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By Marcelo Jimenez Bustos

The Chagres Smelter was the first in Chile to follow environmental regulations to control sulfur dioxide emissions. Because of this, the operation and development plans have had to incorporate environmental planning as part of its policies for almost three decades. The present article shows the development of the environmental standards applied to its operations, investments and operational improvements carried out to meet the regulations and improve competitiveness. Results to-date and future plans are outlined, as well as their impact on operations and the environment.

Jan 1, 1993

By Sevinc Yildirim, Cigdem Oruclus

"Metal-Porous Silicon (PS) based structures dipped in water show the direct hydrogen fuel cell behavior. The effect of the thickness of the cupper (Cu) film on the electrical properties of direct hydrogen fuel cell is studied by fabricating Cu/Porous Silicon/n-Silicon/Indium structures. PS samples were produced electrochemical etching of n-type single crystalline silicon with a resistivity of 1,25 Ocm and (111) orientation. The thin films of Cu with different thickness between 200 and 600 nm were deposited on PS surface by electron-beam technique. Investigation of the effect of Cu layer on the performance of the structure indicates that the performance parameters such as open circuit voltage (Voc) and short circuit current (Isc) strongly depend on the Cu layer thickness. It was observed that the divice with an 350 nm Cu layer exhibits the highest open circuit voltage (0,5 V), short circuit current (0,01 mA) and power density (10 W.m-2).IntroductionHydrogen is the most attractive and ultimate candidate for a future fuel and an energy carrier. Hydrogen is recognized as the environmentally desirable clean fuel of the future since it can be used directly in different types of hydrogen fuel cells [1]. In the past years, the rise in portable electronics requires the development of miniature fuel cells compatible with standard silicon micro fabrication technology. Most silicon micro-fuel cells have used the polyperfluo-rosulfonic acid membranes (Nafion R) as a proton exchange membranes (PEM) that is not really integrated with standard micro fabrication techniques [2-5]. The composite materials such as inorganicorganic hybrid materials (Nafion-silica, Nafion-borosiloxane etc) are next generation of proton conducting membrane [4-8]. But, fuel cells run on pure hydrogen gas, which can be produced with other energy resources. Hydrogen smallest atom and thus the H2 gas can leak easiliy. The application of hydrogen for power sources has been greatly restrained due to the lack of safe and convenient generation and storage methods.A kind of hydrogen fuel cells Metal-PS-Si structures used as an energy water directly. There is no need pure hydrogen. Cu-PS-Si Schottky-type fuel cells with as proton-conducting membrane and the thin-film cupper catalist and water as fuel, which are interesting for fabrication of lowcost miniature fuel cells. Generation of the open-circuit voltage and short-circuit current has been observed by Cu-PS-Si structure dipping in different hydrogen-containing solution."

Jan 1, 2014

By Hang Goo Kim

A mathematical analysis based on equilibrium modeling has been developed to describe the distribution behavior of minor elements such as Pb, Zn, Bi, Sb, and As among gas, slag and recovered copper phases during the reduction of copper oxide in slag cleaning with CO gas. The results show that large fractions of the impurities transferred to slag during smelting or converting are recycled to the recovered copper metal. It is also shown that there is a limit to the recovery of copper from slag because iron oxides are also reduced to form a copper-iron alloy at low oxygen potentials. The effects of various operating parameters such as temperature, the activity of FeO, the initial amounts of the elements in the slag and CO content in process gas, on the behavior of these minor elements are discussed. The predicted results were compared with the results of a pilot plant operation in which pulverized coal was used as a reductant. Consistent trends between the two cases were obtained.

Jan 1, 1992

By Ahmad Ghahreman, James McNeice

Separation of rare earth elements (REE) is often achieved by acid leaching of mineral concentrates followed by subsequent solvent extraction (SX), to purify individual rare earth metals (REM). Cerium, the most abundant REE, is usually the largest component of these ores. Demand for less prevalent REE, such as praseodymium and dysprosium; have led to a market saturation and price collapse of cerium. One method of improving the economics of REE separation is to remove cerium from solution prior to SX. This is accomplished via the oxidation of cerium (III) to cerium (IV), which precipitates as cerium hydroxides. This study probes the efficacy of four oxidants; hydrogen peroxide, sodium hypochlorite, potassium permanganate, and Caro’s Acid with the goal of improving cerium removal whilst minimizing REE and reagent losses. The effect of oxidant type and dosage, pH, cerium concentration, and temperature on the kinetics of the process will be discussed.

Mar 1, 2018

By Ch. -A. Gandin, M. Rappaz

"The grain selection mechanism which occurs during the growth of columnar dendritic structures is routinely used in the investment casting industry to produce directionally solidified (DS) and single crystal turbine blades. However, the evolution of the grain density with increasing distance from the chill has rarely been correlated with the evolution of the grain texture. This contribution presents a three-dimensional (3-D) stochastic modeling approach which permits the computation of grain maps, pole figures and grain density evolutions in DS superalloys. These predictions are compared with measurements resulting from an automatic indexing technique of Electron Back-Scattered diffraction Patterns. This 3-D stochastic model, which applies to uniform temperature situations, has to be extended to the dendritic growth in a thermal gradient. As a preliminary step, a 2-D Cellular Automaton (CA) has been coupled recently to Finite Element (FE) heat flow computations in order to predict the grain structures in complex shape investment cast part. The application of this CAFE model to the investment casting of a turbine blade is presented. Considering these results, the extension of the CAFE algorithm to three dimensions is discussed.INTRODUCTIONThe selection of columnar grains during the directional solidification of alloys plays a key role during the investment casting of directionally solidified (DS) and single crystal (SC) components for aerospace applications [I]. This selection mechanism, leading to a competition of the dendritic network propagation at grain boundaries, has been the subject of many investigations. In particular, the study of Walton and Chalmers [2] is remarkable since it provides a link between the evolutions of the density and of the texture of columnar grains with increasing distance from the mold wall. Since this original work of Walton and Chalmers, two new tools have become available, which enable one to revisit the problem of grain selection in much greater depth. The first one is a fully automatic indexing technique of Electron Back-Scattered diffraction Patterns (EBSPs) [3-6] which directly gives the crystallographic orientation of the solid at any location of the specimen. Pole figures, orientation distributions, misorientations between grains can be visualized very easily with this technique. This information can be directly compared with the results of a second tool: a three-dimensional (3-D) stochastic model (SM) describing the nucleation and growth of grains in a uniform temperature field [6-9]. In order to extend this model to non-uniform temperature situations, a preliminary 2-D model has been developed [10]. It is based on a Cellular Automaton (CA) algorithm coupled with Finite Element (FE) heat flow computations. Since the details of both the automatic indexing technique of EBSPs and the simulation tools have already been published [3-10], only a brief summary is given here."

Jan 1, 1994

By John M. Boyle

The use of high vacuum mercury retort recovery as a safe and effective means of removing mercury from mercury hazardous waste solids rendering them non-hazardous and recovering mercury suitable for recycling.

Jan 1, 1995

By Stavros A. Argyropoulos, Henry H. Hu

"The assimilation of exothermic additions in liquid metals exhibit an array of unique coupled heat, mass and momentum transport phenomena. These phenomena are further complicated by the presence of a moving boundary.This paper describes a) A mathematical model which simulates the complex phenomena, and b) An extensive verification of the mathematical model. The SIMPLER algorithm was employed to solve numerically the pertinent partial differential equations. The computational results indicated that the exothermic heat of mixing led to a rapid increase in temperature around the moving boundary, which produced an enhanced convective flow in the liquid phase. The intensification of fluid flow around the moving boundary resulted in an acceleration of the melting process.Verification of the model was carried out in two contexts. The first was, in a low temperature physical model consisting of ice immersion in different sulfuric acid solutions. In this physical model, both temperature and velocity measurements were carried out. The model results were compared with experimental measurements and they were found to be in excellent agreement. The second context employed high temperatures, involving the assimilation of silicon in high carbon liquid iron. The model was also applied to predict fluid flow, heat and mass transfer for these high temperature experiments and a good agreement was obtained.In addition new dimensionless heat transfer correlations that quantify these complex phenomena will be presented."

Jan 1, 2001

By H. J. Garcia

Biodegradation of cyanide by microorganisms isolated from solids previously exposed to cyanide has been investigated. Initial sodium cyanide concentration was 300 ppm at pH 10.5. The kinetics of biodegradation were found to be first order with respect to cyanide concentration, and the overall reaction rate constant is k = 0.102 day-1. The activation energy and the frequency factor were determined to be { A }Ea = 5.45 Kcal/mol and A = 1.28 x 10-2 sec-1, respectively. Based on these values, thermodynamic properties of an intermediate activated complex were assessed. All tests resulted in cyanide concentrations less than 0.1 ppm in about 35 days at 250C, whereas at 350C the time of biodegradation to reach this cyanide level was 30 days. Kinetic data were also established to relate biodegradation to amount of inoculum. The maximum theoretically-attainable rate, Vm , and the optimum amount of inoculum, K , were determined to be 4.8 x 10-4 M NaCN/day and 7.5 % of amount of inoculum. With respect to the mechanism of biodegradation, cyanide was shown to decompose to carbonate, bicarbonate and ammonia. Titrimetric analyses revealed concentrations of 5.6 x 10-3, 4.8 x 10-3 M, and 70.2 ppm for carbonate, bicarbonate and ammonia, respectively. The average cell population was determined to be 3.75 x 108 cells/mL.

Jan 1, 1994

By Edgar Blanco

At the Deer Trail Mine, interest in recovering noble metals from oxide ore and tailings oxide ore with 6.0/1.0 g/t Au and 200/140 g/t Ag respectively has led to metallurgic studies focused on finding an adequate treatment for these materials. Using cyanide leaching, the silver/gold recoveries from oxide ore and oxide tailings were 39%/95% and 36%/96%, respectively. Since these recoveries were less than spectacular for silver, it was decided to explore a non-cyanide leaching process that would extract silver and gold better. Based on previous research the possibility of using aqua regia in combination with sulfuric acid was evaluated. On a laboratory scale, variables such as mineralogical composition, concentration of reagents, dissolved oxygen, reaction time, pH and temperature were evaluated. Under optimal conditions it was possible to achieve >65% silver recovery and >85% gold recovery for both oxide ore and tailings.

Jan 1, 2009

By Carlos G. Levi

"The principles involved in the rapid solidification of supercooled metal droplets and existing numerical models are reviewed. The limitations of these models for studying alloy solidification are discussed in terms of the effects of alloying elements on the relevant heat transfer, thermodynamic and kinetic parameters. Analysis of the enthalpy-temperature diagram reveals how the extent of rapid solidification is hindered by the addition of solute. A solidification model incorporating thermodynamic and kinetic relationships into a Newtonian heat transfer formulation is used to analyze the thermal history and concurrent solute redistribution during recalescence. IntroductionIt is well acknowledged that microstructural evolution during solidification is intimately associated with the thermal history of the liquid-solid interface. Structural parameters like chemical homogeneity, morphology and size scale of the phases can be related to the interfacial temperature and velocity. These in turn change by the interaction of the interface with the thermal and solutal fields in its neighboring environment.The thermal history of powder solidification can be conveniently described on the enthalpy-temperature diagram for a pure metal shown in Figure 1 and discussed in detail elsewhere [1). A system can conceivably follow any path of decreasing enthalpy in the supercooled region of Figure 1 (~ < 1), starting at the nucleation temperature (oN < 0) on the liquid line, and ending at some point on the solid line. A vertical path represents an isothermal transformation, of which a limiting case is solidification without significant barriers to nucleation and growth, with the interface at the equilibrium temperature TM (path one in Figure 1). A horizontal path represents isenthalpic (or adiabatic) solidification whereby the system could form an amount of solid proportional to the initial supercooling of the liquid without further heat loss to the environment. A liquid that can completely transform to solid under adiabatic conditions is said to be ""hypercooled""."

Jan 1, 1986

By Stanko Nikolic

Ferrous calcium silicate slags are potentially important for future practice in copper converting operations and processes and can be described by the ?Cu2O?-FeO-Fe2O3-CaO-SiO2 system. Despite its industrial importance the phase equilibria in this system have not been fully investigated. Characterization of this slag system is necessary to improve the design and optimization parameters of new processes, including fluxing and operating temperatures. Experimental methods have been developed to investigate the phase equilibria of these slags at copper saturation and without copper. This technique involved equilibration of samples at a fixed oxygen partial pressure, rapid quenching, and analysis of the compositions of phases using electron probe x-ray microanalysis (EPMA). Liquidus and solidus data are reported for the primary phase fields of spinel, wollastonite and tridymite at 1250oC and an oxygen partial pressure of 10-6atm. The resulting data has been used to construct liquidus isotherms in the ?FeO?-CaO-SiO2 system both in equilibrium with and without molten copper. The experimental results were compared with the predictions of a thermodynamic computer package utilizing a self consistent thermodynamic database. The predictions of the model were in good agreement with the experimental isotherms when projected onto the FeO-CaO-SiO2 section, however the copper concentrations in the liquid phase at copper saturation were lower than predicted using the current database of the model.

Jan 1, 2006

By Helena Byrdziak

KGHM Polska Miedz SA, in existence since nineteen seventies, operates three underground mines and three smelters with total production of over 400 000 mtpy of electrolytic copper. Its impact on the environment, very serious in the past, has been gradually reduced. While in general emissions into the air and water have been brought under control, attention recently has shifted to the disposal of wastes and residues. The main streams of wastes are flotation tailings, slags and dust captured from the dedusting systems. Much effort has already been expended and is still being spent to utilize this waste for by-products production or to dispose of it within the process by recycling. The most effective measures taken up thus far, as well as present activities directed at tailings disposal, are presented.

Jan 1, 1997

By Ashwini Kumar

Flame impingement on the burden is routinely encountered during the initial phase of melting in aluminum reverberatory furnaces. This impingement causes an obstructed pathway for the hot gases, and hence the circulation and residence time of the hot gases are greatly impacted. Moreover, as the load melts, the flames gradually achieve an unobstructed path leading to reduced gas residence times. This flame impingement and constantly changing combustion space volume will lead to vastly different fuel and oxidizer mixing patterns and thus affect the overall furnace performance. Fine tuning the burner operating conditions such as flow rates and injection angles with the changing combustion space could result in significant improvements to the furnace efficiency. However, one has to gain a better understanding of the furnace dynamics to know the suitable parameters to adjust. Physical modeling can be elaborate and expensive to conduct on a regular basis while Computational Fluid Dynamics (CFD) can cost-effectively address this challenge. In this study, the furnace model is created with a particular loading pattern to understand the flame dynamics in the presence of a piled load. This configuration can be thought of as a computational model of the furnace with the burden at a particular stage of the melting process. Thermal efficiency and behavior of the furnace are quantified and the predicted values are compared with the operational data from an experimental reverberatory furnace.

Jan 1, 2008

By Guozhi Lyu, Ting-an ZHANG, Biyu Long, Yajing Tian, Xuejiao Cao, Weiguang Zhang

Aim to the separation problem of high concentration V–Fe in stronger acidic leaching solution of vanadium slag, a novel chelating extraction system is proposed to separate V and Fe. Influence factors including initial pH value, the extractant concentration, the phase ratio, temperature and time are investigated. The experiment results show that single extraction rate of V and Fe reach 85.57 and 0.39% respectively, when pH value is −0.4, organic phase composition is 30% Mextral 973H + 70% sulfonated kerosene oil, O:A = 1:1, stirring time is 10 min, extraction temperature is 30 °C. The industrial experiment results of three levels countercurrent extraction show that the total extraction rate of vanadium and iron can reach 97.44 and 0.23%, separation factor is 6410. The effective separation of V and Fe in high acid and high iron solution can be accomplished.

Mar 1, 2018

By A. Siegmund, Gerhard Martin

The recycling of metal containing scrap is a common practice in the industry and has a long tradition. . In rec~nt years, this philosophy has been transferred to organic materials, in particular to thermoplastic polymers. BSB . Recycling GmbH, a company with a long experience in the treatment and recovery of lead from battery scrap,· had recognized this exploitation at an early stage and challenged it by a consequent continuation of the idea to recycle materials other than metals without degradation and maintaining the quality. These efforts resulted in an economic and environmentally acceptable solution producing high quality polypropylene compounds at BSB beside lead and lead alloys from battery scrap. The raw material fair the production of polypropylene compounds is shredded plastics from the separated casings of spent lead-acid batteries. The production of polypropylene with specific physical and mechanical properties is carried out by the accurate dosing of organic as well as inorganic additives. The result of the procedure is a novel product group "Seculene PP", a registered trademark of BSB Recycling GrnbH.

Jan 1, 2000

By W. G. Davenport

Inco flash smelting blows industrial oxygen, dried Cu"Fe-S concentrate, Si02 flux and recycle materials horizontally into a hot (-1500 K) furnace. Once in the furnace, the oxygen reacts with the concentrate by Reactions 1.1, 1.2 and 1.3 to give: (a) liquid matte, 55 to 60 mass%Cu (b) liquid slag, 1 to 2 mass% Cu (c) off gas, 60 to 75 volume % S02. The matte is tapped into ladles and sent to converting, Fig. 1.3. The slag is tapped into ladles, and sent to a stockpile; with or without a Cu-from-slagremoval step. The off gas is water-quenched, cleaned of dust and sent to a sulfudc acid plant. The [nco flash furnace is also used to recover Cu from molten recycle converter slag. The slag is poured&apos; into the furnace via a steel chute and water-cooled door, Fig. 3.1. In 2000 there are five Inco flash furnaces in operation: at Almalyk, Uzbekistan (Ushakov, et at. 1975); Hayden, Arizona (Marczeski and Aldrich 1986); Hudey. New Mexico (Belew and Partelpoeg, 1993); and Sudbury, Ontario (two furnaces, Carr etal, 1997, Humphris et ai, 1997; Molino et ai, 1997). The Almalyk, Hayden and Hurley furnaces smelt Cu-Fe-S concentrates. The Sudbury furnaces smelt Ni-Cu-Co~Fe-S concentrates&apos;to produce -45% Ni+Cu+Co matte and -1% Ni+Cu+Co slag.

Jan 1, 2001

By James Bennett, Jinichiro Nakano, Anna Nakano

Efficiency of the chemical looping combustion technology is adversely influenced by surface properties of oxygen carrier materials during oxidation–reduction process changes at elevated temperatures. In this work, natural hematite (Fe2O3) and alumina (Al2O3) supported Cu-spinel (CuFe2O4) oxygen carrier particles were isothermally exposed to redox gas cycles (air and 10 vol% CO–90 vol% Ar) at approximately 800 °C and studied using a high temperature confocal scanning laser microscope for real time alterations in surface morphology, roughness, and particle volume. 3D topological scans from each cyclic gas exposure indicated hematite particles exhibited noticeable volume expansion in reduction and shrinkage in oxidation, corresponding to respective phase transformations. Materials surface changes during the redox gas cycles are discussed.

Mar 1, 2017

By Moelans. N.

A method using an ex-situ electrochemical measurement device was developed to determine the oxygen potential of non-ferrous metallurgical slags. The electrochemical cell consists of the molten slag sample, an inert Ir electrode, a stabilized Zr02 solid electrolyte and a NilNiO reference electrode. Different slags from non-ferrous pyrometallurgical processes were analysed at I 100 and 1200 °C and pO2values between 10-3 and 10-12 bar were obtained. The measurements were evaluated with thermodynamic calculations and using processing considerations. It was found that the reproducibility and stability of the measurement was significantly improved by shielding the molten slag from the atmosphere by a thin layer of carbon, especially for slags with a low oxygen potential.

Jan 1, 2003

By Bora Derin, Adnan Aydin, Onuralp Yucel, Hakan Morcali

"The steelmaking industry which uses electric arc furnaces (EAF) generates approximately 250.000 tons of EAF flue dusts annually in Turkey. These flue dusts contain valuable metals such as zinc, iron and lead. For example, if these flue dusts can be treated efficiently, disposal problems certainly decreases and annually almost 40.000-75.000 tons of zinc can be recovered. In this study, powder and pellet forms of EAF flue dusts taken from a steel mill were carbothermally treated in a temperature controlled pilot scale rotary furnace via carbothermal reduction in order to investigate the reduction behavior of Zn and Pb. Temperature (900-1000 and 1100 °C) and time (0-90 minutes) were selected as reaction parameters. The chemical analysis was performed for the sample residues.IntroductionTurkey’s steel production reached to 23.3 million tons in 2006. There are three integrated steel plants of which capacities vary from 0.7 to 3 million tons per year and seventeen EAF steel plants of which capacities vary from 0.06 to 2 million tons per year [1]. When it is considered that more than 74 % of the Turkish steel production is produced by EAF method and approximately 10 - 15 kg of dust is formed per ton of steel during this process, the amount of annual generated EAF dust may be estimated at approximately 0.25 million tons. EAF dust which contains valuable metals such as zinc, lead, iron, cadmium, and chromium, is considered as hazardous waste product in steelmaking industry. If these flue dusts can be treated efficiently, not only the disposal problems certainly decrease, but also annually almost 40.000-75.000 tons of zinc can be recovered. Many studies which exist on recovering of the valuable metals from EAF dust, propose and practice many hydro-metallurgical and pyro-metallurgical treatments [2- 7]. In this study a laboratory scale work were performed to investigate reduction behavior of zinc and lead in EAF dust by carbothermal process in a rotary furnace."

Jan 1, 2008

By Steven C. Torma

The present article reviews some of the technologies available for recycling high-energy yield explosives loaded projectiles. These activities lead to reduction of military ammunition stockpiles and their conversion into commercial and industrial applications. The recycling technologies involve dismantling and separation of ammunition components into recyclable metals, plastics, paper and explosive materials. The metal 1 ic components will be sent to smelters, where they will be converted to products that can be used in a variety of industries, such as construction, automotive, housing and so on. Plastics and paper will be recycled and reused. Explosives will be recycled to be used for industrial purposes in the mining industry. Propellants (ammonium nitrate and ammonium perchlorate) can be ground to small particle size and treated to be used in the agricultural industry as fertilizer. In addition, some of the excess explosive material recovered in the demilitarization process may be incinerated to produce energy for steam production for heating purposes, or for production of electricity. Furthermore, this article reviews the developments in the bioremediation of explosive contaminated soils and industrial effluents.

Jan 1, 1994