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By James R. Craig

The slags generated during gasification of petroleum coke are heterogeneous and con-sist of many different phases. These phases are important because their physical properties affect the operability of gasifiers and because they concentrate many elements that are present in the petroleum coke feed in only minor to trace quantities. An understanding of the chemistry and physical nature of these slag phases is necessary to predict behavior in the gasifier and in considering the ultimate use or disposal of the materials. Slags typically consist of silicate glasses, calcium-silicates, free iron-nickel metallic phases, iron sulfides, and aluminum oxide spinels enriched in iron, chromium, and vanadium. The partitioning of elements among these phases has been analyzed and will be discussed.

Jan 1, 1989

By Neale R. Neelameggham

"Ferrous and non-ferrous metal industries are used to handling several billion tons a year of ore bodies, fuel and fluxing agents by mineral processing techniques and varieties of extractive metallurgy ""Reduction"" processes. Metal industry know-how can be applied to meet the challenge of Reducing CO2 in the atmosphere. Processes for generating alloys of carbon and hydrogen by Reducing the CO2 and water mixture, [carbonated water or water vapor] called Soda, to easily stored fuels are normally endothermic. The processes are similar to generation of hydrogen alone from water which is also endothermic. But hydrogen is more difficult to store than compounds [or alloys] of carbon and hydrogen. This recycling of CO2 and water are possible by using other forms of energy by innovative carbon capture methods.Thermodynamic Diagrams developed for Soda [CO2 and H2O] - metal reactions provide hints for using low cost unused stored energy in un-recycled metallic waste for thermal conversion. Choices for conditions for the electrochemical approaches [using solar - wind - hydropower] are also discussed.INTRODUCTIONIn 2006, I was reading some of the arguments put forth by learned scientists on the benefits and lack of benefits of bio-fuels. I found that the arguments rose partly from the differing system boundaries that were chosen by one versus the other. Some part of the argument may have been based on political climate or atmosphere rather than the analytical science. This situation is seen when scientists discuss which came first - the chicken or the egg, the fuel or biological matter, the oxide or the element, and so on.Then I thought –[just like many of the learned persons participating in this symposium] that common fuels - regardless of them being simple hydrocarbons or oxygenated hydrocarbons or carbohydrates - can all be made from the respective oxides of carbon and hydrogen by simple chemical reductions efficiently carried out in an economical fashion. This is the systematic approach we take when designing a chemical or metallurgical process facility."

Jan 1, 2008

By C. H. Bucknam

A review of phase analysis methods used to characterize refractory gold ores is presented. Updating of assay methods using database technology, on-line instrument interfacing and response surface modeling is highlighted. The use of assay results to classify ores for metallurgical purposes is demonstrated.

Jan 1, 1987

By Alexandra Anderson

A computational fluid dynamic (CFD) model has been developed using ANSYS Fluent 17.0 to help identify areas of high wear within the refractory lining of a secondary lead reverberatory furnace. Once a base case simulation was validated using data from an operational furnace, areas of potentially high refractory wear were determined through the calculation of the temperature and velocity distributions within the furnace and on the hot face of the refractory lining. The CFD model was used to assess whether the predicted areas of high refractory wear could be minimized through changes burden geometry. The results showed that shape of the burden geometry greatly affected the overall flow patterns and heat transfer within the furnace.

By G. R. Waters

NMR360 is developing a suite of chloride-based metals extraction processes, with the first commercial operation scheduled for commissioning late in 2018. It is critical, therefore, that with the introduction of any new technology, that the circuits do not suffer from mechanical failures which will compromise the operation. Although chloride leaching is at atmospheric pressure and relatively low temperature, the main challenge is preventing corrosion, since the high proton activity makes even a small amount of acid behaves as though it were concentrated. An additional challenge in concentrated chloride circuits is the potential for solids precipitation. In this context, therefore, correct valve selection is crucial, and NMR360 has partnered with CGIS to ensure that the Severe Service Valves (SSVs) needed will perform over and above the definitions of the Manufacturers Standardization Society (MSS) of the Valve and Fittings Industry. This paper outlines what the minimum requirements are for SSVs in chloride leaching applications, drawing on five decades of industry experience from one of Canada’s leading valve experts.

By Suzzann Nordwick

The metallurgical treatment of mercury-containing materials for precious or base metals recovery imposes many processing and environmental challenges. Mercury is usually present as elemental or cinnabar. Historically, mercury has been removed from mined ores pyrometallurgically by roasting, but hydrometallurgical methods have also been employed. For example, alkaline sodium sulfide solution acts as an universal solvent for most mercury compounds. While, most other metals are highly insoluble in this solution. This allows for a high degree of selective separation of mercury from other metals with the exception of tin, antimony and arsenic. Mercury leached with a solution of sodium hydroxide and sodium sulfide or sulfur can be re-covered by cementation or stabilized through sulfide precipitation. Hydrometallurgical technology for the pretreatment of mercury removal from gold, silver, and base metal ores using alkaline sulfide leaching will be discussed with a focus on alkaline sulfide leaching of mercury sulfide-containing materials.

Jan 1, 2003

By Jilai Xue, Jun Zhu, Germain Kouma Ndong, Qiaochu Liu, Luxing Feng

"High-temperature oxidation and corrosion behaviors of Ni-Fe-Cr alloy as inert anodes for aluminum electrolysis have been studied in oxygen and molten electrolyte. The oxidation and corrosion scales on the anodes tested were analyzed using XRD and SEM-EDS. The oxidation rate is found to increase with increasing temperature from 700 °C to 950 °C, which can be approximately described by an inverse power rate function. The oxidation scales at 750 °C, 920 °C and 950 °C contain Cr-rich phase along with FeCr204 and (Feo.6Cro4)203. The corrosion extent of Ni-Fe-Cr anodes in electrolyte is dominated by temperature, which can make the scales thickness double from 700 °C to 750 °C or from 920 °C to 950 °C. Cr and Fe in the scales on the anode in electrolysis corrode preferentially into the molten electrolyte, while the nickel oxides could better sustain the corrosive environment in electrolysis. The results can be useful for developing inert anode material for potential application in aluminum electrolysis.IntroductionThe development of an inert anode for aluminum electrolysis has been a long term goal for aluminum industry. The present process for primary aluminum production involves the reduction of alumina with carbon anodes, forming carbon dioxide:"

Jan 1, 2013

By Dalene Joalet Steenkamp

Excavation of industrial-scale furnaces allows for the systematic study of reaction sequences by identifying the different reaction zones within the furnace. In 2013, Transalloys excavated a 48 MVA submerged arc furnace that was used for silicomanganese production using the ore-based route. The excavation method was reported elsewhere as was observations made in terms of refractory wear and modes of electrical energy dissipation prior to excavation. The paper presented here, reports on the process reaction zones observed during the excavation and subsequent phase chemical analyses of a number of process samples obtained during the excavation. The zones identified were a loose burden zone, a dry coke-bed zone, a wet coke-bed zone, a hard build-up zone, and an alloy zone. The results are compared to observations made in the excavation of an industrial-scale SAF and a pilot-scale SAF in Norway. The presence of the hard build-up zone below one of the electrodes and absence of a slag zone below all three electrodes are unique features of the SAF excavated at Transalloys.

By Shujian Jia, Mingming Song, Gaoyang Song, Bo Song, Yuhou Yang

An innovative method is investigated to separate inclusion particles from liquid metal by super gravity. To make clear the characteristics of the inclusion separation, Al melt containing MgAl2O4 particles with diameters less than 150 μm has been treated under various super-gravity fields. The thickness of particle-accumulated layer formed at the bottom of the sample and the area fraction, number density and size of inclusions were measured. It is found that the thickness of the particle-accumulated layer decreases and the area fraction of particles at this location increases with the increase of super-gravity field. With the gravity coefficient G=500, time t=2 min, and temperature T=1023 K, it is hardly to find any solid particles in the upper and middle areas of the sample and the separation efficiency is up to 90%.

Jan 1, 2015

By Jörg Wallner

In order to limit SO2 emissions, the Montanwerke Brixlegg AG has installed a desulphurisation plant with the primary aim of reducing the peak emissions from the copper converter that are of particular ecological concern. The author discusses the process requirements, the desulphurisation process selected and the results achieved.

Jan 1, 1996

By Xudong Liu, Feng Chen, Yufeng Guo, Wei Chen, Tao Jiang

Willemite is typically found in oxidized zinc ores and metallurgical secondary resources but without effective extraction method yet. Based on the ideas of zinc phase reconstruction in the willemite, the extraction of zinc from willemite by calcified-roasting using CaO as additive and ammonia-leaching process was studied in this paper. The influences of CaO dosage, roasting temperature, roasting time on the phase transformation and zinc leaching rate were studied, which were characterized by XRD. The results indicated that Zn2SiO4 was transformed into ZnO or Zn2CaSi2O7 .After roasted with 1.4 times of theoretical CaO dosage at l280 for 40 minutes, willemite was thoroughly transformed into ZnO. The zinc leaching rate of the roasted sample was 97.45% in NH4Cl-NH3 H2O leaching system, which increased by 91.40 % compared with zinc leaching rate of 6.05% when willemite was directly leached in NH4Cl-NH3 H2O system.

Jan 1, 2016

By J. B. Cocanour

Pioneering work at the U.S. Bureau of Mines (USBM) has produced a personal computer (PC)-based, software-driven video photometric color sensor for real time process control of metallurgical streams. The video photometer is an inexpensive optical sensor which operates in the visual area of the electromagnetic spectrum and collects color information through plastic optical fiber. The red, green, and blue (R/G/B) voltage components of the color video signal are digitized and characterized through software and then presented as the control variable for software-based proportional-integral-differential (PID) control. This sensor has been successfully employed in the control of a laboratory copper electrolytic circuit. With this sensor, copper solutions were analyzed on-line without the need for sample removal, dilution, mixing or reagent addition, thereby allowing for the real time control of the circuit.

Jan 1, 1994

By Jiakai Zhang

Many postconsumer electrical and electronic equipment wastes contain a considerable amount of rare earth elements (REEs); however, the current level of REE recycling from them is limited (<1%). Neodymium–iron–boron (NdFeB) magnets, used at both small- and large-scale, from computer hard disk drives and small tools to wind turbines and cars, are a good example of such waste materials that contain high content of neodymium (Nd) and dysprosium (Dy). These elements are considered critical metals because they are the main building block of emerging green technologies that will allow for GHG emission reductions. Because demand for these green products is increasing around the world, the demand for REEs is increasing quickly, putting their supply at risk in the near future. Thus, it is critical to develop efficient, robust, and cost-effective processes to recycle these elements from this class of electronic waste materials. Here, we performed a thorough characterization of a N52–NdFeB magnet to identify its composition, crystal structure, and morphology. Furthermore, we developed an efficient hydrometallurgical process to extract Nd and Dy with high efficiency (more than 95%).

By Makiko Takahashi

A tool is being developed to predict and visualize the microstructural evolution of steels during quenching. This tool utilizes experimental data and reference data that are stored in a database to predict the microstructural development. The visualization tool animates qualitative representation of two- dimensional microstructure drawings as well as the quantitative volume fractions of phases present as a function of time. This is achieved by superimposing the Jominy End-Quench test results over the Continuous Cooling Transformation diagram of the alloy. The predicted microstructure is presented through the web browser to maximize the ease of use. In addition, a parallel coordinate system is used to aid in identifying similarities within the data set by presenting the large number of data at a glance. The results for 4140 steel that was quenched in a wide variety of quenchants will be presented to illustrate the prediction and visualization tools. Keywords: Quenching, Microstructure Prediction, Simulation, Data Visualization, Database, Applet, Animation

Jan 1, 2003

By Yong-ming Chen, Chao-bo Tang, Yun Li, Long-gang Ye, Sheng-hai Yang, Hao-tian Xue

In order to achieve high recovery of Cu and Co during cobalt-bearing copper sulphide ore smelting process, reducing agent (coke) and sulphidizing agent (pyrite) were added into molten smelter slag for reducing-sulphidizing smelting to product Cu-Co matte. Effects of reductive atmosphere, pyrite dosage, smelting temperature and smelting duration on Cu, Co, Fe distribution behaviours were investigated. The results show that the distributions of Cu and Co are mainly enriched in Cu-Co matte, and the distribution ratio, LCu and LCo, improve with increasing of coke amount or pyrite addition, whereas above 6 wt.% coke or 20 wt.% pyrite, Cu and Co tend to transfer from matte to cleaned slag. A properly high temperature(1300) and smelting duration(3h) are beneficial to the enhancement of the distribution ratio of valuable metals, and under the given set of conditions, LCu > LCo generally. However, an undesired high Fe contents in matte limit further increase of LCu and LCo.

Jan 1, 2015

By Leonid M. Lerner

High temperature aluminum Alloy 8009 is a rapidly solidified/powder metallurgy aluminum-iron-vanadium-silicon alloy. This alloy in combination with hard oxide aluminum film has unique engineering properties which may recommend its use in compressors and impellers for aerospace applications. Various anodizing processes (including Sanford Low Voltage DC+AC Process) for these task will be evaluated and normal chemical composition, physical properties, and macrostructures of 8XXX aluminum alloys will be presented.

Jan 1, 2006

By Lv Guozhi, Niu Liping, Shi Guanyong, Liu Yan, He Jicheng, Du Yanjun, Dou Zhihe

"We proposed thermit reduction-electroslag remelting method of preparing the large scale CuCr alloy. But there are pores and oxide inclusions in CuCr alloy prepared by thermit reduction process. This paper studied mainly the effects of ratio of reactant and additive on the inclusion type and their occurrences in CuCr alloy. The alloy prepared in different process conditions was characterized via XRD, SEM, OM and TEM and metallographic microscope, in which the existing state and micro-structural defects of inclusions are analyzed. The results show that there are three distinct regions: copper-rich regions, chromium-rich regions and the inclusion regions. Inclusions are mainly in the form of stomata and Alz03 phase, mainly locating in the copper-rich phase and the interface area of chromium-rich phase and the copper-rich phase. Adding Na3AlF6 and heating agent can effectively reduce the inclusion content in the alloy.1 IntroductionIn recent years, with the development ofhigh power vacuum and high-pressure technology ,the CuCr alloy contact material which has many advantages gradually replaced the traditional W-Cu and Cu-Bi series alloy contact material, and become the first choice of material in high-voltage and high-power vacuum switch contacts['-3l. The traditional powder metallurgy method, infiltration method and vacuum arc melting method[4-SJ are using metal Cu powder and Cr powder as raw material by casting molding, and have disadvantages such as high production costs, complicated process, poor product density and low yield, especially in the large size alloy ingots[9-12l. At present, the world regards CuCr alloy new preparation technologies as the first place, and how to achieve a large size the CuCr alloy ingot preparation has become a hot research of CuCr alloy[3l. Zhang Ting-an and Dou Zhihe[l-3l who are supported by national natural science fundation of china successfully successful developed new technologies and core equipment to prepare large-size copper-chromium alloy through aluminum thermal reduction-secondary refining method, and obtained two national invention patents. The method includes two key steps: one is get CuCr alloy consumable ingot by Thermit-SHS with electromagnetic stirring, the other is to refme the CuCr alloy ingot to remove the pores, inclusions and other defects by electroslag remelting technology to get dense and uniform CuCr contact material. The preliminary study results show that means of electromagnetic stirring evidently inhibit effect of alloy ingot macrosegregation during the electromagnetic casting stage, but there are still microstructure defects such as alumina inclusions and pores in the alloy ingots. Therefore, Zhang Ting-an et al refer new ideas of using the electroslag remelting to refine Cu Cr alloy ingots and effectively remove the defects of the ingots such as pores and inclusions [3l _ At present, there is no report of study on the electroslag remelting refining processes of CuCr alloy (the refining slag, remelting current). This article will research mode of occurrence and distribution law of inclusions in the large-size CuCr alloy ingots by Al Thermit-SHS under magnetic field stirring action and provide a theoretical basis for chosing refining slag to remove inclusions by electroslag refining. Meanwhile the article analyses the effect of reduction conditions of Thermit-SHS on the types of inclusions, mode of occurrence and distribution of regular inclusions in alloy ingot, and refer theory for inclusions regulation in the large-size alloy ingots."

Jan 1, 2013

By Mingchun Lu, Yunjin Yan

"This paper describes a new type of bell-less top installed on two relined blast furnaces at Tianjin Iron Works and another new-built at Echeng Steel Works in China. A compact installation was presented for existing furnace top innovation with the least reformation of existing top structure. A water cooling and sealing gearbox used for driving the chute discards completely the traditional idea about necessity of continuous supply of cooling gas for the gearbox. A multiring spreader and its dozens of selectable charging patterns enables an operator to achieve optimal burden distribution easily under the condition of a minimum investment of control equipment. Some useful conclusions have been made through a small-size model and a full-scale model tests. The excellent characteristics and the superiority of the new top have been fully proved at both works.IntroductionIt is known that there are some advantages with the bell-less top of a blast furnace: suitable for furnace to operate at high top pressure, capable of realizing optimal burden distribution, less investment and maintenance costs, etc. But why do most of blast furnaces in the world still remain using conventional bell top. One of the concerns is that current bell-less tops still have some shortcomings:1) The height of a current bell-less top might be lower than three or four-bell top or two-bell plus valve seal top, but still much higher than an ordinary two-bell top.2) The gearbox for driving the rotating chute is positioned onto the lip of the furnace. It is subject to attack by crude hot bf gas. Continuously pumping cooling gas (pressurized nitrogen or clean bf gas) into the gearbox is indispensable to withstand such a harsh working environment. Therefore, a plant furnished with blower8 and its ancillaries has to be built, It involves a large sum of investment and much expense in its annual running costs.3) Although the current bell-less charging device as a means of controlling burden distribution possesses a wide range of freedom, it is difficult to realize optimal burden distribution. There are some large blast furnaces realized better burden distribution, but sophisticated control means is indispensable so that the investment of control means is much higher."

Jan 1, 2000

By E. C. T. Chao

Micro-optical and synchrotron radiation-induced X-ray fluorescence (SXRF) techniques have been used to study unoxidized and oxidized samples of Carlintype sedimentar,y rock-hosted disseminated gold ore. In these samples, Where much of the gold is submicroscopic, the SXRF technique, which has a spatial resolution of about 20 ~m and a minimum detection limit (MDL) in the ppm range, is an ideal and necessary tool for precisely locating gold-rich areas in a sample. Gold-rich areas pinpointed by SXRF were later studied in detail by micro-optical methods, principally optical microscopy and scanning electron microscopy with energy-dispersive X-ray analysis (SEM-EDX). In two unoxidized and one oxidized ore samples, SXRF analyses have shown gold to be present predominantly in discrete clay-rich and silicified areas. Gold was not detected by SXRF in association with pyrite or carbonaceous materials. SEM-EDX examination of the gold-bearing areas in the unoxidized samples succeeded in identifying only two free gold particles, 0.2 and 0.5 ~m in size. In the oxidized sample, gold particles appear to be larger (but still submicroscopic) in average size and more evident in micro-optical examination after SXRF location of goldbearing areas. The findings of these studies may help to improve the efficiency of processing and recovery of gold from unoxidized ores.

Jan 1, 1987

By Sergio N. Monteiro

Jute fabric obtained from discarded sackcloth is a promising low cost and post-used material being considered as reinforcement of polymeric matrix composites. In particular, the combination of this fabric with a recycled plastic constitutes an environmentally correct composite with both economical and environmental advantages. The present work investigates the toughness of recycled polyethylene composites reinforced with up to 40 wt% of post-used jute fabric extracted from discarded sackcloth. Standard Izod notched specimens were impact tested and the results showed an increase in toughness with the amount of jute fabric. Observation of the composite fracture by SEM revealed that the fabric weave, in spite of damages caused by the previous use of the sackcloth, act as an effective obstacle to crack propagation.

Jan 1, 2009