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By P. Henry

A novel electrochemical cell has been developed for the recovery of MnO2 from residue of pyrolusite ore leading loaded with Fe, Al Ni, Co and Si impurities, This new process can be considered as an alternative to the traditional methods : S02, H2O2 or bioleaching. It has been observed to proceed fairly rapidly and could prove to be a more economically viable process, as well as being more environmentally acceptable. Electrochemical characterization and kinetic studies have shown that MnO2 is effectively leached by electrogenerated ferrous ions at high current density from a pulp containing less than 5 g8 Fe. The chemical reactions are : Cathode (inox) : 2F23+ + 2e ? 2 Fe2+ Bulk: MnO2 + 2 fe2+ 4H+ ? Mn2+ + 2 Fe3+ + 2 H2O Anode (Pb-Ag) : H2O ? ½ O2 + 2H+ + 2e Global: MnO2 +2H+ Fe2+ = Mn2+ + H2O + 1/2 O2 The catholyte (MnO2 pulp) circulates upward in the expanded mesh cathode separated from the sulfuric acid solution anolyte by a separator which shows high mechanical resistance, low porosity, low potential drop, and reasonable cost. Laboratory and mini-pilot tests have led to the construction of an OT crating pilot plant (100 kg/hr) able to leach more than 95% of Mn, Ni, Co at 1000-1200 A/m2, 50°C with high faradic yield (> 95 %) and low power consumption (3.2 kWh/kg kWh/kg &4D). New applications like the treatment of spent Zn-Mn batteries, polluted soils, spent catalysts and oxide ore (cobalt, nickel) with electrogenerated redox species are now investigated at a laboratory and mini-pilot scale.

Jan 1, 2000

By Wing Ka Ng

Substitution of pulverized coal injection by solid biocarbon fuel has the potential to achieve substantial reduction in GHG emissions associated with blast furnace ironmaking. A systematic evaluation was conducted on the performance of solid bio-carbons produced from a single raw biomass source using different pyrolysis technologies. The potential of solid biocarbon in reducing GHG emission of the blast furnace ironmaking process is strongly influenced by its O/C mass ratio. In order to achieve substantial GHG reduction, it is necessary to replace coal injection by solid biocarbon having a low O/C mass ratio. The pyrolysis technology and conditions employed are key parameters influencing O/C mass ratio of the resultant solid biocarbon. Close collaboration between steelmakers and solid biocarbon producers is critical for producing suitable solid biocarbon fuel to replace pulverized coal injection. A successful partnership should pave the way in achieving substantial reduction in GHG emissions of the blast furnace ironmaking process.

By Noel A. Warner

Modern steelmaking is based on direct use of oxygen in high intensity batch reactors. A totally new approach is proposed in this paper, based on the view that pursuit of high intensity is unlikely to lead to successful coal-based continuous steelmaking. By substituting carbon dioxide and water vapor as the oxidants rather than using oxygen directly, the intensity is greatly reduced. Accordingly. subsurface formation of carbon monoxide bubbles can be avoided by careful manipulation of the three participating rate processes, gaseous diffusion, interfacial chemical kinetics and liquid phase mass transfer. Steelmaking can then be carried out without explosive ejection of molten droplets and the generation of micro-spray but rather in a controlled and fumeless fashion. The vital component is the introduction of generic melt circulation technology. Three melt circulation loops in series are envisaged. Starting with a composite feed of iron ore fines, pulverized coal and lime flux, a metallized solid raft floating on molten iron is propelled out of the ironmaking loop onto the first of two downstream steelmaking loops. In the first, a liquid slag is formed, primary decarburization is undertaken not with oxygen but rather with CO2 and H2O and the melt is desulfurized. The semi-product stream enters the third melt circulation loop, where open-channel decarburization is effected along with dephosphorization to yield a low carbon steel product. Alternatively, the melt leaves the last loop to irrigate a packed tower countercurrent to argon at around 100 mbar to continuously produce ultra-low carbon (ULC) steel.

Jan 1, 2003

By Sharif Jahanshahi

Calcium ferrite slags are often associated with Professor Yazawa due to his pioneering work on the thermodynamics of this type of melts. Over the past years CSIRO has invested some effort in studying physico-chemical properties of such melts to fill in some gaps in our knowledge and explore opportunities for application of the understanding developed. These investigations cover thermodynamics, transport properties of calcium ferrite based slags, as well as the kinetics of reactions of such slags with refractories. The present paper provides an overview of some of these studies and highlights some of the interesting behavior of such melts. The oxidation state of copper and arsenic in calcium ferrite based slags are predominantly Cu+ and As3+, respectively, at oxygen potentials below 10.1 atm. The concentration ofCu2+ in such slags becomes significant at oxygen potentials of greater than 10'1 atm at 1300 ?C. The activities of CuOo.s and AsOl.S in calcium ferrite slags show strong deviations from the Raoultian Law, while that of CoO is very close to ideal behaviour with respect to pure solid CoO. Addition of Si02 to calcium ferrite slags can have significant effects on the activities of FeO and Fe2O3 and hence the stability of magnetite phase. Transfer of oxygen in calcium ferrite slags is fast with diffusivity of 2xlO?3 cm2/s at 1350 °C and activation energy of 16 kcal/mol Presence of solid phases, such as magnetite, has pronounced effect on the viscosity of calcium ferrite slags. The observed dependence on solid loading and shear rate indicates deviation from Newtonian behaviour. The interfacial tension between copper mattes and calcium ferrite slags is strongly dependent on the matte grade, with the determined values being much lower than the corresponding ones for interfacial tension between similar mattes and iron silicate slags. MgO, Cr2O3 and MgCr2O4 have low solubility in calcium ferrite slags and their solubility increases with increasing copper oxide content of the slag at 1300 °c. The oxidation state of the slag has strong effects on phase transformation, dissolution rate and disintegration of refractories in calcium ferrite slags. Other key factors with major impact on slag-refractory interactions include viscosity and surface tension of slags as well as the contact angle between slag and refractory material.

Jan 1, 2003

By Jing Zhang, Chenguang Bai, Fusheng Pan

"The microstructure and hot deformation behaviour of an Er-modified Mg-Zn-Ai alloy were evaluated. The results showed that the addition of rare-earth Er changed the morphology of the quasi-continuous grain boundary networked eutectic compound to globular particles. Moreover, a self-strengthening effect was identified for the alloy, which determined its deformation behavior. After hot extrusion, the yield strength and elongation to failure of the Mg-Zn-AI-Re alloy at 200°C were increased by 105% and 120%, respectively, due to an emerged dynamic precipitation strengthening mechanism.IntroductionMagnesium alloys are attracting increasing attention for applications in automobile, electronic devices and hand tools for weight reduction and higher fuel efficiency, because of their lightweight and a high specific strength. However, application of Mg is still very limited. The largest applications are still those non load-bearing castings used at room temperature, such as box case, housing, and covering. One of the main reasons is the inadequate absolute strength both at room temperature and elevated temperatures (> 100°C) of the commercially used AZ, AM series alloys, due to the incoherent interface between the secondary phase y-Mg17AI12 and Mg matrix, as well as the low thermal-stability of the y phase [1]. Besides, the heat-resistant magnesium alloys which contain rare earth (Re) as the main alloying element are very expensive. The other reason is their poor deformability. The key solution is therefore to develop low-cost heat -resistant wrought alloys."

Jan 1, 2012

By R. J. Kuczynski

The U.S. Bureau of Mines operated a 2,000-9 (4.4-lb) batch process development unit for recovering platinum-group metals (PGM) from automobile catalysts. Virgin monolith, used pellet and used monolith catalyst samples were tested. Leaching twice with 1-pct sodium cyanide (NaCN) solution at 160' C for 1 h in a pressure vessel dissolved over 95 pct of the PGM from virgin catalysts and over 90 pct from used pellet catalysts. Over 85 pct of the PGM was dissolved from used monolith catalysts when a third leaching step was added. PGM concentrates as metallic powder containing over 99.8 pct of the dissolved PGM and analyzing greater than 70 pct PGM were recovered by heating the pregnant leach solutions from virgin catalysts to 250' C and used catalyst to 275" C for 1 h. The solution after heating contained primarily sodium carbonate from cyanide decomposition and less than 0.2 ppm total cyanide.

Jan 1, 1993

By A. Dutta, B. Devulapalli, A. Mukhopadhyay, E. W. Grald

"Computational Fluid Dynamics (CFO) has matured over the past two decades as an analysis tool for conducting virtual experiments with significant time and cost savings. It complements and reduces physical testing. CFO has penetrated the diverse materials industry in much the same way as Computer Aided Design (CAD) did more than a decade ago. As the basic numerical algorithms used in CFO have steadily improved, so have the reliability, consistency and user-friendliness improved significantly, too. Other recent trends have also contributed to the rapid growth and widespread adoption of CFO. In this presentation, CFO applications from several materials processing industries will be presented using case studies. Emphasis will be on metals, glass and semiconductor applications.IntroductionThe term materials processing covers a diverse array of industrial applications and products today. From the continuous casting of steel, to the deposition of semiconductor materials atom by atom, to the extrusion of molten polymers, materials processing applications span an incredible range of length scale, process times, pressures, temperatures and velocities. The properties of the materials themselves, in terms of density, viscosity, thermal conductivity, etc., can be complex functions of temperature, shear rate, chemical composition and time. And the processing equipment may be very complicated in geometric shape.Computational fluid dynamics (CFD), the technique of solving the governing equations of fluid motion and other related phenomena using a computer, has enjoyed widespread and rapid growth, which started in the aerospace and automotive industries. More recently, CFD has also been successfully applied to a great many materials processing problems, in spite of the challenges described in the previous paragraph. The reasons for the growing usage of CFD in materials processing are many. Using CFD to test design options and reduce the number of physical prototypes can decrease the time and cost associated with new product and process development. CFD gives insight and provides detailed predictions of operating conditions in lieu of difficult, intrusive and often expensive experimental methods. CFD can be used as an aid to scale-up processes from lab or pilot scale to full production. Troubleshooting the performance of existing equipment is often carried out with the help of CFD. Determining how an existing piece of process equipment will operate under new conditions, or with new input ,materials, is also a common task for CFD."

Jan 1, 2004

By Vaughan R. Voller

"Solidification systems from conduction controlled freezing of a pure material through to alloy phase change that include flow and segregation processes are described. The components in a general solidification model-variables, governing transport equations, and local scale relationship-are outlined. A central focus is the presentation of an explicit procedure for coupling between macroscopic and local scale variables.IntroductionSince the seminal work of Byres et al.[!] in the 1940's there has been a steady progress in modeling solidification systems with increasing levels of complexity. The object of this paper is to track the evolution of these solidification models and present a general modeling approach that applicable to a wide range of the solidification systems of current interest.Solidification SystemsIn a broad sense the underlying physics in a solidification process occur at two distinct length scales:1. The macroscopic scale of the process over which the governing transport equations of heat, mass and momentum hold.2. The local scale at the solid-liquid interface where the solidification phenomena are operative."

Jan 1, 1999

By Caryn Wendt, Donna Post Guillen, Armando McDonald, Erik R. Coats, Chaston Ellis, Kevin Feris

Dairy operations constitute ~2.5% of annual U.S. greenhouse gas (GHG) emissions, making dairies one of the largest sources of industrial GHG emissions. We are developing a novel, integrated system to achieve a net reduction in dairy GHGs while producing value-added materials and products. This integrated manure-to-commodities system converts dairy manure to bioenergy, sequesters carbon by converting volatile fatty acid-rich fermenter supernatant to bioplastics, and utilizes anaerobic digester (AD) and polyhydroxyalkanoate (PHA) reactor effluents to produce algae that can be harvested and internally recycled to enhance PHA production and sequester carbon. A decision-making tool is being developed for the integrated system that quantifies net GHG reduction, carbon sequestration, nutrient management and economics.

Jan 1, 2016

By Sanaz Mosadeghsedghi

The feasibility of the application of electrodialysis in separation of light and heavy rare earth elements (REE) in synthetic solutions was investigated. The experiments were carried out using single and binary solutions of a light (cerium) and heavy (ytterbium) REE. The effects of electrical voltage, electrical current, and the addition of complexing agent (EDTA) to increase the separation selectivity were investigated. Separation of Ce and Yb was achieved in binary solutions with and without the addition of EDTA. Higher degrees of separation were seen at higher voltages. Ce–Yb separation was more significant in the presence of EDTA. The separation factor of Ce–Yb and Ce–Yb-EDTA were 1.44 and 2.60, respectively.

By D. H. H. Quon

Results of a study conducted to determine the properties of iron ore pellets made from Mount Wright and Carol Lake ore concentrate fines with partial and full substitution of bentonite by several organic binders are presented. Carboxy methyl celluloses 7H and 6TL, hydroxy ethyl cellulose (natrosol) and modified guar gum all produce pellets of acceptable wet, green and dry strength. However, when fully substituted, an inorganic binder such as calcium carbonate is required for satisfactory strength development after induration. Mixing the Carol Lake ore with Mount Wright ore in a 50-50 ratio also achieves the same result. The failure of the Carol Lake ore in the pelletization process is attributed to the low hematite content of the ore. The results are very similar to those from the extrusion studies reported earlier (8).

Jan 1, 1989

By A. Kontopoulos

The extraction of nickel and cobalt from low-grade greek laterites by sulfuric acid leaching has been studied. Batch and continuous mini-plant atmospheric leaching as well as pressure leaching techniques were employed. Atmospheric leaching at temperatures as high as 95 OC generally resulted in low Ni extractions (up to 82%), high acid consumption (650-850 kg/t ore or 80-100 kg/kg Ni) and high Fe co-dissolution (30%). Pressure leaching at 260 OC increased Ni extraction to over 98%, with minimal Fe co-dissolution (2.5%); acid consumption was 300 kg/t ore (31 kg/kg Ni). Detailed experimental results and conceptual flow sheets for atmospheric and pressure leaching are presented.

Jan 1, 1991

By Eric J. Beckman

Recovery of metals from dilute solution, whether the matrix is solid, or liquid, remains a considerable technical and financial challenge. Methods currently exist whereby metals can be extracted from either type of matrix, yet these methods consume significant quantities of reagents and can also generate multiple waste ,streams in the process. Technology developed in our lab allows efficient application of environmentally-benign CO2 to a number of separation problems involving metals. For example, we have employed biphasic mixtures of C02 and water as a green acid leach medium. Metals have been extracted from a steelmaking process residue and then recovered as metal carbonates through depressurization. In this process, metals are extracted and recovered without the use of reagents other than CO2 and water, and CO2 is sequestered as a solid. In addition, through synthesis of Cal-miscible phase transfer agents, we have shown that CO2 can replace the organic solvent currently used in refining of precious metals, The sensitivity to pressure of phase behavior in a CO2-mixture may allow significant streamlining of the process as well. Finally, CO2 soluble chelating agents have been used to extract toxic metals from acidic effluent such as that found in plating facilities.

Jan 1, 1999

By Kafui Nyavor

The indirect, and the direct contact mechanisms of bacteria oxidation of sulfides were studied using Thiobacillus ferrooxidans and pyrite. The aim was to determine which of the two generally aeeepted mechanisms played a dominant role, if any, during acid mine drainage (AMD) formation from the oxidation of sulfide minerals. The results show that at a pH of 4.5 where T. ferrooxidans are quite active, but where initial chemical oxidation of pyrite to Fe2+ is limited, the bacteria were unable to directly oxidize pyrite to any significant extent. Whereas, in the presence of Fe2+, T. ferrooxidallS assisted oxidation of pyrite by the indirect mechanism was observed and sustained over the pH and Eb range where the bacteria is active. The results lead to the conclusion that the direct contactmechanism of pyrite oxidition by T. ferrooxidans is insignificant. The predominant, and possibly the only, pathway involves the indirect bacteria oxidation of available Fe2+ to Fe3+, which in turn oxidizes FeS2 to generate additional Fe2+ and acidity in a cyclic process.

Jan 1, 1996

By N. L. Piret

In copper smelting minimization of solid waste generation is receiving increased attention with more stringent environmental legislation and lower disposal space availability. Copper smelting slags generally being valorizable, solid waste generation is attributed to the presence in the feed of unvalorizable impurities which do not report to the slag and to the unavoidable formation of contaminated dilute acid solutions which need neutralization. As to unvalorizable impurities, solid waste minimization is achieved by rejecting them in the highest possible concentration. Dilute acid is mainly due to the formation of SO3 in the smelter gases and to the discard of decopperized bleed-off electrolyte. Its generation is substantially lowered by preventing SO3 formation, by converting the dilute acid to a valorizable product, e.g., by thermal decomposition for H2S04 recovery or by precipitation as chemical gypsum, and by suitable treatment of the bleed-off electrolyte for impurity removal. Industrial processes are evaluated and alternatives are discussed.

Jan 1, 1994

By Y. Mori, K. Kawanaka

The permeability changes during the sintering of the feed for the Imperial Smelting Process (ISP) were investigated using an experimental sintering pot, as well as with a mathematical model. The results obtained were as follows. The blowing resistance in the sintering bed changes as the sintering reaction proceeds. It increases at the beginning of the reaction when the temperature of the bed is still low. Then it decreases as the reaction continues, accompanied by an increase of the bed temperature. The increase of the blowing resistance in the bed during the sintering process mainly occurred in the drying zone, and was comparatively small in the reaction and cooling zones. Based on Erugen's equation, the change of the permeability during sintering is explained by the decrease of the apparent fractional void volume in the drying zone of the bed.

Jan 1, 2000

By R. R. Odle

A laboratory and pilot-scale investigation of direct smelting of copper concentrates was conducted to determine the effect of concentrate analysis and the degree of roasting on the yield and quality of copper produced in a subsequent smelting step. A stoichiometric :mOdel of direct smelting is presented which predicts the? quantity of copper; slag, and white metal' prOduced'and the distribution of copper in these phases as a function? of the concentrate '(calcine) analysis.

Jan 1, 1983

By M. Furuta, M. Hasimoto, Y. Komoda, K. Haiki

"Tamano Smelter & Refinery started its operation in 1972 with high current density electrolysis (350Nm2 of maximum) applying PRC technology. After the start up, four times of expansion have been done, the cathode production capacity has increased from- 84,000 t/y to 191,000 t/y. However, recent refining technology with permanent stainless steel cathode enabled to increase current density up to 300 Nm2 or more without PRC method. In order to increase current density more than 350 A/m2 , experimental work using commercial size cell has been carried out at several conditions, such as current density, PRC conditions, electrolyte composition and electrode condition. As a result, it was found that high quality (LME A grade) cathode can be produced at such a high current density as 405 A/m2•IntroductionWhen considering the production increase of electrolytic copper, what becomes important is the improvement of productivity per unit of production facility. Conventionally, production had been expanded by increasing the number of cells but a huge investment required for this had a influence to the business profitability. Because of this, increase of current density, which is one of the methods to improve unit productivity, 'was expected and this method at the same time has another advantage of shortening the retention time of copper and other precious metals in the cells. At present, the average current density at Tamano during full capacity production is around 350 A/m2 and this used to be the limit throughout the world (1)."

Jan 1, 2000

By F. H. (Sam) Froes, C. Suryanarayana, K. C. Russell, C. M. Ward-Close

"Far from equilibrium synthesis allows development of novel crystal structures and microstructures, leading to achievement of enhanced physical and mechanical properties. A number of ""far from equilibrium"" techniques are reviewed with emphasis on the amount of departure from equilibrium. The ability of two such techniques, mechanical alloying (MAl, and physical vapor deposition (PVD) to develop novel structures are discussed in detail. For the MA process emphasis is placed on intermetallic compound compositions. Solubility extension, beyond rapid solidification (RS) levels, is found in terminal compositions but not for the intermetallics. Nanostructure-sized grains (< 100nm) form which can be retained after ""low temperature"" compaction. On continued milling in many cases the nanometer-sized grains transform to an amorphous structure. Ordering is destroyed by MA, except in those intermetallics with large negative enthalpies of formation. For the PVD process, a review of application to terminal light alloy compositions is presented. This includes a new high-temperature aluminum alloy, layered materials with nanometer spacing, corrosion-resistant magnesium alloys and low-density titanium compositions. IntroductionTo enhance the mechanical property combinations of advanced structural materials innovations in process/synthesis are required [1-6]. In this paper the capability of various ""far from equilibrium"" synthesis techniques [7,8] to produce novel constitutional and microstructural effects, and hence potentially enhanced physical and mechanical properties, in advanced materials is presented. The application of two such methods, mechanical alloying (MA) and physical vapor deposition (PVD) is discussed in detail. For the MA process emphasis is on intermetallic compositions with consideration given to solid solubility extension, microstructural refinement, amorphization, and formation of intermetallic compounds. For the PVD process application to terminal light alloy compositions is discussed."

Jan 1, 1994

By T. W. Turk

In May 1984, Davy McKee Corporation was awarded a contract for engineering design, procurement assistance, project management and startup services for two gold recovery plants? in the People&apos;s, Republic of China (PRC). The basic design of these two projects was to be accomplished by a combined effort of the Chinese and Davy McKee Corporation (DMC). The, design goals were to provide a state-of-the art plant while maintaining Chinese standards and design practices whenever possible. Chinese-manufactured equipment was to be used as much as possible. This paper discusses the project organization and procedures developed to accomplish the design goals, the process selection and design, and the selection and procurement of equipment outside of the PRC. Design development for grinding, leaching and carbon adsorption, and gold recovery are discussed in detail. The major goal of process selection and design was to provide common criteria for both plants. Equipment .sizing and selection was identical for carbon-in-leach adsorption, gold recovery, acid washing, and carboo regeneration for both plants. Of special importance is the design of the wastewater treatment system. Due to the cl0se proximity of a major population area, slurry discharging from these mines must be treated to meet drinking water standards. The process development and design of this system is also discussed in detail.

Jan 1, 1989