Search Documents

By Bogdan Petkovic, Boban Todorovic

In the early 90's a completely unknown problem was encountered at the converter Department: it was a chronic shortage of the cold copper charge needed for the second operating period. A high temperature operating regime was caused which further provoked a chain of consequences such as a drastic drop of the number of operations in campaigns. The consumption of repair bricks reached the quantity of 8.3955 kg / tonne of anode Cu. In 1994, we won the process of cold material smelting during the "copper" blowing [2]. The number of operations per campaign reached 180-200 again. Also in 1994 we won the process of smelting cold materials to obtain "tin" blowing with the purpose of completing their processing cycle [2]. During the period 1994 – 2007 a total of 107,845 tonnes of cold material were remelted to make copper and 56,794 tonnes were re-smelted to obtain "tin". Upon synthesizing these two processes, a completely new model was achieved in 2005, by Bogdan Petkovic, which entirely utilized all available energy of the Peirce-Smith (PS) converters of the Bor Copper Smelter and now represents the basis of the time cycle. The cold material now enters the converter plant, copper recovery is increased and the method itself is environmentally friendly. 167

Jan 1, 2009

By Qiang Zhong, Bin Xu, Qian Li, Yong-bin Yang, Tao Jiang, Yan Zhang

The occurrence of different ringing behaviors in oxidized pellet kiln for two kinds of coal (A and B) with similar properties, is difficult to explain based on the relationship between kiln ringing and coal properties. In this paper, the interaction of coal ash with pellet scrap powder was considered by studying the cohering behavior of powders consisting of them. The results showed that the cohering briquette strength of pellet scrap powder increased considerably when mixed with a small amount of coal ash; a maximum could be reached when the mass percent ratio of coal ash was 1.5%; the strength of powder mixed with coal B ash was always higher in same firing system. This obviously illustrated that coal B caused a more serious ringing problem. The relevant mechanism was that the stronger reactivity of coal B ash made cohering briquette have a more perfect crystallization and a more compact structure.

Jan 1, 2015

By Mary Cunningham

The EPA and DOE have collaborated on a series of studies to evaluate the effectiveness of treatment technologies at stabilizing bulk elemental mercury and wastes containing high concentrations (i.e., with greater than 260 mglkg total mercury) and multiple forms of mercury. The data from these treatment demonstrations are intended to help EPA to determine if regulatory revisions to allow a stabilization alternative for high-mercury subcategory wastes are warranted. In addition to mercury-contaminated wastes, the disposal of bulk elemental mercury is of concern because of the excess quantity of mercury in the Defense Logistics Agency (DLA) stockpile, as well as other potential sources of excess elemental mercury. The studies evaluated the effectiveness of several technologies at: I) stabilization of mercury in a "hard-to-treat" matrix; and 2) conversion of elemental mercury into a stable waste form for disposal. A surrogate waste was designed for the study on high-mercury wastes, which included an organic form of mercury, elemental mercury, and several mercury salts in an inorganic matrix. The surrogate waste and the bulk elemental mercury were treated by the vendors, and the treated waste forms evaluated for mercury Icachability, using both the TCLP and an automated, constant-pH leaching protocol. Constant pH leaching was conducted at pH 2,4,6,8 10 and 12 for 14 days at each pH. The leaching data demonstrate that the stability of the mercury in three treated waste forms varies widely across the pH range tested. Clearly, the stability of mercury in these treated waste forms will be highly dependant on the disposal conditions. The combination of site-specific disposal conditions and appropriate treatment technology must be considered as decisions are made about disposal of high-mercury wastes.

Jan 1, 2003

By M. Wu, A. Kharicha, A. Ludwig

"The droplet formation during melting of a 400 mm diameter electrode is simulated with a multiphase-MHD approach. The computational model includes a layer of slag and a layer of liquid steel. A VOF approach is used for the interface tracking and a potential formulation is used for the electric and the magnetic field. The Lorentz force and the Joule heating are recalculated at each time step in function of the phase distribution. The first results provided by this model are presented.IntroductionThe Electro-Slag-Remelting (ESR) process is an advanced technology for the production of components of e.g. high quality steels [ 1-9]. An alternating current (Figure 1) is passed from a conventionally melted and cast solid electrode through a layer of molten slag to the baseplate. Because of the electrical resistivity of the slag, Joule heating is generated and the slag transfers this energy to ingot and mould surfaces and to the melting electrode tip. The molten metal produced in the form of droplets passes through the slag and feeds a liquid pool from where directional solidification takes place. The slag and the ingot are contained in a water cooled copper mould. As also the baseplate is water cooled, a heat flow regime is imposed that gives controlled solidification, and this results in improved structure characteristics of ESR ingots.This process involves two liquids, a liquid metal and a liquid slag. Each liquid is subject to a phase change due to melting and/or solidification. From a fluid dynamic point of view, the ESR process is clearly a multiphase process, with free interfaces (slag/pool, gas/slag), and with a mixed area (slag and falling steel droplets) [ 10-15].Physically, the development of the heat and mass transfer at the slag/droplet interface is important for the final ingot quality, composition and cleanliness. Visual observations of the droplet formation just under the electrode being melted is almost impossible. Due to the presence of high temperatures, opacity of the materials, and the presence of the mould it is not possible to directly observe the behaviour the slag/pool interface. Although usually assumed flat [1-9], a previous work [10] using a Volume of fluid (VOF) model has shown that the interface shape between a layer of slag and steel layer in a cylindrical cavity is highly coupled with the distribution of the electric current. A full scale simulation of the ESR process using a VOF model has shown that the shape of the pool interface is likely to be non flat."

Jan 1, 2011

By I. D. Reznik

Regularities of cobalt and nickel distribution between slag and matte, slag and metallic alloy on the base of concepts on exchange reaction equilibrium are considered. It is shown that the distribution of cobalt and nickel in industrial processes approaches to equilibrium one. Oxysulphiae influence on the bahaviour of cobalt, nickel and sulphur is shown. The recommendations on conduction of the processes of smelting, converting and slag cleaning based on the analysis of the methods or" non : ferrous metal separation from iron are given.

Jan 1, 1993

By Vinod K. Sikka, René Cooper

"Cohoes, New York 12047 Intermetallics are an attractive class of advanced materials. The aluminide intermetallics offer advantages including: (1) lower density, (2) oxidation resistance, (3) carburization resistance, and (4) interesting mechanical properties because of their ordered crystal structure. Even though the attractive properties of the aluminides and other intermetallics have been known for nearly four decades, their practical applications have not been developed for two reasons: (1) the poor ductility (in some cases, both ambient and high temperatures) and (2) the lack of processability into meaningful components. Recent advances such as ductilization of Ni3Al by small additions of boron and the knowledge that environmental effects are the major cause of poor ductility in Fe3Al and FeAl systems have brought the intelmetallics into the forefront of research and their commercial applications. This paper has described a method for melting Ni3AI-based alloys that successfully utilize the exotherrn for the formation of NiAl from the elemental materials. The reaction-synthesis method has also been utilized for the production of NiAI and NiAI-based alloy powders from the elemental powders. The reaction-synthesized powders of NiAI and NiAI-based alloys were consolidated by hot extrusion and evaluated for tensile properties over a temperature range from room temperature to 1050ºC. The powder-processing conditions have been found to have more influence on the ductile-to-brittle transition temperature of NiAI than the powder-production method.IntroductionIntermetallics are an attractive class of advanced materials [1-11]. The alum in ide interrnetallics offer advantages including: (1) lower density, (2) oxidation resistance, (3) carburization resistance, and (4) interesting mechanical properties because of their ordered crystal structure. Even though the attractive properties of the aluminides and other interrnetallics have been known for nearly four decades, their practical applications have not been developed for two reasons: (I) the poor ductility (in some cases, both ambient and high temperatures) and (2) the lack of processability into meaningful components. Recent advances such as ductilization of Ni3Al by small additions of boron and the knowledge that environmental effects are the major cause of poor ductility in Fe3Al and FeAl systems have brought the intermetallics into the forefront of research and their commercial applications. The paper will briefly review the processing techniques being pursued for the commercial applications of Ni3Al-based intermetallics. The major emphasis of the paper will deal with synthesis of Ni3Al and NiAI intelmetallics."

Jan 1, 1994

By R. M. Taylor

Lime addition to acid mine drainage (AMD) leads to precipitation, predominantly of metal hydroxides and calcium sulfate, and is the benchmark for remediation by precipitation. Geo2 Limited of Melbourne, Australia has developed and patented a novel alternative precipitation scheme based on the formation of mixed valency, M(I1)-M(III), hydroxide sulfate salts. When the composition of AMD is appropriate, the Green Precipitate Process provides a useful and more effective alternative to conventional liming. The characteristics and utility of the Green Precipitate Process are described in terms of the underlying chemistry, and a case study where the Green Precipitate process outperforms conventional liming. A mobile pilot pipe reactor rig which was built by Geo2 to demonstrate the process, and used successfully in both Australia and the United States, is described.

Jan 1, 1998

Two pilot-plant investigations were conducted in which strong-base resins were compared with activated carbon for the extraction of gold cyanide from leached pulp from the Golden Jubilee Mine. The results show that gold can be recovered with carbon, but that the extraction efficiency is poor, probably because high concentrations of humic and fulvic acids are. present m the pulp. .However the extraction of gold cyamde from this material with strong-base resins JS very effo:1ent, and the overall efficiency of extraction is better with resin than with carbon, even when the concentration of resin is one-third that of carbon, and the flowrate of resin is one-third that of carbon. The results of the pilot-plant campaign reported in this paper led to the conversion of the Golden Jubilee plant from carbon-in-pulp to resin-in-pulp in February 1988.

Jan 1, 1989

By Juan Patricio Ibáñez

Separation of arsenic and copper from Cu-As-H2S04 electrolytes by electrodialysis has been investigated at room temperature. The effects of current density and pH were studied. An arsenic-free copper solution was obtained for all the tested conditions. The transport efficiency for copper ions was found to be higher than 98% after 3 hours' test. Transport of arsenic and copper through the ion exchange membranes was increased by increasing pH and current density. Solution pH was found to be a key parameter for the separation process, since it controls the speciation of the ions to be transported and the formation of unwanted precipitates which reduce the global efficiency of the electrodialysis process. The main conclusion is that electrodialysis is a promising technique to be used in separating and/or concentrating ions of interest in copper electrometallurgy.

Jan 1, 2003

By M. K. Mohan

Lead recovery from process solutions contributes not only to the conservation of resources but also clean environment. Zeolites are natural aluminosilicates, which finds applications as catalysts and in wastewater treatment. In the present investigation, studies were taken up on the processing of Pb from process solutions by zeolites. Effects of pH of the solution, time and type of zeolite viz. chabazite, mordenite, erionite and clinoptilolite on the removal of Pb from solutions was investigated. Rate of sorption was found to depend on the pH of the solution and about 99 pct. recovery was observed at pH 6. Optimal conditions were established for the maximum recovery of lead from process solutions. Possible sorption mechanisms were proposed. The calculated adsorption constants calculated from Langmuir and Freundlich equations showed that the adsorption of lead on chabazite was strong.

Jan 1, 1999

By I. M. Ritchie

Cyanide owes its great success as a lixivant for gold to the great strength of the Au-CN bond. A replacement for cyanide must similarly be a strong complexant for gold (I) or gold (III). The various alternatives are briefly considered and it is concluded that only thiosulfate has a reasonable chance of replacing cyanide as a relatively non-toxic lixivant at the present time. However, there are considerable technical problems to be overcome before thiosulfate can be considered to be a realistic alternative to cyanide. Firstly, the leaching of gold using aerated ammoniacal thiosulfate with copper as a catalyst is a complex process which needs to be understood and controlled carefully in order to achieve maximum recoveries with minimum reagent losses. Secondly, there needs to be an option similar to the CIP process for recovering and concentrating the dissolved gold thiosulfate complex from pulps produced in the processing of low grade gold ores. The prospects for overcoming these technical' challenges are evaluated and discussed.

Jan 1, 1998

By J. S. Pitsillos

A new furnace tapping technique involving the simulation of a control valve at the exit to a furnace is being investigated. The purpose of this new tapping technique is to regulate the flowrate of liquid furnace products( slags, metals and mattes). Numerical modelling and experimental work has been carried out on tapping of slags leaving a SIROSMELT reactor and the results found to be in good agreement. Numerical modelling has also enabled prediction of the important industrial conditions for the onset of blockage from the shape of the pressure versus flowrate curves. Slag launder experiments have been carried out and a one-dimensional heat transfer model was used to evaluate the effectiveness of launder covers and different coolants. From the experimental results and mathematical model some launder design guidelines such as inclination angle, covers and coolants have been developed.

Jan 1, 1991

By R. Elliott, H. Bayati

"Effect of time and temperature on microstructure and mechanical properties of an austempered ductile iron, ADI, of composition 3.6%C, 2.6%Si, 0.4%Cu, 0.2%Mn are reported. Xray analysis and. microstructural observations indicate that lowering the working temperature, aging temperature, increases the lifetime of ADI significantly. Results show· that lowering the aging temperature increases the strength and reduces the ductility of ADI. DSC traces for ADI austempered at 340°C are presented. Comparison of the DSC analysis and kinetic measurements demonstrates that the DSC traces can be· used to predict the life time of ADI successfully.IntroductionAustempered ductile iron, ADI, is one of the most significant developments in cast iron technology over the past two decades. Outstanding properties of high yield, ultimate strength, ductility, fatigue and wear· resistance make ADI suitable for a range of applications including gears, connecting rods, crankshafts and agriculture machine components. The austempering reaction in cast iron occurs in two stages, Fig. I, in contrast to the single stage reaction in steel. In stage I the relatively low carbon austenite produced during austenitising transforms into ferritic plates and high carbon austenite, a metastable structure called·ausferrite. The high carbon ailstenite and supersaturated ferrite produced in stage I decompose into ferrite and carbide in stage II: to form a structure similar to the bainitic structure in steel. This behaviour exposes a well-defined processing window, t1 - t2, over which the maximum amount of ausferrite is produced, Figure 1. Whereas the bainitic structure determines the properties of austempered steel, ADI properties are mainly affected by volume fraction of retained austenite (VRA), austenite carbon content (ACC), unreacted or martensite volume fraction (UA V), compositiori and amount of carbides, and morphology of ferritic plates[l,2]. Due to the detrimental .effect of martensite and carbides on properties of ADI, an ideal structure of ADI consists only of ausferrite [l,2]. Thus, it is common to determine the processing window for each austempering treatment in order to identify the optimized austempering time. Decomposition of austenite (stage II) signals the end of the life time for an ADI component, therefore, the aging behaviour of ADI at different working conditions can be studied by determining the t2."

Jan 1, 2000

By Maija-Leena Metsärinta

The behaviour of copper and lead in zinc roasting has been studied in laboratory scale roasting experiments as well as in large scale trials in an industrial fluidized bed, with the background of Outokumpu Kokkola Zinc smelter. Commercial zinc concentrates with a low and high ( up to 3 wt % ) copper content and with a low and high (up to 3.5 wt % ) lead content were oxidized to various desulphurisation degrees in the fluidized bed to establish the reaction mechanisms and the paths for copper and lead oxidation in the roasting. Influences of the agglomerate size on the roasting kinetics and micro-scale phenomena were also determined. Optical microscopy was used on the calcine and the findings are presented as numerous photographs of the polished cross sections. SEMIEDS techniques were used for analyzing chemically the phases and particle morphologies present in the samples. Computational thermodynamics was applied to the complex phase equilibria occurring during roasting in the agglomerating calcine. A complete oxidation of zinc concentrate with a high copper and lead content requires a careful control of oxygen coefficient in the roasting in order to maintain a stable operation of the fluidized bed. Oxygen coefficient thus seems to have a significant impact on the hydrodynamic stability of the fluidized bed with fine raw materials.

Jan 1, 2003

By Michael J. Marinigh

"Increased safety requirements, higher operational costs, greater environmental restrictions, and new competitive processing techniques are the challenges smelter operators must confront in order to remain economically viable.In converting furnaces which have tuyères such as the Noranda Reactor and the Teniente, Peirce- Smith and Hoboken converters, efficient tuyère line management is critical to optimizing blowing rates, increasing refractory life, and improving safety.This paper will describe recent improvements made to equipment used for tuyère punching, tuyère silencing, tuyère pyrometry and refractory drilling of tuyères and how the proper application of the equipment can lead to operational and safety improvements."

Jan 1, 2009

By KAGAN BENZESIK, Onuralp Yücel, Mehmet Bugdaycı, Ahmet Turan

ZrB2 and B4C are one of the most significant advanced ceramics. They are being used in various industrial areas from space technology to nuclear industry owing to their physical properties such as high melting point, high thermal/electrical conductivity and low density. Present study was conducted in two main stages: Self-propagating high-temperature synthesis (SHS) reactions and leaching. ZrO2, Carbon black, B2O3 were used as starting material to produce ZrB2-B4C powders by SHS. Also Mg powder was used as the reductant. The reaction mixtures (approximately 100 g) were mixed thoroughly 15 minutes in a turbula mixer and charged into Cu crucible and compacted. W (tungsten) wire was placed at the top of copper crucible and the reaction realized by passing current through the wire. After initiation, a highly exothermic reaction became in a self-sustaining mode and propagated throughout the SHS mixture. The samples were characterized by using AAS and X-Ray Diffraction.

Jan 1, 2016

By Jiakai Zhang

Many postconsumer electrical and electronic equipment wastes contain a considerable amount of rare earth elements (REEs); however, the current level of REE recycling from them is limited (<1%). Neodymium–iron–boron (NdFeB) magnets, used at both small- and large-scale, from computer hard disk drives and small tools to wind turbines and cars, are a good example of such waste materials that contain high content of neodymium (Nd) and dysprosium (Dy). These elements are considered critical metals because they are the main building block of emerging green technologies that will allow for GHG emission reductions. Because demand for these green products is increasing around the world, the demand for REEs is increasing quickly, putting their supply at risk in the near future. Thus, it is critical to develop efficient, robust, and cost-effective processes to recycle these elements from this class of electronic waste materials. Here, we performed a thorough characterization of a N52–NdFeB magnet to identify its composition, crystal structure, and morphology. Furthermore, we developed an efficient hydrometallurgical process to extract Nd and Dy with high efficiency (more than 95%).

By Thomas W. Chapman, Shi-Chern Yen, I-Min Lu

"An electric field was applied to a metal-bearing kaolinite specimen to investigate the efficiency of electro-osmosis in removing heavy metals from contaminated soils. The electric field induces a flow of water through the porous medium, called electro-osmosis, which is superimposed on the hydraulic flow. Because the electro-osmotic flow is relatively stronger in smaller pores, it can enhance the displacement of contaminated solution by fluid convection. Furthermore, local changes in pH caused by the electrode reactions can affect adsorption equilibria and the distribution of solutes between the solution and the solid surfaces.The electro-osmosis experiments were conducted by applying either a constant current or a constant voltage across 8-cm inside diameter, 25 to 30-cm long specimens of kaolinite clay with graphite electrodes. Samples of the pore fluid and of the clay were analyzed to determine metal content, pH, and conductivity as functions of time and position. Results show that removal of heavy metals from soil can be accomplished effectively by electrokinetic treatment of sufficient duration. Approximately 95% of the lead was removed after 189 days.IntroductionRemediation of soils contaminated with toxic chemicals is a difficult and expensive task. Washing or leaching are not particularly effective if the contaminate is sequestered in small pores; hydraulic flows of water pass through larger pores leaving the smaller pores relatively untouched. Electro-osmosis appears to be the most promising new technology for removing heavy metals and organic substances from contaminated soils (Segal, 1980; Hamed et al., 1991, Masliyah, 1994).Electro-osmosis is one of several electrokinetic phenomena that occur through the interactions among an electric field, fluid motion, solute adsorption, and the existence of a net charge on a solid-fluid interface (Newman, 1991, Masliyah, 1994). Electro-osmosis refers to the fluid flow in a porous medium that results when an electric field acts on the mobile region of the electrical double layer, the solution-side region of charge separation that exists at the pore walls."

Jan 1, 1996

By Boyd Davis, Vladimiros Papangelakis, Joshua LaMarre, Jan de Bakker

"HCl leaching using molten salt hydrates has the potential to improve the extraction of nickel from laterite ores. However, as in other HCl leaching applications, recovery of HCl is key to process economics. Spray pyrohydrolysis, which is used in current chloride-based flowsheets, is associated with a high energy cost. The authors have developed a proposed laterite leach circuit using an alternative HCl recovery route. The leach circuit envisions a leach by concentrated (33%) HCl in an MgCl2 molten salt hydrate (MSH) or brine medium, followed by Ni/Co recovery and iron precipitation. Magnesium and chloride are precipitated from solution as magnesium hydroxychloride; this hydroxychloride is thermally decomposed to produce HCl gas. The proposed flowsheet employs a chloride leach circuit with simpler equipment and lower energy cost than in the conventional practice of pyrohydrolysis. Laboratory work investigated key aspects of the flowsheet, including precipitation of magnesium hydroxychlorides and their composition; magnesium hydroxychloride thermal decomposition; and iron control.Introduction As sulphide nickel ores become harder to mine and more complex to process, laterite ores will increase in importance. Laterite ore deposits can be divided into two main mineralogies. Limonite ores consist mostly of hydrated iron oxide, FeOOH, with 1-3% nickel substituting for the iron. Saprolite ores consist of iron-magnesium silicates, (Fe, Mg)2Si04, again with some nickel substituting for the metal ions. Limonite ores can be treated using the HP AL (High Pressure Acid Leach) process, in which the ore is reacted with sulphuric acid at high temperature in an autoclave. HP AL, however, cannot in general be used to treat saprolite ores because the magnesium enters solution and consumes sulphuric acid, which results in excessive spending on lixiviant. It is therefore desirable to find a hydrometallurgical process specifically for saprolite ores that can provide better results than the treatment options currently available."

Jan 1, 2011

By Maija-Leena Metsiirinta

The behaviour of copper and lead in zinc roasting has been studied in laboratory scale roasting experiments as well as in large scale trials in an industrial fluidized bed, with the background of Outokumpu Kokkola Zinc smelter. Commercial zinc concentrates with a low and high ( up to 3 wt % ) copper content and with a low and high ( up to 3.5 wt % ) lead content were oxidized to various desulphurisation degrees in the fluidized bed to establish the reaction mechanisms and the paths for copper and lead oxidation in the roasting. Influences of the agglomerate size on the roasting kinetics and micro- scale phenomena were also determined. Optical microscopy was used on the calcine and the findings are presented as numerous photographs of the polished cross sections. SEM/EDS techniques were used for analyzing chemically the phases and particle morphologies present in the samples. Computational thermodynamics was applied to the complex phase equilibria occurring during roasting in the agglomerating calcine. A complete oxidation of zinc concentrate with a high copper and lead content requires a careful control of oxygen coefficient in the roasting in order to maintain a stable operation of the fluidized bed. Oxygen coefficient thus seems to have a significant impact on the hydrodynamic stability of the fluidized bed with fine raw materials.

Jan 1, 2003