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By Thomas Weyand, Thomas Claridge, Dale Nickels

"This paper addresses the initial results of a project to evaluate the suitability of copper mining tailings as raw material for the production of structural products using PMET’s patented technology. Preliminary testing indicated that high performance structural products were possible using these materials. A demonstration scale project produced approximately 1,500 bricks in various colors. These products fall under under ASTM C- 73 and were found to present properties suitable for severe weather applications. Although the products in this project were of typical brick dimensions, other products are possible, for example concrete block substitutes or pavers. These products from the PMET process are commercially known as Brixx. This paper will provide operational details of the production process, mineralogy and mechanical properties of the products.INTRODUCTIONPMET has developed process technology that can convert various siliceous waste materials into competent structural products. This technology is the subject of US patent # 6,068,803. In general, the process consists of mixing lime, water and the major feed stock, pressing to form a “green” shape, and curing the product in an autoclave for 6 hours with saturated steam at ~200oC. The curing process forms Tobermorite, which acts as a crystalline binder. Freeport-McMoRan approached PMET to see whether mine tailings from the Sierrita mine, containing significant amounts of clay, might be a suitable feed material for the production of structural products. “Brixx” is the commercial term used to describe the resultant structural product formed in the test work. This paper is a preliminary evaluation of a technology that is being considered by Freeport-McMoRan. This report is not an endorsement by Freeport-McMoRan of the process or products, nor is it a commitment to use this technology."

Jan 1, 2008

By Daniel Bennett

There are few methods currently applied towards on-line bulk mineralogical analysis. Yet on-line knowledge of process mineralogy could potentially provide large benefits, such as increased extraction efficiency or resource optimization. The work described in this paper involves the development of radio frequency methods for bulk mineralogical analysis. Some resonances that occur in the radio frequency spectrum are mineral specific, and potentially allow quantitative estimation of mineralogy in an ore stream. Results will be presented on the specific detection of chalcopyrite. Initial quantitative measurements investigating matrix effects have indicated the feasibility of on-line mineralogical estimation using radio frequency techniques.

Jan 1, 2006

By Dachun Liu, Xutao Guo, Wenlong Jiang, Baoqiang Xu, Bin Yang, Yong Deng, Heng Xiong

Typical copper dross, the byproduct of lead bullion pyrometallurgical refining for copper removal, mainly contains Pb, Cu, S, As, Sb and Sn etc. In traditional treatment process, copper dross is transformed to be copper matte by smelting with iron scarp and iron pyrite. Here, a new treatment process of converting-vacuum distillation (CVD) was proposed and investigated. Based on this concept, the converting process was tentatively investigated in this paper. The results of element distribution of converting samples showed the sample has three layers. The upper layer is mainly sulfides of lead and copper, the middle layer is mainly copper arsenide, and the lower layer is lead arsenide and crude lead. On the condition of oxygen flow rate 400 ml/min, the converting temperature 1000 °C, the holding time 1 h, the converting time 10 min, the lead copper alloy containing 0.17% S was obtained.

Mar 1, 2018

By Fumitaka Tsukihashi

Phase diagrams of the CaO-SiO2-FeOx-MgO, Al2O3 systems arc necessary for the analysis of copper smelting reactions and sintering process of iron ore. The effect of MgO and Al2O3 addition on the liquidus of the phase diagram of the CaO-SiO2-FeOx system at low oxygen partial pressure was observed. The liquid phase area changed bi the addition of MgO and Al2O3 with a changing oxygen partial pressure from 10-8 to 10-3 atm (10-3 to 10 2 Pal at 1573K. The effect of Fe3+ / Fe2+ ratio on the melting mechanism is discussed.

Jan 1, 2003

By Esperidiana A. B. Moura, Elizabeth Carvalho L. Cardoso, Glauson Aparecido F. Machado, René R. Oliveira

Plastics global annual production exceeds 250 million tons and more than 40% of the total plastic production is used as packaging materials. In recent years polymeric materials derived from biomass have received great attention due to scarce petroleum resources and environmental concerns. PLA is one of the most extensively studied bio-based and bio-compostable aliphatic polyesters; nevertheless, high brittleness and low toughness limits its application. Blending PLA with PBAT (Poly(butylene adipate-co-terephthalate)), an aliphatic-aromatic copolyester, was the solution found due to its high toughness and biodegradability. Differences between PLA and PBAT solubility parameter values lead to the formation of immiscible blends as well as reduction in their mechanical performance besides a poor morphology; so, 5% of pre-irradiated PLA and a previous compatibilized PLA/PBAT (EcovioTM) were added to PLA/PBAT blends in order to improve miscibility phases. Investigations were accomplished on phase morphology (SEM), mechanical properties, thermal behavior and X-ray diffractions (XRD).

Mar 1, 2017

By Walter Curlook

An atmospheric acid leaching process for leaching nickel and cobalt from highly-serpentinized saprolitic fractions of nickel laterite deposits has been developed and patented [I]. The process involves leaching the highly-serpentinized saprolitic portion of the nickel laterite ore profile in strong sulphuric acid solutions at atmospheric pressure and temperatures between 80°C and 100°C, essentially autogenously, to extract over 85% of its contained nickel content and a large proportion of its cobalt content after leaching times of about one hour. The amount of sulphuric acid used in the leaching process is between 80% and 100% by weight of the finely ground highly-serpentinized saprolite ore on a dry weight basis. The metal values are recovered as intermediate products. Key words: Atmospheric Leaching; Nickel Oxide Ores; Laterites

Jan 1, 2004

By A. J. Rigby

Refractory linings in converters or anode furnaces used to over-oxidize the blister copper will suffer rapid deterioration, due to prolonged contact with copper oxide-rich slag. Nitrogen stirring with COP KIN porous plugs and use of SEMTECH OPC in converters and anode refining vessels can considerably reduce both refractory wear and processing times. In addition, careful control of the vessel atmosphere and the use of real-time optical process control minimize both slag volume and contact time with the vessel refractory.

Jan 1, 2005

By Sergio N. Monteiro

Wastes generated by our society and the question on how to dispose them is, nowadays, a relevant matter of concern. The objective of the present work was to characterize the technical properties of composites made of discarded jute sackcloth with its coarse wove fabric, serving as reinforcement phase, and polyethylene wastes collected from city dumps, as continuous matrix. Different amounts, up to 30 wt.% of jute plain weave, fabric were press molded at 160°Ctogether with sieved polyethylene particles. The resulting composites displayed mechanical properties that could compete with those of low-density wooden board. Both by presenting a solution to, otherwise, disposed wastes and by helping to prevent deforestation, the investigated composite may be regarded as an environmentally correct material.

Jan 1, 2006

By S. Tanaka

The Tamano Smelter of Hibi Kyodo Smelting Co. Ltd. was commissioned in 1972. Since start up, the anode production capacity has increased from 101,000 tpy to 290,000 tpy, as a result of the application of continuous improvements at each phase of the expansion projects. The Tamano Smelter had developed several innovations, including the original coke combustion technology for Flash Smelting Furnace operations (T-FSF), and has also been able to extend the operating life of the Peirce-Smith converters. This paper will present several improvements implemented at the Tamano Smelter, and will discuss relevant P-S converter operation.

Jan 1, 2005

By Tianzu Yang, Weifeng Liu, Lin Chen, Wei Chen, DUCHAO ZHANG

Ni-M (Metal=Cu, Fe, Co, Mn, Zn, Cr) aerogel catalysts were tested for CH4 oxy-CO2 reforming. It was found that the Ni-Co bimetallic aerogel catalyst had the highest activity and stability in methane oxy-CO2 reforming among all the Ni-M aerogel catalysts. It exhibited a steady activity of 79 % (in terms of CH4 conversion) at 750 oC, which is the highest activity under a similar reaction condition as compared with those published in literature. Characterizations for the reduced catalysts indicated the formation of Ni-Co alloy, while other transition metals separated from Ni during the reduction process. Therefore, the active species in the Ni-Co bimetallic catalyst showed a stronger interaction than those in other Ni-M catalysts, which might be one of the main reasons for the better catalytic performance of the catalyst.

Jan 1, 2016

By Zvi Rivlin

Classical nucleation theory states that in first order phase transformations, such as liquid to solid transition, nucleation of the product phase starts with the formation of small, unstable clusters (embryos). When the thermodynamic barrier to nucleation is overcome, the embryos grow and attain a critical size, beyond which they are stable, i.e. they become nuclei. If nucle- ation does not occur, the parent, liquid phase remains in metastable equilibrium. At temperature lowers, undercooling increase and atomic mobility decreases. The viscosity change in the undercooled liquid may result in the formation of glassy state. As demonstrated in previous papers [I-21, in solidification involving surface nucleation of the product phase, as the case is in rapid quenching by melt-spinning, both nucleation temperature and nucleation time depend upon the number of atoms available at the isothermal surface in contact with the substrate. As a result of the thinness of the melt-spun ribbons, the embryo clusters that form at the freezing temperature may not be supplied by the amount of atoms necessary for their growth to critical nuclei sizes. In such extreme conditions, the liquid does not crystallize, it forms a metallic glass. A numerical simulation method is proposed for the reactions involved in embryo cluster formation and growth, at the atomic level. The simulation enables the caIcuIation of either the nucleation or the glass transition temperatures. Calculations made for the well-known glass forming CuZr and FeB systems afford prediction of the geometrical and thermodynamically conditions necessary for the formation of either crystalline or amorphous ribbons in melt-spun ribbons.

Jan 1, 1994

By V. M. Paretsky

The basic work conducted by Prof. A.Yazawa has demonstrated that in order to ensure single-stage white metal production by autogenous smelting of copper sulfide raw materials, it is most favorable to use highly basic slags, in particular oxide systems CaO-FeO-Fe2O3-Sio2. he special studies have been conducted in the Gintsvetmet Institute to investigate the composition and structure of slags produced on a semi-commercial scale when testing the KFP and FBP processes for white metal smelting, as well as the slag obtained in a full-scale KFP furnace at the Almalyk copper smelter. The investigations conducted have demonstrated why production of high-grade matte or white metal is associated with lower loss of copper in slag in a series: silicate slag I silicate-calcium slag I ferrite-calcium slag.

Jan 1, 2003

By M. Hochenhofer

Keywords: desulfurization, mathematical model, slag reaction To produce ferroalloys like ferro-nickel for alloying purposes in a quality that meets the requirements of today?s steel industry, refining processes like desulfurization and dephosphorization are indispensable. The performance of desulfurization-treatment by slag reaction depends on various parameters, such as: sulfide capacity and viscosity of the slag, sulfur distribution between metal and slag, activity of sulfur in melt and movement of melt. Within this work, the combined influences of these parameters on the desulfurization of a ferro-nickel alloy were examined. As a basis for this examination, a mathematical model, based on data from plant trials, was created. This model demonstrates the relationship between desulfurization rate and initial values of the above mentioned parameters. With this model the relevant parameters were evaluated and assessed concerning their influence on desulfurization.

Jan 1, 2005

By L. Xia

Sodium silicate(s), also known as “water glass”, are one of the oldest and most widely used industrial chemicals. Its first use in Canadian operations can be traced back to around 1925, which coincided with early use of xanthates in mineral flotation. Silicate functions as a sulphide and non-sulphide gangue mineral dispersant, depressant and modifying reagent in grinding and flotation operations. It is believed that soluble sodium silicate promotes selectivity of value added sulphides against gangue minerals, resulting in both grade and recovery improvement. This paper seeks to link improved grade/recovery to the interaction characteristics of minerals and the sodium silicate. A systematic study was performed with individual mineral species, an artificially designed model ore and the feed ore from a copper flotation operation. The function of sodium silicate was evaluated in the context of colloidal chemistry and linked to mineral surface chemistry. Measurement of pulp rheology and mineral zeta potential identified that sodium silicate works as a dispersant. The dispersion is accomplished by increasing a mineral’s net surface charge, resulting in a change in slurry viscosity. Bench scale laboratory flotation tests suggest that better dispersion leads to a diminished interaction of chalcopyrite with gangue. The improved Cu grade and recovery then are likely in response to an increased accessibility to collector along with a linked increase in particle bubble attachment resulting in better separation efficiency. ToF-SIMS surface chemical analysis of the flotation samples found a higher proportion of sodium silicate on minerals from the flotation tailings relative to the concentrates. Moreover, attachment of sodium silicate appears to be mineral specific; the data indicates that sodium silicate favours the surface of gangue phases over the value sulphides.

By Juliana Gutiérrez-Paredes

Keywords: Slag, chromium oxide, recovery, stainless steel Experimental and theoretical work was performed to estimate the effect of slag basicity and amount of reducing agents on the reduction of chromium oxide from the slag which interacted with molten steel at 1600°C. The slag system contained CaO, MgO, SiO2, CaF2 and Cr2O3 together with Fe-alloys (Fe-Si and Fe-Si-Mg). The CaF2 and MgO contents in the slags were 10 mass % each; Cr2O3 was 25%. The amount of the ferroalloys ranged from 12.5 to 50 g per 100 g of slag. The (CaO+MgO)/SiO2 ratio was held at 1 and 2. The Cr yield was determined using both Fe-alloys as reducing agents. Some estimations were made to determine the theoretical effect of temperature, slag basicity, (CaO+MgO)/SiO2, and amount of reducing agents in the slag on the chromium recovery. The FACT (Facility for the Analysis of Chemical Thermodynamics) computational package is used to determine the equilibrium between the slag and molten steel.

Jan 1, 2005

By Junji Shibata

Keywords: Synergistic effect, Solvent extraction, Nickel ion, extractant mixture Waste solution from the Ni non-electric plating process contains 4.0 kg/m3 Ni (II), 0.1 kg/m3 Fe (III), 0.01 kg/m3 Zn (II), 48 kg/m3 SO42-, 98 kg/m3 HPO32- and 31 kg/m3 lactic acid as a typical composition. Solvent extraction, cementation, ion exchange resin and precipitation methods may be used for the treatment of this kind of solution. In this study, solvent extraction of Ni (II) is investigated by using two kinds of extractants in order to clarify the relationship between extraction equilibrium (static synergistic effect) and extraction rate (dynamic synergistic effect) for several extractant mixtures. The static synergistic effect does not take place significantly for the extractant mixtures of acidic extractants and neutral organphosphorous compounds, while a large static synergistic effect is confirmed when the extractant mixtures of acidic extractants and nitrogen-containing compounds are used. Nickel ions can be extracted in the wide pH range of 3.0-8.0 without any pH adjustment by using the several extractant mixtures. At the same time, the extraction rate remarkably increases by using the extractant mixtures of acidic extractants and nitrogen-containing compounds.

Jan 1, 2005

By María Eugenia Castro, Silvia Galasso, Jorge Duca, Claudia Osuna, Ernesto Esparza

"We present a procedure for treatment of non-active solutions equivalent to the solutions obtained from dissolution of ionic exchange resins used in purification of a nuclear reactor primary cooling system containing Co, Ni, Cs and its isotropic varieties as main radioactivity source. Finally it is immobilized into a ferritic matrix by calcination which avoids its future leaching into environment.In order to achieve the objective of this treatment, a bivalent and a trivalent iron salt is added to the solution. Then, either a base or an acid is added, depending on the initial pH of the treated solution, with a Cs precipitating additive in order to reduce Co and Cs by precipitation, flocculation and adsorption. Controlling the amount of precipitating reactives it is possible to modify the activity/volume rate becoming a medium into a low radioactivity waste.The leaching test result applied over the ferritic sample is lower than the minimum limit established by law. Therefore, it can be kept safely in a interim storage."

Jan 1, 2008

By Toshiyuki Kawai

Copper concentrate smelting directly in P-S converters was started at Onahama Smelter in 1983. Thereafter, the tonnage of concentrate smelted through the P-S converters increased, such that by 2002, it equaled the tonnage smelted through the reverberatory furnaces. In 2003, 56% of the total copper concentrates treated at Onahama Smelter were processed directly through the P-S converters. Technical improvements are reviewed and advantages of direct smelting in P-S converters are reported.

Jan 1, 2005

By Tsunehisa Nishimura

Stable operation of the blast furnace needs adequate control of the lower part. To clarify the behavior of the lower part of the blast furnace with accurate consideration of the property of slag and its flow characteristic, a new mathematical model has been developed. Using this model, the effects of the change of operational conditions on the behavior of the lower part of the blast furnace were studied. Further, means to control of the lower part of the blast furnace, especially effective means to maintain adequate temperature, were discussed. And desirable slag property and composition, especially the method to control FeO concentration dripping from the bottom of the cohesive zone to avoid a decrease in temperature of the lower part of the blast furnace was estimated.

Jan 1, 2006

By V. M. Paretsky

Oxygen-flame converting of a solid ground matte containing heavy non-ferrous metals in a wide range of concentrations is one of the perspective trends meeting the demands of modern non-ferrous metallurgy. As. a result, of semicommercial tests on oxygen-flame smelting of nickel matte containing 13,5-17,5% Ni; 0,45-0,65% Co under continuous autogenous conditions a converter matte containing 68 8-75,0% Ni and 0,48-1-,0% Co and ferrite -calcium slag containing 1,4-8,4 Ni and 0,16-0,56 Co were pro¬duced. Nickel recovery in a converter-matte was 76,2%, copper - 58,'2% and cobalt recovery in. a slag was 90%. Slag cleaning in an electric furnace allowed to after-recover nickel and cobalt in an alloy to produce a dumpy slag containing 0,03% Ni and 0,02% Co. The development of modern' ecologically pure energy-saving autogenous technologies of the treatment of sulphide raw materials containing heavy non-ferrous metals makes certain demands of the perfection of a process of converting rich sulphide-metallic intermediate products obtained at autogenous smelting. These-demands were connected first of all with the fact that converting process stages because of process periodicity are more unfavourable from the point of ecology, power intensity and unit stability. Besides, during rich matte treatment the problems connected with heat shortage when using air blast and heat excess-when using top oxygen blast to treat luquid matte a-rise and when enriching air blast by oxygen up to 26% fast erosion of the brickwork of a tuyere zone takes place. The technology of Outokumpu and Kennecott companies-on solid- copper matte converting in a flash smelting furnace using air blast is not universal as its possibilities are limited by certain composition of mattes. Besides, flash smelting to produce highly basic or combined slags requires larger enrichment-of blast by oxygen or extra fuel feed. Naturally a flowsheet with continuous converting of matte of various composition up to white matte production is simple,

Jan 1, 1993