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By Javier Enrique Basurco Cayllahua

In this work, a gram-positive bacteria was used as biosorbent to elucidate the aluminum load capacity under different conditions related to metallurgical and chemical plants. The sorption data followed the Langmuir, Freundlich, Dubinin-Radushkevich isotherms. In order to determine the best isotherm fit, three error analysis methods were used to assess the data: correlation coefficient (R2), residual root mean square error (RMSE) and Chi-square test. The error analysis established that the Dubinin-Radushkevich model fits better the aluminum biosorption data. The maximum sorption capacity was found to be 41.59 mg.g-1. The maximum removal of aluminum was 95% at pH around 5. The experimental kinetics data was evaluated considering two models (pseudo-second order and pseudo-first order). This study indicated that the R. opacus is an environmental friendly biosorbent.

Jan 1, 2009

By Klara Kodrikova, Vera Kasparkova, Michaela Uhlirova, Karel Kolomaznik

"Potentially hazardous wastes from leather industry (blue shavings) are processed into various biostimulators within two steps. The first step takes place at high pH (11-12) and hydrolyzation is implemented with potassium alkali, in the second step the pH is lowered to 9 with phosphoric acid after enzymatic dechromation occurs. The resulting hydrolyzates were analyzed in the sense of molecular weight distribution and tested as biostimulators on rape (Brassica napus). The hydrolyzates can be also directly used as universal NPK fertilizers. It has been proved that the nitrate content in the edible parts of tested vegetables (radish, lettuce, and cucumber) was approximately 200 times lower compared to the vegetables fertilized with an inorganic nitrogen fertilizer. The harvests of vegetables fertilized with the hydrolyzate and the inorganic nitrogen fertilizer were almost the same.IntroductionDuring processing raw hide into leather (tanning processes), only 20% of the collagen material is used for the final product. The remaining 80% ends up as waste, both tanned and non-tanned. Non-tanned waste such as calcimine can be used for production of artificial collagen casings for sausages, gelatine and also in pharmaceutical industry as collagen capsulates. Further processing and recycling of tanned leather waste (especially chrome shavings) is more complicated. Although many technologies producing various quality collagen hydrolyzates have been developed and tested in laboratories, few have been implemented on industrial scale. A promising turn came in the works of ERRC USDA [1,2]. They worked out an enzymatic dechromation technology (hydrolysis) and achieved a considerable decrease of the amount of relatively expensive proteolytic enzyme, which solved the difference between the quality and price of the final product. The American experience of enzymic hydrolysis were applied on industrial scale in the Czech Republic, where a plant was built with daily processing capacity of 3 tons of chrome shavings. The experience of real operation was published in [3] and the cooperation between the Czech Republic and USA partners resulted in a patent [4]. The main asset of the patent was the use of volatile organic bases in the hydrolysis process giving high quality and cheap hydrolyzates with low ash content."

Jan 1, 2008

By Yasuhiro Konishi, Norizoh Saitoh, Toshiyuki Nomura

This paper describes a new recycling method, based upon biotechnology, in order to extract platinum group metals (PGMs) from post-consumer products. The metal ion-reducing bacterium Shewanella algae was found to exhibit the ability to reduce and deposit PGMs. An integrated bioprocess using Shewanella bacteria to selectively recover Pd, Pt, and Rh from aqua regia leachates of spent automotive catalysts is demonstrated.

Mar 1, 2017

By S. K. Kawatra, T. C. Eisele

"Recent advances in microbiology have made the application of biotechnology to metallurgical processes possible. Hydrometallurgy stands to gain the cost from the use of microorganisms, as they are useful for both dissolution aids and for removing metals from solution. The development of genetic engineering techniques promises to greatly increase the importance of bioprocessing of metals and minerals by the year 2000.In this paper, the basic effects of microorganisms on metallurgical processes are reviewed, and the applications which are currently either in use or near being used are presented. Representative data collected at Michigan Technological University is also given.IntroductionMany hydrometallurgical operations exist which are thermodynamically possible, but which are industrially impractical due to slow kinetics, high reagent costs, or the need for a highly corrosive environment. However, recent discoveries in microbiology indicate that in many cases these difficulties can be reduced greatly by the action of bacteria and other microorganisms (1-8).A major advantage of using living organisms in hydrometallurgy is that once the culture is established the microorganisms produce their own reagents either from the material being processed or from low-cost nutrient supplements. They thus allow extremely complex chemical reactions to be carried out at reasonable cost. The major drawback of using microorganisms is their inability to tolerate extremely high temperatures, excessive concentrations of toxic metals, or very highly acidic, alkaline, or corrosive conditions. However, the complex reactions which bacteria make possible frequently eliminate the need for such extreme conditions. Also, in recent years a number of organisms have been isolated from such exotic environments as hot springs and deep-ocean vents which can tolerate temperatures higher than was previously thought possible for any organism, and can catalyze a number of metallurgically important reactions (8)."

Jan 1, 1988

By Johannes Boonstra

High rate bacterial catalyzed processes can serve to improve hydrometallurgical operations. These solutions are not only economical but also environmental sustainable. With references around the globe, the value of this new approach is recognized by industry worldwide. For instance, metals can safely and economically be separated from process and waste streams using biotechnologically produced sulfide, recovering a valuable metal sulfide product instead of a waste gypsum stream for disposal. Both the natural biological sulfur and nitrogen cycles offer bioconversions that are applied on industrial scale. The shared advantage of these processes is that waste compounds are converted in either a reusable raw material or in a harmless product. This way, natural product cycles can be closed. Applications based upon bioconversions are for example: Sulfur based: Bioleaching, reduction of oxidized sulfur compounds to elemental sulfur, metal recovery with biogenic produced H2S, SO2removal from gas streams, etc. Nitrogen based: Ammonia removal using the anammox-process, biological removal of NOxfrom gas streams, nitrate removal from water streams, etc. Metals: Bacterial processes for the reduction of metals such as uranium, selenium and manganese have proven to offer great potential for clean-up of groundwater streams. This paper contains a description of the above applications. Further, a short introduction on engineered high rate bioreactor systems and a description of industrial biotechnological applications will be provided.

Jan 1, 2003

By H. Dijkman

The PAQUES Bio Systems' core technology, marketed under the name THIOPAQ®, consists of various high-rate biological processes for metal-sulfur-water systems, complemented with common solid/liquid and gas separation steps. Sulfur species are converted to sulfide, which is a valuable component as it can be used for metals reduction and precipitation. Selective recovery of valuable metals can be employed, leading to revenue from metal values. In this paper, biotechnological systems for the treatment of metal sulfate solutions and dilute SO, gases are described. These installations can be designed to either produce predominantly aqueous (NaHS) or gaseous (H2S) sulfide. The emphasis here is on hydrogen sulfide gas. The main case history discussed is the demonstration plant that ran on hydrogen gas at Kennecott Utah Copper. Three years of operating experience clearly show that sulfate reduction with hydrogen gas is a viable option. Furthermore, the selective recovery of copper from leach water with the hydrogen sulfide produced was shown to be very effective.

Jan 1, 1999

By Zhucheng Huang, Yuanbo Zhang, Kecheng Zhang, Guanghui Li, Tao Jiang

"With rapid development of Iron and Steel industry, plenty of metallurgical dusts and sludges are generated, which have not been effectively utilized because of their poor hydrophilicity and bad ballability. Agglomeration and roasting of metallurgical dusts & sludges with a new-type composite binder are studied in this paper. The results indicate that the dosage of the new binders can be decreased to 2.5 wt% from 3.5 wt% when using the wet-grinding process. Under the optimal conditions of briquetting pressure 2070 N/cm2, briquetting moisture content 13 wt%, roasting temperature 1000 °C and roasting time 40 min, the qualities of the green, dry and roasted briquettes meet the requirements of the industry production. The finished products have the compression strength of more than 2000 N/cm2, which can be used as high-quality burdens for blast furnaces.IntroductionWith rapid development of Chinese Iron & Steel industry, there are more and more serious resource shortage and environmental pollution existing. Converter sludges, containing 30% ~ 40 wt% moistures, are typically difficult for recycling [1]. Foreign processing technologies for sludges treatment are relatively advanced including cold-bonded agglomerates for blast furnace, RHF reduction for the dusts and sludges with high content of Zn and Pb, smelting and reduction. Domestic iron and steel companies use a small amount of sludges in sintering. However, the sludges have the characteristics of high moisture and containing harmful impurities, which directly affect the sintering mixture permeability and product quality [2-5]. There are also other technologies such as production of metallized pellets, cooling agents for steelmaking, etc [6]. All of these deficiencies and applied are not in large-scale."

Jan 1, 2011

By Jorge Gibson, P. Chris Pistorius, Megha Jampani

"The main reason for the significant carbon intensity of integrated steelmaking (approximately 1.8 tons of CO2 per ton of steel) is the use of carbon-based reductants in blast furnace ironmaking. Several changes to blast furnace ironmaking have been proposed as ways to reduce carbon intensity and cost. A conceptually simple two-zone blast furnace mass and energy balance can be used to quantify the expected impact of such process changes on coke rate, carbon intensity, and productivity. Examples to be discussed include top gas recycling, combining lower blast temperatures with increased coal injection to produce a rich top gas, using prereduced feed, and tuyère injection of natural gas. The use of the operating window – which illustrates how allowable flame temperatures and top-gas temperatures constrain feasible oxygen enrichment levels – is illustrated. Increased use of natural gas would lower the carbon intensity of blast furnace ironmaking.IntroductionBecause of the significant carbon intensity of steelmaking (approximately 1.8 tons of CO2 emitted per ton of steel produced) and the high production rate of steel (more than 1.4 billion tonnes per annum), steelmaking is responsible for a large percentage, approximately 6.7%, of world anthropogenic CO2 emissions [1]. By far the largest input of the carbon into conventional steelmaking is as coke, which is essential to blast furnace ironmaking. A typical fuel rate for blast furnace ironmaking is 450 kg of fuel per tonne of hot metal (THM). (""Fuel"" includes coke and injectants which partially replace coke; pulverized coal and natural gas are typical injectants.) Assuming the fuels to contain 90% carbon on average, and since nearly all of this carbon exits the steel plant as CO2, a fuel rate of 450 kg is equivalent to a CO2 intensity of 1485 kg/THM – by far the largest part of the total CO2 intensity of steelmaking.Blast furnace ironmaking is expected to remain the main source of new iron units; this paper gives some estimates of the extents to which further reductions in carbon intensity from blast furnace ironmaking is possible. A recent European assessment suggested that blast furnace process intensification options such as increased pulverized-coal injection or natural gas injection would yield only modest energy savings [2]. However, if the focus is on CO2 emissions rather than on total energy use, there would be an advantage to using fuels – such as natural gas – which have lower carbon contents relative to energy content."

Jan 1, 2014

By Reinhard F. Dobner

After a short introduction about the HK's secondary smelter process and explanations concerning the anodes produced the regulation and buffering of bleed will be described and the principles of technology for processing of bleed will be presented. Modernization aspects, especially installation equipment, and the different types of evaporators used will be described in detail. Besides, experience made with acid-resistant materials - stainless steel, enamel, plastics - will be reported. Environmental aspects such as water and air pollution will be outlined briefly and in conclusion the quality of products obtained as well as quality control will be presented.

Jan 1, 1997

By Jukka Tuominen

The history of making blister copper in an Outokumpu Flash Smelting Furnace dates back to the late 1960?s, when Outokumpu first piloted the Outokumpu Direct Blister (ODB) process. The first commercial scale applications have been in use at Glogow, Poland, since 1978 and at Olympic Dam, Australia, since 1988. These applications utilize special concentrates, which are low in iron, and thus the formation of slag is also low. In 1995 the same principle was applied to smelting copper matte into blister copper in industrial scale at Kennecott Utah Copper. This application, the Kennecott-Outokumpu Flash Converting process, will celebrate its 10th anniversary of commercial scale operation this year. This paper outlines the development in efficiency and flexibility of Blister Flash Smelting processes compared to other smelting and converting options. The focus is on the economical aspects i.e. on the total feasibility of both greenfield investment projects and revamping of existing smelters.

Jan 1, 2005

By Theo Lehner

"The Boliden Rönnskär Smelter operates in the European Context of tight EH&S limits, with ever increasing regulations and tribulations. The near future promises to bring new burdens in the form of C02 trading, miners and pre-treaters increased appetite for a larger share of contained values, and changing compositions and competition in raw materials. On the other hand, European Smelters such as Rönnskär, Harjavalta have demonstrated an astonishing power of survival. This presentation lists and comments on current challenges but opportunities for increased survival power are also presented. One example of the latter is the ongoing investment into increased treatment capacity for e-scrap.UPDATE ON RÖNNSKÄR OPERATIONSThe Rönnskär Smelter has achieved 80 years of age with no signs of retirement. The smelter is most active in spite of its age! And it has undergone some face lift operations to maintain its attractiveness.Raw material, processing facilities and a market for the products are some essential prerequisites for a viable operation. To justify long term survival, economic terms such as return on investments and positive cash flow need to be considered. Below, we illustrate how the Rönnskär Smelter complies with these terms. To update the reader on current operations, our current flow sheet is depicted in Figure 1. The figure summarizes our current input and output."

Jan 1, 2012

By Björn Lindquist

Boliden has developed a number of specialised technologies for smelter gas handling and effluent treatment. These technologies will be described. Special attention will be given to the high-pressure venturi, Editube wet electrostatic precipitator, mercury removal processes, and two-stage effluent treatment.

Jan 1, 2002

By Mitchell L. Spencer, Viswanathan Panchanathan

"Bonded magnets are important category in permanent magnets. They are made by one of the following processes: compression bonding, injection molding, extrusion, calendering. An overview of the various bonded magnet processes and properties of products made with different magnet materials along with their applications are discussed. The main emphasis will be on the use of bonded NdFeB and ferrite magnets.IntroductionBonded magnets are a major growth area in permanent magnets. Bonded magnets are made by any one of the following processes: Compression bonding; Injection Molding; Extrusion and Calendering [1,2]. Compression and injection molded magnets are rigid magnets. Materials used in calendering process produce flexible magnets. Only the extrusion process makes both rigid and flexible magnets. The binders used for the bonded magnets vary depending on the processes. Thermoset, thermo-plastic and elastomeric binders are respectively used in compression, injection and the calendering process. Extrusion molding uses elastomers or thermo-plastic materials. The most co=on magnetic materials, Ferrite, SmCo, Alnico and NdFeB can be used in any of the above processes either alone or in combination as hybrid magnets. Another material that has been developed for co=ercial application is SmFeN. Making the material has been challenging and it is being used in niche market applications in limited quantitiesIn the extrusion process, a highly loaded compound is used to produce strip or sheet and is continuously extruded through a die. In calendering the granulated compound is rolled to produce a continuous wide sheet. In the compression bonding process a uniaxial pressing force is used. These magnets have higher loading compared to injection molded magnets. In injection molding the material is forced into a mold cavity and has lower loading compared to compression molded magnets [2,3]. Most of the flexible magnets are made using extrusion and calendering processes and the most co=on magnet material is inexpensive ferrite. Flexible magnets have been made using rare earth materials, but on a very limited basis.The major advantages of magnets processed by extrusion and calendering are as follows: inexpensive tooling, automation; practically any 2D geometry; fast production rates; no chipping or breaking; a wide range of properties; on-line magnetization; easy to convert (e.g. cut, punch or shape).Compression bonded magnets are inexpensive to manufacture. They have higher magnetic properties compared to injection molded magnets; however lower than their sintered counterparts. The magnet shape is restricted to simple geometries and they require careful handling. Their isotropic nature allows complex magnetizing patterns."

Jan 1, 2013

By Godwin J. Igwe

For soil remediation technology to be effective, a thorough understanding of the interactions between a targeted contaminant and the soil matrix is crucial. Proper selection of remediation technology, based on understanding the bonding/binding characteristics of the soil and contaminant, can often result in significant remediation cost savings. Contaminated soil cleanup is complicated by both the physical nature of the soil formation and the behavior of contaminants introduced into the formation. Contaminants can exist in the subsurface in different phase attached to the soil surfaces, dissolved in the ground water, or occupying pore spaces as a separate gaseous or liquid phase. Contaminants properties and how they exist in the subsurface influence their toxicity, mobility and treatability with different remediation technologies A soil characterization study was performed to provide information for remediation technology selection for an inorganic lead contaminated soil. The soil pH, TCLP analysis, thermogravimetric analysis, the soluble anions and cations present, equilibrium leaching tests, analysis by x-ray fluorescence, sequential extractions and speciation analysis using scanning electron microscopy, were all used. Results provided many insights into contaminant behavior in the soil, indicating ultimately whether soil washing or solidification/ stabilization remediation technologies were applicable.

Jan 1, 1994

By Egil Krystad, Merete Tangstad, Kai Tang, Gabriella Trenell

"A new UMG-Si refining concept has been proposed in this paper. Liquid Si and another liquid metal phase (Me) were separated by the molten slag spontaneously based on their different physicochemical properties. Two metal/slag distribution reactions are able to occur in the system simultaneously. Experimental investigation on the B and P distribution equilibria among Si/slag/Me was carried out in the graphite resistance furnace under the inert atmosphere. The B and P doped silicon was in equilibrium with either the SiO2-CaO or SiO2-CaO-l0%CaF2 slags at 1600 and 1650°C, respectively. The pure Fe and Cu metals were used in order to ""capture"" B and P in the slag phases. B and P in samples were determined by the ICP-MS. B and P distribution coefficients for the Si/slag/Me equilibria were compared with the theoretical calculations. The possible kinetic barriers for the Si/slag/Me three-layer equilibria have been analyzed. The metal contaminations in the three-layer equilibria were also examined. The present study provides a new approach for the refining of MG-Si.IntroductionMost of the impurities in the metallurgical silicon (MG-Si) are rather ""dilute'', ranging from few to several thousand ppms. However, the target impurity levels for upgrade metallurgical silicon (UMG-Si) feedstock are often far below the level of ppm. In such extreme case, the conventional refining technologies face the great technical challenges. B removal by slagging has already been implemented industrially. Removal of Pis frequently carried out by the vacuum distillation. The separating treatments for B and P removals lead to increase refining cost, total CO2 emission and longer pay-back time of solar cell module.It is well known that the phosphate capacities of slags in equilibrium with liquid silicon are extremely lower. However, if we introduce another phase that possesses high ""phosphor capacity"" into the Si/slag system, one would expect to continuously remove P from Si through molten slag to the new ""phosphor capturer"". The so-called three-layer refming concept is thus proposed in the present study. Liquid Si and another liquid phase (Me) are separated by the molten slag spontaneously based on their different physicochemical properties. Two metal/slag distribution reactions are able to occur in the system simultaneously."

Jan 1, 2013

By Patrick R. Taylor

Sub-micron sized boron carbide powders have been synthesized in a non-transferred arc thermal plasma reactor. Precursors for this synthesis are boric acid or boron oxide powders and methane. The powders produced were characterized in terms of size, shape and purity. Methods to increase the purity of the product were evaluated and included hot water leaching to remove unreacted oxides and controlled temperature, air roasting to remove excess carbon. Theoretical results are also presented on the thermodynamics and mechanisms of the synthesis reactions.

Jan 1, 1994

By Takeshi Yoshikawa

For the development of low-cost silicon refining process for solar cells, the present authors have been studying the low temperature refining technique, ?solidification refining of Si with Si-Al melts at 1173 ? 1273K?. In the present work, we have investigated the B removal in that refining, utilizing the segregation effect and also the effect of Ti addition to the melt. Segregation ratio of B between solid Si and Si-Al melt was measured by the temperature gradient zone melting technique and it indicated the B removal fraction would be as much as 90%. Titanium addition to the melt was found to produce the TiB2 precipitation with soluble B in that melt and bring the effective B removal of refined Si to its content of 1ppma.

Jan 1, 2006

By D. M. Fermino, C. G. Bastos Andrade, V. F. Justo, F. R. Valenzuela-Diaz, M. G. S. Valenzuela, C. Volzone

The present paper presents the study of light green smectite clay, from Paraiba, Brazil, submitted to mild acid attack under moderated conditions. Usually, clays are subjected to treatment with strong inorganic acids at temperatures near the boiling point and at high acid concentrations and then, widely used as bleaching agents. The treatment occurred under bellow boiling temperature and at short times of reaction (90°C, reaction times of 1, 6, 12, 18 and 24 hours in close reactor, concentration of the aqueous solution of hydrochloric acid 1.5 M, clay/acid solution ratio of 1g/10mL). The purpose of these attacks is to reduce the concentration of impurities providing color, with minimal change in the clay minerals structure, aiming at use in products of high value such as cosmetics and polymer/clay nanocomposites. The raw clay and the attacked samples were characterized by X-ray diffraction (XRD), cation exchange capacity (CEC), stereomicroscopy, scanning electron microscopy (SEM) and energy dispersive X-ray detector (EDS).

Jan 1, 2015

By C. L. Lin

Multiphase, irregularly-shaped randomly-oriented PARGEN particles were grown to determine the breakage/liberation characteristics of such locked particles. The simulated locked particles were randomly broken to establish the liberation characteristics of the broken fragments. The progeny size distributions are consistent with Gilvarry's volume and surface flaw model for single particle breakage. The extent of liberation of both continuous and dispersed phases can be described from the conservation of interfacial area. In this regard the data can be normalized and liberation described for a wide range of dispersed phase grades and dispersion densities.

Jan 1, 1988

By Godwin Beene

During recent years, copper and acid production from Nkana Smelter has formed a significant proportion of ZCCM's total output, but a number of problems affecting the smelter over the last decade have only been recently overcome. This paper discusses recent developments in the smelting practice, highlighting some of the operational problems experienced and associated solutions. The smelter performance over the decade is discussed and the innovations in the smelting technology employed to sustain production in the wake of limited re-capitalization are dealt with in detail.

Jan 1, 1999