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By Gerald M. Rich

Magma Copper Company, a subsidiary of Newmont Mining Corporation, has initiated many changes in the continuous casting of 5/16 inch diameter copper rod since startup of the San Manuel rod plant in early 1972. With rod production at forty percent over design capacity, many production records have been established including a record cast of 761 tons of salable rod in a twenty-four hour period. The most challenging and rewarding introduction was the continued utilization of an alloyed copper casting wheel in lieu of the conventional steel wheel. With proper cooling and careful control of the mold release agents. as much as 58.000 tons of copper were cast on a single copper wheel. Other advantages are: 1) Fifteen percent increase in available casting time 2) Reject rod from steel inclusions was reduced by nearly one-hundred percent 3) Wheel cost was decreased by ninety-one percent 4) Natural gas consumption dropped approximately fifteen percent 5) Large increase in refractory component life 6) Reduction of manhours/ton. Many other modifications have contributed to excellent rod quality and high operating efficiency. A two-piece launder was replaced with a single castable launder which reduced oxygen pickup and provided better slag removal. Modifications to the bar preparation unit, pickling system, and coiler resulted in considerably higher milling efficiency.

Jan 1, 1976

By Peter Sylvén, Darwin Morales

Despite being crucial for the smelting process, furnace tapping using oxygen lances has not been considered an operation that brings value. Therefore, these important tools have not seen a significant change in over 100 years. Problems related to the use of oxygen lances include: • Inaccurate tool: causing damages shortening the life of the taphole refractories. • Safety: extended exposure to the operator in an unsafe area of the furnace. • Cost: high oxygen consumption & high lance consumption. • Time consuming and frustrating to connect one lance to another. This paper will suggest a very good solution; new concept thermal lances. We will show how these provide an outstanding performance for a more efficient, faster and cost-effective furnace tapping operation. These new lances are very accurate tools that enable the operator to perform a more controlled operation; resulting in longer taphole life, fewer repairs and less down-time.

Jan 1, 2016

By Chen Ya

Layered LiMn0.5Ni0.3Co0.2O2 was prepared from Mn(NO3)2, Ni(NO3)2, Co(NO3)2 and LiOH by co-precipitation and solid state reaction. XRD, C-V and galvanostatic charge-discharge methods were used to examine the structural and electrochemical characteristics. The LiMn0.5Ni0.3Co0.2O2 delivered a high discharge capacity of 167 mAh/g between 2.5 and 4.3 V with excellent cycling stability.

Jan 1, 2006

By Alessandro Blasi, Massimo Morgana, Corradino Sposato, Pietro Garzone, Giuseppe Devincenzis

A comparison among (2-ethylhexyl)-mono (2-ethylhexyl) ester Phosphonic acid (P507), Secondary-octyl phenoxy acetic acid (CA-12) and Bis(2,4,4-trimethylpentyl) phosphinic acid (Cyanex272), in heavy rare earths separation via hydrometallurgical processes has been investigated. The separation coefficients, , were obtained and the extraction selectivity has been evaluated using a mixture of heavy rare earths from Samarium to Ytterbium. The experimental results indicated that P507 and Cyanex 272 display a greater affinity for heavier rare earths while CA12 proved to be more effective for the lighter rare earth metals.

Jan 1, 2014

By Marko Suput

Titanium is a high-strength, low-density metal nearly immune to corrosion, but limited in use by its high price. The high price is due to the cost of smelting and processing the ore. The research on titanium production using the Solid Oxide Membrane (SOM) process aims to consolidate most of the processing steps required for conventional titanium production into a single step making it an energy-efficient and cost-effective method for producing CP billet and ingot and possibly also powders used to make titanium alloys. In the SOM process experiment, a steel crucible contains MgF2-CaF2-TiO2 flux; an inert metal/carbon rod serves as the cathode; an oxygen-ion-conducting yttrium-stabilized-zirconia (YSZ) membrane in the form of a one-end-closed tube contains either a liquid metal that acts as the anode or liquid MgF2-CaF2 ionic flux that connects the YSZ membrane to an anode. During electrolysis, when the voltage between anode and cathode is higher than the reduction potential of titanium oxide, titanium ions are reduced at the cathode and the oxygen ions pass through the YSZ membrane and are oxidized at the anode. The oxygen ions are oxidized at the anode by a reducing agent, hydrogen gas or carbon, forming steam or CO(g), respectively. To date, a suitable MgF2-CaF2-TiO2 flux has been selected and the operating temperature for the SOM process has been determined. Several electrolysis experiments have been performed. As expected, lower valence deposits of titanium oxides have been witnessed at the cathode prior to depositing pure titanium. Continuing work will aim to extend the electrolysis time in order to pass enough charge to produce a significant amount (100 g) of titanium at the cathode.

Jan 1, 2006

By Yasuyuki Murayama

MF is the semi-blast furnace which has been developed at Mitsui Miike Smelter in the 1960's to treat vertical retort residue. The MF has also been tested for treatment of various recycling materials and wastes. Now various secondaries and wastes (steel dust, zinc leaching residue, Cu-Ag sludge, spent catalyst and spent rubber, etc.) are mainly treated. Powder materials are briquetted with reductant before being fed to the furnace. Products are crude zinc oxide, matte, non-hazardous slag and steam. Zinc and lead are recovered in oxide dust, and copper and silver are recovered in the matte. The MF furnace can be widely applied to many kinds of materials which contain such non-ferrous metal-valuables. In addition, the improvement in operation and technology has effectively made the unit capacity much larger. The MF furnace now has many advantages for these treatment processes.

Jan 1, 1992

By Qiang Zhong, Qian Li, Yongbin Yang, Tao Jiang

Thermogravimetric analysis (TGA) has been used to research the pyrolysis and combustion processes of coal used in rotary kiln of iron ore oxide pellet. Furthermore, the effects of air flow and oxygen concentration on the combustion behavior of coal were examined with TGA. The results showed that two individual stages can be distinguished for the pyrolysis of coal, the water evaporation stage and the de-volatilization stage. And the information on ignition and burnout characteristics can be obtained from the combustion process analyzed by TGA. Large air flow almost has no effect to the combustion process except that it enhances combustion intensity. However, the combustion process is further accelerated under oxygen-enriched conditions. With all experimental results, it could provide an attractive approach of analyzing coal for the rotary kiln process.

Jan 1, 2016

The paper describes the propensity of tin to form intermetallic compounds with microalloying elements such as Nb, Ti and aluminium, which are commonly used as additions to achieve particular combination of strength and toughness. Two series of alloys were prepared by arc melting under an argon atmosphere. Each series was based on Fe, Sn and A1 with either Nb or Ti additions. The microstructures were studied using scanning electron microscopy, transmission electron microscopy, energy dispersive X-ray spectroscopy and microprobe analysis. It was found that the level of Nb addition has an effect on the formation of Sn-rich compounds. For small Nb additions, no Sn containing compounds were found, whereas in higher Nb alloy, a Laves phase (FezNb, hexagonal, a = 0.4830 nm and c = 0.7879 nm) containing about 1 at % Sn was found. A FezNb3 phase (cubic, a = 1.1261 nm) associated with the formation of alumina was also found but did not contain tin. No Sn containing compounds were found with Ti additions. The experimental observations have been compared with thermodynamic calculations performed using MTDATA.

Jan 1, 1999

By S. Street

The Environment process, invented by Prof. H.K.Womer and developed at the University of Wollongong, simultaneously treats ferruginous and organic wastes via bath smelting. Conceived in the late 1980's, the patented process was originally developed using steelworks dust to settle solids from sewage, producing a composite material suitable for smelt reduction. Work began on the process in 1990 with the Australian patent having a priority date of February 1990. Early research focussed on settling of solids from sewage, while pyrometallurgical investigations examined smelting in small induction furnaces. By 1992 smelting trials had been undertaken in pneumatic and electric arc furnaces, the process being successfully demonstrated up to on 8 tonne scale. The success of this particular trial, and other smaller trials, resulted in construction of a 100kg DC arc furnace which was commissioned in 1993. By 1994 the main project focus was on development of the smelting technology. Over 3 years of trials on the DC arc furnace have identified and clarified many of the pyrometallurgical reactions. optimum operating parameters, as well as demonstrating the versatility of the process for treating a wide range of wastes. Currently the Illawarra Technology Corporation (lTC), the commercial arm of the University of Wollongong, is pursuing commercialisation of the process.

Jan 1, 1996

By Richard J. Abitz

Thennodynamic geochemical models have been applied to assess the relative effectiveness of a variety of reagents added to aqueous waste streams for the removal of radioactive elements. Two aqueous waste streams were examined: effluent derived from the processing of uranium ore and irradiated uranium fuel rods. Simulations of the treatment train were performed to estimate the mass of reagents needed per kilogram of solution, identify pH regions corresponding to solubility minimums, and predict the identity and quantity of precipitated solids. Results generated by the simulations include figures that chart the chemical evolution of the waste stream as reagents are added and summary tables that list mass balances for all reagents and radioactive elements of concern. Model results were used to set initial reagent levels for the treatment trains, minimizing the number of bench-scale tests required to bring the treatment train up to full-scale operation. Additionally, presentation of modeling results at public meetings helps to establish good faith between the federal government, industry, concerned citizens, and media groups.

Jan 1, 1996

By Minjun Tang, Jianfeng Zhou, Feng Chen, Linjiang Qing, Xiaolei Song, Yufeng Guo, Tao Jiang

"Reduction swellability index (Rsn and low temperature reduction disintegration index (RDI) of vanadium-titanium magnetite oxidized pellets are harmful to the processing of ironmaking, for example, causing serious gas permeability, decreased yield, higher coke ratio and more furnace dust. Thus, the improvements of RSI and RDI of vanadium-titanium magnetite oxidized pellets were investigated in this paper, including the pretreatment of raw material, additives of dolomite or boric acid, pellets treated in chloride solution and so on. The results showed that damp milling as pretreatment and boric acid added in pelletizing were conducive to the RSI which decreased 5% and 7% respectively, while they were not efficient enough in improving RDI. Dolomite was efficient in improving RSI, but had negative effect on RDI. There was no evidence to show that RSI and RDI would be improved when pellets were treated in chloride solution. Pursuing this further, the mechanism of those improvements were investigated.IntroductionIn the world, vanadium-titanium magnetite utilization is investigated around how to recover iron, titanium, vanadium, and divided into blast-furnace method and non-blast-furnace method according to respective characteristics. Blast furnace method [1, 2] can recover iron and vanadium effectively, but Ti02 cannot be recycled. Non-blast-furnace methods include rotary kiln-electric furnace method, pre-reduction electric furnace method, reduction- grinding method and sodium vanadium-rotary kiln-electric furnace method and so on. [3-7]Comparing to the Non-blast-furnace method, the method of blast furnace smelting has been put into industrial applications. And it has the following advantages: First of all, effective recycling iron and vanadium; Second, technical problems of high titanium slag in blast furnace smelting; Third, it has mature technology in blast furnace smelting."

Jan 1, 2013

By René Bustamante

The subject of this paper is a comparative evaluation of different copper smelting gas cooling techniques, using "productivity and quality" criteria. The first section presents a brief description of the operation of the radiant and the evaporative cooling systems, focusing on the differences between each other, in particular regarding. a) mass and energy balances; b) gas flow, temperature and composition; c) dust concentration and recovery. This section includes a brief discussion of the "client-server chain", i.e. the links between the cooling equipment and the down-and up-stream operations. More in particular, the up-stream server relationship impacts on the operating stability of the furnace, and in turn on furnace down-time and Cu production losses; and the down-stream client relationship affects the operation of the electrostatic precipitators, in terms of workload and cost of handling larger quantities of dust of a given dust size The second section deals with the development of indexes to measure and compare value added through the "utilization, productivity and quality" that can be expected of both cooling methods at the physical and economic levels, and the impact on the overall smelter productivity and the final cost composition of copper. The final section presents the results and includes a discussion of the comparative advantages and disadvantages of both cooling systems.

Jan 1, 1999

By Yoichi Takeda

The CaO-FeOx-Cu20 slag has been practically applied to continuous converting of copper, and also has potential for refining of copper. Liquidus lines of the slag system and phase stability diagram for the liquid slag and the existing solid compounds under copper saturation are presented. Liquidus composition was determined by chemical analysis of slag sample saturated primary solid. The temperatures of invariant equilibria were investigated by thermal analyses. Oxygen potentials on the liquidus lines, the univariant and invariant equilibria were estimated from the relation slag composition and oxygen potential that relation was confirmed in separate experiments.

Jan 1, 2003

By Yoichi Takeda

The CaO-FeO,-Cu20 slag has been practically applied to continuous converting of copper, and also has potential for refining of copper. Liquidus lines of the slag system and phase stability diagram for the liquid slag and the existing solid compounds under copper saturation are presented. Liquidus composition was determined by chemical analysis of slag sample saturated primary solid. The temperatures of invariant equilibria were investigated by thermal analyses. Oxygen potentials on the liquidus lines, the univariant and invariant equilibria were estimated from the relation slag composition and oxygen potential that relation was confirmed in separate experiments.

Jan 1, 2003

By Zhi-yong Liu

A novel process, which includes hydrochloric acid leaching, iron powder cementation, sulphide precipitation and spray pyrolysis, was proposed to treat iron concentrate recovered from zinc kiln slag for comprehensive utilization. Treated by two-stage hydrochloric acid leaching, the leaching extents of Ag, Pb, Cu, Fe and Zn are 96.78%, 95.14%, 97.72%, 94.51% and 87.74%, respectively. More than 99% Cu and Ag are recovered from the leach liquor when iron powder is 25% higher than the stoichiometric requirement. More than 96% Pb and Zn is removed with three times of theoretical consumption of FeS, and the concentration of impurities of the final solution is less than 500 mg/L. Fe2O3 powder, which is spherical with a mean size of 12 μm and purity of 99%, is prepared with final solution at 700 °C. In this process, not only the metal values can be recovered effectively, but also the iron resources of zinc kiln slag can be converted into high purity Fe2O3, thus, the comprehensive utilization of iron concentrate recovered from zinc kiln slag can be realized.

By Yu Hu, Gabriella Tranell, Song Zhang, Eivind Johannes Øvrelid

"In the present research, recycling feedstock of silicon for Photovoltic (PV) application is investigated. Whether these recycling feedstocks are reliable in the future use is discussed in this work to assess the properties of the crystal silicon ingot, which is commercially pulled from top-cuts of casted multicrystalline ingot via one kind of Czochralski method - FerroTech. Dopant is the acceptor type Boron (B) and growth direction was <100>. Crystal diameter and the length were 190mm and about 1700mm, which were controlled by the temperature and the pulling speed, then cut to 156mm * 156mm wafers with 2000um and 200um thickness. Resistivity measurements of these wafers by Four Point Probe (FPP) are in good agreement to the calibrated profile after Rapid Thermal Process (RTP). In this work, the Minority Carrier Lifetime MCI, shown by Carrier Density Image (CDI) and Quasi Steady State Photo Conductance (QSSPC), gives the mapping results on the cross section and the relationship to the injection level, increases in an arrange from 40us to 90us along the ingot height, which is abnormal distribution compared to the standard ingot. Then Oxygen and other metal impurities distributions, measured by Flourier Transform Infra - Red (FTIR) respectively, account for the novel phenomenon of the continuously increased MCI. Various types of heat treatments were performed on these wafers (different ingot and different positions) in N 2 and 0 2 mixture atmosphere. Before and after heat treatment, micro-defects were revealed by copper decoration and etching work. Solar cells are fabricated by Energy Research Center of the Netherlands from the experimental ingot, and processed under an industrial standard line. Compared to results of the reference mono-crystalline and multi-crystalline silicon solar cells, the performances of experimental ones show excellent efficiency values up to 18.5%, and Jsc values up to 37mA/cm2.IntroductionThe PV industry has gone through rapid development, with a high growth rate resulting in an increasing demand for silicon feedstock. In addition, costs in production need to be reduced such that solar energy can compete other conventional and renewable energy. Searching low cost, reliable and efficient feedstock is one promoting way to improve and enhance the competitiveness of the PVindustry.More and more researchers start searching new raw materials for PV application [1]-[4]. The key to make full use of low cost raw materials is to control the distribution and effect of impurities, such as Carbon, Nitrogen, and other metal contamination [5]."

Jan 1, 2013

By Michael J. McGuire

Rostoker, Inc. has developed a process to smelt solid hazardous/non-hazardous inorganic wastes. Near seven hundred experiments were performed. Actual industrial wastes as well as reagent grade chemicals were used. By mixing a multiplicity of these wastes to proper formulations, then furnacing them, it was determined that saleable end products could be reclaimed; metal, fume and slag. The slag, due to its siliceous structure was tested to be leach resistant (40 CFR). This formed the essence of our patent, #5,180,421 "Method and Apparatus for Recovering Useful Products from Waste Streams". What is unique is that a HTMR (High Temperature Metal Recovery) process has been developed that can treat a multiplicity of wastes within the same furnace. The discussion will include a list of waste streams we have treated, details of proper waste formulation and experimental results.

Jan 1, 1994

By S. P. Ball

A major limitation to maximising the rate of gold extraction in commercial operations occurs as a consequence of the limited solubility of oxygen in cyanide liquors. The use of additions of solid inorganic peroxides as an in-situ supply of oxygen to the lixiviant has been studied, in particular in its application to heap leaching. Experimental studies showed-that the release of oxygen into solution from these peroxides is very sensitive to solution pH. Agitated leaching tests showed that, when either Ba, Ca or Sr peroxides were used as the-sole source of oxygen, both the rate and extent of gold extraccion was enhanced. Column leach tests were used to simulate heap leach conditions. These showed that significant increases in the rate of gold extraction could be achieved by additions of calcium peroxide, made to the ore, prior to it being loaded into the columns.

Jan 1, 1989

By Shengfan Zhou, XUEWEN WANG, Changjun Jiang, Mingyu Wang

In the process of extracting vanadium from stone coal by sulfuric acid leaching - P204 solvent extraction, Fe(III) can accumulate in the organic phase which reduces the extraction of vanadium. In order to eliminate the effects of the accumulation of iron, oxalic acid was used as the stripping agent to strip the Fe(III). The effects of oxalic acid concentration, phase ratio O/A, stripping time and shake velocity on the stripping of Fe(III) were studied. The results showed that the Fe(III) stripping rate can reach beyond 96% at the room temperature with 70g/L oxalic acid using an O/A of 2 at 160 rpm shake velocity for 20min. After 2-stage stripping, the concentration of Fe(III) in organic phase was 0.008g/L.

Jan 1, 2016

By Pengcheng Li, Wei-Tong Du, Yu Wang, Gang Wen

Carbon dioxide could be utilized as a weak oxidant and a kind of coolant to oxidize elements, meanwhile, helping control the temperature during the converter vanadium extraction process. However, the optimum content of CO2 and the cooling effect of CO2 at low content have not been reported. In this study, experimental research based on the influence of different CO2 contents from 0% to 25% injected to the vanadium-containing hot metal was carried out, as well as contrast experiments of O2-N2 mixed blowing. The results indicated that the optimum content of CO2 was 15%. Under the optimum condition, the oxidation of [C] was the lowest and the oxidation rate of [V] was 96.9%, while the temperature was also lower than the O2-N2 mixed blowing. This paper provide a potential property for utilizing CO2 during the converter vanadium extraction process.

Jan 1, 2016