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By Noboru Masuko, Sachiko Ono

"The structure and composition of anodic films formed on aluminum in a borate solution have been investigated by using TEM and SIMS with respect to the effect of current density and electrolyte temperature. The film is composed of a boron-containing outer layer and a boron-free inner layer with disc-like crystals present at the interface. The thickness of the film formed at constant current density up to an identical voltage, decreases with increasing current density. The thickness increases remarkably with elevated temperature. The transport number of Al3+ estimated from the thickness ratio .of the cuter to the inner layers is 0.4 when the film is formed at the current density of 20 Am-2 at 60°C. It increases slightly with increasing current density and decreases significantly with increasing temperature. Content of boron in the outer layer increases 1.5 times when current density .increases 10 times. These changes in film structure and composition with electrolysis conditions must have a significant role in the determination of electric properties of anodic alumina films as a capacitor material.IntroductionThe growth of anodic alumina film in ·a neutral electrolyte proceeds at both film/electrolyte and film/substrate interfaces giving a duplex structure. The oxide layer formed at the former interface includes electrolyte anions while a-pure alumina layer is formed at the latter interface. The thickness ratios of each layer respectively represent transport numbers of Al3+ and 0 2 - (1). The film thickness and the incorporated anion content as well as transport numbers of both ions must affect the dielectric properties of the film as a capacitor material. However, the correlation between film structure and electrolytic conditions is not fully understood (2). For the further clarification of anodic film growth mechanism, more detailed characterization of anodic films in relation to electrolytic conditions is advantageous. In the present paper, therefore, the effect of current density and electrolyte temperature on the microstructure and composition of anodic barrier films formed in a neutral borate solution was studied. The films were characterized by direct observation using transmission electron microscopy (TEM) and depth profiles of constituent elements obtained by secondary ion mass spectroscopy (SIMS)."

Jan 1, 2000

By Richard L. Werner

The petrographic microscope as a tool in determining impurities and grain size of limestones, clays, sand and coal ash for possible use as raw materials is discussed. Its use in the determination of the mineral composition of various size fractions of the raw mix, after fine grinding in ball mills, and of the waste dust from the rotary kiln. A description is given of the typical clinker crystals; alite, belite, tricalcium aluminate and ferrite. The process problems indicated by various changes in the crystal characteristics are listed with possible solutions. Finally the microscope as used in relation to field problems with concrete such as air void volume, percent hydration of the cement, cement aggregate bonding and the determination of solid additives, is presented.

Jan 1, 1982

By Annette Revet

Aluminum fluxes have been used for the remelting of secondary aluminum since the beginning of the recycling industry. During the last sixty years, a number of fluxes have been designed, researched and tested at the laboratory and plant scale. Fluxes are primarily a mixture of potassium chloride and sodium chloride with the addition of some other chloride and fluoride containing salts. The conventional Mining methods of potassium chloride and sodium chloride yield products that are not high in purity without costly reprocessing or additional refining. In 1993, Kalium Chemicals, Ltd. began supplying flux mixtures to the aluminum industry. Kalium produces potassium chloride and sodium chloride which are mined and refined by a patented solution-mining process. The salts produced by this process are high in purity with lower concentrations of iron oxide, sulfates, and other impurities. This paper will present the different mining methods used in the production of sodium chloride and potassium chloride. The paper Will address how these mining methods affect the purity of the final product as well as the effect of purity on the performance of the fluxing salt.

Jan 1, 1995

By John Wallace, Chib Iheagwara

"Refinements in sensor design have produced low-cost rugged elements to act as loop coupled with stable detection hardware for eddy current measurement in difficult environments. This has allowed direct dimension gauging of nonferrous and ferrous products above the curie point for absolute dimensions and electrical conductivities independently. The software was developed for the analysis of electrical conductivity profiles in CZ silicon crystal growth, then refined for monitoring bar properties and tube properties. Since in most metal working operations, speeds at the minimum of a few hundred feet per minute are encountered the design of the gauge was optimized for a rapid measurement. Independently extracting electrical conductivity provides data in some metal systems for determining the temperature of the monitored product.IntroductionThe primary reason for the use of eddy currents in gauging is that in hostile environments of metal working techniques such as laser gauging and ultrasonics are not always robust enough for in process measurements. Our goal is to use the technique of eddy current measurement as a quantitative control element in various hot and cold processing operations. Inspection in the early stages of metal and semiconductor processing is usually too costly to introduce in a well developed process and these tools are usually only employed in process development. Until recently there has been no efficient general analysis to allow real time measurements in the cylindrical and the probe geometry that could separate dimensional changes from material property changes both which effect the eddy current response. The basis for these measurements is that forward electromagnetic problem for conductors can be solved exactly for the test geometry which allows an inverse analysis to be made by relaxing the dimensions and conductivity to values which reproduce the measured response[!]. This transformation is based on analysis developed in Robert Siegfried' s thesis and was explored both by modeling and by physical measurement. This analysis was extended over the last few years to allow a more compact data set to be used to exact physical properties. The main result was that the technique would work on high ·quality physical data on as little as three test frequencies with the penalty being that the analysis is computational intensive. The main result of this work was that a quantitative inverse analysis of eddy current response would allow a general instrument to be used for a variety of measurements rather than being tailored for a specific measurement on a specific material test geometry. The development of these instruments has progressed over the last ten years for monitoring real time solidification, crystal growth[2] and hot seamless tube forming where the use of standards in traditional eddy current is limiting. The specific instrument design was dictated by the requirements of the algorithm for both frequency selection and levels of systematic noise that could be tolerated. Because the data is need for real time information this dictated that the system be a parallel multifrequency eddy current instrument feeding the same sensor. The sensor have to be simple and robust and usually a single loop or several loop of heat resistant wire or tube. This presentation is about using inversion of multifrequency eddy current data in real time to produce dimensional and property data on cylindrical conductors and planar conductors in real time. The object of the measurements is to produce dimensional outputs on measurements of conducting material without having to establish a detailed standard for each material or size tested. The dimensional measurements using eddy currents is complicated by material variations in conductivity due to temperature and composition. Those variations that are not geometric are often not of critical interest and complicate the measurement. The dimensional changes are often of more importance"

Jan 1, 1997

By Katsuyoshi Kondoh

The synthesis processing of Mg2Si or Mg2SiIMgO at lower temperature from the elemental magnesium alloy powder/chips and Si or SiO2 powder mixture was established via the repeated plastic working (RPW) based on Powder Metallurgy (PIM) process. RPW is much effective on the mechanical breakage of MgO surface films, which prevent from the solid-state reaction between Mg and Si powder. The solid-state synthesized Mg2Si particle of 200nm-2um is extremely fine, compared to that via the conventional casting process, causing the coarse one of 50-100um. This is because of not coarsening during the solid-state synthesis of Mg2Si. By using in-situ fonning process of Mg2Si via RPW and pre-heating before hot working such as extrusion and forging, the magnesium composite material with Mg2Si or Mg2Si/MgO dispersions was developed in employing Si or SiO2 particles, respectively. For example, when employing AZ31 chips as raw materials of the matrix, it has low density of 1.85g/cm3 and extremely superior mechanical properties, such as tensile strength over 350MPa with 5-10% elongation and Young's modulus of 47-50GPa, to the conventional Mg-Al-Zn alloys. The Mg composite alloy wires and pipes were produced via the hot extrusion process in the manufacturing plant, and also showed excellent mechanical properties.

Jan 1, 2003

By Katsuyoshi Kondoh

The synthesis processing of Mg2Si or Mg2Si/MgO at lower temperature from the elemental magnesium alloy powder/chips and Si or SiO2 powder mixture was established via the repeated plastic working (RPW) based on Powder Metallurgy (P/M) process. RPW is much effective on the mechanical breakage of MgO surface films, which prevent from the solid-state reaction between Mg and Si powder. The solid-state synthesized Mg2Si particle of 200nm-2JIm is extremely fine, compared to that via the conventional casting process, causing the coarse one of 50-100um. This is because of not coarsening during the solid-state synthesis of Mg2Si. By using in-situ forming process of Mg2Si via RPW and pre-heating before hot working such as extrusion and forging, the magnesium composite material with Mg2Si or Mg2Si/MgO dispersions was developed in employing Si or SiO2 particles, respectively. For example, when employing AZ31 chips as raw materials of the matrix, it has low density of 1.85g/cm) and extremely superior mechanical properties, such as tensile strength over 350MPa with 5-10% elongation and Young's modulus of 47-50GPa, to the conventional Mg-Al-Zn alloys. The Mg composite alloy wires and pipes were produced via the hot extrusion process in the manufacturing plant, and also showed excellent mechanical properties.

Jan 1, 2003

By Juan B. Cabezas

"The favorable characteristics and workability of plastics as a replacement of wood, lead, stainless steel, asphalt and other materials are described. Various types of plastic have proven to be the most favorable choice for handling a variety of acidic, alkaline and organic solutions, as well as pulps, chemical wastes, slurries or tailings for impoundments. The material origin of various plastics, methods of manufacturing and specifications applied to leaching solutions are discussed, including availability and costs. Examples of select plastics are considered for use as alternatives of other materials under severe environmental requirements.IntroductionHydrometallurgical processes applied to gold recovery, as well as other metals, require the use of strong solutions of alkaline, acidic or organic nature, and may also include a variety of materials with extraneous characteristics and complications for handling in storage.The technology of leaching has been in use for more than 100 years, but the applications of leaching processes in metallurgy have become more commonly used in the last 15 years. Suitable materials for the construction of containers, launders, piping, and various accessories, to be used in the handling of leach solutions or slurries, have become a serious problem. Various metals such as brass, lead, stainless steel, etc., and non metallics including wood, clays, glass, rubber, ooncrete, tars or miscellaneous compounds have been tried in the past with serious limitations in workability and resistance to wear and corrosion. For example, the use of metallic, wooden or glass piping systems would require extraordinary shop maintenance to keep such systems in operation"

Jan 1, 1997

By Hyun Soo Kim, Joon Soo Kim, Myong Jun Kim, Jyothi Rajesh Kumar, Jin-Young Lee

Rare earth materials have an ever growing variety of applications in the modern and hitech technology. They apply to many an industry with crucial materials and they provide numerous a customers with benefits. Rare earth materials utilization increasing day-by-day in the worldwide, at the same time the resources is very limited in many countries like Korea. The present general article divided four sorts such as 1) mineral processing of Korean ore deals the gravity, magnetic separation and froth flotation, 2) decomposition and leaching of concentrates included sodium hydroxide fritting, sodium hydroxide hot digestion, hydrochloric acid leaching, 3) separation and purification of rare earth elements in mixed rare earth chloride solution consists reduction and oxidation method, solvent extraction, 4) preparation of rare earth oxide compound from purified elemental rare earth chloride solution having oxalate salt precipitation by reaction crystallization. The last part consists of a summary of the present study.

Jan 1, 2015

By H. J. Garcia

Biodegradation of cyanide by microorganisms isolated from solids previously exposed to cyanide has been investigated. Initial sodium cyanide concentration was 300 ppm at pH 10.5. The kinetics of biodegradation were found to be first order with respect to cyanide concentration, and the overall reaction rate constant is k = 0.102 day-1. The activation energy and the frequency factor were determined to be { A }Ea = 5.45 Kcal/mol and A = 1.28 x 10-2 sec-1, respectively. Based on these values, thermodynamic properties of an intermediate activated complex were assessed. All tests resulted in cyanide concentrations less than 0.1 ppm in about 35 days at 250C, whereas at 350C the time of biodegradation to reach this cyanide level was 30 days. Kinetic data were also established to relate biodegradation to amount of inoculum. The maximum theoretically-attainable rate, Vm , and the optimum amount of inoculum, K , were determined to be 4.8 x 10-4 M NaCN/day and 7.5 % of amount of inoculum. With respect to the mechanism of biodegradation, cyanide was shown to decompose to carbonate, bicarbonate and ammonia. Titrimetric analyses revealed concentrations of 5.6 x 10-3, 4.8 x 10-3 M, and 70.2 ppm for carbonate, bicarbonate and ammonia, respectively. The average cell population was determined to be 3.75 x 108 cells/mL.

Jan 1, 1994

By John Fallavollita

Conventional gas atomization produces powders that vary widely in size distributions and microstructures, thus making it very costly to produce powders tailor made in a narrow size distribution and microstructure. Furthermore, it is difficult to determine the relationships between atomizer operating conditions and resulting powder characteristics. The Impulse Atomization Process (IAP) was developed at the Advanced Materials and Processing Laboratory to produce powders with narrow size distributions. Powders produced by the IAP were reproducible and their sizes could be easily controlled by adjusting experimental conditions. Characteristics of Zn, Sn-Pb, AI-Cu, and Cu powders will be described to illustrate the flexibility of the process to tailor-make powders.

Jan 1, 1994

By Osarnu Inoue

In Mitsubishi Continuous Copper Smelting and Converting Process, smelting, slag-matte separation and matte converting are continuously carried out in series in three furnaces connected by launders. As a result of this operational configuration of the furnaces, influence of the change in operating condition in upper stream, such as variation of feeds in the smelting furnace, propagates to down stream with some delay. In order to achieve stabler operation, process control algorithm based on the dynamic characteristics of each furnace would be very effective. In this study, the dynamic process simulation model was developed for the smelting furnace. The model consists of two mathematical modules, i.e. the thermodynamic module and the mixing module. The calculation results using operating data obtained at Naoshima Smelter showed good agreement with the actually observed change in temperature, composition and flow rate of matte and slag at the outlet of the furnace. In addition, operation parameters such as reaction efficiency of oxygen and coal, dead volume of melts were estimated.

Jan 1, 1999

By W. Dutton, D. Simms

"The clearing of tuyeres on copper and nickel converters or similar metallurgical, vessels has, for many years, been done using mainly a manually- operated ""puncher"". One such device is the ""Gaspe Puncher"" developed in 1962 at Noranda's Gaspe Smelter. In an attempt to remove the operator from the cab of the Puncher, and to relieve him of a tedious, uncomfortable job, Noranda's Horne Division, in cooperation with Heath & Sherwood (1964) Limited and the Noranda Research Centre, undertook to automate the Gaspe Puncher used on the Noranda Continuous Smelting Process Reactor.The automated puncher is controlled by a Texas Instruments Model 530C Programmable Controller (PLC). Position measurement and control is done using non-contact position measuring equipment from the Tele-Controls Division of Geodimeter Inc. The entire automation system was installed on an existing Gaspe Puncher with minimum disruption to the operation of the smelting process. The operator's panel allows the user to ""block out"" any individual tuyere, and to select any of a variety of operating modes.The development of the automated puncher is described, and the results of several months operation are given.IntroductionThe tuyeres of copper and nickel converters and similar metallurgical vessels become blocked with solidified material formed by the cooling action of the blowing air. This restricts the converting operation. Clearing these blocked tuyeres has for many years been done mainly using a manually-operated ""puncher"" which uses a hydraulic or pneumatically-operated piston to drive a steel bar into the tuyere. The Gaspe Puncher, developed at Noranda's Gaspe Smelter in 1962 is one such device. It is currently being built and sold by Heath & Sherwood (1964) Limited, under license to Noranda. There are over 200 units in operation world-wide.In an attempt to remove the Puncher operator from the cab of the Puncher, and to relieve him of a tedious, uncomfortable job, and to increase productivity, Noranda's Horne Division, in cooperation with Heath & Sherwood (1964) Limited and the Noranda Research Centre, undertook to automate the Gaspe Puncher used on the Noranda Continuous Smelting Process Reactor. This paper describes the development of the automated Gaspe Puncher, its installation at the Horne Smelter, and the results of its operation after several months."

Jan 1, 1989

By F. Qian

An impinging gas jet on a liquid surface is found in many industrial process systems such as electric arc furnace, welding, steel-making operation and others. Fundamental understanding of the interaction of a gas jet on a liquid pool can provide important insights into process behavior resulting in improved efficiency. A numerical model is developed for solving the flow fields of both impinging gas jet region and liquid pool below, in which the deformed interface shape is predicted simultaneously. Using curvilinear coordinates, the Navier-Stokes equations of each phase are solved separately through coupling of static pressure, shear stress and velocity at the interface. Several cases for jet distances and flowrates were investigated both numerically and experimentally with an air-water model. Favorable comparison of numerical results with experimental data confirms the validity of the present numerical approach. An existing phenomenological model for 'penetration depth' prediction was extended for smaller 3et exit height to jet diameter' ratios.

Jan 1, 1995

By M. Nilmani, J. Sofra

The transverse distributions of the solids discharge velocity and mass flux at the discharge end of vertical and inclined lances were measured in order to detennine the transverse distributions of the axial momentum flux, which is a dominant factor influencing the penetration behaviour of particles into melts during submerged injection. The effects of gas velocity (10 - 30 m/s), solids loading (5 - 10), lance length (0.15 - 1.0 m), lance inclination (vertical downward - horizontal) and particle density (2500 - 8900 kg/m3 ) were investigated, while the lance diameter and particle size were fixed at 10 mm and 220 µm respectively. The particle velocities and mass fluxes were measured by image analysis of particles illuminated in a laser-generated light sheet aligned vertically through the axis of the lance at the discharge point. The particle discharge velocity profiles for vertical downward flows were synunetrical about the centre-line of the lance, with the maximum velocities occurring at the centre-line. The velocities increased with increasing gas velocity, increasing lance length and decreasing particle density in accordance with previous observations. The transverse mass flux profiles were also synunetrical for vertical downward flows, however at the lower gas velocities the peaks in the profiles were displaced from the centre-line of the lance by a fractional diameter of about 0.15. The particle discharge velocity profiles become increasingly asynunetric as the lance orientation was changed from vertical to horizontal, with higher particle velocities present near the top wall of the lance. The mass flux profile also became asyrrunetric as the horizontal orientation was approached, however in this case, the profile became biased towards the bottom of the lance. The effect was much more pronounced for a gas velocity of 10 m/s than for 30 m/s, showing the relatively stronger gravitational influence as the velocity was reduced.

Jan 1, 1996

By Jin-yan TIE, Ke-xin JIAO, Qian Li, Hai-bin ZUO, Jian-Liang Zhang, Meng SHEN

This paper designs three factors such as temperature, pH, conductivity and three levels of orthogonal test. Temperature is a significant factor. However PH and conductivity are not significant through poor analysis. Further research is conducted on the temperature. Temperature stability is 50 . Suitable water velocity is 2.3m/s, which is calculated based on the largest part of the heat flux intensity and the corresponding water temperature should be controlled with 1.5. Meanwhile, water velocity increased has little effect on the heat transfer capabilities.

Jan 1, 2015

By C. Lupi

In 1996 the Italian Agency for Environmental Protection (ANPA) has initiated a study of the environmental impact of the industrial sector of steel produced by Electric Arc Furnace (EAF). Within the framework of this study a hydrometallurgical process to treat EAF dusts was considered and developed. The paper describes the zinc and lead recovery from fumes coming from carbon steel production. The zinc extraction consists in acidic leaching followed by SX-EW steps. The leaching sludge containing lead sulfates was treated to obtain pure lead salt and inert solid residue. The whole process, that minimizes effluents by recycling the main liquid streams, has been developed to obtain marketable products. The solid waste, containing spinels, was subjected to elution tests in order to verify its compatibility with environmental regulation. The process, that has been set-up and tested in the laboratories of the University of Rome, will be transferred and studied on a pilot plant in order to assess its industrial and economical feasibility.

Jan 1, 1999

By Dao Su, Kelang Mu, Yufeng Guo, Jinghua Zeng, Tao Jiang

"The influence of high pressure roller grinding (HPRG) on sintering of iron concentrate fines was investigated. Results of mini-sintering tests showed that assimilation temperature of iron concentrate fines decreased from 1230 ? to 1220 ? and assimilation time was shortened from 10 min to 5 min when the iron concentrate fines was pretreated by HPRG. Sinter pot tests showed that the yield of sinter increased from 60.33% to 72.92% , tumble index increased from 44.35% to 46.66%. The investigation indicated that, after being pretreated by HPRG, iron concentrate fines are improved in ballability and the fraction of fine particles increased, resulting in the improvement of granulation property and reactiveness in solid state reaction. As a result, sintering of iron concentrate fines were strengthened.IntroductionWith the rapid development of iron and steel industry and the decrease of high-grade ores, the imports of iron ore are increasing continually. It is of immensely strategic importance for development of iron and steel industry and energy security in our country to make good use of iron concentrate fine which is low price, high grade and has a refractory sintering property. When iron concentrate fine is used in sintering, granulation property of sinter mixture and permeability of sinter bed get poor. As a result, yield and quality of sinter fall down. Many researches show that, when HPRG is used in pelletization, quality of pellets is improved dramatically. Meanwhile, HPRG has a low energy consume, a large handing capacity and it is benefit for environment protect. At this theme, strengthening of sintering of iron concentrate fine pretreated by HPRG was investigated in this paper."

Jan 1, 2012

By Philip L. LeHoux

"Kennecott Barneys Canyon Mining Co. is a gold heap leaching facility that has been in operation since 1989. In 1994, a flotation plant was commissioned to remove sulphide minerals from refractory sulphide ore. Tailings from the plant are mixed with oxide heap leach material in order to produce a geotechnically stable agglomerate from which the gold is leached and recovered in a conventional heap leach cyanidation process. The experience to arrive at an effective blending methodology is discussed.IntroductionAgglomeration is the practice of binding fine particles to coarser rock or other fines in order to avoid the deleterious effects of mobilizing the fines during the course of heap leaching(l-Chamberlin). Agglomeration has been considered a key component of successful operation at many heap leach sites. If the ore is of sedimentary origin and crushed, there is a high likelihood that the resulting product will contain a significant quantity of fines and a skewed gradation, that i~, a disproportionate amount of coarse and fine particles, with few in the intermediate size range. The exact methodology for determining whether the practice of agglomeration will have to be integrated into the operating scheme has been well discussed. These conditions are primarily geotechnical and geochemical. This paper will deal with the specific experiences of Kennecott Barneys Canyon Mining Company in modifying the agglomeration practices to suit evolving operational requirements."

Jan 1, 1997

By Yasuhiko Ito

"This talk is concentrated on the topics of compound film formation on the substrate electrode by interdiffusion of substrate element and electrochemically deposited species and/or by direct electrochemical implantation of the component element of the film into the substrate. As a typical example, electrochemical implantation of nitrogen atom into Ti metal to form TiN surface film is described. Another example is the formation of various kinds of intermetallic compound films including Ni2Y, Ni2Dy and Pd3 Y by the electrochemical implantation of lanthanoid elements into transition metal electrodes. By combining these two methods, Sm-Fe-N ternary material film also could be formed. The principle and application of the ""electrochemical implantation"" are discussed in detail.IntroductionGenerally speaking, surface film formation by molten salt electrochemical process can be divided into the following three categories:(i) single element film formation on the electrode by electrodeposition,(ii) compound film formation on the electrode by electrocodepostion of more than two elements, and(iii) compound film formation on the substrate electrode by interdiffusion of substrate element and electrochemically deposited species and/or by direct electrochemical implantation of the component element of the film into the substrate.This talk is .concentrated on the topics of category (iii), especially on the electrochemical implantation. Typical example can be seen in the electrochemical implantation of nitrogen atom into Ti metal to form TiN surface film. Another example is the formation of various kinds of intermetallic compound films including Ni2 Y, Ni2Dy and Pd3 Y by the electrochemical implantation of lanthanoid elements into transition metal electrodes. By combining these two methods, Sm-Fe-N ternary material film also could be formed. The principle and application of the ""electrochemical implantation"" are discussed in detail with examples above as well as other experimental results also obtained very recently in the author's laboratory."

Jan 1, 2000

By James T. Staley

Quenching and aging are critical processing steps used to produce precipitation hardenable aluminum alloy products. This work describes personal computer programs that employ models to predict certain properties after quenching and aging and graphically display them. One of the programs allows the user to predict the attainable strength and toughness of aluminum alloy products after an arbitrary quench. Another program simulates the changes in strength and electrical conductivity occurring during second-step aging alloy 7050-T7X products as a function of thickness, furnace temperature set point, and furnace characteristics.

Jan 1, 1993