Abstract:
The primary aim of this project is to establish whether it is feasible to determine and to model accurately surface deformations caused by former mining activity in space (3D) and time (4D) domains. Source cartographic materials will be identified and analyzed, followed by modeling geological, mining and environmental conditions responsible for the process of mining deformation in complex and complex rock mass conditions. Deformation models using spatial and deterministic statistics will be developed. They will be based on the results of spatial deformation mapping using satellite radar interferometry and GNSS satellite positioning, as well as UAV photogrammetry (unmanned aerial vehicle), geophysical exploration and precise leveling.
The aim of the work is to examine which conditions are important for the occurrence and development of deformations, what is the measure of this meaning and whether deformations can be accurately predicted using a deterministic and spatial modeling approach. As a result, the deformation process associated with the extraction of shallow brown coal deposits in a complex glacitectonic environment will be described and modeled.
The geomorphological landscape of the Mużakow Arc research area is characterized by numerous and diverse forms of anthropogenic origin, associated with underground and open-pit lignite mining, which ended in the 1970s. The complex and complicated geometry of these coal deposits is the result of glacitectonic processes associated with subsequent stages of accumulation and weathering. The entire area is subjected to geodynamic processes related to weathering of exposed areas, destruction of shallow underground excavations and changing hydrogeological conditions of the rock mass. Secondary process deformations and their effect on the surface are currently unknown.

As part of the project, KGHM Cuprum will cover the following tasks:

1. Analysis, verification and processing of source data,
2. Development of a comprehensive spatial database,
3. Geodetic, geophysical, geological and hydrogeological field surveys
4. Development of Finite Element Method based deformation models,
5. Description of the deformation process and development of an universal methodology for modeling secondary deformations.

The final result of the project will be an universal methodology for studying and modelling secondary mining deformations applicable to areas with complex and complicated mining and geological and tectonic conditions, as well as a knowledge database describing the process of deformations in the glaciotectonic environment of the Muzakow Arch area and mining of shallow brown coal deposits.

Name of Beneficiary:  
KGHM CUPRUM sp. z o.o. Research and Development Centre
Wrocław University of Science and Technology

Duration:
2020-2022

Project value:
Total project value: 1,346,428.00 PLN
Including budget of KGHM CUPRUM: 731,808.00 PLN

The project aim is to develop the integrated system for processing natural stones, being the environmentally friendly production line based on the ​​sustainable development idea. The assumption of the project is to develop modern and innovative technologies in the field of measurement, design and presentation of a product, the production process, and then the processing of post-production waste. The natural raw materials processed in the production system will be natural stones, including granite, gneiss, marble, sandstone, onyx, travertine. The end products will be: stairs, window sills, kitchen and bathroom counters, and other stone products.

The main project results:

• construction of the innovative production system, the operation of which may be entrusted to disabled people,
• implementation of devices ensuring sustainable development,
• innovative technology for testing the technical condition of machines.

The saving of natural resources will be realized through the technological water recovery from rainfall and closing it in a closed cycle. Electricity production technologies that can significantly reduce its consumption will be tested. The production of waste will be minimized thanks to the use of an appropriately designed processing process – minimizing material losses through initial measurements (innovative in the industry), product design, line software (nesting) and the use of unused material parts by processing into aggregate (crushing).

Name of Beneficiary:  
KGHM CUPRUM sp. z o.o. Centrum Badawczo – Rozwojowe
Kamienna Grzegorz Kurpiński

Duration:
2021-05-01– 2023-08-31

Project value:
Total project value: 3 431 494,50 PLN
Including budget of KGHM CUPRUM: 1 076 630.00 PLN

The aim of the project is the development of system based on low-cost GNSS and IMU sensors for precise monitoring of deformations and dynamic impacts. System will consist of measuring devices, teletechnical and IT solutions. The developed product will provide a wide measurement range, allowing for monitoring of land surface changes in the scope of slowly changing deformations and dynamic displacements. Flexibility of the proposed solution also enables monitoring of the engineering structures. This approach is a novelty on the Polish market. The project involves conducting research and development works to create a multi-sensor measurement station and software for processing observations and system management. As part of the work, a research network consisting of multi-sensor measurement stations developed in the project will be built. Measurement campaigns will be carried out to collect data to validate the developed system, to determine its final technical parameters and to test applied solutions. The obtained measurement results will allow to determine the deformation indicators important from the point of view of the infrastructure safety (roads, pipelines, elements of the mine technological line, railroad tracks) on the ground surface and the parameters of dynamic impacts. Significantly reduced cost of the monitoring station will enable the density of their distribution to be optimally adapted to the nature of the studied phenomenon. The results of the work will be introduced into the business activity of one of the consortium members, by starting production on the basis of the project results, and then selling the complete system.

Leader/Coordinator:
Geotronics Dystrybucja Sp. z o.o.

Name of Beneficiary:
KGHM CUPRUM sp. z o.o. – Research and Development Centre
Uniwersytet Warmińsko Mazurski w Olsztynie

Duration:
01.12.2021 – 31.12.2023

Project value:
Total project value: 9 253 846,30 PLN
Including budget of KGHM CUPRUM: 2 479 125.00 PLN

The aim of the project is related to developing an innovative technology for pre-concentration of a selected raw material using a sorting machine which is extended with a hybrid analysis system and using artificial intelligence algorithms, as well as implementing this technology in industrial applications.

The project will be implemented in ten stages:

1. Study on the possibility of sorting raw materials and determining technological requirements for the feed and sorting process products in terms of enrichment technology.
2. Study on the potential of the sample variations and prediction of the sorting limit indicators as well as determination of the possibility of the effective implementation of the sorting processes under the constrains of existing technological flowsheets.
3. Analytical study on determining the key characteristics of selected raw materials to carry out the multi-parameter characteristics of samples variations, using the X-ray (Selective and Multi Energy) and optical (ultraviolet – UV, visible light, near and short infrared – NIR and SWIR) analysis.
4. Construction of the basic neural network for automatic classification of the sorted particles, using the multi-parameter data identification.
5. Modeling of the neural networks for automatic classification of the sorted particles, using the multi-parameter data identification.
6. Studies on the possibility of using the artificial intelligence algorithms in the sorting systems in the laboratory scale, being close to the real industrial conditions.
7. Developing the enrichment technology for non-ferrous metal ores using the sorting process.
8. Studies on sorting under the simulated operational conditions in the full industrial capacity.
9. Demonstration of the prototype enrichment technology for the selected minerals using the sorting process.
10. Analysis of the possibility of implementing the innovative sorting system at the enrichment plants processing copper ores as well as zinc and lead ores.

Name of Beneficiary:  
KGHM CUPRUM sp. z o.o. Centrum Badawczo – Rozwojowe
Comex Polska Sp. z o.o.|
Sieć Badawcza Łukasiewicz – Instytut Metali Nieżelaznych

Duration:
2021-02-01– 2023-10-31

Project value:
Total project value: 10 974 447,85 PLN
Including budget of KGHM CUPRUM: 1 528 964.60 PLN

Abstract:
The project includes industrial research and development aimed at developing and constructing a system that enables coating thin copper wires with graphene layer. The system solves two important issues for the electronics industry: coating of copper wires with a homogeneous graphene monolayer with a thickness of up to 1 mm drawn from a commercial spool as well as graphene coating of copper interconnects on chips for electronic applications. In the initial stage of the project, two systems, for high and low temperature graphene synthesis will be built. Then the quality of the graphene coatings will be verified the adaptations made to meet the requirements of the market. The result of the project will be two copper graphene coating systems for which the following parameters will be verified and optimized: coating quality, coating speed and efficiency, electrical conductivity and durability of coating layers for industrial use. The identified target group for the product are companies that produce copper wires/electronic components using copper wires or traders who plan to optimize the processes that use gold. The project fits in with the latest trends in the electronics industry, where miniaturization of systems is needed while reducing the cost of manufacturing.

Name of Beneficiary:  
KGHM CUPRUM sp. z o.o. Centrum Badawczo – Rozwojowe
Sieć Badawcza Łukasiewicz – PORT Polski Ośrodek Rozwoju Technologii
ADVANCED GRAPHENE PRODUCTS sp. z o.o.

Duration:
2019-08-01– 2022-07-31

Project value:
Total project value: 4 023 577,48 PLN
Including budget of KGHM CUPRUM: 1 500 174.00 PLN

Abstract:
The aim of the research work is to develop an integrated measurement system consisting of geodetic platforms and seismic apparatus, enabling visualization of the influence of high-energy seismic tremors on the surface of the mining area. The proposed solution will enable automation of detection and determination of effects of paraseismic events. Due to seismic measurements it will be possible to determine the level of vibrations and to determine the range of their impacts. Development of satellite surveying measurements (PSInSAR interferometry and GNSS satellite techniques) will allow to determine the deformations of the area occurring after the recorded phenomenon. The software developed as a result of the project will enable to collect the obtained measurements, their automated joint study and analysis, as well as to determine appropriate indicators of the effects of paraseismic events. The system of visualization of the obtained results will be implemented in the GIS environment, which will allow to present the user with complete information on the effects of mining activities on the surface. The result of the project will be a ready-to-implement product, i.e. an automated measurement system enabling the visualization of impacts generated by a high-energy seismic tremor on the surface. The system is dedicated to mining areas, where seismic activity occurs and the end user may be both mining entrepreneurs and local governments.

Name of Beneficiary:  
KGHM CUPRUM sp. z o.o. Research and Development Centre
Uniwersytet Warmińsko Mazurski w Olsztynie
Geotronics Dystrybucja Spółka z ograniczoną odpowiedzialnością

Duration:
01.09.2018-31.08.2021

Project value:
Total project value: 8,535,847.59 PLN
Including budget of KGHM CUPRUM: 2,699,101.50 PLN

Abstract:
The objective of the project is to elaborate comprehensive technologies and installations for processing and economically effective management of fine-grained carbonate fractions from the flotation tailings stream, originating from the current production of the Ore Enrichment Plant of KGHM Polska Miedź S.A.
It was assumed to develop a system of technologies including the separation of fine-grained carbonate fractions and shale from flotation tailings, preparation of tailings material and production of innovative and pro-ecological materials for the construction industry, including hydraulic binder, building mixes and proppant materials for mining.

Name of Beneficiary:
KGHM CUPRUM sp. z o.o. Research and Development Centre
Institute of Ceramics and Building Materials
KGHM METRACO S.A.

Project Value:
PLN 3,997,675.00

Co-financing value:
PLN 3,421,812.00

Duration: 
09.2019–06.2024

Abstract:
The project assumes the development of an innovative integrated radio communication system providing communication, data transmission and warning signals in chamber-pillar excavations on the operational front. The purpose of the proposed solution is to build a radio communication system, functioning in these areas of the mine where the use of solutions based on wired connectivity is not possible. The new system shall provide radio coverage in longwalls of the mining front, using autonomous (battery-powered) transceivers operating at frequencies in the bands: 868 MHz (ISM) and 2,4 GHz (Wi-Fi). Modification of wireless infrastructure (battery powered radio nodes) will not require additional activities except for their development and movement with the progress of longwalls. In this solution, the transceivers will be equipped with interfaces providing communication with other systems working in the copper ore mines.

Name of Beneficiary:  
KGHM CUPRUM sp. z o.o. Centrum Badawczo – Rozwojowe
Politechnika Śląska
Sieć Badawcza ŁUKASIEWICZ-Instytut Technik Innowacyjnych EMAG
SEVITEL Spółka z o.o.

Project Value:
PLN 6,029,260.00
Co-financing value:
PLN 4,942,072.50
Including budget of KGHM CUPRUM:
PLN 900,000.00

Duration: 
2017.06.01 – 2020.05.31

Abstract:
Based on a parametric analyses and computer mimicking of drill and blasting, a higher effectiveness of this process in LGOM mines conditions is expected to obtain. Each phase of the blasting process will be characterized by its own specific parameters and afterwards a multi-dimensional space with given limit conditions will be created and later systematically searched to identify those solutions which meet the highest level technical and economic requirements. Different computer techniques will be engaged for modeling of faces’ firing conducted in a variety of geological and technical conditions (dynamics) as well as the geomechanical conditions in the broad vicinity of the selected test sites (statics). Series of underground tests verifying the best solutions will permit generalizing the obtained results in the form of an IT tool enabling to select the firing pattern which has revealed to be the most suitable for using in the given geological/mining conditions.

Name of Beneficiary:  
KGHM CUPRUM sp. z o.o. Centrum Badawczo – Rozwojowe
Wojskowa Akademia Techniczna im. Jarosława Dąbrowskiego w Warszawie
Główny Instytut Górnictwa
NITROERG S.A.

Project Value:
PLN 4,302,553.00
Co-financing value:
PLN 4,251,553.00
Including budget of KGHM CUPRUM:
PLN 1,898,513.00

Duration:
2017.04.01 – 2020.03.31

Abstract:
The aim of the project is to develop an innovative technology that will allow to gain access to the deep orebody, within less than three years time. Particular emphasis will be on Foresudetic Monocline and Grodzieck Syncline areas. Through a series of case study analysis and research in real-life conditions, including long-term pumping, the most efficient and optimal method of rock mass treatment will be developed. Its relationship with the results of the current technical solutions that are used in KGHM as well as the most efficient, global solutions will be used to develop a new, efficient in terms of time and cost, method and technology of gaining the access to the orebody. It will be tested with both analytical and numerical modelling methods. Comparison of the “new” technology with an “old” one, based on a currently developed GG-1 shaft, will allow to estimate economical efficiency and to create a temporal model, achieving a V level of technological readiness.

Name of Beneficiary:  
KGHM CUPRUM sp. z o.o. Research and Development Centre
Przedsiębiorstwo Budowy Kopalń PeBeKa S.A.
The Stanisław Staszic University of Science and Technology in Cracow
Wrocław University of Technology
Central Mining Institute

Project Value:
PLN 12,057,627.25

Co-financing value:
PLN 11,384,721.45

Duration: 
2015.01.01 – 2017.12.31

Abstract:
General concept of the proposed project consists in developing innovative technology of copper ore preparation for flotation, using high-energy comminution techniques. It should rely on replacing current two-stage wet grinding process with one-stage dry grinding. The grinding would be realized in a high-energy mill with horizontal shaft of beater wheel. The new technology of ore preparation for enrichment totally differs from solutions applied so far in the processing of non-ferrous metals ores. A feed for the high-energy mill will be copper ore, pre-crushed in a hammer crusher to grain size below 25 mm, whereas grain size of product obtained from the high-energy mill will be at a level below 0,5 (1) mm. Grinding product after classification in a cyclone will constitute a feed for the preliminary flotation process.

Name of Beneficiary:
Instytut Metali Nieżelaznych
KGHM CUPRUM sp. z o.o. Centrum Badawczo – Rozwojowe
Instytut Podstawowy Problemów Techniki Państwowa Akademia Nauk
Politechnika Warszawska

Project Value:
PLN 6,764,480.00

Co-financing value:
PLN 3,382,240.00 PLN

Duration: 
2015.01.01–2017.12.31

Abstract:
Decreasing ore grade, its fine and complex mineralization, presence of organic carbon, worsening upgradeability and 50 years old technology, create difficulties in achieving high quality final copper concentrates, which are further utilized for pyrometallurgical copper production. Within HighCopper project it is planned to develop, on a laboratory and next pilot scale, a new technology of copper ore beneficiation adapted to the properties of the current and future copper ores. Newly developed and verified unit operations, together with construction of new devices, will guarantee production of better quality final concentrates for pyrometallurgical copper production. The new technology, verified on the pilot scale, will be used for a new technological flow-sheet for KGHM, and provide data for prefeasibility study and determination of potential investment risks as well as fulfil the requirements for 7th level (pilot scale) of readiness for technological application.

Name of Beneficiary:
Wrocław University of Technology
KGHM CUPRUM sp. z o.o. Research and Development Centre
Institute of Non-Ferrous Metals
The Stanisław Staszic University of Science and Technology in Cracow
Wrocław Research Centre EIT+

Project Value:   
PLN 10,007,678.00

Co-financing value:  
PLN 5,003,839.00

Duration:  
2015.05.01 – 2018.04.30

Abstract:
The project of the new solution named “Type URB/ZS-3 automatic rock crushing machine” is a continuation of the development of URB/ZS-1 remote control system by ZANAM (remote control of 3 points at the same time). New automatic operating system will allow for concentration and reduction of operators, and will improve control over individual machines. URB/ZS-3 will enable the complete elimination of operators, reducing their activities to controlling and monitoring of the output and technical condition of the equipment. Project objectives are as follows: complete automation of the crushing process and reduction of yield haulage costs. An additional objective will be to relocate the operators from areas of high exposure to unfavourable environmental factors (heat, limited ventilation) to remote and automatic control centres (Pol. “CZAS”), which are free from these risks, as well as to enable rich ore mining in areas unexploited these days due to the threat to operators’ health.

Name of Beneficiary: 
KGHM ZANAM S.A.
KGHM CUPRUM sp. z o.o. Research and Development Centre
The Stanisław Staszic University of Science and Technology in Cracow

Project Value: 
PLN 6,764,480

Co-financing value:  
PLN 1,812,808.75

Duration: 
2015.03.02 – 2017.02.28

Abstract:
In a quest for the most profitable way of limited Rhenium resources of a high value it is an important option to sell rather selected items covered with a thin Re-based coating by means of modern coating techniques instead of selling similar ones with uniformly distributed Re admixture in the total volume of the items. Therefore a series of coatings of industrial importance will be deposited in the project with use of CVD, PVD or SPS techniques, namely one superhard ReB2 and two oxidation resistant coatings NiAlCrYRe and Mo10ReAl, as well as a thin Pt-Rh catalyst, Cu-C-Re layer on electrical contacts and pure Re decorative one. After deposition, the coatings will be characterized, the most profitable one will be selected, a pilot installation will be constructed for verification of the technology and the coating and basic assumptions for designing of an industrial installation for coatings deposition will be elucidated.

Name of Beneficiary: 
Łódź University of Technology
KGHM CUPRUM sp. z o.o. Research and Development Centre
Warsaw University of Technology
BOHAMET S.A.

Project Value:   
PLN 7,995,656.00

Co-financing value:  
PLN 3,497,328.00

Duration:  
2015.05.01 – 2018.04.30