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By James P. Ulery

In This Chapter [Geologic features associated with anomalous methane emissions Gas outbursts and blowers Methane drainage strategies for mitigating anomalous methane emissions and General considerations for a methane drainage program] This chapter summarizes how certain geologic features may be associated with unexpected increases in gas emissions during coal mining. These unexpected emissions have the potential to create explosive conditions in the underground workplace. Also discussed are the generally used practices to alleviate potential hazards caused by gas emissions associated with these geologic features. INTRODUCTION Unforeseen mine gas emissions in quantities sufficient to create hazardous conditions have been attributed to sources outside the mined coalbed since the first documentation of methane explosions in coal mines [Payman and Statham 1930]. Geologic features such as faults have long been recognized as conduits for gas flow from strata adjacent to mined coalbeds [Moss 1927; Payman and Statham 1930]. Other features such as sandstone paleochannels, clay veins, and localized folding have also been recognized for their impact on gas emissions into mine work-ings [Darton 1915; Price and Headlee 1943; McCulloch et al. 1975; Ulery and Molinda 1984]. The fact that strata adjacent to mined coalbeds can emit large quantities of methane gas into mine workings is not surprising from a theoretical perspective. Many researchers have recognized that during the burial and diagenesis of the organic matter forming today’s minable coalbeds, similar dispersed organic matter in adjacent strata has produced methane in quantities far exceeding the storage capacity of the coal and surrounding rock [Juntgen and Klein 1975]. It is not surprising then that large quantities of methane can remain trapped in these strata. A potential hazard occurs when mining of a nearby coalbed causes pressure differentials and mining-induced fractures conducive to gas flow into the mine workings from these strata. This gas flow may be facilitated or temporarily impeded by the presence of geologic structures or anomalies.

Jan 6, 2006

By Neil J. Mansfield, Setsuo Maeda

The purpose of using experimental subjective and/or perception methods is: (a) to understand human subjective impressions of the physical characteristics of vibration; (b) to determine the relationship between the subjective perception of some aspect of the vibration and an evaluation index of the physical vibration characteristics; and (c) the establishment of target values for design of vibration environments in terms of human sensation of vibration characteristics. In order to understand the relationship between a physical measure of the mechanical vibration and the subjectively perceived aspect of the vibration environment, experimental methods shown in Table 1 have been used1. [ ] The constant measurement methods of Table 1 are mainly used for measurement of the threshold of human sense. The subjective scaling methods are mainly used for obtaining subjective (or proportional) scaling between the perceived quantity and physical quantity. In this review, the fundamental approach of experimental methods for obtaining the target values used in the design of vibration environments, and the different findings between the subjectively perceived methods for evaluating human response to vibration characteristics and the physical quantity of the vibration environment are summarized. Fundamentals of Subjective Scaling The relationship between the experimental psychological methods for providing target values in the design of the vibration environments and the physical quantities is illustrated in Fig. 1. Vehicle mechanical vibration can be characterized using many metrics, and these can be considered the ‘input’ to the human. In order to predict subjective responses to the vibration, it is necessary to link the characteristics of the source of vibration and human reactions, the ‘output’.

Jan 6, 2006

By N. Grosland, G. Kopp, T. Hunstad, D. Wilder, M. Contratto, S. Rahmatalla, T. Xia

Chronic whole-body vibration exposure, as expected in large construction and mining vehicles, has been associated with neck and back pain and injury.1 While work has been done towards gaining a better understanding of the relationship between vibration and shock and muscle activity of the back musculature2, relatively little information regarding the activity of neck, shoulder and upper arm muscles is known. Today’s equipment designs must conform to domestic and international standards, however these standards do not specifically address the vibration exposure in the head and upper quarter. Further it is not well known how the control configuration within a vehicle (e.g. steering wheel versus arm controls) influences muscle voluntary and reflex activity levels. Greater muscle activity may lead to greater muscle fatigue – which in turn may be associated with greater risk of injury.2 Thus, muscle contractions needed to maintain static postures as well as those resulting reflexively should be considered during an analysis of seating position. Unfortunately, little is known regarding the influence of arm position on head and neck muscle function. The purpose of this study was to investigate the relative muscle activities of 5 neck, shoulder, and upper arm muscles during riding simulations of large construction equipment, using three different arm control options. Methods Five typical heavy equipment ride files were “played back” through a man-rated Servo Test 6-degree of freedom (dof) vibration system. Each ride was repeated using 3 seat and control configurations (steering wheel (SW), floor mounted arm-rest controls (FM), seat mounted arm-rest controls (SM)). Two trials were performed for each ride and seat control combination (each trial: 60 sec of 6-dof and 60 sec of vertical vibration). Five channels of surface electromyography (EMG) of the right-side cervical erector spinae muscles (neck extensors), sternocleidomastoid (neck flexor), upper trapezius (shoulder elevator), biceps brachii (elbow flexor) and triceps brachii (elbow extensor) muscles were collected throughout each ride (~ 2min) using pre-amplified (10x), 1 cm silver bar electrodes, with 1 cm fixed inter-electrode distances (Delsys, Inc). Further analog amplification was set at 10k (1k for one subject), and sampled at 1000Hz using a 12-bit DAQ card and Labview 7.1 software (National Instruments). A total of 7 right-handed male subjects were tested, but only 5 had complete EMG data sets to analyze for this sub-study. EMG was analyzed using root mean square (RMS, in mV) of 20 ms moving windows, and then averaged across the entire trial for a measure of mean total muscle activity (voluntary and reflexive). The muscle activity to maintain the static posture was estimated as the mean RMS EMG over a 1 sec interval just prior to and/or after completion of the ride. Repeated Measures ANOVAs were used to test for with-in subject differences using a = 0.05.

Jan 6, 2006

By Jérôme Boutin, Rémy Oddo, Sylvain Ouellette, Paul-Émile Boileau, Gilles LeBlanc, Pierre Marcotte

ackleg rock drills are widely used in the mining industry and are known to generate high levels of hand-arm vibration which contribute to the development of the hand-arm vibration syndrome for exposed miners.1-3 To reduce the vibration levels, a prototype of an antivibration handle was developed as part of a previous study.4 To provide some bench marking for this handle prototype and to follow the evolution of its performance over time, a test bench was developed to characterize the vibration emission values of jackleg drills under controlled operating conditions. As the current ISO 8662 series of standards could not apply directly to this type of tool, there was a need to design and validate a test bench to evaluate the vibration emission values of jackleg drills, while taking into account the conditions specific to the operation of this type of tool. Methods A test bench including an energy absorber, was developed for testing jackleg drills based on the ISO 8662-3 standard 5. The energy absorber was bolted to a 3300 kg concrete block to ensure tool stability. A pictorial view of the device is given in Figure 1. For validation purposes, acceleration measurements at the handle of a conventional jackleg drill were taken simultaneously along the three axes (xh, yh and zh) in an underground rock drilling operation as well as on the test bench. The handle accelerations were measured for three different jackleg angles (13º, 28º and 43º) determined with respect to the floor. Moreover, each measurement was repeated at least three times to asses the data repeatability. [ ] Results As a preliminary validation of the test bench, Figure 2 provides a comparison of the frequency weighted rms acceleration spectrum measured along the zh-axis, for both underground drilling and operation on the test bench (28º jackleg angle in both cases). It is shown that the vibration measured on the handle of a jackleg drill operating on the test bench is representative of that recorded during typical rock drilling operations, despite the fact that some harmonics of the percussion frequencies are generated with a higher amplitude on the test bench. Table 1 provides

Jan 6, 2006

By Ren G. Dong, Dan E. Welcome

Instrumented handles or dynamometers are widely used to measure hand forces and/or the biodynamic response of hand-arm system. To study hand-transmitted vibration exposure, six generations of instrument handles were constructed or initially developed by researchers in ECTB/HELD/NIOSH. This presentation provided a summary of these handles. Their basic characteristics, limitations, and usefulness are described, which may help their appropriate applications and further improvements. Six Designs of Instrumented Handles Handle 1: The conceptual design is recommended in ISO 10819 (1996)1 for glove test. The grip force is measured by detecting bending strains on a measuring beam in the handle. A special handle fixture was designed to connect the handle to a shaker. Except the screws, the handle and fixture were made from aluminum. Handle 2: The design is based on the principle of shear strain measurement.2-3 Both grip and push forces can be measured simultaneously using this handle. This handle was directly designed for a simulated vibrating tool. Handle 3: This design is basically composed of a handle base, a measuring cap, and two charge-based sensors (Kistler 9212) sandwiched between the base and cap. The handle was also made from aluminum. The fixture for Handle 1 was also used with this handle. This generation of handle has three different handle diameters (30, 40, and 50mm).4 Handle 4: This design is an improvement from Handle 3. The handle fixture was totally redesigned and it was much stiffer than the previous one. The aluminum measuring cap was replaced with a magnesium cap. Handle 5: The basic structure of this handle is the same as that for Handle 3. However, the piezoelectric sensors were replaced with two strain gage based sensors (Interface SML-50). Handle 6: This handle includes two measuring caps, four piezoelectric sensors, and a handle centre base. The handle fixture was the same as that with Handle 4. Methods for Handle Examinations The static and dynamic characterizations were performed using the methods reported by Dong et al.5-6 Results and Discussion Handle 1: The static force measurement depended on the hand grip location on the handle. Its natural frequency was less than 200 Hz.5,6 Because the transmissibility of gloves may not vary significantly with the applied grip force, this handle may be acceptable for glove test. However, the force measurements with this handle may not be reliable. Handle 2: The static force measured with this handle was insensitive to the hand acting location. However, when the handle was vibrating, the force signals could be totally distorted. For this reason, it was not used for vibration studies.

Jan 6, 2006

By R. Demont, A. Pranesh, S. Rakheja

Ethical concerns of in-vivo procedures and poor repeatability of non-invasive techniques have been major limitations in estimating vibration-induced spine loads through experiments. The biodynamic models of seated human body exposed to whole-body vibration (WBV) have evolved for defining the frequency-weightings, enhancement of human responses to WBV, and developing anthropodynamic manikins for seating assessment activities. The widely reported mechanical-equivalent models, solely based on through- or to-the-body biodynamic response functions, do not seem to resemble the biomechanical structure and do not yield information on the dynamic loading and deflections of segments of concern, namely the spine. On the other hand, biomechanical models with representative anatomical structure and anthropometry are being attempted to simulate segmental movements and the coupling effects, using Finite elements (FE) or multi-body dynamics (MBD) formalisms, which could provide important insights into the inter-vertebral forces [1]. While the FE models pose considerable complexities primarily related to characteristics of the bio-material properties, the MBD technique with discrete rigid bodies offers the flexibility to create multi-segment models with relative ease and lower computational cost. In this study, a preliminary multibody dynamic model of a seated human body exposed to WBV along the vertical direction is formulated using MSC/ADAMS software. The model validity is demonstrated by comparing selected responses with the available measured data. Methods The seated human is represented by nine rigid body segments, including: head, neck, thoracic and lumbar torso, pelvis, hands and thighs, as shown in Fig. 1. The rigid bodies are coupled through different rotational and translational joints, some of which are force elements to allow vertical translations and sagittal–plane rotations of the segments. The measurements of transmission of vertical vibration through-the-body generally require subjects to voluntarily maintain a vertical head position to reduce head-accelerometer orientation errors. The head–neck–shoulder joint is thus considered to be rigid. The shoulders are assumed to be rigidly attached to the thoracic segment. The torso is made up of three (upper, middle and lower) segments connected by visco-elastic revolute and translational joints to permit relative pitch and vertical motions. The forces and torques generated by the joints are derived assuming linear stiffness and damping properties, which were identified from published studies. The pelvis is connected to the rigid seat by similar elements representing the visco-elastic properties of the buttock tissues. The two thighs are rigidly connected to the pelvis, while the segment masses are chosen from the anthropometric data for the 50th percentile male subject. The initial model parameters for the joints were obtained from [2]. The model was analyzed to determine the force-motion relationship at the buttock-seat interface expressed in terms of

Jan 6, 2006

By H. Nelisse, S. K. Patra, A. Natani, S. Rakheja

The current laboratory methods for assessing the vibration attenuation performance of seats involve repetitive trials with a number of human occupants, and raise certain ethical concerns. Moreover, the measurements with human subjects yield considerable variability in the data. Alternatively, several anthropodynamic manikins have been developed for effective assessments of the coupled seat occupant system [1]. The effectiveness of a manikin in predicting the response of a coupled seat-occupant system lies in its ability to reproduce the biodynamic response of the seated human body in terms of force-motion relationship at the body-seat interface, such as apparent mass (APMS). A number of prototype manikins have thus been developed on the basis of biodynamic characteristics of vertical vibration-exposed seated occupants of different body masses in the vicinity of 5th, 50th and 95th percentile male population. This study concerns with the analysis of a passive prototype manikin to enhance its ability to reproduce the idealized APMS response characteristics of the vibration-exposed seated human subjects defined in ISO-5982[2] for mean body masses of 55, 75 and 98 kg. Methods The APMS responses of a prototype anthropodynamic passive manikin were thoroughly characterized in the laboratory under different excitations and body mass configurations. The manikin was designed with sufficient flexibility to configure mechanical-equivalent models corresponding to seated body masses of 55, 75 and 98 kg, by adding/removing specified masses and springs (Fig. 1). The manikin, configured for a specific body mass, was positioned on a rigid seat without a backrest, which was fixed to the force platform of a whole-body vertical vibration simulator. The simulator was programmed to synthesize random vertical vibration with flat acceleration power spectrum in the 0.4-20 Hz frequency range with two different magnitudes: 1 and 2 m/s2 overall rms acceleration. The total static and dynamic forces of the manikin to and the seat were measured using the force platform, while a single axis accelerometer was installed on the seat pan to measure acceleration due to vertical excitation. The measured data was appropriately corrected for the rigid seat inertia force, and the apparent mass [ ]

Jan 6, 2006

By Fred N. Kissell

In This Chapter [Ventilation and methane sampling guidelines for conventional shafts Dealing with restricted spaces where methane can accumulate Ventilation and methane sampling at raise bore drills and Filling shafts at closed coal mines] It is not unusual to encounter methane gas during shaft excavation or shaft-filling operations. Shafts into coalbeds usually produce the most methane, so the information in this chapter applies primarily to shafts at coal mines. Nevertheless, much of the information is relevant for noncoal mines that have methane in the mine or in the overlying strata. METHANE IN SHAFTS EXCAVATED BY CONVENTIONAL MEANS (DRILL, BLAST, MUCK) [ ] Ventilation. Shafts excavated by conventional means are ventilated with a fan on the surface connected to ductwork that extends down into the shaft (Figure 9–1). Shafts into coalbeds should have ventilation systems designed to handle the higher gas flows to be expected as the shaft excavation passes through any over-lying gas-containing strata and nears the coal-bed to be mined. Following are some simple ventilation guidelines for the minimum amount of air required and the selection of the ventilation duct: • Provide enough air to meet the mini-mum OSHA tunnel requirement of 30 ft/min air velocity in the open shaft, as specified in 29 CFR2 1926.800(k)(3). For example, a 20-ft-diam shaft having

Jan 6, 2006

By Douglas Ketcham, Thomas Jetzer

While the neurological and vascular aspects of Hand-Arm Vibration Syndrome (HAVS) has been generally accepted as a medical condition, the medical criteria and the clinical findings used to establish the diagnosis has been more difficult to bring to consensus. The criteria was first quantified by the Taylor-Palmear scale.1 This criteria was subsequently modified in 1986 at the 1st Stockholm Workshop2,3 to included more acceptance for the neurological effects that characterized the predominate findings in some workers. The relationship between hand-arm vibration and Carpal Tunnel Syndrome was defined in NIOSH 97-1414. While the aforementioned documents have defined the clinical entities associated with hand-arm vibration exposure, agreement on the clinical findings and test to confirm the diagnosis has be been more difficult to bring to consensus. Clinicians assessing HAVS has relied on a number of varied neurological and vascular tests. The neurological testing has focused on assessing damage to the sensory capability of the fingers for the neurological component including tests to measuring ability to sense vibration, cold or other end point finger sensor functions. However, the vascular testing has been traditionally focused on the ability to either measure vascular function or to reproduce the vascular blanching that occurs in HAVS with cold water provocation. Recent assessment of this testing in the United Kingdom Coal Miner’s study has questioned the value of this testing especially in reviews by McGeoch.5 In an attempt to provide some type of definitive testing to substantiate vascular damage from hand-arm vibration exposure, angiography is an alternative or adjunct to cold water provocation testing. The standards that have been established to predict the level, type and incidence of HAVS have been based on clinical studies and reports that have essentially been all male populations. However, the recent entry of women into more vibration intensive jobs has brought about the exposure of some women to high levels of vibration previously only previously experienced by men. However, there have been only few studies that look at HAVS in women6. Although exposed the same vibration levels, it has not been clear that the latency and type of pathology of HAVS in women will be the same as for men. The purpose of this study is to look at recent case studies of men and women exposed to jobs with high levels of hand-arm vibration with extensive clinical testing for both the neurological and vascular components of HAVS as well as other associated upper extremity conditions such as Carpal Tunnel Syndrome.

Jan 6, 2006

By James D. Noll, Jon A. Hummer, Shawn E. Vanderslice, Aleksandar D. Bugarski, George H. Jr. Schnakenberg, Steven E. Mischler, Larry D. Patts

The National Institute for Occupational Safety and Health designed and conducted a study in an underground metal mine to assess the effects of selected diesel emissions control technologies on the concentrations of diesel particulate matter and gases in underground mine air. The control technologies studied included diesel particulate filter (DPF) systems, filtration system with disposable filter elements, diesel oxidation catalytic converter, and biodiesel blends. Each technology was tested on a mining vehicle operated in an isolated area of an underground mine supplied with fresh air. These isolated zone tests allowed for the operation of vehicles under conditions and over duty cycles that closely mimic actual duty cycles of production equipment. The DPF systems reduced the elemental carbon (EC) concentrations in mine air between 88% and 99%. The same systems reduced total particulate matter (TPM) concentrations in mine air by approximately 75%. The biodiesel blends B20 and B50 caused a reduction in the EC concentrations of 26% and 48%, respectively. Those blends also reduced TPM concentrations by 9% and 24%, respectively. The use of #1 diesel fuel reduced EC concentration by 13% compared to #2 diesel fuel. An increase in nitrogen dioxide concentration of up to two times was seen when platinum-catalyzed DPF systems were tested.

Jan 5, 2006

By Edward L. McHugh, Charles Sabine, Jami Dwyer, David G. Long

Slope failure accidents were responsible for about 12% of U.S. surface mine fatalities between 1995 and 2003. Small surface movements on a mine highwall may be precursors of failure that, if detected, could provide sufficient warning to enable workers and machinery to be withdrawn to safety. Radar interferometry offers the necessary precision to detect these movements. Radar has some advantages over other methods in its ability to cover large surface areas for true two-dimensional monitoring day and night under almost any weather condition. Radar’s active transmit/receive mode of operation provides for more direct sampling than do passive optical methods that depend on solar illumination. Improvements in microprocessor speeds and capacities have led to the development of a number of small, portable, ground-based systems; such systems are now being deployed at several locations around the world. As part of an ongoing study of monitoring technologies, researchers from the National Institute for Occupational Safety and Health and Brigham Young University, Provo, UT, cooperated to assess the feasibility of using interferometric radar to monitor mine slope stability. Field tests of a device incorporating prototype equipment were successful in that small, centimeter-scale displacements on rock slopes were detected.

Jan 4, 2006

By D. R. Tesarik, F. M. Jones, J. B. Seymour, L. A. Martin, T. J. Williams

Determining backfill stress is an important part of evaluating mine safety, whether personnel are working in proximity to backfill or in other areas of the mine where backfill is an integral part of regional support. To assist in determining stress in backfill more accurately, researchers from the Spokane Research Laboratory of the National Institute for Occupational Safety and Health, Placer Dome, Inc. (Turquoise Ridge Mine), Peabody Energy Co. (Foidel Creek Mine), and Hecla Mining Co. (Lucky Friday Mine) used temperature readings recorded by thermistors to correct for the influence of temperature on stress data. These thermistors were positioned in the stems of earth pressure cells installed in backfill. Corrections were then calculated and compared using four different methods: polynomial equations fit to temperature-versus-stress plots before the pressure cells were loaded by overburden, a factor provided by the manufacturer, a theoretically derived factor, and a linear correction factor based on information collected during periods when no mining was taking place. To evaluate the accuracy of these methods, corrected stresses were calculated using each method and results compared to cumulative stresses caused by blasting at one of the mines. Results indicated that only a small percentage of the temperature effect on stress was corrected using the factor from the manufacturer because that factor accounted for only the pressure transducer and not the entire instrument body. Stresses adjusted with a linear correction factor based on information collected during periods when no mining was taking place were the most accurate. Stresses recorded at two other mines were corrected using the theoretical method and the polynomial equations method; the two methods produced similar results. For some time intervals, the results were identical.

Jan 4, 2006

The NIOSH suite of coal mine ground control software addresses nearly every aspect of coal mine ground control planning, including geologic characterization, mine layout, pillar design, and support selection. Mine planners who use the soft-ware have access to the knowledge gained during years of NIOSH research—packaged in a simple, easy-to-use format. Several of these software packages have recently been updated and improved. Analysis of Roof Bolt Systems (ARBS) (Figure 1) helps select the proper roof bolt system design from the immense variety of available bolt types and patterns. It was developed from statistical analysis of extensive bolt performance and roof fall data. New features in Version 2 include— • The capability to analyze roof bolt systems that use two types of bolts; and • A roof support cost module that estimates the total in-stalled cost of different patterns, considering the costs of consumables, labor, maintenance, and other factors. The Support Technology Optimization Program (STOP) (Figure 2) can be used to make judgments regarding which secondary support system will be the most effective in a particular mine condition and to evaluate the advantages or dis-advantages of alternative support systems. Version 3.0 includes additional improvements: • Supports with large load-shedding following yielding can be designed based on the peak loading capability as well as the residual loading capability; • Seven new support systems have been added to the program; and • Easier access to photo gallery has been provided. The Coal Mine Roof Rating (CMRR) replaces com-plicated geologic information with a simple numerical rating that mine planners can use in many ground control applications. The CMRR can be readily integrated into a geologic exploration program, and the software package is capable of generating an AutoCAD CMRR "layer." Version 1.2 contains— • The complete CMRR database with more than 250 ratings obtained from 70 different U.S. coal seams; and • An all-new "Help" file that clearly explains all aspects of the program. Analysis of Horizontal Stress in Mining (AHSM) can help find the optimum mine layouts for control of horizontal stress. It can be used to analyze both development and longwall retreat designs, and it shows how the stress condition varies as the entry, crosscut, and panel orientations are changed. Version 2 features— • Improved graphics that enable the user to observe the effect of design changes without adjusting the display on the computer screen; and • Resource files containing information on stress map-ping, advance-and-relieve mining, stress measurements in U.S. coal mines, and other topics. [ ]

Jan 4, 2006

By Elaine Cullen, Launa Mallett, Mike Jenkins, C. M. K. Boldt, Thomas Camm

The material in this Information Circular was presented at the National Institute for Occupational Safety and Health’s (NIOSH) open-industry briefing held during the 2004 Northwest Mining Association conference in Spokane, WA. The open-industry briefing discussed results of recently completed and on-going mine safety- and health-related research conducted at NIOSH’s Spokane and Pittsburgh Research Laboratories on the human side of mining—the miner. The first paper sets the stage for what mining has achieved and what we mean by “getting to zero.” The second paper, “Help Experienced Miners Become Great On-the-Job Trainers,” distinguishes between experienced miners and trainers. This paper provides some key concepts for turning great miners into great trainers. “The Power of Story-Telling in Getting Through to Miners” explains the history and importance of stories in the culture and training of miners. Finally, “Understanding Self in Stressful Working Environments,” describes the personal and social aspects of the working environment, much of which parallels familial theories. The downward trend of deaths in U.S. mining has been remarkable. The number of miners killed or injured each year has decreased steadily over the past 100 years. Some charts show these trends overlain with important events such as World War II and the Mine Safety and Health Act. However, this downward trend in mining fatalities has flattened out. How can you get to zero accidents? Do you concentrate on technological advances and equipment maintenance to avoid malfunctions? Do you concentrate on developing work processes and organizational structures that minimize risk? Do you combine them and take a systems approach that links one to the other with an evaluative loop? Safety efforts in mining have used all of these approaches. What more can we do to get to zero? Getting to zero will require two objectives: A clear and unshakeable belief that it can be done and attention to the human side of mining. Getting to zero is not a new idea; it has been used by mine companies and safety professionals for years as the safety goal. But getting to zero is not so much a physical goal as it is a belief that there are no insurmountable barriers to achieving the goal.

Jan 3, 2006

To provide operators of large-opening mines with a ventilation planning tool that will help them develop a healthier, safer, and more efficient ventilation system in the underground workplace.

Jan 3, 2006

By J. Kempken, T. A. Schreiter, R. Degel, H. Schmieden

Keywords: Pyrometallurgy, SMS Demag, Germany, submerged arc furnace, ferro alloys, non-ferrous, FeCr, FeNi, FeMn, copper, cobalt, slag cleaning, PGM, rectangular furnace After a short summary of the SMS Metallurgy part of the SMS group, the paper will focus on Submerged Arc furnace technology. After general aspects of furnace design, the focus will shift to different applications and their specific furnace requirements. Finally, a state-of-the-art design tool as well as a new invention to improve slag-cleaning technology will be featured.

Jan 1, 2006

The Thermo-MIE personal DataRAM dust monitor (pDR) is a light-scattering instrument approved for use in gassy underground mines by the U.S. Mine Safety and Health Administration (MSHA). However, the use of light-scattering monitors has been inhibited by concerns about inaccurate readings resulting from changes in dust size distribution and composition, as well as concerns about the impact of moisture in the mine air. Because of this concern, the National Institute for Occupational Safety and Health (NIOSH) evaluated the pDR using available data from laboratory tests and mine surveys. The data show that accuracy can vary widely from test to test and mine to mine. In most cases, the results can be improved by using a companion gravimetric measurement to adjust the pDR data.

Jan 1, 2006

By E. Nejati, S. Khoshkooei, V. Firouzdor, M. Akbari, F. Khomamizadeh

In this study the effects of Si content on mechanical and thermal fatigue properties of Al-Si casting alloys were investigated. Repeated heating and cooling cycles were applied on the samples at 230°C to develop thermal fatigue cracks. Crack growth mechanisms and microstructural influences were investigated by optical and scanning electron microscopy. Thermal fatigue behaviors were improved successively by increasing of silicon content up to 7wt%. However, addition of more than 9wt% silicon decreased the thermal shock resistance of the alloy. Silicon contents of about 9wt% presented the best mechanical and thermal fatigue resistance in the alloy.

Jan 1, 2006

By J. A. Jr. Carpenter

Expanding world economic prosperity, probable peaking of conventional petroleum production in the coming decades and environmental concerns require efforts to increase the efficiency of, and the development of alternatives to, petroleum-based fuels used in automotive transportation. In January 2002, the U.S. Department of Energy (USDOE) and the U.S. Council for Automotive Research (USCAR) of the "Big Three" traditionally-USA-based automakers, DaimlerChrysler, Ford and General Motors, formed the Freedom Cooperative Automotive Research (FreedomCAR) Partnership to fund high-risk, high-payoff research into advanced automotive technologies with the potential for eventually lowering the USA's nearly complete (95%) dependence on petroleum, 55% imported, for its transportation fuels. FreedomCAR replaced the Partnership for a New Generation of Vehicles (PNGV) which existed from 1993 to 2001. In January 2003, the energy-supply industry joined with the FreedomCAR Partnership forming the FreedomCAR and Fuel Initiative (FC&FI) to develop the technologies needed for the mass production of fuel-cell vehicles using hydrogen as fuel and the infrastructure needed to deliver the hydrogen to the consumer. The goal is to enable the automotive and energy-supply industries to make commercialization decisions in 2015 on large-scale introduction of such vehicles and on developing the infrastructure beginning in 2020. In addition to work on fuel cells and hydrogen infrastructure, the FC&FI conducts research on technologies with the potential for nearer-term energy efficiency and environmental benefits, such as new engine concepts, lightweight materials, and engine-electric hybrid propulsion systems. Lightweighting is seen as crucial for shorter and for longer term benefits because hybrid and fuel-cell powertrains are expected, at least in the early stages of adoption, to be heavier and more costly per unit of power than the standard internal-combustion, gasoline- or diesel-fueled powertrains they replace. Research and development (R&D) on casting of aluminum automotive components were major parts of the PNGV and R&D on casting of magnesium automotive components have been and are so under FreedomCAR. This presentation will review those efforts.

Jan 1, 2006

By M. Kolahdoozan, H. Noori

"Molybdenite flotation at the Sarcheshmeh Copper Complex has been studied as a function of pulp potential controlled using two types of sodium sulfide (mineral and chemical origin). Air and either plant or laboratory nitrogen was used as a flotation carrier. Potential measurements were taken in the rougher cells as it was proved to be vital for molybdenite flotation. Flotation test with reducing potentials between -525 and -575 mv gave the highest molybdenum recovery (93%) and the lowest copper recovery of between 4 to 15% can be achieved. These potentials did not change considerably by adding increasing amounts of sodium sulfide. At more oxidizing potentials, i.e. more than -450 mv, the recovery of copper increases while the recovery of Molybdenite drops.INTRODUCTIONThe average copper ore feed grade to the Sarcheshmeh flotation circuit is typically set at about 1.2% Cu. to be delivered to processing unit is set at 1.2%. There is no control of molybdenum (Mo) which usually varies between 0.01 and 0.04%. During concentration, a Cu-Mo concentrate is produced by one stage of roughing, one stage of scavenging and two stages of cleaning. Final concentrate contains 0.5% of Mo and 32% of Cu while the particle size is 90% under 42 microns (325 mesh). Because of the high grade of Mo in this concentrate and economic interests, a molybdenite flotation circuit plant was built in 1984. This plant was designed to treat 1432 tons of Cu-Mo concentrate (on dry basis) and consists of one stage of roughing followed by seven stages of cleaning. After dewatering the concentrate contains 53.7% Mo which is dried and shipped overseas.The majority of molybdenite production worldwide comes as byproduct of copper porphyry ores. The Mo grade typically varies between 0.01 and 0.06% and accompanies chalcopyrite and chalcocite. Due to the hydrophobic nature of molybdenite, it can be floated along with copper sulfides. Thus the overall concentrate of Cu and Mo contains 0.2-1% of molybdenum as well as 20-42% of copper. To separate the Mo, Cu and Fe minerals, depressants are used. The most important of which are sodium sulfide, sodium hydrosulfide, Anomal D, sodium cyanide, ferropottasium and ferro-cyanide. The first three regeants have been extensively used for successfully treating porphyry ores [1]. In the molybdenum plant of the Sarcheshmeh Copper Complex only sodium sulfide has been used to date."

Jan 1, 2006