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Some examples of the results of research projects, conducted in the KOMAG Institute of Mining Technology are presented. Special attention is paid to mining machines and equipment, and improving work safety and comfort of miners in underground workings. From numerous scientific and technical achievements of the KOMAG Institute within the last 2 years, a few design solutions have been selected for a presentation. Some results of European projects on innovative solutions are described as well, highlighting KOMAG?s role in the national and international research area.

Aug 1, 2013

Bellows Connector Fabricated of chemically inert Teflon, the new bellows type connector has many pipe line applications where vibration, expansion and electrolysis exist in the handling of corrosive liquids or gases and solvents. The new connector is electrically non-conductive, flexible even at 94°F and as strong as 480°F as at 70°F, according to the manufacturer. This bellows connector serves as a [ ] vibration dampener as well as an expansion joint and connects misaligned couplings and insulates flanges electrically. End flanges of the joint are French-type envelope gaskets made integral with the joint for easy assembly between companion flanges and a tight, leak-proof seal on installation. Circle No. 1

Jan 1, 1952

By A. J. Kraemer

This report on the physical and chemical properties of crude oils of California is one of a series on the producing districts of the United States. It includes a short discussion of results, tabulated data, and individual analyses of California crudes. Analyses of crude oils from the fields of Fresno, Kern, Los Angeles, Orange, and Ventura Counties have been published in Serials 25952 and 26083. The analyses reported in this paper corer samples that were obtained subsequent to the publication of Serials 2535 and 2608. The samples were obtained by members of the San Francisco office of the Bureau of Mines. The collecting of samples was facilitated by the courtesy of representatives of oil companies in California.

Jan 1, 1927

By K. Mansfield

Spent Pot Lining (SPL) is an unavoidable waste product of the electrolytic process in the smelting of aluminium. SPL is considered to be a hazardous waste in various countries because it contains significant quantities of absorbed fluorides along with traces of cyanide. In 1995, Portland Aluminium undertook the investment of AUD$26,400,000 to construct a Research and Development processing facility at Portland, Victoria, Australia, to treat SPL. Extensive research, development and design were carried out over 5 years prior to the investment decision. This study led Portland Aluminium to install an Ausmelt pyrometallurgical furnace to combust and melt the SPL producing a hydrogen fluoride (HF) laden gas, which was cooled and then converted to aluminium fluoride (AlF3). Both the cooling and AIF3 manufacture were processes developed by Portland Aluminium. Many commissioning, equipment reliability and process problems have been encountered that had not been experienced in the trials at Ausmelt or in the developmental process for the treatment of the furnace offgases to form AlF3. Designs based on anticipated process expectations have had to be re-engineered by the SPL team to ensure plant and operational success. In June 2001, the installation of the final major component - a slag granulation process - was completed. This has produced a vitrified (glassy) slag that is expected to have leachability qualities acceptable to the Victorian Environment Protection Authority (EPA) to allow commercial end uses of the slag material to be developed. Today (September 2001), the smelter has successfully used the fluoride product, namely 65- 70% AIF3, in aluminium production and the SPL plant has significantly increased throughput with expectations to be at annual design rates of 12,000 tonne of SPL in early 2002. "The Alcoa Portland SPL Process" has been technically developed and is a proven process for the treatment and recovery of valuable components from SPL materials.

Jan 1, 2002

By Qian Li, Honggui Han, Jun Wang, Shichao Yu, Chunxiao Zhao, Maoxing Hong, Rui Liao, Xingxing Wang

In this study, bioleaching experiments, synchrotron X-ray Diffraction (SR-XRD), X-ray absorption near edge structure (XANES) and X-ray Photoelectron Spectroscopy (XPS) were conducted to investigate the intermediates and surface species of bornite leached by mesophilic mixed bacteria of Leptospirillum ferriphilum, Acidithiobacillus caldus and Sulfobacillus thermosulfidooxidans. CuS, Cu9Fe9S16 and S8 were the main intermediate species during bornite bioleaching by mesophilic mixed bacteria, and CuFeS2 was also detected. The surface species of S2− and S2 2− would be polymerized to Sn 2− during bioleaching. The formation of element sulfur and the increase of its content were confirmed by the fitted results of XPS spectra. The presence of polysulfide and element sulfur did not inhibit the bornite bioleaching. The formations of CuS and CuFeS2 were confirmed by the results of Cu K-edge XANES spectra.

Mar 1, 2018

By J. W. Lyman

The U.S. Bureau of Mines investigated methods of separating valuable rare-earth materials from Fe in neodymium iron boron (NdFeB) magnet scrap. A selective oxidation treatment of the scrap oxidized the rare-earth portion while leaving elemental Fe. Magnetic and leaching procedures were tried for separating the metallic Fe and rare-earth oxides, but the extremely fine grain size of the oxidized scrap prevented recovery by either technique. The best separation of rare earths from bulk NdFeB magnet scrap was obtained by dissolution with H2S04 followed by precipitation of recyclable rare-earth salts. By precipitating neodymium-alkali sulfate double salts as an intermediate that can be converted to a variety of useful products, many materials-handling and economic disadvantages found with direct precipitation with fluoride or oxalate were avoided. Iron was removed from magnet leach solutions by precipitation as a jarosite, eliminating a major disposal problem. Research was also conducted with contaminated mixed SmCo5 and NdFeB swarf. Using a flotation-leaching technique allows the SmCo5 to concentrate in the froth, while the grinding-medium contaminant sinks and is removed as tailing. The NdFeB is dissolved by H2S04 during the process.

Jan 1, 2010

By W P. Breytenbach

"The phased application of statistical process control (SPC) infers that processes are classifiable as pre-SPC (or phase zero), phase I and phase II processes, with different objectives being pursued in the different phases. Phase zero processes, defined as processes affected by assignable causes of variation, are characterised as follows: out-of-control with unknown autocorrelation structure having an unknown statistical distribution not performing consistently on target with minimum variability potentially incapable of conforming to the product specifications. The objectives of phase I SPC is to obtain estimates of the mean (µ), variance (s2), probability density function (f(X)) and the autocorrelation structure, as well as transforming the process into a phase II process (defined as a process conforming to specifications and performing on target with minimum variability). As in any other type of research or pragmatic improvement intervention, sampling is required is to achieve these objectives. The challenge of deciding a phase I sampling plan is multifarious since it has to cope with the aforementioned effects of assignable causes and provide for rigour estimates of the unknown parameters. Furthermore, deciding sampling plans in phase I invariably presents a classical catch-22 situation: appropriate sampling is required to determine the autocorrelation structure of a variable, but knowledge of the autocorrelation structure is required to formulate an appropriate sampling plan. This paper suggests, for random variables, guidelines to formulate sampling plans, and presents a methodology to estimate the inherent process parameters of process variables and an approach to identify assignable causes in phase I. CITATION:Breytenbach, W P, 2014. Rational sampling and standard deviations for random variables in phase i application of statistical process control, in Proceedings Sampling 2014, pp 141–154 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Jul 29, 2014

Rougher Cells The photo shows one of three carloads of new Denver Equipment Co. rougher flotation machines destined for a single customer. [ ] Low level froth overflow on both sides, and double impeller mechanisms in an open-flow type tank, were designed to enable control of variable conditions in the rougher circuit for better metallurgy. Intense agitation and aeration are claimed, for effective recovery of low-grade mineral particles. Standard parts are used, interchangeable with regular Denver Sub-A units. The Super Rougher is now in production and a 2-cell No. 24 machine will be displayed at the Mining Show. Circle No. 1 Fans A line of industrial fans built for air or materials handling is available in eleven sizes from 670 to 44,000 cfm capacity from Westinghouse Electric Corp. The air hand¬ling wheel has backwardly-inclined blades. Circle No. 2 Trolleyphones The Femco Trolleyphone, plug-in model, 2550 series, is offered as a simple mine or mill communications system by Farmers Engineering & Mfg. Co. More compact, easier to install and service, the new model is powered from existing trolley wire or power line. Circle No. 3

Jan 1, 1952

By L. Figueroa

Electrochemical methods have potential to treat waters impacted by mining, while simultaneously producing a recoverable metal product to off-set treatment costs. Mining-impacted waters may present challenges with electrochemical treatment due to low concentrations and complex solutions of numerous dissolved metals. This paper presents an evaluation of the potential strengths and limitations of abiotic electrowinning of mining-impacted waters. In particular the impacts of chemical composition on metals removal are evaluated. Results of bench-scale experiments demonstrate the potential to remove metals on the cathode (copper, cadmium, lead), as well as the anode (manganese). Pre-treatment for iron and aluminum may be needed and post-treatment pH adjustment would be necessary. INTRODUCTION Due to continually increasing demand for metals, new technologies and innovative applications of existing technologies are needed to recover metals from mining-impacted waters. Electrochemical methods have long been used for metallurgical processes with solutions containing high concentrations of the target metal. However, electrochemistry also has potential to treat waters with lower metal concentrations, while simultaneously producing a recoverable metal product to offset treatment costs. Electrochemical water treatment may have several benefits over traditional alkaline treatment for acid rock drainage (ARD). Sludge produced from alkaline treatment has high water content that is difficult to dewater, even for treatment plants producing a relatively high-density sludge. For example, the Argo Tunnel Water Treatment Facility (Argo Facility) in Idaho Springs, Colorado uses hydrated lime to produce a high-density sludge with a solids content of 20 to 25 percent and filter cake with solids content from 30 to 35 percent [1]. Furthermore, costs for managing the sludge are significant, approximately $90,000 per year for treating approximately 150 million gallons of water [1]. Although not the case for the Argo Facility, sludge produced from alkaline treatment of ARD has potential to be classified as hazardous. Disposal of sludge also opens up the potential for future liability depending on the sludge’s chemical stability and methods of disposal. In contrast to alkaline treatment, electrochemical treatment produces metals in elemental and other highly-dense forms on the cathode. If metals concentrations and flow rates are sufficiently high, the metals recovered may help offset overall treatment costs. In addition, sludge production would be reduced, if not eliminated altogether, thereby reducing both disposal costs and potential future liabilities as well.

Jan 1, 2019

By Robert S. Becker

The results of a laboratory investigation of coal cutting mechanics and noise is presented. These experiments were performed using a linear cutting apparatus that operates over a broad cutting speed range. The influence of several coal cutting parameters on the noise, force, productivity, and specific energy associated with linear cuts is ascertained. Some basic theoretical aspects of coal cutting mechanics and noise generation are discussed, and the results of the laboratory experiments are used to Formulate analytical models of the coal cutting forces and noise. The analytical model For coal cutting noise is then generalized to account for the more important effects of rotary cutting. Based on the generalized model, an estimate of the sound pressure level at an operator's position is made for a typical continuous mining machine. It is concluded that by employing linear rather than rotary cuts, using deeper depths of cut, slower cutting speeds, and more efficient cutting tools, it is possible to reduce the level of coal cutting noise, as well as Provide benefits to other important areas of underground health and safety.

Jan 1, 1980

By I. B. Scorzelli

The aim of this paper is to make a detailed mineralogical characterization of a typical brazilian xenotime and zircon from the Pitinga Mine using SEMIEDS techniques, On the other hand, superficial pretreatments with HCI, HN03 and HF were done to evaluate the modifications on surface compositions and the morphology of the particles for flotation purposes, The studies showed that both xenotime and zircon present very small inclusions of thorite; zircon is strongly metamictizated given rise to malacon. The HF pretreatment deeply affected the morphology of the particles as well as the surface properties in relation to flotation.

Jan 1, 1996

By Jean-François Stumper, Mario Moser, Mark Kruessmann, Volker Langer, Daniel Bastos Martins Cruz, Claude Meisch

The latest generation of probes and casthouse machines provide a wealth of data that has not been available a few years ago. The evaluation of this data gives direct feedback to improve the blast furnace efficiency, the equipment maintenance and design and it allows the early detection of critical or deviating process situations. A stable operation with lower operation and maintenance costs are the final customer benefits.

Oct 1, 2019

By Jorge Blázquez, Pablo Ravanal, Paulo Couceiro, Juan Navarro

Blasting performance is influenced by rock mass properties and blast design parameters. From them, the rock is the only variable that cannot be modified, but it can be measured, so that, blast design variables can be adapted to optimize the results. A new methodology to assess rock mass quality from drill-monitoring data from both autonomous and manual rotary drilling modes is described to guide blasting in open pit operations. For that, a thorough normalization process has been developed to minimize external influences induced in the data by the rig system for autonomous mode and by the operator intervention for manual mode. Principal component analysis has been used to combine MWD information. Two rock description indexes are derived directly from Measurement While Drilling (MWD) data collected. The first index is a Structural factor that classifies the rock mass condition in three classes (massive, fractured and heavily fractured). The second index is a Strength factor that classifies the rock according to the strength properties. Both indexes have been combined to obtain an overall drilling rock factor along the hole. This has been named by the authors as the X-Rock model.

Feb 6, 2023

By Vahid Javaheri, David Porter, Tun Tun Nyo

A field emission scanning electron microscope equipped with EBSD has been employed to evaluate the role of 0.013 wt% Nb on the evolution of the microstructure and texture of a novel thermomechanically processed low-alloy, medium-carbon steel. Specimens were subjected to hot-rolling with a total reduction of 80%, four passes in the recrystallization regime and four passes below the non-recrystallization temperature. Immediately after rolling, the strips were quenched to 420 °C and subsequently cooled slowly in a furnace to simulate strip coiling with transformation of austenite to bainite. The results showed that Nb microalloying results in a finer microstructure with a sharper texture when compared to an identical steel but without Nb. In addition, analysis of the retained austenite texture indicated that the main bcc texture components are the product transformed brass and copper components in the parent austenite.

Mar 1, 2018

By Robert Peele

TWO outstanding members of the Institute will be honored at the Annual Meeting this month: Robert Peele, who will accept his election to the small group of Honorary Members; and Clinton Hoadley Crane, president of the St. Joseph Lead Co. and William Lawrence Saunders Medalist for 1936. Eminence in the profession character, interest in Institute activities, and general recognition as a gentleman and a friend by so many people, have contributed to the election of Professor Peele. The Saunders Medal is for "achievement in mining." In awarding it to Mr. Crane the citation reads "For distinguished achievement in the successful development and operation of low-grade lead mines."

Jan 1, 1936

By M. Kamyab

The Deep Exploration Technology project, as part of the Australian Cooperative Research Centre, is developing technologies to drill deep boreholes for mineral exploration purposes. The aim of the initiative is to transfer drilling technologies from oil and gas into mining applications. Several modifications have to be pondered due to this technology exchange: smaller cuttings sizes because of using impregnated diamond bits; narrower annulus space; higher drilling fluid velocity and likelihood of turbulent flow regime in the annulus; and higher pressure loss. In particular the results of our lab experiments have shown that the increase in concentration of small size cuttings can significantly change the rheology of the mud when drilling in hard rocks. This, in return, could have a noticeable increase in the pressure loss encountered along the annulus space. As a continuation of the above study, numerical simulations were conducted to investigate the cuttings transport behaviour in small size annulus space. Fluid velocity, annulus size, cuttings concentration, cuttings density, and cuttings size were some of the parameters that were varied to see their effects on cuttings transportation and the pressure loss along the annulus space. The results indicate that, due to the differences between oil and gas and mining drilling, conventional oil well planning is not applicable for mineral exploration drilling and numerical simulation would help in this matter.

Aug 1, 2013

By William W. Shilts

"In carrying out a geotechnical survey of a proposed gas pipeline route from the Arctic Islands south to Longlac, Ontario, the Polar Gas Consortium contracted the drilling of several hundred 2- to 2D-m-deep boreholes in drift and bedrock. Samples from these holes were made available to the Geological Survey of Canada, where they were subjected to stratigraphic and trace-element geochemical analyses. The geochemical characteristics of the clay and sand-sized heavy mineral fractions of till samples from these boreholes have been summarized in a series of geochemical profiles.From the proposed pipeline terminus at Longlac northward to the vicinity of God's River in Manitoba, tills contain significant amounts of Paleozoic carbonate rocks and Proterozoic sedimentary rocks derived from the Hudson Bay basin and lowlands. Within this section, two sites were enriched in base metals, indicating the possibility of local mineralization of possible economic interest.From God's River northward to Seal River, Manitoba, no evidence of local mineralization was noted. The heavy mineral fractions of the tills are universally enriched in Mn-rich siderite thought to originate on or in the Paleozoic section of the Hudson Bay lowlands.From Seal River northward to Thelon River, near Baker Lake, tills contain only components originating west of the Hudson Bay sedimentary basin. Near the Keewatin-Manitoba border, all till is enriched in uranium, which probably originates in the ""young"" porphyritic granites underlying much of the region, and produces a distinctive airborne radiometric anomaly.At the Thelon River, multiple till sections are variously enriched in Cr, Ni, U, Cu and Mo in the vicinity of a distinctive aeromagnetic anomaly.From Thelon River northward, several coincident zones of chromium and uranium enrichment are found where the line of boreholes crosses east-west-striking belts of volcanic, ultramafic and sedimentary rocks of the Prince Albert Group.The results of this study indicate that till tends to have characteristic element associations or concentrations over each of several broad regions along the pipeline route. These are related both to large-scale bedrock associations and to largescale effects of glacial dispersal. In addition, the samples, collected more or less at random with respect to local bedrock geology, have intersected several small-scale geochemical anomalies that appear to be related to zones of mineralization of possible economic interest."

Jan 1, 1980

By John C. Stankus, Xiaoting Li

"Underground structures such as square/arch steel sets, king beam structure, etc. are widely used for the roof support in underground mines. In designing and calculating the required carrying capacities of these underground structures, how to identify the potential rock loads on the structures over long term is a challenging question for ground control engineers. Based on design practices of both surface and underground structures, the authors have designed and applied appropriate load factors in underground structural design projects to accommodate different rock types, entry/intersection dimensions, roof geologic conditions, availability of roof bolts and water, etc. Classification of load (reduction) factors for large-span underground intersections are presented for reference. Success of designed underground structures in effectively controlling roof stability over years indicates the applicability of the load factor concept for underground structural design, and its same significance as of the load factor specifications in ASCE/SEI 7-10, ANSI/AWC NDS (2015), and AASHTO LRFD Bridge Design Specifications (2012). The load factor concept will facilitate ground control engineers to appropriately utilize popular structural design software, such as RISA-3D or -2D to efficiently design and analyze underground structures.LOAD FACTORS IN STRUCTURE DESIGN APPLICATIONSIn structures, loads cause stresses, deformations, and displacements. Assessment of their effects is carried out by the methods of structural analysis with the help of load factors. Loads can be increased or decreased by load factors to meet the requirement that design strength be higher than maximum loads. For example, in designing a staircase, a dead load factor may be 1.2 times the weight of the structure, and a live load factor may be 1.6 times the maximum expected live load based on the Load and Resistance Factor Design (LRFD) method. These two “factored loads” are combined (added) to determine the “required strength” of the staircase. Some typical load (adjustment) factors used for structural design are as follows:"

Jan 1, 2019

Shovel To further increase the efficiency in the production of their foundry sand, the American Silica Sand Co. has purchased a new and improved shovel that will be used for loading trucks at their Reynolds Pit. The [ ] new shovel will greatly facilitate winter mining operations and make possible larger winter shipments of the company's foundry sand. The Reynolds Pit is one of three sand pits in the Ottawa district owned by American Silica which produce sand that is refined for foundry use. Circle No. 1 Electric Switches The Crane Electric Co. has just announced the production of their R-1000, a new rotating limit switch designed to control the travel of any rotating device requiring interruption or establishment of electrical current after a predetermined number of revolutions. It is useful for machinery, lifts, and other power equipment. The switch is presented in a finished case, 16 gage, reinforced, with walls of sufficient strength to hold the entire mechanism and all the parts in accurate alignment. The worm gear combination has a 60 to 1 ratio, sufficient for most industrial uses. The number of revolutions can still be increased by using various combinations of driving sprockets, either on the shaft of the switch, or on the sprocket of the unit controlled by the switch itself. Circle No. 2

Jan 1, 1952

Dump Truck Kenworth Motor Truck Corp. is beginning full scale production of its new heavy-duty, end-dump earth mover, model 801, a truck engineered for earth moving under the most adverse operating conditions. Payload capacity of the Kenworth earthmover is 30,000 lb and it is over-tired for safety, flotation and high tire life. The truck's body capacity, struck measure, is 9.9 cu yd, with heaped [ ] load at 11.9 cu yd. The earth-mover has a full anti-friction bearing mounted, power assisted steering gear, simplified controls, minimum turning radius and wide axle track to insure ease of handling, maximum maneuverability and high stability. The offset cab of the Kenworth visibility for the driver, before and after. Circle No. 1 Safety Equipment A compact, safe, and efficient valve assembly approved by the United States Bureau of Mines for use with MSA air line respirators, abrasive masks, and abrasive helmets has been developed by Mine Safety Appliances Co. The new MSA continuous air flow control valve regulates air flow from a compressed air source to an operator using respiratory protective air line equipment. Three parts-a centridge container, a cartridge and the air flow check valve-comprise the entire assembly of the control valve. A position action adjustment knob on the cartridge container regulates the amount of air flowing to the operator. The valve can be detached from the air line instantly by pressing the trigger on the cartridge container near the check valve. As the trigger detaches the hose, the spring loaded ball-type valve, which is attached to the end of the hose, automatically stops the flow of air. Circle No. 2

Jan 1, 1952