Search Documents

By William Gregg

Recent environmental and workplace safety legislation has Imposed more stringent limits on the amount and type of particulate emitted Into the air. In the past, the mass of particles contained In a volume of air was the governing criteria. Now the size and precise chemical nature of the particulate must be known and controlled In addition to it's ?mass. Processors of metallic materials have to implement stricter control practices and more efficient control equipment to meet the new regulations. Pulse-Jet dust collector systems are being used to control particulate emissions from various process gas streams. Pulse-jets :are also being used for maintaining a healthy environment In the workplace. this paper will discuss the impact of these regulations, the control techniques used to comply with such regulations, and the equipment needed for compliance.

Jan 1, 1992

By M. Kawakami

In relation to the designing of a new-type blast furnace, the reaction of carbonaceous materials with C02 is expected to occur at as low temperature as possible. In order to get a highly reactive carbonaceous material at low temperature, the reaction kinetics was investigated by measuring such quantities as the reaction rate from weight loss, the amount of CO adsorption and specific surface area by BET method. The reaction rates were large in the order of the Bintyo char, metallurgical coke, graphite and glassy carbon. If the rate was converted to the rate per unit area, however, those of the Bintyo char was smaller than that of graphite. Thus, it is suggested that the rate of the Bintyo char is influenced by the pore diffusion of C02. The rate had a positive relation with the amount of CO adsorption, showing that the rate determining step would be the desorption of CO from the active side on the surface. The rate independent of surface area was derived, combining al\ the obtained data.

Jan 1, 2003

By Walter E. Dean

Twenty six samples of carbonaceous gold ores and associated rocks from outcrop and mine localities in northcentral Nevada were analyzed for concentrations of major. minor, and trace elements, total sulfur, and organic carbon. Q-mode factor analysis was used to define six distinctive carbonate, organic, and detrital associations of elements, and to group samples based on these associations. The trace metals that have clearly enriched the organic-carbon-rich samples are V, Zn, Ni, Cu, Cr, and Mo, although few of the samples could be considered "metal-rich" when compared to other organic-carbon-rich black shales. Rock-Eval pyrolysis was used to evaluate thermal maturity and hydrocarbon yield of the samples. Unfortunately, most samples were too thermally altered to be suitable for routine organic geochemical characterization of organic matter. The 813C values of organic carbon in rocks from different deposits have a trimodal distribution, but there is no clear distinction between the three groups of deposits that can be related to age, thermal history, or depositional environment.

Jan 1, 1987

By Paul E. Queneau

The QS (Queneau-Schuhmann) copper converter is a gently sloped, stepped, horizontal kiln-type tilting reactor in which desired bath oxygen activity, compositional and temperature gradients are created by countercurrent flow of matte and slag phases through a series of controlled bubble plume, mixer-settler configurations. Flow of gas and slag is normally concurrent. Copper sulfide concentrates are top-fed, employing oxygen flash burners. Oxygen and oxygen-carbonaceous fuel mixtures are bottom-blown into the smelting bath through judiciously located, independently regulated submerged injectors. Composition and mass flow rates of injector inputs are controlled to produce bubble plumes of desired character, without jetting through and out of the bath. The mixer-settler pattern can be reinforced if desired by employment of suspended shallow baffles. State-of-the-art instrumentation provides timely information required to govern key process variables. The outstanding capabilities of the QS converter for coppermaking have now been indicated by the current success of industrial QSL (Queneau-Schuhmann-Lurgi) leadmaking reactors. Modified converter designs are employed for leadmaking, nickelmaking and steelmaking.

Jan 1, 1993

By B. K. Chakrabarti

Modeling and a screening design of experiment (DOE) was performed with the process variables to identify the greatest effect of variables on the response quality in the dead burning of magnesite refractory in a rotary kiln. Among various interdependent variable factors, the design variables chosen were raw magnesite (RM) feed rate, kiln rotation time i,e, seconds per rotation(SPM) and burning zone temperature (BZT). The response variables chosen were exit gas temperature and density of dead burnt magnesite(DBM). ANOVA and normal plots were used to evaluate the effects.This work had enabled to correlate the BZT, RPM, RM feed with the exit gas temp and density of magnesite produced. The result opens up an avenue to look into the optimum region of operations within the ranges of variables considered in order to conserve energy and to minimize the exhaust gas temperature and to maximize the density of the DBM produced

Jan 1, 2015

By Philip E. J. Green

Two of the cornerstones of total quality management, the use of statistical and problem solving tools, and the involvement of employees, are directly applicable to environmental protection. The reduction in variation decreases the chances of violations and mishaps. Involving employees in minimizing environmental impacts is critical. One mistake, even with the best technology, and your plant can be shut down, customers lost and fines and penalties imposed - your reputation and the environment damaged. Proven strategies for involving employees in environmental protection, and over-coming the frequently strong differences of opinions about what constitutes environmental protection, will be discussed.

Jan 1, 1992

By Thomas F. Nederpel

The production of zinc and zinc-aluminum coated strip can be reasonably accomplished on a single operating unit. However, if the hot dip coating line is equip d with only one mo 7 ten metal holding furnace, it is necessary to transfer liquid metal of different chemistries and reintroduce virgin material to obtain the 18" necessary balance of elements in the bath. Dofasco produces Galvanize and Galvalume on a coating line with a sin le liquid metal furnace and has developed not only an efficient liquid metal trans& system but also an effective means of reutilizing the zinc-aluminum mixtures without detrimental quality affects.

Jan 1, 1992

By Ping Long, Bin Yang, Jian Wu, Xiumin Chen, Wenli Zhang

In this study, the analysis method of trace element in pure indium using glow discharge mass spectrometry (GD-MS) has been established by correcting the analysis result, which was obtained from non-standard quantitative method of GD-MS. The effect of instrument operating parameters, the resolution and isotopes and the pre-sputtering time on the determination results were investigated respectively. The optimized operating parameters of the instrument were obtained as follows: the discharge current was 37.5mA and discharge airflow was 475ml/min. Mass spectral interferences have been eliminated using selected resolution and isotope. The pre-sputtering time was 30 min. 4 trace elements in two pure samples were determined for 6 times. The RSD were less than 20%. The content of trace elements in indium samples was determined by GD-MS and Chemical Analysis Method of Indium which is tested by inductively coupled plasma atomic emission spectrometry, respectively. The results were consistent with each other.

Jan 1, 2016

By Jim Sarvinis, Mark Berkley, David Clarry, Jason Berzansky

"Technologies developed to sequester CO2 or use CO2 for enhanced fossil fuel recovery are currently being utilized across the globe. Taxation regimes and CO2 credit trading are becoming drivers for a number of projects. Some mining companies have also identified ancillary opportunity to sequester CO2 in their by-products; recent work in the alumina industry is a prime example. In addition to process plant emissions, mining companies are becoming increasingly aware of their overall carbon footprint, including CO2 generated during the production of utility power. New power plant designs, in various stages of development, include CO2 separation and sequestration techniques. This paper summarizes the state-of-the-art for these technologies; including integrated gasification combined cycle (IGCC) power plants. A concept to use the gasification products as reductant in metallurgical processes is also described. The relevance of technology from power plant designs with post-combustion capture to the processing of off-gas generated in metallurgical facilities is also reviewed.IntroductionGlobalization and international economic growth have led to an increase in energy demand worldwide, and a corresponding increase in greenhouse gas (GHG) emissions. In 2005, 81% of global energy supply came from fossil fuels [1]; and while alternative energy technologies are emerging, it will require many decades to curb society’s fossil fuel dependence. Given the global concern of climate change and its scientific relationship with anthropogenic carbon dioxide (CO2), there is at present great interest in the development of techniques to reduce emissions of CO2. While most of these efforts are related to power generation and energy efficiency, the development of technologies for CO2 capture may offer opportunities in reducing emissions from industrial processes."

Jan 1, 2008

By R. C. Hubli

A chemical model has been developed to investigate the dissolution of sulphide minerals in brine solutions containing copper and iron chlorides. The model has been employed to study the dissolution .of synthetic NiS using different initial concentrations of Cu(II), Cu(I), Fe(III) and temperature. The speciation of copper with particular reference to the formation of hydroxy-chlorides as a function of total chloride and H+ has been computed. The model predictions are in agreement with experimental results. It has been found that addition of Fe(III) results in the maintenance of a high Cu(II)/Cu(I) ratio leading to enhanced rates of dissolution and suppresses the loss of Cu(II) due to the formation of hydroxyl-complexes.

Jan 1, 1997

By Guanghui Li

Nickel pig iron (NPI), used as a substitute for electrolytic nickel, is able to reduce the production cost of stainless steel greatly. Aiming for preparing NPI from nickeliferous laterite ore, a pilot-plant scale test of coal-based rotary kiln direct reduction of laterite ore was performed and reported in this study. In this process, the ground laterite sample (18.85% TFe and 1.52% Ni) mixed with additives, pulverized coal and binder was briquetted into briquettes with the size of 40mm×40mm×31mm, laterite ore briquettes and reducing coal were charged into a rotary kiln with the diameter of 1.6 m and the length of 16 m, for a retention period of 6~7 hours, in which reduction section temperature was ranging from 950~1050 oC. The reduced briquettes were water quenched, ball mill ground and beneficated via low intensity magnetic separation. A magnetic concentrate, Ferronickel powder, with 86.9% TFe and 8.0% Ni was obtained, and the corresponding magnetic recovery of iron and nickel are 75% and 96.3%, respectively.

Jan 1, 2014

By Ilija Ilic

Recovery of tin from tinplate and production of good-quality detinned-plate for further processing in ironworks has been the subject of interest for many years. Tinplates are mostly used for production of tin containers for food industry and consumer goods. The research carried out so far included determination of the parameters of dissolution of tin from tinplates by alkaline solution of NaOH and electrochemical recovery of tin from the alkaline solutions. During leaching, NaNO3 and methanitrobenzoic acid (MNBA) as oxidants were studied. By leaching the waste tinplate which contains 0.31 % of tin with a solution of 1.12 mol/dm3 NaOH, 0.26 mol/dm3 Na2CO3 and 0.09 mol/dm3 MNBA at temperature of 70°C for 60 mm, a degree of tin leaching of 97 % was attained. MNBA facilitates oxidation of Sn2+ into Sn4+ suitable for obtaining compact, and not spongy, Sn cathode deposit, as it was the ease earlier. Recovery of tin by electrolysis from solutions obtained by leaching was studied to determine the effect of electrolyte composition on the quality of cathode deposit and the degree of electric current efficiency. Experimental results obtained at a laboratory level were checked on an enlarged laboratory set up where continuos leaching of tin from waste tinplate and its electrolytic recovery from the solution obtained were carried out. The experimental set-up -operated under semi-industrial conditions, and about 500 kg of waste tinplate was processed yielding about 1.160 kg of tin (99 % Sn).

Jan 1, 2000

By Elders. Wilfred A.

Petrological and geochemical methods, the utility of which has long been established in the mining industry, are proving useful and cost-effective in elucidating the thermal evolution of active geothermal fields. In return, they yield insights into sulfide-silicate equilibria, mass and energy transfer in convecting hydrothermal systems, and the genesis of hydrothermal ore bodies. Within the Plio-Pleistocene sediments of the delta of the Colorado River, in the Salton Trough, several active geothermal systems are known. Temperatures vary from 100-365°C, at less than 2 km depth, and salinities vary from 3,000 to 280,000 ppm, total dissolved solids. The hydrothermal alteration causes marked induration of the sediments, producing greenschist facies metamorphic minerals, including hydrothermal ore minerals. Subsurface authigenic minerals show strong correlation with increasing temperature. A typical sequence in sandstones is (below 150°=C) montmoril-lonite-kaolinite, (above 180°C) chlorite + illite, (above 225°C) calc-alumino-silicates, (above 325°C) biotite. There is a transition from porosity-dominated\to fracture-dominated permeability in the hottest and deepest geothermal reservoirs. This regular series of minerals provides a practical tool during exploration drilling. From drill cuttings, we can make predictions on reservoir temperatures, useful in making decisions on well completion. Other types of geothermometry we have employed include light stable isotopes, fluid inclusions and vitrinite reflectance measurements. A combination of these techniques not only improves our temperature predictions, but together with fission tack annealing studies, permits us to model the dynamics of temperature change and fluid flow in these geothermal reservoirs.

Jan 1, 1981

By Jean P. Murray

The extractive metallurgical industry is a major consumer of high-temperature process heat. It is, consequently, a major contributor of C02 emissions and other greenhouse gases derived from the combustion of fossil fuels for heat and electricity generation, or from the process itself. These emissions can be substantially reduced by replacing fossil fuels with solar energy as the source of process heat. Concentrated solar radiation can supply a large amount of thermal energy to endothermic reactions at temperatures exceeding 2000 K. Another potential for C02 emission reduction exists as well. Thermodynamically, the total amount of energy required for metal production at any given temperature is the enthalpy change of the reaction, AH. Of this total, an amount equal to the Gibbs free energy AG must be supplied as high quality energy in the form of electrical work or by using a reducing agent. Many conventional metallurgical electrolytic processes and reducing furnaces are unable to add only the thermodynamically required electricaVchemical energy due to process inefficiencies. Electrical work in excess of AG for the reaction may be used to supply process heat, or excess chemical reducing agent burned to supply process heat. Besides the thermodynamic and economic drawback, this inefficiency results in excess C02 emissions derived from the combustion of fossil fuels. With these practices, energy becomes an important cost element of the metal produced. Highly-concentrated solar energy has the demonstrated potential to separate these two forms of process energies, allowing the addition of only the thermodynamically required high-quality energy while high-temperature solar process heat is provided to the reactor. Examples of metal oxide reduction processes that have been studied experimentally in solar furnaces include the production of Fe, Al, AI/Si alloy, Mg, Zn, Tic, Sic, CaC2, TIN, Si3N4, and AIN by carbothermic reduction of their oxides, and the high-temperature solar- electrothermal reduction of ZnO.

Jan 1, 1999

By Vasil Kopaleishvili

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

Jan 1, 2006

By S. Ozbilen, B. Erdogan, M. Erdogan

To study by thermal analyses the response of precipitation hardenable alloys of Al-Cu-Mg and Al-Li-Cu-Mg system to natural and artificial ageing, a series of ternary and quaternary Al-alloys with nominal compositions of Al-l.13wt%Cu-0:65wt%Mg (alloy-I), Al-1.15wt%Cu-0.57wt%Mg-0.07wt%Li (alloy-2), Al-l.19wt%Cu-0.56wt%Mg-0.75wt%Li (alloy-3), Al-2.0lwt%Cu-0.89wt%Mg (alloy-4), Al-2.14wt%Cu"0.56wt%Mg-0.07wt%Li (alloy-5) were used in the present investigation. Samples in the form of rolled sheets are subjected to water quenching at 25EC after solution treatment at 530EC for 20 min. Alloys were aged naturally at room temperature (25EC) up to 2 months and artificially at 190EC up to 2 days. By using differential scanning calorimetry (DSC) in the temperature range of25-300EC, differential thermal analysis (DTA) in the temperature range of25-600EC together with Vicker's hardness measurements, the response to natural and artificial ageing of the alloys used in the present study were investigated. It was observed that in these alloys, GPB(Cu, Mg) zones [Guinier-Preston zones with Cu and Mg] do form during water quenching at 20EC following solutionizing heat treatment. Natural ageing of the same alloys causes formation of more GPB(Cu, Mg) zones, which results in hardening in the alloys. Artificial ageing at 190EC up to l day results in GPB zone dissolution causing preliminary decrease in hardness values while two days of artificial ageing in the alloys cause S' (Al2CuMg) precipitation confirmed by DSC/DTA analyses resulting in an increase in hardness values. Li addition up to 0.75wt% helps T1 (Al2CuLi) and T 2 (Al6CuLi3) phase formation together with S' precipitation as DSC/DTA analyses show after the same heat treatment.

Jan 1, 1998

By Courtney Young, Jerome Downey

"The various technologies developed for treating spent potlining (SPL) from primary aluminum smelters have been reviewed on several occasions. The technologies generally involve physical, chemical, and thermal processes, either individually or in combination, with the primary objective of total recycle, waste minimization, or complete disposal. In general, those technologies geared for recycling involve separations and are therefore subject to recovery inefficiencies that are attributed to several factors. However, the inefficiencies could be reduced or possibly eliminated if the pots were designed for recyclability. This concept is applied to SPLASH, a recently developed SPL management technology.IntroductionAluminum is produced by molten salt electrolysis via the Hall-Héroult process. The process is conducted in an electrolytic “pot,” which is comprised of a steel frame first lined with insulating refractory brick, and then conductive graphite blocks, which serves as the carbon cathode [1, 2]. These materials are collectively referred to as “potlining.” Anodes comprised of petroleum coke/pitch are suspended above the pot and extend down into the molten cryolite (Na3AlF6) electrolyte. The electrolyte temperature is maintained at approximately 980 °C by resistance heating as low voltage (4-5 volts) and high current (50,000-300,000 amps) are applied across the two electrodes.High purity alumina is added to the cryolite bath, where it dissolves and becomes amenable to aluminum reduction at the cathode:"

Jan 1, 2008

By Batric Pesic

Calcium silicate slag (Di-Cal) and magnesium oxide condensate (MgO) are the by-products of magnesium smelting operations, As these oxides have acid neutralizing and metal precipitating properties, it was decided to examine their reactions with (a) individual heavy metals and (b) with a mixture of metals in solution, The resulting solid reaction products were further tested with respect to the stability of the contained metals, The stability of the solid precipitates were examined as a function of the method of precipitation and as function of the solution pH With respect to the method of precipitation, the performance of Di-Cal and MgO was compared to the performance of lime, an industry standard for heavy metal precipitation, Four different pH solutions (4,0, 5,0, 7,0 and 1 LO) were used to study the effect of pH on the stability of the precipitates. It was found that Di-Cal, in most cases, produced the most stable precipitates and thus, outperformed lime, Metal precipitates prepared by the addition of MgO were the most soluble for each metal studied, except for Se,

Jan 1, 2001

By Shengli Tao, Hongxu Li, Hao Bai, Yu Chen, Daqiang Cang

"China is the world's largest steel producer, in order to give environment load comprehensive analysis of steel and iron industry in china using LCA method, the life cycle inventory was compiled and assessment model based on Gabi software was also established. Environmental impact of two different routes ofBF-BOF and the EAF were analyzed respectively and intercompared. The results show that the modem EAF route is superior to the traditional BFBOF route on almost all the environmental impact indexes, which including acidification potential, eutrification potential, global warming potential, ozone depletion potential, etc. In the whole life cycle ofBF-BOF route in China, the transporting process ranks the biggest contribution part to the overall global warming potential, which can be explained by the fossil fuel burning of transporting vehicles during the long distance from Australia to China as the iron ore used are mainly imported from Australia. Apart from transporting process, Coking, blast furnace and iron mining processes could induce great environmental problems, while for the EAF route, the electricity consumption is considerable, which causing large amount ofC02 emission indirectly. Based on the analysis, several further countermeasures were proposed. Key words: Iron and steel industry, LCA, Gabi software, C02 emissionIntroductionCrude steel of china which reached 101.24 million tons in 1999 ranked the first column in the world since1999, So far has been to keep the world's largest steel output. At the year of2009, China crude steel output of 568 million tons, accounting for 46.6% of the global crude steel production, more than the total sum of crude steel production produced by 20 countries ranked behind. In 2011, China's crude steel production which is expected to be or close to 700 million tons, an increase of 12% than last year, will account for half of the global steel production.The steel industry, however, is intensive resources industry with huge consumptions of energy and water together with mineral resources. Energy consumption of the iron and steel industry has been about 10% of the total energy consumption since 1980. Coal dominants, power next and other energies share least in the energy consumption structure, for example coal accounts for 72.19%, power 23.52% and other total sums less than 5% in the steel energy consumption at year of 2002[2,3]. The consumption of coal discharges much emission of CO2, yet emissions of C02 in China steel industry, secondary only to the power and cement industry, ranked the third, and the coal dominant energy structure and its process have a close relationship. The aim of this research is to target steel production of typical blast furnace-converter (BFBOF) and electric furnace, using GABI software to evaluate and analyze resources and environment influence of LCA, directing at the existing problems in the development of China steel as well as finding the possible way to improve ability of reducing pollution and energy consumption in order to realize the sustainable development of the steel industry [ 4-7]."

Jan 1, 2012

By Takashi Miyamoto, Hideo Nakae, Hideki Yamaura, Takeshi Yanagihara

"For the production of partially composed metal matrix composites, namely discontinuous MMCs, using a casting· process, the interpenetrated phase composites with SiC particles were fabricated by pressureless iDfiltration using molten Al-Si alloys. This process is based on a wetting phenomenon, therefore, we discussed the technique based on the reactive wetting. The SiC particles coated by diluted water glass were sintered in a mullite Tammann tube and simultaneously infiltrated with molten Al-Si alloys in air at 1173~1573K. As for the improvement of the wettability between the SiC and the liquid aluminum alloy, Fe3O 4 powder was mixed with the water glass due to the thermit reaction between Fe3O4 and molten aluminum alloy. In some experiments, pure aluminum powder was placed on the sintered SiC to increase the interfacial area and the chemical reaction between the sintered Sic. and the melt. By combining these conditions, we succeeded in the complete infiltration without pressure at 1173K.IntroductionAs is well known, the mechanical properties of metal matrix composites (abbreviated MMCs) are superior than that of ordinary metals. However, their use has not been widely accepted because the production cost is very high due to their poor machinability. Therefore, the production of partially composed, namely discontinuous MMCs, by as the Lanxide process [l,2] has been investigated for many years. The Lanxide process, it takes a long time, sometimes up to 10h, in a nitrogen atmosphere for the infiltration. Therefore, the cost will be higher for common use. On the other hand, a high 'pressure process has been adopted for the production of discontinuous MMCs by the Toyota Motor Corp.[3]."

Jan 1, 2000