortly after introduction of the first hydraulically powered, self-advancing supports in 1960. Since then, use of the longwall technique has grown to the point where it is currently providing more than 5% of the annual output of underground coal mines in the United States. The shortwall system had its origin in Australia, but was first introduced into this country in 1962 following the development of powered roof supports. It, too, provides for continuous cutting, loading, and roof support (see Fig. 2), but has not experienced the widespread popularity of longwall due to its inherent inability to easily provide for continuous haulage. While there are in the neighborhood of 100 longwall systems currently in operation in this country, there are only a handful of short- wall operations providing production of slightly more than 907 184.7 t/a (1,000,000 stpy) Both of these systems provide uninterrupted roof support for face operations by means of hydraulically powered steel roof supports. In each case, the coal removal consists of open-end cuts made from the narrow end of a large rectangular pillar (panel) which has been blocked out by continuous miners developing entries around its perimeter. However, this is the extent of the similarities between the two systems. It is hoped [ ] that the information presented in this chapter will enable the reader to better understand the two mechanical systems and the mining concepts involved in their employment.

Jan 1, 1981

By D. François-Bongareon

"In previous publications by the author, significant advances and generalizations of the theory of sampling of broken ores, prompted and confirmed by experimental results, have been presented. This paper shows how to implement these theoretical results in practice. The models to be used are reviewed, with a description of the various sampling parameters involved. Then the methodology for the experimental assessment of those parameters, including segregation factors, is described in simple and practical terms, along with the use of handy sampling protocol charts. Finally, the particularly important case of processing data from a sample-tree experiment is detailed, and examples of applications covering all situations and types of experiments are provided.IntroductionThe reliability of a sample of crushed material , i.e. the expected (average) deviation between its true grade and the true grade of the lot it comes from, mostly depends upon six factors:• the size (mass) of the sample (and to a minor extent, for small lots, the size of the lot);• the size of the rock particles (degree of comminution)• the nature of the mineralization at microscopic scale (i.e., within even the smallest particles);• the geological nature of the mineralization and mineral of interest;• the grade of the lot in the mineral of interest; and• in some cases, the state of segregation of the lot.In practice, one should first disregard segregation problems, and assess sample variability in the segregation-free case. Once the numerical parameters governing this variability have been assessed, then segregation factors can be assessed in turn. In the case of laboratory standard sample preparation procedures, segregation can usually be disregarded altogether."

Jan 1, 1993

By A. L. Mular

"IntroductionSince the mid -1960s, automatic control of grinding circuits has become the rule, to avoid losses attributable to frequent circuit upsets associated with uncontrolled disturbances such as ore hardness variations. Higher capital costs of grinding equipment and corresponding operating costs-especially with respect to energy consumption-are major factors that continue to stimulate interest in grinding control.Grinding circuit control strategies depend upon the control objectives defined by the processing plant and are subject to constraints such as: maintain final per cent solids within some range, do not transport steel ball s out of the discharge trunnion, or do not overflow or empty the pump box and so on. Constraints depend on the nature of equipment employed within the grinding circuit and may actually determine the characteristics of the control scheme. Typical control objectives are:1. Maintain final particle size at set point by ,a. manipulation of fresh feed rate with circulating load maintained by manipulation of pump box water addition rate, orb. manipulation of pump box water addition rate with circulating load maintained by manipulation of fresh feed rate, where the methodology utilized to accomplish either (a) or (b) is dependent upon equipment/circuit constraints such as the availability of a variable speed pump.2. Maintain circuit throughput at a maximum by,a. manipulation of fresh feed rate subject to constraints on final particle size and variables such as power draw, circulating load and mill overload.3. Maintain mill load at set point by a. manipulation of fresh feed rate subject to constraints such as on power draw.4. Maintain mill power draw at set point bya . manipulation of fresh feed rate subject to mill load constraints. Often, a grinding control objective is dictated by the recovery vs fineness-of-grind characteristic that exists for downstream separation circuits. When recovery is relatively insensitive to size, maximum throughput in the grinding circuit is advantageous.The purpose of this paper is to review control strategies for primary ball mill grinding circuits, rod mill/ball mill grinding circuits and semi-autogenous grinding mill circuits. Primary sensors employed are highlighted and modern trends are documented briefly."

Jan 1, 1989

By Ward E. Kilby, Bruce I. Mcclymont

"Data from the South Fork Pit Area of the Bullmoose deposit in northeastern British Columbia are used to demonstrate the usefulness of microcomputers to the on-site geologist. The technique utilizes a series of digital surf aces in the form of a network of points to define various geologic parameters such as seam positions, topography and coal quality characteristics. Manual digitizing, kriging and combinations of these techniques are used to calculate these digital surfaces, the best method depending upon the type and quality of the data in question. Digital surfaces, each modelling a specific feature when combined and manipulated with the computer form a powerful tool, the deposit model. The resultant model, containing all the surfaces, is used to examine seam and inter-seam thicknesses, deposit volumetrics, seam quality characteristics and the adequacy of sampling.IntroductionCoal deposit modelling using computer-based techniques has become routine. However, a geologist working in the field, without access to mainframe or minicomputer, ha s considerable difficulty implementing these procedures. However, microcomputers, which are portable and inexpensive can handle exploration data, perform various geological analyses, and produce deposit models virtually at the same time as the data is being collected. For the on-site geologist this means that quick access to the results of such modelling could point out inadequacies in deposit definition and trends in coal quality deserving investigation."

Jan 1, 1985

By W. H. Bassett

IN the commercial annealing of cartridge brass there are four points regarding which definite data are essential. They have to do with the correct interpretation of grain count in its relation to annealing temperature and, incidentally, to Brinell hardness. These points are: 1. The comparison of the grain sizes of two cartridge-brass mixtures: 69 copper, 31 zinc, 0.376-in. (9.5-min.) gage; and 68 copper, 32 zinc, 0.130-in. (3.3-mm.) gage. 2. The comparison of the grain sizes of annealed metal that had previously been reduced by rolling varying amounts; for instance, 20.0, 36.6, 50.9, and 59.1 per cent. 3. The determination of standards for grain sizes on annealed brass of the composition 68 per cent. copper, 32 per cent. zinc and 69 copper, 31 zinc. 4. The comparison of grain size with Brinell hardness on identical samples of annealed metal. In their comprehensive and thorough investigation of the recrystallization of cold-worked alpha brass on annealing,1 Mathewson and Phillips have discussed the relations between temperature of anneal, degree of deformation, and structural alteration in alpha brass. They have also shown certain comparisons between the ordinary physical properties and the grain size of annealed brass. The purpose of the present investigation is mainly concerned with the grain size of cartridge brass, its relation to Brinell hardness, and the publication of sufficient data to enable those engaged in the inspection of such material to have a correct foundation upon which to work.

Jan 1, 1919

As part of the United States Department of the Interior, Bureau of Mines Health and Safety Research Program, Walter C. McCrone Associates, Incorporated has examined 71 samples of airborne mine dusts using the techniques of x-ray diffraction, electron microprobe analysis and light microscopy. This report details the procedures which were used in this work and documents the results which were obtained.

Jan 1, 2011

By Gilberto Thiago de Paula Costa

Este artigo apresenta o SALF, um software nacional desenvolvido para simular o processo de laminação a frio de chapas através do método dos elementos finitos. O programa utiliza a formulação implícita/rígido-plástica em suas análises. Simulações retiradas da literatura foram realizadas com o software, sendo os materiais simulados alumínio e aço, com espessuras de 3,0 mm e 1,0 mm, reduções de 5% e 30% e atrito de 0,06 a 0,15. Os resultados do SALF ficaram bem próximos dos resultados descritos na literatura. Desta forma, a partir de agora, as siderúrgicas nacionais têm uma ferramenta nacional para simular o processo de laminação a frio, a qual pode auxiliar na melhoria de seus processos e produtos.

Aug 17, 2017

By Hernan Escalante, Jonathan Alvis, Paulo Alcazar

Constancia Mine, operated by Hudbay Perú and located in the district of Velille, Chumbivilcas province, Cusco, is an open-pit operation characterized by low-grade ore. In this context, operational efficiency and process optimization are essential to ensure long-term profitability. This paper presents an innovative strategy based on the processing of large volumes of data (Big Data), primarily from the drilling and blasting stages. By consolidating approximately 9 million records per month into a georeferenced block model, an analytical platform was developed to directly correlate material fragmentation quality with plant mill throughput. The implemented methodology integrates multiple operational and geometallurgical data sources, enabling dynamic visualization of blasting conditions and their impact on material behavior during crushing and grinding. Through this correlation, operational patterns that maximize plant throughput while minimizing energy consumption and processing costs were identified. Beyond the direct benefits in the plant, this approach significantly improved mine planning by enabling more informed decisions regarding drill pattern design, explosive loading, and blast sequencing. Improved coordination between mine and plant departments was also observed, contributing to better alignment of operational goals and an integrated business perspective. The application of Big Data in this context represents a step toward digital transformation in mining, demonstrating that advanced analytics can be effectively implemented in large-scale, complex operational environments. This solution was validated under real operating conditions and shows high scalability potential for other operations facing similar challenges. In conclusion, this study demonstrates that systematic analysis of drilling and blasting data, when integrated with geological and operational models, can lead to substantial improvements in plant performance. This contributes directly to the competitiveness and sustainability of low-grade mining operations.

Jan 26, 2026

By Rosa Maria Sales da Silveira

O objetivo do presente trabalho foi caracterizar a camada de óxido formada na superfície externa de tubos de reforma retirados de serviço após diferentes tempos de operação, em função da temperatura em que os mesmos estão expostos que varia com altura dos tubos. A caracterização consistiu da análise morfológica da camada de óxido utilizando um microscópio eletrônico de varredura de alta resolução e mapeamentos de composição química por EDS para verificar a distribuição dos óxidos presentes na mesma. Observou-se que a distribuição dos diferentes óxidos apresentou uma sequência padrão e que a camada de óxido aumenta com a temperatura e tempo de operação, bem como a camada subsuperficial empobrecida de carbetos de cromo.

Oct 30, 2017

By Forrest T. Moyer

The overall disabling work injury experience, excluding office- workers, at nometal mines and mills during the period 1961-63, as reported to the Bureau of Mines by operators, was 77 fatal and 7,201 nonfatal injuries during an aggregate worktime of 335,029,685 man- hours. These injuries, fatal and nonfatal combined, occurred at a frequency rate of 21.72 per million man-hours, comprising 0.23 for the fatal and 21.49 for the nonfatal injuries. The combined severity rate of the disabilities was 2,312 days lost or charged per million man-hours, consisting of 1,379 for the fatal and 933 of the nonfatal injuries, The average severity of all disabilities during 1961-63, was 106 days per injury, The number of days lost or charged, excluding officeworkers, at nonmetal mines and mills during 1961-63, was 462,000 days charged to fatal injuries and 312,461 days lost from nonfatal injuries. The outstanding causes for fatal injuries were explosions (18 fatalities occurred in a major mine-explosion disaster in a potash mine in Utah in 1963) and falls of rock or ore from back or side, while most nonfatal injuries were caused by handling materials, slips or falls of persons, haulage, and machinery. The parts of the body most frequently injured during the period 1961-63 were the trunk, hand and finger, and foot and toe, An average of 52,810 men were at work daily, There were 20 nonfatal disabling injuries reported for office- workers at nonmetal mines and mills during the period 1961-63 during an aggregate worktime of 23,088,496 man-hours, These injuries occur- red at a frequency rate of 0.87 per million man-hours, There were no fatal injuries reported.

Jan 1, 1967

By Ronald F. Balazik

The introduction of "high-tech" materials such as new polymer composites presents significant competitive challenges and opportunities in conventional mineral markets. Moreover, rapid advances in materials science are critical to the resolution of important economic and strategic issues, including national competitiveness and import dependence. This Bureau of Mines study examines the displacement of conventional nonfuel mineral materials by certain new materials, specifically advanced plastics and ceramics. Analyses of substitution by plastics are conducted for five major U.S. industrial sectors: motor vehicle manufacturing, aerospace applications, building and construction, packaging, and heavy machinery production. Based on interviews with more than 60 scientists, executives, and other professionals engaged in materials development and sales, forecasts of substitution by plastics during the 1990's are made for aluminum, steel, and glass. In addition to these forecasts, study findings identify key factors that will influence the emergence of advanced materials in the next decade.

Jan 1, 1987

By Jacqueline A. McClaskey

The U.S. Bureau of Mines Information and Analysis Directorate collects world-wide data on virtually every commercially important nonfuel mineral commodity. These data form the base for tracking and assessing the health of the minerals sector of the U.S. economy. The Bureau's data collection activity was instituted by the 47th Congress in an appropriations act of August 7, 1882 (22 Stat. 329), which placed the collection of mineral statistics on an annual basis. The most recent authority for the U.S. Bureau of Mines survey activity is the National Materials and Minerals Policy, Research and Development Act of 1980 (public Law 96-479, 96th Congress). This act strengthens protection for proprietary data provided to the U.S. Department of the Interior by persons or firms engaged in any phase of mineral or mineral-material production or consumption.

Jan 1, 1993

The Technology Transfer Seminar on Mine Communications held on March 21-22, 1973, at the Pittsburgh Mining and Safety Research Center, Bruceton, Pa., presented information about recently developed equipment, instruments, and techniques for use in mine communications systems. All of the basic ideas presented in the fine seminar are operational in the Bureau of Mines Safety Research Mine in Bruceton.

Jan 1, 1974

[A Aall, Christian H., M49 B VP, Dir of Smelt & Refin, Am. Metal Climax Inc., 1270 Ave. of the Americas, N.Y. Aaroe, Stanley L., A54 B VP, The W. S. Tyler Co. of Can. Ltd., St. Catharines, Ontario, Canada Abalos, Toodulo Q., J57 A Prod Foreman, Lepanto Cons. Mng. Co., Mt. Province, Philippines Abbass, G., M55 P. O. Box 680, Hong Kong, China Abbitt, James M., A54 770 Sole Blvd., Bartow, Fla. Abbott, Raymond C., J59 3442 Greenwich Ave., Columbus 24, Ohio Abdullah, N. Y., J53 Dept. of Mines, Res. Div., P. O. Box 1016, Tiger Lane, Ipoh Perak, Malaya Abel, John F., Jr., J53- 100 Maple, Littleton, Colo. Abell, Leo M., M31 B Conc Supt, Phelps Dodge Corp., Morenci, Ariz. Abendroth, Harry E., A57 A Geol, Union Carbide India, 183 Brabourne Rd.. Calcutta. India]

Jan 1, 1961