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By J. Bostjancic

As wastewater discharge regulations become more stringent, power plants, manufacturing plants and other industrial sites are looking for ways to reduce makeup water requirements and to recycle and reuse as much wastewater as possible. In some cases, environmental regulations require zero liquid discharge, meaning all wastewater must either be retained on site or reduced to solids for disposal off site. Zero liquid discharge or "closed-loop" wastewater treatment systems using evaporators and other process equipment have been well-accepted in recent years. Often overlooked is the fact that zero discharge is not just the latest fashion--many commercial zero liquid discharge systems have been in operation since the mid-70's. This paper will give specific examples of zero liquid discharge operations from 1974 to the present, showing how evaporation equipment and processes have changed to meet the requirements of industry and environmental regulations.

Jan 1, 1996

By J. L. Jambor

Previous crystal-structure determination of magnesian annabergite (Ni,MgMAsO4)2 8H2O indicated that ordering of Ni and Mg occurs in non-equivalent octahedral sites; such ordering supports the possibility of miscibility gaps on the Ni3(AsO4)2 8H2O -MgiAs04)2 8H2O. (annabergite-hornesite) join. In a predecessor study based on analyses of natural specimens, it was proposed that solid solution is incomplete both for annabergite-hornesite and annabergite-erythrite [Co, (AsO4)2 8H2O]. In the current study, syntheses by use of a slow-addition technique and aging of the precipitates indicated that the annabergite-erythrite solid solution is complete, and that no miscibility gap is present on the annabergite-hornesite join to at least 58 mol % Mg. Thus, interpretation of the compositions of these phases in oxidized mill-tailings impoundments can be done with the normal precautions for homogeneity, and without the added concern of the possible presence of miscibility gaps in the ternary system.

Jan 1, 1995

By Ralph P. Hackl

Bacterial leaching of the Doe Run Company?s cobalt/nickel-containing copper concentrate at low pH (pH 1.0-1.2) and high redox potential (>750 mV vs. SHE) enabled the cobalt and nickel to be preferentially dissolved over copper and iron due to the rapid passivation of the chalcopyrite component. Selective leaching of the cobalt and nickel was achieved with a mesophilic culture comprised mainly of Leptospirillum-like bacteria and Acidithiobacillus thiooxidans. This finding led to the conception of a novel hydrometallurgical process for passivating chalcopyrite and recovering the cobalt and nickel. The bacterial leaching process was tested extensively at the bench and pilot plant scales during 1997-1998. A pilot plant containing four leaching stages processed 30-40 kg/day of chalcopyrite concentrate continuously for 87 days. The cobalt extraction ranged from 75% to 86% during 6- and 8-day retention times respectively, whereas the copper extraction was limited to about 9%

Jan 1, 2003

By M. Nilmani, J. Sofra

The transverse distributions of the solids discharge velocity and mass flux at the discharge end of vertical and inclined lances were measured in order to detennine the transverse distributions of the axial momentum flux, which is a dominant factor influencing the penetration behaviour of particles into melts during submerged injection. The effects of gas velocity (10 - 30 m/s), solids loading (5 - 10), lance length (0.15 - 1.0 m), lance inclination (vertical downward - horizontal) and particle density (2500 - 8900 kg/m3 ) were investigated, while the lance diameter and particle size were fixed at 10 mm and 220 µm respectively. The particle velocities and mass fluxes were measured by image analysis of particles illuminated in a laser-generated light sheet aligned vertically through the axis of the lance at the discharge point. The particle discharge velocity profiles for vertical downward flows were synunetrical about the centre-line of the lance, with the maximum velocities occurring at the centre-line. The velocities increased with increasing gas velocity, increasing lance length and decreasing particle density in accordance with previous observations. The transverse mass flux profiles were also synunetrical for vertical downward flows, however at the lower gas velocities the peaks in the profiles were displaced from the centre-line of the lance by a fractional diameter of about 0.15. The particle discharge velocity profiles become increasingly asynunetric as the lance orientation was changed from vertical to horizontal, with higher particle velocities present near the top wall of the lance. The mass flux profile also became asyrrunetric as the horizontal orientation was approached, however in this case, the profile became biased towards the bottom of the lance. The effect was much more pronounced for a gas velocity of 10 m/s than for 30 m/s, showing the relatively stronger gravitational influence as the velocity was reduced.

Jan 1, 1996

By Muhammad Abid, Kh. .. S. Karimov

"In this study, design and investigation of biogas digester consisting of methane tank with built-in solar collector to utilize solar energy for the heating of the slurry prepared from the dung and heat exchanger is designed, developed and tested. The digester was laboratory type and consists of cylindrical metallic tank of size of 0.5 m in diameter; 1 m in height and 200 liters in volume. The surface of the digester from outside was covered by thermo insulated material a glass wool, except of south side (in northern hemisphere). This side played the role of built-in collector and was blackened to increase absorption of solar irradiation and covered under 45o by glass. In the blackened side of the digester on the different heights it was installed metallic pipes for the inlet and outlet of the air, connected with heat exchanger installed inside of the digester. The heat exchanger was fixed in the level above of the inlet pipe. The horizontal plane reflector concentrates solar beams to blackened side of the digester. In the winter period, it was found that the retention time of this digester is shorter on 15% and produced biogas volume is larger on 20% with respect of ordinary biogas digester. This digester is used for the demonstrative purposes and as a teaching aid presently and base on the results it may be used for the construction of large volume digesters for use in the farms, especially located in the remote and mountain areas where the climate in the winter period is cold. Introduction At present many experts around the world have focused their efforts to energy crises because energy is one of the most important factors for the development of the society. It is known that consuming energy is proportional to quality or standard of life. There is a close relationship between energy consumption and the Gross National Product (GNP). It is obvious that for further development of the country additional sources of energy is required, which are cheap, safe and environmentally compatible with respect to the action on possible wastes. Utilization of renewable energy is one route to help in solving the above mentioned problems. In particular, biogas as a source of renewable energy is produced by biotechnology and used wide on residential scale [1]. The biogas was produced for the very first time in 1814 by Deivy from organic wastes. In 1900 production of biogas was started in Bombay (India) [2, 3]. Biogas consists of 55-70% methane (CH4) and around of 27-44% carbon dioxide (CO2) and less than 1% H2 and H2S. At present biogas is used widely in some countries for lighting, machines, and vehicles, generators, cooking and heating. Biogas generation is suitable for small to large scale operation and at present is realized in a number of developed and developing countries as USA, Hungary, China, India etc. Since 1990s biogas projects construction in China has developed steadily by the end of 1998, there were altogether 6.88 million household biogas digesters [4]. In Russia biogas digesters are used for processing of hard dung into biogas [5]. Over the last few years the very first biogas digesters were constructed in Tajikistan as well [6,7] and it was found that the digesters can work with sufficiently high efficiency in mountain areas as well ."

Jan 1, 2008

By Thor Pedersen

Elkem's technologies for the processing of waste materials, dusts, sludges and other residues, are based on the use of their Multi-Purpose Furnace as the primary processing component. The Multi-Purpose Furnace? is an electric slag resistance reduction furnace equipped with a hot media, Modular Freeze Lining and Elkem's proprietary, air tight electrode seals. The oil cooled? freeze lining allows specific heat fluxes 2 to 3 times higher than furnaces lined with conventional refractory. Reduction activities taking place within the furnace are free from the reoxidation potential of infiltrated air as Elkem's electrode seals are positively gas tight. Small quantities of highly concentrated off gas of controlled composition are produced to suit the requirements of downstream processing. The high electrical thermal efficiency achieved by generating heat within the slag itself, combined with the ability to operate at high melting rates and intense power density, makes the Multi-Purpose Furnace 9 an unique implement for the design of furnace products. These characteristics are utilized in the processing example cited, "Elkem's EAF Dust Processing Technology", which combines two proven technologies in an economically feasible system for the recovery of contained metal values from K061 wastes at the same time producing a disposable slag product. The portion of the example dealing with the condensation of zinc was prepared with the assistance of Imperial Smelting Processes, Limited of Bristol, England with whom Elkem has a non- exclusive license.

Jan 1, 1990

By William A. Fuchs

A study of carbonaceous ore at the Santa Fe mine (Corona Gold Inc.) shows that there is no quantitative relationship between organic carbon content and preg rob, although much of this material preg robs. However, there is a relation between K20 and preg rob. Preg rob generally occurs only in those samples with greater than 2% K20. X-ray diffraction and chemical . studies show that the critical factor is the illite content of mixed (possibly interstratified) illite-smectite. Apparently illite, at a certain threshold, "geo-activates" the carbon. The potential for easily monitoring preg rob using a gamma ray spectrometer is discussed.

Jan 1, 1990

By William Petruk

"Heap leaching is a developing technology for recovering native gold and electrum from low grade deposits and from tailings. Recovery depends on permeability of the rock and ore minerals, size of particles in the heap, and ore textures that influence exposure of gold grains to cyanide solutions. These ore textures include gold-bearing veinlets and microveinlets along fractures and microfractures, gold grains in porous minerals and rocks, and gold graim. occurring along grain boundaries of other minerals. On the other hand, small encapsulated gold grains arc not likely tote exposed even with fine grinding. Most gold grains that occtir along grain boundaries of other minerals can be exposed with a moderate to fine grind, but the. resulting material will be too fine-grained to be permeable in a heap. Such finely ground ore, as well as tailings from flotation operations, can however be prepared for heap leaching by agglomerating the material into porous briquettes. Oxidized and weathered zones above. orebodies are frequently amenable to heap leaching because the gold-bearing pyrite and arsenopyrite have become permeable by conversion to porous iron oxides and ferric oxyhydroxides. A review of ore textures in several types of gold deposits suggests that:(1) the gold in vein deposits would gtmerally be amenable to heap leaching of both oxidized ores and fresh non-refractory ores,(2) the gold in Carlin-type deposits and in volcanogenic massive sulfide deposits is not likely to be amenable to heap leaching fresh ore, but oxidized zones above the orebodies are generally amenable to cyanidation, and(3) the gold in porphyry copper-gold deposits and in Witwatersrand-type deposits would likely be amenable to heap leaching of both fresh and oxidized ores but with high cyanide consumption."

Jan 1, 1997

By Wenjie Zhu

Chromite ore processing residue (COPR) is a hazardous waste containing high concentration of chromium. We describe here a pioneer trial of detoxification of COPR in column reactor with an indigenous chromate reducing bacterium Leucobacter sp. Ch1, which showed high chromate reducing ability at high pH. Under the optimum conditions, at 30°C and pH 10.0, pH of leachate decreased from 10.3 to 8.3, and Cr(VI) concentration in solution decreased to zero mg L-1, and 76.4% of Cr(VI) was removed from COPR samples. The leaching toxicity of detoxified residue was 1.1 mg L-1 that was lower than national standard of China.

Jan 1, 2008

By Malti Goel

"Technology advancements in fossil fuel based energy generation and consumption are currently being aimed at minimization of CO2 emissions. To attain energy security, India must accelerate the pace of economic development, while achieving reduction in CO2 emissions per unit of energy consumed. It would need access to advanced coal utilization technologies to be demonstrated on indigenous coal characteristics. Of specific importance would be: improvement in coal quality, increasing energy efficiency and suitability of other CO2 sequestration technologies for reducing CO2 footprints. There is need to address related risks and financial burden through adoption of policies and regulations including the issue of open access in energy research. In this paper, seven important areas of strategic plan that need to be pursued for managing CO2 emissions in steel energy sector in India are discussed.IntroductionWorld is facing a crisis of climate change, which follows in the footsteps of global energy and environment crises. Accumulation of carbon dioxide from the generation and utilization of energy is leading to greenhouse warming and climate change. The global warming is causing the boundary between four seasons to be fuzzy and resulting in more spiky weather. Significance of its impact on environment is also determining the technology development needs in various sectors of economy for taking remedial measures.To respond to climate change concerns, the steel industry is undergoing a transition. It is at the threshold of a rapid change in technology as it targets innovation to achieve 50% reduction of CO2 emissions per ton of steel produced. Fossil fuel use is the main contributor of increasing concentration of carbon dioxide in the atmosphere. The control of air pollution and CO2 capture are thus relevant for a coal based industry, whether thermal power plant or a demand side energy intensive industry. World steel production has shown phenomenal increase in first eight years of 21st century increasing from 780 Mt in 2000 to 1343 Mt in 2008 [1]. It was merely 28 Mt in 1900. The global CO2 emissions from steel industry are also increasing and became 2550 Mt (3-4% of total GHG). Indian industry contribution was 161 Mt (15% of direct emissions from industry). It is likely to grow further to keep pace with the accelerated economic growth of 8-9% per annum."

Jan 1, 2010

By A. Mukhopadhyay

Gas stirring, simultaneous arcing, chemical additions are some basic steps in the secondary steel making. From tap to team however, there are enough uncertainties and several in-situ decision making required to match the fmal composition and temperature in the given amount of processing time. Currently available control algorithms rely on overall material and heat balance coupled with a self-learning regression based tuning of model constants. In this paper we demonstrate the capabilities of Computational Fluid Dynamics (CFD) in modeling and analyzing the thermo-chemical aspects of secondary Steelmaking. These models take advantage of scientific and engineering advances in computational tools and provide almost real time speed of analysis. This can be a very effective tool for operator training, process debugging and improvement as well as new innovations. Keywords: Argon purging, Secondary steelmaking, Arcing, Ladle Furnace, Process Control.

Jan 1, 2003

By Michael K. Rhodes

A 120 tonne per day BacTech bacterial oxidation plant treating refractory gold concentrates for Gold Mines of Australia's Youanmi project in Western Australia commenced operation September 1994. This was the first commercial application of the BacTech process. A pilot plant trial on concentrates produced from Youanmi ore was carried out at BacTech's laboratory in Perth. Results and measurements from this trial were used by Signet Engineering Pty Ltd to design the commercial plant. This paper cover the results obtained from the piloting, their implementation in the plant design and the initial commissioning of the full scale plant.

Jan 1, 1995

By Gregor Kücher

Lack of basic knowledge on the semi-direct recycling methods for hard metals hinders the application on an industrial scale. However, advantages like reduced expenses and lower environmental impact draw interest at future potentials. Consequently, this report aims to offer insight into the influence of varying bulky hard metal substrates during their lixiviation in acidic media with an oxidant. The statistical software Modde 11 assisted in the development of a design of experiments (DOE) for evaluation of the impact of average grain size, binder and tantalum carbide (TaC) content on the leaching characteristics. The other experimental parameters were constant. Among them were temperature, solution concentration and quantity, duration and substrate surface exposed to liquid volume. Eventually, prediction plots and factors of the computed model equation describe the effects of varying substrate qualities on leached binder metal and selectivity.

By T. Shi, Q. Yuan, S. P. Vanka, B. G. Thomas

"The quality of continuous cast steel is greatly affected by fluid flow in the mold region, especially involving transient phenomena. Mathematical models are being applied to investigate many different aspects of these phenomena, but their accuracy must be validated before they can be applied with confidence. As part of a long-term effort to develop and apply comprehensive models of the continuous casting process, this work evaluates the relative accuracy of models of three different fluid flow phenomena in continuous casting through comparison with measurements.Firstly, transient flow simulations of velocities in the mold region are compared with digital particle image velocimetry (PIV) measurements in a single phase water model. Large-eddy simulations (LES) are found to reasonably match the flow measurements, including transient flow variations, except at long time scales, which could not be modeled owing to the excessive computation costs. The standard K-e model produced very good agreement with time-averaged velocities for relatively little computation time, although it is inaccurate at predicting the transient variations. Secondly, particle trajectory calculations are compared with water model measurements to study the distribution and flotation removal of inclusion particles. The LES model was able to match the measurements both qualitatively and quantitatively. Thirdly, steady, multi phase flow computations are compared with flow patterns observed in both a water model and an operating steel caster with argon gas injection. For the same conditions, the water model and steel caster produced very different flow behavior. The computational model was able to match the measured flow patterns in both cases.This work suggests that computational flow modeling has the potential to match real processes as well or better than water models, especially when complex related phenomena such as particle motion and multiphase flow are involved. Much work is still needed to further improve the models and to apply them in parametric studies."

Jan 1, 2001

By James B. Pfeiffer

TETRA Technologies, Inc., has applied its HDS? metals precipitation system to control a mine drainage problem. The effluent from the mine contains primarily zinc, manganese and iron, plus varying small amounts of cadmium, copper and lead. The flow from the mine averages 350 gpm, and varies considerably depending on season and weather conditions. The plant was designed to treat 1000 gpm of the water and generate a dense sludge suitable for recycling. The HDS? system contains a number of reactors, followed by post filtration and meets stringent metals discharge criteria as specified by New Source Performance Standards.

Jan 1, 1994

By P. M. Prasad

The last two decades have witnessed the emergence of numerous hydrometallurgical and direct processing techniques for the extraction of some metals from pocketed/lean/complex sulfide ore deposits. A new approach with some inherent technological merits, investigated in recent years, is the lime-enhanced reduction of metal sulfides. Thermodynamic aspects relevant to the lime-enhanced reduction of metal sulfides by H2,C0 and C are discussed. A survey of the researches on the basic features of and factors influencing the lime-scavenged reduction of selected sulfides and sulfide concentrates reveals that lime tremendously enhances the sulfide reduction rates (up to 100 times) and drastically reduces the sulfur emission into off-gas to negligible levels. Further successful practice of lime-enhanced reduction requires only a moderate temperature of reduction (characteristic of each sul¬fide) and, in the case of gaseous reduction, relatively low gas flow rates. Relevant kinetic aspects of the concerned reactions that have a bearing on process development and its understanding are also briefly discussed. A conceptual scheme of general applicability for the processing of sulfide concentrates by the lime-enhanced reduction technique consists of three main steps: (0 lime-enhanced reduction by a suitable reagent (e,g., H,2, CO, gasified coal, water gas), (ii) separation of the product metal from the dry slag (CaS + unused CO) by mechanical separation, magnetic/gravity concentration or flotation and (iii) melting and refining by standard procedures. This novel approach, which is patently less complex, is expected to employ basically simpler flow sheets at comparatively lower operational temperatures and aid in pollution abatement. Potential for developing such a route for the small scale extraction of metals like copper, molybdenum and antimony is indicated. Possibility of utilizing this technique for the production of fibers/ filaments of some metals is also outlined.

Jan 1, 1983

By Reed M. Izatt

SuperLig® materials are capable of individually separating Rh, Pd, and/or Pt in highly purified form (99.95 to 99.99%) from a variety of chloride-based feed streams in a single stage operation. The hydrophillicity and associated kinetics of the supported materials allow for operation at relatively high flow rates of both loading and elution in a packed bed format. Pilot and commercial systems have been operated with Rh, Pd, and/or Pt present in the feed from single digit ppm (mg/l) to tens of g/l. A dual SuperLig® system for one pass Au(CN)2- separation followed by Cu and CN- recovery for CN- recycle has also been tested up to a pilot level,

Jan 1, 1999

By B. Balamurugan, D. J. Sellmyer, J. E. Shield, G. C. Hadjipanayis, Damien Le Ror, R. Skomski

"Rare-earth transition-metal (R-TM) alloys show superior permanent magnetic properties in the bulk, but the synthesis and application ofR-TM nanoparticles remains a challenge due to the requirement of high-temperature annealing above about 800 °C for alloy formation and subsequent crystalline ordering. Here we report a single-step method to produce highly ordered R-TM nanoparticles such as YCO5 and SmCO5, without high-temperature thermal annealing by employing a cluster-deposition system, and we investigate their structural and magnetic properties. Nanoparticles of size = 10 nm are monodispersed (s /d ~ 0.15) and have Hc values at T = 300 K of 8.0 and 4.5 kOe for YC05 and SmC05, respectively. Alignment of the easy axes is performed via a field applied to the clusters before deposition. These processing steps are highly desirable to create and assemble R-TM nanoparticle composites for future permanentmagnet applications.IntroductionMagnetic nanoparticles with high magnetocrystalline anisotropies (Ki > 1 MJ/m3) are required for permanent-magnet, recording-media, and other significant applications [1-3]. In this regard, bulk rare-earth transition metal alloys (R-TM) especially RC05 (R = Y and Sm) crystallized in the hexagonal CaCu5-type structure have shown a large Ki = 5 MJ/m3 (YC05) and 22 MJ/m3 (SmCo5) along with an appreciable saturation-magnetic polarization (Js, > 10 kG) and high curie temperatures (Tc > 1000 K) [2]. The challenges in controlling the size, sizedistribution, phase purity and crystalline ordering, however, limit the research on RCo5 nanoparticles [4,5]. The conventional arc-melting technique requires high-temperature annealing for alloy formation and subsequent crystalline ordering, which causes excess growth and thus results in nanocrystalline powders of particles sizes larger than 30 nm [6, 7]. Low-temperature wet-chemical techniques yield SmC05 nanoparticles of sizes smaller than 20 nm [5], but the control of phase purity is challenging due to the presence of surfactants and formation of other secondary phases [8]."

Jan 1, 2012

By C. A. Nogueira, F. Pedrosa, F. Margarido, R. N. G. Guerra

"A hydrometallurgical process for recycling spent Zn-MnO2 batteries was developed, involving leaching with sulfuric acid, purification by precipitation and metals separation for further recovery. Leaching of zinc oxide was easily attained while for manganese oxide was rather difficult depending on temperature and acid concentration. At 90°C and with the liquid/solid ratio of 20 L/kg, more than 95% of zinc is recovered in 30 minutes with 0.5M H2SO4. To attain similar recovery for manganese, higher levels of acid concentration and time are needed (e.g 0.7 M and 2 hours). After leaching a purification step is necessary to remove iron co-dissolved through Fe(III) precipitation. Separation of zinc from manganese by solvent extraction with 1M DEHPA follows in the process route. The countercurrent multistage separation diagram developed allows the production of a zinc electrolyte with 120 g/L Zn and 0.005 g/L Mn, and a raffinate with 16 g/L Mn and 0.013 g/L Zn.IntroductionThe recycling of spent Zn-MnO2 batteries is carried out by dedicated recyclers using several process alternatives [1]. Most of the running processes use pyrometallurgical technologies [2] based on zinc distillation. Alternative treatments by hydrometallurgy have been reported [3-5] but its application is scarce.In order to contribute to the development of alternative solutions, a process for recycling batteries based on Zn-MnO2 systems has been studied. The process is based on the hydrometallurgical treatment of spent batteries in sulfuric acid media (Figure 1). The process starts with the physical processing by shredding using cutting grinders, where the batteries are opened and size reduced, allowing the liberation of the interior electrode particles or pastes. The fines can be then separated and the coarse material containing the steel scrap can be treated to remove the remaining aggregate electrode. The final scrap also contains some plastics and other non-metal materials and can be further valorized."

Jan 1, 2008

By Takeo Fujino, Nobuaki Sato, Yarong Wang, Kohta Yamada

"Ternary mixed sulfides of some transition metals MTS3 (M=Ba, ·Pb, T=Ti, Zr) were synthesized by a relatively low temperature process using sulfur melt. The mixture of starting materials, such as, metals and/or binary sulfides and a large excess of sulfur was reacted in a vacuum-sealed Pyrex or quartz ampoule at 350- 600 °C for one to three weeks. After the reaction, the remaining sulfur was completely removed by a process composed of filtration of sulfur melt and followed dissolution in CS2• The binary sulfides impurities coexisted in the products were removed by rinsing the products in water and acetone. By using the above method, BaTiS3, PbTiS3 and BaZrS3 'Were obtained in pure form. The effect of addition of halides on the yields of these ternary sulfides were also discussed.IntroductionThere have been a vast number of studies on the preparation and physical and /or chemical properties of mixed metal oxides. As is well known, some of such compounds exhibit excellent materials properties, causing them for use in mechanical, electronic, magnetic and chemical devices. Not a few mixed metal sulfides show similar physico-chemical properties to those of the corresponding mixed metal oxides. However, the study of the mixed sulfide crystals is rather sparse mainly due to difficulties in preparing these compounds. In various methods which have been adopted for preparing mixed sulfides, the simplest method would be the solid-solid reaction of the component binary sulfides or elements. However, there are always diffusional constraints with regard to the reactions in solid phases causing it necessary to heat the reactants at sufficiently high temperatures, viz. 800-1200°C. On the other hand, some mixed sulfides are unstable at high temperatures or to change their materials properties due to sulfur nonstoichiometry and structural modification depending on temperature, i.e., synthesis of such compounds needs to be made at lower temperatures. Processing in alkali halide melts is hopeful to overcome the above problems but to obtain the halide melts the temperatures above ~ 600 °C is needed. Low temperature reaction has been carried out for the preparation of Hg1.24TiS4, which was formed by the ·combination of TiS2 and molten Hg metal at 320°C[l]. Reaction of WS2 with LiBH4 melt at 350°C yielded LixWS2[2]. These sophisticated methods, however, can be applied only to the vary special cases."

Jan 1, 2000