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By Guo Xueyi

The method of Substance Flow Analysis (abbreviated as SFA) provides a helpful tool for the study of the industrial metabolism of a certain metal within a regional level. In this work the flow of lead in China, 2006, was traced within the STAF model, and the situation of production, consumption and recycling of lead resources in China were introduced. The SFA is performed on lead flows during its one year life cycle in detail. As one of the biggest producer and consumer of lead in the world, China is facing a problem depletion of lead resources. How to increase the resource efficiency is a significant issue for lead industry of China. Based on the result, several suggestions were proposed in the paper, aiming to contribute important reference information for the industrial metabolism and resource management and recycling of lead industry in China.

Jan 1, 2009

By Patricia Martínez Nicolás

Nickel and ferronickel are some of the major components in the production of special alloys; however, the energy consumption for their production greatly increases their price. A cheaper option could be to use NiO and a reducing agent. This work presents experimental and theoretical analysis to estimate the effect of slag basicity and amount of reducing agents on the NiO reduction from the slag which interacted with molten steel at 1600 °C in an EAF. The slag system contained CaO, SiO2, CaF2 and NiO together with a reducing agent, ferrosilicon or carbon. The NiO content in the slag was 25 mass%. The amounts of the reducing agents (Si and C) were 1 to 4 times the stoichiometric mass to reduce NiO. The CaO/SiO2 ratio was 1.5 and 2.5. The kinetics of the process was very fast since after few minutes the maximum nickel yield was obtained. The slag basicity had a negligible effect on the reduction of NiO.

Jan 1, 2006

By David Arana

The use of gas-water dispersion of a molten material flow onto a vibrating surface is developed as a process to minimize water pumping requirements, minimize the risks of explosions, and minimize the post solidification dewatering and fines handling equipment requirements. The process uses existing vibration transport technologies and common plant utilities. Plant trials using the smaller footprint and the progressive molten particle cooling time have yielded encouraging results. The results are analyzed and reported.

Jan 1, 2006

By John R. Goode

Barrick Gold Corporation operates gold mines in the United States, Chile, 'Peru, Canada, and in the near future, in l1anzania. Barrick meets environmental requirements and limits the potentially adverse effect of cyanide discharge to the environment using various cyanide destruction techniques. Barrick operations use, or have used, natural degradation, ferrous sulphate, hydrogen peroxide, Caro's acid, alkaline chlorination, and the SO/Air process for cyanide destruction. This paper presents a general discussion of the options for controlling cyanide in plant effluent and provides details of Barrick's operating experience including general notes on costs.

Jan 1, 1998

By Yuanyuan Wang, Yuhao Ding, Hao Bai, Kang Zhou, Guangwei Du

"In this paper, the list analysis of GHG emissions of aluminum industry was conducted based on the data from typical electrolytic aluminum plants of a China’s northwest province. The results show that under the conditions of average anode effect coefficient as 0.16 times/(cell• day) and anode duration as 5 minutes per day, equivalent emissions of CO2 reached 1.23 ton per ton of aluminum, in which PFC emissions accounted for about 71%. Compared with foreign advanced level, which is 0.87 ton per ton of aluminum under the conditions of average anode effect coefficient as 0.01 times/(cell•day) and anode duration as 0.46 minutes per day, there is much room for China’s aluminum industry to reduce GHG emissions. Since anode effect plays an important role on PFCs generation in electrolytic aluminum process, how to control anode effect strictly becomes the key factor for remarkable reduction of GHG emissions in China’s aluminum industry.IntroductionTechnology of aluminum electrolysis is a mature and efficient process of aluminum production. Due to the huge demand on aluminum worldwide, so resource consumption, energy consumption and pollutant emissions in the process of aluminum production are still large. The global output of aluminum reached 45193 kt in 2012. A large amount of CO2 and PFCs are produced in the process of aluminum production, and the greenhouse effect and environmental pollution caused by emissions of them is a concern. PFCs belong to a powerful greenhouse gas, thus emission reduction of PFCs is very important for aluminum electrolysis industry. At present, China's aluminum production accounts for about 33% of the world's aluminum production, and controlling PFCs emission has become the key point of pollution control of aluminum electrolysis industry in China [1].Taking the case of a typical electrolytic aluminum plant of a China’s northwest province, this paper studies the list analysis of GHG emissions of aluminum industry in China. GHG emissions of a China’s northwest province were calculated through investigating existing situation of aluminum electrolysis industry in the province, knowing capacity, output, main production technology and equipment level of aluminum electrolysis industry, and using the calculation framework and methods of GHG emissions of aluminum electrolysis industry, which were put forward by the intergovernmental panel on climate change (IPCC), the international aluminum association and other organizations at home and abroad. The list analysis of GHG emissions of aluminum electrolysis industry will offer useful information in promoting emission reduction of GHG in aluminum electrolysis industry, improve the efficiency of energy utilization."

Jan 1, 2014

By Varadarajan Seshadri

A physical model based on similarity principles was constructed for simulating the RH degasser of CST (Companhia Siderurgica Tubarao, Vitoria, ES, Brazil) to evaluate the circulation rate of the metal which essentially defines the degree of exposure of the metal to vacuum in the chamber and thus of the refining rate, The circulation rate on the other hand will influence the decarburization rate and removal of dissolved gases like nitrogen and hence it is essential to optimise this parameter to get maximum refining efficiency with minimum refining times, thus improving the productivity of the secondary refining process. Mixing characteristics in the ladle is evaluated by pulse tracer addition using conductivity-meters located at the down leg as well as at several locations in the ladle. The influence of gas injection through nozzles in the upleg with simultaneous bottom injection of gas as well as nozzle blockage on the circulation rates were investigated. Also simulation experiments of kinetics of decarburization were carried out using CO2 adsorption-desorption process in sodium hydroxide solution as circulating fluid and the effect of, bottom gas flow rate in this case was also evaluated. The results were carried over to prototype and to optimize the process.

Jan 1, 2003

By Jian Yang

The mechanism of resulfurization in the desulfurization process with magnesium vapor produced in situ by aluminothermic reduction of magnesium oxide was clarified in the present work. The influences of various operating parameters on the resulfurization were studied and the methods that could prevent resulfurization were proposed. There are two kinds of mechanisms of resulfurization in the desulfurization process with magnesium. One is decomposition of the desulfurization product of MgS under the inert atmosphere. The other is oxidation of MgS under the oxidative atmosphere. Under the present experimental conditions, lowering operating temperature and oxygen partial pressure in the atmosphere could effectively prevent the resulfurization. Adding CaO onto the melt surface was an effective method for preventing the resulfurization due to transformation of the desulfurization product of MgS into the more stable compound of CaS. Since addition of the activated charcoal powders greatly decreased the transfer rate of oxygen in the atmosphere to the melt surface, it also reduced the resulfurization remarkably.

Jan 1, 2006

By Hong Yong Sohn, Miguel Olivas-Martinez, Zhixue Yuan

A novel flash ironmaking process that directly reduces iron oxide concentrate particles by gas is under development. The goal of this work was to study the possibility of reoxidation of iron particles in various gas mixtures. As the product iron cools down in the lower part of the flash reactor, conditions may become favorable for reoxidation because of equilibrium and high reactivity of iron particles. The effects of temperature (823 – 973 K) and H2O partial pressure (40 – 100 pct., Ptotal = 86.1 kPa) on the reoxidation rate were examined. The pressure dependence was first order with respect to water vapor, and the activation energy was 146 kJ/mol. A complete rate equation that adequately represents the experimental data was developed. For oxidation in O2-N2 mixtures, the effects of temperature (673 – 873 K) and O2 partial pressure (5 – 21 pct., Ptotal = 86.1 kPa) were determined. Reoxidation in pure CO2 was also investigated at 873 – 1073 K for comparison.

Jan 1, 2014

By T. T. Chen

Canadian Electrolytic Zinc has developed the "cement-stabilization of jarosite residue" Garofix) process to stabilize zinc plant jarosite residues for disposal. The cement-jarosite mixtures cure quickly, have good mechanical strength and low hydraulic permeability; they possess good neutralizing capability and chemical stability. In the jarofix process, Portland cement partly decomposes jarosite to form (SO4MOH)12.nH2O, ferric hydroxide and an alkali sulphate. Approximately 40% of the jarosite reacts in mixtures containing 30% cement. The jarofix product also contains various Ca-Al-Fesilicate-sulphate-hydrate phases and gypsum, which bond the individual particles together imparting mechanical strength and reducing the permeability. Most of the reactions take place in the first few hours of curing. Ammonium jarosite is slightly more reactive than sodium jarosite but releases NH3 gas; water-soluble Zn in the jarosite residue is stabilized in the cement reaction products.

Jan 1, 1996

By Ho-Sang Sohn

The kinetic study on desulfurization of copper matte by gas bubbling was designed under the presumptions of lower FeO activity and of no slag formation, Copper matte with 59% Cu and 22.6% S in weight was oxidized at 1523K by bubbling of Ar + O2 gas through a submerged nozzle. The effects of oxygen partial pressure and flow rate of gas on the oxidation rate of matte were discussed. The desulfurization rate and the evolution rate of SO2 gas of copper matte were significantly influenced by the oxygen partial pressure, but the dependence on gas flow rate was rather complicated. The desulfurization rate and evolution rate of SO2 gas of copper matte were described by the mass transfer rate through the gas film around the rising gas bubbles. Thermodynamic correlation equations between the partial pressure of gaseous species and matte composition were incorporated to the kinetic calculation, The present model shows that the reaction path starts to transiently cross over an isobar line of PSO2 to asymptotically approach to the particular isobar line drawn in a matte composition plane of %S and %O.

Jan 1, 2003

By K. Narayana Swamy

The traditional approach to improving the operating efficiency of a metallurgical plant has been to study individual unit operations and focus on improving the poor-performing unit operations. The complex nature of most metallurgical plants call for a holistic approach that will consider the whole rather than just focus on the individual units of a plant. This holistic approach is part of the systems thinking principles. Numerous case studies highlight the importance of the need to apply systems thinking principles in improving the effectiveness of metallurgical operations. Improving the efficiency of one unit operation without considering its effect on the performance of other unit operations has in many cases lead to lower overall operational efficiency. Modeling and simulation are key to the application of the systems thinking principles. Standard flowsheet models are very useful in scenario analyses though they have to be supplemented with other models for useful predictions.

Jan 1, 2006

By Wenming Wang

Recycling of retired cadmium telluride (CdTe) photovoltaic (PV) modules has attracted attention due to new European environmental regulations. Recycling tellurium from CdTe PV modules is becoming more important because of the low availability of this metal. We investigated several treatment paths for reclaiming tellurium from solutions obtained from leaching fragments of CdTe PV modules. Our experiments showed that conventional soda ash neutralization/hydrolysis methods recovered only 50~60% of tellurium. However, by appropriately combining neutralization and sulfide precipitation, almost all the tellurium present in the leaching solution was precipitated and recovered; the concentration of tellurium in the processed solution was reduced from 900-1000 mg/L to less than 1 mg/L, yielding a tellurium recovery greater than 99%. This method can be incorporated in the scheme of recycling spent CdTe PV modules and manufacturing wastes. It may be also an alternative to the current operations for removing tellurium from copper anode slime leaching solutions.

Jan 1, 2006

By Holger Cordes

X-ray diffraction has long been used for qualitative and quantitative mineral analysis but Rietveld data analysis is still an under utilized method for mineral exploration and processing applications. In this full-profile approach the structural parameters of each mineral phase, together with experimental parameters, are refined by least-squares methods to minimize the difference between observed and calculated diffraction patterns. The result is a standard-less, quantitative analysis of the mineral abundance in the sample that is more accurate and considerably faster compared to traditional methods. The TOPAS software package combines a user-friendly interface with a unique approach to resolve overlapping peaks. Automated analysis options are also available and significantly reduce analysis time for routine samples. Several examples on a wide range of naturally occurring rock types are shown that illustrate the capabilities and limitations of the method. The examples include several options for the quantification of amorphous constituents like volcanic glasses.

Jan 1, 2006

By Patrik Fredriksson

Thermodynamic data concerning FeO-containing slags is of importance in ladle refining of steel. With a view to generate a set of reliable and self-consistent thermodynamic data for these slags, experimental determination of the activities of FeO in binary and ternary slags was carried out using the gas equilibration method involving CO-C02-Ar gas mixtures at steelmaking temperatures. The slag samples in Pt crucibles were quenched after the equilibration and subjected to chemical analysis. The thermodynamic activities of "FeO" in the slags were calculated from the experimental data. The results are incorporated into a thermodynamic description of silicate melts in the present laboratory. The model is based on a Temkin-Lumsden approach and is able to compute the thermodynamics of higher order systems from the lower order ones.

Jan 1, 2003

By B. Bichel

For the last 70 years, molten blister copper has been transferred by rail in hot metal cars from the Copper Cliff Smelter to the Copper Cliff Copper Refinery (ex Ontario Refining Company) where it was processed in two (2) reverberatory anode furnaces by poling with logs, cast on four (4) wheels, and then electrorefined. This practice was modernized in 2001 with the installation of two (2) rotary anode furnaces at the. Copper Cliff Smelter which employ steam and. natural gas for reducing and which provide a significant reduction in emissions. A new casting shop with a single anode casting wheel is used to cast regular and stripper constant weight anodes which are transported by truck to the Copper Cliff Copper Refinery for anode preparation and electrorefining. This paper provides an overview of the copper circuit at the Copper Cliff Smelter and a description of the CDN$31 million capital project.

Jan 1, 2002

By Deborah A. Kopsick

Several minerals were observed and collected in a small gully originating from a weathered coal processing waste (gob) pile in Barton County, Missouri. The rapid alteration of these various minerals after collection suggested that they might represent a dehydration sequence. X-ray diffraction of the dehydrated and rehydrated minerals deposited on the gob pile indicated the presence of the monohydrate and heptahydrate forms of ferrous sulfate, szomolnokite and melanterite respectively. The occurrence of melanterite (FeSO4.7H2O), was limited to isolated areas of ponded water while szomolnokite (FeSO4.H2O), was associated with the outwash areas of the pile. Laboratory dehydration of melanterite collected at the gob pile revealed the formation of rozenite (FeSO4.4H2O), an intermediate form of ferrous sulfate. Szomolnokite was shown to be the stable form of these ferrous sulfates during these experiments while melanterite and rozenite were shown to alter readily. Chemical analysis of szomolnokite revealed enrichment in Fe, Mg, Zn, Cd, Cu and Mn relative to the chemical composition of the gob ad the lechate generated from the gob wastes. Although this gob pile had been weathering for more than 35 years, significant concentrations of trace metals were still being released from the pile through the generation of leachate and the formation of various soluble metal enriched ferrous sulfate minerals.

Jan 1, 1982

By William Petruk

An investigation was conducted to determine whether mineral liberation data obtained by one image analysis technique are the same as data obtained by another image analysis technique. The liberated vs non-liberated, volume % and weight % techniques for measuring mineral liberations by image analysis were tested. The results show significant differences between the values obtained by the different techniques. The lowest liberation values were obtained by the liberated vs non-liberated technique and highest by the weight % technique. It is interpreted that the weight % technique produces the most realistic results. The weight % technique also produces data that can define mineral associations for the unliberated grains. These include (1) mineral quantities in particles that contain different amounts of unliberated mineral, (2) mineral quantities in particles that have different size ranges, and (3) mineral quantities and degrees of liberation for specific minerals in particles of different size ranges.

Jan 1, 1996

By Pengfu Tan

In order to understand and control the formation of dioxins and furans in iron ore sinter plants and to possibly avoid expensive end-of-pipe removal stages, thermodynamic calculations on the stability of PCDD/Fs have been combined with sinter process modeling by means of kinetic simulations and computational fluid dynamics. Three thermodynamic databases of PCDD/Fs, derived using the Group Additivity approach and two computational molecular modeling methods, MNDO and PM3, respectively, combined with the SGTE database have been used to model the PCDDIF formation and the PCDD/F isomer distributions in iron ore sintering. The results show very similar conditions for the PCDD/F formation using the different databases. Concerning the isomer distributions of toxic PCDD/Fs, the calculated data derived from the MNDO method showed optimum agreement with measured values from industrial furnaces. The thermodynamic calculations also proved that the isomer distributions found in combustion processes are equilibrium values, while the concentration ratio of PCDDs and PCDFs in the wind boxes does not represent an equilibrium state. A CFD model of iron ore sintering was developed including the kinetics of 15 relevant chemical reactions with the aim of describing the temperature fields and the gas flow patterns in the sintering bed. On the basis of these information and experimental observations reported in the literature possible pathways for the PCDD/F formation in sinter plants have been identified: PCDD/Fs are formed in the critical temperature region of 250 to 450 °C below the combustion zone, are then carried downwards with the gas and condensed close to the bottom of the sinter bed. Transported to the discharge end with the solid mixture, they are again released into the gas phase when the flame front approaches the bottom. PCDD/Fs are also formed in the last wind boxes when the hot off-gases cool down and reach the critical temperature range. Consequently, methods to reduce the dioxin formation reactions are proposed including inhibitor addition to the sinter feed and off-gas quenching.

Jan 1, 2003

By Elli Nurminen

In this work the thermodynamics of the metallic sulphate decomposition reactions were studied through thermodynamical calculations and thermogravimetric methods. The decomposition temperatures and mechanisms were determined for cupric sulphate, ferric sulphate and also for industrial flue dust from a copper flash smelting process. The aim was to determine the thermodynamic conditions for sulphate decomposition and to estimate whether the reactions are kinetically likely to take place in the flash smelting process heat recovery equipment. The information is essential in CFD-modelling of the reactions taking place in the boiler and for optimising the process.

Jan 1, 2006

By Dirk Verhulst, V. I. Lakshmanan

Why Chloride Hydrometallurgy?The most available, cheapest and best known reagent for treating ores and other raw materials for the metallurgical industry is sulfuric acid. Hydrochloric acid is second in line. What often happens is that a process is developed on the basis of sulfuric acid, and that at some point the question arises: wouldn't hydrochloric acid do this better?Considering hydrochloric acid immediately opens a very interesting field of research. To summarize a few comments from another paper presented at this symposium [1]: chlorides are far more soluble than sulfates (with a few interesting exceptions); the hydrogen ion activity is greater in chloride than in comparable sulfate solutions; higher oxidative conditions are possible; regeneration is more straightforward; more diversity is possible and better conditions for the separation of species can be found for solvent extraction and ion exchange; sulfur in the ore can be separated as elemental S; higher metal concentrations in solution and more flexibility in the chosen oxidation state means significantly lower energy costs.Also, the volatility of many chlorides at higher temperature allows further separation without the need to go to a different system. Chlorides also form molten salts with a low melting point, providing another means of separation and purification in the same chloride medium.

Jan 1, 2011