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By J. Koponen, K. S. Stadler, A. Fuerst, S. Gaulocher, Th. von Hoff, R. Veldsman

"Gearless mill drives (GMDs) are the workhorse in the mineral processing industries, more specifically when it comes to grinding crushed ore and cement (in various production stages) in semiautogenous (SAG) mills and large ball mills. They are renowned for their excellent reliability and robustness, long lifespan, and little need for maintenance, and thus yield a low total cost of ownership (TCO).A GMD represents a major investment for a mineral processing plant, and its availability is pivotal for the grinding process. As a basic rule, shut-down periods are to be minimized, but even much more important is that unscheduled shut-downs be avoided. In this contribution, we will present a portfolio of innovative remote diagnostic that consist of the following three key components:1. Trouble shooting is a form of corrective maintenance and is based on state-of-the art remote access technology, thus enabling highly skilled engineers to access the current sensor readings anytime and from anywhere in order to resolve urgent problems together with the GMD user.2. Periodic maintenance reports are a form of preventive and predictive maintenance and aim at continuous improvement based on long-term historical records and analyses of multiple measured signals. These detailed reports highlight the health and operational status of the GMD and are periodically (e.g. 3 months) submitted to the customer.3. Remote condition monitoring spans across preventive and predictive maintenance and is based on continuous recording and automatic analyses of relevant signals using advanced algorithms. The main issue is how to handle the enormous flood of data in an intelligent manner. The results of these analyses are made available to both the GMD user and supplier in real time in order to increase the availability and reliability of the GMD.In this paper, we consider various parts of the GMD, e.g. the cycloconverter, the ring motor, the auxiliary devices (e.g. cooling and lubrication systems), and also phenomena related to the mill itself (e.g. state and quantity of charge). The signal analysis techniques range from simple threshold-based analyses to complex time and frequency domain analyses. We will illustrate the benefits of the proposed approaches with some selected examples."

Jan 1, 2012

By B. N. Nandi

This paper is a study of the application of the science of coal petrology to the use of coal in the iron and steel industry. The petrography of coal is given the most attention, with some mention of coal palynology. The history of the petrographical analysis of coal is first out-lined, with a description of the various coal entities, and then the apparatus and experimental techniques employed for coal evaluation are discussed. The coke stability factor and the relation of coke strength to petrographical data are also covered, and some space is given to the new science of coke microscopy, in particular its use in following the oxidation of coals.

Jan 1, 1966

By S. Dessureault

The relatively recent explosion of available data in all business sectors has induced a common expression of “drowning in data, starving for information.” The mining sector is affected by the information age through equipment-based sensors, process monitoring, and traditional enterprise data sources. Information technologists have developed techniques such as data mining that apply new and old statistical algorithms to large datasets. Mine planners and managers can apply these tools for improved planning and control, thereby increasing the use of the highly underutilized information system infrastructure in most modern mines. This paper describes the use of data mining and its enabling technology, data warehousing, in the development of an energy consumption model for large surface mines using real historical data.

Jan 1, 2007

By M. L. Wacker

"Cigar Lake high-grade uranium mine in Saskatchewan is operating after 25 years of test mining, construction, and mine flood remediation. Factors include ground stability, groundwater control, radiation exposure, and ore handling. A 10 year test program resulted in validating “jet boring”, a non-entry mining method involving artificially freezing the orebody and surrounding rock; tunnelling to develop access crosscuts below the orebody; installing cased pilot holes through ore; extracting ore using rotating high-pressure water jets within pilot holes; and cavity concrete backfilling. Ore slurry is prepared underground, pumped to surface, and trucked to McClean Lake mill for processing to uranium concentrate.RÉSUMÉ Après 25 années d’essais sur les méthodes minières, de construction et d’assainissement suivant les inondations à la mine, l’exploitation de minerai à haute teneur en uranium Cigar Lake, localisée dans la province de la Saskatchewan, est opérationnelle. Les principales difficultés concernent la stabilité du terrain, le contrôle des eaux souterraines, l’exposition aux rayonnements et la manutention du minerai. Un programme d’essai de 10 ans a abouti à la validation du « forage à érosion », une méthode minière qui consiste à congeler artificiellement le corps minéralisé et les roches environnantes ; à creuser des tunnels pour développer des travers-bancs d’accès en dessous du corps minéralisé ; à installer des puits de fondation pilotes à travers le minerai ; à extraire le minerai à l’aide de jets d’eau à haute pression dans les puits pilotes ; et à remblayer les cavités avec du béton. La boue de minerai est préparée sous terre, pompée vers la surface puis transportée par camion jusqu’à l’usine de concentration de McClean Lake pour le traitement afin d’obtenir du concentré d’uranium.INTRODUCTIONThe Cigar Lake deposit is in northern Saskatchewan, 660 km north of Saskatoon, Saskatchewan, Canada, at the east edge of the Athabasca basin (Figure 1; Bishop, Mainville, & Yesnik, 2016). The operation is jointly owned by Cameco Corporation, AREVA Resources Canada Inc., Idemitsu Canada Resources Ltd., and TEPCO Resources Inc. Cameco has been the operator of Cigar Lake since January 2002. The discovery hole was drilled in 1981. Commercial production was declared in May 2015 and the Phase 1 operation will have a mine life of 15 years."

Jan 1, 2017

By W. S. Urbanski, A. L. Devernoe, R. W. Stuart, M. S. Walker

"Although many investigators have successfully achieved separations using variations of a concept wherein particles are buoyed upwards against gravity in a magnetically attracted fluid, none have succeeded in separating fine particles in a manner that is practical tor mineral beneficiation. This paper describes laboratory tests and preliminary economic analyses for a new mineral separation process which provides enhanced magnetic buoyancy and separation capabilities. The process provides a means of gravity separation in a regime where conventional gravity separation is inadequate; that is for small differences in mineral densities and for very fine particles. Although early interest centers on gravity separation, the process has also been successfully used for precise magnetic separation.Tests were conducted on a variety of mineral mixtures, ore samples and concentrates including; a sphalerite ore, pyrochlore ores and concentrates, cassiterite pre-concentrates, a chromite pre-concentrate, and heavy mineral placer samples. Separations requiring high discrimination between fine particles narrowly different in density or weak magnetic properties were obtained. Of particular interest is the ability of the process to concentrate or remove oxide minerals or gangues, especially silicates. Potential applications are discussed."

Jan 1, 1985

By T. R. Skerry, H. P. Hudson, T. E. Warren

"ALTHOUGH coal is generally the cheapest fuel on the basis of heating value it has been at a disadvantage in competition with other fuels because means have not been available for efficient •Conversion of its thermal energy to mechanical work. Taking the •railway application •as an example, the cost of Diesel oil is about three times that of its thermal equivalent in coal, but the overall efficiency of a Diesel locomotive is about five times that of a coal-fired steam locomotive. Accordingly, the Canadian railways are replacing all coal-fired steam Locomotives, as they are retired from service, with Diesel units. This conversion in itself represents a major loss to the coal industry because the value of railway fuel is approximately 130 million dollars per year, and there are other applications in the medium power range where oil is displacing coal. There is, therefore, a strong incentive to attempt development of an efficient coal-burning engine.Coal has never been a promising fuel for reciprocating internal combustion engines because of the time required for its combustion in pulverized form . This is not less than one-tenth of a second so that the speed of such an engine would have to be very slow. There are also serious difficulties of a mechanical nature arising from the necessity for intermittent combustion and the use of close-fitting pistons."

Jan 1, 1952

By W. J. Blackstock

Introduction To The great majority of people, the term 'strip coal' has little or no meaning, or if it has any significance it is thought to refer to a poor grade of coal that had to be accepted during the war because no other fuel was available. Few people in the Province of Alberta realize the magnitude of our coal stripping industry, and fewer realize that strip coal has been available to domestic consumers for at least forty years. Among the first in the field of strip coal mining in Alberta were the Tofield Coal Company, Ltd., and Sterling Collieries Company Ltd. It was not until the advent of World War II, with its huge drain on industrial and domestic coal sup? plies produced by the underground mines, that some other source of coal was seriously sought. The tremendous shortage of manpower du ring this period of National emergency made it imperative that any increase in the coal production must be procured on a high tonnage per man-hour basis. It was therefore natural that the highly mechanized strip mine should be eagerly encouraged and subsidized by the Governmental agency - the Emergency Coal Production Board - under the very able direction of Mr. G. A. Vissac.

Jan 1, 1949

By R. Plassart, F. Laigle

"As a powerhouse, a transformer or a valve chamber, large underground caverns are a major element of hydropower plant. On the contrary to galleries and shafts which are linear and long underground structures, large caverns are designed with often complex geometries and large spans. Moreover, as these caverns are generally located on the foot of the hydraulic scheme, the high overburden is often responsible of a high stress state. Thanks to current experiences in France and around the world, the Hydro Engineering Centre (CIH) of EDF has defined great principles in the design of caverns leading to a more general methodology. The project of Tehri in India is an example of difficult ground, with in the same time a high overburden, a ductile material and an important schistosity. These physical realities are attempted to be approached in numerical modelling thanks to a constitutive law with softening behaviour and an oriented criterion integrated in the continuum model. As a result, a flexible support is advised, based on a high density bolt system and a thin lay of shotcrete. This methodology has been developed in the case of Gilboa in Israel, except the schistosity which has not been observed in situ. At last, the example of Gavet (France) illustrates a discontinuous case of numerical modelling for a good quality but fractured rock mass.PRINCIPES ET METHODES DE CONCEPTION DE GRANDES CAVERNESHYDROELECTRIQUES SOUTERRAINESRESUME Les grandes cavernes souterraines abritant les turbines, les transformateurs et certaines vannes sont des ouvrages majeurs dans les aménagements hydroélectriques. A la différence des galeries et des puits qui présentent de longs linéaires, les grandes cavernes sont des structures à la géométrie souvent complexe et avec des portées conséquentes. De plus, ces cavernes étant généralement situées en pied du circuit hydraulique, la grande couverture rocheuse peut se traduire par un état de contraintes important. Forte de ses expériences récentes en France et dans le monde, le Centre d’Ingénierie Hydraulique d’EDF a identifié de grands principes de conception des cavernes permettant l’élaboration d’une méthodologie plus générale. Le projet de Tehri en Inde est un exemple de terrain difficile, présentant à la fois une forte couverture, un matériau ductile et une schistosité marquée. Ces réalités physiques sont approchées au mieux grâce à la prise en compte dans les modélisations numériques d’une loi de comportement radoucissante avec un critère orienté intégré dans un modèle continu. Les résultats ont conduit à privilégier un soutènement souple basé sur un boulonnage systématique relativement dense associé à une fine couche de béton projeté. Cette méthodologie a ensuite été reprise pour le projet de Gilboa en Israël, exception faite de la schistosité puisque non observée sur site. L’exemple de Gavet (France) enfin permet d’illustrer un cas de modélisation numérique discontinue d’un massif rocheux de bonne qualité mais fracturé."

Jan 1, 2015

By F. P. Hassani, M. Hefni, M. F. Kermani

"This study is part of large and an ongoing investigation into the development of a light-weight and highly fluid mine fill for various applications in mining and civil operations. Foam mine fill is the new material proposed for backfilling mines, and is fabricated by mixing stable foam into a mixture of tailings, binders, and water. This paper investigates the effects of both binder dosage and the amount of foam used upon the mechanical and physical properties of foam fill, mainly in regards to compressive strength, porosity and density.Samples were prepared using tailings from a copper mine as the inert material, Normal Portland Cement as the main binding agent, and a foaming agent with a foam generator. Samples were cured for 7, 14 and 28 days and were then subjected to unconfined compressive strength (UCS) testing. Select samples were subjected to mercury intrusion porosimetry, so as to study the microstructural properties. An empirical model was then developed, using a response surface methodology to establish a relationship between the investigated parameters. INTRODUCTION AND BACKGROUNDThe disposal of mine tailings is a significant issue in the mining industry, particularly as mine production increases. Many mines re-use mine tailings for backfilling, which is a method for reducing environmental exposure to tailings, maintaining underground stability, and increasing ore recovery (Benzaazoua, Belem & Bussière, 2002).This paper introduces a new type of backfill called ‘foam mine fill’. This proposed backfill material is similar to cellular concrete, as air bubbles are entrained in cement or lime mortar, resulting in a cellular structure (Narayanan & Ramamurthy, 2000). Air voids can occupy up to 70% of the volume of concrete, which makes it light- weight, and thus can be used for a wide range of civil applications, including backfilling (Tarasov et al. 2010; Panesar, 2013). Unlike cellular concrete, the incorporation of air bubbles into a mixture of tailings, binder and water makes foam fill a potential new backfilling material. Furthermore, a preliminary investigation on foam fill samples found that pulp densities should be optimized before adding the foam, in order to produce consistent samples without foam segregation or losses (Hefni et al., 2014)."

Jan 1, 2015

By A. L. McAllister

"MASSIVE sulphide deposits are found in two areas of New Brunswick, the St. Stephen area and the Bathurst-Newcastle area. In both, the geology in the immediate vicinity of the sulphide bodies is largely inferred from drilling results as outcrop is not plentiful and is, in fact, almost lacking in most places. With few exceptions these deposits have not been explored by underground methods. Consequently much of the. detail on the geology will only become known over a period of years as economic conditions make mining feasible.Much of the information contained in this paper has been supplied directly by company geologists. As a result of the number of contributors, some confusion of nomenclature bas to be anticipated. Cross-sections and plans of the individual deposits are, in most cases, as supplied by the companies concerned. Most of the interpretations are the responsibility of the author."

Jan 1, 1960

By B. Wasmund, M. Parravani, M. Jastrzebski, Z. Coull

"One of the main drivers of overall profitability of pyrometallurgical vessels is refractory lining campaign life. Increased economic pressure to improve vessel life requires innovative solutions to the problem of refractory cooling. Hatch has recently developed a high-intensity, waterless cooling system that bridges the performance gap between external shell cooling and internal water-cooled copper elements. External shell cooling has a limited effectiveness in protecting the refractory lining, because it is thermally insulated from the hotface of the lining by its thickness. This situation does not improve until the lining itself has become worn near the end of the campaign. The patented technology developed by Hatch overcomes this problem by positioning high-velocity air-cooling channels within the lining, closer to the hotface where the cooling benefits can be realized throughout the entire duration of the campaign. The current paper presents the development and application of Internal Air Cooling technology as well as results from the pilot campaign in an operating commercial vessel. Various adaptations for this novel, cost-effective and inherently safe system are also discussed."

Jan 1, 2015

By M. Epiney, A. Ghahreman, R. Kim1and

"In the presence of sulfidic refractory ores, increasing the dissolved oxygen (DO) concentration can positively affect the gold leaching rate. To identify the role of DO in gold cyanidation, electrochemical behavior was studied in the presence of 3 different ores. Sample 1 was a low sulfide pyrite ore, contained 5.14% pyrite, 0.19% galena and 3.09% S. Sample 2 was a pyriticore as well, contained more sulfide as 8.35% S, and 12.4% of pyrite. Sample 3 was a tailing of silicate gold ore, still containing75 g/tAu, 0.13% Pb and 0.18% S. Gold cyanidation kinetics were studied by cyclic voltammetry (CV) and chronoamperometry tests. With sample 1, the gold oxidation peak current density from CV curve was increased to 1.38mA/cm2under oxygen injection, while it was only 0.66 mA/cm2with air injection. From chronoamperometry test, the reaction rate was also faster under oxygen injection. Sample 2 showed similar behavior with sample 1, but the gold oxidation peaks higher than sample 1, i.e. 1.75 and 2.27 mA/cm2, under air and oxygen injection, respectively. However, it seemed that the gold oxidation was impeded by sulfide ions for a longer period. In the presence of sample 3, the gold oxidation peak was the highest among three ores –2.75mA/cm2under oxygen injection, because of its lowest sulfide content. However, from chronoamperometry test, it was also shown that the gold oxidation was impeded because of a significant amount of Pb in the ore sample.INTRODUCTIONIt is well known that gold is leached under oxidative condition (Marsden &House, 2006). Through the most representative and oldest gold leaching technique, cyanidation, more than 90% of gold can be selectively leached from an ore. According to Elsner’s equation, gold is leached in cyanide solution by forming cyanide complex [Au (CN)2–], and oxygen is consumed as an oxidant(Eq. 1)."

Jan 1, 2017

By G. H. K. Pearse, R. P. Taylor

The Big Whopper, one of only four giant economic rare metal pegmatites worldwide, is set to become a producer of the highly valued lithium mineral petalite (LiAlSi4O10) used in glass, ceramics and the specialty glass-ceramics familiar as Corningware® and the new ceramic stovetops. The deposit has a strike length of 1.5 km, a width of up to 80 m and a resource, open in all directions, of 11.6 Mt, grading 25% petalite. It is amenable to open pit mining and Avalon Ventures Ltd. holds a patent on a flotation process that produces an exceptional quality petalite product. The project will also produce: superb quality Na-feldspar which, too, finds use in glass and ceramics; the unusual Rb- K-feldspar for high voltage porcelain insulators; tantalum, in high demand for electronics; lepidolite, an ore of rubidium; and mica and tin. A positive prefeasibility study has been completed and it remains only to undertake bulk sampling and a full feasibility study.

Jan 1, 2001

By M. Kosugi, Y. Kon, M. Kawata, J. V. Satur, K. Mitsuhashi, C. Tokoro, K. Horiuchi, R. Kawarabuki, B. Calabia

"Liberation of copper minerals is important in ensuring high flotation efficiency in copper sulfide flotation. The high pressure grinding roll (HPGR), microwave (MW), and electric disintegration (ED) are known to feature enhanced liberation over conventional comminution machines such as jaw crushers and ball mills by producing internal stresses on minerals or mineral grain boundaries through high compressive forces, thermal expansion of minerals, and pulsed high voltage discharges, respectively. In this study, each of these methods was applied before ball mill grinding to investigate its effect on enhancing the liberation of copper minerals in a low grade and fine-grained copper ore. The copper minerals observed in the tested ore sample are bornite, chalcocite, and chalcopyrite, and their grain sizes range from 10 to over 100 µm. Calcite, quartz, and feldsparare confirmed as gangue minerals. The liberation of the copper minerals by the different methods was analyzed using the mineral liberation analyzer (MLA) and compared. The result showed that the HPGR crushing was the most effective for enhancing copper mineral liberation. HPGR bench-scale test was then conducted on the copper ore and flotation was applied on a HPGR-treated sample to confirm the improvement in the flotation performance by applying HPGR.INTRODUCTIONIn order to recover copper minerals by flotation, copper ore is usually ground by ball milling to liberate the copper minerals from gangue minerals. In the case that the fine size copper minerals are targeted, grinding of the copper ore to a finer size is necessary to increase the copper recovery. However, finer size grinding by ball mill increases energy consumption significantly, which might deteriorate the economies of the mineral processing operation. HPGR, MW, and ED have been recently the focus of researchers as new techniques for enhancing the mineral liberation in mineral processing (Tavares, 2004; Kingman, 1998; Wang, 2010).HPGR crushing is considered to generate micro cracks along mineral boundary when rocks pass between two rolls by applying high compressive force. In the MW treatment, micro cracks are reported to be generated at crystal boundaries by differential thermal expansion of crystals attached to each other. In the ED treatment, micro cracks are known to be produced by plasma current flowing along mineral grain boundaries. These treatments are expected to increase mineral liberation (Fujita, 2001),improve flotation performance(Michaelis, 2005), and reduce ball mill work index(Kaya, 2010)."

Jan 1, 2017

By S. Hume, J. Shepherd

Meso-2,3-dimercaptosuccinic acid(DMSA) was studied as an additive for thiosulfate leaching of gold. DMSA was added to solutionscomposed of either sodium thiosulfate or calcium thiosulfate and the solutions were tested for their ability to leach pure gold samples as well as a calcined gold ore from Barrick Gold Corp. Results showed prolonged leaching of pure gold samples when DMSA was added at a concentration of 5µM; however, higher concentrations were shown to inhibit leaching. Differential capacitance measurements of the interface indicated that DMSA adsorbed as a defective monolayer on the surface of gold at low concentrations and formed a more compact monolayer with increased concentration. It is proposed that a concentration of 5µM DMSA produces a defectivemonolayer on the surface that still allowsthe transport of oxidants to the underling metal while inhibiting the formation of polysulfide passive layers that arise fromdecomposed thiosulfate.The 5µM DMSA/CaS2O3 system was also studied using calcined ore. Results showed that the initial leaching rates in the presence of DMSA are lower than those obtained in thiosulfate alone. However, after 10h, prolonged leaching is again observed when DMSA is included.

Jan 1, 2015

By F. Pinto, C. A. Prato, R. J. Rocca, P. F. J. Huerta Soaje

"The seismic hazard for civil engineering structures is generally defined in terms of deterministic or probabilistic acceleration response spectra at an equivalent rock outcropping. The design of tunnels, however, requires the definition of demands in terms of accelerations at ground surface (near the portals) and in terms of both accelerations and velocities at different depths within the alignment. The design near the portals is controlled by inertial effects and is often times impacted by the possibility of slope instability and rockfall, whereas the design at deep sections is controlled by kinematic effects. These effects are accounted for in practice by introducing deformation patterns in the structure that are related to an assumed wavefield, often times ignoring the effect of the structural stiffness in the response. This paper presents a study regarding the definition of seismic demands for different sections of 14-km long tunnel in the Andes (Argentina-Chile), with a maximum overburden of 1750 m in a seismically active region. The tunnel will pass through volcanic massifs mainly composed by andesites and rhyolites.The study includes the definition of spectrum-compatible seismograms, deconvolution, and definition of accelerations and peak particle velocities for different overburden conditions. A kinematic interaction study for a 500-m tall ventilation chimney shaft is also described, where a simple formulation for the interaction analysis is considered in order to more accurately evaluate shear and bending demands. INTRODUCTIONThe seismic design of linear underground structures, such as shafts and tunnels, generally considers the inertial forces near the shallow sectors (e.g., portals) and the kinematically imposed deformations for the deep sections (e.g., Hashash et al. 2001). The inertial forces are often times evaluated on the basis of design spectra recommended by seismic hazard studies. The kinematic demands for the deeper sections, however, needs to be defined in terms of additional information which is not always indicated by the seismic hazard studies, e.g.; peak particle velocities and accelerations, and their variation with depth. These parameters can be determined by means of a site response analysis, whereby outcrop motions can be deconvoluted in order to evaluate motions inside the ground mass (e.g., Schnabel et al., 1972). Hashash et al. (2001) defines factors that may be used in order to account for attenuation of motions inside the ground mass. However, these factors are provided for depths up to 30 m only, whereas depths of tunnels structures can range up to thousands of meters."

Jan 1, 2015

By V. Aitken

Line-of-sight radio control has received widespread acceptance for use in many mining methods because today’s technology offers improved economics and personnel safety. Significant advances in higher autonomy for mining machines are not currently seeing widespread use even though they offer great future potential. With autonomous capabilities being a longer-term goal, a logical sequence of advances based on TeleRemote control is proposed. Under Tele - Remote control, the operator is in direct control of the machine at all times. Three levels of Tele - Remote control systems are presented including line-of-sight, extended line-of-sight, and full load-haul-dump applications. Distributed control and sensing subsystems arranged in a vehicle control area network support incremental system expansion through the three levels of TeleRemote control and prepare the machine for integration of higher levels of automation as mature technology becomes available. This approach allows full exploitation of today’s mining automation technology with a flexible future growth path.

Jan 1, 1998

By J. Convey, S. L. Gertsman

"THE EXPANSION of steel capacity is seldom spectacular. It may be for this reason that the remarkable progress made in Canada has not been generally recognized. In 1950, Canada's output of steel ingots amounted to 3,270,000 tons ( l ), which is a ll8 per cent increase over the tonnage produced in 1939. It can therefore be readily seen that Canada's growth curve for steel production is climbing at a rate paralleling her growth as a nation. It is by no means •an exaggeration of its importance to consider the steel industry as the cornerstone in the economic structure of Canada's manufacturing activities. From the humble diaper pin to the giant members of massive bridges, fortifications, and other steel structures, steel accompanies us as a necessary and inescapable companion in our journey through life. The Age of Steel has a literal meaning, and refinements in the manufacture of the products of steel are adapting it to more and more varied uses as time passes.The integrated iron and steel works of Canada fall into two natural geographical divisions. One has its base on the Great Lakes and draws its supply of •coal and some of its ore from the United States. In this division lie the works of the Algoma Steel Corporation, at Sault Ste. Marie, at the junction point of lakes Huron, Superior, and Michigan; and the works of The Steel Company of Canada, at Hamilton, on lake Ontario."

Jan 1, 1952

By L. Drisdelle, S. Gendron

"Survival in today's business climate requires participation of all employees in a Total Quality Management Program encompassing everything - ""safety, quality of products, quality ofet1ch and every job done, and of course production "". We all know what needs to be accomplished, but struggle with how to do it, especially in an industry which has not always experienced management/union cooperation, and mistrust is still present.This paper describes a process to improve team work and employee involvement in Inco's nickel carbonyl refinery at Copper Cliff The process involves facilitatorship training for all employees, and a system for reinforcing and accomplishing the required behavioural change. The system is described in detail and a number of examples are presented. At the refinery, the staff is starting to understand as Max DePree recently wrote ""Without Quality Behaviour, you cannot have Quality Product"". IntroductionThe Copper Cliff Nickel Refinery (CCNR) is Inco's largest and most modern nickel refinery, which celebrated its twentieth year of successful operation in April 1993.The heart of the refinery is the Inco pressure carbonyl (IPq plant which produces high purity nickel pellets and specialty powders by refining an approximate 80% nickel granule feed. The carbonyl plant is a modem chemical plant with very special and demanding requirements for safety and environmental protection due to the toxic nature of the refining gas.Since 1987, there has been an emphasis at CCNR on a comprehensive Total Quality Improvement (TQI) Program which was designed based on recognizing customers' needs for improved systems for quality management. This program is customer oriented and comprises such elements as team organizational concepts, customer audits, process assessment and internal quality auditing.A detailed review of progress was made in early 1991 and it became apparent that the ""ownership"" of the TQI program was not broad based. In fact, the program was very much a staff driven effort and fell far short of total employee involvement and relentless continuous improvement that are now considered essential to remain competitive and stay in business.Inco staff has now come to regard that early phase of our TQI program as ""the technical aspects of total quality improvement"".The safety experience was also puzzling. Even though the safety statistics were good with an average lost time frequency of 1.6 for the last five years, the perfonnance improvement had plateaued and remained pretty much the same. Clearly a new approach was required if significant progress and continuous improvement was to be made."

Jan 1, 1994

By Ainul Akhtar, Steve Cockcroft, Jixiang Xu, Daan Maijer, Lu Yao

"Nitrogen rich Ti-N inclusions are one of the more difficult inclusions to remove during liquid metal refining of titanium. If present in the final component, they can significantly decrease the mechanical performance of titanium and its alloys in applications involving cyclic loading. Understanding the kinetics of dissolution of Ti-N particles during consolidation/melting of titanium can help us better operate and design the melting processes to minimize their occurrence in Premium Quality Titanium production. A numerical model based on finite difference method has been developed to calculate the dissolution of a spherical Ti-N particles in molten titanium. Analytical solutions were used to verify the finite difference code for calculation of concentration profile and the dissolution of spherical solids. Taking into account the limitations in these approaches for the different cases examined, the invariant field approximation showed good agreement with the results from the numerical analysis. Evolution of the size of a spherical Ti-N particle during dissolution was predicted by the numerical model and the particle dissolves in 163 s.INTRODUCTION Properties like low density, high specific strength and excellent corrosion resistance make titanium attractive for a variety of applications. Key characteristics in the processing of titanium and its alloys include its high sensitivity to impurities, especially atmospheric oxygen and nitrogen and its high reactivity in the molten state. Nitrogen rich inclusions Ti-N, also known as Type ? or hard alpha defects, usually have substantially higher hardness and lower ductility than the surrounding material. Because they can act as fatigue initiation sites, Ti-N inclusions can significantly decrease the mechanical performance of titanium and its alloys in applications involving cyclic loading, even in minor amounts (tenth of a percent) (Lampman, 1990; Moiseyev, 2005; Lütjering & Williams, 2007). Ti-N encompasses as a broad range of nitrogen contents from a few wt% up to stoichiometric TiN. The liquidus temperature of Ti-N titanium increases substantially with increasing nitrogen content. Consequently, depending on the concentration of nitrogen, the melting point of Ti-N inclusions can be above bulk liquid metal temperatures during melt processing. Thus, removal of Ti-N defects hinges on dissolution and not melting."

Jan 1, 2017