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By Derek J. Fray

The need for on-line sensors is outlined and it is demonstrated that the control of many processes is prevented by the availability of these devices. The use of solid electrolytes is described for the sensing of elements in molten pyrometallurgical phases. In the cases where there is no suitable electrolyte, the addition of a second phase of a compound containing both the element to be measured and the element whose ion is mobile in the electrolyte can be used. For the measurement of high concentrations of an element a method based on current measurement is proposed.

Jan 1, 1994

By Xiangwen Wang

Electrochemical measurements associated with the electrowinning of lead metal from concentrated brine (NaCI) - lead chloride (PbCI,) electrolytes at temperatures in the range 328 to 353°K (55 - 80°C) were conducted. The electrodeposition of lead metal onto a lead rotating-disk electrode may be described by the electrodic reaction: {PbCl 4 2 + 2e- = Pb° + 4Cl-} The deposition-overpotential requirements are low (approximately 41mV per decade of current density - Am+), with a corresponding high exchange current (approximately 0.018 A.cm2). The diffusion coefficient of the electroactive PbC142- species in a 3.5 NaCl electrolyte at 353°K was insensitive to the total PbCI, concentration (0.01 to 0.1M), and its value was found to be (1.21*0.1)~10-5 cm2Is with a temperature-sensitivity coefficient (E,/R) of approximately 1.98x103K-1 (328OK(T<353OK).

Jan 1, 1993

By Nathanael Hudson, Ruel A. Overfelt, Sushil H. Bhavnani

"In the aerospace and automotive industries, complex shapes exist which require casting. The problem with these cast parts is the empiricism required to develop the casting process and the accompanying time and expense to develop that process.There has been an interest in using fluidized beds to allow molding sand to better encapsulate the complicated surface geometries of lost foam patterns. Fluidization coupled with a mixing jet helps to homogenize the sand through stirring and may improve the integrity of the casting.At issue is the hydrodynamics of the sand and air around the foam pattern. The commercial package PHOENlCSTM is used to simulate the flow around the pre-casting foam geometry. Employing a two fluid approach, each component is considered a fluid that interpenetrates the other phase. To this end, the kinetic theory of granular 'flow for the sand phase was incorporated into the re-compilable PHOENlCSTM code.The results of this study consist of time-averaged void fraction patterns, with voidage being defined as the fraction of air in the mixture, around the foam pattern submerged in a two-dimensional fluidized bed. The model was benchmarked against past fluidized bed experiments. In order to better understand the dependence of the void fraction pattern around the lost foam pattern, certain physical parameters are varied and the resultant void fraction maps are predicted with the model. Physical parameters such as the aspect ratio of length to width, the placement of the mixing jet, and different mixing jet velocities are varied to illustrate the dependence of the time-averaged void fraction on those variables.Results consistently indicate the presence of channeling around the lost foam pattern, with the extent of the channeling and void formation reliant to a greater degree upon the placement of the mixing jet, and to a lesser degree on mixing jet velocity and aspect ratio.The increase in radial position of the mixing jet from the bed centerline had the desirable effect of granting the churning benefits of a penetrating jet, while at the same time minimizing the formation of excess void fraction at the top of the pattern."

Jan 1, 2001

By E. N. Mounsey

Ausmelt Technology was selected by Bindura Nickel Corporation (BNC) as the basis for a new copper circuit to process nickel plant copper leach residue to blister, anode and finally cathode copper and recover PGM values at the Bindura Smelter Refinery (BSR). The process selected, based on Ausmelt Technology to smelt and convert the residue to matte and blister copper and produce a discard slag, is novel incorporating smelting, converting and slag reduction process steps in a single Ausmelt vessel. The process demands a high quality blister copper product with low levels of arsenic and nickel. This paper reviews the project and the initial operational results to the end of 1997 of the Ausmelt Top Submerged Lancing (TSL) smelter and discusses the implications for the wider TSL converter market.

Jan 1, 1998

By F. A. Myzenkov

The technology developed by the authors uses new methods for raw material smelting in electric furnaces, a new autogenous method and apparatus for subliming smelting for antimony trioxide production and separation of antimony and gold. Concentrate produced from the ore deposits in Yakutia has the following average contents of main constituents, % by weight: 29.4 Sb, 1.2 Fe, 13.1 S, 40.0 SiO2, 0.2 As, 2.6 CaO and 45 g/t of Au. Unlike the technology used abroad a new autogenous method makes it possible to increase considerably specific capacity and reduce gold losses with antimony trioxide by several times. At the same time mineralogical composition of trioxide has improved considerably ? it has mainly a cubic base with prevalence of senarmontite. The content of a main component (Sb2O3) in the final product has increased from 99.0% up to 99.6% which means better quality and makes it suitable for use in special technologies. Despite a lower antimony content of the concentrate (29.4% as compared with over 33% as common in the world practice), an antimony recovery of 85.3% into a commercial-grade product has been achieved, as well as a gold recovery of 96.65% into a gold-antimony alloy. The technology for processing gold-antimony materials developed and introduced at the Ryaztsvetmet plant is unique in the world with respect to gold recoveries.

Jan 1, 2006

By Mansoor Barati

The present paper is based on a term project for final year undergraduate students, requiring them to evaluate a process for producing silicon from rice husk. The traditional method for production of silicon involves carbothermal reduction of quartz in electric arc furnaces at temperatures exceeding 2000 °C. The technology consumes a considerable amount of electrical energy as well as fossil fuels, resulting in significant CO2 emissions. A flowsheet for production of silicon metal from rice husk is laid out in this paper. The technology will consist of combustors, which will generate steam using the rice husk biomass, power generator, and electric furnace for reduction of the rice husk. Materials and energy balance calculations presented here indicate that such process can be operated independent of external electricity.

Jan 1, 2014

By J. L. Liow

Studies have been carried out on the causes and effects of slopping in an annular cylindrical geometry such as the top submerged combustion reactor. Properties of standing waves formed such as the wave profile, period, pressure distribution and velocity have been derived analytically. The wear profile due to wave erosion was calculated based on the assumption of linear motion and that the wear is a dissolution process. The use of the j, factor showed that the wear was proportional to the square root of the wave velocity at any point. Using the dimensions of the lsasmelt reactor given by Errington et al. (1987)[11, the wear profile due to wave erosion was calculated using the analytical solution. The wear profile calculated was shown to have a maximum just below the initial bath surface. The wear was found to be concentrated in the region where the first asymmetric standing wave was most active. The results showed that the refractory near the bath surface will be affected by wave erosion, more so than any other parts of the reactor. The contribution of wave erosion on wear must be accounted for in assessing the total refractory wear of a vessel in which slopping exists.

Jan 1, 1991

By Min Zhu, Yu Ji, An-chao Ren

"After being welded in the weld plant, the 100-meter heavy rails with the specification of 60kg/m are found broken during the straightening process in four planes. Failure analysis is made using the optical microscope and SEM with the result showing that the broken rail contains the imperfection of protrusion which exists at the edge of rail foot, about 1 00mm away from the rail end. When the protrusion is peeled off by deseamer from rail surface, cold scratch is generated which causes the rail to be broken during the subsequent straightening process. By adjusting the roll diameter differences between top and bottom roll of universal finishing mill and the height of pass line, it is possible to maintain the rails flat when leaving the mill. This prevents the upsweep and downsweep phenomena and, thus, the imperfection of protrusion can be eliminated. IntroductionThe development of rail transit worldwide has entered into a new era since the 1960s. The hi-tech rail transit system has gradually gained recognition over the world. In particular, the emergence of new-type passenger trains represented by TGV of France, ICE of Germany and Shinkansen of Japan and heavy haul trains as well, has revealed the charming way and more prosperous future of the modern and hi-tech rail transit system to the people all over the world. It should be pointed out that rail transit system is still the most effective solution to traffic jams among urban cities and in the central cities during the 21 '1 century, especially high-speed railway and subway which take overwhelming advantages over air transport, marine transport and road transport in terms of high speed, high efficiency, safety, comfort, environment protection and high flow. With the trend of increasing speed and heavier load of trains, higher product quality of rails is demanded. The rails for passenger dedicated lines require high cleanness, high accuracy in size, high flatness, high surface quality and large size (100-meter fixed length). The rail quality has direct influence on the operating performance of rail and railway traffic safety. The 100-meter heavy rails with the specification of 60kg/m are broken subject to the straightening process in four planes after being welded in the weld plant. This paper analyzes the reason for rails being broken and provides the theoretical proof for determining the rolling process."

Jan 1, 2013

By Carvalho A. Felipe de

The search for environmentally friendly and cost-effective methods for gold extraction has been undertaken in order to provide alternatives to the use of cyanide leaching in the gold industry. Among such alternative reagents is the combination of chloride and hypochlorite ions due to their oxidation of metallic gold and its complexation. Therefore, the current work aims at investigating gold leaching from an oxidized material by means of a solution comprising calcium hypochlorite and sodium chlorite. The sample used in the current research contained 66.1% Fe2O3, 20.4%SiO2, and 35.7 g/t of Au. In addition, XRD and SEM-EDS analysis revealed iron oxide, quartz and muscovite as the main crystalline phases in the sample. For comparison purposes, cyanidation of the oxidized material resulted in 90% gold extraction in 24 h. The reference conditions for the leaching tests with the chlorite-hypochlorite system were: particle size −37 μm, solid/liquid ratio of 10% (w/v), 10 g/L NaCl, 10 g/L Ca (OCl)2, pH 5–6, 3 h of leaching. The effects of the: (i) Ca(OCl)2 concentration, (ii) NaCl concentration, (iii) pHrange and (iv) the effect of pulp density in the extraction of gold were assessed. In addition, the stability of the hypochlorite solutions (OCl−) was investigated. The ideal concentrations of Ca(OCl)2 and NaCl were determined as 25 g/L and 15 g/L, respectively, whereas the optimal pH range was 4–6. Under these conditions, the final gold extraction reached approximately 84%. By varying the solids content of the pulp (10%, 20% and 30%), it was observed that the lower solids value resulted in greater gold extraction (84%). The degradation of the hypochlorite solution and the possible catalytic effect of the presence of the solid were evidenced. To sumup, in the experiment, high gold extractions were achieved in shorter periods of time (3 h), as compared to the cyanidation of the same sample. On the other hand, itwas necessary to use significant amounts of the reagent due to hypochlorite instability at the pH conditions recommended for high gold extractions.

By Hebi Yin

A coupled cellular automaton (CA) - finite element (FE) model was developed to calculate the growth of dendrites during the solidification of cubic and hexagonal metals. The model solves the conservation equations of mass, energy and solutes in order to calculate the temperature field, solute concentration and the growth morphology of dendrites, including the grain structure and the dendritic microstructure. Validation of the model was performed by comparing the simulation results with calculation results from previously published works, showing qualitatively good agreement in the dendritic morphology. Application to magnesium alloy AZ91 illustrates the difficulty of modeling dendrite growth in hexagonal systems, observed as deviations in growth direction caused by mesh-induced anisotropy. The model was applied to the simulation of small specimens with single- and multiple- equiaxed grain growths and columnar grain growth in directional solidification. The influence of cooling rate and some kinetics parameters on the grain morphology are also discussed.

Jan 1, 2009

By C. M. Wai

Metal species in solid and liquid materials can be extracted by supercritical carbon dioxide containing a suitable ligand. This in situ chelation-supercritical fluid extraction technique offers, several advantages over conventional solvent extraction including minimization of organic liquid waste generation and exposure of personnel to organic vapors. One unique feature of this technique is that metal species can be removed from solid materials directly using supercritical carbon dioxide as a solvent. Several ligand systems including dithiocarbamates, ß-diketones, organophosphorus reagents, and macrocyclic compounds have been tested for metal extraction in supercritical carbon dioxide. This novel extraction technique may have important applications for metal recovery and mineral processing.

Jan 1, 1996

By C. Beckermann

"A diffuse interface model is derived for the direct simulation of two-phase flows with surface tension, density differences between the phases, and phase change. The derivation starts from the balance equations for a sharp interface and uses a formal averaging procedure on an atomic scale to obtain diffuse interface versions of the equations. Two approaches are considered: (i) the two phases have different velocities inside the interface and separate conservation equations are solved for each phase, and (ii) the two phases have the same velocity inside the diffuse interfuce and mixture conservation equations are solved. Based on a superposition of microscopic (atomic-scale) and macroscopic interface morphologies, an expression for the interfacial momentum source term is introduced that models surface tension effects and accounts for immiscibility between the phases.IntroductionDiffuse interface methods have been a popular tool in the direct simulation of two-phase flows [I]. In diffuse interface approaches, the interface between the two phases is characterized by a rapid but smooth transition in the properties, such as density and viscosity. Usually, a phase function ? is introduced to represent this transition, and the evolution of ? in the domain is computed from a separate equation or recipe. A unique set of conservation equations (e.g., mass and momentum) is solved on the entire domain, irrespective of the phase present, by accounting for the transition in the properties and introducing terms that account for interfacial sources. The continuum surface force (CSF) model of Brackbill et al. [2], which accounts for surface tension, is an example of the latter. The volume-of-fluid (VOF), level set, and phase-field methods are all examples of diffuse interface approaches. The major advantage of diffuse interface methods is that explicit tracking of the interface and the application of traditional sharp interface conditions are avoided. A disadvantage can arise from the artificial smearing of what is in reality an interface of atomic-scale width; however, techniques have been developed to overcome this problem."

Jan 1, 2004

By Ronald J. Roman

The shrinking core model for coarse particle leaching has been generally accepted as describing the leaching of a copper oxide or sulfide ore. However, when a mixed oxide/sulfide ore-is leached this model can not be used in its simple form because at least two and possibly three separate leaching processes are occurring simultaneously (dissolution of oxide copper minerals, secondary copper minerals and primarily copper minerals). It has been impossible to isolate their individual leaching curves from the recovery/time curve generated by the column leach test. This paper describes a tests program carried out at the Groupo Mexico, Mexicana de Cobre&apos;s La Caridad operation in which the individual recovery/time curves for the leaching of copper oxide mineral, secondary copper mineral and primary copper minerals were developed from standard column leach tests. Once the individual recovery/time curves were developed scale-up of the column leach test results to the commercial heap leaching operation is possible by using the shrinking core model.

Jan 1, 1999

By Alan DonaldsoN

Plasma Quench production of titanium is the thermal dissociation of titanium tetrachloride into gaseous titanium and chlorine followed by rapid quenching to prevent back reactions. Titanium tetrachloride dissociates into titanium and chlorine atoms at 5000 K. Expansion through a Delaval nozzle accelerates the gas to supersonic speed cooling it very rapidly. Cooling rates are as high as 7exp 1 0 Kelvins per second. Injected hydrogen reacts with condensed titanium particles to form titanium hydride and with the chlorine to form hydrogen chloride. We have produced titanium powder at 20 kglh in a continuous reactor. Costs are projected to be lower than the Kroll Process at large enough scale. Most of the cost reduction would result from elimination of magnesium as a reducing agent and much lower capital costs.

Jan 1, 2001

By K. Morsi, S. K. Kassegne, A. El-Desouky, K. S. Moon

"Current Activated Tip-based Sintering (CATS) is a new process for the powder-based fabrication of macro, micro and possibly nano-scale features and shapes. This new and unique process enables selective sintering of powders by localizing electrically activated sintering conditions through a stationary or moving electrically conducting tip. We present preliminary experimental results on the effect of tip size in the CA TS process as well as the effect of initial powder particle size on the sintering behavior of nickel powder.IntroductionSpark Plasma Sintering (SPS) has been the center of attention of numerous researchers due its noticeable advantages over conventional sintering techniques such as rapid heating rates, lower sintering temperature and shorter holding times. Research on SPS has been applied on a wide variety of materials such as pure metals [ 1], ceramics [2], composites [3], nano-materials [ 4], biomaterials [ 5], shape memory alloys [ 6] and many other material systems. However, it has been mostly limited to bulk materials with simple shapes with a few exceptions ofresearch efforts where the effect of electric current was combined with metal forming processes such as spark plasma extrusion [7,8] and electric rolling of powders[9]. In this paper a novel process (Current-Activated Tip-Based Sintering (CATS)) is discussed where electric current and pressure are applied simultaneously through a small conducting tip (stationary or moving) over a conducting powder compact. This process has the potential advantages of sintering complex geometries with minimum energy requirements as unconventionally high current densities can be achieved due to the small contact area between the tip and the powder compact. Furthermore, by controlling the tip size, it can be possible to sinter features on the macro-, micro- and even nanoscales."

Jan 1, 2011

By Yoshinobu Fukumori, Testuya Watanabe, Futoshi Shikata, Hiroyuki Tokumitsu, Hideki Ichikawa, Masahito Miyamoto

Nano-particulate systems have attracted much attention recently in pharmaceutical field as drug carriers and functional components of pharmaceutical dosage forms. This paper describes our approaches in design and preparation of nano-particulate systems, including lipid nano-emulsions, chitosan nanoparticles and thermosensitive acrylic nanoparticles, for certain pharmaceutical applications mentioned below. The lipid nano-emulsions with their particle size smaller than 100 nm were prepared for gadolinium neutron-capture therapy (Gd-NCT) of cancer by a thin-film hydration method with sonication, and intraperitoneally injected into Greene's melanoma (melanotic No. 179)-bearing Syrian hamsters. This provided such a high gadolinium concentraton in tumor as 107 µg/g tumor (wet basis) at 48 h after administration. As an alternative gadolinium nano-carrier for Gd-NCT, biodegradable and highly gadopentetate-loaded chitosan nanoparticles (Gd-nanoCPs, 426 mTI in particle diameter and 9.3% in Gd content) were prepared by a novel emulsion-droplet coalescence technique. A significant tumor-killing effect could be obtained when Gd-nanoCP suspension was injected intratumorally twice 24 and 8 hours before neutron irradiation into B 16Fl O melanoma-bearing mice and subsequently thermalneutron was irradiated toward tumor site with a flux of 2 x 109 n/cm2/sec for 60 min. As one another application of nanoparticles, a novel acrylic composite latex with a hydrophobic core and a thermosenstively swellable shell was designed for fabricating microcapsules showing thermosensitive mode of drug release. The microcapsules with the composite latex-dispersing membranes exhibited an exceptionally rapid on-off response of drug-release in a thermosensitive manner.

Jan 1, 2000

By Chuanyu Feng

In this paper, a load-based micro-indentation technique suitable for field applications was developed. This technique bears the same theoretical background as traditional load-depth sensing indentation, and does not need any direct measurement of indentation depth or contact area. The removal of this requirement will reduce much of the cost associated with traditional instrumented indentation. To demonstrate the feasibility, a portable indentation system suitable for online material characterization was developed. Design issues of the portable unit were discussed and preliminary results using the portable unit were also presented.

Jan 1, 2009

By A. Iván, Patiño C. Francisco, Flores B. Javier, Peréz L. Miguel, Hernandez A. Juan, Trapála P. Norma, Salinas R. Eleazar, Rivera L. Isauro, G. Flores, U. Mizraim

"Tills work is related with the production of tiles using wastes from mining and metallurgical industry of Hidalgo State, as raw material. These wastes present a majority particle size (60 %), minor than 53 m (mesh 270, in Tyler Series) with the following composition; 70.01 % wt. of Si02, 12.82 % wt. of Ah03, 3.80 % wt. of Fe, 0.70 % wt. of Mn, 3.98 % wt. ofK20, 3.34 % wt. of CaO, 2.50 % wt. ofNa20, 0.04 % wt. of Zn, 0.026 % wt. of Pb, 56 grams per ton of Ag and 0.6 grams per ton of Au. In this work, the partial results and experimental conditions for the preparation of some composites to produce tiles are shown. The composite that offers the best results in productions of tiles was that with 66.67 % wt. of mining waste, 26.67 % wt. of red mud and 6.67 % wt. of black mud.IntroductionTo now, mining activities carried out during more than 457 years in Hidalgo State, Mexico; has lead a great volume of wastes; which can be classified into different types, having among the more common; Acid mining water, solid transport water, elements in radical form, abandoned minerals without processing and processing minerals wastes known as burrows, being these the most abundant in the region counting with an approximated volume of 110 million of tons, presenting a fine particle size that can affect population health during windy epochs [1 -4].Form metallurgical point of view, is well known that a fundamental characterization study it is necessary to know the viability of reusing or recycling of these wastes. According this, these residues can also be considered as raw materials in other economical activities, due its Si, Fe, AI, Ca, Na and P oxides contents, its mineralogy and the distribution of chemical elements in the primary and secondary phases [1,2,5,6]."

Jan 1, 2012

By Jesús Contreras

Within its programme for continuous improvement and cultural change, Atlantic Copper has installed the Six Sigma methodology as a basic tool for the improvement of management techniques in all its production centres. Following an implementation period, the methodology is widely used for analysis and improvement, not only in the fields of production and maintenance, but also in other areas of the business such as supplies or energy management. The present paper describes, phase-by-phase, the project that was developed to improve the quality of converter slag through the application of Six Sigma techniques, from the initial set up to the final results obtained.

Jan 1, 2005

By Li Qian

Mechanisms of bio-dephosphorization from iron ore was investigated in this Paper. The results show that there are two bio-dephosphorization ways from iron ore, the one is that Acidithiobacillus ferrooxidans directly derive phosphorus from the ore, the other is phosphorus is able to be leached acid produced during metabolizing of Acidithiobacillus ferrooxidans, and the latter is more important than the other. Adding suitable pyrite can enhance the bio- dephosphorization process through providing nourishment and producing acid directly due to S 3oxidized or indirectly due to Fe3 as oxidant. The potential varies in the range of 0.434~0.498V and pH is in the range of 2.5 ~ 1.25 during bio-leaching process. It can be founded that, according 2+to the E-pH graph of Fe-H2O system, Fe wouldn?t be oxidized under sterile system in this potential and pH ranges. It can be obviously concluded that the Acidithiobacillus ferrooxidans are 2+able to reduce the potential for the oxidization of Fe and make the oxidization occur in the above pH and potential zone, so the bio-leaching process can proceed. the investigation of E-pH graph of P-H2O system show that H3PO4 can exist steadily.

Jan 1, 2009