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By Yves Dardel

THE literature concerning the remelting of aluminum and its alloys is very rich. Unfortunately the greater part of the papers about this subject have no scientific value, for the theories or explanations are too often in opposition to the laws of physical chemistry. Furthermore only a few of the methods of purification1,2 are considered in the literature. Hence it has seemed necessary to the author to sketch a general theory of the purification of secondary aluminum. The purpose of the purification is to eliminate the impurities that the charges and the atmosphere of the furnaces bring into the bath during the successive remeltings. Indeed scrap as well as metal can be used when soiled with oil, greases, water, .. , if it has been sufficiently dried and contains oxides. At the melting point of the metal, the oils and greases are decomposed into their constituent elements H2, 02, H2O, C02, CO, CH4, and others. These gases are added to the corresponding gases in the atmosphere of the furnace. The impurities introduced into the metal during the remelting will accordingly be the products resulting from the action of these gases on the liquid bath. The quantity of hydrogen that is soluble in aluminum and its alloys is given by the relation of Sieverts3 as a function of its partial pressure PH2 in the atmosphere [m = K _%/PH, [I]] where K is a constant, which depends only upon the temperature and increases with it. The experiments of Röntgen and Braun4, Röntgen and Möller5, Bircumshaw6 and Winterhager7 have rendered it possible to determine the value of K, when the temperature is inferior to 1.000°K. One obtains: [log K = - 4,702.5 + 0.238 [2]] Besides its usual signification, the term PH2 represents also the internal pressure of dissolved hydrogen, since in the equilibrium, that is, when no gas exchange occurs between the two phases, the pressures of hydrogen in the metal and in the atmosphere must be equal. Eq I shows that when the partial pressure of H2 increases the amount of dissolved hydrogen in equilibrium increases, and that, if the contrary occurs, the quantity of H2 should diminish. However, if for any reason the diffusion of hydrogen is hindered and the total amount of dissolved gas remains constant while the temperature lowers, the internal pressure of H2 increases until it reaches the value of the hydrostatic pressure. At this point, bubbles of hydrogen appear in the bath and escape out of it. The amount of hydrogen in the metal is then limited by a maximum depending on the hydrostatic pressure, which is practically equal to one atmosphere. Indeed hydrogen does not accumulate in the form of a hydride appearing as a separate solid phase. However, even the mechanism of the solubility is not yet elucidated. One does not know exactly as yet, whether the

Jan 1, 1947

By M. C. Flemings, R. Mehrabian, G. E. Nereo

Analytical expressions derived previously are used to describe quantitatively effects on macrosegregation of some solidification and mold design variables. Al-4.5 pct Cu alloy is used as example. It is shown that abrupt changes in heat transfer rate result in solute-rich or solute-poor "bands". Severe solute-rich bands accowzpany "reheating" that can result, for example, from abrupt formation of an air gap at a mold-metal interface. With planar isotherms, solute-poor regions also result from reduction in cross section through which fluid flow to feed shrinkage takes place. It is suggested that the negative "cone" of segregation often found at the base of large ingots results from this reduction in cross section for feeding. Consideration is given to the positive and negative segregation to be expected in laboratory ingots in association with changes in ingot cross section. Under-riser positive segregation is considered and it is concluded this segregation results when vertical temperature gradient is low in the region of the riser; the segregation is accentuated by the temperature gradient reversal which can occur in inadequately insulated risers ("'hot tops"). Finally it is shown for Al-4.5 pct Cu alloy that the assumption of constant k and p in analytic solutions gives calculated results close to those obtained for the case of ziariable k and 0. A basic "local solute redistribution equation" was derived earlier' for calculation of macrosegregation resulting from flow of solute-rich liquid to feed solidification shrinkage, thermal contraction, and/or other contractions occurring during solidification. This expression relates fraction liquid, g~, to liquid composition, CL, at a given position x, y, z, in a solidifying Eq. [I] is for the general case of three-dimensional heat and fluid flow assuming constant solid (but not necessarily liquid) density during solidification, negligible net solute change from diffusion, and no pore formation. In this paper we first demonstrate application of this equation for calculation of macrosegregation in several examples involving one-dimensional heat and fluid flow. Specifically considered are examples in which segregation results from sudden changes in heat flow conditions. Next, Eq. [I] is used to describe segregation in examples where isotherms remain planar but where fluid flow is no longer one-dimensional. Application of this expression illustrates the type of segregation to be expected in unidirectionally solidified ingots of gradually or abruptly varying cross section. For segregation calculations, A1-4.5 pct Cu alloy is employed with constant k and p Vz = 0.172, 4 = 0.055), eutectic composition (CE = 33 pct Cu). In all examples, fraction eutectic is neglected in velocity calculations; this was previously shown to introduce little error.' A linear distribution of fraction liquid in the liquid-solid zone is assumed. In a concluding section it is shown that the assumption employed of constant k and /3 gives results close to those obtained when the actual (variable) values of k and 0 are employed.

Jan 1, 1969

By Lee T. J

The area, A, under a gamma-ray log that passes through a horizontal bed given by: A = gl/k. Here is the equivalent concentration of U3O8 in the body, l the thickness of the body, and k the calibration factor or sensitivityof the logger. The area is independent of the logging speed or logger time constant.This relationship, together with the first moment about the maximum of the log and its value there suflicient to determine the thickness, position of the centre of the bed from the log maximum and the concentration of U3O8.Numerical results obtained from artificial and field data show that the computed results arc as good as those obtained by methods such as the inverse filter technique and the iterative method. The present method yields results that arc easier to feed into an ore reserve data base.

Jan 1, 1981

By H. Zhu, Q. Jiang

The leaching kinetics of iron during the atmospheric direct leaching (ADL) of marmatite concentrate was studied under the following conditions: reaction temperature of 343-383 K, slurry pressure of 0.3-0.7 MPa, particle size of (-74 ?m, +63 ?m), (-63 ?m, +44 ?m), (100%-44 ?m). The statistical effects of reaction temperature, total pressure and particle size of concentrate on the extraction and the leaching rate of iron were analyzed. The results show that reaction temperature is a significant factor while slurry pressure and particle size are not statistically meaningful with respect to the extraction or the leaching rate. The extraction of iron fits better to the mixed-controlled shrinking core model and the apparent activation energy was calculated to be 37.66 kJ/mol. The leaching of iron is mixed controlled by the interfacial chemical reaction and diffusion across the product layer.

Jan 1, 2014

By T. Sharma, T. C. Rao

Laboratory studies have been carried out on acid leaching as a possible route for the extraction of potassium from glauconitic sandstone. Leaching efficiencies with sulphuric, hydrochloric and nitric acids were investigated. The effects on potassium dissolution of temperature, concentration and type of acid, stirring speed and leaching time were also studied. The results show that it is possible to recover 87.5, 93 and 85% potassium with 5 M H2SO4, HCl and HNO3, respectively. During the initial stages of the sulphuric acid leaching process the chemical reaction at the mineral surface is the rate determining step, whereas during the later stages diffusion through the product layer is rate-controlling. Overall, the process follows a mixed-control model that includes both chemical reaction and diffusion. The activation energy for the dissolution of K was found to be in the range 25.79-106 kJ/mol.

Jan 12, 1992

By J. S. Kirkaldy

A theoretical procedure is demonstrated for calculating two-dimensional binary cellular single-valued interfaces and extended to triple-valued (remelt) shapes. The numerical calculations for the single-valued local equilibrium problem which yield unique shapes as functions of the supersaturation parameter a and the partition coefficient k are reviewed. The cell amplitude L and wavelength A scale identically as the inverse velocity to the 112 power and the aspect ratio r is a constant equal to 312, independently of a and k for a < 0.5.. For 0.5 < a < m, L, A and r decrease asymptotically to zero indicating the finite amplitude nature of the instability at a = 1 and the existence of sub-marginal states which converge to a flat interface at a- m (Glv- m). Scaling comparisons between equilibrium single-valued and triple-valued and deep-rooted non- equilibrium cells are made.

Jan 1, 1992

By B. N. Whittaker

The paper briefly reviews the type of support and stability problems encountered in mining tunnels in U.K. Carboniferous rock conditions, particularly the Coal Measures where almost all such tunnels are located. Stability prediction of mining tunnels is discussed and a computer-based model which deals with stratified rock conditions is described. Various schemes for monitoring the stability of mining tunnels are examined and the application of the results discussed. Comparisons between predicted and measured Closure values are presented for a major Coal mining tunnelling project at Selby in the North Yorkshire Coalfield. Conclusions are drawn concerning the application of the present prediction technique together with the importance of underground monitoring. Examples of different types of mine tunnel stability problems encountered in the U.K. Coal Measures are discussed and comments made on the secondary effects of tunnel peripheral rock weathering and corrosion of the associated support systems.

Jan 1, 1987

By M. S. Shishvan, J. R. van Duijvenbode, L. M. Cloete, M. W. N. Buxton

Geochemical and mineralogical datasets from Tropicana Gold Mine, Australia, have been used to define ore fingerprints. VNIR/SWIR spectral data were represented by four normalised wavelength regions and were clustered to form spectral classes. Sequentially, these spectral class proportions within a block and collocated XRF data were clustered to form material types (fingerprints). The material types were related to an Equotip-BWi correlation. These correlations can be used to extrapolate a hardness signature and generate a BWi proxy for different blocks. The combined fingerprints and BWi proxy can assist as a tool for enhancing the prediction of comminution behaviour. They can explain specific domain-related hardness variations. For example, one material type could be separated into a softer (~15-18 kWh/t), and harder (>20 kWh/t) material blend. This was accomplished using the commonly overlooked VNIR region at 605 nm. This outcome has significance for blending strategies.

Sep 1, 2021

By Chengyi Ding, Xuewei Lv, Senwei Xuan, Chenguang Bai, Kai Tang, Gang Li

Sinter is an important iron-bearing material charged into blast furnace. Calcium ferrite (CF) is one of the most significant liquid phases in fluxed sinter. The isothermal reduction kinetics of CF and CF8M (n(CaO):n(Fe2O3) = 1, wt%(MgO) = 8) with 30% CO and 70% N2 gas mixtures at 1123, 1173, and 1223 K were investigated through thermogravimetric analysis in this study. Rate analysis illuminates that the reduction processes of CF and CF8M are mainly expressed as a typical two-stage reaction. Sharp analysis indicates that CF and CF8M reduction is expressed by the Avrami–Erofeev equation presenting a 2D shrinking layer reaction. The apparent activation energy values of CF and CF8M reduction are 46.9 and 31.8 kJ mol−1 individually based on model-free method.

Mar 1, 2018

By A. A. Hejja

The effect of composition on electrical conductivity, viscosity and liquidus temperature of the slags was investigated in the temperature range of 1300" to 1450°C. The synthetic slags containing CaO, MgO, SiO,, A1,0, and FeO were similar to those employed in the electric furnace smelting of sulphide Cu-Ni concentrates containing PGM (Platinum Group Metals) from the Merensky Reef of South Africa. FeO and SiO, were found to affect the viscosity and conductivity the most while liquidus temperature depended on MgO content in addition to these. The activation energy for electrical conduction was found to vary from 67 to 159 kJ/mol and that for viscosity from 125 to 209 kJ/mol. Optimization of the slag composition was attempted on the basis of opposite trend of the viscosity-electrical conductivity relationship with slag composition.

Jan 1, 1994

By Boyes B. A, Haydon D. J

The Paddington project is a gold mining and processing operation located 35 km north of Kalgoorlie in the Eastern Goldfields region of Western Australia (Figure 1). The project, which is operated by Pancontinental Goldmining Areas Pty Ltd, treats 1.25 Mtpa of oxidised gold ore, derived mainly from open cuts adjacent to the plant, with minor tonnages from other pits in the region treated on a custom-milling basis. Gold is recovered using a conventional CIL process. The process raw water supply of 3 500 kUd is derived from the local groundwater system. Average salinity of the raw water is around 90 000 - 100 000 mg/L total dissolved solids. A small portion of the raw water is passed through a vacuum distillation desalination plant to produce the project&apos;s 200 kUd requirement for high quality water for potable use and gold recovery.

Jan 1, 1988

By J. Grumer

Nine dust and gaseous inhibitors of propagating coal dust-air flames (lean, stoichiometric, and rich) were evaluated in a newly developed 15-cm-id, 3.6-meter-long instrumented flame duct, under conditions such that wall quenching was virtually absent and the dust concentration was temporally and spacially uniform to within about t5 percent. Listed roughly in order of increasing efficiency, the inhibitors evaluated were rock dust (calcium carbonate), powdered oyster shells (calcium carbonate), Halon 1301 (trifluorobromomethane), Halon 1211 (difluorochlorobromomethane), sodium chloride, Super-K (potassium chloride), regular-grade fire extinguishant powder (sodium bicarbonate), Purple-K (potassium bicarbonate), and Monnex (potassium bicarbonate combined with urea). Experiments were extended to clouds containing 1 and 2 volume-percent of methane. The inhibition of lean, stoichiometric, and rich methane-air flames without coal dust was also examined in a few instances; results agreed with those obtained for coal dust-air flames.

Jan 1, 1971

ANDERSON, ALEXANDER, Captain, Royal Garrison Artillery. ANDERSON, GEORGE K., JR., Lieutenant, 30th Co., 3d Replacement Regiment. ARMSTEAD, H. H., Captain, Quartermaster Corps, U. S. N. A. ARMSTRONG, HAROLD KERR, Student Flight Officer, U. S. Naval Reserve Flying Corps, Dunwoody Naval Training Station, Minneapolis, Minn. BAKER, HARRY A., Captain, Co. M, 53d Pioneer Infantry. BASSETT, THOMAS E., Corporal, 340th. Field Artillery, Battery A, 89th Division, A. E. F. BATES, Wm.. T., 3d Reserve Officers&apos; Training Camp. BAUMMGARTEN, K., 1st Lieutenant, 1st Corps School A. P. 0. 703. BAYLESS, G. E. S., Supply Dept., U. S. Submarine Base, New London, Conn. BENSEL, J. A., Major, U. S. R., Board of Control, War. Construction Activities, Norfolk, Va. BILLICK, DON C., Co. C, Ordnance. Supply School. BILLINGSLEY, PAUL, 1st Lieutenant, National Army, Statistics Branch,. General Staff. BLANDY, S. H. B., B. E. F.

Jan 8, 1918

By Bob Butler

Brunswick Mine has been involved in a comprehensive research program investigating site specific aspects of thiosalt management to eliminate its adverse environmental effects. Minimum annual reagent cost estimates for thiosalt treatment using hydrogen peroxide and sodium hypochlorite are $400K and $1.5 million respectively. Also, minimum costs for the use of bicarbonate to buffer the pH depression associated with thiosalt oxidation in the receiving environment is in the order of $400K annually. A design of experiment (DOE) research program identified that natural UV radiation, temperature, DO and water chemistry are key factors influencing the natural oxidation rate of thiosalts within Brunswick?s water management system. A DOE surface response model was used to describe the thiosalt oxidation kinetics, which were then used to develop a predictive oxidation model for thiosalt and pH control of the mill?s reclaim water system.

Nov 1, 2002

By J. L. Wyatt

THE strain sensitivity, K, a property of metals defined as the unit change in electrical resistance per unit strain, was measured for commercial purity titanium wire to determine its usefulness as a strain gage material. A Kelvin double bridge, accurate to 0.000001 ohm, was used to make measurements from 0 to 1 pct total strain. A positive value of 0.17 for K was found. This compares with 2.15 for constantan and 3.5 for cold-worked invar, two of the more common strain gage materials. The effect of temperature also was determined. It was found that a change in temperature of 30°F caused the same resistance change as 1 pct strain. It is therefore concluded that titanium would have utility as a strain gage only if the thermal fluctuations in the specimen could be controlled to a high degree and in applications of very large total strain.

Jan 1, 1953

By Byung-Su Kim

Most electric arc furnace dust (EAFD) treatment processes employ carbon as a reducing agent for the zinc oxide in the EAFD. In the present work, the reduction reaction of zinc oxide with carbon in the present of various additives was studied. The effects of temperature and the additives of calcium carbonate, magnetite, and mill scale on the kinetics of the reduction reaction were measured in the temperature range of 1173 K - 1373 K under nitrogen atmosphere using a weight-loss technique. The mill scale is one of byproducts generated from the steel rolling process. From the experimental results, it was concluded that all three additives accelerates the reaction rate of zinc oxide with carbon, but the effect of addition of calcium carbonate is the highest. It was also found that magnetite, mill scale, and calcium carbonate in the reduction reaction of zinc oxide with carbon promotes the carbon gasification reaction.

Jan 1, 2006

Convential smelting of copper - cobalt - iron sulphide concentrates result in th eoxidation of cobalt and iron, which are subsequently lost into the slag. The emission of SO2 bearing gas from smelting causes serious health and environmentsl problems. In this investigation, three different types of copper - cobalt - iron sulphide concentrates, derived from froth flotation, were investigated, the concentrates, each containing more than 40 wt % percent gangue material, were directly reduced in the presence of lime and corbonin the temperature rnage of 1073 K - 1573 K, fo rthe production of an alloy containing copper, cobalt and iron. We demonstrate the basic principles of process physical chemistry for the recovery of alloy by carrying out a detailed process analysis utilising the predictions from thermodynamic equilibrium and results from the kinetics of reduction reaction. The effect of temperature on the reduction kinetics and alloy formation were determinedand analyzed in detail.

Jan 1, 2012

By Murray Johnston

New measurements have been made on the equilibrium distribution of selenium and tellurium between molten slag and metal phases. Distribution coefficients of Se and Te between magnesia-saturated calcium ferrite slag and copper or silver alloys were measured over the temperature range 1473 and 1673 K under controlled oxygen patrial pressures of 10-11 to 10-0.68atm. The results demonstrate that the minor elements are present in the calcium ferrite slag as the selenide (Se2-) and telluride (Te2-) respectively, up to a PO2 of 10-6 atm. As conditions become more oxidising, Te undergoes a transition to the divalent oxide whereas Se does not. Increasing the temperature was found to enhance partitioning of the minor elements to the slag. In terms of activities, at 1573 K, Se showed strong negative deviation from the ideal behaviour in the slag, while Te showed only slight positive deviation.

Jan 1, 2006

By W. Curlook, V. G. Papangelakis, M. Baghalha

A pressure acid leaching process has been developed for the extraction of metal values, nickel, copper, cobalt and zinc, from base metal smelter slags. The basic concept contemplates cooling the smelter slags through solidification sufficiently slowly to induce a good measure of crystallization; and subsequently, after fine grinding, to pressure leach such slags at around 250°C while applying oxygen overpressure, utilizing smelter byproduct sulphuric acid. High levels of extraction of the slags&apos; metal values are thereby achieved. It has been shown that if the same slags are quenched thereby producing an amorphous structure, the resulting metal extractions are very low. The process is applicable to smelting furnace throwaway/discard/dump slags, as well as to in-process converter slags. By extracting the bulk of the residual base metal values in the throwaway/discard/dump slags, the resulting leached residues are rendered virtually benign vis-à-vis the external environment.

Jan 1, 2004

By J. L. Havenga, L. J. van der Walt, J. T. Nel, H. Bissett

"SynopsisNew technologies used to manufacture high-quality components, such as direct laser sintering, require spherical powders of a narrow particle size distribution as this affects the packing density and sintering mechanism. The powder also has to be chemically pure as impurities such as H, O, C, N, and S causes brittleness, influence metal properties such as tensile strength, hardness, and ductility, and also increase surface tension during processing.Two new metal powder processes have been developed over the past few years. Necsa produces zirconium powders via a plasma process for use in the nuclear industry, and the CSIR produces titanium particles for use in the aerospace industry.Spheroidization and densification of these metal powders require remelting of irregular shaped particles at high temperature and solidifying the resulting droplets by rapid quenching. Spherical metal powders can be obtained by various energy-intensive methods such as atomization of molten metal at high temperatures or rotating electrode methods. Rapid heating and cooling, which prevents contamination of the powder by impurities, is, however, difficult when using these methods for highmelting- point metals. For this reason plasma methods should be considered.Thermal plasmas, characterized by their extremely high temperatures (3000–10 000 K) and rapid heating and cooling rates (approx. 106 K/s) under oxidizing, reducing, or inert conditions, are suitable for spheroidization of metal powders with relatively high melting points. Thermal plasmas for this purpose can be produced by direct current (DC) plasma arc torches or radio frequency (RF) inductively coupled discharges. In order to obtain chemically pure spheroidized powder, plasma gases such as N2, H2, O2, and CH4 cannot be considered, while Ar, Ne, and He are suitable. Neon is, however, expensive, while helium ionizes easily and it is therefore difficult to obtain a thermal helium plasma at temperatures higher than 3000 K. Therefore argon should be used as plasma gas. Residence times of particles in the plasma region range from 5–20 ms, but this is usually sufficient as 7–8 ms is required for heating and melting of titanium or zirconium metal particles in the 30 µm size range at 3500 K. In this study the melting and spheriodization of titanium powders was investigated by DC non-transferred arc and RF induction plasma methods. The powders were characterized before and after plasma treatment by optical microscopy and scanning electron microscopy (SEM) to observe if any melting or spheroidization had occurred."

Jan 1, 2015