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By B. R. Conard

Occupational epidemiology of the nickel-producing industry has found that inhalation exposures to certain nickel-containing substances are linked to respiratory cancers and to nonmalignant respiratory endpoints. Establishing such a linkage, however, is complicated by the fact that some diseases occur long after exposure to a causal agent (i.e., some diseases have long latencies). Furthermore, most chemical agents (especially nickel substances) vary significantly in their toxicological properties and their concentrations in workplace air have varied over processing history. Because of these complications, it is critical to understand historical exposures to specific nickel substances. To assist in this effort, the author focuses on the history of smelting and its related processes at Vale Canada’s (Inco’s) Ontario operations in the first half of the 20th century.

Jan 1, 2012

By J. Worden, D. Hughes, S. Smart, H. Zughbi

The enterprise wide optimization (EWO) of steelmaking and manufacturing is a multi-level, hierarchical problem which spans higher level corporate planning and scheduling through to the lower level operations of processes that produce and manufacture steel. External and internal system dynamics combined with process unit co-ordination create complex changing circumstances for the enterprise. This paper presents a scoping study as a prelude to enterprise wide considerations at an integrated steelworks to help inform the choice of appropriate model types and optimization techniques. The hierarchical, multi-level structure of the enterprise and the important spatial-temporal scales to consider are defined. Insights into the system were gained by analyzing a large set of dynamic operational data. Over two years of data were subject to both univariate and multivariate analysis with the intent of understanding the complex interrelations of energy flows on site, the inherent system dynamics of the energy network, system operational modes, aspects of planning and scheduling and the coordination between major processing units. This analysis was further used to evaluate the performance of the system in regards to energy utilization and understand the potential economic benefits derived from improved operational decisions.

Jan 1, 2015

By H. E. Miard

"IntroductionIT HAS BEEN SAID, with good reason, that the future of the coal mining industry, in our mountainous regions at least, depends on ability to extend operations successfully to depths greater than those reached until now. However, at many points, Nature has given definite hints that trespassing there could be fraught with very un-pleasant possibilities, unless the intruder be governed by a series of rigidly observed principles. In the coal mines of British Columbia, so far, bumps have taken place only at the Coal Creek colliery, but there they gave ample evidence of the extent to which they can hamper underground operations. Some of these manifestations have also been experienced at the McGillivray Creek colliery, in Alberta, at Carbonado, in Washington, and at Sunnyside, in Utah.Cognate phenomena, known as 'air blasts', have been experienced also in some deep metalliferous mines in British Columbia. Such occurrences were responsible for three fatal accidents at the Le Roi and War Eagle mines, near Rossland, in 1916 and 1917.In more or less disturbed coal fields, another form of stress release, equally detrimental, has been still more generally experienced than have been the bumps. Coal outbursts have taken place at Morrissey and Coal Creek, in the Crow's Nest Pass district, and at Cassidy, South Wellington, and the Nanaimo Reserve colliery, on Vancouver island. Manifestations of this kind have been made the subject of intensive study in European countries where they occurred on a really impressive scale, which must not be construed as meaning that some of our own outbursts did not approach a comparable magnitude."

Jan 1, 1953

By Fred Horne

1N THIS PAPER, the writer proposes to limit his comments to few generalized phases of the subject, based on his personal experience in the midwestern United 'States and in one section .of the Coal Branch in Western Alberta. The following statistics are submitted to show the importance that strip mining has assumed in the coal mining industry of the United States. In 1914, 1,281,000 tons of strip coal were produced, amounting to 0.3 per cent of the total production. In 1948, the total was 13~,505,000 tons, representing 23.3 per cent. In 1949, the percentage figure dropped slightly and this can be partially accounted for by the labour disturbances prevalent throughout the year. In 1914, there were 48 power shovels and draglines being used in the stripping of coal; in 1949 there were 3,712, not to mention other types of coal stripping equipment such as bulldozers, tractors and scrapers, rotary excavators, and stackers. At the bituminous coal mines in Western Canada, strip mining was introduced only a few years ago, two of the major reasons for its development being the need for increased production during the war and post-war years and the need to hold the line on increasing production costs, but even in these few years the percentage of strip production has in-creased to such an extent that some mines that, five or six years ago, were producing all their tonnage from underground operations are today obtaining up to 80 per cent of their total output from strip mines.

Jan 1, 1951

"Bay d'Espoir is in the approximate center of the south coast of Newfoundland. The geology of the area can most conveniently be considered in terms of three units: (1) an Ordovician or older polydeformed terrain termed the Little Passage Gneisses; (2) a Lower-Middle Ordovician volcano-sedimentary sequence assigned to the Baie d'Espoir Group; and (3) granitoid intrusive rocks of mid-Paleozoic age. Mineralizing events accompanied the formation of the latter two units.The Baie d'Espoir Group comprises a dominantly sedimentary sequence of pre-Middle Ordovician shelf and distal turbidite sediments deposited on the eastern margin of Iapetus. A significant volcanic component is, however, present in the Isle Galet Formation, consisting of up to 30% felsic volcanic rocks interbedded with sedimentary and epiclastic rocks. The Isle Galet Formation hosts several disseminated to thinly bedded Pb-Zn-Ag occurrences associated with altered felsic tuff and graphitic shale. They occasionally grade laterally into pyrite iron formation and appear to have been deposited in a very distal volcanic environment. The Isle Galet Formation is a time equivalent of the mineralized pre-Caradocian island-arc sequences of central Newfoundland, but differs from them both in style of volcanism and in the nature of the associated mineral deposits. It is, however, comparable in many respects to mineralized volcanic sequences in the La Poile Bay area of southwestern Newfoundland.Mineralization associated with granitoid rocks in Bay d'Espoir is best developed around the southeast margin of the North Bay Granite, where two-mica leucogranite forms a marginal phase. Numerous minor base metal showings occupy quartz, quartz-carbonate and barite veins in the adjacent sedimentary rocks. Collectively, the showings exhibit a well-developed, zonal pattern around the granite margin; molybdenite (±py, cpy) predominates near the contact, giving way outward to galena (±sph, py, asp, cpy) and eventually to stibnite (±asp, py) at the periphery. Mineralization associated with granites in similar settings elsewhere in southern Newfoundland includes tungsten in the Grey River and Granite Lake areas and molybdenite in the Rencontre Lake area."

Jan 1, 1982

By N. A. Warner

Virtually zero gas emission smelting is promoted as a means for securing environmental advantages and the general public’s acceptance. Concerns about climate change will increasingly make it more difficult for new primary metals projects to come to fruition unless greenhouse gas emissions are decreased. Assuming a sustainable market for sulphuric acid is not locally available, the next best option is high temperature reaction of strong SO2 with limestone or dolomite. This is followed by CO2 liquefaction and disposal either underground or in the deep ocean. The Voisey’s Bay nickel project is cited as an example where appropriate location of a new smelter close to large dolomite or limestone deposits would lead to a virtually zero gas emission operation. Most of the electrical energy required for producing technically pure oxygen and for liquefying CO2 and transporting it to disposal can be derived from smelting a bulk sulphide concentrate and then reacting SO2 at high temperature. Provided the smelter gases are properly cleaned before sulphur fixation, the sulphated stone should be uncontaminated and environmentally benign and possibly of use in the building and construction industry.

Jan 1, 1999

By John A. Hansuld

Geochemical dispersion of metals under various environmental conditions is discussed within the frame-work of Eh (oxidation potential) and pH (acidity). In general, two aspects are considered -(1) the oxidation of certain primary sulphides in the outcrop or sub-outcrop environment, and (2) the movement of metals in different dispersion media. Practical applications of each are illustrated by means of exploration case histories representing environmental conditions in the Canadian Shield, the southwestern United States and the Caribbean.

Jan 1, 1966

By Krishna Parameswaran

In this paper, we attempt to answer an often asked question, how can metal mining be compatible with the principles of sustainable development. Starting with the classic Brundtland Commission definition of sustainable development as "development that meets the needs of the present without compromising the ability of future generations to meet their own needs," we make the case that mining is or should be sustainable, using examples of sustainable practices at ASARCO LLC, an integrated U.S primary copper producer. These examples cover the entire mining cycle starting with exploration, mining, beneficiation, smelting, refining, closure and post-closure and post-mining land use. It is hoped that the presentation will challenge the mining industry to even greater innovation as future mineral development projects are planned.

Jan 1, 2015

By U. Erb, L. Monaco

"Electrodeposited nanomaterials are increasingly implemented in advanced industrial applications in the aerospace, automotive, defence, electronic and energy sectors due to their outstanding physical, chemical and mechanical properties, including increased strength and wear resistance, and superb magnetic properties. As with the development of any class of new materials, the corrosion behaviour of these electrodeposits requires considerable attention. This presentation reviews major developments in the understanding of the corrosion behaviour of nanocrystalline metals, alloys and metal-matrix composites over the last 20 years, with emphasis on how their intrinsically high density of intercrystalline defects does not compromise their corrosion resistance as initially expected.INTRODUCTIONOver the past 20 years there have been considerable advances in the understanding of the corrosion behaviour of nanocrystalline metals, alloys and metal-matrix composites. In this paper, the corrosion properties of nanocrystalline nickel, cobalt, zinc, and copper and some of their alloys are reviewed with emphasis on how a reduction in grain size affects their corrosion behaviour in different environments.It is possible to synthesize nanocrystalline material with microstructural refinement down to the range of 1 to 100 nm using a large number of processing methods. There are five basic synthesis methods that can be used to classify the different techniques: vapor-phase processing, liquid-phase processing, solid-phase processing, chemical synthesis, and electrochemical synthesis. Depending on the synthesis method, different microstructures (equiaxed, textured), shapes, and forms (films, particles, bulk material) may be produced. In addition, other factors may be introduced (eg. residual porosity or amorphous phases), aside from microstructural refinement, which can contribute to the observed properties (Erb, 2010). In order to interpret and categorize the resulting microstructures, a dimensional structure modulation scheme was introduced by Siegel (1996) in which zero-dimensional nanomaterials refer to individual particles, clusters, etc. One-dimensionality results from a layered (less than 100 nm thick) structure. Two-dimensional nanomaterials are thin, layered structures containing grains (less than 100 nm) within each layer. Finally, three-dimensional nanomaterials are bulk structures with an average grain size less than 100 nm."

Jan 1, 2012

By Patrick Mclaren, Peter B. Hale

Canada, with one of the largest continental shelf areas in the world, has done little to evaluate its offshore unconsolidated mineral resources which include heavy minerals (gold, chromite, rutile etc.) and industrial minerals (silica sand and aggregates). During glaciation much of the continental shelf was covered with an ice sheet and later subaerially exposed with the result that glacial, glaciomarine and fluvial processes deposited sediments that may contain heavy minerals derived from onland locations. With rising sea-levels, beach and nearshore processes may have served to concentrate heavy minerals by winnowing and removing the lighter mineral components. These potentially valuable resources can be found with suitable exploration techniques such as seismic profiling and bottom sampling. Gold deposits are known to exist off the coast of Nova Scotia, and on the basis of form er beach mining, gold deposits probably occur off Vancouver Island and the Queen Charlotte Islands. Large deposits of silica sand occur near the Madeleine Islands and it appears likely that supplies of marine aggregates are present close to urban markets or sites of future mega-projects such as oil field developments. This paper, which is based upon a review of literature and consultation with members of the Department of Energy, Mines and Resources' Coordinating Committee on Ocean Mining (DCOM), is the first step in assessing the Canadian offshore f or its resource potential with respect to quantified deposits, known and speculative mineral occurrences. Although this is a subjective evaluation, the potential appears promising. A more detailed resource inventory is required to provide a more certain assessment.

Jan 1, 1984

By T. Plikas, T. Porretta, M. Al-Dojayli, B. Pretorius, J. Woloshyn, H. Ghorbani

"Water-cooled ducts represent an integral part of high temperature off-gas systems in metallurgical processes. Typically, off-gas enters these ducts at significantly elevated temperatures; therefore, water cooling may be required to maintain the duct skin temperature within allowable design limits. These off-gases are typically of high mineral content that could lead to dust buildup, and there is a possibility of slag buildup / molten metal splashing. Therefore, dust cleaning provisions may be necessary in order to remove or minimize accretion on the duct wall, which could otherwise impact the water cooling and the system process efficiency. These ducts may have complex geometry and experience a wide range of loading, including gravity loads, water and gas pressures, cyclic thermal loading and dynamic impact forces. Consequently, the thermo-mechanical assessment of such water-cooled ducts is critical and requires consideration phenomena such as high temperature gradients, potential nucleate boiling, thermal ratcheting and fatigue failures. Such assessment is not comprehensively covered by design-by-rule design codes and guidelines due to its complexity. This paper presents a successful implementation example of design-by-analysis methodology to improve the design and extend the life of a water-cooled furnace transition duct using Computational Fluid Dynamics (CFD) and Finite Element Analysis (FEA).INTRODUCTION Water-cooling represents an important part of high temperature off-gas systems in metallurgical processes. Typical temperatures of the off-gas in the furnace uptake are in excess of 1400°C, and thus there is a need to maintain the water-cooled duct and jacket skin temperatures within their material allowable design limits. Water-cooled channels have been used effectively in arc furnace roof design (Sosonkin et al., 1972; Smolyarenko and Khainson, 1988) and other furnaces as well as in furnace fuming jackets (Scholey et al., 1994). The design of these systems was based on one-dimensional analysis to ensure sufficient cooling is available under extreme furnace conditions (Smolyarenko and Khainson, 1988; Scholey et al., 1994). With advancement in furnace and fuming system designs, water-cooled duct designs have become more complicated in geometry. Numerical techniques, such as three-dimensional fluid flow and heat transfer modeling, are therefore needed to more accurately calculate water velocity, temperature and convective heat transfer coefficients in the water-cooled channels (Haywood et al., 2002; Henning et al., 2010). This is of particular importance around geometric corners where stagnant water flow may lead to local nucleate boiling at the critical heat flux, causing hot spots (Bergman et al., 2011). High wall skin temperatures increase the risk of failures due to thermal stresses as well as increasing corrosion rates (Gelfi et al., 2012), leading to costly equipment downtime and potential safety risks."

Jan 1, 2017

By P. Mundell, R. Torbin

"There are many physical and operational obstacles in pipelines that make the passage of inspection robots impossible including:•,Small radius bends•,Low operating pressure•,Plug valves•,Large changes in pipe size•,No permanent access to the pipeline.The inspection of unpiggable pipelines requires the marriage of a highly agile robotic platform with NDE sensor technology operating as an integrated system. Foster-Miller and GE/PII are developing a robot that is essentially a battery powered, train-like platform. Both front and rear tractors propel the train in either the downstream or upstream direction. Like a train, the platform includes additional ""cars"" to carry the required payloads. The cars are used for various purposes including the NDE sensor module(s), the power supply, and data acquisition/storage components. The robot is designed with a slender aspect ratio and the ability to change shape as required by the physical obstacle presenting itself. The MFL sensor module must also morph itself through the physical obstacles, and thus, will require some level of segmentation. The segmented MFL magnetizers and transformable sensor module represent a major advance in the science of sensor technology and pipeline inspection."

Jan 1, 2005

By M. R. Hegge

The Jabiluka One and Two uranium deposits occur in Lower Proterozoic metasediments of the Cahill Formation, which is part of the Pine Creek Geosyncline in the East Alligator River area, Nothern Territory. The Jabiluka One deposit coincides with a "window" through unconformably overlying Middle Proterozoic sandstone of the Kombolgie Formation; Jabiluka Two is completely covered by that sandstone. The observed part of the Cahill Formation exhibits four horizons which are favourable hosts for uranium mineralization. These have been folded into an east-southeast-striking, gently plunging, open asymmetric syncline-anticline structure. The host rocks are mainly chlorite and/or graphite schists and their brecciated equivalents which have undergone initial regional prograde metamorphism to the amphibolite facies, then retrograde metamorphism to the greenschist facies. Mineralization consists of pitchblende, mainly filling open spaces and to a lesser extent in disseminated form. Chlorite, pyrite and quartz are commonly associated with the uranium mineralization. A portion of the Jabiluka Two deposit contains economic concentrations of gold. Structural preparation with low-pressure conditions at these sites appears to be the most significant ore control. Genetic hypotheses favour initial deposition in Lower Proterozoic sediments, followed by remobilization during later orogenic events. The deposits bear a marked similarity to some pitchblende deposits in central Canada.

Jan 1, 1977

By D. G. E. Kerfoot

In September 1945, when the Lynn Lake nickel orebody was discovered Sherritt Gordon Mines was a small copper mining company with rapidly depleting ore reserves at its single producing mine at Sherridon in the Cold Lake area of Manitoba, 100 miles north of The Pas. The company has been formed in 1927, largely through the efforts of Eldon L. Brown, a 27-year old mining engineer, with the financial backing of Thayer and Halstead Lindsley and the Gordon family. The Lindsleys were American mine promoters who had been successful in the Sudbury area, and the Gordons had extensive interests in the lumber industry in northern Ontario. Carl Sherritt, who gave his name to the company, was an American trapper and prospector who had staked the copper property and sold his interest to the new company. Carl Sherritt died in a flying accident at The Pas in 1928. The Sherritt Gordon Mine started production in 1931, shipping copper concentrate to the new Hudson Bay copper smelter at Flin Flon, Manitoba. In 1931 the price of copper was 18¢/lb. Within a year the price had fallen to 5¢ /lb and the mine was forced to close. It remained closed through the Depression years.

Jan 1, 1999

By E. W. O'Brien

Personnel protection involves effective grounding and positive clearance of faults. This paper deals, in a general sense, with various schemes to achieve fool-proof personnel protection and reduce, to a minimum, the effects of human error and equipment failure.

Jan 1, 1966

By A. Galip Ulsoy, K. V. S. Sastry

"This review paper is intended to provide, the mineral process engineer with an introduction to the concepts, terminology. and practice of mineral process control. It also provides an extensive sampling of the vast body of literature relevant to this topic. The topics discussed include the principles of automatic control, instrumentation, mineral processing unit operations, process modeling and simulation, and process and plant control. IntroductionEconomically accessible higher-grade ores are being rapidly depleted, and at the same time the demand for mineral raw materials continues to increase. Mineral recovery from the remaining low-grade or finely dispersed ores requires grinding for liberation. High energy consumption during grinding and poor efficiency associated with the beneficiation of fine minerals are two important problems facing the mineral industry . These problems, coupled with advances over the last 10 to 15 years in the areas of process modeling, instrumentation, computer technology and control theory, have made automatic control of mineral processing systems an important research area(23,52,66,67,120,129,152)."

Jan 1, 1981

By A. Galip Ulsoy

This review paper is intended to provide, the mineral process engineer with an introduction to the concepts, terminology and practice of mineral process control. It also provides an extensive sampling of the vast body of literature relevant to this topic. The topics discussed include the principles of automatic control, instrumentation, mineral processing unit operations, process modeling and simulation, and process and plant control.

Dec 1, 1981

By E. Eccleston, E. Gardner, F. Letarte, R. Schonewille

"In 2005, after nearly a decade of process development and feasibility work, the commercialization of the Falconbridge Nickel Smelting Technology (NST) began in earnest with the design and construction of a grassroots ferronickel plant at Koniambo Nickel in New Caledonia. The NST process was developed as an alternative to the conventional Rotary Kiln-Electric Furnace (RKEF) process for production of ferronickel from saprolitic nickel laterite ores. The NST process promised environmental and energy efficiency advantages over the conventional route. A key step of the NST process involves fluidized bed pre-reduction of calcined laterite ore using direct injection of pulverized coal as the reductant. Two parallel fluidized bed reduction roasters (FBRs) were installed at Koniambo Nickel, each designed for a maximum capacity of 4,200 MTPD of calcined nickel laterite ore. This paper describes the process development and scale-up of the fluidized bed pre-reduction process, the design challenges associated with the prototype commercial units, and the current status of the FBR operation at Konaimbo.INTRODUCTION In the mid-1990s, Falconbridge began to develop a new flowsheet for production of ferronickel from nickel laterite ores. The process that developed came to be known as the Falconbridge Nickel Smelting Technology (NST). The flowsheet, which is particularly appropriate for saprolitic ores, involves several major unit operations, including: drying in a hammer mill-flash dryer, calcination and preheating in a flash calciner, pre-reduction in a fluidized bed reactor, and smelting in a DC arc furnace to produce the ferronickel product. This paper focuses on the fluidized bed pre-reduction step of the process and provides an overview of the process chemistry, laboratory and pilot plant development work, scale-up and commercialization of the pre-reduction step, and the results obtained in the prototype commercial units."

Jan 1, 2017

By Jeffrey T. McGinty, Frank M. Wheeler

Plant layout is the arrangement of equipment, process areas, departments, infrastructure, and support facilities. Plant logistics is the flow of parts, people, resources, and information throughout the production process. This chapter: outlines key factors and provides checklists to facilitate layout development; presents risk management approaches to test the logistics and functionality of alternative layouts; and uses real-world examples to illustrate effective simulation modelling to assess plant layouts.

Jan 1, 2015

By Ed McConaghy, P. LaRochelle

The Ambatovy Nickel Project comprises the development of mine, hydrometallurgical processing facilities and necessary infrastructure in Madagascar, positioning Ambatovy as one of the world’s largest producers of nickel and cobalt from lateritic ore. SNC-Lavalin successfully provided comprehensive Engineering, Procurement, Construction Management (EPCM) services for this major capital project which, apart from its sheer size, scope, and engineering design, represented significant location, infrastructure, labour, environmental and climatic challenges. Today, the project has reached 90% of its nameplate capacity and is in its final performance optimization stage. This paper will discuss the significant project management effort that was required to successfully address the complexity of this major project. It will cover the main project management control systems and the engineering tools and processes used during the detail engineering, procurement, and construction phases to achieve optimum project execution.

Jan 1, 2015