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By R. D. Pehlke

The history and present status of continuous casting of steel are reviewed, including a genera 1 description of current processes. Plant layout, process development and elements of machine component design are outlined, and key steps in integration into a stee-1 production system are detailed. Recent productivity advances and improvements in quality are described. Process developments are reviewed, and some future avenues for this technology are considered.

Jan 1, 1985

By A. D. Zunkel

Increasing amounts of electric arc furnace dust (EAFD) are being generated worldwide as more steel is produced from electric furnace melting of galvanized steel scrap. In most countries, the management of this material is a costly technical, economic, and legal problem for minimill steelmakers. Many technologies and processes are being developed and implemented worldwide to manage this material to recover contained zinc, lead, and iron values and render it nonhazardous. These processes are pyrometallurgical, hydrometallurgical, or hybrid in nature. Some produce zinc oxide, some zinc metal, some lead metal, and some lead cement. Some are successful, some have failed, many are dormant. or abandoned, and others continue to be developed and emerge. This paper updates the current status of 20-30 processes in various stages of commercial application and development used worldwide to manage EAFD and recover its nonferrous, particularly zinc and lead, and ferrous values.

Jan 1, 2000

By Herman Wotruba

Mercury emissions and other environmental impacts in small-scale gold mining are a world-wide problem. "Clean" or better: "Cleaner" technologies have -apart from being environmentally sound -to guarantee a higher income and better working conditions for the miners in order to have a chance for long-term acceptance. In small scale primary gold mining in several South American countries, a number of techniques have been adapted and improved so that they not only were accepted due to their efficiency and easy handling, but they could also significantly lower mercury emissions.

Jan 1, 2003

By Zhigang Zak Fang, Michael L. Free, Jaehun Cho, Syamantak Roy, Amarchand Sathyapalan

Leaching characteristics of impurity removal from the Upgraded Titania Slag (UGS) using hydrochloric and boric acids has been investigated. Specifically, this study has focused on removal of iron oxides from the UGS that has been reduced by hydrogen gas and magnesium at 750oC for 5 hours. Reduced UGS is mainly composed of titanium hydride and impurities like iron oxides, silicon oxide, aluminum oxide, and magnesium oxide. The concentration of hydrochloric and boric acids and the leaching temperature have been chosen as the prime variables to identify the optimum conditions and leaching characteristics for removal of iron oxides. It was observed that under the constraint that 1 wt % of titanium hydride loss is the maximum amount tolerable, 0.1M HCl with 1M boric acid and 90oC are the most effective parameters for iron removal from the reduced UGS. Also, the overall rate of reaction seems to follow interfacial reaction controlled kinetics. The calculated activation energy of the reaction is 73.90kJ/mol.

Jan 1, 2016

By Djalma Souza, Rubén Sánchez, Regina Maria Pinheiro, Carlos Maurício Fontes Vieira, Sergio Neves Monteiro

"This work has for objectives to characterize a waste generated in the form of sludge during the treatment of the effluent of a paper making industry and to evaluate the effect of its incorporation up to 10 wt.% on the properties of a clayey body used for brick production. For the characterization of the waste the following techniques were used: X-ray diffraction, X-ray fluorescence, differential thermal analysis and termogravimetric analysis with mass spectrometry. Specimens were prepared by uniaxial pressing at 20 MPa before firing at 750 °C. The physical and mechanical properties evaluated were: linear shrinkage, water absorption and flexural rupture strength. The results showed that, in agreement with the characteristics of the waste, its recycling into red ceramic can contribute to decrease the consumption of fuel during the firing stage. However, the waste changes the physical and mechanical properties, generating a deleterious effect on the water absorption and flexural rupture strength of the ceramic.IntroductionAccording to the Brazilian Association of Pulp and Paper, in the last 10 years, the global production of paper grew 35%. Brazil produced 8,2 million tons of paper in 2004 and held the position of the seventh largest world manufacturer of pulp, with about 9,4 million tons per year [1]. The pulp and paper industry generates effluents that present problems related to their disposal, even after the treatment. Among the solid wastes generated by this industry, the main waste is the primary sludge from the effluent treatment plant (ETP).After the initial treatment the decanted solids go through a dewatering stage, generating the solid form denominated primary sludge. This sludge resembles a paper paste of dark gray color when humid, and clear gray color when dry. This primary waste is composed basically of kaolin, pulp, traces of chemical substances and water. This waste generated in the pulp and paper industry depends on the characteristics of the process and of the employed techniques. It can vary significantly from one industrial unit to another, even in the case that the final products are similar. Its composition is approximately 60% of kaolin and 40% of pulp, and these percentages can vary in some moments as a function of the process [2,3]."

Jan 1, 2008

By Rzyman Michal, Nakamura Takashi, Shibata Etsuro, Grabda Mariusz, Oleszek-Kudlak Sylwia

"Tetrabromobisphenol A (TBBPA) and many systems based on the synergistic effect of brominated organic compounds with Sb2O3 are extensively used as effective brominated flame retardants (BFRs) in many materials such as plastics and textiles. Thermal degradation of BFR containing plastics leads to the formation of hydrocarbons and gaseous compounds such as HBr and SbBr3. Our thermodynamic considerations indicate that these gases can act as bromination agents for metallic oxides such as ZnO, Cu2O, CuO, PbO and FeO. Moreover, these metallic oxides have the thermodynamic tendency to brominate easier than does Sb2O3. The aim of this study was to investigate experimentally the reactivity of ZnO with 1) HBr originating from the thermal decomposition of TBBPA and 2) SbBr3, which is formed during thermal degradation of brominated flame retardant plastics. The thermal treatments of the mixture of compounds of interest were investigated by thermogravimetry coupled with mass spectrometry.IntroductionTetrabromobisphenol A (TBBPA) and many systems based on the synergistic effect of brominated organic compounds with Sb2O3 are extensively used as effective brominated flame retardants (BFRs) in materials such as plastics and textiles. For instance, 4.5 million tons of flame retardant plastics containing BFRs are produced in Japan each year. Thus, in thermal treatments such as the incineration and melting of solid wastes, BFR containing plastics are intentionally or unintentionally included in the wastes. Thermal degradation of BFR-containing plastics leads to the formation of hydrocarbons and gaseous compounds such as HBr and SbBr3 [1-5]. Our thermodynamic considerations [6] indicate that heavy metal oxides such as ZnO, Cu2O, CuO, PbO and FeO should easily react with HBr prior to Sb2O3 and also with SbBr3, the main gaseous product in the thermal decomposition of TBBPA, forming low boiling point metallic bromides suitable for the volatile separation of heavy metals. The metal oxides are also expected to qualitatively and quantitatively affect debromination and decomposition of the flame retardant."

Jan 1, 2008

By Stuart D. Miller, Clayton L. Rumble

"A field net acid generation (NAG) test procedure has been utilized on-site to identify, classify and map potentially acid forming overburden at the PT Kaltim Prima Coal (K.PC) mining operation situated in the tropical equatorial region of East Kalimantan, Indonesia. The field procedure involves routine use of a calibrated, site specific NAG test (rapid oxidation test using hydrogen peroxide) which has a tum-around time of less than 24 hours and requires minimal sample preparation. It is used on geological drill-hole samples, for forward planning and overburden management; blast-hole samples, for day-to-day operational control and overburden scheduling; and final dump surface samples, for verification testing. This operational monitoring program has been in use at KPC for the past four years.Calibration and implementation of the field procedure has involved validating the NAG test using conventional acid-base accounting techniques, producing an overburden geochemical classification scheme, optimizing laboratory and sample preparation procedures, and ongoing quality management. This paper presents background theory and practical application in a case study format."

Jan 1, 1999

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 Kent D. Peaslee

When supersonic oxygen jetting is used in electric furnace steelmaking, the lance jet axis is typically inclined at larger angles to the vertical than is used in basic oxygen steelmaking. The supersonic jet is important not only for refining the steel, but for sustaining the foamy slag in the electric furnace. Physical modeling was carried out using a room temperature, two-dimensional slice apparatus in which mercury represented the metal and water-glycerol the slag. High speed video photography with image analysis was used to study the effects of the angle of inclination on the slag/metal bath. Mathematical modeling using FLUENT provided a method of predicting flow patterns and the trajectories of drops injected at various points in the flowfield. A one-half scale water model of the system, in which lance heights, angles, and flowrates simulated those encountered in steelmaking operations, was used to provide a better understanding of some aspects of the oxygen blowing process in electric furnace steelmaking.

Jan 1, 1994

By Biswadeep Saha, Meenakshisundaram Ramanathan, Chai Ren, Sivaraman Guruswamy

"Fe-Ga alloys have a large low-field magnetostriction and these alloys are attractive candidates in energy conversion and harvesting applications. Small additions of W also increase the magnetostriction of Fe. In this paper changes in magnetostriction by W substitution for Ga in various Fe-x at.% Ga alloys are presented. Fe-Ga-W single crystals were grown using vertical Bridgman Growth technique. [001]-orientated single crystal samples were prepared with faces within 1 degree off <100> orientation. The samples were annealed at 1150 °C in the alpha-phase region and water quenched. The magnetostriction coefficient (3/2)A-100 measurements were made on these Fe-Ga-W single crystals. The result on the effects of W substitution and annealing on the magnetostrictive behavior of these alloys are discussed.*Support of this work by NSF-DMR under the award DMR-0854166 is gratefully acknowledged.IntroductionMagnetostrictive materials changes their dimension exhibit reversible strains and changes in elastic properties in the presence of an applied magnetic field or the reciprocal effect of changes in the magnetic properties with the application of stress [IJ and are very important in sensor, actuator device, linear motor, magnetomechanical devices, microelectro- mechanical devices, active vibration dampening devices application areas. The discovery of an order of magnitude enhancement in the magnetostriction of Fe with Ga addition coupled with low saturation magnetic fields, and excellent mechanical properties opened up the possibility of obtaining larger magnetostriction values in other low-cost ductile a-Fe phase based alloys with alloying additives that are less expensive than rareearths such as Tb and Dy [2·4l_ The magnetostriction values observed in Fe-Ga single crystals are sensitive to thermal history and composition. The formation of second short range ordering phases and local defects inside crystal structure can also cause a dramatic change to this alloy's magnetostriction behavior [5-9l_"

Jan 1, 2012

By Roger Wilmoth

Exposed, open pit mine highwalls contribute significantly to the production of acid mine drainage (AMD) thus causing environmental concerns upon closure of an operating mine. Four innovative technologies were evaluated under the U.S. Environmental Protection Agency?s, Mine Waste Technology (MWTP), Prevention of AMD Generation from Open-Pit Highwalls Demonstration Project. This project is funded by the U.S. Environmental Protection Agency (EPA) and jointly administered by the EPA and the U.S. Department of Energy (DOE) through an Interagency Agreement. The objective of the field demonstration was to evaluate the technologies ability to decrease or eliminate acid generation from treated areas of the highwall in comparison an untreated highwall area. The field demonstration was performed at the Golden Sunlight Mine (GSM) a subsidiary of Placer Dome U.S., located near Whitehall, Montana. GSM is an operating gold mine. The highwall at GSM was divided into five plots measuring 15.24 by 15.24 metres (m) and each technology was assigned a plot with the fifth plot being used for comparison as a background control plot. The four technologies were spray-applied. The applied insitu treatment technologies included: 1) A modified, furfuryl alcohol resin sealant, utilizing wood and agricultural by-products to coat the rock surface. 2) EcobondTMARD, a phosphate based process that forms a stable, insoluble compound, coating the rock surface. 3) Two ARD passivation technologies, magnesium oxide and the Dupont technology developed to create an inert layer/coating on the pyrite, preventing oxidation. The technologies were evaluated using the following methods: 1) ASTM D 5744-96, Accelerated Weathering of Solid Materials using a Modified Humidity Cells, 2) mine wall residual wall rinse sampling, 3) microscopy, and 4) core drilling followed by water injection testing.

Jan 1, 2003

By Carlos Eduardo Gomes de Souza, Luis G. S. Sobral, Paulo A. Medeiros da Silva, Selma G. F. Leite, Renata de B. Lima

"The use of mixed cultures of acidophilus microorganisms that act in different temperature ranges, aims at speeding up the digestion of chalcopyrite, highly refractory sulphide mineral, the major mineral in the flotation concentrate of Caraíba Mining Co., with an attractive processing cost. The concentrate under consideration contains mainly chalcopyrite (CuFeS2) and bornite (Cu5FeS4) with contents of, approximately, 70 and 30%, respectively. It was observed in this study, the performance of consortium of mesophiles, moderate and extreme thermophile microorganisms, in the oxidation of the aforementioned sulphides minerals, evaluating operational parameters such as pH of the leaching solution, the reaction temperature and redox potential, with consequent extraction of 80% of the concentrate copper content within 60 days of bioleaching. Such high copper extraction was achieved in column bioleaching tests.INTRODUCTIONThe solubilization of metals by the application of microorganisms from the mineral ores and the subsequent recovery of metals from solution are referred to as bioleaching (Rohwerder, T et al, 2003). This is an economical method for the recovery of metals from minerals; especially lowgrade ores, overburden, and waste from current mining operations which requires moderate capital investment with operating cost (Watling, 2006).Furthermore, bioleaching is generally more environmentally friendly than conventional metal recovery processes such as concentration and smelting. Those physicochemical metal extraction processes generate sulphur dioxide, a toxic emission that is increasingly the target of regulatory legislation (Stott et al., 2000; Olson et al., 2003). Bioleaching of chalcopyrite is the key industry target. The main problem hindering commercial application of chalcopyrite bioleaching is the slow dissolution rate (Fu et al, 2008).Dissolution of acid-soluble sulphide minerals such as sphalerite, and to a lesser extent chalcopyrite, occurs by a combination of ferric iron and proton attack via the polysulphide pathway (Rohwerder et al., 2003)."

Jan 1, 2008

By Dan A. Mackie

Cyanide leaching operations have taken a beating from the press and the public at large for its seemingly haphazard approach to control of cyanide solutions and containment of tailings. Major spills in Colorado, Guyana, Spain, and more recently, Romania, have highlighted what had already been perceived to be a bad scene. Citizen initiatives and legislative actions are increasing. Whether these indictments are justified or not will not be debated in this paper. What this paper presents is that the technology to avoid these disasters and future ones has been around for more than ten years but has been ignored by the industry, despite demonstrated&apos; cost effectiveness. It is time for miners to wakeup, and use emerging, instead of old, technologies.

Jan 1, 1998

By Donghai Li, Cheng Pan, Xuyang Liu, Xuewei Lv, Chenguang Bai

"Fine chromite ore is the common raw material to produce ferrochrome alloy through the submerged electric furnace process. The electric resistivity of fine chromite ore plays an important role in the operation efficiency because it determines the current distribution. The effect of particle size and the contact area of the particles on electric resistivity for several of chromite were investigated at room temperature, and the relationship between the electric resistivity of mixed particles and the volume fraction of lump ore to fine ore was also studied. The results shown that the electric resistivity increases with the increase of particle size, and the electric resistivity of mixture decreases with the increase of volume ratio of fine ore.IntroductionChromium is one of the most important alloying elements in manufacturing of stainless steel that used at high temperature and corrosive environment applications [I, 2]. As the raw materials to be charged into the steel, ferrochromium alloys and charge chromium are produced directly by smelting of chromite ore with the reducing agent in submerged electric arc furnace (SAF). During the process, the oxides of chromium and iron were reduced by carbon and meanwhile the electrical energy were consumed [3,4]. The ideal industrial process is to achieve high recovery level of Cr and Fe with minimal power consumption. In SAF process, the electric resistivity of charge stock has significant effect on the current distribution, which determines the heat distribution, molten bath structure and chemical reactions in the furnace. High resistance of the charge is desired to reduce the current distribution through the charge stock, thus the electrodes may insert into the charge stock with proper depth to form a high temperature arc heat source, and proper smelting can be realized[5]."

Jan 1, 2012

By Samir N. Shoukry, Mourad Y. Riad, Gergis W. William

"Setting of concrete material is defined as the transitional period between states of true fluidity and true rigidity. Initial and final setting times are measured in the laboratory on the mortar sieved from the mix in a controlled environment where temperature and moisture values are constant. On the other hand, field applications are held in outdoor environments where environmental variations have direct impact on setting time values. In this study, initial setting time of class K concrete, usually used for bridge decks and concrete pavements, are investigated highlighting discrepancies between laboratory and field measurements. 72 mixes have been cast in variable environments and collected data from concrete mixes and the ambient conditions are reported. In light of the collected data, the effects of variable setting times on early age cracking of concrete material are studied and means to minimize such cracks are presented.BackgroundSetting of concrete material is defined as the transitional period between states of true fluidity and true rigidity [1]. Continuous hydration of the cement within the matrix transfers the mix from a state of setting to hardening. Initial and final Setting times are measured in a laboratory setting following ASTM C 403 specifications. Initial setting approximates the time at which the cement paste can no longer be plastic under compaction (or can be handled in a proper fashion), while the final setting approximates the time at which hardening occurs. The standard test described in ASTM C 403 is conducted on the mortar sieved from the mix (paste passing from 4.75 mm sieve opening). Initial and final settings are described as the elapsed time after the initial contact of water and cement till the mortar reaches a penetration resistances of 3.5 MPa (500 psi), and 27.6 MPa (4000 psi) respectively."

Jan 1, 2012

By Jing Zhan, Chuanfu Zhang, Yonglin Yao

"The Ni/Co arbitrary ratios of fibrous precursor were investigated during coordinated coprecipitation by changing the precipitating medium. The results show that the original molar ratio ofNi2+ to Co2+ in reaction solution can be maintained in the coprecipitate at pH'.'05.0 and the coprecipitate is single phase solid solution using water and water-X precipitating medium. But the original Ni/Co ratios are no longer kept and composition of the coprecipitate is not uniform at pH>5.0 in water precipitation medium. In order to obtain the precursors with the required morphology and accuracy Ni/Co ratios, the optimum conditions of fibrous precursors were chosen as follows: ammonia used as complex agent and pH adjustor, water-X solvent as precipiting medium, oxalate as coprecipitated agent, 8.0-8.4 for pH value, 50-70°C of reaction temperature, 0.5-0.8 mol/L of initial nickel and cobalt salt concentrations and excesses of oxalic acid of 10% - 20%.IntroductionNi-Co alloy as an important transition metal alloy with high mechanical strength, good anti-deformation, corrosion resistance, thermal conductivity, thermal stability, electrical conductivity, electrical contact, and special magnetic properties indicates that it can be used as high-temperature catalyst, special magnetic material, high-temperature electrochemical devices, and so on [1-6]. An ideal composite powder should have an appropriate stoichiometric ratio, good uniformity of chemical composition, appropriate phase, low impurity content and small particle size [7]. Similarly, the composition of nickel-cobalt alloy powder has an important impact on its crystal structure, properties and applications. Guo[8] found that magnetisms of CoxNi1-x such as magnetic anisotropy, curie temperature, and the shifts of the spin steering are very sensitive to the composition of alloy powder."

Jan 1, 2013

By A. Rosenfeld

The feasibility of applying laser induced optical emission spectroscopy to the high speed sorting of mixed alloy aluminum scrap is investigated. The basic spectroscopy for analysing aluminum alloys for the major alloying elements over their full concentration ranges is established. Materials handling issues are also described and the components of an overall sorting system are presented.

Jan 1, 1995

By R. Kramer

During foundry sand reclamation process development, molds formed from reclaimed chromite sand showed a rapid decline in tensile strength during thermal cycling tests. Because this characteristic could limit reuse of chromite sand in the. foundry, the sand was examined in detail Scanning electron microscopy, x-ray mapping, magnetic susceptibility, and x-ray diffraction were utilized to evaluate processed chromite sand. It was found that process variables such as binder composition, reclamation temperature, and processing method had a significant effect on the chromite sand particle surface. X-ray diffraction indicated a crystallographic change in the processed sands. Magnetic susceptibility also increased after processing. Diffusion of iron to the particle surface and increased surface roughness were identified as potential causes of the decreased tensile strength in the molds.

Jan 1, 1991

By R. G. Robins

Metal separations based on the selective precipitation of phosphates have a potential application in many hydrometallurgical processes. This paper reviews the literature on the solubility of a number of both divalent and trivalent metal phosphates and presents the result of some additional experimental measurements. The systems examined have been modelled to obtain free energy of formation data for the various species. Computer generated solubility diagrams which are described can be useful in predicting a variety of metal separations.

Jan 1, 1991

By Toru H. Okabe

As part of a systematic study on the thermodynamic properties of complex nitrides, phase equilibria of the system Li-M-N (M Mg, AI, Ga) at 900 K were investigated. An attempt to determine the thermodynamic properties of complex nitrides was made by using the galvanic cell method, which utilizes LiMgN as an electrolyte under nitrogen atmosphere. The electromotive force (Emf) of the cell at temperatures between 800 and 1100 K was measured. While the Emf of the cell at 900 K was measured to be 0.137 V, data discrepancies of ±0.03 V were found. It was difficult to determine temperature dependence of the Emf. The Gibbs energy change for the reaction, 113 Li3N (s) + 1/3 Mg3N2 (s) = LiMgN (s), at 900 K was determined to be !&apos;J.Go, (LiMgN) = -13.2 (±2.9) kJ/mol. Using thermodynamic information on the binary nitride from literature, the standard Gibbs energy of LiMgN was derived to be !&apos;J.Go f (LiMgN)= - 121 kJ at 900 K. The thermodynamic stability range of nitride was discussed by constructing isothermal chemical potential diagrams that provide a better understanding of the stability region of the LiMgN phase. The diagram was found to be in good agreement with the isothermal phase diagram determined by the alloy equilibration method. Although the obtained data includes large uncertainties, the results provide a better understanding of the thermodynamic stability of nitrides. The potential application of this complex nitride to nitrogen chemical sensors or a medium for controlling nitrogen potential is also shown.

Jan 1, 2003