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By N. Hosking, M. Nichols

Aluminum alloys are increasingly used for automotive body construction but are susceptible to filiform corrosion or paint blistering in service. Filiform corrosion resistance of two 6000-series aluminum alloys was investigated in this work. Test panels were produced with full automotive coating layers and scribed parallel and perpendicular to the rolling direction. The corrosion exposure comprised an inoculation step with acidified salt solution followed by a 6-week exposure period at 95% relative humidity and either 25°C or 70°C. Greatest corrosion activity was measured on the alloy with higher copper content, AA6111. Higher temperature exposure led to greatly enhanced corrosion activity for AA6111 compared to the lower temperature exposure. The 70°C exposure also led to greater mean corrosion-affected area measurements for the low copper aluminum alloy, AA6022, but the effect was not as stark as that observed for AA6111. Rolling direction affected the propagation direction, and possibly mechanism, of the corrosion effects. Cross-sectional analysis revealed dense corrosion products within the filament, comprising mostly aluminum and oxygen but with traces of chloride and sulphate. Development of varying filament and blister types on a single test panel and the progression of corrosion underneath a filament into the substrate indicate that several corrosion mechanisms can develop on the test panel, testament to the complexity of the corroding surface developed on an aluminum automotive body panel.

Jan 1, 2015

By Fidelis T. Suorineni

The conditions for rockburst occurrence are traditionally identified as: high stress, high extraction ratio, strong brittle rocks, folding, faulting, and unfavourable excavation geometry. Based on a critical review of case histories, this paper identifies oblique loading of orebodies by the major far field principal stress as a cause of rockbursts. Orebodies subjected to this loading condition are termed orebodies in shear. Orebodies in shear are subjected to compressive and shear loads. The case histories presented unambiguously show that the magnitudes of the far field principal stress alone, and a knowledge of the conventional rockburst causing factors are not sufficient for mine planning and design. The orientation of the major far field principal stress, or for that matter the driving stress relative to the orebody axis, should be recognised as one of the causes of rockbursts. It is suggested that since stress orientation is an important factor, and orientations from stress measurements are so variable, orientations from stress measurement data be complemented with underground observations from borehole and excavation breakouts to determine the actual in situ stress orientation, whenever possible. Also stress modelling for the design of critical elements (pillars) should include a sensitivity analysis on the relative critical field stress direction. The paper emphasises that special attention should be paid to or

Jun 1, 2012

By C. Piribauer, E. Feichtenhofer, A. McEneaney

"As part of a major diversification project, RHI AG, through its plant in Drogheda Ireland, has developed a Caustic Calcined Magnesium Oxide (CCM) for use in the Cobalt (Co) & Nickel (Ni) hydrometallurgical extraction industry. In the course of the project, the company investigated the chemical and physical properties of a number of different Magnesia’s used in Co & Ni hydrometallurgy applications and has been able to determine the important parameters for a successful Magnesia for this application. A number of live plant trials have confirmed the results of this testwork and the company is now proceeding to produce this product in commercial quantities at Premier Periclase Ltd., the RHI AG plant in Drogheda, Ireland. This paper will outline the development work conducted by the company and highlight the important chemical and physical properties that make a successful CCM. Much of the research was conducted at the RHI Technology Centre in Leoben, Austria. In addition, a number of external laboratory studies were conducted on behalf of RHI AG. The result of this work has allowed the company to develop a Magnesia product with optimised properties for use in the Cobalt and Nickel hydrometallurgical extraction process.INTRODUCTION Premier Periclase is part of RHI AG, a globally operating supplier of refractory products, systems and services, headquartered in Vienna, Austria. The company produces Magnesia from seawater at its plant in Drogheda, Ireland. While the main focus is on production of refractory grade Dead Burned Magnesia for the steel industry, the plant also produces a number of different grades of Caustic Calcined Magnesia as well as Magnesium Hydroxide products. As part of a major project to diversify the company’s product base, the use of CCM in the Cobalt (Co) & Nickel (Ni) hydrometallurgical extraction industry was investigated. One of the company’s highly reactive grades of Caustic Calcined Magnesia was found to be particularly suitable for this application. In an effort to understand what makes a successful Magnesia for hydrometallurgy the chemical and physical properties of different Magnesia’s used in Co & Ni hydrometallurgy were investigated. This paper and conference presentation outlines the findings of this process."

Jan 1, 2017

By V. Prasad, A. Afacan, K. Popli, S. Dubljevic

Froth flotation is one of the most common and widely used separation processes in the mineral processing industry; however, its complexity means that complete understanding of the process has not yet been achieved. A dynamic fundamental model is needed to enhance the understanding of the process and to improve process control. It is challenging to capture all the phenomena involved; hence, we propose a multiscale modeling approach with a framework ranging from macroscopic (equipment scale) to microscopic (attachment, detachment) models along with distribution models for ore particle sizes. Real-time froth properties are obtained using a vision-based sensing system. These measurements can be used for developing a soft sensor for grade using statistical methods such as PCR (principal component regression) and PLS (partial least squares) regression. The fundamental model is updated in real-time using extended Kalman filtering. Attachment dynamics are studied for different particle size distributions. The modeling and soft sensing is tested on batch flotation cell for the pure mineral galena with different particle size distributions using Xanthate and MIBC as collector and frother, respectively. The model, online measurements and soft sensor are useful in developing monitoring methods for froth flotation.

Jan 1, 2015

"Real-time, on belt analysis of minerals is becoming increasingly important and critical in modern operations, especially in the mine-to-mill. Prompt gamma neutron activation analysis has long been utilised for real-time elemental analysis in bulk materials, with Scantech's GEOSCAN being the instrument of choice in the minerals sector. Working in the minerals space for 15 years, the GEOSCAN has been successfully implemented in a wide range of minerals applications including iron, copper, lead-zinc, manganese, phosphate and more, and it caters for the very high demands and increasing requirements of a contemporary processing facility. An area of focus has been on increasing the analysis frequency to allow for rapid analysis results with the same high degree of accuracy typically expected of the GEOSCAN. This paper discusses the underlying research and technology that has enabled such rapid analysis and presents a range of examples using a thorough statistical approach on real production material, demonstrating achievable accuracy over a short analysis time, and dispelling common myths about the speed of the technique. Potential applications are discussed to conclude the paper.INTRODUCTION Technology and the information it can provide plays a critical role in the evolving modern mineral processing landscape. The importance of technology to analyse various features of ores and concentrates being processed is obvious, and recent years has seen the advance of numerous technologies to provide a variety of real-time measurements on conveyed material flows. From sampling apparatus to particle size analysis to weight and density meters to full elemental analysis, the availability of information enables a variety of improvements in the process leading to improved efficiency and increased revenue. To maximise the potential benefits, access to real-time information is imperative, and rapid updates of information become necessary to make appropriate process control decisions based on the most relevant and up-to-date information."

Jan 1, 2017

By G. Cailletaud, I. Guillot, D. Larouche, R. Martinez, D. Massinon

The precipitation of Al2Cu particles in a 319 T7 aluminum alloy has been modeled. A theoretical approach enables the concomitant computation of nucleation, growth and coarsening, based on an implicit scheme using the finite differences. The equation of continuity is discretized in time and space in order to obtain a matricial form. The inversion of a tridiagonal matrix allows us to determine the evolution of the size distribution of Al2Cu particles at t + dt. The fluxes of solute in-between the boundaries, as well as the ones at the boundaries, are computed in order to respect the conservation of the mass of the system. The main results of the model are compared to TEM measurements. Simulations provide quantitative features on the impact of the cooling rate on the size distribution of Al2Cu particles in good agreement with the TEM measurements. This metallurgical model is integrated into FEA software in order to perform mechanical computations. This kind of multiscale approach allows new perspectives to be investigated in the process of designing cylinder heads. It enables a more precise prediction of the microstructure, its evolution as a function of continuous cooling rates and its impact on the integrity of the structure.

Jan 1, 2015

By Ian Ewart, Trevor Bergfeldt, Gourab Satapathy, Ajay Patel

"Conventional electrowinning (EW) of nickel from sulfate electrolytes is complicated by several factors including the requirement for a diaphragm cell to separate the anolyte and catholyte and the need to minimize nickel mist emissions. Developed and commercialized by emewCorporation, this novel process electrowins high purity nickel cathode (99.5%) from copper refinery bleed streams using the proprietary emew vortex EW technology. The emew nickel process incorporates high flow rate in an enclosed cylindrical EW cell operating at high current densities that overcomes the challenges of conventional nickel EW and completely eliminates the risk of nickel mist emissions. The tubular cathodes are easily harvested and mitigate the effect of plating stresses inherent in nickel EW. The present paper describes the emew nickel process and its most recent application to copper refinery bleed streams at full-scale.INTRODUCTION To meet the stringent demand of customers, nickel producers are giving prime importance to production of high purity nickel cathodes. The major challenge for refineries is to improve cathode quality and appearance despite fluctuating electrolyte impurity levels. The basis of achieving good quality cathode includes the control of electrolyte impurities and consistency of specific process conditions. The commercial operation of emew nickel technology has been successfully implemented and has demonstrated the ability to produce high quality nickel cathode from refinery bleeds. This paper emphasizes the importance of upstream impurity removal to achieve the required nickel emew feed composition by evaluating the benefits of using selective precipitation as a purification scheme with the aim of improving the overall nickel recovery while ensuring suitable nickel concentration in the advanced electrolyte is achieved. Nickel electrowinning is similar to other electrowinning processes that employ insoluble metal anodes & cathodes. It requires the passage of direct current between two electrodes that are immersed in a conductive, aqueous solution of nickel salts. For the recovery of nickel from solution, the most common methods are electrowinning and hydrogen reduction. Electrowinning usually occurs from sulfate, chloride or mixed sulfate/chloride electrolytes. In sulfate electrolytes, nickel electrowinning cells are normally designed to achieve specific criteria as outlined below (Robinson & Tuppa, 2002):"

Jan 1, 2017

By D. Paul Bishop, Kevin P. Plucknett, Hung-wei Liu

"Spark plasma sintering (SPS) process has been evaluated for producing the commercially pure (CP) Ti, TiAl and a TiAl-B4C composite. Comparisons were made between the materials in terms of the sintered density, resultant hardness and microstructures. In the present work, the titanium aluminide powders (Ti-48Al, producing a mixture of y-TiAl/a2-Ti3Al) were synthesised „in-house? using a simple reaction-sintering and mechanical attrition approach. This allowed various size distributions to be generated. The powders were then blended with a fine boron carbide (B4C) powder (up to 6 wt.%), and the resulting mixtures were consolidated using spark plasma sintering (SPS) under vacuum in graphite dies. An applied stress of 50 MPa was used for all SPS runs. The SPS parameters were varied in terms of the ultimate sintering temperature (up to 1300°C) and hold time (up to 10 minutes) for each material. It is demonstrated that high densities can be achieved this approach (exceeding 95% of theoretical, with optimised samples close to full density). Microstructural characterisation was conducted using optical microscopy, scanning electron microscopy, and X-ray diffraction. The B4C additions were seen to partially react with the TiAl to form reinforcements, such as TiCx and TiBx. Preliminary mechanical property assessment will also be briefly discussed.INTRODUCTION Titanium- and titanium aluminide-based alloys possess many unique properties, such as excellent corrosion resistance and high temperature strength, respectively (Cardarelli, 2001; Leyens & Peters, 2003). Compared to many other competing materials (e.g. stainless steel or Ni-based alloys), Ti- and TiAl-based alloys also have relatively low densities (~4.5 and ~3.9-4.1 g/cm3, respectively), which is critical for performance in aviation and automobile applications. However, the manufacturing cost is high, due to the expensive raw Ti material and difficulties in machining. TiAl-based alloys are particularly difficult to produce because of their limited ductility (Lütjering & Williams, 2007). To overcome those problems, powder metallurgy (PM) technologies have shown great potential as near-net shape processes for Ti- and TiAl-based alloys. The general PM process largely avoids laborious post-machining and minimises material use. In industrial production, the PM approach has been successfully utilised to manufacture aluminium- and iron-based alloys (Huo & Heath, 2008)."

Jan 1, 2017

By E. V. Konopleva, H. J. McQueen

Steels in high variety have been providing strength and ductility for more than a century mainly through complex heat treatments following hot shaping. The economical and sustainable goal was a steel with the two operations combined through applying knowledge of dislocations and strengthening mechanisms aided by new mechanical and microstructural techniques. Primary hot reversing-mill rolling produced static recrystallization (SRX) between every pass to significantly finer grain size. Hot torsion showed that with lay-on temperature and rate of reduction suited to gradual precipitation of minor additions of Nb, the austenite grains would become highly pancaked; the existence of very fine subgrains along the grain boundaries (GB) could be deduced from tests on stainless austenite. The HSLA strip had to be water-jet cooled immediately to prevent SRX at austenite GB and ensuring complete transformation to ferrite avoiding grain growth after coiling. Confirmation on old mills and successful product led to the design of more flexible mills for wider range of compositions and products. A significant one was auto bumpers that reduced crash damage. More crack-resisting compositions were developed for strip welding into line pipe for arctic oil transport. Lower metal consumption and easier fabrication has resulted in more sustainable welded bridging.

Jan 1, 2015

By R. K. Mishra, A. Kula, X. Jia, M. Niewczas

The mechanical properties of Mg-Gd and Mg-Y solid solutions have been studied under uniaxial tension and compression between 4K and 298K. The results reveal that Mg-Gd alloys exhibit higher strength and ductility under tension and compression attributed to the more effective solid solution strengthening effect and grain boundary strengthening. Profuse twinning has been observed under compression, resulting in a material texture with strong dominance of basal component parallel to compression axis. Under tension, twining is less active and the texture evolution is affected mostly by slip. The alloys exhibit pronounced yield stress asymmetry and significantly different work-hardening behaviour under tension and compression. Increasing of Gd and/or Y concentration leads to the reduction of the tension-compression asymmetry due to the weakening of the recrystallization texture and more balanced twinning and slip activity during plastic deformation. The results suggest that under compression of Mg-Y alloys slip is more active than twinning in comparison to Mg-Gd alloys.

Jan 1, 2015

By David Ulrich Furrer

Materials and manufacturing processing technologies have played an important role in the development and capabilities of nearly all manmade products. Market drivers for fuel efficient, low cost, environmentally friendly, more capable transportation has given rise to significant materials challenges and subsequent developments. The rate of improvement and implementation of new commercial products can be limited by the rate of new materials and process technology development and qualification. As many materials are being designed for unique requirements and even location-specific unique properties, the implementation of tools and methods to enable rapid characterization and validation of material definitions and design systems must also be accelerated. A review of new integrated material, manufacturing process and component designs, engineering processes and emerging tools and methods will be discussed. The linkage of computational materials science and engineering into component design will also be discussed along with the challenges and opportunities for further growth and application of integrated computational materials engineering (ICME).

Jan 1, 2015

By D. Cruden

DISCODAT is a system of computer programs written for CANMET, Canadian Department of Energy, Mines and resources, to be used in analyzing geological data for rock slope design. The programs were written in Fortran IV for an IBM 360/67 computer. A program conditions field data from field forms for storage in a line file. Data may be selectively retrieved from the line file by a general retrieval program which uses a variety of relational operators. The retrieved data may be displayed as structural diagrams or histograms produced on a line printer or in a number of maps produced on a drum plotter. There is a logical sequence which leads to the characterization of those elements of the subfabrics of a rock mass which may be kinematically active. Structural domains within the rock mass can also be outlined by a procedure described as areal analysis. Costs for a complete analysis are usually substantially less than $l/discontinuity.

Jan 1, 1978

By G. Goodall, M. Muinonen, R. Pandher, R. Jabbar, S. J. Muinonen

"The implementation of a new and highly efficient converting practice at the Glencore Sudbury Integrated Nickel Operations Smelter has opened the possibility to further capacity increases by using larger ladles. To quantify the impact of increasing ladle sizes from 200 to 300 ft3, XPS constructed a detailed discrete event simulation using the commercial software package Rockwell Arena®. The challenges associated with implementing a model on an intricate and tightly scheduled process, and the solutions needed to derive meaningful results will be presented. The aisle capacity is predicted to increase by approximately 17 %, with a reduction in furnace tapping demand of 8 %. Arena modeling capabilities and the key factors contributing to the overall capacity increase at the Sudbury INO Smelter will be reviewed and presented.INTRODUCTION The Glencore Sudbury Integrated Nickel Operations (INO) comprises two Ni-Cu-PGM mines, Strathcona Mill, and the Sudbury Smelter. The Smelter has operated continuously since 1929 using different processes to produce nickel-copper Bessemer matte. Feeds to the Sudbury INO Smelter are a blend of concentrate from Strathcona Mill, Raglan concentrate produced at the mine-mill complex in Raglan, Quebec, as well as third party concentrate feeds shipped to Sudbury from around the world. In 2016, the Sudbury INO Smelter produced 75,900 tonnes of nickel and 20,000 tonnes of copper in Bessemer matte. The product matte is shipped to Glencore’s Nikkelverk refinery in Kristiansand, Norway where it is refined to produce nickel and copper cathode. A schematic of the Sudbury INO Smelter’s flowsheet is shown in Figure 1."

Jan 1, 2017

By S. Esfahani, M. Barati

Heat recovery from blast furnace slags is often contradicted by another requirement, to generate amorphous slag for its use in cement production. As both the rate and extent of heat recovery and slag structure are determined by its cooling rate, a relation between the crystallization kinetics and the cooling conditions is highly desired. In this study, slags with different basicities were studied during non-isothermal cooling. Their continuous cooling transformation (CCT) diagram were plotted and compared with each other. Then, a mathematical model was developed that predicts the amount of crystallization during cooling. The results were validated by experiments performed by Single Hot Thermocouple Technique and image analysis. A second mathematical model that calculates temperature history of slag during its cooling was coupled with the above model, to allow optimizing the slag/air ratio for both heat recovery and slag glass content.

Jan 1, 2015

By S. Usui, Y. Shinohara, C. Tokoro, K. Horiuchi, S. Owada

Process optimization of heating and physical separation for Cobalt (Co) recycling from spent lithium ion battery (LIB) was investigated. LiCoO2 in spent LIB was transformed to LixCoO2 which was more easily decomposed than LiCoO2 by heating. Coexisting materials of aluminum and carbon, and sealed atmosphere of the LIB promoted LixCoO2 decomposition. In an atmosphere of Argon, 95 % of LixCoO2 in the spent LIB was decomposed to 76 % of Co oxide and 19 % of Co metal in 10 min at 823 K; a lower temperature than the theoretical value for LiCoO2. The Co oxide and Co metal exhibited magnetic properties and could be recovered by wet magnetic separation. Furthermore, slow heating was effective for grain growth of Co oxide and Co metal. At 2 K/min rate of heating, average grain size of Co oxide and Co metal were 239 µm and 28 µm respectively, whereas at 30 K/min they were 190 µm and 15 µm respectively. Therefore, separation efficiency for Co recovery by wet magnetic separation was increased when spent LIB was slowly heated at 2 K/min.

Jan 1, 2015

By K. Horikawa, S. Kitahata, H. Kobayashi

"It has been clarified that the Al-5%Mg alloys containing 200 mass ppm of sodium showed grain boundary (GB) fracture, even when tested at room temperature, as well as at high temperatures (~500°C). SEM/EDX study revealed that the GB fracture was associated with the segregation of sodium on grain boundaries of the Al-Mg base alloys. Differential scanning calorimetry (DSC) revealed that the GB fracture at room temperature of Al-Mg alloys was caused by sodium segregation in the solid state. It was also shown that the tendency of the GB fracture strongly depended on the heat treatment; the alloys after the solution heat treatment showed severe GB fracture compared with the alloys after the homogenizing treatment. Moreover, it was shown that the GB fracture at room temperature by sodium segregation was suppressed by the addition of bismuth or indium. The suppression of the GB fracture by the additional elements was believed to be the scavenging effects by forming the sodium bearing compounds in grains.INTRODUCTIONIt is widely known that Al-Mg base alloys containing high amount of magnesium(~5 mass%)show better workability at room temperature, while that the alloys show grain boundary (GB) embrittlement at higher temperatures ranging from 200 to 500°C, depending on grain size(Otsuka, 1984), sodium impurity level(Ransley, 1959, Okada, 1997, Horikawa, 2001)and testing strain rate(Yamada, 2012). In the case of coarse-grained Al-5%Mg alloys (~300 ?m), 2 mass ppm of sodium causes severe GB fracture around 300°C, however, the Al-5%Mg-2ppm alloy does not show GB fracture at room temperature. It has also been shown that the GB embrittlement caused by 2ppm of sodium was suppressed by the additional elements, such as bismuth (Talbot, 1995), antimony (Ueda, 1997) and indium (Horikawa, 2012). Basedon these facts, we have concluded that the GB embrittlement at higher temperatures of Al-Mg alloys is attributed to the synergy effects of GB segregation of atomic sodium and GB sliding. For the GB embrittlement mechanism of Al-Mg alloys, involvement of low melting point metallic phases has been pointed out (Lynch, 2002),since the GB embrittlement appeared only at high temperatures. Up to date, the effects of high amount of sodium addition more than 2 ppm on GB fracture were not fully investigated in Al-Mg alloys. In the present study, the effect of 100 ppm ordered sodium impurity on GB fracture of Al-5%Mg alloys was examined, together with the effect of another additional elements."

Jan 1, 2017

By M. Kim, M. Ha

"The effect of red mud on the melting behavior of ferronickel slag was investigated by a laboratory-scale horizontal tube furnace. Melting and softening of slag samples fluxed with different amount of red mud was examined by in-situ visualization technique at temperature range from 1400 to 1550°C. FactSageTM 7.0 was used for the thermodynamic calculation of multi component system of ferronickel slag and red mud. Liquid phase area was extended to lower temperature by adding red mud indicating its suitability as a flux material. X-ray diffraction analysis confirmed the dependency of the phase changes on the red mud content. Microscopic observation by scanning electron microscope (SEM / EDX) clarified the phase transformations from olivine to spinel along with red mud additions.INTRODUCTION Ferronickel smelting by submerged arc furnace (SAF) is an energy intensive process performed at high temperature range 1500–1600°C. During the smelting process of saprolitic nickel laterite ore with a nickel content of 2.2–2.3 pct, a large quantity of ferronickel slag is being produced that account for 97 pct of ore charged. To achieve ferronickel grade of 15–20 pct Ni, electrical energy of 80 to 85 MW is used for the melting and reduction of nickel oxide (NiO) and iron oxide (FeO) in the ore (Rodd et al., 2010). Unreduced components, mostly MgO, SiO2 and partly FeO are removed from the furnace in a liquid slag form by a tapping operation. Due to the high melting temperature, forsterite (Mg2SiO4) based slag containing approximately 10 pct FeO requires typical process temperature of 1600°C. Flux in metallurgical process is a medium that decreases melting and operating temperatures while it increases fluidity of the liquid slags. Calcite and fluorite are examples of flux materials used for the ironmaking, steel refining and continuous casting process. Oxide systems based on CaO - CaF2 - SiO2 - Al2O3 - MgO cover most of the slag composition in ferrous metallurgy accordingly. Crucial operating factors for ironmaking and steelmaking slags are basicity (typically CaO/SiO2 ratio), viscosity and impurity levels. These are extensively controlled by the fluxes. General metallurgical fluxes such as limestone, dolomite and calcium fluoride are abundant in nature and supplied to steel mills at low prices. Meanwhile, in copper flash smelting process, silica is supplied with copper concentrate to remove iron oxide (FeO) generated from sulfide oxidation. FeO - SiO2 binary system formulates eutectic area at 25–38 pct of silica that has low melting temperature below 1205°C. Fayalitic system (Fe2SiO4) that has low viscosity (0.1 Pa·s) (Park et al., 2011) facilitates easy separation of slags from molten sulfide mattes. Recently, copper plants actively utilize recycled raw materials as a flux. Various recycled glasses are ground and fed to copper smelting process as a partial replacement of silica ore. Applying industrial wastes to smelting processes is advantageous since the operators can reduce the production cost remarkably. Not to mention the consumption of recycled materials can ultimately minimize the environmental risks and the waste management costs. The authors, therefore, investigated the reasonable waste materials that can be effectively used for ferronickel smelting process. Prerequisites for potential fluxing materials are non-recyclable property, low transportation cost and excellent performance as a flux."

Jan 1, 2017

By Quenton Johnson, W. A. Gough, David Carr

"This paper describes the application of the BrainWave Model Predictive Controller (MPC) and Advanced Control Expert (ACE) Advanced Supervisory Control System on the SAG Mill, Ball Mill, and Rougher Flotation cells for a new gold processing line at the Oceana Gold - Haile Gold mine in Kershaw, South Carolina. For this project, ANDRITZ supplied the control system design and programming, operator-training simulator and advanced control. The advanced control was tested against the IDEAS™ dynamic simulator, and commissioned during the startup of the processing plant to help achieve target production as quickly as possible. Operators were able to run the equipment in a consistent and optimized manner from an early stage of the plant operation, increasing efficiency and profitability. MPC is able to reduce process variability beyond the best performance that can be obtained with conventional Proportional Integral Derivative (PID) control methods. MPC is able to optimize the control of processes that exhibit an integrating type response in combination with transport delays or variable interaction, which are characteristic of many gold processes including SAG mill weight control and Flotation cell froth level control. The experience and benefits of applying MPC during the startup of a new gold processing plant are presented in this paper.INTRODUCTION Mineral processing operations present many challenges for automatic process control due to variations in unmeasured ore properties, material transport delays, and non-linear response characteristics. Advanced process control technologies such as expert systems and multi-variable model predictive controllers are often used to improve the control of these processes to increase productivity and recovery efficiency. Typically these systems are applied after the mine has been in operation for a period of time. For this project, a complete dynamic process simulator was developed using the IDEAS platform for the purpose of training operators before the plant was constructed. Operators were able to become familiar with the process and the control system in order to become proficient in the use of the controls before the plant was ready to start. They were able to practice abnormal condition management including startup and shutdown of the process using the simulator and develop complete Standard Operating Procedures (SOPs) for these situations. The simulator was also used to test the control system functionality and operator Human Machine Interface (HMI) configuration to reduce errors and improve the performance of the control system during plant start-up."

Jan 1, 2017

By S. M. Chentouf, M. Jahazi, N. Bombardier, T. Belhadj

The main limiting factor in the commercial expansion of superplastic forming (SPF) of thin sheet aluminum alloys is the extent of cavitation phenomenon that takes place during the processing. The severity of the cavitation process is mainly dependent on the uniformity of deformation (i.e. level of local thinning) during processing. In the present paper, correlations are made between thickness variations in several formed sheets and the characteristics of the cavities observed in the material. The 1.4 mm thick 5083 aluminum alloy sheets were hot pre-formed at around 450°C for 4 min and then air-cooled. Opto-digital and Scanning Electron Microscopy were used to examine the microstructure and analyse the cavities. Also, grain size measurements were carried out for different location in the SPF formed piece. The surface and volume fractions of the cavities were measured with the aid of metallography image processing (MIPTM) on as-polished samples prior to etching. The results are analyzed in terms of the influence of applied strain and microstructure conditions on the propensity to cavitation of the alloy.

Jan 1, 2015

By J. R. Donald

"Project development has been increasingly formalized in the past decade, with most organizations having extensive and descriptive deliverables documents and processes to govern the stage gate progress of capital projects. Although this has improved the general governance of capital project development and execution, it has perhaps not led to improved business success. This paper identifies specific challenges associated with developing complex projects with multiple stakeholder interests over the long timeframe of the project life cycle. The paper outlines these challenges and suggests management approaches and aspects of project development where increased focus is required to achieve improved business outcomes."

Jan 1, 2015