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By John Frederick Colloghon, O&apos

Bulong remains the only hydrometallurgical process plant in the world that recovers nickel and cobalt directly from high pressure acid leach (HPAL) laterite leach liquors without need for precipitation of an intermediate product (e.g. sulphide, hydroxide or carbonate). Direct solvent extraction (DSX) of both nickel and cobalt in combination with electrowinning of nickel has been operation at Bulong since early 1999. Focus in the first years has been on ramp-up and resolution of commissioning problems. More recently the focus has been on de-bottlenecking and process optimisation. A number of significant process problems have been resolved, the most difficult being the formation of gypsum in the nickel solvent extraction circuit. Sound control of process chemistry is essential to ensure the production of high quality nickel and cobalt products at the lowest possible cost. This paper describes the numerous changes and enhancements to the process chemistry and plant equipment at Bulong and discusses the importance of ore leach chemistry on downstream impurity metal removal. Potential additional enhancements to further reduce unit costs are also presented.

Jan 1, 2004

By G. Riverin, C. Simard, W. D. Stevens

"An on-line technique to measure the efficiency of decoating I delacquering processes is being developed by Alcan' s Arvida R & D Centre. Decoating processes are used to remove moisture and coatings from shredded coated material such as Used Beverage Containers (UBC) before melting. Complete removal has been demonstrated to maximize metal recovery. Quantifying the weight of carbon and organic residue adhering to the shred surfaces is very difficult to measure directly, as the material can be highly folded. The technique developed indirectly measures the residue remaining by analysing the concentration of CO evolved in the decoater end zone exhaust gas.A commercial CEMS (Continuous Emission Monitoring System) incorporating an infrared type CO gas analyser was modified for on-line process exhaust gas analysis. Both pilot and plant trials had demonstrated that the CO concentration measured was inversely proportional to the efficiency of the organic removal achieved. As the quality of coated purchased scrap can be highly variable in moisture and organic content, continuous measurement should permit adjusting the feed rate and other decoater process parameters to the quality of decoating required."

Jan 1, 2000

By Peng Fan

Nitride capacity is usually employed as the measure of slag?s ability to remove nitrogen from liquid metal, since nitrogen distribution ratio between slag and metal can be calculated from nitride capacity provided that the value of oxygen activity in liquid metal is available. However, during liquid metal refining processes, oxygen activity in liquid metal is usually unknown and thus it is impossible to get nitrogen distribution ratio from nitride capacity under this usual condition. In this paper, thermodynamic analysis indicates that the activity coefficient of nitride in slag can be used to measure slag?s ability to remove nitrogen from liquid metal, because nitrogen distribution ratio between slag and metal can be calculated from the activity coefficient of nitride in slag provided that the content of oxygen potential controlling element like Al in liquid metal is available. Review of reported nitrogen removal studies and our recent study has verified that for a given Al content in metal, the lower the AlN activity coefficient in slag is, the higher the nitrogen distribution ratio. Titanium monoxide based slag has been found to be much more effective to remove nitrogen than other slags. Since Al content in liquid metal is usually available during liquid metal refining processes, AlN seems to be a better measure of slag?s ability to remove nitrogen from liquid metal.

Jan 1, 2006

By Justin Karl, Ali Gordon, James DeMarco, Yongho Sohn

"Aluminum metal-matrix composites are lightweight materials that have the potential to supplant steel in many applications. The current work helps to identify the parameters that confer maximal strength and ductility. Torsion tests were performed on the as-cast aluminum metal-matrix composite A359-SiCp-30% at a variety of temperatures and twist rates. Dependence of material properties on temperature and strain rate were identified from equivalent stress-strain curves constructed from the reduced data. Examination of the microstructure was performed on the as-cast material and on fracture surfaces. A temperature-and strain rate-dependent constitutive model was applied to simulation of the mechanical response of the torsion specimen. Trends in material properties corroborate and extend trends identified previously under tensile loading with regard to temperature and strain rate dependence. Shear properties of simulated specimens agree with properties obtained through experimentation.IntroductionAluminum metal-matrix composites (A1-MMCs) have become increasingly popu1ar in recent years. While unreinforced aluminum alloys have low densities and high ductilities, they are not suitable for many applications due to their lack of strength and stiffness. To provide added strength and stiffness while maintaining favorable densities, it has become common to reinforce aluminum alloys with silicon carbide in various forms, although usually the inclusions are in the form of whiskers or particles. The result is a composite material with superior specific strength and stiffness. While whisker-reinforced composites are expensive due to the necessity of processing by nonstandard techniques and have low transverse properties when rolled, particle reinforced Al-MMCs have transverse material property values almost as high as the longitudinal properties and are not as expensive to process as whisker-reinforced Al-MMCs [1]."

Jan 1, 2012

By Samir N. Shoukry, Mourad Y. Riad, Gergis W. William

"Setting of concrete material is defined as the transitional period between states of true fluidity and true rigidity. Initial and final setting times are measured in the laboratory on the mortar sieved from the mix in a controlled environment where temperature and moisture values are constant. On the other hand, field applications are held in outdoor environments where environmental variations have direct impact on setting time values. In this study, initial setting time of class K concrete, usually used for bridge decks and concrete pavements, are investigated highlighting discrepancies between laboratory and field measurements. 72 mixes have been cast in variable environments and collected data from concrete mixes and the ambient conditions are reported. In light of the collected data, the effects of variable setting times on early age cracking of concrete material are studied and means to minimize such cracks are presented.BackgroundSetting of concrete material is defined as the transitional period between states of true fluidity and true rigidity [1]. Continuous hydration of the cement within the matrix transfers the mix from a state of setting to hardening. Initial and final Setting times are measured in a laboratory setting following ASTM C 403 specifications. Initial setting approximates the time at which the cement paste can no longer be plastic under compaction (or can be handled in a proper fashion), while the final setting approximates the time at which hardening occurs. The standard test described in ASTM C 403 is conducted on the mortar sieved from the mix (paste passing from 4.75 mm sieve opening). Initial and final settings are described as the elapsed time after the initial contact of water and cement till the mortar reaches a penetration resistances of 3.5 MPa (500 psi), and 27.6 MPa (4000 psi) respectively."

Jan 1, 2012

By Alexandr I. Volkhin

It is practically useful to separate copper from nickel at the fire refining stage of blister copper by transferring nickel in electrochemical inert silicides which are being concentrated further into the tank-house slimes. The treatment of copper melt by silicon-containing reagents is resulted in lowering the interfacial tension of the melt, its deoxidizing, selective siliconizing of in-melt nickel and forming a by-product with fluxing properties. Si-containing reagents have positive influence on results of fire and electrolytic refining, and further pulverizing of copper in plant conditions.

Jan 1, 2006

By Donald R. Sadoway

Fused salt electrolysis is used extensively in the primary extraction of metals (electrowinning), in the refining of metals (electrorefining), and in the formation of coatings (electroplating). In the case of rare earths, fused salt electrolysis competes with nonelectrochemical processes to make the same products. However, fused salt electrolysis has the potential to produce these metals in a variety of technologically useful forms: thin films and epitaxial layers, powders, and a variety of nonequilibrium structures. The theory and practice of fused salt electrolysis as it applies to the extraction, refining and plating of rare earth metals are described. The potential of fused salt electrolysis to synthesize advanced materials containing the rare earth elements is assessed.

Jan 1, 1989

By Hong Yong Sohn

On the occasion of this symposium in my name, I reflect upon the contributions of my academic mentors and early associates who helped shape my professional career. I was fortunate to have these people around me during my graduate work and at the start of my professional career. In forming my view of the technical field and career, they represented academia, research institutions, industry, and different parts of the world.

Jan 1, 2006

By R. J. Wesely

Non-ferrous smelters traditionally have a hot gas handling system. In these systems, the dust is captured as a dry material which is often recycled to the process. Some smelters use wet gas cleaning methods with the recovery of the dust as a wet sludge. Although this sludge can be recycled to the process, in some cases it is preferable to dispose of the sludge. This paper will discuss the disposal methods available and specifically will deal with one type of sludge which has a high arsenic and high lead content. Problems with this sludge were investigated and methods were tested with the aim of stabilizing the sludge so that it passes the EPA TCLP test. Results of the laboratory tests are given.

Jan 1, 2000

By Julian Szekely

Transport phenomena, that is heat transfer, mass transfer and fluid flow, play a critical part in the operation of metallurgical reactors. In this paper, we shall present a review of our current state of ability to model these systems mathematically, with emphasis on the use of computational codes that are generally accessible to the public and on the comparison of the theoretical predictions with measurements.

Jan 1, 1993

By Kurt Westerlund

The design of the economically most profitable and technically most feasible smelter process gas handling .and treatment as an integrated part of the total metallurgical process is discussed and exemplified, with alternative flow sheets including material and energy balances, investment and operating costs. Retrofitting and de-bottlenecking of existing gas handling lines will be described and exemplified. Methods of increasing total gas handling line availability will be described.

Jan 1, 1992

By Kurt Westerlund

The design of the economically most profitable and technically most feasible smelter process gas handing and treatment as an integrated part of the total metallurgical process is discussed and exemplified, with alternative flow sheets including material and energy balances, investment and operating costs. Retrofitting and de-bottlenecking of existing gas handling lines wil1 be described and exemplified. Methods of increasing total gas handling line availability will be described.

Jan 1, 1992

By D. P. Briand

Falconbridge Limited operates a smelter in Sudbury, consisting of fluid bed roasters, acid plant, electric furnaces and Peirce-Smith converters, to treat local concentrate and other custom materials. The products are a low iron, nickel- copper-cobalt matte and sulphuric acid. This paper describes the operation and highlights some of the recent efforts to improve human resource effectiveness, to reduce sulphur dioxide emissions and ground level concentration excursions, to develop and expand the custom feed business, to improve productivity and performance in safety and hygiene, and to improve furnace integrity and process control.

Jan 1, 1993

By Robert S. Sokolowski

The future of Materials Processing in Space (MPS) in the Space Station Era is being assured today by a strong coordinated science program which looks to solve these problems, the answers to which serve to underpin the technical foundation upon which future metallurgical and materials processes will be built. The critical link between the product and process development activities that accompany this science endeavor is the "nuts and bolts" hardware that will ultimately operate in the space environment. Ground-based facilities including drop facilities and aircraft provide excellent product development and process concept study tools. Shuttle flights with Spacelab and commercially developed space facilities represent the evolutionary path to Space Station processing facilities. Today the most promising areas of MPS are crystal growth, containerless, and quasicontainerless processing. The unique features of these processes will be highlighted. Finally a more visionary perspective of MPS will be presented that incorporates the limits of today's knowledge with the economic "necessity" of tomorrow.

Jan 1, 1988

By Hong Yong Sohn

On the occasion of this symposium in my name, I reflect upon the contributions of my academic mentors and early associates who helped shape my professional career. I was fortunate to have these people around me during my graduate work and at the start of my professional career. In forming my view of the technical field and career, they represented academia, research institutions, industry, and different parts of the world.

Jan 1, 2006

By Admire Chaendera

A gas jet was blown through submerged nozzles to stir the bath in the presence and absence of slag. Mixing and mass transfer rates were then studied. Water and kerosene (10% by volume) were used to simulate the metal and slag phases respectively in the cold model. The mixing time (Tmix), defined at 99.66% bath homogeneity level, increased with bath height and decreased with an increase in the gas injection rate. Its value in the model vessel was related to gas flow rate (Q), bath weight (W), and bath height (H) by, Tmix = 4.39Q-0.73W0.24H1.12. Inclusion of the slag phase increased Tmix by about 16% and the mass transfer parameter, [(Reloc,r)0.25(Ret)0.32], values by about 32%. Mass transfer rates were higher near the bath surface and in the gas-liquid plume region. They increased with gas flow rate but decreased with an increase in bath height. The relationship, K Q0.08, showing derived mass transfer coefficient (K) dependence on the gas injection rate (Q) was established. The proportionality constant in the equation varied with gas flow rate and sample location.

Jan 1, 2006