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By Noel A. Warner

Modern steelmaking is based on direct use of oxygen in high intensity batch reactors. A totally new approach is proposed in this paper, based on the view that pursuit of high intensity is unlikely to lead to successful coal-based continuous steelmaking. By substituting carbon dioxide and water vapor as the oxidants rather than using oxygen directly, the intensity is greatly reduced. Accordingly, subsurface formation of carbon monoxide bubbles can be avoided by careful manipulation of the three participating rate processes, gaseous diffusion, interfacial chemical kinetics and liquid phase mass transfer. Steelmaking can then be carried out without explosive ejection of molten droplets and the generation of micro-spray but rather in a controlled and fume less fashion. The vital component is the introduction of generic melt circulation technology. Three melt circulation loops in series are envisaged. Starting with a composite feed of iron ore fines, pulverized coal and lime flux, a metallized solid raft floating on molten iron is propelled out of the ironmaking loop onto the first of two downstream steelmaking loops. In the first, a liquid slag is formed, primary decarburization is undertaken not with oxygen but rather with CO2 and H2O and the melt is desulfurized. The semi-product stream enters the third melt circulation loop, where open-channel decarburization is effected along with dephosphorization to yield a low carbon steel product. Alternatively, the melt leaves the last loop to irrigate a packed tower countercurrent to argon at around 100 mbar to continuously produce ultra-low carbon (ULC) steel.

Jan 1, 2003

By Yun Li

An innovative lead recycling process from scrap lead-acid battery paste is presented. The novelty in the process is avoiding SO2 generation and emission by using reductive sulfur-fixing technique. Iron-bearing secondary wastes produced from metallurgical industry were utilized as sulfur-fixing agent to capture sulfur in the form of FeS (s) instead of generation of SO2 (g). Na2CO3 molten salt was added to the smelting system to speed the reactions and improve valuable metals’ recovery and sulfur-fixation efficiency. Furthermore, this process can simultaneously co-treat various lead and iron-bearing wastes. At the same time, some precious metals, such as Au and Ag, contained in iron-bearing wastes can be recovered. The feasibility and reliability of this process was investigated thermodynamically and experimentally with the help of HSC 9.0 database and XRD and SEM-EDS analysis. A possible reaction mechanism and path in PbSO4–Fe2O3–Na2CO3–C smelting system was also clarified.

By D. Doungdeethaveeratana

The extraction kinetics in a novel solvent extraction process have been investigated. In this process, the liquid-liquid emulsion is generated by bottom gas injection into countercurrently flowing aqueous and organic phases. This process has a number of advantages over the mixer-settler unit or the spray column in terms of simple equipment configuration, without any mechanical moving parts, and the ease of cleaning and process control, while providing a sufficiently large interfacial area for rapid mass transfer. The overall rate increased with increasing gas injection rate and height of the aqueous phase but decreased with increasing injector diameter at the same gas injection rate. The variation of the overall rate constant was correlated against a set of dimensionless numbers, representing the operating conditions. Extraction rates and efficiencies comparable to those in a mechanically generated emulsion were attained in this new process.

Jan 1, 1998

By J. Grogan

Leaching of galvanized steel coatings allows the steel substrate to be used as a zinc-free scrap source to steel and iron furnaces. In this study the behaviors of sulfuric acid leaching solutions are investigated. The ranked significance of the variables are shown to be acid concentration > temperature > zinc concentration. Examination of the leaching mechanism finds the rate-limiting step to be the cathodic hydrogen reduction reaction. This rate is not only influenced by acid concentration, but also by the hydrogen reduction exchange current density. Dezincing leaching rates are improved by taking advantage of the higher exchange current density of the iron substrate versus the zinc coating. This is accomplished in practice by increasing the exposed interfacial zinc:iron surface area through shredding. Also, a leach control mechanism is proposed through online monitoring of the zinc-iron couple mixed potential.

By Liang Sha

In this study, adsorption of copper by chemically modified orange peel was investigated. A conspicuous change occurs in the surface morphology of the biomass due to modification, which is depicted by SEM images. Equilibrium isotherms and kinetics were obtained and the effects of various factors, including solution pH, contact time, initial metal ions concentration and temperature, were studied by batch experiments. Kinetics was found to be best-fit pseudosecond- order equations. Equilibrium was better described by Langermuir isotherms rather than Freudlich isotherms. At 25?, pH5.30, the maximum adsorption capacity was 70.67mg?g-1 . With increase of temperature, adsorption efficiency decreased. The biosorbent was suitable for repeated use for more than five cycles.

Jan 1, 2009

By B. R. Davis, Neale R. Neelameggham, R. E. Brown

The element Calcium element has a unique place in the production of etals, intermetallics and other compounds. The unusualness arises from the fact that we have several possible reductants – metallic calcium, calcium carbide, calcium cyanamide and calcium hydride. A review of how metallic calcium is manufactured and utilized is presented. The difficulties involved in producing the metal in large quantities and price implications are noted. . Fundamental thermodynamics of how these act as reductants are shown, along with the historic application of these in metal production during the past century and a half. Alternate applications as to how to control the cost of the reductant is indicated, such as the numerous attempts in making low cost titanium utilizing direct or indirect calcium reductant.

Jan 1, 2014

By Anne Kvithyld

Silicon solar cells, that convert the energy of sunlight into electric energy, are attractive sources of energy. In the production line wafers of solar cells are sliced from a multicrystaline ingot solidified unidirectionally. Recycling scrap from top and sides of such ingots is addressed. SiC and Si3N4 inclusions are a major problem. Scrap from Scan Wafer ASA is melted in a high vacuum furnace at around 1500ºC. The filters, from commercial producers, are C and SiC with 10, 20 and 30 ppi. Characterisation of inclusions before and after filtration, and in the filter itself, is performed by microscopy. Dissolution of silicon in acid and counting of the un-dissolved inclusions is also carried out. In the filter Si3N4 needles and SiC inclusions were identified. The amount of these inclusions in the filtered silicon is much less than in the input. In conclusion, filtration using SiC and C filters in vacuum system in argon atmosphere removes SiC and Si3N4 inclusions from solar cell scrap. Flow of metal through the filters is not a problem. These results are promising with scale-up to industrial application in mind.

Jan 1, 2006

By Guohua Bai, Mingjun Rao, Jianchen Lim, Guanghui Li, Tao Jiang

"By using thermogravimetry, optical microscope and chemical phase analysis, the solid-state reduction of carbon-burdened chromite pellets in the absence and presence of additives were investigated. The effects of reduction temperature, reduction time and additives on the metallization of chromite pellet were studied. The results indicate that the pre-reduction ratio of carbon-burdened chromite pellets is improved with the increase of reduction temperature and the addition of additives. The metallization of chromium is increased from 63.9% to 92.8% at 1300 °C for 4h with the addition of 2 wt.% of sodium borate. Investigation suggests that the reduction of carbon-burdened chromite pellets is diffusion controlled. The apparent activation energy without additive is 192.1 kJ/mol, while it decreases to 170.4 kJ/mol in the present sodium borate.IntroductionFerrochrome is used to produce high strength, corrosion resistant, wear-resisting, high temperature resistant and oxidation resistant special steels, and it is becoming one of the most important alloy materials for the production of stainless and high alloying ferritic steels [1-5]. Demand for ferrochrome is steadily on the rise due to the growth of stainless steel industry. Nowadays, more than 80% of the world's ferrochrome is utilized in the production of stainless steel [6-7].Ferrochrome is mainly produced in submerged-arc furnaces (SAF) with chromite lump ore. However, lump ore merely accounts for 20% of the chromite ore output, while fine ore (< 8 mm) accounts for about 80% [8]. Therefore, agglomeration of chromite fine ore is necessary before charging into SAF."

Jan 1, 2011

By H. Y. Sohn

The considerable progress made in the sulfide smelting technology since the first International Sulfide Symposium of 1983 is discussed. The new developments and innovations have largely been driven by the recognition of environmental concern as well as the need for increased productivity. The smelting technologies for various nonferrous metals are reviewed, with an emphasis on the industry trend towards larger plants and continuous processes. The tremendous advances made in process modeling and computer simulation to describe the complex smelting processes are also reviewed. The goal of these mathematical models is the quantitative description of the processes and the reactors that will provide a means for the control and optimization of smelting operations as well as the optimal design of the operating conditions and the reactors. Environmental issues remain a key consideration in the smelting industry. One of the most remarkable improvements made in the last fifteen years since the 1983 Sulfide Smelting Symposium is the rapid increase in the sulfur capture by nonferrous smelters. This and other related issues are briefly discussed. Finally, the challenges that the smelting industry faces as the new millenium approaches are discussed. The industry continues to face technical challenges to improve productivity and efficiency, while being responsive to ever-increasing public pressure for environmental protection. It also faces external challenges from factors that may cause the reduction of metal uses as a result of substitutions by other materials. Another serious challenge and dire consequence that the primary metals industry is expected to face is the serious diminution of university-educated manpower as well as basic-research output. To remain competitive and healthy, the industry should take up the void left by the complete disappearance, at least in the U.S., and the reduction in other nations, of the governmental support of higher education and basic research in the field of primary metals production.

Jan 1, 1998

By K. Morsi

Carbon nanotube (CNT) reinforced metallic composites have been recently generating significant scientific interest, due to their expected superior properties compared with other composites. Out of the metallic matrices investigated for reinforcement with CNTs, aluminum has received considerable attention. A major problem has been the dispersion of CNTs in metallic matrices. This paper discusses preliminary results on the mechanical dispersion of CNTs in aluminum powder, powder processing, stability and characterization of aluminum dispersed with CNTs at reinforcement levels equal to and below 5 wt.%.

Jan 1, 2009

By Nikhil Dhawan

Electronic waste (e-waste) is a collective name given to discarded electronic devices such as Television, Cellular Phones and Personal Computers. Among the heterogeneous metals present in the e-waste are the base metals: copper, aluminium, nickel, tin, zinc, iron and precious metals: gold, silver, palladium, platinum apart from several hazardous and halogens metals. Hence there is a need to recover these metals from electronic scrap by recycling and then re-use, which can meet large amount of metals demand. Hydrometallurgical processing was employed for the recovery of metals from television printed circuit board (TV PCB). Different lixiviants such as hydrochloric acid, Sulphuric acid, and nitric acid were used to understand the dissolution behavior of copper, iron and lead present in the TV PCB. Effect of increasing concentration of nitric acid was also studied. Selective recovery of tin over 95% in the form of tin oxide was precipitated. The precipitated tin oxide was identified by X-ray diffraction technique. Tin oxide of purity more than 99.9% was obtained.

Jan 1, 2009

By Art Cooper

Granulation systems are common in the metals industry. The process of granulating slags, mattes and metals is more than a century old, and a number of different systems have been developed to accomplish this task. These systems have followed an evolutionary path, and may be characterized by common elements in terms of molten material handling, granulation methods and post-granulation processing. This paper will summarize the more common systems used in the metals industry, with particular reference to non-ferrous applications.

Jan 1, 2006

By Ragnhild E. Aune, Mark William Kennedy, Shahid Akhtar, Jon Arne Bakken

"To determine the heating rate of billets using ‘short coils’, an appropriate correction factor must be applied to the theoretical relationship. In 1945, Vaughan and Williamson published a semi-empirically modified Nagaoka coefficient applicable for moderate frequency induction heating processes (10 kHz). Recently it was demonstrated that the method of Vaughan and Williamson gives <10% error in the estimated power when heating aluminum billets at 50 Hz.In the present study, experiments have been conducted on aluminum billets in order to verify an empirical frequency corrected ‘short coil’ equation. Measurements of electrical conductivity (<± 0.5%), current (± 1%), heat (± 1-3%), and magnetic flux density (± 1-2%) have been performed. The results are compared with 1D analytical calculations, and 2D axial symmetric FEM modeling using COMSOL 4.2®. The frequency corrected equation has proven to provide accurate predictions of power (<4% error) within the frequency range 50 Hz to 500 kHz.IntroductionInduction heating is commonly applied to the re-heating of billets before forging or extrusion processes. The resistive heating produced by eddy currents in the solid or semi-solid work piece during this procedure, is driven by the time varying magnetic flux density in the air-gap between the work piece and the coil. The flux in the air-gap is created by the current flowing in the induction coil, i.e. the magneto-motive force. In Figure 1 it can be seen that the currents present in the work piece are concentrated in the outer ‘shell’, or the first electromagnetic penetration depth (dw), and flow in a direction which opposes the magnetic field produced by the induction coil."

Jan 1, 2012

By Neale R. Neelameggham

"Ferrous and non-ferrous metal industries are used to handling several billion tons a year of ore bodies, fuel and fluxing agents by mineral processing techniques and varieties of extractive metallurgy ""Reduction"" processes. Metal industry know-how can be applied to meet the challenge of Reducing CO2 in the atmosphere. Processes for generating alloys of carbon and hydrogen by Reducing the CO2 and water mixture, [carbonated water or water vapor] called Soda, to easily stored fuels are normally endothermic. The processes are similar to generation of hydrogen alone from water which is also endothermic. But hydrogen is more difficult to store than compounds [or alloys] of carbon and hydrogen. This recycling of CO2 and water are possible by using other forms of energy by innovative carbon capture methods.Thermodynamic Diagrams developed for Soda [CO2 and H2O] - metal reactions provide hints for using low cost unused stored energy in un-recycled metallic waste for thermal conversion. Choices for conditions for the electrochemical approaches [using solar - wind - hydropower] are also discussed.INTRODUCTIONIn 2006, I was reading some of the arguments put forth by learned scientists on the benefits and lack of benefits of bio-fuels. I found that the arguments rose partly from the differing system boundaries that were chosen by one versus the other. Some part of the argument may have been based on political climate or atmosphere rather than the analytical science. This situation is seen when scientists discuss which came first - the chicken or the egg, the fuel or biological matter, the oxide or the element, and so on.Then I thought –[just like many of the learned persons participating in this symposium] that common fuels - regardless of them being simple hydrocarbons or oxygenated hydrocarbons or carbohydrates - can all be made from the respective oxides of carbon and hydrogen by simple chemical reductions efficiently carried out in an economical fashion. This is the systematic approach we take when designing a chemical or metallurgical process facility."

Jan 1, 2008

By Harrison Cooper, Stephen Pack

"Data from samples taken during rotary air blast and reverse circulation drilling are crucial to properly assessing economics of mineral deposits in the case of exploratory work, and are equally critical in accurately delineating ore and waste in execution of mine operation plans. Past studies of sampling procedures, comparing results of conventional splitting to more precise extraction of representative samples, illustrate the significant degree of error frequently encountered. Economic impact of error in mine blast hole sampling work can be shown to result in theoretical losses valued at millions of dollars annually in operating large scale mining projects. Results of past drill sampling studies are reviewed.Drill sampling technique can be improved by collecting coarse and fine particles together and extracting samples for assay from the complete flow of rock and dust simultaneously. This can be accomplished with a collection unit attached to the drill stem through which all except a small proportion of extreme fines are retained. The bulk mass can be static sampled as flow takes place through the collector when size reduction is not required. Alternately, collected mass with fines and coarse intermingled can be processed for increased accuracy through size reduction to obtain proportional samples."

Jan 1, 1999

By D. Morin

A general study of gold refractory arsenopyrite-pyrite concentrate bioleaching has been carried out including two continuous bioleach testworks at different sizes, namely one at a laboratory scale with a 100 I unit at a 2 kg/d dry solid flowrate and the other at a pilot scale at a 100 kg/d dry solid flowrate. Both tests show a 80% bioleaching of arsenopyrite in about four days of treatment and with the same kinetic. Pyrrhotite is attacked at the earlier stage of the bioleaching but pyrite remains unaffected. The weak potential of oxidation associated with the decomposition of arsenopyrite and the abundance of arsenite leads to a high grade of elemental sulfur in the bioresidue which consumes the major part of the cyanide during the gold recovery. Furthermore. the arsenite and ferrous produced in solution have to be oxidized to obtain a stable precipitate in the waste products and as outlined in previous works of other authors on this subject the addition of iron to obtain a Fe/As molar ratio at least above 3 is necessary. The agitation equipment used in the pilot unit allowed an optimization study calculation for scaling-up the design and power requirements of an industrial installation. For the pretreatment of a gold refractory As high-graded concentrate the reagent cost has the greatest part in the operating cost of the biooxidation step due to the necessary retreatment of the biosolution. In that conditions the power cost is quite marginal. actually it is significant for the treatment of pure pyrite.

Jan 1, 1991

By Peter Olubambi, Babatunde Obadele, Oluwagbenga Johnson

"The microstructure and corrosion behaviour of titanium carbide (TiC) reinforced duplex stainless steel matrix surface composites synthesized by laser melt injection technique was investigated. The surface melting operation was conducted using a 4.4 kW CW Nd:YAG laser with laser power of 1.5 kW, scanning speed of 0.4 to 1.0 m/min, beam size of 3 mm and argon shield gas flow rate of 4 L/min. The morphologies and microstructures of the coatings examined using field emission gun scanning electron microscope (FEGSEM) revealed homogeneous distribution of fine precipitates of TiC in the matrix, while X-ray diffraction (XRD) analysis confirm no phase change. TiC addition to the steels significantly increased hardness value to about 547 Hv0.1 but slightly decreased the corrosion resistance of the steels in 3.5% NaCl possibly due to the intergranular carbide coating that prevented chromium from forming continuous passive oxide layers.IntroductionComposite materials evolve from the idea of combining two basically dissimilar materials with different physical and mechanical properties to arrive at a product whose final properties are superior to those of the individual components [1]. Metal matrix composites (MMCs) are receiving much attention and are the focus of intense research and development worldwide for aerospace, automotive and other applications because of their excellent combination of ductility and toughness of the metallic matrix with high hardness and strength of carbides reinforced in the matrix [2]. Surface modification techniques such as laser, thermal spray, plasma spray, chemical vapour deposition have been use to fabricate MMCs. Laser melt injection (LMI) is a surface modification technique known since the 1980s [3] has been used to improve surface properties of metallic alloys such as aluminium, titanium and steels [4-6]. It involves the lateral injection of carbides, ceramics and cermets blown by a gas stream into a liquid metallic pool, created by laser irradiation of the top surface of the base material."

Jan 1, 2012

By M. Bilal Khan

Thermal stress relief by means of a typical heat treatment cycle (660oC for one hr) is compared with the one achieved through vibratory stress relief at resonant and multiple resonant frequencies for the D-406 HSLA material. Our analysis of the data is based on the microhardness profiles measured for the entire length of scales, namely, base metal, heat affected zone (HAZ) and the weld bead itself. The profiles obtained using the two techniques mimic each other, for an equivalent 70% stress relief level. The data are further qualified by impact testing wherein the zone of interest is projected in the retention groove to provide impact by the pendulum striker in the Charpy mode. Higher equivalent energy absorption in the treated specimens confirms the efficacy of the vibratory method. The present work rectifies earlier anomaly where heat treatment has been reported at 310oC for the same material.

Jan 1, 2009

By Zhang Chuanfu

Keywords: modified coprecipitation method, Ni-Co alloy powders, solid-solution oxalate, growth mechanism Homogeneous solid-solution oxalates of Ni2+ and Co2+ ions were synthesized by modified coprecipitation method and the composition and morphology of the fibrous solid-solution oxalates precursor were characterized by XRD, IR, DTA/TG and SEM analysis. The effects of feeding methods, pH values, precipitation temperature, reactant concentration, addition surfactant, alcohol washing and drying process on the morphology and dispersion of the precursor were investigated in detail. The experimental results showed that the coprecipitated powders have characteristics that are different from those of the mechanical mixtures with the same stoichiometry. Based on the observations of precursors growth and SEM morphology of the precursor, the oriented attachment was proposed for the well-aligned growth of the fibrous Ni-Co alloy precursor particles.

Jan 1, 2005

By Paul-Dominique Oudenne

For many years, CMI NESA has gained considerable experience in the field of alternative thermal processing processes by which useful by products result in addition to the destruction of the raw wastes. The CMI NESA pyrolysis process has been extensively applied to a wide range of sewage, industrial sludge and residues. This paper describes in details the development works carried out at the pilot stage as well as the key parameters of the process. Some of the industrial realisations are briefly described, the most recent one being the erection of a sludge pyrolyser on predried sludge at 90% dryness of a capacity of 100 tons of dry matter per day for the Valenton plant of the SIAAP (city of Paris).

Jan 1, 2006