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By Zhou Jun

Water-quenched samples were taken from a commercial flash furnace at three levels along its reaction shaft during operation at high feed rate. The samples were subjected to a series of analysis and observation. Such processes of the feed in reaction shaft as oxidation, desulfurization, melting, slag and matte formation and etc., variations of particle size along axial and radical direction of the shaft are investigated. The following smelting mechanism in reaction shaft named as “Multi-particle and multi-phase fusion model” is proposed: (1) Fragmentation and collision of concentrate particles take place simultaneously in reaction shaft with particle size growing up. Collision produces large-size “unit melt” which falls into the reaction layer in the settler bath. (2) In the settler reaction layer below the shaft, weak bath smelting reactions take place among the shaft products, producing final matte and slag which separate into two layers. (3) The processes in the shaft are all progressive along the whole height of the shaft. The predominant reaction in the shaft is oxidation, not reduction.

By W. Petruk

The behaviour of galena, chalcopyrite and tetrahedrite during floration of a fine-grained base metal ore from New Brunswick was investigated by image analysis study of the mill concentrates and tailings. The minerals were analyzed to determine the grades and recoveries as related to free and unliberated mineral grains and their size distributions. The results show that only 37 wt % of the galena was liberated but 88 wt % of the free galena was recovered, indicating good mill performance for the lead. The lead recovery was 65 wt %, with the main loss due to unliberated galena. Most of the unliberated galena lost to mill tailings is so fine-grained that galena liberation and Pb recovery would not improve significantly by re-grinding. Chalcopyrite liberation was 56 wt % but only 75 wt % of the free chalcopyrite was recovered. Copper recovery was 45 wt %, with the chalco-pyrite loss in the mill tailings being both as large free grains, and as small and large unliberated grains. It was calculated that copper recoveries could be improved about 8 to 10 wt % by changing the concentrator operations and by regrinding. Concentrator operations hive already been modified and copper recoveries have improved about 5 wt %. About 29 wt % of the silver was lost to tailings mainly as both free and unliberated, large and very small, Silver-bearing tetrahedrite grains. It was calculated that about 25 wt % of the silver in the tailings might be recovered by improved milling conditions and by regrinding.

Jan 1, 1981

By N. M. Komkov

The main operation of obtaining zinc from sulfide raw materials by hydrometallurgical technologies is the oxidation roasting of zinc concentrates in fluidized bed furnaces. The technical-economic parameters are determined by the parameters of the roasting process, which depend on the composition of the initial raw materials, the temperature of the bed and on other factors. The predetermined roasting temperature is maintained due to the change of specific efficiency as well as to the quantity of the heat removed from the bed. The efficiency of caissons depends at a high degree on the composition and the thickness of the accretion formed on the surface of the caissons. Forecasting the roasting results is impossible unless we know the mechanism of the accretion formation. The aim of the present paper is the thermodynamic analyses of the behavior of the charge compositions under roasting and the determination of the potential mechanism of the accretion formation. The thermodynamic analyses show that under conditions of the oxidation roasting the thermodynamic probability of the formation of zinc sulfate is higher than the probability of the oxide formation until a temperature of873 OK is reached. The thermodynamic probability of the formation of the lead sulfate is higher than the probability of oxide formation in the entire temperature range of roasting. The probability of formation of ferrites and silicates of zinc decreases only insignificantly the sulfate stability. The results of the investigation of the accretions composItion formed under roasting of concentrates with particle sizes less than 0.02 J..lm (60%), containing 65% of sphalerite (ZnS), 12% of pyrite and chalcopyrite (FeS2 and CufeSz) each, 3% of galenite (PbS), 7% of silica and other non-ore minerals, have shown that the composition of accretion varies depending on the depth of the accretion layer. The accretions on the caissons and the thermo-siphons consist mostly of zinc sulfate (more than 50%). The accretions of forehamber consist mostly of zinc oxide. They also contain ferrites and silicates. The formation of the sulfate zinc accretion in the cold parts of the fluidized bed furnace (the caissons and thermo-siphons) may be explained by a lower temperature on the surface and probably by a catalytic influence of the present oxides in the formation of S02 and sulfates. The nature of the structure of the accretion in the hotter parts of the furnace may supposedly be explained by the formation of elemental vaporous zinc during roasting.

Jan 1, 2003

By K. P. V. Lei

The U.S. Bureau of Mines investigated a hydrothermal sulfidation procedure to recover lead and silver from plumbojarosite. The plumbojarosite, generated during pressure-oxidative leaching of zinc concentrate in a commercial operation, contained, in percent, 25.4 pb, 18.8 Fe, 1.4 Zn, 29.5 SO,2-, 3.2 s?, 13.4 total sulfur, and 7.4 oz/ton Ag. The sulfidation was conducted in an autoclave and converted the plumbojarosite to amorphous iron oxide and liberated the lead and silver as sulfides. The best operating conditions were using 50 9 of plumbojarosite and 7 pct s? (2.04 9 S? added) in 500 mL of 2.0 mol/L NH3, 150? C, and 1 h. The sulfidation product contained, in percent, 37 Pb, 28 Fe, 6 S2-, 2 SO,2-, and 11.2 oz/st Ag. Ferric chloride leaching extracted 98 pct Pb and 97 pct Ag from the sulfidation product.

Jan 1, 1990

By Yuan-bo Zhang, Gui-hong Han, Yan-fang Huang, Tao Jiang, Guang-hui Li

"Under isothermal conditions, the reduction behavior of oxidized pellets balled with bentonite was investigated with CO-CO2gas mixers in the temperature range from 900°C to 1100°C. The whole reduction of oxidized pellets was followed up by means of weight-loss technique. And the swelling index of pellets was examined by visualizing physical changes of pellet in a horizontal tube furnace. The results present that the reduction rate of oxidized pellets is increased with the increase of reduction temperature. While the swelling index is firstly increased and then decreased with the increase of reduction time and reduction extent, which can be ascribed to the disruptive stresses induced during the transformation of hematite to magnetite. The maximum swelling index is gradually increased with the increase of reduction temperature and CO content.IntroductionWith the rapidly development of iron and steel industry, direct reduction iron has been considered as one kind of high quality burdens in electric furnace steelmaking [1]. At present, ""Two-step"" coal-based direct reduction process, which employs oxidized pellets as raw materials, has been used in industrial production [2]. The reduction behavior of iron ore oxidized pellets has been becoming one of the most frequently studied topics in extractive metallurgy[3]. The heat and mass transfer in direct reduction processes results in a series of stepwise reduction reaction (hematite--magnetite--wustite--iron), accompany with the volumetric swelling of pellets[4]. A lot of literatures have been reported on the reduction model of ferrous oxides and swelling behavior of pellets. A. A. El-Geassy K, et.al [5-7] revealed that the reduction process was controlled by chemical reaction at early stage by employing pure Fe203 as raw materials and CO as reduction gas. Chen Y [8] made research on the reduction kinetics of porous oxidized pellets and obtained the rate constant and activation energy of at different reduction stage. In addition, the swelling and disintegration of iron ore pellets was affected by chemical composition of pellet and reducing parameters, which have been studied by numerous investigators [3,9, 1O]."

Jan 1, 2013

By Bradley C. Bockrath

Some thirty coals were evaluated for liquefaction activity under a mixture of CO and H2 at 425° C. The viscosity of the liquid products was taken as an indicator of the degree of liquefaction. It was found that the direct liquefaction of a particular coal may be beneficially influenced by the presence of pyrite. Active pyrites are often found in the native mineral matter of the coal itself. For example, subbituminous and bituminous coals and lignites of relatively high pyrite content were found to liquefy more readily than similar coals or lignites which were poor in pyrite. The reactivity of inactive coals could be improved by using blends with active, pyrite-rich coals. In addition, pyrite was effective when added separately as pyrite concentrates obtained from coal beneficiation operations. Various other iron- and sulfur-bearing additives were also effective when used in combination as added slurry-phase catalysts, including iron oxides and mineral residues derived from liquefaction of active coals. Under liquefaction conditions, pyrrhotite ( Fe I- x5) is formed from pyrite or from the iron oxides and many sulfur containing species. Pyrrhotite was shown to be a hydrogenation/dehydrogenation catalyst for tetralin but is not active for initiating a variety of free radical reactions that do occur when pyrite is heated with tetralin. The role of pyrite in coal liquefaction is complex and still not well understood.

Jan 1, 1981

By John Hanna

The University of Alabama Mineral Resources Institute (MRI) has developed a unique process for selective fatty acid flotation of carbonate gangue from sedimentary apatites (francolite) in the pH range of 4-6, without collector conditioning of the pulp. The process, which does not require an apatite depressant, was modified to beneficiate a high MgO siliceous phosphate matrix from South Florida. The modified process includes two flotation stages, one for carbonate removal, as mentioned above, and the other for phosphate recovery from the siliceous gangue. The selective flotation separation of the carbonate and phosphate from siliceous constituents of the matrix at various pH levels and collector dosages are discussed. In the carbonate flotation stage, about 70% of the MgO was rejected in the froth, and the phosphate flotation stage produced concentrates analyzing about 31% P20S' 0.7% MgO and 4% acid insolubles. The overall P20S recovery in the two stages is about 85%.

Jan 1, 1989

By John L. Sundstrom

Complete systems were designed -and are in operation to recycle the effluent streams and to remove impurities from tankhouse. electrolyte, Heavy em¬phasis was placed on making usable products from as many streams as poss¬ible at minimum capital and operating costs. Almost complete recycling: and reuse of water and sulfuric acid were paramount. Techniques used in-clude solvent extraction - electrowinning, evaporation - crystallization and filtration.

Jan 1, 1992

By James Cornwell, John A. Elton

"Thermionic induced reactions and radiation resonance catalysis of aluminum and aluminum oxide materials exposed to microwaves and triboemissions will be described and explained from both a fundamental and practical level. Magnetron operation at distinct operating conditions that generates both plasmon and triboemissive radiation will be explained and the resulting tribochemical and radiation resonance catalytic reactions between aluminum, aluminum oxide, water and graphite will be delineated. The generation of hydrogen from these materials using triboemissive radiation and microwaves will be described, and the application of this methodology for hydrogen based technologies will be discussed.IntroductionProtective Systems Directed Energy RadiationProtective Systems, Inc, has developed a new radiation device called the EMR (Electromagnetic Resonator) that has unique characteristics that separates it from traditional microwave and rf radiation devices. The radiation from the EMR device is generated using a modified electronresonance magnetron with proprietary filters and operating characteristics.Electronic Device Shutoff. When electronic devices such as cell phones, computers, and other IC based electronics are placed within the EMR radiation, these devices become non-functional as long as the EMR beam is active. Upon removal of the EMR radiation the devices either become operational again or become operational after a cold start. The devices are not damaged by the irradiation.Faraday Cage Interaction Effect. When any of the above electronic devices are placed in a Faraday cage and activated within the Faraday cage without EMR radiation, they operate normally. However, these devices will still be rendered inoperative when an EMR beam generated outside the Faraday cage is directed at the electronic."

Jan 1, 2010

By S. W. Marcuson

Smelting of nickel-copper sulfide ores at Vale Inco’s Sudbury operations commenced in 1888 and the first converting plant went into operation in 1892. As the demand for nickel grew, the smelting operations expanded and by the 1960’s the Copper Cliff Smelter featured the longest converter aisle in the world with space for nineteen Peirce-Smith converters. During this long period, different converting techniques and vessels were employed. The evolution of converting is reviewed with special emphasis on the modifications made to the Peirce-Smith vessel to accommodate the metallurgical and process needs of the changing times.

Jan 1, 2009

By C. P. Snyman

Three independent methods of coal classification can be distinguished, namely on the basis of grade, type and rank. The latter two can be determined accurately and unambiguously only by means of microscopical techniques. These three independent variables affect all the coal properties and therefore also the technological behaviour of a particular coal. The influence of the inorganic constituents of coal on the fusibility of the ash and on the length of the slag, and also on fouling and slagging, is discussed. The fractionation of the ash-forming constituents during combustion and gasification of pulverised coal shows that fouling and slagging are not related directly to the fusibility and composition of ash of the coal as a whole. The results of combustion experiments using a drop furnace technique indicate that the ignition temperatures of the light volatiles in the coal, and of the formed char, as well as the burn-out time of the char are more dependent on the rank than on the type or grade of the original coal. High-ash coals, however, apparently ignite at lower temperatures and are more reactive than low-ash coals of similar type and rank. The surface properties of coal, which are important in froth flotation and oil agglomeration, correlate well with the inherent moisture content (and by inference with the heat of wetting and the calorific value) and therefore with the type and rank of the coal. In coal exploration, variations of rank offer the possibility of predicting the presence of an intrusion near the seam, thus contributing to more effective exploration and mine planning.

Jan 1, 1991

By Roberto Parra

The classic criteria of the preparation of the charge for the smelting of copper concentrates in at flash furnace considers the mass and energy balance from the chemical and mineralogy composition of the concentrates. The operation parameters fixed with this method don't assure the stability of the operation and the critical problems of the slag quality and dust formation occurs very often. This paper presents the results of a laboratory test that allows the prediction of the behavior of concentrates blends in the view of the minimization of the dust formation and the magnetite control in the slag. The combustion of different copper concentrates and blends were done in a drop tube furnace The results show that the magnetite and dust formation don't have a linear behavior with the weight proportion of the blend and some optimal blends of 2 or 3 types of concentrates can be identified. From the reasonable hypothesis that the qualitative behavior of blends in the drop tube represents the real behavior in the burner, the preparation of the charge with this approach could help to solve those operational problems.

Jan 1, 2003

By L. Evrard, S. Brouwer, E. Bosly, E. Boydens

"A partial desulfurization roasting process has been tested on a typical copper-zinc sulfide concentrate in a Nichols Herreshoff monohearth pilot furnace whereby the su!fµr is partially removed and iron is to a certain degree preferentially oxidized. The phase changes that occur in the particles during selective roasting at 650°C and 800°C over a range of residence times were investigated by the use of chemical analysis, optical microscopy, X-ray diffraction and electron microprobe analyses. The purpose of this work was to get an insight into the mineral assemblages formed by controlled oxidation roasting and to evaluate if this non traditional approach could be afterwards used to recover zinc, copper and iron by a physical separation method. IntroductionThere has been considerable interest over the years in improving extraction and processing procedures for recovering non ferrous metals especially from polymetallic ores containing copper, lead, zinc and iron sulfides with very fine intergrown phases. Complex sulfide ores, which represent considerable reserves and resources in copper, lead and zinc, as well as precious metals and sulfur, are difficult to treat by conventional physical processes, leading to impure concentrates at low metal recovery. Some methods that can be used to treat such ores were described by G. Barbery (1). Various metallurgical routes generally combining pyro- and hydrometallurgical methods have been explored to develop new processes to recover the metals from zinc-bearing sulfidic ores and concentrates (2, 3, 4). The feasibility of partitioning complex sulfide minerals to simpler phases in order to improve selective extraction of mineral constituents has also been investigated (5)."

Jan 1, 1999

By Michael L. Sorokin

The behaviour of cobalt during processing of nickel raw material is analysed within the Ni-Co-Fe-S-O-SiO2 system using the computer model. For this purpose the thermodynamic parameters for "three-suffix" Margules's equations in Co-Fe-S and Co-Fe¬Ni-O-S1O2 systems were computed! Phase and iso-activity diagrams for Co-Fe-S system, and phase diagrams for the systems Co-O, Co-Fe-O, Co-Ni-O, C-oO=SiO2 and Co-Fe-O¬SiO2 are calculated using the developed computer programs and identified parameters. The diagrams are used to analyze cobalt behaviour at smelting and converting.

Jan 1, 1995

By Duan Xin-hui, Wang Xin, Peng Jin-hui, C. Srinivasakannan, Zhang Li-bo

The work attempts to optimize the process of preparation of modified semi-coke from semi-coke using phosphoric acid (H3P04) as the activating agent using the response surface methodology (RSM). The influences of three major dependent variables, the impregnation ratio, activation time, and activation temperature were assessed on the independent variables yield and the iodine number. The empirical relationship between the dependent and the independent variables were established using the quadratic response surface models, which were utilized to optimize the process parameters. The significance of each of the parameters and interaction among the parameters on the independent variable was assessed based on analysis of variance (ANOVA). The process variables were varied within the range of impregnation ratio (IR) from 1.5 to 4, activation time from 30 to 90 min and activation temperature from 550 'C to 650 'C. The optimized process conditions were estimated to be an IR of 2.29, activation time of 32 min, and an activation temperature of 605°C respectively using the process optimization tool. The BET surface area of modified semi-coke of the optimized sample was estimated to be 915m2/g, with the pore volume of0.71cm3/g, with an average pore diameter of 3.09 nm, with micropore volume fraction being 52.36%. The scanning electron microscope (SEM) images were utilized to visualize the surface pore structure.

Jan 1, 2013

By P. Klut, D. Groult, R. Marechalle, B. T. H. Bonnema

In the past 5 years, Compagnie Europeenne de Dezingage (CED) has developed a successful dezincing process and the St. Saulve pilot plant has evolved into a commercially successful production plant. Currently the plant meets all the required standards for scrap and zinc quality, output capacity, availability, and meets the prescribed environmental emissions standards. The initial process problems relating to zinc recovery, uncontrollable explosions and sodium hydroxide aerosol emissions have all been solved. Presntly, the yearly production of dezinced scrap is around 50.000 tonnes/year; this capacity is enough to supply the local market. This capacity can be increased easily to 65.000 tonnes/year or more. The market for dezinced material is growing due to the increased consumption of galvanized material on one hand and on the other hand the higher demand for high quality scrap. The proven technology of CED is currently patented worldwide, but CED is inviting licensees to implement the dezincing technology in other parts of the world.

Jan 1, 2000

By William Petruk, J. H. Gilles Laflamme, Jean Robitaille, Louis J. Cabri

"A quantitative mineralogical study using ore microscopy, electron microscopy, proton-microprobe, image analysis, and material balances was done on samples from the circuit of a concentrator in Quebec, with particular emphasis on the Cu concentrate. The ore contains many different minerals, of which the principal ones, in decreasing order of abundance, are pyrite, sphalerite, chalcopyrite, bornite, galena, tennantite, and pyrrhotite. Minor to trace amounts of covellite, chalcocite, stannoidite, mawsonite, colusite, wittichenite, miharaite, hessite, petzite, electrum, and an unidentified Cu-Pb-Bi-sulfide also occur.Liberation of pyrite is very high in all size fractions for all samples (ranging from 80-91 %). Liberation of chalcopyrite, bomite, sphalerite, and tennantite is relatively high, on average, in the head .sample and Cu concentrate (55-78% and 66-88%, respectively). Most of the chalcopyrite in the flotation tails is not liberated, whereas about one half of the tennantite and sphalerite are liberated in both the flotation and :final tails. Recoveries calculated for the Cu concentrate (on the basis of assays, mineralogy, and image analysis) are chalcopyrite 72. 5%, bornite 73. 7%, sphalerite 41.0%, tennantite 70.9 %, and galena (together with some trace minerals) 34.2%. It was also calculated that the Cu concentrate contains 10.0 % of the pyrrhotite and i.4 % of the pyrite.Materials balance calculations were done on the five major sulfide minerals to determine the mineralogical distribution of 13 major, minor, and trace elements (as determined by protonmicroprobe analyses). It was determined that tennantite is the principal carrier of Bi (67%), As (90%), and Te (86%) in the Cu concentrate. Therefore, removal oftennantite, which is mostly liberated in the Cu concentrate would significantly reduce these three contaminant elements, but at a loss of9% of the Cu, 2.0% of the Zn, and 0.7% of the Ag. The precious metals (Au, Ag) occur as discrete minerals (electrum, petzite, hessite). Some of the Ag also occurs in solid solution in bornite (23.1% of Ag in Cu concentrate), tennantite, and sphalerite. Four of the major sulfides (chalcopyrite, bomite, sphalerite, tennantite) in the ore also contain measurable concentrations of the following trace elements: Se, Cd, In, Sn, and Sb, occurring mostly as solid solutions. Some of these elements are also concentrated (up to about 18%) in minor and trace minerals such as colusite, stannoidite, and mawsonite."

Jan 1, 1999

By E. Maziar Sauber

In order to prepare a more desirable feedstock for a rare earth elements separation refinery, cerium, a penalty element in the refinery feedstock, should be removed from the mixed rare earth elements oxide or carbonate feedstock. In this study, cerium (III) to cerium (IV) oxidation by calcium hypochlorite and subsequent precipitation was used to remove cerium from a mixed rare earth elements chloride solution. A factorial design of experiments was used to determine the effect of process variables such as temperature, pH, and oxidizer addition on the oxidation of cerium (III) using synthetic solutions. Under certain test conditions, all of the cerium was successfully removed from the chloride solution, and some REE accompanied cerium and reported to the precipitate. This proposed technology can allow for low cost removal of cerium from mixed rare earth elements chlorides.

By I. Mc Dougall

"The matte/slag tidal zone in a platinum smelting furnace is subject to severe process conditions which can often lead to premature failure of the lining. The MgO-FeO-Si02 slag is aggressive to refractory bricks, whilst the Ni-Cu-Fe-S matte is aggressive to water-cooled copper cooling elements, and can penetrate and sulphidize refractory bricks, particularly at the high matte temperatures often experienced in the PGM industry. A novel approach to the lining design was taken at Lonmin's new 10MW Furnace 2. An indirectly-cooled graphite ring was applied in the matte/slag tidal zone, with refractory bricks on the hot face. Thermal Finite Element modeling was conducted to determine the optimal lining design in this region of the furnace. The resistance of two graphite grades to damage by slag and matte was evaluated experimentally. The graphite lining is not wet by the matte, and is resistant to slag attack at operating temperatures. In comparison to water-cooled copper in various configurations, cooled graphite shows promise as an indirect refractory cooling system in the tidal zone area of furnaces.IntroductionIn South African Platinum Group Metals (PGM) smelting operations, the PGMs are associated with nickel-copper sulphides in magmatic rocks. After ore is mined, it is concentrated by means of a flotation process prior to smelting. Both rectangular 6-in-line and circular 3 electrode AC submerged arc furnaces are used for this purpose. A new 10 MW round furnace is currently under construction by Tenova Pyromet at Lonmin's Marikana Smelter Division. An overview of Lonmin's smelting operations and Lonmin's approach to smelting high chromite containing PGM concentrates is given by Eksteen et al. [1]"

Jan 1, 2012

By N. M. Komkov

The main operation of obtaining zinc from sulfide raw materials by hydrometallurgical technologies is the oxidation roasting of zinc concentrates in fluidized bed furnaces. The technical-economic parameters are determined by the parameters of the roasting process, which depend on the composition of the initial raw materials, the temperature of the bed and on other factors. The predetermined roasting temperature is maintained due to the change of specific efficiency as well as to the quantity of the heat removed from the bed. The efficiency of caissons depends at a high degree on the composition and the thickness of the accretion formed on the surface of the caissons. Forecasting the roasting results is impossible unless we know the mechanism of the accretion formation. The aim of the present paper is the thermodynamic analyses of the behavior of the charge compositions under roasting and the determination of the potential mechanism of the accretion formation. The thermodynamic analyses show that under conditions of the oxidation roasting the thermodynamic probability of the formation of zinc sulfate is higher than the probability of the oxide formation until a temperature of 873°K is reached. The thermodynamic probability of the formation of the lead sulfate is higher than the probability of oxide formation in the entire temperature range of roasting. The probability of formation of ferrites and silicates of zinc decreases only insignificantly the sulfate stability. The results of the investigation of the accretions composition formed under roasting of concentrates with particle sizes less than 0.02 um (60%), containing 65% of sphalerite (ZnS), 12% of pyrite and chalcopyrite (FeS2 and CuFeSz2 each, 3% of galenite (PbS), 7% of silica and other non-ore minerals, have shown that the composition of accretion varies depending on the depth of the accretion layer. The accretions on the caissons and the thermo-siphons consist mostly of zinc sulfate (more than 50%). The accretions of forchamber consist mostly of zinc oxide. They also contain ferrites and silicates. The formation of the sulfate zinc accretion in the cold parts of the fluidized bed furnace (the caissons and thermo-siphons) may be explained by a lower temperature on the surface and probably by a catalytic influence of the present oxides in the formation of S02 and sulfates. The nature of the structure of the accretion in the hotter parts of the furnace may supposedly be explained by the formation of elemental vaporous zinc during roasting.

Jan 1, 2003