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By J. A. E. Bell

"Inco has shifted part of its traditional extractive research effort at its J..Roy Gordon Research Laboratory in Mississauga toward new, value-added products. Most of the effort is being expended on new Ni powders for batteries and new Ni-coated products which will be produced in Inco's carbonyl nickel refineries. New products under development are Ni-coated powders, Ni-coated fibres and ultra-fine Ni powders. Other new products for advanced material applications include controlled expansion composites, NiGOLD strip, Thermal barrier coatings on Inco alloys, and plasma coatings.Research and Corporate Strategic ThrustsThe newest strategic thru st of the company is to increase the value of the primary metal products. These new products are to be in addition to any new alloys or downstream alloy fabrication.Historically Inco has had the highest research expenditures in the extractive metallurgy field in North America. This has resulted in many new processes including flash smelting , matte separation, fluid bed roasting, pressure carbonyl refining and cobalt electrowinning which have contributed to establishing Inco as the lowest cost nickel producer. The recession of the 1980s caused a restructuring of Inco research and corporate goals .As shown in Figure I, from 1975-1982, i.e. pre-recession, Inco spent around 33 million dollars per year on research. Some 48070 of that sum was spent in Corporate Laboratories in Sterling Forest in the United States and in the United Kingdom , mostly on alloy associated research. A further 10% was spent on alloy research at the alloy production facilities in Hunting- ton, West Virginia, and Birmingham and Hereford in the United Kingdom. On extractive research, 13% was spent by process technology groups at the plant s, 20% at the pilot plants in Port Colborne and 9% at the J. Roy Gordon Research laboratory.The relative research expenditures (Fig. 2) have decreased so that today they are at the same level as 1975-80. The research as a per cent of sales has been cut from 2.2% to 1.2% of normalized sales. A normalized sale price of $4.00/lb Ni was used in the 1988 figures. This was partly achieved by closing Corporate Laboratories. Most of the essential alloy research was moved to producing plants and total alloy research is now 27%.A new thrust initiated in the 80s was mining research which now accounts for 20% of research expenditures. Over a period of the past five years this research has doubled the mining productivity in Inco. The pilot plant expenditures have been cut in half. One entire research station at Port Colborne was converted into a platinum group metals intermediate refinery. The decrease in pilot plant expenditures has been compensated by full scale plant trials devoted to the S02 abatement program at Sudbury."

Jan 1, 1990

By R. H. Fett

T HE APPROACH to maintenance must always be ?completely positive: there must be no question of putting off difficult problems until it is more convenient to tackle them. By this it is meant that a piece of machinery or equipment which, by experience, is known to be due for a check should not, merely because it appears to be operating satisfactorily, be left until it reaches a critical .condition and breaks down. The mentality of the Maintenance Manager must be completely orderly and methodical and he should, in fact, possess a ledger-book mind, having a debit and credit outlook. The debit side would be that applying to time out of service, cost in wages, material, personnel involved, etc., and the credit side that relating to continuous operational time of the locomotive and therefore to the ultimate benefit of the mine and the personnel who work there. The Maintenance Manager is not concerned with design problems, and although he and the personnel under his jurisdiction are not engaged in productive work, he and his staff do, nevertheless, add greatly to or detract from the overall efficiency of the organization. Provided the machinery placed in his care is good to start with, he must take the best steps he possibly can to keep it running. However, he may, on occasion, be forced to improvise and this is where the ingenuity of a clever man rises to the occasion.

Jan 1, 1956

By Ross Gallinger

In 1997 a group of Canadian mining companies met to review the Mine Environment Neutral Drainage (MEND) program and to consider future activities. They concluded (i) that Canadian industry and NRCan should fund a small secretariat in Ottawa to support technology transfer in Canada and (ii) that it was important for industry to continue the momentum of MEND on an international scale. The need for INAP (International Network for Acid Prevention) was strongly endorsed by company, university, consultant and government experts from Australia, Canada and the U.S. who were convened in Vancouver in February 1998. The initial focus was the development of a solid knowledge base covering the collective experience of INAP's members to promote the dissemination of successful practices, the identification of knowledge gaps and the formulation of effective research proposals. The sharing of information on past successes and failures alone was viewed as sufficient justification for the formation of INAP. INAP was officially launched in October 1998, and is now an effective, industry based initiative to globally coordinate research and development in the management of sulfide mine waste. Significant improvements in the management of sulfidic mine materials through knowledge sharing, research and development of technology by INAP will reduce liability associated with acid drainage. This paper will explore the international efforts and activities of INAP.

May 1, 2002

By A. Banerjee, J. P. Weiler, J. Jekl, J. T. Wood, R. Berkmortel

"The work presented here is part of an ongoing project designed to develop predictive capabilities of the local mechanical properties, and thus, structural behaviour of a thin-walled high-pressure die-cast AM60B magnesium alloy component. This work focuses on developing correlations between process parameters and local microstructure. Numerical simulations of the die filling and solidification behaviour of the AM60B component were used to estimate local process parameters such as solidification rate, temperature gradient, filling velocity, etc. These estimated parameters were used to establish semiempirical correlations with measured VALUES (of the local microstructure measured in regions throughout the component of different solidification conditions. INTRODUCTIONHigh-pressure die-cast magnesium alloys are experiencing increasing use in structural automotive components. A strength-to-weight ratio comparable to steels and its ease of castability allow for these alloys to be utilized in such capacities as instrument panel beams, seat and door frames, and engine cradles, among others (Gjestland and Westengen, 2007). However, the current use of these alloys is limited due to variations in local mechanical properties. These local property variations restrict part designers to assume lower than actual properties, resulting in larger sections, thus diminishing the light-weighting advantages of magnesium alloys. If these local property variations could be predicted, part designers would be able to optimize die-cast magnesium alloy components and fully take advantage of the light-weighting capacity of these materials.The work presented here is part of an ongoing project aimed at developing predictive capabilities of the local mechanical properties, and bulk mechanical performance, from variations in local microstructure, and ultimately from local process parameters in die-cast magnesium alloys. This project, unique in its nature, is based upon the results determined from fifty sequentially cast AM60B magnesium alloy instrument panel beams provided by Meridian Lightweight Technologies (shown in Figure 1)."

Jan 1, 2012

By Mehmet Guney

This article is based on a detailed heat investigation conducted at the Rokana Division of Nchanga Consolidated Copper Mines Limited while both authors were employed in Zambia. Mindola Mine is one of the three underground mines comprising the Rokana Division on the Copperbelt of Zambia, producing about 270,000 tons of ore per month at 1.9% Cu and 0.14% Co. The total volume of air being circulated by means of five primary fan installations slightly exceeds 1,000 m3/sec at standard density. Sectional bulk cooling is practised where air cooling coils are installed at primary splits some considerable distance from the stoping operations. Total capacity of the refrigeration complex is 10,500 kw (3,500 R. tons), of which about 7,000 kw is available as effective cooling power after losses, but the heat removed from the coifs is about 3,500 kw with 61% over-all plant performance. An extension program is planned for a further five production levels with the re-deepening of a sub-vertical shaft. Thermal heat will become a major problem at increased depth associated with higher rock temperature, higher thermal conductivity of the rock groups encountered and fissure water flowing into working areas through the strata with increased rock temperature. This paper describes the ventilation and refrigeration practices in Mindola Mine, with special reference to future thermal heat problems. These are discussed with a view to mining at depth.

Jan 1, 1979

By A. N. May

"This paper describes the present approach of the Mines Branch to the problem of measuring the stress condition in the interior of rocks surrounding underground openings. An instrument, which will be referred to as a stressmeter, has been developed at the Mines Branch to measure un-directional stress changes in absolute units. There are two modes of operation of this stressmeter. It can be regarded as a fixed instrument, in which case it is installed at the end of a diamond drill hole and left in position to record any subsequent stress changes taking place. Alternatively, three of the stressmeters can be used in conjunction with a trepanning opera-tion to allow the existing stress condition to be determined. The initial laboratory work and subsequent experiences in the field with the stressmeter are described. All the field development work on the stressmeter was made possible through the co-operation of Canadian Refractories Limited, Kilmar, Quebec."

Jan 1, 1960

By Blaycock. S. C.

WE should indeed feel proud and satisfied with the accomplishments of our great mining and metallurgical. industries during the past quarter of a century, for they have vastly exceeded those of any previous period of like duration. 1 feel that Canadians, and particularly those in the mining industry, should know more concerning the important role our industry will be called upon to play in the present war. Our Empire metals will be an outstanding factor in this conflict. Every man connected with the industry, from the lowest paid labourer to the highest official, can feel proud that his every effort results in more and more production of those metals which will help to give the Empire supremacy. He can feel assured that, by sticking to his job and by putting his whole heart into his work, he is making a contribution towards winning the terrible struggle in which our Empire and our gallant French allies are engaged. These two great peoples will have ro bear the brunt of the task of ridding the world of the menace of those who would set up force. and might in the place of right and justice in the settlement of international affairs. As the present European crisis developed, it became evident that they, alone, would have to accept the challenge and fight the enemies of Democracy to ensure the survival of the small nations of Europe and, indeed, of the great democratic powers themselves. The acquisitive eye of the German leaders had looked far ahead and they had realized that the eastern European states, already reeming with population, were no solution to Germany's space problem; but they thought that these states could be gobbled up one by one, each in turn strengthening Germany's might until it could successfully challenge France and England. No glimmer of doubt dimmed their vision. The two great democracies once subdued, they could proceed to seize Canada and the United States. This clone, they would have an abundance of room to expand, as well as those resources-grain, timber, cotton, nickel, iron, lead, zinc, copper, gold, silver, sulphur, oil-which German statesmen have always coveted. Von Ribbentrop, von Alvensleben, Bernstorff, and many others have made exhaustive studies of our resources. German rulers had been told that the French would not fight and that the British could not. They knew of the rust on the British war machine. There was no cloud in the sky; their fond dream was at last robe fulfilled.

Jan 1, 1940

By G. C. Milligan

"A regional mapping program, conducted by the Nova Scotia Department of Mines, has shown that the George River Group of pre-Middle Cambrian rocks consists of a wide range of sedimentary and volcanic rocks, intruded by syenite, granite, granodiorite and lesser amounts of gabbro and diorite. Together, these rocks support the high ground of northern Cape Breton Island. Over this large area, the metamorphic grade ranges from low to extremely high.The rocks were folded prior to emplacement of the intrusions in Middle Cambrian time, and there was also post-Mississippian disturbance and faulting, but the structural history and pattern are still only imperfectly understood.Sulphide mineralization is known at Meat Cove, Lime Hill and in a number of smaller deposits. The most Cavour-able host rocks appear to be magnesian Iimestone, or schists derived from shales. Ail known sulphide bodies have an associated halo of retrograde metamorphism; in some cases, this is extensive enough to be used as a prospecting aidA vein of nickel-bearing sulphides has recently been re-discovered in the former gold mine at Second Gold Brook-an association which appears to be unique."

Jan 1, 1971

By J. Basi, J. A. Finch

ABSTRACT Testing the effects of bubble size (Db) in a Mo cleaning ?otation column at Highland Valley Copper mine indicated that increasing the proportion of small (< 1 mm) bubbles signi?cantly improved column metallurgical response, compared to typical operation. The results were a three- to four-fold Mo recovery increase and a 1 to 2% Mo (absolute) concentrate grade increase. The improvedcolumn operation produced a 4% Mo plant recovery increase. This study also showed that modelling the ?otation rate constant (k) as an inverse square function of Db was more accurate than considering k to be inversely proportional to Db.

Jan 1, 2010

By H. Abdollahi

Cold rolling is one of the most important techniques in metal forming since the cold rolling products are almost finished product, The product quality of this process is widely influenced by friction in the roll gap; therefore, controlling the friction and other parameters affecting the cold rolling is very important in order to have a product with high quality, Among the cold rolling parameters, the pressure distribution or friction hill within the roll gap is known as the most significant one, In this study, a new software (Matroll), is introduced which can determine the coefficient of friction (COF) and plot the friction hills for an industrial mill, Besides, based on rolling equations, it offers about 25 rolling parameters as outputs. To verify the software operation, the real industrial rolling data was used as inputs, The results (outputs) are in good agreements with the findings of other researchers, The COF values are very reasonable, The friction hill shows that COF is not constant over the whole arc of contact.

Jan 1, 2005

By Matthew D. Meyer

SMART, an association of surface mining companies formed in 1995 to develop a coordinated approach to technology development for the mining industry, has recognized the need for the establishment of a worldwide database that continuously collects mining equipment data and provides metrics related to productivity and cost. Under the auspices of SMART, Syncrude Canada, Suncor Energy and Albian Sands Energy (three oil sands mining operations located in northern Alberta) have established a pilot project for mine benchmarking. This presentation will include a review of the pilot progress including: ???Data gathering techniques: means of collection and storage, proposed practice for data control and normalization, access to data/reports and format for data. ???Reports/analyses for individuals, across groups, within the total industry pool and publicly. ???Security and confidentiality of information belonging to identified parties. ???Sharing of best practices among members. SMART has identified two key deliverables to ensure success of the project. First, data supplied from surface mines must be validated and normalized to common definitions and then analyzed to provide participating companies with regular reports that allow them to understand their position and resultant opportunities to achieve world-class performance. This model maintains granularity of the data for each operation that can then be recombined into standard comparisons or specific indices as required. The general categories of: operating delays, maintenance downtime, standby, and scheduled downtime, have been used to frame comparisons. Second, participating companies are looking to go behind the indices to identify and share best practices that distinguish particular operations. The spirit of cooperation between the companies involved in the pilot project is meant to be a model for future expansion of the benchmarking project.

Apr 1, 2005

By D. Ortiz, J. R. Frias, E. D. Mast, J. J. Fañas

Falconbridge Dominicana (Falcondo) has operated an integrated tpy nickel laterite mine and ferro-nickel processing plant since 1972 in the Dominican Republic. The operation includes mining, a processing plant, an oil refinery, and a power plant. Falcondo has improved process efficiency over the years via modernisation and better understanding of the process. The present business environment of high fuel prices and high nickel prices present a challenge and an opportunity to Falcondo&apos;s operation. This paper gives an update of Falcondo&apos;s process, improvements in energy consumption, factors affecting energy consumption and how Falcondo is facing up to the current business environment.

Jan 1, 2005

Mining Equipment Challenges Equipment Availability Unplanned downtime Maintenance Costs Secondary damage and catastrophic failures (T282 $750k) Emergency work is 4x the cost of planned work Inspections Troubleshooting time Incorrect repairs (parts, labor, lost production) Equipment Life Mis-operation of equipment

May 1, 2013

By \/eena Sahajwalla, Jonathan Dicker, Paul O'Kane, Cath Skidmore, James Dankwah, Magdalena Zaharia, Rita Khanna, David Knights, N Saha-Chaudhury, Somyote Kongkarat

Due to the inherent limitations of current methods of disposal of end of life polymeric materials, avenues are researched towards developing alternative, environmentally friendly and economic recycling processes. Different polymeric materials (i.e. rubber, high density polyethylene (HDPE) and polyethylene therephtalate (PET)), quite distinct in terms of chemical structure and composition, were considered in the present study as carbon resources in EAF steelmaking. Investigations were conducted in both laboratory and industrial scale steelmaking to assess the effectiveness of using these materials as carbon sources for slag foaming in EAF steelmaking. Slag foaming is important because it enhances furnace efficiency.

Jan 1, 2011

By A. V. Tarasov

There are still a number of copper smelters in the world using the roasting and smelting process flow diagram for treating sulphide raw materials. The technical, economic and environmental performance indicators of such operations are inferior to the respective indicators of advanced processes. First of all with respect to copper and sulphur recovery: 95% and 75% as compared with 98% and over 90%, respectively. Based on the studies of the single-stage smelting process to produce white metal and blister copper conducted during recent years an analysis of the feasibility of roastingsmelting technology improvement was carried out in the Gintsvetmet Institute to substantially increase the copper and sulphur recoveries. On the basis of this analysis, it was proposed to modernize the technology and equipment within the framework of the existing process flow-sheet. The proposed modernization implies an increase in the roasting temperature; higher desulphurization degree in the process of roasting; a number of modifications in the roaster design depending on the particular conditions of a given operation; addition of lime flux to the feed charge to roasting; and transition to combined calcium-silicate smelting slags. The metallurgical and energy computations made have indicated that the proposed modifications of the technology will improve the copper and sulphur recovery up to 98% and 90%, respectively. The required capital investments have been estimated using as an example a particular copper smelter, the payback period determined taking into consideration additional output, fuel saving and a reduction in fines for sulphur emissions. For comparison, the capital cost of a smelter modernization is given for change-over to basically new autogenous Ausmelt, Outokumpu and V anyukov smelting technologies.

Jan 1, 2007

By T. A. Utigard

To improve recoveries of Ni, Cu and Co in the Inco flash furnace, a new operating concept was investigated. By adding sufficient coke to form a supernatant coke layer, a reducing barrier would form allowing for improved reduction of descending oxidized sulfide mineral particles formed in the flame. The objective of this investigation was to study the kinetic mechanism and efficiency of the coke layer to produce a sulfur deficient matte. The mechanism and rate of carbon reduction of each of the phases formed in the flash flame, i.e. sulfides and oxysulfides were investigated by means of X-ray visualization tests. Graphite-slag reduction was also conducted for comparison purposes. In the case of slag, poor wettability and the formation of a gas film on the surface of the carbon reductant are often blamed for limiting the reaction surface area that ultimately results in poor reaction kinetics. The X-ray visualization tests confirmed that matte and oxysulfide wet coke better than slag and that the rates of reduction of matte and oxysulfide are faster than that of slag.

Jan 1, 2005

By Michael R. Brown

A facilities success or failure of doing well during a regulatory inspection is typically measured by the number and type of citations that result, and financial liability resulting from those citations. The success of a facility during an inspection depends on several factors including, the preparation prior to an inspection, behavior and activities during and inspection, and finally, action taken following the inspection. This paper contains suggestions for improving inspection results and establishing an attitude of compliance at manufacturing and mining facilities.

May 1, 2002

By Jarret Thomson

An understanding of groundwater flow is essential for many aspects of mining. This is especially true for the process of shaft sinking through the sandstones of the Manitou Falls Group in the Athabasca Basin of northern Saskatchewan. Experience has shown that the hydraulic conductivities of these sandstones can be relatively high, especially in zones containing natural fractures. To develop a better understanding of the inflow potential into a shaft, a laboratory testing program was undertaken to investigate the hydraulic conductivity of fracture core samples from the Manitou Falls Group. This program involved the measurement of hydraulic conductivities under steady-state flow conditions, while cycling the effective confining pressure across a span that is representative of in-situ conditions. The change in fracture aperture was simultaneously recorded at each confining stress level. It was found that existing relationships relating aperture and flow did not accurately capture the behavior of the samples tested. The effects of fracture staining and infilling were also investigated, and were found to have a notable impact on the hydraulic conductivity.

Jun 1, 2012

By S. F. Guo, B. W. Zheng, X. L. Huang, S. W. Qi

"The study of mechanical characteristics of rock discontinuities under different shear deformation velocities is an important premise of rock slope dynamic response analysis. According to disposing and calculating the experimental results of previous research about peak shear strength of rock discontinuities under different shear deformation velocity of constant normal loading, the law of influence of shear velocity on the total friction angle is studied. Based on the research results, it can be found that the total friction angle of rock joint specimens varies in the form of negative logarithm with the variation of shear deformation velocity. It’s also indicated that the total friction angle of rock joints decreases with the increase of shear deformation velocity for rock joints of relative strong homogeneity and isotropy. However, the total friction angle of rock joints increases with the increase of shear deformation velocity for rock joints of relative strong heterogeneity and anisotropy and the latter amplitude of increase is less than the former amplitude of decrease. The physical property and microscopic geometry of rock joints play an important effect on the increase or decrease tendency and amplitude variation of total friction angle with the increase of shear deformation velocity.INTRODUCTIONThe rock slope dynamic response is largely restricted by rock discontinuities. Hence the study of dynamic characteristics of rock discontinuities, especially the dynamic shear characteristics is an important premise of rock slope dynamic response analysis (Qi et al., 2007). Seismic load is both dynamic load and cyclic load (Liu et al., 2011). Under the dynamic and cyclic shearing actions of seismic load, the rock slope which is stable under the condition of static load may slide along the rock discontinuities whose shear strength reduce and then the earthquake landslides occur. The strength degradation and deformation mechanism of rock discontinuities under the dynamic and cyclic shearing actions is one of the key problems to be solved in the work of earthquake prevention and control of engineering slope. Based on the above understanding, predecessors conduct some researches which focus on the shear behavior mechanical characteristics of rock joints under cyclic shearing actions (Plesha, 1987; Hutson & Dowding, 1990; Jing et al., 1992, 1993; Huang et al., 1993; Qiu et al., 1993; Homand et al., 2001; Lee et al., 2001; Jafari et al., 2003; Liu et al., 2011, 2013). However, there are a few researches about the mechanical characteristics of rock joints under different shear deformation velocities because of the restriction of shear apparatus. Crawford and Curran (1981) conducted a series of one-way cyclic direct shear tests on four kinds of natural rock joints under different shear deformation velocities varying from 0 to 200 mm/s. The tests showed that at low normal stresses the peak shear strength of soft rock joints exhibited an increase up to a certain velocity, after which it remained essentially constant. For rock joints of intermediate hardness, the peak shear strength was essentially independent of shear deformation velocity; whereas for hard rock joints, the peak shear strength of which showed a significant variation with the shear deformation velocity. Jafari et al. (2003) carried out a series of conventional triaxial tests on artificial rock joints of regular saw-tooth shape with axial loading rate from 0.05 mm/s to 0.4 mm/s."

Jan 1, 2015

By Hani S. Mitri

Strainbursts in brittle rock are common to deep underground mines. The state of stress at the boundary of mine openings is dictated by a biaxial stress/loading condition. This paper reports the results of a series of biaxial compression tests carried out on 100 mm cubic samples of norite rock, under different horizontal-to-vertical stress ratios. The results indicate that the biaxial compressive strength is considerably higher than the uniaxial one. It is found that the norite sample behaviour under biaxial loading mirrors field behaviour where shearing and progressive spalling of the opening boundary are observed prior to strainbursting. Sample failure is initiated by rock spalling at the sample free faces, i.e. in the plane of biaxial loading. Finally, it?s the out-of-plane shear failure mechanism that causes the sample to collapse. Shear failure takes place violently and abruptly and is accompanied with considerable audible noise.

Apr 1, 2005