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By John E. Litz

The Denver Process is a chemical/metallurgical process for treating radioactive or mixed wastes by extraction and concentration of the radioactive and/or hazardous component(s). The process was developed at bench scale, evaluated at pilot scale, and will be implemented at full scale to remediate a low-level radioactive sludge. Six unit operations comprise the process: feed handling, leaching, solvent extraction, electrodeposition, precipitation, and tailing preparation. Unit operation design may be modified to tailor the process for varying feed stock composition. Radioactive or mixed waste is reacted with aggressive reagents in an aqueous phase, solubilizing targeted components. These components are then selectively extracted and concentrated in subsequent steps. Waste solids and solution exit the process as non-hazardous non¬radioactive waste. Dehydration of aqueous waste by submerged combustion eliminates aqueous discharge.

Jan 1, 1994

By Tibor Zoltai

Asbestos is a generic term for industrially useful fibers recovered from exploitable deposits of the asbestiform varieties of five silicate minerals: chrysotile, anthophyllite, actinolite-tremolite, cummingtonite-grunerite, and riebeckite. Asbestos and asbestiformm fibers of some other minerals are known to be carcinogenic. Minerals crystallized in the asbestiform habit are characterized by unique properties (morphology, strength and flexibility, physical and chemical durability, and defect-free surface structures). The key to the unusual properties, and health effects, of asbestifarm fibers appears to be in their unusual surface structure. In contrast, non-asbestiform crystals of the same minerals, including the five so-called asbestos minerals do not have these properties and are not carcinogenic (1, 2).

Jan 1, 1989

By Alan P. Prosser

The heap leaching of gold ores by cyanide solution was simulated by computer program. The program uses only basic m1neralogical and chemical data; no process testwork data, such as column leach results, are required. The simulation can be used to forecast the consequences of various changes before and during the testwork, design and operation stages of a particular ore-process system. Also, data about the state of different parts of the heap at various times help create an understanding of what is happening. The effects of mineralogical and process variables on the overall performance of the ?heap leaching process are illustrated. Comparisons are made to column leach tests and production data. The potential of the simulation strategy is discussed for making better use of operating experience and for suggesting specific research objectives. It has become clear that more attention should be paid to other metals that dissolve in the solution.

Jan 1, 1989

By Nobuo Takahashi

Effective solvent extraction media have been investigated for purification of rare earths. At first, a quaternary ammonium compound was studied. The counter anions of rare earths and organic dielectric substances were tested to improve separation factors,. And second, crown ethers were selected for extractant. Several diluents of crown-adducts were tested to improve solubility and distribution coefficient as well as the counter anions of rare earths. Especially, in the presence of strong reducing agents, highly selective extraction of europium from other rare earths was observed. The third extactnts were ß -diketones. Presence of organic dielectric substances was very effective to improve separation factors. Though those. three groups of extractants were suitable for mutual separation of light rare earths, alkyl esters of alkyl-phosphonic acids were suitable for mutual separation of heavy rare earths because of their high separation factors. To keep proper pH value was necessary for acidic extractants, so control method of the solution pH was studied with high molecule insoluble amines or salts of those.

Jan 1, 1995

By Bryn Harris

Much has been written over the past twenty years on the removal and chemical stabilization of arsenic from metallurgical process solutions. This paper reviews again the latest developments in this field, and concludes as before that the high-iron arsenical ferrihydrites, together with the high temperature arsenic minerals, scorodite and Type II, remain as the best and most viable vehicles for industrial control and disposal. However, a cautionary note is introduced, in that chemical environments cannot be considered in isolation, and that cogniscence has to be taken of microbiological activity in determining the disposal method. Data are also presented on a survey of industrial practice, which shows that arsenical ferrihydrite is by far the most widely-practiced and accepted method used worldwide. Finally, the disaster in Bangladesh is briefly discussed with reference to lessons that the metallurgical community might learn from this.

Jan 1, 2003

By Craig A. Johnson

Cyanide speciation and behavior have been examined at three active heap leach operations, three heaps undergoing rinsing, and three sites with cyanide contaminated groundwater, all in the southwestern U.S. Data from these studies demonstrate that strong cyanometallic complexes of iron and cobalt can play ?an important role in cyanide behavior throughout the lifetimes of heap leach operations. In active circuits, we find evidence that significant amounts of cyanide combine with iron and cobalt to form strong cyanometallic complexes, and that these species can be adsorbed, probably onto iron hydroxides, or precipitated as insoluble cyanometallic compounds. When spent heaps are rinsed, the release of this cyanide is likely controlled by the slow kinetics of desorption from, or dissolution of, solids that have gone largely uncharacterized. We find evidence that strong cyanometallic complexes can give rise to transient free cyanide in some settings by rapid photo dissociation where heap rinse effluent is exposed to sunlight in open channels or translucent sample bottles. Thus, these species can complicate the ,preparation of spent heaps for decommissioning, even where regulatory standards ?are based on weak acid dissociable cyanide. There is a critical need for information on the form and stability of adsorbed and precipitated cyanide in spent ore heaps, on the concentrations of strong cyanometallic complexes in mineral processing effluents -particularly the complexes of cobalt, and on the natural attenuation of iron and cobalt cyanometallic complexes in both surface and subsurface waters.

Jan 1, 1998

By F. T. Principe

In order for solvent extraction technology to be acceptable as an alternative to existing jarosite precipitation circuits, iron must be cleanly separated and concentrated into a feed stream suitable for downstream iron by-product recovery which meets market specifications and economics. Ten years ago, significant progress was made in a joint McCill University/CANMET project that involved iron extraction with mono(2-ethylhexyl) phosphoric acid and stripping with HCI. Our iron solvent extraction research was reactivated recently by looking into this and other members of the organophosphorus extractant family. Our research focuses on the mechanisms and control of anion (SO42/CI) transport across the various phases (Rafinate/Organic/Strip), iron build-up in the strip liquor, and extractant stability/selectivity. In this paper, these issues along with some other performance parameters are discussed using data derived from an extensive search of the two commercially available and best known members of the organophosphorus family, di-2-ethylhexyl (D2EHPA) and mono-2-ethylhexyl (M2EHPA) phosphoric acid. Further in this discussion, the challenges lying ahead in the development of sx systems that overcome the deficiencies of D2EHPA and M2EHPA are outlined. In particular, the necessity of considering secondary separation technologies that can further concentrate iron values in the chloride strip liquor to levels economically attractive for the production of saleable iron oxide by pyrohydrolysis is addressed.

Jan 1, 1998

By Ann E. Visser

Aqueous Biphasic Systems (ABS) form upon the admixture of certain water-soluble polymers or polymers and salts above critical concentrations, and thus represent liquid/liquid extraction systems whose nature is entirely aqueous. We are currently investigating the utility of ABS (and its solid phase analogs) as "green" alternatives to the use of volatile organic diluents in separations of metal ions. Chaotropic (water-destructuring) metal ions with small negative AGhyd (e.g., Tc04) tend to partition quantitatively to the PEG-rich phase of an ABS, but even hydrated metal cations can be partitioned to the PEG-rich phase if a suitable extractant (e.g., halide, dye, crown ether, etc.) is used to produce a more chaotropic ion-complex.

Jan 1, 1999

By R. Burkhard

Recovery of metals from complex mixed wastes is a challenging task of modem material and waste management strategies. Thermal methods are an important tool in this respect. Plasma turned out to be particularly useful for treatment of complex or toxic wastes and residuals. In order to study plasma processes at reasonable costs, a pilot plasma plant has been used and wastes like ~pent Raney-Nickel catalysts, copper and ah.:lminum drosses, and. other metal containing wastes were investigated. The paper summarizes the most significant findings

Jan 1, 1995

By E. T. White, Dean Ilievski

"The population balance is one of the basic relations for analysing particulate mineral processing operations. It is an exact relation. The principles of the population balance are reviewed and applications in the minerals industry discussed.IntroductionMathematical modelling has proved to be a very successful approach for improving the design and performance of mineral processes, particularly since the availability of computers to handle the complexity usually necessary to give a useful model.Mineral processes almost invariably involve particles, as either solid fragments, liquid drops or bubbles. Process performance usually is highly dependent on the behaviour of these particles. In modelling particle behaviour, the basic relation to be used is the population balance. This paper discusses the role of the population balance and the range of its applications in minerals processing.The Population BalanceThe population balance was developed for demographic studies, ego predicting the change in the population (numbers) of, say, school children between one census and the next. The first sustained application to the processing industries appears in the 1960s for crystallization. However it was recognised almost immediately that it had application to all particulate processing."

Jan 1, 1996

By Takahiko Okura

Sulphur, with its multiple oxidation states, play critical roles in many processes, ranging from regulating enzymes in plants, to acidifying aquatic systems, and to affecting the global climate. Most of non-ferrous smelters have been contributing to reduce atmospheric emissions of sulfur dioxide to acceptable levels, converting it to sulphuric acid and/or gypsum. However, some amount of SO2 gas is still emitted from isolated smelters. Furthermore, sulphuric acid is competing with involuntary elemental sulphur in the market. This situation puts the non-ferrous metallurgical industries to develop a new sulphur fixation process. This paper briefly describes the new technologies for fixation, followed by the novel proposal to convert SO2 gas to elemental sulphur using organic materials. Finally, the feasibility will be presented technologically and economically.

Jan 1, 2006

By Mostafa O. El-Bealy

"To estimate the interdendritic cracking tendency in casting processes, a new model for interdendritic cracking criteria has been proposed. The model combines a concept of the alloying element effect on the interdendritic strain generation and therefore on the susceptibility of interdendritic cracking phenomena. A susceptibility of interdendritic cracking is modeled by using El-Bealy's interdendritic cracking susceptibility function ""BJCSF' and the opening displacement between the dendrites ""EIA "". These concepts are modeled based on the previous experimental observations and ElBealy' approach. The model is implemented numerically for a one-dimensional model problem with some similarities to the casting of steel. The variation of some key parameters that are known to influence the frequency and severity of the interdendritic cracking is then studied.I. INTRODUCTIONInterdendritic cracking ""hot tearing"" commonly encountered in both ferrous and nonferrous castings (1,2]. It is generally believed that interdendritic cracks start to nucleate and develop in the interdendritic strain region within the mushy zone [l-5]. The interdendritic strain region is then definitely coherent, but continuous films of liquid still exit (4,5]. This distinguishes interdendritic cracks from cold cracks forming during the casting process after complete solidification (6,7].Much effort has been put into the understanding of the interdendritic cracking phenomena, and several theories have been proposed. Fellini [8] stated that interdendritic crack ""hot tear"" will result if the material is subjected to too high of accumulated strain within so called vulnerable part of the solidification interval. Kinosita et. al. [9] and Campbell (10] also emphasized the role of tensile stresses in the forming of interdendritic cracks. Most interdendritic cracks criteria simply consider the size of solidification interval, stating that solidification range is associated with a lager interdendritic cracking susceptibility than a short range. Clyne and Davies (11] formulated a more refined such criteria based upon the time spent in different regimes of the solidification interval. They defined a vulnerable region in which thin continuous films of interdendritic liquid exist, and the permeability is low. When thermal strains are induced in this region, the film is not able to sustain the stresses, and an interdendritic crack will form."

Jan 1, 2001

By Akira Yazawa

The similarities and differences in copper, nickel and lead smelting processes are discussed based on the sulfur-oxygen chemical potential diagrams and the free energy minimization assessments using a thermodynamic software. The prominent features of copper smelting are ascribable to the fact that copper has a strong affinity for sulfur but weak for oxygen and the liquid phase immiscibility between Cu and Cu2S. During the oxidation of sulfides, nickel metal is not stable except at temperatures higher than 1500°C, well miscible with its sulfide, and is oxidized more easily than copper. Metallic lead looks as stable as copper during the oxidation of the concentrate but Pb and PbS. are much more miscible with each other and the vaporization loss is considerable. In the reductive smelting of oxides, the effects of oxygen potential and temperature on the copper contents in slag are not significant due to the monovalent character of copper and the reduction of copper content in slag is not easy in practice. The effect of the slag compositions on the oxidic metal contents of slag is much more significant for lead than either copper or nickel. Due to the immiscible nature between Pb and Fe, high grade lead bullion is easily obtained and lead is more tolerant to impurities.

Jan 1, 1998

By E. T. White

The population balance is one of the basic relations for a:n:aIysing particulate minera1 processing operations. It is an exact relation. The principles of the population balance are reviewed and applications in the minerals industry discussed.

Jan 1, 1996

By Florian Kongoli

Non-ferrous smelting slags .can contain magnesia, which substantially increases the liquidus temperature. One option to counter this increase is to flux with calcia. In this work, experimental liquidus measurements including new measurements on industrial slags have been compared with a FACT-based thermodynamic model, which predicts the liquidus surface of multi-component iron silicate smelting slags containing both magnesia and calcia. The predictions, which agree well with experimental results, are summarized in both isothermal and non-isothermal diagrams to give a quantitative description of the liquidus surface.

Jan 1, 1998

By Avijit Moitra

The behavior of the solidifying shell in the early stages of solidification has an important influence on the final quality of continuously-cast steel slabs. In order to understand the thermal and mechanical behavior of the shell, a two-dimensional transient piecewise-coupled finite-element model has been developed. The model simulates a transverse section of the slab as it moves down through the mold and incorporates the effects of heat conduction, solidification, shrinkage, turbulent fluid flow, thermal distortion of the mold and the visco-plastic behavior of the steel. Coupling between the thermal and the mechanical model is based on the mutual dependence of heat transfer across the interface between the shell and the mold and the size of the gap. The effects of mold distortion and taper on the gap size are also included. The effect of fluid flow has been incorporated via a heat flux imposed at the solid-liquid interface, which is obtained from a separate fluid flow model. The high temperature creep and plasticity of the steel is incorporated through a unified constitutive law defining the inelastic strain rates as a function of temperature, time and stress state. The model can be applied to various problems in continuous casting, such as the formation of surface defects and the design of mold taper.

Jan 1, 1992

By David B. Dreisinger

Mass and heat balance modeling is a powerful tool for the design and analysis of hydrometallurgical process flowsheets. In this first of two papers, we examine the basic fundamentals of mass and heat balance modeling, and apply these concepts to several flowsheets using a simple spreadsheet model. In this way, we aim to demonstrate how such models are not only easy to construct, but can also be indispensable for comparing various flowsheet alternatives, for making rational economic decisions, and for developing a basic understanding of existing process behaviour.

Jan 1, 2002

By Mike Trovant, Stavros A. Argyropoulos

"A fixed grid numerical model for phase change problems is proposed. The model solves for heat transfer and fluid flow, via the coupled solution of the energy, continuity and momentum equations. In addition, the numerical scheme accounts for temperature varying thermophysical properties and determines the shrinkage profile resulting from phase and density change. Simulations are run to determine the effect of varying model parameters and wall cooling rates on the location and shape of the shrinkage void formation in cylindrical casts. Results are shown for both aluminum and magnesium.IntroductionThe mathematical modeling of phase change processes (be they solidification or melting problems) entails solving for many interrelated phenomena. A comprehensive numerical simulation of the casting of a metal, for example, would have to account for: (a) heat transfer in both the solid and liquid portions of the metal and in the mold, (b) the release of latent heat during phase change, (c) fluid flow behavior in the liquid portion of the metal, (d) temperature induced shrinkage caused by liquid contraction and solidification contraction, and (e) the development of thermal stresses with accompanying shrinkage in the solid portion of the cast and mold. A schematic of the relationships that exist between the coupled equations which govern solidification is shown in Figure 1."

Jan 1, 1994

By Cameron Hams

Noranda's Process Reactor and Codelco's Teniente Converter are physically similar vessels, which leads to the commonly held misconception that the two processes are the .same. However, notable differences in chemistry, operating philosophy, and construction make them quite dissimilar. This paper compares and contrasts the Noranda Reactor and the Teniente Converter, and attempts to explain some of the apparent differences in behaviour and performance. The results of a worldwide survey of most operating Noranda Reactors and Teniente Converters, along with those processes that have ceased operation or are planning to be started-up in the future, are presented.

Jan 1, 1999

By P. Regan

Following the introduction of the Contilanod process over 10 years ago at Copper Range and IMI Refiners, significant changes and advances have been made to this pioneering anode production technique. A new radial flow metal feeding concept has been developed that allows a substantial increase in casting rates on the Hazelett® twin-belt caster. To cut the 45 mm thick continuous anode plate into shaped anodes at rates of 100 t/h or more, a filly moving hydraulic shear designed by Mannesmann Demag has replaced the slower speed plasma cutting torch. Details of the.new caster and shear are presented along with operating results from the new lines starting up in 1999 at the Gresik smelter/refinery in Indonesia and the completely revitalized Mansfelder Kupfer und Messing complex in Germany.

Jan 1, 1999