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By Z. Yang

The flotation behavior of the. green algae Chlorella vulgaris and a wild Chlamydomonas spp. was studied in the presence of Zn(II) using dodecylammonium chloride as collector. At about pH 6. both organisms readily float as amine concentration approaches lx10-3 kmol/m3. In addition, electrokinetic measurements were made on the organisms as a function of pH in both the presence and absence of Zn(II). It was found that the Zn(II) has a considerably greater effect on the zeta potential of C. vulgaris than on Chlamydomonas. Zn(II) adsorption studies also indicated that C. vulgaris is able to accumulate more Zn from solution than the Chlamydomonas.

Jan 1, 1991

By R. Y. Wan

Low grade sulfidic-carbonaceous refractory ore from Newmont Gold Company's Carlin deposit was microbially pretreated. The biological pretreatment process gave partial oxidation of the sulfidic components of the refractory ore but the preg-robbing carbon continued to be active resulting in approximately zero cyanide gold extraction. A 495 ton pilot plant test heap was conducted using acidic thiourea leach following biooxidation. Activated carbon and cation exchange resin adsorption were tested for gold recovery from the thiourea pregnant solution. The results obtained from the test heap were not satisfactory. Gold extraction was low due to slow reaction kinetics which was caused by relatively large particles and very low winter temperatures. Problems existed in the thiourea-test heap and are discussed in this paper. An alternative heap leach process using thiosulfate has been successfUl at the pilot scale for gold extraction following biooxidation pretreatment of refractory sulfidic-carbonaceous ores.

Jan 1, 1995

By M. L. Cunha

The lack of control of As and Sb compounds from copper smelters and converters has rendered some chalcopyrite containing arsenopyrite, stibnite and tetrahedrite minerals unusable for metal extraction. In the present investigation, we have studied the carbothennic reduction of Portuguese chalcopyrite mineral concentrate in the presence of lime/CaS04 and CaS04/Si02. Thermodynamic equilibrium calculations were performed to study the distribution of As and Sb between metal and the CaO-Si02-FeO slag phase. The phase equilibrium calculations also show the effect of oxygen partial pressure on the increase in the volume of the slag phase, which helps in lowering the copper metal formation temperature and facilitates a better separation between metal, matte and slag. The reduction reaction kinetics was studied between 850°C and 1100 °C, and the phases formed were identified by X-ray powder diffraction and scanning electron microscopy techniques. The importance of this research for using recycled matte, lean and rich minerals with As and Sb is also explained.

Jan 1, 2001

By R. E. Sundell, S. M. Correa

"A mathematical model is developed for the fluid flow in tungsten-inert gas weld pools. The fluid is taken to be incompressible, viscous, electrically conducting, and confined within a pool of specified shape. The flow is driven by surface-tension gradient (thermocapillary), electromagnetic, and buoyancy forces generally in this order of importance. Analysis indicates that the electromagnetic field may be calculated a priori and so decoupled from the nonlinear fluid mechanics and heat-transfer problem. The resulting set of equations is solved numerically by a line relaxation process. Computational errors caused by truncation in finite-difference schemes and by inadequate grid distributions are considered. The model is used to study several cases of differing heat and current input to the pool with and without surfactant-induced thermocapillary forces. The principal conclusions are that the thermocapillary flow, when present, is dominant with surface velocities on the order of 1 m/s. The heat transfer, as deduced from isotherms within the pool, is crucially dependent on the flow. Also, flow velocities and weld-pool surface temperatures were measuredand agree well with the model.2. IntroductionThe requirements of improved control and of automation in the TIG (tungsten-inert gas) welding process have led to the development of mathematical models for the heat transfer to the workpiece. It is now widely recognized that the fluid flow in weld pools sufficiently distorts the conduction heat transfer pattern to warrant inclusion in a process model. The experiments of Woods and Milner (1), among others, demonstrated that TIG weld pools could be driven by the electromagnetic J x B body forces present, J being the current distribution and B the induced magnetic field. Atthey (2) calculated that in typical pools the buoyancy force was about an order of magnitude less important - despite the large temperature gradients present - and neglected it in a computational study of the magnetohydrodynamic (MHD) flow. This work also reviewed many earlier studies of MHD flow caused by a source of current at a fluid surface, including analytical studies by Shercliffe (3), Sozou (4), and Sozou and Pickering (5), and a numerical study by Andrews and Craine (6). These works establish the importance of the electromagnetic force in the weld-pool flow."

Jan 1, 1986

By A. V. Tarasov

Investigations of thermodynamic properties of Cu-Ni and Cu-Ni-S systems and mattes have been conducted with the aid of a MC-130 I mass-spectrometer designed for studies of processes of vapor formation of hardly volatile substances. The instrument comprised a combination of an evaporator of Knudsen chamber type with a mass-spectrometer for analysis of the vapor phase. In the process of studies of molten Cu-Ni-S systems and commercial-grade mattes within a temperature interval of 1400-1800 K the partial pressure of sulfur was measured by means of complete isothermal evaporation and the partial pressure of copper and nickel by comparison of ionic currents. The partial pressure values of the components above the molten Cu-Ni-S were used for calculation of activities of the respective components in the melt. The copper and nickel activity data obtained was used for assessing the amount of dissolved losses of these metals in autogenous smelting slags.

Jan 1, 2003

By Mikiya Tanaka

This paper outlines our attempt to establish a recycle process of nickel in the spent baths and waste rinse water of electroless nickel plating plants using solvent extraction and solvent-impregnated support, Solvent extraction studies of nickel from actual spent baths revealed that (i) nickel is efficiently extracted by a hydroxyoxime extractant such as LIX84I at a pH greater than 6 and is readily stripped with sulfuric acid, and (ii) the mixtures of LIX63 and acidic organophosphorus extractants (D2ERP A, PC88A, and Cyanex 272) enhanee the nickel extraction efficiency to a sufficient degree without pH adjustment, but at the same time, reduce the stripping efficiency. The application of acidic organophosphorus extractants to selectively remove impurity metal ions (iron and zinc) from a real spent bath before extracting nickel lead to the finding that PC88A and Cyanex 272 effectively remove iron and zinc without pH adjustment leaving nickel in the raffinate. The removal of nickel from the waste rinse water was also studied. Solvent-impregnated supports with a macroporous resin and oil sorbents made of natural kapok fiber and synthetic fiber as supports were applied using D2EHPA and LIX860 as the extractants. During the batch operation, nickel is removed with a high efficiency without pH adjustment. During the column operation, however, the effective removal is hindered by (i) the dissolution of the nickel-D2EHPA complex into the aqueous phase in the high loading region, and (ii) the slow removal rate of the LIX860-impregnated support.

Jan 1, 2003

By René Winand

Due to chemical and electrochemical behavior of the most common additives in copper electrorefining i.e. gelatine, thiourea and chloride ions, it is essential to simulate as far as possible true industrial practice while performing laboratory experiments. The three additives must be studied simultaneously, and added continuously to the electrorefining cell. Ratio electrolyte volume to cathode area; ratio bleed flow to cathode area; hydrodynamic conditions; residence time of electrolyte in the cell; current density; electrolyte and soluble anode must be as near as possible to industrial ones. Experiments performed in the author's laboratory show that under these conditions, reproducible results can be obtained at normal industrial current density and at high current density as well. Problems are however still encountered when developing a sensor for additives monitoring, due to electrolyte redox potential and to substrate influenced thin layer deposition.

Jan 1, 1995

By Robert E. Moore

Synthetic spinel is proving to be a highly effective refractory for specific applications, but its cost limits applications. Formation of spinel from a raw material such as diaspore or bauxite could provide a suitable and less costly starting material. In the study reported here, finely ground (-325 mesh) diaspore from Missouri and bauxite from Guyana and China are combined with hardburned MgO (-325 mesh) in appropriate proportions to yield spinel and spinel with secondary phases. A classical sintering and creep study was completed, accompanied by a microstructure study to determine completeness of the reactions and morphologies of the reaction products.

Jan 1, 1991

By J. B. W. Bailey

The Noranda Horne smelter in Quebec, Canada has change considerably during the last two decades to accommodate varying custom concentrate receipts, closure of the Horne mine, better working conditions, environmental programmes, new technology and increased energy and labour costs. This paper highlights the reasons for changing the smelter from two calcine charged and one wet charge reverberatory furnaces fired by coal to a smelter using. tonnage oxygen oil, natural gas and coal in a single wet charged reverberatory furnace and a Noranda Process continuous Reactor. The current operation 1 described, including three major topics; the use of oxygen/fuel burners on the charge banks of the reverberatory furnace which has increase the smelting rate from 680 to 1100 tonnes of concentrate per day; the oxygen enrichment of the Noranda Process converting air to achieve smelting rates of over 1800 tonnes of concentrate per day; the converting of the mixture of 73 percent copper matte produced from the Noranda Process and the 33 percent copper matte produced from the reverberatory furnace.

Jan 1, 1983

By I. Perus, M. Fazarinc, G. Kugler, M. Tercelj

"Ledeburitic tool steels are highly alloyed steels used for specific highly loaded applications but are characterized by low and variable hot workability. In this contribution the importance of selecting the right choice of some essential process parameters, i.e. casting temperature, solidification rate and soaking temperature, needed for improving the intrinsic hot deformability of ledeburitic tool steels, is studied. An inappropriate selection of casting temperature and cooling rate results in precipitation of unusual eutectic carbides that decreases the hot workability, whereas with the selection of appropriate soaking temperature the temperature range of safe hot working can be broadened. For each initial as-cast microstructure individually determined soaking temperature should be selected.IntroductionThe surface cracking during hot deformation of ledeburitic tool steels reduces mechanical properties and their industrial yield. These tool steels have high hardness, wear resistance and high tempering resistance on one hand, and high flow stresses and low hot deformability on the other. Decreased hot deformability of the tool steels is attributed to the type, size, shape, distribution, fraction of eutectic carbides and/or other phases, grain growth, etc. at upper limit while precipitation of secondary carbides and decreased recrystallization rate at lower limit of the safe hot deformation temperature range, [1-6].The occurrence of cracks on most exposed areas of workpiece are related to the areas where similar conditions related to upper and/or lower limit of temperature working range prevail, i.e. areas with accelerated cooling, areas with higher value of accumulated strains where also decreased recrystallization rate with simultaneously presence of higher tensile stresses takes place, furthermore areas of workpiece which are due to combustion conditions in furnace heated to higher temperatures, etc. Thus the areas, where combination of previously mentioned conditions prevails, are more exposed to cracking. This additionally requires that hot deformability of ledeburitic tool steel should be considered as a complex problem. Publications in the literature with regards to hot deformability of tool steels are predominately of a partial nature thus all reasons for unexpected occurrence of cracks are not sufficiently explained in available literature so far. Furthermore modern practice proves that previous processing parameters significantly influence the hot deformability and thus this cannot be considered as a constant value. During heating, soaking and hot deformation various processes take place: decay (decomposition) of carbides, formation of new carbides, dissolution of carbides and of alloying elements, etc. Thus depending on variation of process parameters and chemical composition, that consequently influences the processes related to carbides, shifting of decreased deformability at both limits of temperature working range to higher and/or to lower temperatures can occur, [1-14]."

Jan 1, 2012

By S. R. Reddy

Thennodynamic properties of several quaternary systems are calculated using our recently modified Margules equations. The modified Margules equations are expressed up to infinite order in the vicinity of solvent. Quaternary system of one solvent and three,solute partials are derived. First order interaction coefficients of binary, ternary and cross -interaction parameters of quaternary system are used to'evaluate the partial functions. In the original fonn of Margules equations,derived partial functions are convergent and same 'as Unified ,Interaction Parameter Fonnalism. But considering up to infinite order of the Margules coefficients, the functions are divergent, in order to overcome this restriction, Margules equations are modified to get consistent equations. Derived partial functions are thennodynamica Hy consistent with Maxwell and Gibbs Duhem relations. The derived logarithmic activity coefficient of the solvent and solutes are consistent with the ternary systems. The calculated data, ie., activity coefficient values of nitrogen and interaction coefficients are in good agreement with the data of Fe-Cr-V -N. Fe-Ni-V -N, Fe-Cr-Ta-N and Fe-Ni-Ta-N systems.

Jan 1, 1999

A novel pressure leaching process for platinum group metal (PGM) feedstocks is described. The process is particularly well suited for treatment of ores or concentrates that are too low grade for economic processing by the conventional smelting/leaching process. Operating conditions have been identified under which gold, the PGM's and the base metals dissolve simultaneously in a pressure leaching autoclave. The product of this leaching process can then be treated by one of several flowsheets, of which the preferred will likely involve solid/liquid separation, followed by precipitation (or adsorption on activated carbon) of gold and the PGM's, followed by copper solvent extraction/electrowinning. Depending on the concentrations of nickel and cobalt, the copper raffinate would either be partially recycled to the autoclave to allow NilCo concentrations to build up, or it would proceed directly to a Ni/Co refinery. This paper deals with the pressure leaching process and the recovery of gold and the PGM's from the pressure leach product.

Jan 1, 2000

By I-Min Lu

An electric field was applied to a metal-bearing kaolinite specimen to investigate the efficiency of electro-osmosis in removing heavy metals from contaminated soils. The electric field induces a flow of water through the porous medium, called electro-osmosis, which is superimposed on the hydraulic flow. Because the electro-osmotic flow is relatively stronger in smaller pores, it can enhance the displacement of contaminated solution by fluid convection. Furthermore local changes in pH caused by the electrode reactions can affect adsorption equilibria and the distribution of solutes between the solution and the solid surfaces. The electro-osmosis experiments were conducted by applying either a constant current or a constant voltage across 8-cm inside diameter, 25 to 30-cm long specimens of kaolinite clay with graphite electrodes. Samples of the pore fluid and of the clay were analyzed to determine metal content, pH, and conductivity as functions of time and position. Results show that removal of heavy metals from soil can be accomplished effectively by electrokinetic treatment of sufficient duration. Approximately 95% of the lead was removed after 189 days.

Jan 1, 1996

By Carlos A. Nunes

V-AI alloys have been used commercially to produce pure vanadium by Electron Beam Melting (EBM), as well as to obtain Ti-based alloys (ex. Ti-6AI-4V). The aluminothermic reduction of vanadium pentoxide (V205) is the primary method to obtain these alloys. Concerning the obtention of pure vanadium, earlier studies have indicated alloys presenting Al content between 10 and 15wt% as the most suitable alloys for direct EBM. In the present work we investigated the aluminothermic reduction of V205 in order to define process parameters for the obtention of V-AI alloys with composition in the previously mentioned range. It was studied basically the effect of excess AI, CaO addition and reaction atmosphere (air, argon) on the alloy composition (AI, 0, N). In addition, microstructural analysis of selected alloys by SEM (BSE images) and EPMA (WDX) were also performed.

Jan 1, 1996

By Arpad E. Tonna

Recycling of materials from lithium-oxyhalide batteries is a complex task, since the dismantling of batteries is associated with many hazards. The electrolyte and the lithium anode metal are extremely reactive in the presence of water or water vapor. Therefore, the dismantling process is a complex task. In this process, the lithium battery is electrically discharged, then frozen in liquid argon, and cut into small size pieces. These are fed into an incinerator, where the unreacted portion of lithium metal, thionyl chloride, plastic separators and carbon paste are decomposed and burned to gaseous products. The aluminum, iron (steel) and nickel pieces are recovered as saleable scrap metals. The off-gases are scrubbed with an alkaline sodium carbonate containing solution. The clean gases are released to the environment. The particulate mater recovered from the scrub-suspension would be available as additive to the cement industry . The recycling of battery decomposition products improves the economic viability of the disposal processes. Work is in progress to develop safe handling, processing and recycling large size lithium batteries.

Jan 1, 1995

By J. K. S. Tee

Using a novel method, zinc has been selectively removed from galvanized steel scrap on a laboratory scale. The separation is based on thermodynamic principles: during chlorination in air-chlorine (10:l) mixtures at 800 OC, zinc forms a volatile product (zinc chloride) while iron does not chlorinate as its oxides are more stable than the respective chlorides. As much as 92 % of zinc is removed from the surface of steel within 10 minutes. This process overcomes tedious and costly preparatory stages associated with leaching - electrowinning methods.

Jan 1, 1999

By Zhang Libo, Li Wei, Peng Jinhui, Guo Shenghui, L. Jing

Partially stabilized zirconia ceramics (PSZ) were prepared by microwave sintering using natural baddeleyite which was obtained by flotation of baddeleyite ore as starting materials. Because of using natural baddeleyite as raw and the process producing no waste, it realized shorter process, energy savmg, environmentally-friendly and non-damage processing. In this work natural baddeleyite stabilized with 3.8wt.% CaO were sintered at 1300°C for 60min in a multi-mode 2.45GHz microwave furnace. Microwave sintering could fast heating and sintering. Besides that, microwave sintering could heat materials wholly, low the sintering temperature, improve the materials properties and save energy. X-ray spectrum displayed the product composed by the tetragonal phase and monoclinic phase that also showed the product was PSZ. Fine and uniform microstructures were observed in the product through scanning electron microscopy. PSZ which was with high density was confirmed by the method of the Archimedes technique.

Jan 1, 2011

By S. E. Khalafalla

A method for preparing ferrochromium alloys containing less than 2 pct carbon has been devised in a single vacuum furnace reactor. This method can conserve chromium and should reduce the capital and energy requirements relative to chromite electrothermal reduction. Reduced products containing less than 2 and as low as 0.01 wt pct carbon were obtained by reacting pellets of chromite and carbonaceous reductant mixtures at pressures of 0.1 to 1 ton and temperatures of 1,230° to 1,320° C. The extent of reduction increased with increased temperature and decreased pressure; however, operating conditions were limited due to the onset of significant chromium vaporization at higher temperatures and lower pressures. Foundry coke, anthracite, and carbon black were found to be superior to graphite as reductants. The reduction of chromite to metallics was found to proceed via the carbide intermediates Fe3C or Cr3C2. Lime accelerates the. rate of solid state reduction of chromite and can shorten the furnacin1r time at 1,3000 C under vacuum from 13 hours to less than three hours. Additional lime and silica are added to the hot reduced chromite after releasing the vacuum and raising the furnace. temperature to 1, 700° C. Soaking the charge for about 20 minutes gave a button of low carbon ferrochromium alloy beneath a well-defined slag layer.

Jan 1, 1985

By Mark Kruzynski, Srinivas Garimella, James T. Wiswall

"A flue gas recirculation (FGR) system for a combustion fired aluminum melting furnace is experimentally investigated. The FGR system flows combustion air in a turbulent jet within the flue gas stream, and the turbulent jet flow is collected in a tube at a distance from the jet exit. Entrainment of the flue gases as well as heat transfer between the flue gases and the jet occurs over the length of the exposed jet. Heat transfer between the flue gases and the jet, and the amount of flue gas entrained into the jet (derived from temperature, flow rate and oxygen fraction measurements) were measured as a function of nozzle exit velocity and the distance between the nozzle exit and collection tube. In addition to flue gas entrainment, a fuel savings of up to 7%, due to heat transfer over the length of the jet, was projected from the measurements obtained.IntroductionFlue gas recirculation can be applied to aluminum melting furnaces to control combustion temperature. When coupled with a device to improve furnace efficiency by recovering heat from the furnace exhaust, flue gas recirculation provides a control technique that is integral to achieving the goals of reducing fuel consumption, increasing product yield, increasing the longevity of infrastructure, and reducing pollutant emissions. In particular, combustion temperature control can help reduce reactivity of the products of combustion with the molten metal surface and furnace refractory materials. Combustion temperature control can also help improve the life of heat exchangers used to recover energy lost to the environment in the flue gases, and reduce NOx formation in the combustion process. Flue gas recirculation can also dilute oxygen used in oxy-fuel combustion to reduce reactivity.Flue gas recirculation has been used since the 1970s to control flame temperatures in the automotive industry [1-3] and has successfully reduced NOx emissions. Many different flue gas recirculation approaches for high temperature melting such as melting aluminum and glass have been patented since the 1980s [4-12]. There has also been academic interest to determine the fundamental performance characteristics of flue gas recirculation in high temperature furnaces and in combustion [13-15]."

Jan 1, 2014

By F. J. J. van Loo, J. K. Kivilahti, M. Paulasto

"Activation mechanism and interfacial reactions in brazing of ShN4 with different AgCuTi filler alloys has been investigated thermodynamically and experimentally. During brazing the AgCuTi filler alloy is divided into two liquids Ll and L2, where the (Cu,Ti)-rich liquid L2 gathers at the ShN4 interface and reacts with it. The concentration of Ti in L2 is high, but due to the strong attractive interaction between Cu and Ti, the activity of Ti in L2 is considerably low. In reaction between ShN4 and Cu-containing brazes a Ti-Cu-Si-N compound is typically formed at the interface. In absence of Cu, in joints brazed with AgTi based filler alloys, extremely Ti-rich solution reacts with ShN4 and as reaction products TiN and TisSh[N] are formed. IntroductionAdvanced ceramics like silicon nitride are increasingly used as structural components in demanding applications as well as in electronics industry. Complex, multicomponent structures for engineering applications generally require interconnections and therefore joinability of ceramics largely determines the possibilities of metal-ceramic structures to enable demanding functions. Brazing with active filler metals, most of which are based on the Ag-Cu-Ti system, has been commonly employed for joining of ShN4 to other ceramics and metals. The interfacial microstructures formed when ShN4 is brazed with Ag-Cu-Ti braze alloys have been discussed in several recent studies [1-7]. However, some inconsistencies exist in the reported results. The formation of layers of TiN and titanium silicides, possibly TisSh, next to the ShN4 has been reported in several studies [1-5], while in another investigation, a layer of an orthorhombic TiSi- Cu-N phase was found beyond the TiN layer [6]. In few investigations the thermodynamics of the ShN4-Ti system has been considered, but no detailed thermodynamic analysis of the chemical interactions between the braze and ShN4 has been provided. In order to resolve which chemical reactions are possible under various joining conditions and thereby to be able to control the brazing of ShN4 the reactions in brazing has to be studied using both microstructural and thermodynamic analysis."

Jan 1, 1996