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By Evgenii Pavlov, Ivan Tronin, Viktor Timofeev, Vladimir Kislov, Sergei Bogovalov

"Modeling of the magnetohydrodynamical (MHD) and thermodynamical processes during the industrial scale Direct Chill (DC) casting of aluminum slabs is performed using a combination of ANSYS/CFX and ANSYS/EMAG software. The electromagnetic field is modeled through ANSYS/EMAG, while hydrodynamic and thermodynamic processes are modeled through ANSYS/CFX. Both packages were modified in order to calculate MHD flows in the liquid pool that forms during aluminum DC casting, and they were unified into a software combination that provides simultaneous simulation of all the above processes. The simulation shows that the electromagnetic stirring of the molten aluminum changes the shape of the solidification front (solid-liquid interface) very dramatically, namely it becomes significantly flatter. This effect should improve the internal structure of aluminum DC slabs and allows us to increase the casting velocity.IntroductionProduction of Aluminum alloys with high mechanical properties and structural uniformity is one of the main goals of industry. The preferred production method of aluminum alloys in most modern plants is Direct Chill (hereafter DC) casting because it offers high productivity and commercial success. One important limitation of this technology is the development of centerline shrinkage in slabs larger than about 1 meter. The improvement of the internal structure of long DC cast slabs can be achieved by electromagnetic stirring (hereafter ES) of the liquid metal above the solidification front. This intensifies heat transport in the zone close to the solidification front and suppresses shrinkage formation."

Jan 1, 2013

By Vasil Kopaleishvili

The bainitic Fe-C-Si alloys with optimum content of retained austenite serve as ?containers? for storing of hydrogen. Both the vacancies of fcc lattice and the possibility of forming hydrides of silicon and other alloying elements will be used. The idea is based on our scientific hypothesis. There is the silicon threshold (Si=0,50%) in "Fe-Si" system and Fe-C bainitic alloys, above which it causes self-organized phenomena: sudden increase of hydrogen solubility and amount of retained austenite in the alloy after ??ß transformation, formation of two supersaturated solid solutions <a??r>, "rejuvenation? and its reverse process. Rapprochement of iron atoms when Si=0,50%, causes appearance of new covalent forces where uncompensated electrons of 3d-subshell are involved and it provokes synergetic phenomena. They ?free? silicon atoms from the previous bonds. After that silicon itself becomes a getter of hydrogen using vacancies (14) of 3P2(6)d0(10) subshell and it results in sudden increase of hydrogen solubility in metal. Simultaneously sudden decrease of iron activity takes place. That in its turn ?releases? the carbon. Thus, its redistribution, controlling the bainitic transformation, is hastened. It stipulates for creation of ?brittle bainite" B[a(C,H)+?r(C,H)] after ??ß transformation. While weathering of metal, "rejuvenating", hydrogen diffuses in ?islets? of retained austenite and ?relaxed bainite? (B[(C)+?r(C,H+H)]) is obtained. When heating austenite ?(C,H) is obtained, and after cooling ?brittle bainite? is obtained, etc. Presented scientific hypothesis explains the available experimental facts ("rejuvenation? and its reverse process, graphitization, weldability, forming of flakes, reaching high strength, etc.) in a new manner, as well as, gives real opportunity for creating of new trends in many fields, e.g. iron based HAA. Provisional data having been obtained are encouraging.

Jan 1, 2006

By W. E. Straszheim

Computerized microscopic techniques were used to determine the size and identity of the ash-forming mineral components, as well as their association with the organic coal matrix, in order to aid in the development of physical methods of beneficiation which require such characterization for the most effective cleaning. Examples of particle size measurements, mineral phase identification, and especially coal-mineral association results are given for selected samples of raw and physically cleaned coals. These measurements can reveal certain characteristics of coals which can be be of significant value in predicting coal recovery and mineral matter rejection for coals undergoing beneficiation.

Jan 1, 1989

By P. N. Anyalebechi

The effects of Si (0.19-0.52 wI. %), Fe (0.20 wI. %-0.44 wI. %), and Cr (0-0.10 wI.%) on the response of ingots of aluminum alloy 3004 solidified at different rates (O.IO°C/s to 30°C/s), to homogenization heat treatment have been investigated. Response to homogenization was determined by quantifying the following microstructural parameters: (i) amount of Mn retained in solid solution; (ii) types, relative amounts, sizes, size distributions, shapes, and chemical compositions of second phases; (iii) extent of the alpha-transformation (i.e., AI6(Fe,Mn) --7 (XAI12( Fe,MnhSi) reaction; (iv) dispersoid formation; and (v) alleviation of dendritic microsegregation. Of the three alloying elements investigated, Si had the greatest effect on the response of aluminum alloy 3004 to heat treatment. Increase in Si content, fineness of cast microstructure, and homogenization temperature facilitated alpha-transformation reaction, dissolution of Mg2Si, loss of Mn supersaturation, and formation of AldFe,Mn)3Si and Mg2Si dispersoids.

Jan 1, 2008

By . Menad Gaballah I

Three samples of solid wastes generated by the non ferrous metallurgy were characterized. These residues contain up to 42 % of valuable metal compounds ( Cu, Pb and Zn ) and 23 %of toxic compounds t As, Hg, Cd and Se ). These sample were subjected to thermal treatments between 200 DC and 800 °C in controlled oxidizing. reducing and chlorinating atmospheres. Up to 99 % of As, Cd, Hg and Se were eliminated from these industrial wastes. Cu, Pb, and Zn compounds were concentrated in the treatments&apos; residues of these samples. A Global Decontamination Factor&apos; GDF &apos; was defined to measure the efficiency of the elimination of toxic elements and the recovery of valuable elements for a specific sample submitted to a given treatment. It seems that the thermal treatment in a reducing atmosphere was the most efficient in decontaminating these solids and the concentration of valuable elements. a.

Jan 1, 1995

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 Hong-ying Xia, Bao-bao Wang, Jin-hui Peng, Bing-guo Liu, Li-bo Zhang, Zhi-qiang Li

Based on optimization using response surface methodology designed by Box- Behnken, to study the interaction of wet industrial salt with moisture drying temperature (50-90 ); duration (10-50s); and the weight of the materials (20-60g). The results show that: the experimental parameter conforms to the quadratic equation model to influence the moisture content and the dehydration speed., in analyzing the significance and the interaction of various factors, the optimum by the Design Expert software conditions for drying with microwave radiation include temperature of 90 , duration of 10s, and sample mass of 26g. Verified by experiment, the moisture content after drying is less than 0.25% and the dehydration rate reached 1.37g/min, between the predicted value and the actual value confirmed good fitting degree.

Jan 1, 2015

By Norimasa Yamasaki, Masao Kurosaki

"The effects of plating conditions on the crystal orientation of electrodeposited zinc were investigated by varying elecyrolyte flow rate and current density. Precipitation of the Zn (00 • 2) basal plane is promoted at lower current density and higher flow velocity. Effect of the flow velocity on the mass transport was evaluated based on the polarization measurement in which Cu was used as the tracer. As a result, it has been clarified that the crystal orientation of electrodeposited zinc can be uniquely arranged by the overvoltage (iU0.5) that can be simply calculated by considering -the current density and boundary layer thickness. At the same time, the electrode potential during electrodeposition that can be calculated by using a model based on the competitive reactions of hydrogen reduction 'and zinc reduction exhibits an extremely good correlation with the crystal orientation of electrodeposited zinc.Introduction Electrogalvanized steel sheet has better surface properties than hot-dip galvanized steel sheet, and is used in home electric appliance and automobile applications. Factors such as crystal morphology, crystal orientation and surface roughness have a large influence on its appliance, formability and corrosion resistance [1-3].Electrolysis, condition, bath composition and alloying elements are reported as factors that affect the crystal orientation of the electrogalvanized coating. Factors that can be controlled on time in the production site are electrolysis condition that-is current density and plating solution flow velocity.Some studies[4-6] report that the crystal- orientation of the Zn(00 • 2) plane is increased by promoting, the mass transfer of zinc ions in the plating solution or decreasing the concentration overvoltage, but did not investigate in detail the plating solution flow conditions in the plating cell nor quantitatively determine the effects of both current density and plating solution flow conditions on the crystal orientation of ' electrodeposited zinc."

Jan 1, 2000

By Lucas L. da Costa, Sergio N. Monteiro, Romulo L. Loiola, Tammy G. Rodrigues Portela

"The fibers extracted from the petiole of the buriti palm tree are relatively strong as compared to other lignocelluloses fibers, with a potential for composite reinforcement. In this work, polyester matrix composites incorporated with these fibers were investigated for their flexural behavior. Specimens with up to 40% in volume of continuous and aligned buriti petiole fibers were bendtested until rupture. The results showed an increase in both the composite mechanical strength and the stiffness with incorporation of these fibers. A fractograph analysis by SEM disclosed a moderate adhesion mechanism between the buriti petiole fiber and the polyester matrix. This mechanism is apparently responsible for the improved performance of the composites.IntroductionIn recent years, the substitution of energy-intensive synthetic materials for natural ones is being considered in many industrial sectors including automobile, packing and textile [1]. A typical case is that of natural fibers, mainly those obtained from cellulose-based plants also known as lignocelluloses fibers. They have being investigated in the past two decades, aiming to replace synthetic fibers, particularly the glass fiber, commonly used as polymer composite reinforcement [2-8]. From the engineering point of view, lignocellulosic fibers present today important environmental, economical, societal and technological advantages already discussed [7-8]. Moreover, several lignocellulosic fibers are known since the beginning of our civilization and still cultivated or naturally extracted all over temperate and tropical regions of the world. According to Kalia et al [1 ], these fibers can be classified by their origin, as shown in Table 1."

Jan 1, 2011

By John B. Cocanour

The U.S. Bureau of Mines (USBM) has developed a laboratory-scale on-line analysis and process control system for a decopperization electrolytic circuit. This system is software driven, running on a 486DX-33 personal computer (PC) utilizing a portable energy- dispersive x-ray fluorescence (XRF) spectrometer as the sample analyzer. The XRF copper reading obtained was used as the control variable through an RS-232 serial interface to the PC for software-based control of feed flowrates. When the copper concentration in the electrolytic cell (as measured by the XRF) deviated from the set point, the feed flowrate to the cell was automatically altered using software-based proportional-integral-differential (PID) computer control to yield the desired copper concentration at the electrolytic cell outlet.

Jan 1, 1994

By Hannu Johto

Boliden Harjavalta has operated a flash smelter for nickel sulphide concentrates in Finland since late 1959. The original nickel flash smelting process was modified in 1995 to a novel nickel matte smelting (DON) with semi-low iron where the batchwise operated converting became obsolete. Since that, the process has been applied to multiple chemically variable nickel sulphide concentrates with high environmental performance. In this paper, the status of the current smelter operations is described together with the recent modernizations of the nickel flash smelting furnace and the slag cleaning furnaces.

By LeoJ. Miller

Exploration for an ore deposit commences with an outline of the regional ore controlling environment and is followed by the application of tools to focus the target area. One of the most essential focusing is the mapping of the mineral assemblages within the area of the ore. Key elements of mineralizing fluids, either epigenetic or syngenetic, enter into mineral assemblages that extend far beyond ore deposits. Portions of these assemblages may consist of new matrix minerals or alteration of previously existing minerals. Today, ore deposits are divided into genetic classes and each class is d8fined by a specific geological environment. Ore deposits within a given class are associated with a mineralogy, that is characteristic of the ore deposit class. So faithful is the mineral assemblage surrounding, or within an ore deposit, that recognition of the assemblage may be sufficient to define the class. Porphyry copper deposits have long been noted for their halos of alter-ation minerals. The outermost ring of chlorite, epidote and calcite extend thousands of feet away from the main ore zone. The mineral associated with porphyry copper deposits have been well documented by our distinguished speaker Paul Kerr, at Santa Rita (1), and Silver Bell&apos; (2), and by excellent papers from S. C. Creasey, 1959 (3), Sales, 1948 (4), T. S. Lovering, 1949 (5), our Co-Chairman John Guilbert, 1970 (6), and many others. Several recent porphyry copper mines have been discovered in recent years by utilizing the mineral assemblage model described by Lowell and Guilbert, 1970 (6). Dave Lowell applied his own model of mineral halos for the discovery of Kalamazoo at San Manuel (7), Arizona, and Casa Grande West, Arizona. The purpose of this paper is to outline the application of mineralogy for discoveries of deposits other than porphyry copper mines and in particular, to ore discoveries in which mineralogy has played a key roll.

Jan 1, 1981

By Raymond E. Healy

Mercurian e1ectrum (Au-Ag-Hg alloy) is the principal Au-bearing phase in the massive sulphide ores at Trout Lake, Manitoba. The average composition of this phase (in wt %) is 49.2 % Ag. 38.7 % Au and 11.0 % Hg, with ranges of 17.34 to 76.47 % Ag, 1.62 to 79.86 % Au and 1.29 to 30.87 % Hg. Compositional variation reflects solid solution in the a-phase of the Ag-Au-Hg system. Backscatter electron imagery reveals systematic zoning and suggests a general crystallization sequence from metamorphic pore fluids of progressively Ag-rich compositions. Investigation of the occurrence of gold in mill products demonstrates that mercurian electrum accounts for over 90 % of the Au in Trout Lake ore. I Invisible" gold in pyrite (x = 0.72 ppm Au) and arsenopyrite (x 30.2 ppm Au) is confirmed by SIMS analyses, and accounts for 7-10 % of the Au in the ore, and 35 % of the Au lost to the tailings. The remaining 65 % of the Au lost to the tailings consists principally of mercurian electrum locked with pyrite. No significant losses of mercurian electrum in the size range amenable to flotation and/or regrinding is indicated.

Jan 1, 1989

By Björn Saxen

Outotec atmospheric Direct Leaching has so far been implemented for zinc production capacities of around 100,000 t/a. Lately, there has been growing interest for small scale direct leaching plants, producing circa 30,000 t/a of Zn. Such small leaching plants can provide extra front-end capacity in existing roaster-based plants and enable treatment of feed materials not suitable for roasting. In small scale plants the proven OKTOP® 9000 Direct Leaching reactors are not readily applicable, due the large size. For smaller installations a modular approach is proposed providing multiple advantages, such as reducing the construction time and amount of the site work required causing less disturbance to regular plant operation with reduced cost. In this paper, we present advantages that can be achieved by using modular OKTOP®C reactors and discuss also process design when connecting a small scale direct leaching process to an existing zinc plant. Also benefits of direct leaching expansion are presented.

By Pingchao Ke

A crystalline polyferric sulfate (PFS) adsorbent was synthesized by oxidizing and precipitating ferrous ions under atmospheric conditions. The morphology, structure, composition and specific surface area (SSA) and adsorptive efficacy to As (III) of the adsorbent were characterized by SEM/EDS and TEM images, XRD patterns, FT-IR spectra, BET SSA analyses and adsorption experiments. The adsorbent presents as morphology of near-spherical aggregate and good crystallinity. A small amount of goethite co-precipitated with PFS in the case of the initial ferrous concentration of 1 mol/L and increased the SSA of the aggregates. The absorbent with co-precipitation of goethite showed good adsorption to As(III) and good filtering performance in the high As(III)-content solution of 10–100 mg/L under acidic, neutral and alkaline conditions (pH 2.09–9.01), and its maximal adsorption capacity and adsorption efficiency were 7911 μg/g and 96% separately. After Adsorption, the stability of the absorbents adsorbing As(III) were evaluated by TCLP tests, and the results indicated that the absorbents adsorbing As(III) were extremely stable, and the concentration of arsenic in all leaching solutions were less than 0.01 mg/L.

By Zhongning Shi, Ramana G. Reddy, Min Li, Zhaowen Wang

Electrodeposition of cobalt from cobalt tetrafluoroborate (Co(BF4)2) was investigated using 1- butyl-3-methylimidazolium tetrafluoroborate (BMIMBF4) ionic liquid. The experiments were conducted at 353 K. Chronoamperometry experiments confirm that the electrodeposition of cobalt on tungsten electrode proceeds via three-dimensional instantaneous nucleation with diffusion-controlled growth process. The average diffusion coefficient of Co(II) was found to be 7.5 × 10-8 cm2s-1 at 353 K, which is in good agreement with the estimated value from cyclic voltammetry. The electrochemical deposit was characterized using SEM-EDS and XRD methods. The SEM image shows formation of a dense and compact deposit at - 0.75 V. The EDS and XRD analysis confirm that the obtained deposit is pure cobalt metal.

Jan 1, 2015

By Florian Kongoli

New operating conditions and process parameters are often necessary in today&apos;s industrial practice of non-ferrous smelting and converting in order to accommodate various new chemical compositions of mineral charges and environmental requirements or to conceive new and more efficient industrial technologies. An important parameter in non-ferrous smelting and converting is the liquidus surface of multicomponent slags. This surface is affected by multiple factors such as temperature, gaseous potentials, the content of each component in the slag, etc., and cannot be quantified by the existing ternary liquidus diagrams. In this work a new type of representation of the liquidus surface of multi component systems has been presented by means of a thermodynamic model. This representation waives the need of the multidimensional representation of multi component systems and yields practical two-dimensional diagrams, which can be easily used in the industrial practice.

Jan 1, 2000

By John W. Cash

The mineralogy and textures of cyclone dust, sludge, and occasional build-ups in the American Iron and Steel Institute (AISI) direct ironmaking pilot plant at Universal, Pennsylvania have been studied by reflected light, transmitted light, and cathodoluminescence microscopy, and phase compositions have been determined by SEM-EDS. The cyclone dust consists of particles of carbon, metallic iron, sulfur-bearing iron, and wustite. Measurements of particles in the sludge indicates that 69% are less than 2.5 um across, 21 % are 2.5-5 um, and 10% are larger than 5 um. Mineralogically the sludge particles are mainly carbon and metallic iron, with minor wustite and sulfur-bearing iron. Build-ups that sporadically develop in the furnace consist of olivine, hercynite spinel, metallic iron, wustite, pyrrhotite, pseudobrookite, akermanite-ferroakermanite and gehlenite. The microtextures shown by the build-ups indicate that much of that material has precipitated at the build-up loci. This study has been supported by AISI and the U.S. Department of Energy.

Jan 1, 1995

By Guanghui Li

In the paper, the recovery technology of gallium from zinc-leaching residue by cold-bonded coal-based direct reduction process following magnetic separation was developed. The results show that the scattered metal Ga can be concentrated obviously after the reduction of zinc-leaching residue briquette and magnetic separation of reduced product. At the same time, the volatilization of Zn in the residue is enhanced during the reduction. When the residue, bear¬ing 18.60% Zu.21.18% Fe and 527 g/t Ga, was reduced with coal at 1100°C for 150 min, the results of Zn volatilization of 9842% and Ga recovery of 89. 10% were obtained in reduction. After magnetic separation of the reduced product, the concentration of Ga in sponge iron is 2164 g/t, and the separation recovery of Ga reaches 92.42%. The enriched mechanism of Ga during reduction -separation process was studied by using electron microscope, scanning elec¬tron microscope, energy spectrum and mineralogical analysis. The investigations show that there is no formation of independent phase of Ga during reduction process. The Ga occurs mainly in metallic iron phase (the concentration of Ga in metallic iron phase is 0.04%-0,4%), in addition, there exists a little Ga in poorly crystalline sulphide (o.08%-0./5Y& Ow). But Go does not exist in most of glass and silicate phase. The affinity of Ga for metallic iron is the enrichment basis of Go in reduction, and it is also in favor of recovering Go during magnetic separation. Key Words: Gallium Zinc-leaching Residue Cold- Bonded Direct Reduction

Jan 1, 2003

By Rudolf Keller

"EMEC Consultants is developing a process to extract oxygen, aluminum and silicon from lunar anorthositic soil. The process will provide oxygen in space for propulsion, aluminum as a structural material, and possibly silicon for the construction of solar cells.The evolution of the process concept in the course of our present NASA-sponsored SBIR effort is discussed. A molten salt electrolysis producing aluminum and oxygen is the central step; inert anode technology is to be employed. Silicon will be produced by reducing the anorthite, CaAI2Si20S' with aluminum. In a steady-state operation, all components of the ore added have to be removed from the process, and the removal of calcium is a major topic of our experimental studies.Utilization of Lunar ResourcesUtilization of lunar resources may play an essential role in the exploration of the solar system and the conquest of space. High costs are involved in overcoming Earth's gravity to supply missions in space. Even at a low projected cost of $ 300 for transporting a pound of payload into Earth orbit -- today's costs are many times higher -- it appears attractive to use resources in space to produce needed materials. Processing of lunar resources on the lunar surface is an obvious possibility.Oxygen is a product of major interest. It is required for support of human life in space. Even greater quantities may be needed for propulsion, to conduct further missions into space. To satisfy this demand for oxygen through lunar processing requires a quite different solution than to supply oxygen on Earth, where oxygen gas is abundant and easy to extract from air or water. On the lunar surface, solid oxide materials have to be used. Hydrogen reduction of ilmenite and subsequent electrolysis of the resulting water is being studied [1]. Other suggestions include fluorination of lunar soil [2], reduction with lithium and electrolytic decomposition of the resulting lithium oxide [3], and aqueous HF leaching [4]."

Jan 1, 1988