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By P. Peczak

A Monte Carlo simulation technique has been used to study dynamic recrystallization in polycrystals. A continuum microstructure of the polycrystal is modeled employing a discrete lattice. The response of the material to hot deformation is simulated by adding stored energy and recrystallization nuclei continuously with time. The experimentally observed nonuniform character of deformation substructures is modeled by employing a phenomenological expression for inhomogeneous distribution of the stored energy. All simulations were performed on HP-Apollo 9000 Series 700 workstations. A program written in FORTRAN with use of PHIGS graphics library calls was used to interactively monitor the current state of the matrix and all relevant parameters: deformation stress, average grain size and effective nucleation rate. Visual analysis of the simulated microstructure allows a better understanding of the data developed by averaging over a number of very long Monte Carlo runs. Since the essential features of dynamic recrystallization are accurately reproduced by the model, it is used to discuss the role of the controlling mechanisms of the dynamic recrystallization in real polycrystal.

Jan 1, 1993

By Jerome P. Downey

The Indium Corporation of America - Colorado School of Mines Indium Separation Technology was evaluated as a potential means of treating smelter flue dusts stockpiled at the Pintlar Corporation property in Kellogg, Idaho. The patented technology represents a method for segregating the contained indium, lead, and other metals in forms acceptable for downstream processing and recovery. Separation is effected by treating the dust with metallic sodium in a bath of molten lead. Process effectiveness was measured by determining the relative distribution of key metals between the bullion and dross products at small pilot plant scale. The study indicated that application of the technology to the Pitlar samples results in a highly efficient concentration of lead in the bullion, while indium is collected in the dross. The distribution of other key metals between the bullion and dross products and the effect of varying selected process parameters are also discussed.

Jan 1, 1994

By John Pilling

The concept of microstructure, its evolution through materials processing and its effect on the properties of the material is, perhaps, the foundation upon which the science of materials is built. PHAUST, a computer aided learning program, attempts to provide instruction in establishing the relationships between phase diagrams, thermal processing and microstructure. Using phase diagrams derived from a database or created by the user, the evolution of microstructure during processing is quantified using the lever rule and/or the Scheil equation and tracked through a doubly linked list (a form of binary tree). Microstructures, in the form of full colour cartoons are then drawn using the quantitative and logical information contained within the linked list using bitmapped templates and logigal operators such as NOT. AND, OR and XOR, giving the student a view of the structure as it would be seen under the optical microscope. The software provides complete diagnostics of student answers, locates errors and misconceptions as well as providing tutoring towards the correct solution method and answer.

Jan 1, 1991

By Guy Deschênes

Thiourea solutions can be used as leach liquors to treat gold ores or slimes. It is also efficient to elute resins or strip solvents that were loaded in cyanides solutions. The hydrogen pressure reduction is a practical step to recover gold and silver from leach solutions, and strips and eluates without any destruction of thiourea. It is a critical point because these processes have to consider the recycling of the liquors to be irore economical. The effect of temperature, pressure, acidity, compotation of the solution and the nature of catalysts on pressure reduction by hydrogen were investigated. An electranetallurgical study was? carried out to investigate the mechanism. The composition of the products was studied by different analytical methods. The process shows a good selectivity to precipitate gold and silver in a thiourea solution containing iron and copper. Gold and silver concentrations can be decreased to 0.2 ppm and 0.1 ppm at respectively 70 KPa H2 and 28°C. No decomposition of thiourea was evident during the tests. Metals such as nickel powder or platinum activate the reaction and improve the reduction.

Jan 1, 1989

By D. M. Hausen

A computer program has been developed by Newmont Exploration to convert mineralogic data by XRD into rock type and ore type classifications. This method has proven useful in identifying lithology from cuttings samples, where percussion drilling was an alternative to expensive core drilling. Computer printouts of rock type and ore type identifications can be generated simultaneously with mineralogic analyses, resulting in a considerable time savings in manual calculation. XRD-computer logging was first applied to the Carlin mine in north central Nevada, and later to the Maggie Creek and Gold Quarry gold deposits, southeast of the Carlin mine. Impure Paleozoic limestones of the "lower plate" Roberts Mountain Formation and the "upper plate" transitional facies have been decarbonatized to altered siltstones and shaley units along vertical faults and permeable stratiform horizons. Advanced stages of decarbonatization were accompanied by silicification. Quantitative XRD data are initially sorted into principal rock type units (limestones, siltstones, dolostones, shales) based on major mineralogic components (calcite, quartz, dolomite, clays). On the basis of relative amounts of less major constituents, descriptive subclassifications (dolomitic limestones, dolomitic siltstones, argillaceous cherts) are made. XRD lithologic data provide assistance in correlating lithologic units, and delineating favorable replacement horizons associated with gold mineralization.

Jan 1, 1982

By Anja Pfennig, Axel Kranzmann, Phillip Zastrow

"Properties of pipe steels for CCS technology require resistance against the geothermal corrosive environment (heat, pressure, salinity of the aquifer, CO2-partial pressure). To predict the reliability of two different injection pipe steels with 13% chromium and 0.46% carbon (1.4034, X46Cr13) as well as 0.20% carbon (1.4021, X20Cr13) steel coupons were heat treated by comparable routines prior to long term corrosion experiment (60°C, 100 bar, artificial brine close to a CCS-site in the Northern German Basin, Germany). In general higher carbon content exhibits better corrosion resistance with respect to corrosion rate, amount of pits and maximum intrusion depth in the case of local corrosion. At 100 bar hardened steels with martensitic microstructure have the lowest corrosion rates with an average of 0.003 mm/a after 2000 h exposure time. At ambient pressure normalized steels show the lowest corrosion rates, indicating that the corrosion is driven by grain boundaries.IntroductionEngineering a geological on-shore saline aquifer CCS-site (CCS Carbon Capture and Storage [1-3]) corrosion of injection pipe steels may become an issue when emission gasses, e.g. from combustion processes of power plants, are compressed into deep geological layers [4-8]. Typically 42CrMo4 (1.7225, AISI 4140) is used for casing, and for injection pipe the steel X46Cr13 (1.4034, AISI 420 C) or X20Cr13 (1.4021, AISI 420 J) is used. Saline formations are the most favorable storage sites in Germany [9], because of their large potential storage volume and their common occurrence. Leakage of CO2 back into the atmosphere may be a problem in saline aquifer storage, especially around the water level within the borehole. Carbon dioxide corrosion may cause failure of pipelines and wells as known from the oil and gas industry [4,6,10,11, 12].From thermal energy production it is known, that the CO2-corrosion is sensitively dependent on alloy composition, contamination of alloy and media, environmental conditions like temperature, CO2 partial pressure, flow conditions and protective corrosion scales [6-8,13- 20]. Considering different environments, aquifer waters and pressures, the analyzed temperature regime between 40 °C to 60 °C is a critical temperature region well known for corrosion processes as shown by Pfennig et al. [21-23] and various other authors [10,24-28] (figure 1). Here a maximum around 4.7 mm/year was found for the pit intrusion depth of 13% Cr steel X46Cr13. Still this may be predicted by the rather conservative Norsok-Model used in the oil and gas industry to calculate surface corrosion rates of carbon steels [29]."

Jan 1, 2014

By N. Can

Kinetics and mechanism of the chemical interactions between Si3N4 and TiC were investigated by isothermally reacting samples under nitrogen and argon atmospheres at temperatures between 1600°C and 1700°C? The initial composition of the powder compact contained 20, 30 and 40 volume per cent TiC? Kinetic analysis were performed by measuring mass losses and composition of the titanium carbonitride (TiC1-xNx) at predetermined time intervals? It was found that in the Si3N4-TiC system the degree and rate of the reactions increased with increasing temperature and content of TiC in both nitrogen and argon atmospheres? Si3N4 in the presence of TiC was stable in nitrogen atmosphere and the reactions were confined to Si3N4/TiC and TiC/N2 interfaces? At both interfaces interchange reaction occurs by simultaneous diffusion of nitrogen towards the centre of the particle and desoprtion of carbon in the opposite direction resulting in formation of titanium carbonitrides with various compositions? Reaction products under nitrogen atmosphere were B-SiC, TiCl1-xNx and N2? The maximum "x" value in TiC1-xNx was found to be 0?67 under nitrogen atmosphere? Si3N4 was found to be unstable in argon atmosphere in the presence of TiC and dissociated into liquid silicon and nitrogen gas within approximately four hours of reaction time, depending on temperature? The reaction mechanism in the initial stages of the interaction between Si3N4 and TiC under argon atmosphere proceeds similar to reactions under nitrogen atmosphere? However, considerable amount of Si3N4 dissociates within the first half hour? Liquid silicon aggressively attack both TiC1-xNx and unreacted or partially reacted TiC particles through cracks and pores and diffuses into interier part of the particle forming liquid solutions? After this stage, reactions under argon atmosphere proceeded according to Si-Ti-C ternary system?

Jan 1, 1999

By Zdzistaw MiGzkowski

At KGHM Polska Miedi S.A. a direct flash smelting process is used for smelting of chalcocite concentrate for the production of blister copper. The paper presents a model of complex oxidation process of single concentrate grains smelted at KGHM. The description covers main chemical reactions, phenomena of heat and mass ex-change inside the grains and between a grain and the surrounding space. In the model, two zones describing the course of process inside the grain were distinguished: ? The first one, which moves faster towards the centre of a grain, both organic and carbonate carbon are freed. The process takes place without the presence of oxygen and results in an increase of the temperature in the core of the particle. ? The second zone moves slower into the grain and the rate of the movement is deter-mined by the presence of oxygen. In that zone the sulphur is eliminated and the oxidation of the organic compounds vapours moving from deeper layers of a grain takes place. Based on the results of laboratory tests, the coefficients that describe the oxygen transportation into the grain and decide the progress in the chemical reaction were determined. The paper contains the results of model calculations for single grains reacting in environment of various content of oxygen as well as the results of model calculations for the laboratory reactor system.

Jan 1, 2003

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 C. Coetzee

Additives are commonly used in copper electrowinning to improve cathode morphology. Polysaccharides such as guar are generally favoured as additives due to their compatibility with solvent extraction. Polyacrylamides are, however, being considered as possible alternatives. Understanding the influence of the structural chemistry of additives on electrowinning performance is critical to utilise them efficiently. This paper investigated polyacrylamide additives which are structurally different; their effects on copper electrodeposition were characterized and compared to that of guar. Electrochemical impedance spectroscopy (EIS) were used to characterize the effects of molecular weight and ionic charge of the polyacrylamides on electrodeposition. The findings were compared against results obtained with an industrially used guar product. Equivalent circuit modelling of EIS data indicated that an increase in polyacrylamide concentration and a decrease in additive molecular weight increased the overall system resistance.

By Metehan Erdogan, Ishak Karakaya, Fuat Erden

"Mg-Ni system draws attention due to the promising hydrogen storage properties of Mg2Ni. The proposed method involves the use of NiO and MgCl2 in an electrochemical cell to from Mg-Ni intermetallics directly. The electrodeoxidation of NiO was followed by combination of Mg and Ni in molten salt electrolytes. The products were characterized by XRD analysis and SEM examinations. The quantitative results from Rigaku supported by Rietveld Refinement method conducted by Maud showed that more than 50 percent of the input Ni was converted to Mg-Ni intermetallics.INTRODUCTIONIt is well known that fossil fuels are the most common energy producing materials throughout the last century although, they are not renewable and their usage cause critical environmental problems [1, 2]. Hydrogen, on the other hand, is known as a clean, renewable energy carrier and instead of fossil fuels; usage of hydrogen for energy production will be the benefit of mankind. However, there are problems that hinder more common usage of hydrogen such as hydrogen storage [3]. Mg2Ni is known as Mg based hydrogen storage material with high hydrogen storage capacity [3-6]. Common Mg2Ni production methods are; mechanical alloying [8-11], vacuum induction melting [12, 13], vacuum arc melting [14], combustion synthesis [15], melt spinning [16], repetitive rolling [17] and isothermal evaporation casting [18] were also used. However, in all of these, pure Mg and Ni are required to be produced previously. Therefore, difficulties arise during handling, preparation and combination of Mg and Ni due to highly reactive nature of especially magnesium (i.e. oxidation of Mg) [11, 17, 19, 20]. Although hydrogen desorption dynamics can be significantly improved with usage of nanostructured Mg2Ni [7], it is difficult and it requires very long processing durations to produce nanostructured Mg2Ni by above processes."

Jan 1, 2014

By R. H. Hanewald

The INMETCO process has been modified so as to recover nickel. chromium and Iron from a wide variety of metal containing waste-streams. This now includes the recovery of metals from spent acid solutions such as chromic acid etching I1quids. nJcke1 and chromium plating solutions; stainless and superalloy pickling solutions. etc. In addition. hazardous electric furnace stainless steel and. superalloy baghouse bags can be processed so as to recover the valuable metall1cs. A detailed review of the above new recovery techniques w1ll be discussed as well as the current operating methods used at INMETCO.

Jan 1, 1992

By Peter C. Hayes

"The high temperature reduction of solids through the use of reactive gas atmospheres has application in a wide range of industrially important processes. Whilst significant advances have been made in understanding and describing these processes, some key aspects of the chemical reactions and reaction mechanisms operating in these systems, for example, the transformation from metal oxide to metal, remain poorly understood. A number of different product morphologies have been identified in these reaction systems and the reaction rates have been shown to be critically dependent on the product structure.Theoretical examination of the elementary process steps taking place in the region of the gas/metal/metal oxide interface, combined with electron microscope studies of the resultant product microstructures, have enabled the key process and material variables responsible for the development of the various product morphologies to be identified. By considering i) established criteria for the stability of moving interfaces in a thermodynamic potential gradient, ii) the relative rates of chemical reactions on the oxide and metal surfaces, and iii) key process phenomena and physico-chemical properties of the solid phases, the mechanisms and conditions for the formation of various product morphologies are identified. Interestingly the analysis points to direct analogies between these phase transformations and, the phenomena and microstructures observed in metal solidification, and the potential to develop generic models of these fluid/solid reaction systems."

Jan 1, 2013

By Larry G. Twidwell

The removal of dissolved arsenic from mine waste waters utilizing a lime/phosphate precipitation technique has been studied on a laboratory scale at Montana Tech of The University of Montana and on a pilot scale at MSE Technology Applications as a wastewater treatment process potentially capable of removing dissolved arsenic to <50 µg/L. Arsenic bearing lime and lime/phosphate slurries were subjected to laboratory extended-time air-sparged aging for over four years. The lime slurries released their arsenic back into solution in a relatively short period of time, whereas the lime/phosphate slurries showed limited release of arsenic. The developed process has been pilot scale tested by MSE-TA for the EPA Mine Waste Technology Program on three waters, ASARCO smelter blowdown water, ASARCO thickener overflow water, and Mineral Hill Mine groundwater. The laboratory study results will be presented and discussed in this presentation. The pilot scale results will be presented and discussed in a companion presentation. Stability, Aging, Apatite, Johnbaumite

Jan 1, 2005

By Zhi-biao Yin

Copper smelter flue dusts often cannot be directly recycled to the smelting process and accumulate as hazardous wastes requiring environmentally acceptable disposal. Because of the limited amount of flue dust, a separate copper extraction process must be simple and require-a small plant investment. A flue dust process has been developed, consisting of the following steps: (1) roasting a pelletized mixture of hydrated lime and flue dust to fix arsenic and sulfur as insoluble calcium salts, (2) heap leaching the roasted pellets with a buffered ammonia/ammonium salt solution to extract copper as an ammine complex in a lined cell that is the final repository of the leached pellets, and (3) boiling ammonia from the lixiviant to precipitate copper. Condensed ammonia and the filtered solution are returned to leaching. Heap leaching in the final repository cell lowers the capital investment significantly compared with competing extraction processes. Chemistry with respect to arsenic, sulfur and copper is discussed.

Jan 1, 1992

By Michele L. Bustamante, Gabrielle Gaustad

In recent years, t h e future supply of tellurium has been called into question due to the anticipated rapidly increasing demand from thin film cadmium telluride photovoltaics. Since tellurium is produced as a byproduct of other extractive processes – principally, the electrolytic refining of primary copper sulfide ore – it is important to explore the dynamics of the parent metal extraction and processing – in this case copper – when attempting to answer this question. This research explores the changing landscape of global copper production; introducing system diagramming and the concept of byproduct intensity (BPI) to illustrate concerning downward trends in tellurium supply potential. Upon closer inspection, it is concluding that, while a likely contributor to these downward trends, the increased use of non- traditional copper production techniques alone are not responsible; other factors include market substitution and incomplete data reporting. Additionally, a review of literature on tellurium recovery processing reveals a promising outlook for future supplies; highlighting potential for improvements in yield, which allow producers to make better use of what is available, even in the face of suppressed BPI.

Jan 1, 2014

By Kazutoshi Haga, Atsushi Shibayama, Altansukh Batnasan

This study presents a viable approach for recovery of precious metals such as gold (Au), silver (Ag), palladium (Pd), and base metals, including copper (Cu), nickel (Ni), cobalt (Co), lead (Pb) and zinc (Zn) from waste printed circuit boards (WPCBs) via iodine-iodide leaching and precipitation. The behaviours of dissolution and precipitation of precious and base metals during iodine-iodide leaching and precipitation processes were discussed. Sodium hydroxide (NaOH) was used to remove base metal impurities exist in the pregnant leach solution under alkaline conditions. Precious metals remained in the resulting solution from NaOH precipitation were recovered by reduction using ascorbic acid (L-AA) solution. Results show that under optimum leaching conditions, almost all (> 99%) of Au was dissolved in an iodine-iodide solution when the dissolution efficiencies of other precious metals (Ag, Pd) and base metals, besides calcium (leaching of 25%) were less than 1 and 6%, respectively. The study revealed that more than 95% of Cu, Ni, Pb, Zn, Fe and Mn were initially removed from the pregnant leach solution at pH of 9.3 with addition of 0.1 M NaOH. Then 99.8% Au, 81.7% Ag and 74% Pd were precipitated from the obtained solution after NaOH precipitation while L-AA dose was 0.6 ml/ml at the condition. It can be concluded that the precious and base metals could be recovered selectively and economically from WPCBs via iodine-iodide leaching followed by precipitation using NaOH and L-AA.

Mar 1, 2018

By John M. Gaines

Lead concentrates from the Viburnum Trend in the Southeast Missouri Lead district are sintered prior to smelting to bind the particles together homogenize the feed, and reduce the sulfur content. Good sinter forms competent masses about 4 to 6 inches across, that hal!e about 15% porosity and good mechanical strength to withstand transport and the weight of the overlying load in the smelter. Bad sinter has poor mechanical strength and forms fine fragments that retard the circulation of reducing gases in the furnace and lengthen the time required for reduction. The productivity of the lead smelter depends on good sinter feed. Because some lead sinter plants produce bad sinter about 20% of the time, this applied mineralogy study has been undertaken to determine the mineralogical and microtextural differences between good and bad sinter. A reflected light microscopic study of 130 polished sections has shown that good and bad sinters differ distinctly in their mineralogy, tex1ure. and character of, porosity. Good sinter consists of hardystonite, franklinite. lead-zinc-bearing magnesium-calcium silicate, lead silicate matrix, and large crystals of calcium-magnesium-iron silicate, together with minor amounts of lead oxides, lead-zinc silicate, metallic lead, specular hematite, magnetite, lead-iron-bearing zincite and zinc-Iead-magnesium-bearing wustite in a tightly intergrown mesh of crystals and with an evenly distributed porosity of 15% to 20%. Electron microprobe analyses show that the principal phases contain lead (or zinc): hardystonite (4-20% Pb) franklinite (2-14% Pb) and lead silicate matrix (65-74% Pb). Bad sinter differs from good sinter in the greater abundance of lead silicate matrix, galena metallic lead, and lead oxides and the lesser abundance of hardystonite, franklinite and calcium-magnesium-iron silicate. Bad Sinter is characterized by a lack of an intimate intergrowth of the constituent phases. Its porosity is much lower commonly 0 to 5% and those pores are concentrated in local areas rather than distributed evenly throughout the sinter.

Jan 1, 1991

By G. A. Bala

As part of ongoing research to define mechanisms of microbial enhanced oil recovery (MEOR), this work describes the activity of Bacillus l1chen1formis JF-2 (ATCC 39307) Mosurfactant against crude oils with varying compositions. Surfactant based MEOR improves oil recovery by lowering the oil/brine interfactal tension (IFT) therefore permitting oil to be displaced or solub1lized into the aqueous phase.? MEOR is an Enhanced Oil Recovery (EOR) process which allows for the introduction of chemical and miscible fluids, in the form of microbial metabolic end-products, through the injection of microorganisms into the reservoir or stimulation of indigenous reservoir microbial populations. These microorganisms represent a replenishable in situ source of acid, gas, biopolymer, solvent, or surfactant products which can be. supported and manipulated by the addition of simple and inexpensive nutrients to enhance the recovery of oil. Microbially mediated surfactant production represents one mechanism of MEOR. Bacillus licheniformis JF-2. has been used in a mode 1 MEOR system based on Berea sandstone cores (permeabilly .85 to 400 md) to examine surfactant based MEOR of medium to heavy crude oils (API gravity 38.1° to 17.5°). Enhanced oil recovery was achieved with all oils tested using either cell free culture supernatants or microbial suspensions as injectants with no detrimental effect to the oil. Spatial distribution of cells following mf?crobtal flooding was analyzed with scanning electron microscopy. Data indkate complete distribution of cells with a predominance of organisms located distal to the point of injection. There appears to be no sign:if1cant recovery trend with respect to oil composition.. The biosurfactant produced by Bacillus lichen1form1s JF-2 lowers the interfacial tension of all oils tested equally well.

Jan 1, 1991

By Harrison Hodge

In the Bayer process for alumina production, between 2–35% Al2O3 is lost with bauxite residue due primarily to incomplete dissolution of aluminiumbearing minerals during caustic leaching or the precipitation of sodium alumino-silicate solids. The recovery of sodium and aluminium from the residue, and particularly from the contained sodium alumino-silicates, is becoming an increasingly critical issue from both an environmental and economic standpoint. Lime-soda residue sintering followed by selective leaching has been proposed as a method to recover sodium and alumina. The factors influencing the sintering mechanisms and kinetics, and the subsequent leaching have not been well described to date. In this study, the physical and chemical changes taking place during isothermal sintering of bauxite residue in air, particularly at short reaction times are investigated using scanning electron microscope (SEM) and X-ray diffraction (XRD). The impacts of these changes on the recovery of valuable materials are reported.