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By Corrie Pitzer

Safety performance in many companies and even industries has stalled in the last decade. Accidents rates are improving but more slowly and yet, serious accidents and fatality rates are not: in fact, these rates of more serious incidents have plateaued or deteriorating. In more dramatic cases, organizations that had ?exemplary? safety statistics, suddenly had a catastrophic or multi-fatality event occurring. Popular books such as In Search of Excellence of Peters and Waterman or Good to Great of Jim Collins created many delusional ?secrets? or recipes, to achieve great performance and yet, most of those ?great? or ?excellent? companies have now declined in their performance, some dramatically and some have fallen from grace, like Fanny Mae, a company Jim Collins identified as a ?great? one, that had to be bailed out in the latest financial crisis. These organizations share several ?delusions? about managing a business, and often, these delusions are created by academics, consultants and authors of popular books about (safety) management. More damaging however is that safety management is defined by a set of key practices or axioms: a focus on human error, compliance to rules and regulations, creating consistency of systems and actions, reacting to accidents and incidents and on prevention of those, measuring safety with performance metrics and rewarding employees on those measurements. All of these axioms contain the seeds of destruction, and they create conditions and dynamics that precede the disaster - and ironically, they are all 'good things' we do in safety management. For example, a mere focus on safety in the business, and the measurement of it, create a culture of repression of mistakes and incidents, leading to a situation where the organization knows incrementally less and less of risks and risktaking behaviour - until the day it all coincides destructively! This paper discusses seven such safety delusions and how they impact on the views and safety management approaches. They are: ??The delusion of (risk) control, that risks can actually be identified, analyzed and mitigated. ??The delusion of compliance, that mere compliance to rules will safeguard the business ??The delusion of consistency, that standard operating procedures will ensure safe operations ??The delusion of predictability, that accidents and trends tell us everything about the risks of the future ??The delusion of human error, that people are the weakest link and that it can actually be dealt with through discipline and enforcement. ??The delusion of statistical trends, that safety is measurable with statistics ??The delusion of invulnerability, that we have achieved high levels integrity and capability to deal wit risks. Organizations that suffered catastrophes all share some or all of these delusions and this paper traces how these played a role in many disasters, ranging from the Titanic, Challenger, Piper Alpha, Bhopal, BP Deepwater Horizon and many more.

Aug 1, 2013

By H. Fuchs, W. Hilger, E. Prosser

"The Lone Gull discovery of Urangesellschaft Canada Limited was made in 1974 as a result of extensive exploration activities for unconformity related uranium deposits in the Baker Lake area of the Northwest Territories. The structurally controlled mineralization is hosted in Aphebian metasediments and intrusive granitic stocks located approximately 2 km south of the unconformity between the Lower Proterozoic Aphebian and the Middle Proterozoic The/on Formation.The original discovery was made with a helicopter mounted radiometric system during systematic prospection over the unconformity. Diamond drilling was first carried out in 1977 and continued, with an interruption in 1981, to the present. A total of 25,500 metres and 199 holes have been drilled and outlined three ore zones. Preliminary geological reserves are estimated at some 16 million kgs. U30 8 at an average grade of approximately 0.4%.IntroductionUrangesellschaft initially entered exploration in Canada as a participant in joint ventures in 1968, and was incorporated in Canada in 1974 as Urangesellschaft Canada Limited. Subsequently, UG was among the first companies to apply exploration criteria developed from the Athabasca Basin, namely the Middle Proterozoic unconformity over Archean/ Aphebian basement, for selection of exploration targets in the geologically similar Thelon Basin.The Baker Lake area in the Keewatin District of the Northwest Territories was selected from the extensive Thelon Basin because it had the best accessibility (Fig. 1). The hamlet of Baker Lake located close to the geographical centre of Canada, is largely an Inuit settlement with a population of approximately 1,100 inhabitants. The distance from Baker Lake to the Lone Gull property is about 80 km. Baker Lake is connected to the tidewater of Hudson's Bay via Chesterfield inlet and is serviced by scheduled domestic flights several times weekly from Churchill, Manitoba, about 650 km to the south."

Jan 1, 1986

By W. B. Boggs

The Noranda smelter was built by Noranda Mines, Limited, from the designs of A. E. Wheeler, consulting metallurgist, New York, for the reduction of ores and concentrates from the Horne mine, and to treat, on a custom basis, ores and concentrates from other mines in the Rouyn district. The smelter is situated at Noranda in western Quebec, about 330 miles directly north of Toronto. Ground was first broken for construction in November, 1925, before the completion of the branch railway into the district, which was not finished until October, 1926. After many difficulties and delays due to the Jack 'of transportation and the severe weather during the winter months, the smelter was started in December, 1927, and the first blister copper was poured on December 17th. The smelter was built throughout in two duplicate units, each with a rated capacity of 500 tons of ore per day. Operations were started with only one unit, and after several months it was found that one unit alone would smelt 1,000 tons of ore per day. At this time only one shaft, No. 3, existed, and its hoisting capacity and the capacity of the original crushing plant were insufficient to supply ore for two units at the increased tonnage. Accordingly No. 4 shaft was sunk and a new crushing plant provided to handle the ore hoisted there. This work was completed in the latter part of November, 1929, and since that time both smelter units have been operating.

Jan 1, 1930

By S. Shairp

"After cooling and thickening, slurry from the second stage of the Hudbay zinc pressure leach circuit is filtered and washed on a belt filter prior to disposal. At times, the belt filter can be a bottleneck to the process. Preliminary studies show that filterability of the second-stage (HAL) autoclave leach residue can be indicated by particle size distribution of the filter feed and filtered residue cake. In particular, the Volume Weighted Mean Diameter, D[4,3], generated by a laser diffraction particle size analyzer from samples of HAL Filter feed, shows residues that filter more poorly have a lower Volume Weighted Mean Diameter than those that filter better. INTRODUCTIONHudbay produces cast zinc metal from blends of zinc concentrates at its metallurgical complex in Flin Flon, Manitoba, Canada, using Sherritt’s two-stage pressure leach process (Collins et al., 1994; Collins et al., 1995; Barth et al., 1998; Shairp et al., 2006). Pressure leaching replaced the original roastleach- electrowinning process in 1993.Filtration for the second-stage (HAL) leach residue originally consisted of two stages of vacuum drum filtration with intermediate cake repulping stirred tanks. As part of Hudbay’s 777 Project, with a designed increase in cast zinc production, a pre-feasibility study by SNC-Lavalin Inc. showed that losses of soluble zinc in the zinc pressure leach residue could be reduced by installing more efficient filtering and washing equipment. Based on laboratory performance, capital cost, installation ability, and potential operating cost savings, a 70 m2 Filtres Phillipe belt filter was chosen for the HAL residue, and commissioned in 2000/2001.When the HAL belt filter is performing well, there is no pooling of water on the surface, moisture content is relatively low, and subsequent analysis shows that water soluble zinc content is relatively low. There have been occasions where the filter has performed poorly with respect to the aforementioned parameters. Aside from the filter experiencing mechanical difficulties, there are several variables affecting leach residue filtration:"

Jan 1, 2012

By V. C. Pandolfelli, L. Paulino, C. E. Zangiacomi

The continuous improvement in aluminum industry over the last years has increased metal output at lower cost. The potlining plays an important role in this regard due to high cost involved and more recently in its environmental aspects. In order to increase potlife and thus minimize the aluminum cash cost, a systemic approach is needed, through investigating the main cathode failure mechanisms by using a pot autopsy as a powerful tool, and then making the necessary chances to achieve extended potlife. In addition, preheating and pot start-up may also damage the cathode if not performed with an appropriate technique or even if the lining materials are not specified correctly, among other factors. All these aspects will be presented and discussed in this paper. Increased potlife, especially now that the current is reaching values up to 300kA, will allow aluminum plants to match their goals more efficiently at lower costs.

Jan 1, 2006

By R. Augsten, K. K. Feng, K. C. Cheng

"Methane emission and the desorption characteristics of vertical borehole coal samples of Greenhills multiple seams in the vicinity of Elkford, British Columbia were investigated. Three vertical boreholes at depths of 335 m, 380 m and 395 m were drilled along the west wall of an active open pit mine and 44 core samples from various coal seams were obtained for desorption studies.The results are presented in three tables and illustrated with six figures. The methane content was found to increase significantly at depths greater than 200 m. The adsorption equation by Kim and the properties of the coal have been used to predict the methane content and these were compared with the measured values by the direct method.IntroductionThe coalification of plant material in the sedimentary rock produces different ranks of co al and gases of various composition. The gas mixtures are retained in coal beds and rock strata under pressure. The gas content in a coal bed varies considerably depending on the rank of coal and the depth of overburden. The gas content is defined as the volume of gases adsorbed in a unit weight of coal materials. The net amount of gases remaining in a coal seam depends on the difference in the rate of generation of methane by geo-thermal heat and the rate of diffusion of the gases out of the coal bed through sedimentary cover. The major factor that causes the change in rank and the liberation of gases is the temperature, which is governed by the thermal conductivity of sedimentary cover and the heat flux through the underlying rocks. The rate of diffusion of the gases out of the coal is governed by the porosity of the overlying rocks and the degree of fracture. The measured values of gas content in major North American coal beds are from zero up to 24 cm3 per gram of coal(1,2). A gas content of 2.5 to 9 cm3/g is considered ""gassy"" and that of 9 cm3/g or higher is considered ""very gassy"" for underground mining(3). Normally, the gas mixtures released from bituminous coal in Canada contain 90 to 98% methane and the remainder is made up of CO2, N2, 02, H2, He and other hydrocarbons(4)."

Jan 1, 1984

By Peter Hood

Data on world-wide geophysical activity in mining exploration programs are collected annually by the Society of Exploration Geophysicists' Geo-physical Activity Committee as part of a continuing service to the industry. The data are obtained by sending out questionnaires to all organizations which are known to be carrying out mining geophysical work; the organizations canvassed include mining companies, contractors, government departments and universities. The questionnaire is divided into three sections; namely, ground methods, airborne methods and research. The data compiled from the questionnaires show that world-wide utilization of mining geophysical methods reached a new high in 1967 with total expenditures of (U .S.) $32,323,240. This was divided as follows: ground methods, $18,106,785; airborne methods, $10,-123,405; and research, $4,093,050. For the ground methods, most money was spent on the induced polarization technique ($5,681,780); electromagne-tic methods were second in reported expenditures ($2,010,900). The total reported geophysical line mileage flown was 1,275,072 line miles, with aeromagnetic surveying being the most popular airborne method. The total amount spent on aeromagnetic surveys was $5,832,564 for 895,420 line miles. This gives an average cost of (U.S.)$6.50 per line mile.

Jan 1, 1968

A semi-automatic device has been constructed that can be used to check the solution strength of cyanide solutions. It consists of a wheel on which a gold-foil-bearing glass slide is mounted. The wheel moves the gold foil through the solution under test and intercepts a light beam. As the gold foil is attacked by the cyanide solution its light absorption diminishes. The successive in-crease in transmitted light intensity is recorded and gives a measure of the gold dissolution rate. Curves have been obtained to show the effect of cyanide concentration and oxygen content on dissolution rates. Details are presented of the construction of the unit, and some practical operating procedures are outlined. 0 NE of the important, although often neglected, factors in the extraction of gold by cyanidation is the actual dissolving strength of the cyanide solution. This depends in a

Jan 1, 1964

By Emmanuel John M. Carranza, Martin Hale

Abstract- An application of logistic regression to mapping of gold potential in the Baguio district of the Philippines is described. Categorical map data such as lithologic units and proximity classes of curvi-linear features, based on spatial association analyses, are quantified systematically and used as independent variables in logistic regression to predict the probability for presence or absence of gold mineralization. Regression experiments to compare between using all independent variables that are associated spatially with the response variable and using only statistically significant independent variables are performed. The results of the regression experiments are similar; however, the use of all independent variables produces slightly optimistic results but better prediction rates for the known gold deposits in the test district. At least 68% of the ‘model’ large-scale gold deposits and at least 76% of the ‘validation’ small-scale gold deposits were predicted correctly. The predicted geologically favorable zones are also similar to delineated geochemically anomalous zones. The technique presented using logistic regression as a data integration tool is effective for geologically constrained technique of mapping mineral potential.

Jan 1, 2001

By Harry V. Warren

Introduction Any person concerned with the welfare of mining in British Columbia cannot help being perturbed by the fact that the industry, to an alarming extent, is living on its capital. The great majority of mines and mining camps of today represent a heritage handed down by the prospectors of yesterday. It is true that mining engineers, geologists, mineral dressers, metallurgists, and their fellow scientists and engineers have played an honourable, indeed a vital, part in he1ping to make our producing mines, often after costly and extensive underground development and extended researches. It is also true that the mineralization at the Sullivan, Britannia, and Copper Mountain mines was all discovered before the turn of the century. Likewise the Cariboo, Bridge River, Hedley, Ymir, Rossland, Boundary, Slocan, Salmo, and Portland Canal mining areas, although they had not all been developed, were all known more than fifty years ago. Furthermore, every one of these camps owed its discovery and eventual exploitation to the fact that encouraging ' mineralization occurred at the surface. Where would the mining industry of British Columbia be today had those precious outcrops been buried beneath twenty to forty feet of glacial drift or other overburden? Anybody familiar with the geology and geography of British Columbia will probably agree that finding new mining camps is going to be an increasingly difficult and costly business: disappointments there will be in abundance. Nevertheless, most persons will probably also agree that other valuable mines and even mining camps await discovery by those who will prove resourceful and lucky enough to unearth them. It has become increasingly obvious to the authors of this paper that any new too1s which can aid either prospectors or engineers in their search for new orebodies should be welcome. This paper outlines our efforts to develop biogeochemistry and related techniques to the point where they may be considered as useful tools in the search for hidden mineralization.

Jan 1, 1950

By M. Zanini, D. Wong

ABSTRACT: Metals market improvements in 2005 drove the desire to increase nickel throughput and the production of nickel oxide sinter at the Vale Ltd. Copper Cliff smelter. Significant difficulties were encountered due to the unreliable quality of Bessemer matte being produced. Concentrate feed changes and the loss of technical and operational expertise during the previous market downturn contributed to the challenge of making the required improvements. Significant progress has been made in the converter aisle by focusing on employee engagement and standardizing best operating practices for a new generation of skimmers. This paper documents these initiatives and seeks to balance the art and science of converting.

Jan 1, 2012

By T. Kerr, C. Mattich, J. Wilson

"In refractory gold concentrates, gold is occluded in sulphide minerals preventing efficient cyanide leaching. Hence, roasting is used to oxidize sulphur and organic carbon, the latter being necessary to minimize recovery loss through the preg-robbing effect. In 2009, Outotec commissioned the circulating fluidized bed roaster at Syama gold mine in Mali. Since 2013 Resolute and Outotec have been implementing improvements to the roaster performance with the capacity increasing from 8000 t/month in 2013 to above 13,000 t/month in 2016, while achieving a residual sulphide sulphur and organic carbon contents of below 0.1 wt.% and 0.4 wt.%, respectively. Thus a gold recovery in the CIL of above 90% is attained. In 2016, Outotec audited the Syama roaster. The analysis resulted in the Low Carbon Roaster (LCR) upgrade concept which (i) allows re-processing of calcine dust from the spray cooler and ESP after pelletization and (ii) allows the roasting of a further fine-organic carbon rich feed, i.e. de-slime circuit tailings. The LCR upgrade aims to reduce organic carbon to <0.2 wt.% and increase roaster-leaching gold recovery by >3%. Project development included extensive testwork. The LCR process is expected to become operational during FY 2019.INTRODUCTION Double refractory sulphide ores exhibit the characteristics of gold locked within pyrite grains, in the presence of preg-robbing natural (organic) carbon. Hence, to achieve high recovery during subsequent processing steps, i.e. cyanide leaching, oxidation of sulphide sulphur is required, producing a porous calcine by way of a roasting step. This allows for the gold contained within the pyrite grains to be accessible during cyanide leaching. Furthermore, it is necessary to oxidize the organic carbon. Oxidizing the organic carbon is essential as gold recovery loss occurs as a result of gold-cyanide complexes being adsorbed on organic carbon, this phenomenon is termed as preg-robbing (Miller et al., 2016). The gold absorbed on the organic carbon is lost, reporting to the tailings stream. Hence, the aforementioned oxidation of sulphide sulphur and organic carbon is the process goal. Nonetheless, the latter must occur at a controlled temperature which is concentrate/ ore specific, since the pores of the produced calcine should not sinter, as this makes the gold contained in the calcine less accessible during leaching, leading to gold recovery loss. The tight temperature control requirement is a decisive factor in the choice of a Circulating Fluidized Bed (CFB) as the roasting reactor, due to the excellent mixing characteristics of the CFB which results in temperature homogeneity of (+/-10°C). Roasting of double refractory ores, as described above, can be included in the flowsheet after comminution and grinding, a process termed as whole ore roasting, or by including a flotation circuit termed as concentrate roasting. Roasting the flotation concentrate results in less solid flow, increased sulphide sulphur grade and organic carbon content resulting in a higher heating value and higher gold content. A typical composition of the Syama ore and concentrate is given in Table 1. Ore average values presented correspond to the period 2015, while concentrate values are typical for the flotation performance throughout the period 2012–2015."

Jan 1, 2017

By W. M. Silva, PAP. Miotto, M. A. P. Silva, V. P. Ramos, L. R. M. Bittencourt

The major cause of breakdown of anode baking furnace fluewalls is chemical corrosion, which leads to deterioration of the properties of the bricks. Subsequent deformation of the fluewalls occurs, and also extensive cracking of the lining is observed. The present work studies the major changes of the brick during the operation of the furnace, after 22, 60 and 90 cycles of baking; in two different regions: upper and lower. Due to excellent cleaning conditions of the butts, negligible amounts of fluorine were found in the bricks. The major contaminants found were carbon, sulfur and alkali compounds, all of them present in the anode baked during the process.

Jan 1, 2004

By D. C. Van Aken, O. J. Rajtora

A research effort sponsored by the Department of Energy (DOE) and several steel producers, is investigating the benefits of coating steelcasting nozzles with various materials. Coatings were applied to casting simulation nozzles made from industrial tundish nozzles (primarily of magnesia) and industrial submerged entry nozzles (SEN&apos;s) (primarily of alumina-graphite) in order to extend casting time prior to nozzle clogging. Nozzles were coated by air plasma spray (APS) using a 9M series APS system from Sulzer-Metco. The ability of these coatings to provide protection from clogging was evaluated using a steel casting simulation. Substrate-coating compatibility was characterized using optical and SEM microscopy.

Jan 1, 2004

By C. S. Chen, Y. J. Luo, M. W. Gao, B. Li, Z. F. Zhang

"To obtain large-sized billets with fine grains and homogeneous elements distribution, uniform direct chill (UDC) casting process, based on annular electromagnetic stirring coupling with intercooling, was employed to produce 7055 alloy billets with a size of F584 mm in this study. The results indicated that there were the coupled effects of annular electromagnetic stirring and intercooling on grain refinement and element homogenization, and also the billets produced by the UDC casting process showed excellent hot workability in comparison to the normal direct chill casting process.INTRODUCTION The high solute 7055 aluminium alloy has a wonderful combination of high specific strength and hardness, good resistance to stress corrosion cracking and high fracture toughness, which is very useful in aerospace application (Yan et al., 2013; Mondal & Mukhopadhyay, 2005). The production of large-sized 7055 alloy billets with high quality is the basic condition for the subsequent application of 7055 alloy to the aircraft. Inhomogeneous microstructures and performances of 7055 billets result from the high alloying element content and the inhomogeneous cooling condition in different regions of billets during the conventional direct chill casting (Paramatmuni et al., 2004; Lalpoor et al., 2011), which will bring bad influence to processing property, functional performance and utilization rate of materials. To alleviate segregation and obtain fine and uniform grains, some effective treatment methods were proposed including electromagnetic stirring (EMS) (Vives, 1989), ultrasonic vibrating (Zhang et al., 2011) and melt conditioning (Fan et al., 2013), on the melt to obtain fine and uniform grains. However, these methods could not effectively decrease the large temperature difference between central and periphery parts of the billet, because the solidification mainly depends on outside cooling including mould cooling and water spraying cooling. To change the heat extraction pattern of the billet functioned solely from the outer surface, based on annular electromagnetic stirring (A-EMS) invented by Xu et al. (2010), Luo et al. (2017) proposed uniform direct chill (UDC) casting coupling A-EMS with intercooling in the direct chill (DC) casting process. An in-mold cooler was inserted to the melt sump, and thus the alloy melt temperature and concentration at solidification front become more uniform."

Jan 1, 2018

By L. W. F. Mackenzie

The influence of rolling temperature and annealing on the recrystallization and texture of magnesium AZ31 has been investigated. 100x125x6 mm AZ31 plate was cast in a permanent steel mould and then homogenized at 380°C. As-cast and homogenized microstructures were then characterized, and 35x30x6 mm specimens were machined from the homogenized material. Specimens were rolled up to 40% at temperatures between 25 and 350°C; selected specimens were subsequently annealed at 400°C. Following rolling, the microstructures were compared. The influence of rolling temperature on as-rolled texture has been demonstrated, and texture evolution has been evaluated following annealing. The recrystallization behavior has also been characterized. Optical microscopy, scanning electron microscopy and electron backscattered diffraction (EBSD) were used to characterize the microstructures of the alloys. X-ray texture analysis was used to investigate the texture in as-rolled and annealed specimens.

Jan 1, 2006

By N. Dobrin, R. Sheinman, Y. V. Kokotov, L. N. Braginsky

Increasing the production of a Mixer-Settler unit requires either increasing flow rates or increasing extractant concentration. The mixers still have to ensure complete emulsification and to maintain high values of specific interface surface area in order to provide a high rate of mass transfer. Theoretically, an increase in mixing intensity can support increased flow rates without reducing extraction efficiency. Unfortunately, conventional pump mixers and mixing systems create small droplets that do not separate easily. As pumping action and mixing intensities are increased, the quantity of small droplets increases. We describe the development and industrial application of a novel mixing system for efficient mass transfer without forming significant quantities of small droplets, targeting both high mass transfer rate and low entrainment values.

Jan 1, 2014

By P. Keating, J. Goutier, J. Ayer

"New, high-resolution geophysical surveys were undertaken over parts of the Abitibi Subprovince, Canada, to help with geological mapping and to promote mineral exploration. Gravity surveys in the Rouyn-Noranda and Matagami areas (Québec) allowed better 3-D mapping of important geological structures, and a multiscale edge analysis of ground gravity data over the Blake River Group confirms that major faults behave at depth as predicted by surface geology. Airborne gravimetry west of Matagami (Québec) helped to identify a new trend south of Lake Grasset that is almost perpendicular to the assumed geological trend of the area. Electromagnetic (EM) surveys, flown in the Chibougamau (Québec) and Bartlett Dome (Ontario) areas, allowed new conductors to be identified at greater depths than were achievable with previously used EM systems. Airborne magnetic surveys were flown in the Burntbush area (Ontario), and other available high-resolution magnetic data were compiled to produce a continuous and homogenous magnetic grid of the Abitibi region.The resulting compilation map clearly shows the locations of dikes, faults, and shears zones, and reveals some fault extensions in areas of extensive overburden. This grid also allows the computation of enhanced maps, such as vertical derivative and tilt maps (e.g., a tilt map shows subtle magnetic features in the Blake River Group that are difficult to see in the total magnetic field or its first derivative). Results from these new surveys show there is considerable value in (1) resurveying areas covered by older surveys, and (2) recompiling data sets from these older surveys."

Jan 1, 2012

By R. F. Favreau

"After a blast, the volume of the blasted rock normally occupies more space that it did before the explosion. The degree of such swell significantly affects the efficiency of digging the muck with a shovel or dragline. This paper explains why swell occurs, and describes the new subroutine SWELL of the blast simulator BLASP A which can simulate blast-induced swell. Results are also presented which display the effect of various blasting parameters on the degree and distribution of the swell within the muck pile of a bench blast. IntroductionIt is a common opinion that fragmentation is the most important of the various aspects which affect the efficiency of excavating rock with explosives. This paper proposes that, in fact, displacement and swell of the blasted rock are as important as fragmentation if the excavation process is to be rapid and efficient. It must ""a priori"" be recognized that a minimum degree of fragmentation is indeed necessary. For a given shovel or dragline, this minimum degree of fragmentation may be defined as follows: even the largest fragment of rock must be easily contained within the bucket. Once this criterion is met, however, there are good reasons to believe that displacement and swell take over as the key criteria which influence the rate of mucking, in cubic metres/hour. If the muck pile is not well displaced and swelled, the teeth of the bucket have difficulty penetrating between the rock fragments even if fragmentation is good and, as a result, the mucking is slow and inefficient. The purpose of this paper is to use computer simulations on the model BLASP A to demonstrate the effect of the blast design parameters on the displacement and swell of the blasted rock."

Jan 1, 1993

By M. Dupuis

Recently, a new approach to controlling alumina feeding in a H.H. cell has been proposed [1, 2 and 3]. This approach, labeled In Situ aluminium cell control, is based on a correlation between the slope of the cell voltage during a no feed observation period and the dissolved alumina concentration in the bath. Once the dissolved alumina concentration has been estimated, a primary calibration surface uniquely relating the dissolved alumina concentration and the anode-cathode-distance (ACD) to the cell voltage is used to estimate the cell ACD. Once both the alumina concentration and the ACD have been estimated at the end of the observation period, a PID controller can be used to regulate the rate of alumina feeding using only the normalized cell voltage to calculate the error between the estimated dissolved alumina concentration and a target value. The In Situ aluminium cell control algorithm has now been tested with the Dyna/Marc [4, 5 and 6] cell simulator demonstrating that it should be possible to control a H.H. cell in this manner with less variation in the dissolved alumina concentration and other process variables producing a prediction of improved cell current efficiency and power efficiency.

Jan 1, 2011