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By H. Masuda

The lijima Zinc Refinery started operation in 1972, and has today an annual capacity of 200, 000+-Zn. The hematite process was employed for the first time and the ideal of waste-free refinery has been pursued for 30 years. In recent years, however, only half of the hematite produced would be sold to the cement industry and hence a reduction of arsenic level has been necessary in order to sell the entire amount produced, The arsenic cementation process with zinc powder, developed through a long time laboratory research was found among some options as the best for the hematite process. The construction work started in 2000 and the facility was put into operation in 200 I. As a result in the same year all hematite were sold to the cement industry. The outline of this project, present operations and technical issue are reported in this paper.

Jan 1, 2003

By Lisa E. Helberg

"Titanium tetrachloride is produced through the chlorination of a variety of titanium bearing ores, some occurring in nature, and others enriched in titanium content by a variety of ""beneficiation"" processes. The chlorination step can produce a variety of metal chloride impurities, such as iron chlorides and vanadium chlorides, which must be removed from the TiC14 before it can be used to produce pigmentary TiO2, titanium metal or for any other commercial use. The requisite manipulations involve both physical and chemical separations in a multi-step process. The history of various purification strategies will be discussed.TextThere are a wide range of titanium-based products available, all of which start with titanoferrous ore of some type. Two main routes are used to convert ores into products, known as the sulfate and chloride processes. The sulfate process uses sulfuric acid to digest the ore, separate the impurities, and then precipitate titanium dioxide from the resulting titanyl sulfate (TiOSO4) via metatitanic acid. This process can also supply TiOS04 for other applications."

Jan 1, 2011

Silver has the highest electrical conductivity of all metals and consequently this property is an attractive feature which makes it a leading candidate for use in electronic devices. The research conducted was focused primarily on the development of a process for obtaining a deposited silver-coating onto alumina, for applications related to electrical-conducting devices and, ancillarily, catalysts. Alumina balls and plane substrates were utilized for the investigation. The coating process employed an aqueous arnmoniacal silver-nitrate electrolytes with a formaldehyde solution as the reductant. Modifying additives - an activator which would be expected to promote good deposition-characteristics onto the (dielectric) substrate and an inhibitor which would obviate homogeneous reduction (precipitation) of silver was observed when the activator-containing silver-electrolyte reductant constituents were combined. However, the silver-electrolyte/reductant system with inhibitor could be employed (at 80°C) to achieve a viable (subject to future research optimization) coating on alumina. The influence of the processing temperature on the deposition process was delineated during the course of the research. The morphology of the deposited-silver on the alumina balls was assessed by SEM imaging. A tape-peel test was employed, with the plane substrates, to semi-quantitatively characterize the adhesion to the alumina.

Jan 1, 1998

By C. M. Iheagwara

This paper has addressed the issues that constitute major obstacles to the cost- effective and efficient operation of metallurgical vessels from the refractory standpoint. Refractories generally withstand severe conditions of high temperature reactions as well as physical loading/impingement and hence degenerate and need replacement. Scarcity of some refractory materials especially high alumina and magnesite ores in some places, the prohibitive cost and the frequency of replacement of damaged refractories threaten the continued support for metallurgical operations. Some of the causes, prevention and cure for refractory wear have been discussed and rational strategies (short and long term) have been recommended which if implemented should go a long way towards arresting the perennial problems they portend.

Jan 1, 1991

By Georgette Smits

The gun-sprayed refractory lining of electrothermal furnaces used for the manufacture of carbon disulphide from liquid sulphur and charcoal at between 800 and l000°C are severely attacked during the process. A mineralogical study of samples of eroded refractory material disclosed that carbon disulphide had penetrated the lining, causing the precipitation of sulphides and carbon, and the decomposition of mullite, a major constituent of the lining, to corundum and amorphous silica. Calcium, iron, titanium, and chromium are undesirable cations in a refractory that is used in furnaces for the production of carbon disulphide, since they react readily with this substance. A series of tests, in which samples were exposed to different amounts of carbon disulphide for various residence times and at different temperatures, was carried out with eight types of aluminosilicate-based castable and brick refractory materials, to compare their resistance to attack by carbon disulphide. Mineralogical investigation of the test cores showed that castable refractory materials are unsuitable for this type of process because of the presence of calcium aluminates and other impurities in the cement. Of all the refractories that were tested, a mullite brick of low porosity, containing a minimum amount of impurities, appeared to be the most suitable for use in this type of operation.

Jan 1, 1989

By Ligang Zhang, Wen Chen, Xinghua Liu, Jialin Li, Xiaoyin Liu, Zhenhong Liao

A research-scale fluidization and magnetization roasting device was developed to evaluate a processing option that might offset the complexity and high cost of the conventional magnetization roasting process on siderite. In this study, the operating parameters of the fluidization and magnetization roasting device for siderite were evaluated through cold-flow tests and magnetization roasting tests. The reaction mechanism functions of the fluidized roasting process are revealed with kinetic studies.

Jan 1, 2015

By W. John Rankin

The finite and non-renewable nature of mineral resources poses unique challenges for sustainability: How can mineral and material needs of society be satisfied indefinitely? How can the benefits of exploitation of minerals best be captured for present and future generations? How can the environmental problems caused by large scale mining and processing best be ameliorated? These issues are rarely addressed, or if so only incidentally, in traditional courses in geology, mining, metallurgy and materials yet addressing them will increasingly be a major role for professionals in the minerals and materials industry and related sectors and agencies. This paper describes a framework for examining these and other sustainability issues related to meeting future material needs from non-renewable resources. The framework may be useful for educational purposes, either as the basis of a dedicated subject or by including the elements of it throughout a traditional course in relevant subjects.

Jan 1, 2014

By Andreas Dietrich

Laser off-gas measurement of CO, O2 and temperature has been carried online in EAFs. A visualization screen shows the values of CO and Oxygen and temperature for the entire heat, and includes the status of furnace equipment. The historical data of the heats are stored such that the furnace performance can be evaluated and optimized. A short comparison between laser based and conventional systems has been carried out related to speed, influence of dust, water, pressure, protection for bag house explosions. A high water and/or dust content in the sample does not represent a problem for this type of system. The measurement method works without interruption even under worst conditions such as dirty scrap, carbon injection etc. The installation was developed in conjunction with Marienhuette, Graz. They are 100% scrap based with a tap to tap time of ca. 46 min. Keywords: Laser Measurement, Off Gas, CO, O2, Temperature

Jan 1, 2003

By Wentao Guo, Xuefeng She, Qingguo Xue, Jingsong Wang

By the coke gasified reaction device and online measurement high-temperature compressive strength apparatus, the variation of pore structures of coke after gasified reaction with CO2 and H2O was investigated. Research illuminating the influences of solution loss rate, temperature, and carbon species on compressive strength of coke was also carried out. The results showed that the total compressive strength was higher than for the reaction with CO2. The high-temperature compressive strength of coke decreased with the increasing of solution loss ratio or temperature after reacting with CO2 and H2O. At the same solution loss ratio, the damage of pore structure to coke strength after gasified reaction with H2O was relatively smaller and the deformation resistance was stronger when compared with that in CO2.

Jan 1, 2016

By W. G. Davenport

Chapter 10 showed that any given smelting task, e.g. production of 65% Cu matte, 1500 K, from CuFeS2, can be done with many different combinations of: blast%02 hydrocarbon fuel blast temperature. This chapter repeats the Chapter 10 calculations but reports the results in terms of the mass industrial oxygen mass hydrocarbon fuel blast preheat energy combinations that will produce 65% Cu matte, 1500 K, from CuFeS2 concentrate. It also determines the energy inputs equivalent to these combinations.

Jan 1, 2001

By W. G. Davenport

Chapter 11 determined the combinations of industrial oxygen, oil and blast preheat that will steadily produce 65% Cu matte from pure chalcopyrite concentrate. It showed that the . combinations are described by a flat plane. It also showed that the minimum energy requirement for making 65% Cu matte occurs with maximum oxygen enrichment, zero oil and zero blast preheat. This chapter examines the, effect of matte grade on industrial oxygen, oil and preheat requirements.

Jan 1, 2001

By Kenneth L. Reid

The Mineral Resources Research Center at the University of Minnesota has recently installed a QEM*SEM system (Quantitative E.valuation of Materials using Scanning Electron Microscopy) to aid in detailed mineralogical evaluation of potential mineral resource developments in Minnesota and to provide services to the North American mineral industry. A primary application for the unit is to serve the Minnesota taconite industry by providing mineralogical analysis of ores and concentrator products. Minnesota taconite ores contain fine-grained magnetite in a quartz matrix. The ores undergo several size-reduction/magnetic-separation steps to produce a final concentrate with approximately 75% passing 325 mesh and containing about 5% gangue. The paper describes a typical taconite concentrator flowsheet and reports some preliminary results of the applications of QEM*SEM particle image maps and cumulative yield liberation data to samples from selected points in the concentrator circuit.

Jan 1, 1988

By Honggang Zhong, Xin Cao, Qijie Zhai, Hongmei Song, Congsen Wu, Cheng Zhang, Jingzheng Ye

"The influence of superheat on the solidification structure and ferrite/austenite phase transformation of a novel lean duplex stainless steel (DSS) was investigated on a setup, which designed to thermally simulate the continuous casting process. The results showed that the macrostructure of the samples all exhibited chill zone, columnar zone and equiaxed zone. The distance from chill zone to position of columnar to equiaxed transition (CET) moved from 51.0 mm to 39.8 mm with an decrease of superheat from 70 °C to 10 °C, and that the grains in the chill zone tended to be finer. In equiaxed zone, the fme and uniform grains were observed when superheat higher than 40 °C; while, coarse grains were found in samples poured at low superheat. Generally, the volume fraction of ferrite increased along the dendritic growth direction, and stabilized in equiaxed zone. The high superheat decreased the volume fraction of ferrite in equiaxed zone, while it had indistinctive influence on chill zone and columnar zone.IntroductionDuplex stainless steel with approximately equal volume of ferrite and austenite, offering an attractive combination of corrosion resistance and mechanical properties. [ l]. The production of DSS, worldwide application in structural engineering[2] and petrochemical industry[3], have increase by more than 100% in the latest decade[4]. But due to the sharp prices increase of nickel and chromium, lean duplex stainless steels which have lower contents of alloy elements were developed. They perform well in both mechanical and corrosion resistance[S, 6] and even have TRlP(Transformation Induced Plasticity) effect[?]. Nonetheless , the mechanical properties of DSS was affected greatly by the solidification structure, such as columnar to equiaxed transition (CET), grain size and phase content[8]. So, the solidification behavior of stainless steel was investigated widely"

Jan 1, 2014

By Xi-Shan Li, Qian Li, Yong-bin Yang, Tao Jiang, Jie Ge

Compared with other pretreatments of sulfur & arsenic-bearing gold, double-layered pellet roasting has an advantage that sulfur dioxide and arsenic trioxide volatilizing from this refractory gold ores can be solidified into the coating without emission during the roasting. However, the separation of coating from roasted double-layered pellet should be focused on in the novel pretreatment. Based on the difference of physicochemical characteristics between roasted solidified coating and pellet core, several separation methods including grinding, drop impact and water quenching method had been systematically studied in this paper. The results showed that magnetic and gravity concentration could not obtain a satisfactory separation effect. The optimum separation rate of grinding was only 38.94% at grind time 12min, but it increased to 85.05% by drop impact under drop height 0.75m, drop times 20 and impact angle 45°, and that of water quenching taking advantage of slaking reaction of lime could approach 75.32%.

Jan 1, 2015

By Z. Y. Xie

The visualization techniques were employed for the analysis of computer simulation studies of dislocation core structure in ordered alloys. Atomistic computer simulation was used for the study of the local configuration of the material in the vicinity of the dislocation. Stresses were applied in the simulation in order to study the necessary stress level for the dislocation to move and onset plastic deformation of the material. The results were analyzed in terms of the strain tensor as a function of the position (x, y) in the material with the dislocation located at (0, 0). Various visualization packages are used to plot the invariants of this strain tensor and to visualize the changes that the dislocation core undergoes under stresses until it finally moves.

Jan 1, 1993

By E. Legault-Seguin

The current industrial practice in the processing of nickeliferous laterites involves the precipitation and releaching of Ni and Co to allow separation from the major impurities of Mn, Mg and Ca. A direct solvent extraction process has significant advantages over this practice, which suffers from difficult and costly precipitation steps, lower recovery and inherently complex flowsheets. The present investigation involves the examination of Cyanex 272, Cyanex 301 and Cyanex 302 as extractants for the direct extraction of Ni and Co from major impurities associated with laterite leaching, i.e. Mn, Mg and Ca. For Co extraction, Cyanex 301 and Cyanex 302 are superior to Cyanex 272, because they are able to selectively separate Co from Mn, Mg and Ca. Cyanex 272 offers complete extraction of Co from Ni and Ca, but Mn and Mg pose difficulty. Ni can only be extracted selectively with Cyanex 301, thus another extractant selective for Ni, such as Versatic 10 or Cyanex 301, is needed to recover Ni if Cyanex 302 or Cyanex 272 is used for the initial extraction.

Jan 1, 2004

By Takayoshi Fujii, Mitsumasa Hoshi, Chikashi Suenaga, Yoshiaki Suzuki

"In a bid to renovate its Saganoseki Smelter & Refinery and to establish a leading production unit in terms of global competitiveness, Nippon Mining & Metals undertook major - restructuring efforts since 1993.One of its themes was the shift from a two-flash furnaces operation to a single-flash furnace operation. The shift was successfully completed in 1996 while maintaining the production at the same level (330,000 metric tons per year of copper) by adopting such measures as improvements in pneumatic concentrate dryers, the concentrate feeding system, concentrate burners, the furnace cooling system, and a new cryogenic oxygen plant was constructed.With a view to realizing high matte grade operation (at 65%Cu) and increasing the concentrate feeding rate, further steps were taken the capacity of waste heat boiler was expanded and technical improvements were added, including optimization of the smelting reaction in the furnace shaft. As a result, the smelting capacity, as of the year 2000, has increased to 450,000 metric tons per year of copper.IntroductionThe feed rate to the flash furnace was doubled to 140 t/h from 70 t/h in 1996. Teething problems, as a result of the renovation, were almost solved by the end of 1996, and the operation of the single furnace operation has become stable.The main theme was the shift from a two-flash furnaces operation to a single-furnace operation to maintain the production capacity at the same level, namely 330,000 metric tons of copper per year. Then, in a bid to further renovate the Saganoseki Smelter & Refinery and to establish a leading production unit in terms of global competitiveness, further enhancement of the flash furnace's productivity was planned.The purpose of this plan was to raise the copper production capacity to 450,000 mtpy building on the potentialities of existing plants and without installing new equipment."

Jan 1, 2000

By M. M. Coleman

An investigation of the behaviour of sphalerite, chalcopyrite, galena and pyrite during flotation was conducted on selected circuits in the Brunswick Mining and Smelting Corporation Ltd. concentrator in Bathurst, NB. Samples were collected from 59 locations and analyzed for Zn, Pb, Cu, Ag, Fe, As, Sb, Sn, Bi and S. Metal balances were computed using the CAMP Material Balance Program (MATBAL 5) and the metal recoveries for each cell and circuit were calculated. An automated image analyzer interfaced with an electron microprobe was programmed to measure the size of sphalerite, chalcopyrite, galena and pyrite grains in each sample. The percentage of each mineral occurring as free grains and the relative amount of each mineral present in binary and ternary particles was calculated. The recoveries and losses of Pb, Zn and Cu are compared with the amount of liberated and unliberated galena, sphalerite and chalcopyrite present in the concentrates and tailings.

Jan 1, 1989

By John R. Hugens

Modifications in the ALSCAN method of measuring hydrogen dissolved in liquid aluminum have made it possible to monitor the level of hydrogen dissolved in liquid copper. Measurements from the tundish show a correlation with eddy current readings from the continuously cast and rolled copper rod from the continuous casting and rolling system at Amarillo. The measurements also indicate that the copper in the tundish is supersaturated with hydrogen.

Jan 1, 1994

By Ibrahim Yusufoglu, Cem Kahruman, Mert Zoraga

In this study, a strontium sulfate mineral (celestite) was converted to strontium oxalate in solutions containing ammonium oxalate as a reactant. The experiments were carried out under isothermal conditions. The effects of stirring speed, ammonium oxalate concentration, particle size and temperature on the conversion rate were investigated. During the conversion process, definite volumes of solutions were taken from the reactor after different reaction times for the determination of sulfate ions using ICPOES. Fractional conversions of strontium sulfate were determined at different times and fractional conversion vs time diagrams were generated. It was found that the conversion of strontium sulfate was increased by increasing the ammonium oxalate concentration and temperature in addition to decreasing the particle size. The effect of stirring speed was negligible on the reaction rate. It was observed that above 328 K, a protective layer of strontium oxalate was formed on the strontium sulfate particles. X-ray Powder Diffraction technique was used for characterization of solid substances.

Jan 1, 2014