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"An experimental study has been performed to investigate the dispersed phase holdup induced by a high-strength submerged gas injection in a bottom blown air-stirred one-seventh water model of CLU (Creusot-Loire Uddeholm) reactor using two different tuyere configurations. The air flow rates varied from 0.00599 m3/sec to 0.01312 m3/sec. In these series of experiments, water height and kerosene height were kept constant at 0.23m and 0.02m respectively. The dispersed phase holdup was determined at various gas flow rates, and tuyere orientations by using water and kerosene.The dispersed phase holdup increased with gas injection rate and decreased with vertical distance from the original interface. At constant gas flow rate, as the vertical distance increased in the centerline, off-center configuration of nozzles displayed higher values of the dispersed phase holdup than those of the center configuration. The variation of the dispersed phase holdup with the dimensionless axial distance and the gas injection rate was correlated by using the Modified Froude Number. The experimental values of the dispersed phase holdup were found to be in good agreement with the calculated values obtained from the correlation equations."

Jan 1, 1999

By Kazuyuki Kakegawa

The sintering characteristics and the change in the compositional distribution in the PbTiO3 PbZrO3-Pb(Mgl/3Nb2/3)O3 system during the sintering process by spark plasma sintering (SPS) method were examined. They were compared with those by a normal sintering method. The densification by the normal sintering was slow even at high temperatures, When SPS method was employed, much lower temperature and shorter period resulted in sintered bodies having almost the theoretical density. As expected in normal sintering, the compositional distribution decreased as the sintered density increased. On the contrary, the change in the compositional distribution by SPS was much smaller than that in the normal sintering. This sintering characteristic of SPS suggested a possibility of fabrication of sintered material having a desired compositional distribution.-

Jan 1, 2003

By I. D. Reznik

On blowing nickel matte in a converter without quartz, first the oxidation of metallic iron and a part of FeS occurs without evolving sulfur dioxide, the formed FeO dissolves in a sulphide smelt and form a homogeneous oxysulphide smelt. On further increasing the FeO content, the oxysulphide separates into 2 layers. Based on the laboratory investigation of FeO-(FeS+Fe°) - (Ni3S2+Ni°) ternary phase diagram we have identified the separation region at 1250°C. The boundaries of the separation region have the form of an arc and the composition of the separated oxysulphide layers is defined by the canodes. In the nickel or copper-nickel matte - silicacalcium oxide slag system at 1250°C three layers, namely sulphide, oxysulphide, and slag may be formed. A high slag basicity due to the presence of CaO can serve to enhance the activity of FeO; a low nickel content in the matte corresponds to a high concentration of FeS therein; FeO from slag and FeS from the matte form a homogeneous FeO-FeS solution, i.e. an oxysulphide layer. The investigation on the "Camebaks" apparatus and by the nuclear gamma-ray resonance spectroscopy method of the phase composition in a slowly cooled oxysulphide layer has shown the presence of four phases: wustite, troilite, ferronickel grains, and calcium oxide-silica inclusions. Knowledge of regularities in the oxysulphides formation makes it possible to use them in pyrometallurgy of nickel and cobalt or preventing their formation.

Jan 1, 1997

By Pengfu Tan

A thermodynamic model and computer program, CuModel, has been developed to model the distribution behaviors of Cu, Fe, S, O, Ni, Co, Sn, Pb, Zn, As, Sb, Bi, Au and Ag, copper loss in the slag, and heat balance in copper smelting process, matte converting process and copper con-tinuous smelting process. It can be predicted for any set of controllable process parameters such as feed composition, smelting temperature, degree of oxygen enrichment and volume of oxy-gen-enriched air. This model accounts for physical entrainment between matte and slag phases. It can be used in Isasmelt process, copper flash smelting process, Mitsubishi process, P-S con-verting process and Noranda process. The predictions by the present computer model are com-pared with the known commercial data from Guixi Smelter in China, PASAR Corporation in Philippines, Horne Smelter in Canada, MIM Limited in Australia and Naoshima Smelter in Ja-pan. The agreements between the computer predictions and the commercial data are excellent. In this paper, the applications of CuModel in the copper metallurgical industries have been pre-sented. CuModel has been used by Daye Smelter and Guixi Smelter in China, and by PASAR in Philippines as well.

Jan 1, 2004

By J. W. Matousek

Cobalt behavior in pyrometallurgical processes is traditionally analyzed using slaglmatte distribution coefficients as functions of matte grades or matte iron contents. L(s/m) = (%Co) I [%Co] = f [%CuNi] or f [%Fe] The method is inconvenient to use in predictive mass balance work because of the interdependence of assays and mass quantities. An alternative procedure is proposed based on cobaltliron ratios for slags and mattes: Js = (%Co) / (%Fe), Jm = [%Co] / [%Fe], and J, = b + m [Jm]

Jan 1, 1993

By M. Elbert Nigri

Radioactive wastewaters from nuclear source of electrical energy production need to be treated and disposed of properly. Sr, Ca, Mg and Ba are common elements in this effluent, which can cause incrustation in process equipments and being unsafe to human health (90Sr). Fixation of CO2 can be applied to remove the ions mentioned before and to provide a solution where CO2 is sequestered and the deleterious elements precipitated, becoming one of the possible steps to reuse the water into the process. Moreover, removal of several metals from distinct wastewater has been evaluated using bone char through adsorption. The chemical similarity between calcium and strontium makes the exchange of these two metals favorable in the hydroxyapatite structure contained in bone char. This paper evaluated the combined action of precipitation and adsorption process with injection of CO2 and bone char addition in simulated nuclear wastewater. Removal levels of 89.0% (Sr) and 83.3% (Ca) were obtained in the combined process. The presence of bone char as seed increased the precipitation kinetics, allowing a Sr removal of 85.2% in five minutes, higher than 75.3% obtained in absence of seeds. However, removal of 91.6% (Sr) and 89.8% (Ca) were obtained in absence of seeds at 24 h. Analysis of solids have evidenced that CO2 was consumed to precipitate the metals as carbonates, since the hydroxides are formed at higher pH’s.

By Fuming Wang, Xi Chen, Shuai Liu, Changrong Li, Dan Wu, Yaxu Zheng

The effects of B content and austenitizing temperature on hardenability and toughness of Cr–Mo alloy steel have been studied. The results show that the hardenability is deteriorated with increasing B content and austenitizing temperature. With increasing temperature, more and more B containing particles were dissolved in austenite and increase the amount of B atoms segregating at grain boundaries. Moreover, the coarsening grains reduce area of grain boundaries and also increase the amount of B atoms at unit grain boundary, excessive B atoms segregating at grain boundaries promotes precipitation of M2B, which accelerates ferrite nucleation and reduces hardenability. The main elements in M2B phase are Fe, Cr, Mo and B. The B atoms segregating at grain boundaries during austenitizing promote precipitation of M2B during tempering which deteriorate toughness significantly.

Mar 1, 2018

By Ehsan Vahidi, Fereshteh Rashchi, Amirhossein Shahnazi

"The pig iron from steel manufacturing plants contains a high concentration of vanadium-bearing materials smelted with iron ore. During the oxidation process of the molten pig iron with oxygen lances, vanadium transfers to the slag. In this research, recovery of vanadium from LD (Linz-Donawitz) converter slag of steelmaking plant was investigated. The leaching residue was characterized by XRD and XRF techniques. The maximum vanadium recovery was achieved at optimum leaching conditions of 70 °C, S/L: 1/15, sodium hydroxide concentration: 3 M and leaching time: 150 minutes. The dissolution rate increased with rising sodium hydroxide concentration and temperature and decreasing particle size. The experimental data are treated graphically to explain the kinetics of the vanadium recovery process using shrinking core model (SCM). As a result, the controlling regimes in the SCM were analyzed separately using liquid film diffusion control, solid product diffusion control, and reaction control mechanisms.IntroductionVanadium is commercially important as a constituent of several alloys and catalysts. Nowadays, vanadium is mostly recovered as a by-product from secondary sources or from industrial waste streams such as titaniferrous magnetite, fly ash, spent catalysts, and petroleum coke. Steelmaking operations are specifically concerned by this problem due to the production of a huge quantity of by-products [1]. These by-products, including LD converter slag, sludge, fly ash, spent catalyst, ash, and alloyed scrap, contain a notable amount of heavy metals which may cause environmental problems. Solvent extraction is one of the techniques being increasingly used for the recovery of vanadium [2]. Apart from vanadium ore, secondary resources such as titanmagnetite, ilmenite and slag from the ferrous industry are a major source of supply. The pig iron from steel manufacturing contains a majority of vanadium-bearing materials smelted with iron ore. In a heat resistant shaking ladle the molten pig iron is oxidized with oxygen lances, causing the vanadium to be transferred to the slag. Normally, the vanadium in LD converter steel slag (coming from Linz-Donawitz steelmaking process) is ca. 5% as vanadium pentoxide (V2O5). This slag is the world's principal raw material for vanadium production [3, 4]. Moskalyk and Alfantazi [4] reported that a roast-leach process is used in South Africa for the production of vanadium oxides from magnetite ores while some of the slag was converted to ferrovanadium. A portion of the slag was exported to Europe for the production of vanadium oxide. The researchers mentioned that alkaline roasting was the main process at that time employed to extract vanadium pentoxide from vanadium slags."

Jan 1, 2012

By Yan Yuan

Stable Nitroxyl polymers, such as poly (2,2,6,6-tetramenthyl-1-piperidinyloxy-4-yl methacrylate) (PTMA), are known to be effective as cathode active materials for lithium rechargeable betteries.The nitroxide radicals displayed a reversible and very rapid redox performances.We present a new synthesized method to get PTMA powder, then a doctor-blading method was used to prepare the PTMA composite electrodes, enabling successful production of homogeneous electrodes. It was characterized through FT-IR and SEM methods.The organic radical battery consists of lithium metal anode and PTMA cathode with an active material content of 65wt%.The best performance is achieved with a thin cathode that shows nearly 100% utilization of the active material (111mAh/g) at 0.1C.Through the electrochemical tests, it was found that there was a stable plateau at 3.5V while discharging. Besides, the cycling stability and rate capability were measured in detail. Although they showed a certain quantity of irreversible capacity on the first cycle, the capacity stabilized after the second cycle.

Jan 1, 2009

By C. Lupi

The electrorefining of primary copper is a well known technology: in this work copper scrap was directly processed in the same way. he copper and copper alloy scrap was previously pressed by means of a 20 tons apparatus in order to avoid pyrometallurgical operations. The samples obtained in this manner showed a good compactness so that they were used as anodes in the electrorefining tests. The tests were carried out on anodes made by copper scrap, copper alloy scrap and a mixture of the two. The electrorefining tests were performed at both 303 and 333 K, in a perspex cell having a volume of 500 ml using a current density of 250 A/m2. The cathode used was always a sheet of pure copper and the electrolyte composition was 40-50 g/l Cu as CuS04 and 150-200 g/l H2SO4. Current efficiency in the range of 92-97% and specific energy consumption ranging from 0.14- 0.20 kWg of copper were reached in all the tests. The refined copper deposits were analyzed by AAS to verify their purity and observed by SEM to highlight their morphology.

Jan 1, 1998

By Ademar B. Lugão, Sandra R. Scagliusi, Elizabeth C. L. Cardoso

When butyl rubbers are subjected to high energy radiation, they form easy free radicals that initiate various chemical reactions. These reactions alter the molecular distribution of irradiated rubbers by crosslinking or scission affect their physical and mechanical properties. This work aims to the analysis of effect induced by γ-exposure on the crosslinking density in butyl rubbers by swelling measurements accomplished before and after irradiation at 25, 50, 100 and 200 kGy, with further evaluation of crosslinking density accomplished by Flory-Rehner equation; this is a proper procedure for the qualification of radiation resistance. It can be noticed that changes in material structure was due to build-up of new three-dimensional network in studied rubbers. Changes in crosslinking density of butyl rubber compounds emphasize that degradation mechanism is strongly influenced by gamma-radiation doses higher than 50 kGy, since chain scission process predominates over crosslinking reaction.

Mar 1, 2017

By Nina Bianco, Diana Drinkwater

MetSkill is a professional development program for metallurgical engineers that integrates with normal duties in their first one or two years of service. Graduates work together on a structured technical project, facilitated by specialists and supported by formal learning, and ultimately reported to their technical managers. The program enables graduates to “fill the gaps” in their undergraduate education, which is increasingly pertinent as engineering degrees become more general. Participants report that they enjoy the focus on more challenging (rewarding) aspects of their jobs and feel more confident about problem solving. Sponsor companies add that the relationships developed with external technical specialists enhances opportunities for innovation and development. MetSkill was delivered to two major resource companies in Australia in 2012. This paper provides an outline of the program and the reasons for its success, and demonstrates how the learning model could be applied to groups of graduates in other engineering disciplines.

Jan 1, 2014

By A. Kontopoulos

The extraction of nickel and cobalt from low-grade greek laterites by sulfuric acid leaching has been studied. Batch and continuous mini-plant atmospheric leaching as well as pressure leaching techniques were employed. Atmospheric leaching at temperatures as high as 95 OC generally resulted in low Ni extractions (up to 82%), high acid consumption (650-850 kg/t ore or 80-100 kg/kg Ni) and high Fe co-dissolution (30%). Pressure leaching at 260 OC increased Ni extraction to over 98%, with minimal Fe co-dissolution (2.5%); acid consumption was 300 kg/t ore (31 kg/kg Ni). Detailed experimental results and conceptual flow sheets for atmospheric and pressure leaching are presented.

Jan 1, 1991

By Sunil G. Warrier

A rapid infrared forming technique has been developed to fabricate titanium matrix composites. This technique applies infrared heating to infiltrate titanium alloys into carbon and silicon carbide prepregs. The entire process typically takes 1-2 minutes in an inert atmosphere. The advantages of this technique are that the process is fast, simple, does not require a vacuum or a high external pressure. The process is very economical both in energy conservation and operation costs. This technique has been used to produce void free composites with limited, well controlled fiber-matrix reactions and mechanical properties comparable to currently available titanium matrix composites.

Jan 1, 1993

By Animesh Jha

"Fine ceramic powders (<500 nm) exhibit exceptional physical and mechanical properties in engineered structural ceramics. The production of fine powders, in particular the non-oxide ceramics, via a cheaper route than the organic solvent route has been rather elusive. This paper examines the physical chemistry of sub-oxide vapour-phase reduction reaction for the nucleation of non-oxide ceramic phase. Well known vapour species eg SiO and BO in the production of technical ceramic powders (SiC, BN) are particularly discussed for understanding the nucleation process of SiC and BN ceramic phases respectively. The regimes of partial pressures and temperatures are particularly 'identified. The calculated nucleation rate as a function of the temperature is compared with the experimental results on powder morphology. The production of amorphous and nanocrystalline h-BN powders is discussed in the context of substrate structure and thermodynamic parameters.IntroductionThe physical and mechanical properties of ceramic components are strongly dependent on the powder particle size and morphology used for their fabrication. For example the strength (Os) of the structural ceramic components increases with decreasing average grain-size (d) in accordance with the Hall-Petch relationship: Os = 0""0 + k/(d)1/2. Here k is an empirical constant which can be established from the graphical relationship. However as the particle size approaches submicrometer-size range, the dependence of strength on the particle size becomes more complex [1]. The design of ceramic components based on nanometer-size particles have recently become an important field which can offer ceramic materials with properties comparable to their metal counterparts. Several materials based on these concepts have been developed and reported by Niihara [2]. For example, the Al2O 3-SiC nanocomposite, having average B-SiC grain size 0.3-2um with intragranular SiC particulates of 5-10 nm has unusually high strengths (1100 MN/m2) at low and elevated temperatures combined with enhanced fracture toughness (> 4 MN-ml.5) which is an unusual combination in structural ceramics. Besides mechanical properties, as the particle size of ceramic powders approaches the nanometer-size range, the charge transport properties also improve by many times. The effect of particle size on the electrical conductivity of Si3N4-TiN composites has been well documented [3.4]. The size of ceramic particulates without doubt plays a pivotal role in determining the properties of ceramic components."

Jan 1, 1996

By Vânia L. L. Andrade

Igarapé Bahia Mine is located in Carajás area, northern Brazil. Currently Companhia Vale do Rio Doce operates there a CIP / heap leaching plant treating an oxide gold ore containing about 4 g Au /t and 0,2% Cu, which produces 11 t of gold per year. Recent geological survey has identified a signifcant copper-gold reserve underneath the oxide gold ore. The processing aspects of this copper-gold sulphide ore are described in this paper. It includes ore characterization studies, grinding and flotation tests, orebody variability assessment, flowsheet selection and preliminary economical evaluation Emphasis is given to studies aimed at depressing fluorine bearing minerals to achieve a clean and marketable flotation concentrate.

Jan 1, 1999

By Rejane Tubino Geyer

The volume of electric arc furnace (EAF) plus oxygen (BOF) slag produced yearly in the world is about 84 million ton. Because of this, the study of recycling processes as a way to solve the storage problem of these slags rise in importance. There are, however, some inconvenients on using this byproduct: lime, which takes part of the process of steel production, remains as a non-reactive raw product in the slag. Since lime reacts in presence of humidity, forming expansive compounds, slag use is strongly limited. There are some utilizations for the electric arc furnace and oxygen slag in the Civil Construction Industry, mainly as base, subbase and asphalt covering in highways. However, independently of the type of recycling, a period of "cure" of about six months is necessary. Because of this slow cure process this byproduct may turn non-competitive in some regions if compared, for example, with the natural aggregate. The objective of this work is to present the flowsheet of the slags production as a residue both at the electric and oxygen steel plants and, through a bibliographic review, to analize the possibilities and limiting factors for the use of steelmaking slags in the Civil Construction Industry.

Jan 1, 1996

By Masahiro Hirasawa

"As a fundamental study on pyrometallurgical process that involves recycling steel-making dusts, of which major components are oxides of Zn and Fe, and waste polyvinyl chloride simultaneously ·at. a temperature below 1273 K, the reactions between the mixture of ZnO + Fe20 3 and PVC or the compound ZnFez04 and PVC are investigated in a series of thermogravimetric and small scale reactor experiments under inert atmosphere at below 1273 K. The reaction mechanisms are discussed· on the .basis of the thermogravimetric data. From the results of reactor experiments, it is shown that the chlorination of Zn in the oxides by Cl in PVC, the vaporization of ZnC12, the reduction of iron oxide to metal Fe by C and H in PVC, and, thereby, the separation of Zn and Fe in the oxides take place simultaneously at the temperature ~= 1200 K.IntroductionSteelmaking dusts are metallurgical wastes consisting mainly of oxides of Zn and Fe with smaller amounts of other heavy metal elements, such as Pb. In the recent investigation, [1] the present authors have investigated the fundamental aspects of a potential pyrometallurgical process· of recycling steel-making dust with polyvinyl chloride (PVC) at temperature T < 1273 K under Ar atmosphere. The performance of a similar process, in which HCl in the combustion gas of PVC is used to chlorinate Zn in the EAF dust under oxidizing atmosphere, has been investigated by Tailoka and Fray [2] with fundamental experiments. Figure 1 shows an example of the potential ·diagram of Zrt-Cl-0 and Fe-Cl-0 systems. In the figure, we can find two regions where ZnCl2(g) can be separated from Fe containing compounds. One is ZnCiz-Fe20 3 coexistence region at higher oxygen and chlorine potentials and the other is ZnCl2-Fe coexistence region at lower oxygen and chlorine potentials. The process adopted by Fray and coworkers is aimed mainly at the performance of Zn/Fe separation in the higher oxygen potential region. In the present study, the lower oxygen potential region is focused on."

Jan 1, 2000

By Katsunori Yamaguchi

Secondary materials, that contain relatively high concentrations of platinum group metals, (PGMs) are treated in copper smelting process. The PGMs lost in the slag is increasing with increasing quantities of scrap treated amount. To determine the portion of the PGMs chemically dissolved and that associated with the mechanically trapped matte in the slag will be a key factor to improve the recovery of those metals. An experimental study was carried out to determine the distribution of palladium between the FeOx–SiO2 slag and the liquid Cu2S–FeS matte at 1573 K and a fixed partial pressure of SO2 of 0.1 atm. It was found that the distribution ratios are around 10−3 for platinum and palladium. The distribution ratios show a tendency to increase when the grade of matte is increased above 60 mass% Cu. In addition, the solubility of platinum in FeOx–SiO2 slag equilibrated with a pure palladium and the Pd-Cu alloy was determined at 1573 K and the range of oxygen partial pressure from 10−9 to 10−7 atm. The solubility of palladium in the slag tends to increase with increasing oxygen partial pressure and activity of CuO0.5 in the slag.

By Ehsan Vahidi, Fereshteh Rashchi, Ataollah Babakhani, Alireza Zakeri

"The synergistic effect of Cyanex 302 on solvent extraction of nickel and cadmium from sulfate solution with D2EHPA diluted in kerosene was investigated with the aim of increasing separation efficiency. Experiments were carried out within a pH range of 0.1-5.0 using sole D2EHPA and D2EHPA-Cyanex 302 mixtures in different ratios. Increasing Cyanex 302 to D2EHPA ratios in the organic phase caused a left shifting of the extraction isotherm of cadmium and a right shifting of the extraction isotherm of nickel. As a result, optimum separation was found with a Cyanex 302 to D2EHPA ratio of 0.1M:0.5M. In the present system, effect of a modifying reagent such as TBP was studied. The influence of various diluents including kerosene and carbon tetrachloride was also investigated.IntroductionBatteries are popular sources of portable energy. Ni-Cd batteries are manufactured in two main groups of small domestic cells and large industrial batteries with 80% being in domestic use. Ni-Cd cells have various uses, for example in cordless electric utensils, cordless telephones, airplane engine starters, and communicational distribution systems [1].Depleted Ni-Cd batteries are classified as hazardous waste since nickel and cadmium are heavy metals and suspected carcinogens. Given the risk associated with uncontrolled disposal, directions for issuing legislation on disposal and recycling of used batteries have been made in industrialized countries [2]. Recycling of Ni-Cd batteries is important from both economic and environmental points of view. Different methods have been used for recycling these wastes through pyrometallurgy [3], biotechnology [4,5], and hydrometallurgy [1,2].Due to the advantages of hydrometallurgical processes, several studies have been implemented on leaching and solvent extraction (SX) of the used Ni-Cd batteries. Leaching of batteries is usually done in sulfate or chloride media; while solvent extraction has been used in different extractants: two-stage solvent extraction by D2EHPA and Cyanex 272 [6]. Solvent extraction of Cd from leach solutions has been studied using various extractants; Cyanex 301 [1], D2EHPA [7], Cyanex 302 [8], Cyanex 923 [9], Cyanex 272, Tops 99, PC88A [10]. Application of phosphorus based extractants for the solvent extraction studies of Ni such as TOPS 99 [11], D2EHPA [12], Cyanex 272 [2], has been investigated. Separation of Cd(ll), Ni(II), and Co(ll) from chloride leach liquor of spent batteries [13], were explored in the earlier studies. Cd extraction with D2EHPA involves co-extraction of both Ni and Co [14], which causes issues in the separation process efficiency."

Jan 1, 2012