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By R. Padilla, I. Gonzalez, M. C. Ruiz, J. Salgado

The mining companies in Chile are increasingly using chloride salts and/or sea water in the sulfuric acid leaching of copper minerals. For this reason, the effect of chloride ions on the solvent extraction equilibria was investigated. Copper extraction isotherms were determined at 25 and 35 °C for aqueous solutions containing 6 g/l of Cu, 7 g/l of Fe, chloride ion concentrations of 0, 60 and 110 g/l, and a pH of 2.0. The organic phases were 20% v/v solutions of a ketoxime (LIX 84-IC) or a salicylaldoxime (LIX 860 N-IC). It was determined that the presence of chloride in the aqueous solution had a large negative effect on the extraction equilibria for both extractants, particularly the ketoxime. Therefore, as the chloride ion concentration increases, an efficient use of the extractant would become more difficult. An increase in the temperature from 25 to 35 °C positively affected the extraction equilibria for these extractants.

Mar 1, 2017

By Florian Kongoli

While calcium ferrite slags have been successfully used in continuous copper converting for the last 30 years, ferrous calcium silicate slag was proposed about 8 years ago as an additional alternative for copper smelting. Although both slags are normal extensions of each other their phase relations have not been completely clarified. In this paper the liquidus relations of both slags have been quantified at various areas that cover both of them. The existing experimental data have been first reviewed and discussed in relation to the solidification procedure. An original physical model is then used to predict various diagrams of the liquidus surface of both slags. It is shown that the ternary liquidus diagrams normally used for FeOx-SiO2-CaO system are not suitable for industrial slags. The new model diagrams of Fe/CaO versus SiO2 and Fe/SiO2 versus CaO as well as Fe/CaO versus Temperature and Fe/SiO2 versus temperature are proven to be much more convenient for ferrite and ferrous calcium silicate slags. Based on these diagrams the effect of SiO2 and CaO on the melting temperature is quantified. The effect of Cu2O is also quantified through the model. Some Fe/CaO versus Cu2O and Fe/SiO2versus CaO at various copper contents are predicted and the results show good agreement with the experimental data. It is also shown that in the presence of liquid copper, Cu2O is dissolved in the slag depending on the oxidation degree of the system and might lower the liquidus temperature. Some discussions are also presented taking into account plant observations and important conclusions are drawn for copper smelting and converting

Jan 1, 2006

By Florian Kongoli

While calcium ferrite slags have been successfully used in continuous copper converting for the last 30 years, ferrous calcium silicate slag was proposed about 8 years ago as an additional alternative for copper smelting. Although both slags are normal extensions of each other their phase relations have not been completely clarified. In this paper the liquidus relations of both slags have been quantified at various areas that cover both of them. The existing experimental data have been first reviewed and discussed in relation to the solidification procedure. An original physical model is then used to predict various diagrams of the liquidus surface of both slags. It is shown that the ternary liquidus diagrams normally used for FeOx-SiO2-CaO system are not suitable for industrial slags. The new model diagrams of Fe/CaO versus SiO2 and Fe/SiO2 versus CaO as well as Fe/CaO versus Temperature and Fe/SiO2 versus temperature are proven to be much more convenient for ferrite and ferrous calcium silicate slags. Based on these diagrams the effect of SiO2 and CaO on the melting temperature is quantified. The effect of Cu2O is also quantified through the model. Some Fe/CaO versus Cu2O and Fe/SiO2versus CaO at various copper contents are predicted and the results show good agreement with the experimental data. It is also shown that in the presence of liquid copper, Cu2O is dissolved in the slag depending on the oxidation degree of the system and might lower the liquidus temperature. Some discussions are also presented taking into account plant observations and important conclusions are drawn for copper smelting and converting

Jan 1, 2006

By Jinrong (Patrick) Mang

Three of the most challenging problems in phosphate beneficiation are discussed: flotation efficiency, resource conservation and environmental impact. Some new flotation machines offer the opportunity of reducing power and reagent consumption significantly, while increasing specific capacity many fold. Efficiency might also be improved dramatically by replacing the "double float" process with a single-collector scheme. Model based software control is a powerful tool for improving overall plant efficiency. Recovery of phosphate values from the phosphatic clays could extend phosphorus reserve life significantly. phosphate recovery from the slimes might be achieved by sizing-flotation, selective flocculation and bioleaching. Reducing the volume of phosphatic clays produced is another key stop to minimizing phoephate logs. Such a reduction may be realized by floating at finer cut size. Although an ideal' dolomite separation process is yet to be developed, a cationic flotation process may prove to 'be economically feasible. Loss of phosphate in the desliming stage is the major problem with most of the flotation schemes for removing dolomite.

Jan 1, 1995

By Hartmut Rossel

VAW aluminium AG has built a "Recycling-Technikum" (Recycling Research Centre) to add a new arm to the company's Corporate Research and Development Department. The Recycling Research Centre, a pilot plant for scientific research, has been in operation since September 1993. These state-of-the-art facilities allow the investigation and optimisation of recycling techniques in 'a global way and in detail. Research is concentrated on the unit operations - processing, melting and waste-gas purification - with the available installations making it possible to compare different alternative process combinations on a 100-kg scale. One of the main targets of VAW research is the development of recycling techniques for packaging. The paper presents an approach to recover the aluminium contained in flexible packaging materials using an integrated melting and waste-gas purification system.

Jan 1, 1995

By J. S. Becker

Technology developed and first implemented in the United Kingdom enables very low grade aluminum scraps containing oils, organics, plastics and ferrous metals to be directly charged, without pretreatment, into a unique melting furnace. The system has been in full scale production for over three years. The oxy-fuel-based furnace design incorporates internal afterburning in the furnace's hot zone, producing excellent thermal efficiency and very low emissions. The furnace is inherently low in NOx. This paper will provide both theoretical background and extensive operating results for this new melting concept. Applications describing both purpose built new furnaces and retrofits of existing reverberatory furnaces will be presented. Extensive operating emissions data will be presented.

Jan 1, 1996

By Lztok Peruš, Goran Kugler, Matevz Fazarinc, Milan Tercel

"Hot deformability of M42 tool steel additionally alloyed with cobalt and molybdenum was investigated. Hot-compression tests were carried out in the temperature range 850 °C -1200 °C, at strain rates range 0.001--6s-l up to strain of0.9. Field-emission scanning electron microscope and optical microscopy were used for characterization of microstructure of deformed samples, which revealed a very complex precipitation of carbides that strongly depends on the soaking temperature, the soaking time, the stress state, the deformation temperature as well as on the strain rate. Gathered data was used to calculate the processing parameters such as process maps, apparent activation energies and strain hardening exponents. For better understanding of thermodynamical properties of the studied steel a simultaneous thermal analysis was conducted. Furthermore the analysis of phase equilibrium was calculated using Thermo-Cale software. On the basis of these studies the optimal soaking temperature and process windows were determined.IntroductionHot workability ofledeburitic tool steels is important economic factor. This means that for each tool steel individuallysafe range of hot working parameters should be revealed. Publications in the literature with regard to the hot workability of tool steels are rare and therefore more information from this research area is desired.The relatively low hot workability of ledeburitic tool steels, i.e. steels in which the solidification is completed by a eutectic transformation of the residual interdendritic liquid to austenite and various alloy carbides (ledeburitic carbides), is usually characterized by the production of surface and internal cracks during the hot deformation."

Jan 1, 2013

By R. E. Molnar

A number of flowsheets have been designed and operated, or are currently being considered, to extract copper from leach solutions having much more copper than the 4 g/L levels typically found in heap leach liquors. Dealing with these solutions has required that the envelope for ?normal? copper solvent extraction be pushed beyond the usually considered limits. Others have published information on flowsheets to recover copper from leach liquors containing over 25 g/L copper. Secondary solvent extraction circuits are often required to attain satisfactory overall recoveries. This paper reviews some of the issues faced in three pilot plant circuits that were operated by SGS Lakefield Research to produce cathode copper from solutions containing 8 to 20 g/L Cu. The primary objective was to maximize copper extraction using one solvent extraction circuit. The role of feed acidity and the disposition of impurities such as iron and chloride are considered. The challenges of running short SX piloting campaigns are discussed.

Jan 1, 2003

By Ernest D. Mast

Noranda's Altonorte custom smelter, located in the 2nd region of Chile, 20 kilometres southeast of the city of Antofagasta, started operations in 1993. Presently, 1150 tonnes per day of new feed are smelted with an 85% sulphur capture. An oxy-fuel reverberatory furnace produces a 48%-55% copper matte that is treated in 13 ft. x 36 ft. (3..96m x 10.97m) Peirce-Smith converters (two hot and one blowing). Up to thirty percent of the new concentrate is smelted via dry concentrate injection into the converters. This paper reviews the development of the concentrate drying and injection system, and oxygen enrichment at Altonorte from start-up in 1995 to the present time. The relationship between oxygen enrichment and concentrate injection is reviewed from a theoretical and practical standpoint. Concentrate injection has improved the smelter's productivity and added flexibility to the operations. Due to the relatively high matte grades and the subsequent short converting times, maintaining consistent operations was difficult at times and the smelter has gone through a learning curve. Plant operating results and experiences are presented on the impact of concentrate injection in relation to: feed treatment, blowing times, revert generation, slag quality and refractory wear.

Jan 1, 1999

By Tapani Järvinen

Non-ferrous metals and metals in general are considered as being non-renewable natural resources. Metals are needed because of their excellent and irreplaceable properties. The consumption of metals, with the exception of carbon steel, is steadily growing by 1-3 % annually, and that of stainless steel as much as 3-6 %. This is a general trend, which is periodically disturbed by cyclical variations. In recent years so-called "New Economy" has become prominent in the public media and the market value of the traditional industry has been well below its real value and importance. Nevertheless, the modem society requires metals today and also in the future, and the companies using the most modern technology in a responsible way and innovative solutions not only in technology, but also in everything they do will survive. This paper describes the role of Europe as a producer of primary base metals and as a supplier of technologies in the base metals industry. It concentrates on the development and commercialization of technologies and project implementation in the metallurgical industry. As one example ofa European approach to these matters the paper presents Outokumpu's response to the future challenges in the base metals industry. Outokumpu Oyj is one of the leading metals and technology companies in the world of stainless steel, copper, zinc, and sales of technology in metals and minerals businesses. Outokumpu applies its knowledge of metals and processing to generate value for its customers and shareholder. Everything we do, we do in an economically, environmentally and socially responsible way.

Jan 1, 2003

By D. G. Schmidt

Tests were conducted on C86200 high-strength yellow brass in order to ascertain the effect of a low level of nickel on the mechanical properties on this alloy. A series of two alloys was studied, one of which had a nickel content of 0.85% and the other with <0.05% nickel. Copper and aluminum content ranged from 62.5% to 64% and 3.2% to 4.6%, respectively. When compared by zinc equivalents, a nickel addition of 0.75% in high-strength yellow brass does not act like copper but raises the tensile strength, 0.5% yield strength and BHN while lowering the elongation.

Jan 1, 1999

By R. Boom, B. Kraaijveld, H. Kuntzel, Y. Meteleva-Fischer

"Alloying refining with rare earth elements followed by acid leaching was examined for the potential of upgrading of metallurgical grade silicon. Microstructure study of silicon alloyed with small additions of rare earths showed behavior relatively similar to the influence of calcium addition. After alloying with neodymium the phosphorus content was detected in various intermetallic silicides containing neodymium and iron. The content of lanthanum and neodymium in refined silicon was by several times lower than that of aluminium and calcium. Alloying with lanthanum and neodymium at smaller additions than calcium reduced the phosphorus content down to the same level. The efficiency of lanthanum and neodymium in removal of boron and phosphorus at the 1-2 wt% of their additions and their low solubility in silicon make the alloying with these metals followed by acid leaching an attractive option for the refining route of metallurgical grade silicon up to solar grade.IntroductionA striving for a cheap ""green"" energy directs the research interests in silicon solar cells towards new efficient refining routes for metallurgical grade silicon (MG-Si, -98% purity). The silicon price determines up to high extent the solar module's price, so that cheap and efficient metallurgical process is awaited. The research challenge is to fulfil the purity requirements of solar grade silicon (SoG-Si, 6N) by competing with the energy-consuming and environmentally unfriendly Siemens process. Most difficult impurities to remove are boron and phosphorus, so technologies dedicated to their efficient removal attract an attention of industry and academia.Alloying refining (also known as solvent refining) is one of the most promising refining options, which is based on a principle of solid-liquid extraction using limited solubility of impurity elements in solid silicon [ 1]. Various elements were proposed for alloying refining: aluminium [2], calcium [3], tin [4], iron [5], copper [6] etc. The attractiveness of the alloying refining is in decreasing a melting point of the metal mixture and an affinity of the alloying element to the most harmful impurities, especially to boron and phosphorus. However, the difficulties are still faced due to self-solubility of the alloying elements, their low affinity to boron and/or phosphorus, silicon losses and necessity of removal of the silicide impurity phases in an additional step, using acid leaching [7], fractional melting [ 8] etc."

Jan 1, 2013

By Evgenii Pavlov, Ivan Tronin, Viktor Timofeev, Vladimir Kislov, Sergei Bogovalov

"Modeling of the magnetohydrodynamical (MHD) and thermodynamical processes during the industrial scale Direct Chill (DC) casting of aluminum slabs is performed using a combination of ANSYS/CFX and ANSYS/EMAG software. The electromagnetic field is modeled through ANSYS/EMAG, while hydrodynamic and thermodynamic processes are modeled through ANSYS/CFX. Both packages were modified in order to calculate MHD flows in the liquid pool that forms during aluminum DC casting, and they were unified into a software combination that provides simultaneous simulation of all the above processes. The simulation shows that the electromagnetic stirring of the molten aluminum changes the shape of the solidification front (solid-liquid interface) very dramatically, namely it becomes significantly flatter. This effect should improve the internal structure of aluminum DC slabs and allows us to increase the casting velocity.IntroductionProduction of Aluminum alloys with high mechanical properties and structural uniformity is one of the main goals of industry. The preferred production method of aluminum alloys in most modern plants is Direct Chill (hereafter DC) casting because it offers high productivity and commercial success. One important limitation of this technology is the development of centerline shrinkage in slabs larger than about 1 meter. The improvement of the internal structure of long DC cast slabs can be achieved by electromagnetic stirring (hereafter ES) of the liquid metal above the solidification front. This intensifies heat transport in the zone close to the solidification front and suppresses shrinkage formation."

Jan 1, 2013

By Roy J. M. van Lier

In industrial aqueous solutions, germanium generally occurs in trace amounts amid high concentrations of other metals, such as zinc, copper and iron. Separation of germanium from these metals as well as its isolation from gallium and indium pose a real challenge to the hydrometallurgist. After a brief discussion of the aqueous chemistry of germanium, this paper reviews the flowsheet of the Apex Mine in Utah. The Apex property was the only mine in the world to be operated primarily for production of gallium and germanium, but apparently closed due to great operating difficulties. Several process variants proposed for the treatment of the Apex ore, including bioleaching methods, are addressed. Following a more general description of the behavior of germanium in hydrometallurgical zinc processing streams, available technology for its recovery from aqueous solutions is summarized. Precipitation, solvent extraction, ion exchange, electrowinning, ion flotation and liquid-membrane separation are all outlined in terms of the aqueous chemistry of germanium. Finally, the production of high purity germanium dioxide and metal is briefly discussed

Jan 1, 1995

By William A. Hockings

Methods for the measurement of liberation of finely ground iron ores are described. The general method consists of separating a sample of the ground ore into a number of size fractions, followed by measuring the liberation of each fraction. The size separation has been done using electro-formed screens of 20-, 10-and 5-micrometer apertures, and also by air elutriation. Liberation (i.e., the distribution of compositions of individual particles) has been measured by optical microscopy. A computer pro-gram was used to adjust the raw count data so that it agrees with the chemical analyses of the size fractions. Various ways of presenting the results are given, and Some applications of the results to flotation processing are discussed.

Jan 1, 1981

By David G. Dixon, Ahmad Ghahremaninezhad, Edouard Asselin

"In this study pertaining to the electrochemistry of chalcopyrite, the active/passive behavior of a chalcopyrite electrode in 0.5M sulfuric acid solution was investigated. Potentiostatic and potentiodynamic polarization and multi-cyclic voltanunetry were conducted to analyze the electrodissolution parameters of the electrode.The potentiodynamic and potentiostatic polarizations of chalcopyrite revealed the formation of a passive film on the surface of chalcopyrite. From the potentiostatic study in the passive potential region, a decrease in the dissolution current density by increasing the potential was observed. From this, it was concluded that the passive film is an n-type semiconductor and cation interstitial defects or anion vacancies are the charge carriers. From multi-cyclic voltammetry studies, four cathodic peaks at - 0.37, 0.30, -0.10 and-0.20 YsHE were detected on the surface of a passivated chalcopyrite electrode. The cathodic peaks at 0.37 and 0.30 V were connected to ferric to ferrous reduction and copper sulfide formation, respectively. The peaks at -0.10 and - 0.20 were related to chalcopyrite reduction. The products of the chalcopyrite reduction reactions were suggested to be Cu2S, Cu9fesS16 and Cu5feS4 and evolution of hydrogen sulfide gas (H2S).IntroductionChalcopyrite is the most abundant copper bearing mineral in the world and its dissolution behavior represents the most important technological consideration in the hydrometallurgical extraction of copper [I]. Since the current pyrometallurgical methods for copper extraction from chalcopyrite have environmental issues, many studies have considered the leaching and dissolution of CuFeS2 in different aqueous media [2-5]. The main problem associated with leaching processes is the slow dissolution rate of the mineral [6]. During the dissolution process, increasing the potential of the chalcopyrite in the anodic direction will cause the formation of surface layers which hinder the dissolution rate of the mineral [7]. The precise composition of the layers is in dispute. Previous studies have concluded that these layers could be sulfur [8-9], precipitated iron compounds [8], a solid electrolyte interphase (SEI) - which slows the rate of electron transfer- [10], a metal deficient sulfide [ll], or polysulfidic in nature [12-13]. In order to increase the leaching kinetics of chalcopyrite, the characterization of the layers formed during dissolution is essential and electrochemical methods are important to this end. Studies by Biegler [14] show nucleation and growth of a thin two-dimensional sulfide phase on the surface of chalcopyrite during the exposure of a polished sample in HzS04 solution or air. More studies by Biegler and Swift [15] have shown evidence for nucleation and growth of a 3-dimensional phase at low anodic potentials (around 200 mV vs. OCP). The current-time behavior of the dissolution process in this potential area has the characteristics of expansion and overlap of localized dissolution centers."

Jan 1, 2012

By Michael J. Nicol

Growing environmental and occupational safety concerns about the use of cyanide in gold processing has increased the interest in more acceptable alternatives. The most likely of these is thiosulfate. However, the thiosulfate process lacks a proven in-pulp method of recovering the dissolved gold, because activated carbon is not effective for the absorption of the gold thiosulfate complex .. Anion exchange resins do offer a possible route for in-pulp recovery. This paper describes work aimed at the evaluation of the effectiveness of commercially available anion exchange resins for the recovery of gold from thiosulfate leach liquors? and pulps. It has been found that strong-base resins are superior to weak-base resins in that they have a larger capacity, which assists in reducing the competition from other anions within a leach solution. Further studies with a selected commercial strong-base resin have shown that competing polythionateanions (particularly tri-and tetrathionate). Lower the maximum possible gold loading but that gold is selectively recovered over other base metal anions in solution. Kinetic experiments found that while? competilig anibns did not affect the initial rate? of gold loading it was important to minimise the contact time of the resin in solution so to prevent displacement of loaded gold by competing anions over longer times. A small-scale resin-in-pulp plant investigation showed gold can be recovered from a leach pulp by a strong-base resin to yield gold loadings of 3000 mg/L, barren pulp containing less than 0.05 mg/L of dissolved gold and. copper loadings of 500 mg/L. Loaded copper was displaced gold and at a loading of 2000 mg/L gold the copper loading was minimal «500 mg/L). The resin was found to recover gold adsorbed on the solids that would, otherwise have. reported to tails if a solid/liquid separation method were used. A patented two-step elution process in which copper and then gold are separately eluted from the resin is also discussed.

Jan 1, 1998

By Annette Revet

Aluminum fluxes have been used for the remelting of secondary aluminum since the beginning of the recycling industry. During the last sixty years, a number of fluxes have been designed, researched and tested at the laboratory and plant scale. Fluxes are primarily a mixture of potassium chloride and sodium chloride with the addition of some other chloride and fluoride containing salts. The conventional Mining methods of potassium chloride and sodium chloride yield products that are not high in purity without costly reprocessing or additional refining. In 1993, Kalium Chemicals, Ltd. began supplying flux mixtures to the aluminum industry. Kalium produces potassium chloride and sodium chloride which are mined and refined by a patented solution-mining process. The salts produced by this process are high in purity with lower concentrations of iron oxide, sulfates, and other impurities. This paper will present the different mining methods used in the production of sodium chloride and potassium chloride. The paper Will address how these mining methods affect the purity of the final product as well as the effect of purity on the performance of the fluxing salt.

Jan 1, 1995

By Hai-Xing Fang, Bing Xie, Hong-Yi Li

"In the duplex melting process, chromium forms chromium spinels, the study of which will help to exploit the Hongge ores (rich in chromium) in the Panzhihua-Xichang area in China. Mimicked chromium slag was synthesized. The oxidation and decomposition mechanism of the Fe-Cr spinels contained was studied in a sodium roasting process. The effects of temperature, roasting time, amount of soda added and filling reagents were investigated. The leaching-reduction-precipitation-calcination procedure to extract Cr2CO3 was optimized. The results showed that the optimized roasting temperature was 1000~1020°C with a stoichiometric Na2CO3 addition and without any filling reagents. Roasted materials were leached with distilled water and were filtered to obtain a chromium-containing solution, which was adjusted to pH 1.60-1.80. A reducing reagent, NaHSO3, was added in a stoichiometric ratio and the solution was then adjusted to pH 7.25~8.25. Maximum Cr2O3 precipitation was obtained and the precipitate was calcined at 1050°C for 2h to obtain Cr2Ü3 with recovery rate over 96%.IntroductionChromium is widely applied in the metallurgical industry, in refractory materials and in the chemical industry with its particular properties of hardness, wear-resistance, high temperature resistance and corrosion resistance [1]. There is no free state of chromium in nature and chromite is the main chromium containing mineral [2], China is poor in chromium resources, despite its large demand, and there are few deposits of high grade of chromite ores except in some regions in Tibet and Xinjiang province [1, 4]. Hongge, one of largest titanomagnetite mines in Panzhihua-Xichang area, is a polymetallic deposit mainly containing iron and titanium; it is also associated with various beneficial elements such as chromium, copper, nickel, etc. [3]. As investigated in Reference 3, the chromium reserves of Hongge ores are so large that it is of great importance to study how to extract the chromium from them."

Jan 1, 2012

By Eugene Jak

Copper sulphide processing technologies face increasing pressures associated with decreasing concentrate grade leading to increasing thermal inefficiency and lower productivity. Impurity concentrations are on average increasing, creating potential environmental risk and additional treatment costs. In copper flash smelters dust, partially oxidised materials and fume formed from the condensation of volatile impurities, are routinely recycled to the feed. In the converting stage the heat balance is maintained by charging anode reverts and other inert materials. In both cases, the thermal energy available from sulphide oxidation is not fully utilised or optimised. The productivities of both smelter and converter stages can be potentially increased through the addition of a high copper, low iron, low impurity precipitated copper product. Calculations are carried out for fayalite smelter and calcium ferrite converter slags using an optimised FactSage thermodynamic database. The potential for significant increases in smelter and converter productivities using existing technologies are predicted.