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By M. J. Collins

Pressure leaching of zinc sulphide concentrates has been practiced commercially for nearly two decades. The process, which includes direct leaching of concentrate with spent electrolyte in an autoclave, has been commercialized at four separate locations to date. In pilot studies carried out in the Dynatec lab in Fort Saskatchewan, dozens of additional zinc concentrates have been shown to be amenable to pressure leaching. This paper highlights recent improvements in zinc pressure leaching that have been identified through process development studies, and how the experience gained in these studies has been utilized in the development of a new copper pressure leach process.

Jan 1, 2000

By H. Eccles

BNFL, an internationally acclaimed company noted for its nuclear fuel cycle services and waste management technologies, collaborated with Viridian BioProcessing Ltd, a small company acknowledged for developing environmental biological processes, and an internationally recognised professor of biological sciences, to develop an unique bioremediation process for treating toxic, heavy metal contaminated land. This paper describes the process, with particular reference to the problem and scope of land contamination with toxic, heavy metals and the current available technologies. The process technologies are based on using indigenous, soil micro-organisms which can be stimulated to produce acid or sulphide ions to mobilise or precipitate the heavy metals respectively. Laboratory studies have indicated metal removal efficiencies of greater than 90 % can be achieved, whilst recovery efficiencies from the metal loaded leachate are even higher at approximately 95%.

Jan 1, 1996

By P. A. Davidson

"We discuss the influence of a static magnetic field on jets, vortices and turbulence. This is particularly relevant to D.C. braking in slab casting. Our main conclusion is that, typically, the magnetic field destroys mechanical energy, via joule dissipation, but is unable to destroy momentum. Rather, it continually rearranges the momentum in such a way that the energy falls.IntroductionIt is well-known that a static magnetic field can suppress motion of a liquid metal. That is to say, movement of the liquid across the magnetic field lines induces a current. This leads to Joule dissipation and the resultant rise in thermal energy is accompanied by a corresponding fall in kinetic energy.This phenomenon has been exploited in a range of metallurgical processes. For example, in the continuous casting of large steel slabs, an intense, static magnetic field is commonly used to suppress motion within the mould. The objective is to keep the free surface of the liquid quiescent, thus avoiding the entrainment of surface debris. In other solidification processes, such as techniques for growing semi-conductor crystals, it is widely believed that natural convection has a detrimental effect on the metallurgical structure of the solid. Again, the imposition of a static magnetic field is seen as one means of suppressing these unwanted motions. Finally, magnetic damping is used in the laboratory measurements of chemical and thermal diffusivities, particularly where solutal or thermal buoyancy can disrupt the measurement technique.In this paper we shall look at the damping of jets, vortices and turbulence. Our aim is to present a unified theoretical framework from which the many published studies may be viewed."

Jan 1, 1999

By Gordon A. Irons, Diancai Guo

"Uneven movement of scrap during melting in an Electric Arc Furnace causes operation problems: cave-ins interrupt electric power input. The movement also influences the radiation heat loss to water-cooled side panels and roof. An apparatus has been built to simulate the flow of scrap that may be interlocked. It has been observed that flow starts at the point where the suspended length of the pile bottom reaches the average scrap size, and proceeds in the form of cave-ins, but scrap pieces slide with each other as ordinary granules. After a cave-in, the pile angle usually remains much larger than the normally observed angle of repose. The force balance of a partially suspended scrap pile has been analyzed, and the equivalent cohesion due to interlocking estimated. A numerical model has been developed to simulate the scrap flow. Simulated results agree reasonably with observed phenomena.IntroductionWhen one considers the melting of steel scrap in an electric arc furnace (EAF), it is helpful to understand the movement of the material during meltdown. As industrial experience demonstrates, scrap movement greatly affects EAF operation. In a typical operation, scrap is dropped into the furnace from scrap buckets. The roof and electrodes are swung into position, and power is applied to the electrodes situated over the scrap. The electrodes ""bore"" into the scrap by melting into the steel in the immediate vicinity of the electrodes as they are lowered. If solid scrap pieces gradually slide towards the arc area, the electric power supply can be maintained at a high level, with few interruptions or drastic electrode adjustments. This results in a high production rate and low power consumption per tonne of steel produced. On the other hand, if the charge moves down unevenly, i.e. in large surges, usually called cave-ins, the electrodes must be drastically raised, and power supply frequently interrupted. This is also accompanied by a high level of harmonics induced in the power network, deteriorating the quality of electricity supplied to other users.In addition, the movement of scrap in an EAF also influences the furnace heat efficiency, as the scrap pile is much closer to the electric arcs compared to the furnace wall and roof, and absorbs more radiated heat. Early exposure of the wall and roof to the arcs will increase the heat loss due to radiation, and reduce the service life of the furnace."

Jan 1, 2004

By Ted H. Eyde

Natural Zeolites are a less expensive and in certain applications a superior alternative to organic ion exchange resins. Mining and metallurgical waste streams are difficult to treat because the effluents which contain potentially valuable heavy metals such as copper, lead, and silver are often highly acidic and contain significant quantities of suspended solids. Under rigorous operational conditions, certain natural zeolites can remove the metals, which if desired can be recovered by either elution or conventional smelting techniques. There are significant differences in cation exchange rate, selectivity and capacity as well as resistance to either high or low pH, blocking cations and tolerance to elevated or depressed temperature and pressure not only between different zeolite minerals but between the same mineral from different deposits. Applying natural zeolites to the treatment of mining and metallurgical waste streams depends on matching the specific zeolite to the effluent by characterization of the zeolite minerals.

Jan 1, 1993

By S. P. Song

A computational methodology based on the coupled finite element and boundary methods is developed to predict the free surface shapes of electrically conducting liquids supported by the electromagnetic field. The work is an extension of our previous FEIBE model for induction calculations. The free surface algorithm is developed using the Weighted Residual Method, the very same used for nonlinear finite element formulation. This allows the treatment of field computation and free surface prediction in the same manner, thus making easier the formulation of the magnetically-supported free surface problems. Like other nonlinear algorithms, the boundary/finite element free surface scheme is also iterative owing to the fact that free surface shapes are unknown a priori. But the numerical scheme is robust and efficient and is capable of handling rather complex free surface deformations. Computational algorithms will be given and are tested by comparing with other solutions whenever available. Computed results of magnetically-supported free surface shapes are presented for magnetic levitation under microgravity and floating zone refining processes under normal gravity.

Jan 1, 1996

By J. R. Rendón

Cylinders of commercial aluminium alloy 6063 were homogenized under different conditions. The experimental results indicated that the general mechanical behaviour as related to curves of 0.2% yield strength, ultimate tensile strength and Brunnell hardness versus homogeneizing process is the same in both cases. The mechanical properties as compared to those required by plant specifications, tend to be better with increasing values of % Mg2Si in the alloy, as expected. The electron microscopy investigations revealed that in both homogeneizing processes the resulting microstructure consist of significant spheroidizing of the alpha phase (AlFeSi) and fine-needle type structure of beta phase. The alpha phase was also present in a Chinese type scripture. Furthermore, the slow cooling within the furnace resulted in the nucleation and growth of Mg2Si precipitates generally along the grain boundaries.

Jan 1, 1997

By D. C. Foguel, J. L. R. Bravo

For several years, Caraiba Metais S.A. (CMSA) had to stock the arsenic sludge generated from the electrolyte purification process of its tankhouse. The amount stocked · reached approximately 3,500 tonnes, as the effects of its recycling during the smelting process and consequently in the sulfuric acid plant were unknown. Besides, it had as limiting factors the high content of arsenic in the copper concentrates supplied by foreign countries as well as the reduced capacity of the tankhouse's purification plant. The choice for selling the mentioned residue, which generally contains more than 50% of Cu, was attractive, but the environmental policies and regulations had not allowed this option. Other alternatives, such as the production of bicupric arsenic by means of a solvent extraction process or arsenic trioxide, were considered but the economic feasibility was not attractive due to the absence of a domestic market and a poor international market. After a study of the arsenic partition in the metallurgical process, it was verified that the residue could be recycled without causing any operational problems or damage to the environment. To make this possible, the capacity of the purification plant was increased and the way of removing the arsenic sludge from the cells was modified from manual to mechanical, therefore avoiding the direct contact of the workers with this poisonous substance. Moreover, procedures for recycling in the smelter were established and tolerance limits were set for both the smelter and the sulfuric acid plant. The main amount of arsenic to be recycled is released with the smelting furnace off-gas, which is washed during the purification stage of the sulfuric acid plant. The acid water, rich in arsenic, is then treated in the waste plant and the arsenic, in its stabilized condition, is confined in an appropriate area.

Jan 1, 2000

By Wei Yin, Bin Xu, Qian Li, Yongbin Yang, Tao Jiang

Copper anode slime is an increasingly significant resource for precious metals such as Au, Ag and Pd. The extraction of Au, Ag and Pd from decopperized anode slime by different pretreatments and different lixiviants including cyanide, chloride, thiourea and thiosulfate have been investigated. When oxidizing roasting pretreatment was carried out under the conditions of roasting time 120min and temperature 625 ℃, the removal ratios of S and Sb could reach 82.18% and 98.52%, respectively. And the following alkaline leaching of calcine could result in the dissolution of 46.40% Cu and 98.48% Pb. The optima leaching ratios of Au, Ag and Pd reached 99.48%, 97.69%, 94.79% by cyanide leaching, and 95.01%, 79.84%, 96.59% by chloride leaching, and about 95.21%, 95.66%, 48.79% by thiourea/thiosulfate leaching.

Jan 1, 2015

By Mahesh C. Jha

Molybdenum, a major refractory metal, is widely used as an alloying element in steels and superalloys to improve their corrosion resistance, physical properties and mechanical strength, particularly at elevated temperatures. The current worldwide production and consumption is estimated at about 130,000 tons contained molybdenum per year. Molybdenum occurs in nature as molybdenite mineral and is recovered by a flotation process as a primary concentrate at molybdenum mines and as a byproduct concentrate at copper mines. The concentrate is roasted to a technical-grade molybdic oxide (tech oxide) in multiple-hearth roasters. About 80 percent of the tech oxide is sold, as such or after conversion to ferromolybdenum, for addition to iron and steel. The remainder is further refined to pure oxide and molybdate chemicals that are used in the manufacture of catalysts, specialty chemicals, molybdenum metal and superalloys. This paper discusses the various steps in the extractive metallurgy of molybdenum, from flotation of sulfide concentrate to reduction of pure oxide to molybdenum metal.

Nov 26, 1999

By F. J. Tavera

Recently Jameson cell technology has gained acceptance in both mineral and non-mineral applications, mainly because of the high degree of contact between the involved phases in the downcomer, fact that leads to an efficient collection performance. The key for an acceptable performance of the downcomer operation depends on the stability of the jet zone, the mixing zone, and the plug flow zone. in this work the behaviour of the downcomer of a laboratory Jameson cell is reported, as a function of gas hold-up, superficial gas velocity, superficial liquid (or slurry) velocity, and length of the operating zones. The presence of carbon is evaluated in terms of its effect on the gas hold-up and bubble surface area flux. The influence of the downcomer operating conditions on the gas-liquid disengaging cell is presented. Keywords: Jameson cell, downcomer, gas hold-up, mixing, plug flow, conductivity.

Jan 1, 2003

By Jorge Alberto Soares Tenório, Romano Espinosa, Felipe Fardin Grillo, José Roberto de Oliveira, Denise Crocce

"The aim of this work was evaluation of the recovery of Zn and Fe of the EAFD added to the hot metal in the form of briquette at temperature of 1500°C. The EAFD was agglomerated by cold briquetting and introduced in the hot metal. This study utilized a bench-scale equipment to melt, during this process to kept a flow rate of inert gas above the bath. Were collected periodically metal samples and the samples were analyzed for determination of the content of total silicon and carbon by chemical analysis. Zinc oxide, zinc ferrite and other oxides were reduced and were volatized and collected by a cleaning system of dust (baghouse) located on top of the oven. More than 98% of iron were recovered from EAFD during the test. It was possible to produce a dust containing about 68% zinc by means of adding of EAFD.IntroductionIn the first semester of 2010, steel production was about 706 million tons, 27.9 % more than in the first half of 2009. Not a significantly increase if 2010 data is compared with the first semester of 2007 (only 7.2 % higher), before the world’s economic crises. Steel production is divided into two main routes. The first one, and most used, is the Basic Oxygen Furnace Process (BOF process), which in 2008 accounted for approximately 67.1 % of steel production. The second route is carried out in the Electric Arc Furnace (EAF) that in 2008 represented 30.6 % [1 ].Electric arc furnace dust (EAFD) is a solid waste generated during the steel making process. It is classi?ed according to NBR 10004 as dangerous solid waste-class I, because the elements Pb e Cd leach in water exceeding the maximum limits permitted by the NBR 10004 [2 ]."

Jan 1, 2012

By Rollie E. Dutton, David A. Stubbs

"A sensor has been developed and tested that is capable of emitting and receiving ultrasonic energy at temperatures exceeding 900°C and pressures above 150 MPa. The sensor works with standard ultrasonic pulser-receivers and has demonstrated the capability of measuring workpiece deformation during hot isostatic pressing (HIP). Details of the sensor design, performance, and coupling of the ultrasound to the workpiece are described. Ultrasonic data acquired by the sensor, in situ, during HIP runs and at elevated temperatures in air are presented.INTRODUCTIONHigh temperature structural components, such as structural castings for jet engines, nickel-base superalloy turbine blades, and ceramic and metal matrix composites made from powders are often densified by hot isostatic pressing (HIP). For powder consolidification, the HIP process involves sealing the powder (and reinforcing fibers for composites) within an evacuated ""Can"" made of a material that softens at high temperatures. A hydrostatic pressure is then applied by pressurizing the inside of the HIP vessel with argon gas (up to 140 MPa). The hydrostatic pressure densities the powder through the elimination of the porosity between the powder particles.This paper presents details of the development and preliminary testing of an ultrasonic displacement sensor that can be used to monitor materials processing, in situ, at temperatures and pressures significantly higher than current ultrasonic displacement sensors. The target processing environment for this sensor is that typically found in a hot isostatic pressure (HIP) vessel, i.e., temperatures exceeding 1000°C and pressures above 138 MP a."

Jan 1, 1997

By R. Kramer

During foundry sand reclamation process development, molds formed from reclaimed chromite sand showed a rapid decline in tensile strength during thermal cycling tests. Because this characteristic could limit reuse of chromite sand in the. foundry, the sand was examined in detail Scanning electron microscopy, x-ray mapping, magnetic susceptibility, and x-ray diffraction were utilized to evaluate processed chromite sand. It was found that process variables such as binder composition, reclamation temperature, and processing method had a significant effect on the chromite sand particle surface. X-ray diffraction indicated a crystallographic change in the processed sands. Magnetic susceptibility also increased after processing. Diffusion of iron to the particle surface and increased surface roughness were identified as potential causes of the decreased tensile strength in the molds.

Jan 1, 1991

By Stephen C. Britten

An in-situ amperometric slag sensor for measuring the concentration of easily dissociable oxides in slags at temperatures between 1200-1600°C is being developed. The sensor provides the same information as potentiometric sensors while also providing data on the concentration of the transition metal species and the diffision kinetics within the slag. The electrochemical technique utilized in the sensor is similar to methods utilized in aqueous voltammetry.

Jan 1, 1998

By William Petruk

The behaviour of sphalerite during mineral beneficiation of base metal ores has been studied at CANMET and other institutes for at least 15 years by determining the liberations of sphalerite in mill products and calculating the recoveries of liberated and unliberated sphalerite in zinc concentrates. Sphalerite in base metal ores commonly occurs as layers and as interstitial material between pyrite. Layered sphalerite is generally liberated during primary grinding, but interstitial sphalerite requires re-grinding to achieve liberation. Around 95% of liberated sphalerite is generally recovered in zinc concentrates frau zinc circuit feeds. A series of tests was conducted on sphalerite in the ore of Brunswick Mining and smelting during a continuous fine tuning operation of the concentrator. It was found that a grind of 80% minus 37 micrometres was required to liberate the interstitial sphalerite. The fine grind increased Zn recoveries from 75% to 78-80%, but produced liberated slimed sphalerite which was lost. Since regrinding to a fine grain size is needed to obtain the desired sphalerite liberation, a method of recovering the slimed sphalerite is required.

Jan 1, 1990

By J. Fraser Forbes

"The meaning of the term ""process control"" has evolved significantly since its widespread use began in the manufacturing industries in the 1940s. Further, the scope of process control applications has drastically increased both in terms of the breadth of industries using process automation technologies and the vertical integration of these technologies within a single industry. This evolution and integration of process control technologies within the manufacturing industries has proceeded to such an extent that process automation is an integral part of modern business practices.This paper will examine the current status of process control technology from simple process regulation through process performance optimization to business planning. Each layer of the operations automation hierarchy will be discussed both in. terms of the current state-of-the-art and the directions in which these technologies are evolving. The key tools and tasks necessary for success at every level of the automation hierarchy will be introduced. Finally, the critical challenges that must be faced in accomplishing the goal of complete Computer Integrated Manufacturing (CIM) will be described.Finally, although this paper addresses issues of practical importance to any manufacturing company, the discussions will be framed in terms of the particular challenges facing and the opportunities available within the materials manufacturing industries."

Jan 1, 2000

By H. Tan

?Preg-robbing? is the active adsorption of gold from cyanide solution by the ore components. The role of carbonaceous coatings on chalcopyrite surfaces in the preg-robbing of chalcopyrite has been investigated by using pure chalcopyrite and a copper concentrate. Activated carbon and graphite were chosen as representative carbonaceous contaminants. It was found that the carbonaceous coatings enhanced the preg-robbing of chalcopyrite. Activated carbon coating increased gold adsorption onto chalcopyrite to a lager extent, in comparison with graphite coating. In the preg-robbing of the copper concentrate, gold adsorption was increased to larger extent at finer particle sizes and at higher contents of activated carbon or graphite. The preg-robbing of chalcopyrite was reduced or eliminated, depending on the concentrations of free cyanide. However, the gold adsorption on the carbon and graphite coated chalcopyrite could not be avoided even at higher cyanide concentrations, and this adsorption was solely attributed to the carbonaceous coatings. Zeta potential studies indicated that the carbonaceous coatings reduced the negativity of the chalcopyrite surface charge. As shown by SEM analysis, gold not only accumulated at the edges and defect sites, but was also spotted on the smooth surfaces of chalcopyrite with carbon or graphite present. XPS results revealed that gold was strongly reduced on chalcopyrite surfaces, with the sulfide ions of the chalcopyrite being oxidized to elemental sulfur. Diagnostic elution indicated three mechanisms contributing to gold take-up by chalcopyrite, i.e. gold reduction, physical adsorption and chemical adsorption.

Jan 1, 2003

By Robert Vidal

A model of the homogeneous chemistry and transport processes within the separator of a chrome-alum electrowinning cell is introduced, discussed, and compared to experiment. The influence of diffusion, electromigration, and convection are included; it is found that convection was the dominant mode of transport for the experimental conditions. Simulation results explain experimental observations concerning an apparent disappearance of dichromate ions produced at the cell anode. The relation between potential drop across the diaphragm and the current and fluid flow is also illustrated. The model is used to recommend future experimental and theoretical work.

Jan 1, 1994

By Tiruttani Munikamal, Suresh Sundarraj

"A numerical model of the induction hardening process of steel cranks has been developed and the predicted results of temperature and phase distribution during this solid state phase transformation process are verified with experimental data from the literature. This heat treatment process involves heating the crank to the austenitic temperature range followed by rapid quenching in water to harden the surface of the crank. The model has been developed using ABAQUS, commercial FEA software. The formation of martensite, pearlite, and retained austenite phases are modeled and implemented through a user defined function in ABAQUS. A sensitivity study on the various process parameters affecting the amount of phase distribution has been carried out.IntroductionThe type of surface and sub-surface microstructure as well as the residual stresses that are present in a component after manufacturing, significantly affects it fatigue performance. The wear resistance of the automotive components such as crankshaft, gears, camshaft and bearings depends on the surface hardness. In order to achieve the surface hardness, these steel components are subjected to a type of quench hardening heat treatment process. There are several heat treatment processes available for the industrial application to improve the mechanical properties of the final part. Case hardening using induction heating is one of the widely used industrial techniques for improving the surface microstructure of a steel component. It consists of two stages i.e. induction heating cycle, followed by quenching in a fluid medium (usually water or oil)"

Jan 1, 2012