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By P Ridgeway, D Xie, M A. Somerville, S Jahanshahi, H Rogers, J G. Mathieson, Y Pan, N Haque, P Zulli, T E. Norgate, L Lu, A Deev

In 2006 the Australian steel industry and CSIRO initiated an R&D program to reduce the industry’s net greenhouse emission by at least 50%. Given that most of the CO2 emissions in steel production occur during the reduction of iron ore to hot metal through use of coal and coke, a key focus of this program has been to substitute these with renewable carbon (charcoal) sourced from sustainable sources such as plantations of biomass species. Another key component of the program has been to recover the waste heat from molten slags and produce a by-product that could be substituted for Portland cement. This paper provides an overview of the low-emission Integrated Steelmaking Process, progress made over the past seven years and the program’s future direction which includes proposed demonstrations of the technologies developed including large scale piloting and full scale plant trials.

Jan 1, 2014

By J. L. Delplancke

During copper electrowinning in sulphate electrolyte, intense oxygen evolution takes place at the anode. Lead alloy anodes are progressively replaced by dimensionally stable anodes in order to avoid the cathode contamination by dissolved lead. The electroactive coating of these anodes has to be as cheap as possible, adherent to the substrate, electrochemically stable and has to be efficient at high current density and high temperature. This requirement is even demanding in case of copper electrodeposition for the production of thin copper foils for the electronic industry. The production of thin (20 µm thick) copper foils for the printed circuit boards requires high purity copper electrodeposited at a current density as high as 7,000 A/m2. The choice of a long term coating composition is driven by economics. The purpose of this paper is mainly to review the anode compositions suitable for copper electrowinning and for copper electrodeposition at high current density. A short description of preliminary results obtained with a new anode coating on a titanium substrate is also presented.

Jan 1, 1999

By Eren Hüseyin Obuz

In this study, the leaching kinetics of rare-earth elements were investigated using HCl and HNO3 solutions. A standard crushed complex ore was utilized as raw material. The complex ore (particle size of under 54 μm) contains REE (Ce, La, Nd, Pr, etc.). Different leaching durations were selected for the kinetic studies. The highest leaching efficiency was obtained in HCl solution, and the leaching mechanism was identified to diffusion through a product layer. The rate constants of Ce, La, Nd, and Pr were calculated as 1.08 × 10−2, 0.86 × 10−2, 1.87 × 10−2, and 1.34 × 10−2 h−1, respectively.

By T. Nakamura

TiO2 and Ti/TiO2 thin films were deposited on a quartz substrate by laser ablation of TiO2 and Ti targets using Nd:YAG pulsed laser. After sulfurization of the TiO2 film in H2S or CS2 gas at 1273 K for I hour, the surface atomic structure was changed. Furthermore, the Tirri02 film was successfully prepared by the subsequent ablation of Ti and Ti02 targets. The morphology and structure of the films were characterized by XRD, XPS and AFM analyses.

Jan 1, 2003

By Peter K. Liaw, Niann-i Yu, Wei Zhao

"For a plain-weave Nicalon ™ fiber fabric-reinforced silicon carbide (SiC) ceramic composite, little attentation has been paid to the effect of fabric stacking sequence on its mechanical behavior. In this paper, fiber-fabric stacking sequence effects on the elastic stress distributions, ceramic matrix-cracking stress, effective elastic moduli, and flexural strengths of laminated flexural test bars are quantified. A quantification model is established based on the combination of classical laminated plate theories and a fiber undulation model developed by Chou et al. A FORTRAN program is compiled to implement the modeling, which can be run in a SUN work station. The mechanical performance of a continuous fiber-reinforced ceramic-matrix composite (CFCC) with a [0/30/60] lay-up was analyzed and predicted. The variation in the fiber-fabric stacking sequence can vary the elastic stress distributions along the thickness direction of specimens, magnitude of ceramic matrix-cracking stress, effective elastic moduli of the laminate, and crack initiation sites as well as fracture modes. Moreover, all these factors contribute to scatter in flexural strengths of the CFCC.I. IntroductionWith enhanced fracture toughness and the ability of non-catastrophic (graceful) failure behavior, CFCCs are currently under evaluation for high-temperature structural applications in heat exchangers, combustors, hot-gas filters, boilers components, first walls and high-heat flux surfaces gas turbines, space vehicles and nuclear reactors.[1-8] Extensive applications of CFCCs by industry are still hampered by an insufficient understanding of the mechanical behavior, and sometimes, the lack of a well-developed and widely accepted design philosophy, in addition to the high-production costs."

Jan 1, 1998

By Chuan-fu Zhang

In present work, the physical properties of molten FenO-MgO-CaO-SiO2 slags were measured .It is shown by the results that when the slag composition is as follow: MgO 8%~12%, CaO 2%~8%, Fe/SiO2 1.2~1.6, the viscosity of the slags decreases with the increase of temperature. When the Fe/SiO2ratio and the MgO content are fixed, the electrical conductivity increases and the viscosity decreases as CaO content increasing, while the content of CaO exceeds 6% its influence weakens. When the MgO content is 11% and the CaO is 6%, the viscosity of the slag decreases markedly as the increase of Fe/SiO2 ratio. Its influence to viscosity is inconspicuous when the Fe/SiO2 ratio exceeds 1.5. When the CaO content is 6% and Fe/SiO2 is 1.2, the electrical conductivity decreases with the increase of MgO content as temperature is below 1290, but increases when temperature is above 1290. When the MgO content is 11% and the Fe/SiO2 ratio is 1.2, the electrical conductivity increases with the increase of CaO content. When the CaO content is 6% and MgO content is 11%, the electrical conductivity increases as the increase of Fe/SiO2 ratio, while its influence weakens as the temperature increases continuously. The electrical conductivity rises when temperature increases at any slag content. The melting temperatures of FenO-MgO-CaO-SiO2 semi- synthesis slags from this work were below 1290.

Jan 1, 2006

By W. G. Davenport

This chapter shows how flash furnace industrial oxygen and oil requirements are affected by different: (a) product temperatures (b) conductive, convective and radiative heat losses (c) electrical energy inputs (d) hydrocarbon fuels. The calculations of the chapter are all for production of 65% Cu matte from pure CuFeS2 concentrate. Blast temperature is? 298 K throughout.

Jan 1, 2001

By H. Forrest

Lead smelting at Cookson Industrial Materials was formerly carried out using a combination of Blast and Reverberatory Furnaces. In the late 70' s these furnaces were replaced by two 20 tonne capacity Rotary Furnaces. This furnace type has proved to be more flexible in the range of feedstock that can be processed, including lead drosses, battery plate and even whole batteries. High rates of production have been achieved whilst attaining a good level of environmental control. The majority of the sulphur in the feedstock can be fixed by use of appropriate fluxes.

Jan 1, 1990

By Mala Nath, Atjit Mallick, Asheesh Kumar

"The present research work is aimed to focus on the development of chemically stable light weight microporous carbonaceous material, such as activated charcoal incorporated either with titanium n-butoxide, titanium diisopropoxide bis(2,4-pentanedionate), vanadium 2,4-pentane-dionate or zinc 2,4-pentanedionate having varying wt% of the metal (2-8%) using ethanol as solvent at 40--50 oC followed by calcinations at 100, 150 and 200 cC, except the samples with titanium diisopropoxide bis(2,4-pentanedionate) which are calcinated at 80 oC. Atomic absorption studies along with FESEM revealed that the maximum incorporation of metals (Zn, V and Ti) in activated charcoal was observed with 4 wt% of zinc 2,4-pentanedionate calcinated at 150 oC , 4 wt% of vanadium 2,4-pentanedionate at 100 oC, 2 wt% of titanium n-butoxide at 100 oC and 2 wt% of titanium diisopropoxide bis(2,4-pentanedionate) at 80 oC, and equilibration time of 20-24 h was used in each case. Hydrogen sorption behavior in these carbonaceous materials has also been studied at 77.4 K and low pressure up to I bar. The highest hydrogen uptake obtained was 1.45 wt% (164.5 cm3 (STP)/g at P/Po = 1.0) for activated charcoal incorporated with 4 wt% of zinc 2,4-pentanedionate calcinated at 150 oC.IntroductionTwo of the major challenges for humanity in the next twenty years are the shrinking availability of fossil fuels, the global warming and potential climate changes that result from their ever-increasing use. So it is necessary to fmd an energy source that is convenient, flexible and controllable. One possible solution to these problems is to use an energy carrier such as hydrogen, and ways to produce and store hydrogen in electric power plants and vehicles. Hydrogen storage is the bottleneck for the breakthrough of hydrogen as energy carrier in automotive applications [1]."

Jan 1, 2012

By S. S. Chabot, S. E. James

A recent survey of CEOs from major steel companies worldwide revealed the importance of recycling zinc units from EAF dust, mill scale, blast furnace dust, and other zinc containing streams in their plants. Many processes were developed and installed in response to this challenge. The most successful approach involves the production of a crude zinc oxide and selling it to primary zinc producers to recover the metal value. The problem with this process is the high concentration of halides in the crude oxide. This type of material cannot be processed directly in an electrolytic zinc plant because of corrosion problems it will cause in electrolysis. In 1999, BRZ installed a zinc oxide receiving and washing plant to minimize the impact of halides to its circuit. A description of the washing plant and initial operating results are included.

Jan 1, 2000

By R. C. Chaturvedi, S. B. Padwal

"Padwal and Chaturvedi have developed the model based on M-K theory, considering Hosford's yield criterion and critical thickness strain criterion"" to predict the sheet metal forming limits under simple (constant) strain ratio paths. This analysis has been extended in this paper to predict the sheet metal forming limits under complex strain paths. The effects of exponent ""a"" in Hosford's yield criterion and strain paths on the forming limits under complex strain paths are studied using this analysis. The predictions of the present analysis are compared, both for simple and complex strain paths, with experimental results of Ishigaki for A.K. steel and also with the predictions of Rao and Chaturvedi's model. The quantitative analysis of the error in predicting the forming limits has also been carried out using a method suggested by the authors earlier.1. INTRODUCTIONThe constant strain ratio condition has been assumed in the theories developed for prediction of forming limit diagrams (FLO). In actual forming operation, this condition is seldom satisfied. Even in the case of simple single stage press formed components, the strain path becomes curved and non-linear. In the case of pressings with complex shapes, or multiple stages of forming, the changes in strain path are more pronounced and even abrupt.Experimental study of the forming limits, under two stage strain paths, by Ishigaki [1], has shown that the forming limits are path dependent. It has been observed that the forming limits lower than that under simple strain paths, may be obtained under certain strain paths (when the first stage strain path is either equibiaxial tension or uniaxial tension, followed by the second stage strain path as plane strain). Rasmussen's work [2J, on the theoretical study of forming limits under curvilinear strains paths, has shown that a large drop in formability can result from very small changes in strain path. Thus if a deformation process gives rise to failures due to plastic instability, the failure is not necessarily due to insufficient formability of the material. In such cases, FLOs based on constant strain ratio path should not be used directly in predicting the success or failure of the forming operation. Thus the knowledge of forming limits under complex strain paths is of great importance to the interpretation of press-shop problems."

Jan 1, 1994

By Dale Zacherl, Andreas Buhr, Rainer Kockegey-Lorenz

"The microporous calcium hexaluminate insulating material SLA-92 has been introduced as an alternative to refractory ceramic fiber and other insulating refractory materials. Key properties associated with this product include: high chemical purity, long term high temperature stability up to 1500 °C, low thermal conductivity up to 1500 °C, and high thermal shock resistance. The properties of the new material and various applications in the steel and ceramic industries have been reported in previous papers. The current paper summarizes the industrial application experiences with innovative refractories based on SLA- 92 and discusses potential new applications in various manufacturing as well as energyrelated industries.IntroductionSLA-92 was introduced to the refractories industry in 1998 by van Garsel, et al. [1] as a new insulating raw material for high temperature applications, followed by investigations [2] of long term temperature stability for this new lightweight aggregate up to 1500°C.SLA-92 was developed as an innovative alternative to commonly used refractory ceramic fibers. It has unique properties regarding chemical purity and mineral composition and is a microporous, silica-free calcium hexaluminate (CA6 – mineral name: hibonite)."

Jan 1, 2010

By R. F. Hammen

Copper is one of the most widely used metals in industrial processes and is also present in most mining operations. Extraction of copper from solutions often proves difficult due to the presence of complexing agents. ChromatoChem, Inc. has developed a Solid Phase Extraction (SPE) support (HiPAC) for removal and recovery of metals from wastewater. The HiPAC SPE support employs chelating agents covalently coupled to a long linker molecule. Several solutions containing copper and complexing agents were tested including 1) copper and carbonate, pH 9.8, 2) mixed metals and anions with copper and cyanide, pH 11, and 3) copper and the chelating agent EDTA, pH 11. The copper was extracted from solutions one and two at high pH, but the EDTA containing solution needed the pH lowered to make the copper available for capture. In each example, the copper concentration was significantly reduced by HiPAC SPE treatment.

Jan 1, 1994

By Junji Shibata

Through-hole copper plating is performed to make a multi-layer printed circuit board. The through hole plating is first carried out by Pd catalyst treatment, followed by copper non-electric plating. The amount of Pd catalyst used in one plant is about 0.25-2 m3/month (8 g/dm3 PdCl2 base) depending on the plant scale, and the cost of the catalyst reaches 17,000¬I35,000 US$/month. In this study, the flow and material balance of a Pd in Pd catalyst treatment process was investigated. About 60% of Pd catalyst adheres on the through-hole and other part of setup, while 25% is released into the washing liquor. Pd in the washing liquor should be collected by a suitable method like a pressure filtration using diatomite. The material balance of Pd in Pd catalyst treatment process and the recovery method of Pd from waste solution containing Pd catalyst was investigated.

Jan 1, 2003

By Zhongliang Tian, Yun Cheng, Yexiang Liu, Ming Jia, Yanqing Lai

"A fundamental electrochemical study of Si ions in Na3AlF6-LiF melts and electrolysis using liquid cathodes was conducted. Cyclic voltammograms (CVs) clearly showed the depolarization of silicon deposition on liquid cathode by forming chemical complexes with the liquid solvent metals. Besides, co-deposition of Al and Si is possible when Si ions are insufficient in the molten salt. Based on the electrochemical results, silicon diffusion into liquid cathode is modelled and evolution of Si activity with concentration is deduced by a mathematic approach. Electrochemical study using liquid metals as working electrodes, can be used as an alternative approach for the acquisition of basic data on alloy behavior. Galvanostatic electrolysis showed that liquid cathodes are appropriate to collect the deposited solid silicon and the highest collection efficiency is almost 85%.IntroductionRecent years have witnessed an increasing demand for solar-grade silicon (Si) by the photovoltaic industry [1-4]. The preparation of high-purity metals through electrolysis and electrorefining offer many advantages such as low cost, low-energy consumption, and environment-friendly process, and thus has been widely used worldwide. From the perspective of electrochemistry [5-7], by utilizing the electronegativity difference between the impurities and Si and controlling the relevant process parameters, it is possible in principle to electrodeposit monatomic Si from a Si4+-containing compound melt. Moreover, because the carbon content of the high-purity Si obtained through electrolysis can be effectively controlled and used as a very ideal raw material in the preparation of electronic-grade and solar-grade Si, the preparation of high-purity Si through electrolysis has received widespread attention [8,9]. Monnier et al. [9] used a graphite electrode to obtain high-purity Si (99.9 %-99.99 %) from Si02/Na3AlF6 system through electrolysis; however, because the Si was precipitated in a solid form and showed poor conductivity, the deposition rate was too slow. Olsen et al. [10] obtained high-purity Si films via electrodeposition in K2SiF6/KF-LiF system by selecting electrode materials with high surface quality (such as Ag and graphite). However, in order to ensure the film quality, the deposition current density must be relatively low (10-50 mA/cm2), resulting in a low current efficiency and low deposition rate, which are not conducive to reducing energy consumption and applying to practical use"

Jan 1, 2014

By Daoxin Wu

In this paper, the rutile TiO2 were prepared under air, Ar and H2 calcination atmosphere by low temperature hydrolysis using Tetrabutyl titanate (C16H36O4Ti) as raw material. Powers were characterized by X-ray diffraction, UV-vis diffuse reflectance and X-ray photoelectron spectroscopy. The influence of the calcination atmosphere on the photocatalytic reactivity of rutile TiO2 for oxygen production was investigated. The photocatalytic reactivity of rutile TiO2 prepared under air, Ar and H2 atmosphere was compared under ultraviolet and visible light radiation with Fe3+ (c=8.0mmol.L-1) as electron acceptor. The results showed that rutile TiO2 prepared under Ar and H2 atmosphere had higher photocatalytic activity for oxygen production than that prepared under air atmosphere. The oxygen production rates under ultraviolet irradiation were 427.5, 378.2 and 357.0µmol.l-1h-1 respectively when rutile TiO2 was prepared under Ar, H2 and air atmosphere. The oxygen production rates under visible light irradiation were 78.2, 52.2 and 13.5µmol.l-1h-1 respectively when rutile TiO2 was prepared under Ar, H2 and air atmosphere.

Jan 1, 2008

By Brian R. Green

Resin-in-pulp (RIP) technology has been developed for recovery of gold. It is now time to look forward to the potential for application of the technology to other situations. Some cases have been identified and have merited preliminary testwork. Four examples, which illustrate the potential of RIP, are dealt with in this paper. These include removal of metal-cyanides from pulps, recovery of manganese that is difficult to wash from filter cakes, recovery of nickel from low grade pulps, and recovery of zinc from process residues. The discussion includes descriptions of the problems, factors that affect the choice of resin, and factors that will affect the economics of the process.

Jan 1, 1998

By Tiejun Chun, Jian Pan, Deqing Zhu, Vinicius Mendes

"Fine manganese fines are characterized by large amount and low price compared to lump manganese ores. However, fine manganese must be agglomerated as EAF (electric arc furnace) feed. In this paper, high quality fired pellets were produced by simulating grate-kiln process to supply the feed for EAF from some imported manganese ore fines containing high combined water. Manganese ore fines assaying 44.47wt%Mn, 5.89wt%Fe, 12.09%LOI and with 72.7wt% ranging between 0.5mm and 8mm, are pretreated up to the particle size of 84.7wt% passing 0.074mm by HPGR (high press grinding roller) twice in open circuit. The finely ground manganese fines were mixed with 1.2wt% bentonite, balled at 15% moisture for 7min in disc pelletizer. The drop numbers, compressive strength and thermal shock temperature of green balls reach 11 times/0.5m, 11 N/pellet and 360oC, respectively. After the green balls drying in the oven, the dry pellets were preheated at 1050oC for 12 min and then fired at 1300oC for 12 min in electric tube furnace. The compressive strength of fired pellets reaches 2621 N/pellet. Therefore, these pellets are high quality burden for blast furnace or EAF due to high mechanical strength and high Mn grade of 49.11wt% and low detrimental elements.IntroductionManganese, mainly using as deoxidizing agent, desulfurization agent and alloying elements, is widely used in the steel company. With the rapid development of iron and steel industry in China, domestic manganese ores cannot meet the requirement, resulting large quantities manganese ores import to China [1-4]. Compared to lump manganese ores, fine manganese ores containing high combined water are characterized by large amount and low price. However, they must be agglomerated as EAF (electric arc furnace) feed. There are three ways to agglomerate the manganese fine ores, sintering, briquetting and pelletizing [5-6]. Compared to the other two methods, pelletizing technology possesses the following superiorities, such as uniform size distribution of product, stabilizing chemical composition of product and lower energy consumption in producing. Therefore, pelletizing is a superior way to treat the fine manganese ores [7]. The systematic research of producing manganese oxide pellets by fine manganese ores containing high combined water was studied in this paper."

Jan 1, 2011

By Jerry L. Smith

Industry on a whole has not been very receptive to government prodding to implement waste minimization programs. Waste minimization has the appearance of substantial benefits, however, there are underlying difficulties and suspicions that need to be addressed before industry will support pollution prevention initiatives. They can be summarized as follows: - Human behavior resists change, uncertainty, and unknowns. - New waste minimization techniques are difficult to find and research. - Calculating the true cost of present waste practices as well as new techniques being considered is difficult and time consuming. - Getting a consensus opinion of all the individuals affected on the course or technique to be employed in a pollution prevention program. New software products have addressed many of the problems associated with implementing pollution prevention programs: They contain research on a large number of pollution prevention techniques and case studies; they generally are accessed by EPA ID number, chemical name, or synonym; and some programs have the option to print a comprehensive written user-specific pollution prevention program.

Jan 1, 1994

By K. J. Murphy, A. R. Smith, A. P. Odorski

"The need for large quantities of oxygen for use in metallurgical processes was a major driving force in the commercialization of tonnage air separation plants. Oxygen, nitrogen and argon impact the quality, energy efficiency and environmental aspects of metals production. Cryogenic air separation processes have been used to supply most industrial requirements, however, newer technologies are available or under development to meet the needs of today's and tomorrow's metallurgical processes. This paper reviews the technical features and state of development of adsorption, chemical, cryogenic and membrane technologies. The technologies are compared in terms of plant size, oxygen purity and pressure, nitrogen and argon co-production, product use pattern and back-up requirements. Computer control systems are described that optimize operation over varying load patterns and ambient conditions; substantially lowering energy consumption. IntroductionOxygen production totalled 390 billion cubic feet in 1987. Although current production is lower than the peak of 455 billion cubic feet reached in 1979, oxygen remains the fifth leading chemical product manufactured in the u.s. (1) Metals manufacturing and fabrication accounts for sixty percent of the oxygen consumed in the u.s. Oxygen use in the steel industry consists of air enrichment for conversion of iron ore, purification of the iron in basic oxygen or other furnaces, and for cutting and welding the finished steel product. Nonferrous ores are smelted in oxygen enriched atmospheres to reduce energy consumption and increase capture of sulfur compounds to meet environmental requirements. In the future oxygen usage is expected to become even more important in metals production as energy costs increase, environmental standards become more stringent, and as new coal based processes become commercialized. Oxygen usage per ton of metal in the new direct reduction processes can be up to ten times higher than traditional steel making."

Jan 1, 1988