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By L. E. Murr

Preliminary studies of bacterial attachment to MoSp (molybdenite) have indicated a low correlation between dislocation density in the (0001) basal plane and the density of attached microbes. In the present investigation, poly- crystalline thin sections of CuFeSp (chalcopyrite) have been ion-etched or carefully comminuted to electron transparency and observed in the transmission electron microscope. The thinned test sections were then immersed in a culture solution in which bacterial attachment occurred. The attached bacteria were biologically stained in a uranyl acetate solution and the entire thin CuFeSp sections or tiny particles containing thin, electron transparent edges with bacteria attached were observed in the transmission electron microscope, allowing the coincidence of bacteria and their density to be directly observed in relation to lattice dislocations and crystallographic orientations of the exposed surfaces. This technique has the advantage of exposing crystallographic orientations where dislocation lines intersect the free mineral surface, and the emergence sites of dislocations could in principle be directly investigated as a possible preferential attachment site for bacteria. Bacteria morphologies were also extensively observed in the scanning electron microscope. The implications of the results are that although a strong correlation between dislocation density and distribution and bacterial attachment, density, and distribution has not been established, systematic multiplication of dislocation densities in crystalline mineral particles to be leached could enhance leaching rates by increasing the reaction rates as well as the density of attached bacteria at crystalline, metal-rich phases. Techniques for dislocation production in mineral and ore bodies and the particular implications in chalcopyrite leaching are discussed in relation to in-situ leaching where comminution is attained by explosives and the generation of strong shock waves in an ore body. The present study demonstrates the use of microanalytical and microscopic techniques in the investigation of fundamental microstructural phenomena in hydrometallurgical processes.

Jan 1, 1976

By A. Korbel

The progress in understanding the nature of strain localization in metallic materials and in particular the understanding of the role of external (deformation conditions) and internal (material substructure) factors in the development of the tendency toward concentration of plastic flow within transgranular shear bands was the background of the concept given in the title. Following this idea, the practical possibility of replacing the homogeneous in a micro scale mode of deformation by transgrasnular shear bands gives a chance to change the arrangement of the dislocation substructure in the material from that typical for homogeneous deformation into long wavelength (transgranular), pseudo-periodic dislocation walls. The presence or formation of such a substructure in a thermodynamically unstable matrix may result in the formation of the products of phase transformation along shear bands, giving rise to a composite-like structure. This work is aimed to provide a coherent justification to the concept of Natural-Metal-Matrix Composite and summarizes the results of experimental works in this area.

Jan 1, 1997

By B. W. Lightfoot, Neill F. Arthur

"The AusIron process is a new development of the well established Ausmelt bath smelting technology(l). The development of this technology has been tied to the South Australian Steel and Energy (SASE) project which brings dedicated coal and iron resources together with this new technology. SASE is a joint venture between Ausmelt (40%), Meekathara Minerals (40%) and the South Australian Government through Mines and Energy South Australia (MESA) (20%). It will use a multiple lance furnace to process iron ore using steaming coal for both fuel and reductant.It is intended to build the simplest plant economically possible. Refinements such as preheating and prereduction of the ore are compatible with the technology but are not expected to be necessary in the first generation plant.The joint venture is negotiating with suitable partners for funding of the project through to commercial implementation at a target scale of2.5 mt/a of pig iron.ObjectivesAusIron aims to produce pig iron directly from steaming coal and from any of a variety of iron sources in a simple furnace system with a minimum of pre-processing of either coal or iron ore. Preheating and prereduction of ore are compatible with the technology but may not be necessary. The immediate aim is not to be the technology that uses the least quantity of coal to produce iron metal but rather the technology that uses the least number of dollars to produce metal.The chemistry of iron making is well known, probably better known than that of smelting of any other metal. Iron has been made for thousands of years and it is possible to make iron from charcoal and ore in a simple blast furnace the size of a beer barrel. The focus is therefore not making iron but rather making it more cheaply than it is made by current technologies. Large blast furnaces now set the standard and new technologies must perform better if they are to gain market share. It is still the cost of iron, energy units and capital going into these mega blast furnaces which ultimately set the market price for pig iron."

Jan 1, 1996

By J. W. Dini

Introduction The mission of the Materials Fabrication Division (MFD) is to provide fabrication services and technology in support of all programs at Lawrence Livermore National Laboratory (LLNL). MFD involvement is called for when fabrication activity requires levels of expertise, technology, equipment, process development, hazardous processes, security, or scheduling that is typically not commercially available. Customers are encouraged to utilize private industry for fabrication activity requiring routine processing or for production applications. MFD is .a large diversified service organization including approximately 400 full time employees. The group provides a wide variety of processes including all common machining and fabrications operations, laser and water jet cutting, electrical discharge machining, lapping, electron beam and laser welding, vacuum brazing, heat treating, forming, electroplating and metal finishing, optical polishing and grinding, vacuum coating, vacuum engineering and a variety of plastics operations. These operations occupy more than 1,250,000 square feet of floor space. For more detail on the many fabrication related services available from MFD, see Reference 1.

Jan 1, 1992

The copper concentrate market is becoming increasingly unstable. In the early 1990s large concentrate stocks were built up and the glut was cleared only after treatment charges rose so sharply that 'non-traditional' custom smelter capacity, such as in Kazakhstan, could be employed, By 1994 the market had shifted and Western smelters were unable to secure enough concentrates to operate full out. The reason for these sharp swings in the market balance is that virtllally all the recent mine development has been non-integrated. With different companies developing new mine . and smelter capacity, it is inevitable that the pace of expansion in the two sectors will not be coordinated. For many years the Japanese smelters were the major buyers from the new mm-integrated mines. However, Japanese smelter capacity is unlikely to increase appreciably in the future and this stabilizing influence will be very difficult to replace. This paper will examine the likely concentrate/smelter balance over the next five years and will forecast the likely direction of? treatment charges. It will also touch on the critical variables in assessing the viability of new greenfield custom smelter capacity, such as proximity to concentrate sources, by-product sulfuric acid prices and, most importantly, tariff protection.

Jan 1, 1995

By John T. Berry, Robert D. Pehlke, Michael J. Beffel

"Pattern making and metal casting organizations are currently adopting CAD/CAM systems and implementing this technology in design and production. Al though significant progress has been reported, these systems generally are based on two or two and one half dimensional analyses. Very few are based on solid geometric modelers.The present paper emphasizes the need for solid geometric modeling of the casting and rigging system and linkage with a solidification simulator. The nature of some of the technological challenges which have slowed this development are discussed, including accurate description of complex surfaces and their intersections and the bridging of computer encoded information with NC technologies and with FEM-based simulators for stress and thermal analyses. A recently prepared modular-structured FEM simulation code implemented on a micro computer is described.Construction of a solid geometric model of the casting and rigging and validation of the combination for optimum characteristics of soundness, quality and yield by solidification simulation are I inked as key elements in the foundry of the future. Data base support for this CAD/CAM system is rapidly being developed throughout the world.INTRODUCTIONThe simulation of shaped casting solidification using the digital computer, goes back to at least the early nineteen-sixties when Forsund (1) in Denmark applied the technique to the problems of casting surface quality.Prior to that time, the work of Paschkis and co-workers using the analog computer ranges back to the nineteen-forties, when work sponsored by the AFS Heat Transfer Committee at Columbia University revealed many hitherto unknown or only partly anticipated aspects of casting solidification (2).Three reviews of the various historical aspects of simulation should be referenced. Firstly, the AFS monograph by one of the present writers (RDP) and his colleagues - describing background and later work, again sponsored by the AFS Heat Transfer Committee at the University of Michigan (3). Secondly, a review prepared by Durham and Berry (4) which discusses broad aspects of casting solidification simulation. Thirdly, a review by Erickson (5) which contains an excellent bibliography to 1980. In addition to these papers, the publications lists of the CADCAST project* and the proceedings of the two Engineering Foundation Conferences of Casting and Welding Modeling, published by ASME, are also most notable (6) •"

Jan 1, 1986

By Leonard J. Friedman

Modern smelting systems using continuous, flash and/or oxygen smelting processes have a significant effect on the choice of sulfur dioxide control processes and system arrangements. Based on gases from an enriched air or oxygen smelting furnace and copper converters the paper reviews and analyzes alternate processes and system arrangements for recovery of sulfur dioxide. The work indicates the choice system to include a conventional sulfuric acid plant for converter gas and a liquid SO2 plant to handle the high strength smelting fur¬nace gas. The liquid SO2 plant would be used as a fly-wheel to damper the flow and SO2 concentration variations of the con-verter acid plant. Potential energy recovery alternates and product flexibility are also reviewed.

Jan 1, 1983

By A. Lakschevitz

The Amazon region offers a large potential for gold extraction but its peculiar characteristics such as heavy rains, lacking of roads and general infra-structure, nature of the ore deposits, etc.. do require special care in plant design. REMETÁLICA has developed a know-how is designing leaching plants which have been demonstrated to be profitable under those tropical weather conditions. The solutions adopted are related to general process route, leach liquor distribution and flow pattern, conditioning of solids and effluent treatment. These plants, now operating in South America countries, demonstrate the success for the technology developed. A tipical plant with 800 t/day ore processing capacity, may require an investment of US$ 1.200.000,00, arid have? a pay back period of a few months, depending on ore grade.

Jan 1, 1989

By J. T. Stanley

The identification of crystal phases and crystal chemistry can be critical to understanding the mechanisms of waste material interaction with native soils. Understanding these mechanisms can suggest correct methods for remediation and treatment. A program is outlined and examples are given of the development of effective techniques for rapid phase identification of environmental samples using electron microscopy. The program concentrates on the development of integrated object oriented software to aid rapid searching of online databases and rapid simulation of potential crystal diffraction patterns. Examples come from dried sludge taken from a former hard-chrome plating facility.

Jan 1, 1993

By Robert Fritzsch, Ragnhild E. Aune, Mark William Kennedy, Behzad Mirzaei

"The quantitative particle concentration can give important information about the cleanliness of melts for quality control in primary and secondary production of aluminum. Manual quantification of the particle concentration is normally a time consuming process and human control can bias the acquired images and particle count.The present paper explains the automated image-processing steps for the quantification of SiC-particles, with equivalent diameters from 2 to 25 µm, in solidified A356. A total of 700 micrographs, acquired with a standard white light microscope with 10 x magnification, were analyzed. The applied software (Image Pro-Plus 7.0 from MediaCybemetics®) allows for programming of macros which in tum provides the user with a higher degree of control. The automated results are compared with the results obtained by manually counting the particles in the same micrographs. The impact of the automated results on the estimated filtration efficiency was established to be only -3%.IntroductionInclusions are both indigenous and exogenous particulates that are present in commercial metals such as aluminum. If large individual or large numbers of inclusions are present, they can have a significant negative impact on the appearance, mechanical and chemical behavior of products produced from the metal. Aluminum is known to contain large numbers of inclusions: =50 µm in size, e.g. typically <l ppm by volume or <100,000 inclusions of>20 µm per kg of metal as detectable using a Liquid Metal Cleanliness Analyzer, LiMCA [1]. Depending on the final application of the aluminum, inclusions can render the metal 'not fit for purpose', and result in serious economic consequences to metal producers.It is not surprising that the aluminum industry has developed a number of treatment processes to improve metal cleanliness, given the large number of high value products whose quality can be adversely affected by inclusions. CFFs are the most commonly applied filtration process and have been used to filter >50% of the world production of aluminum since the 1990's [2].Inclusions in aluminum may be particles, bifilms [3] or clusters of: oxides (Al2O3 , SiO2), spinels (MgO· Al2O3), carbides (SiC, Al4C3), nitrides (AlN), borides (TiB2), sulfides, phosphides and intermetallics [ 4]."

Jan 1, 2013

By Gabriel A. Torma

This paper provides infonnation on selected technologies available for remediation of metal contaminated soils and industrial effluent solutions. Because some of the industrial sites are contaminated with organics (solvents, gasolines and oils), an effort has been made to introduce the most frequently used cost-effective cleanup methods, such as "bioventing" and "composting." The microorganisms involved in these processes are capable of degrading organic soil contaminants to environmentally harmless compounds: water and carbon dioxide. Heavy metals and radionuclides contaminated mining and industrial sites can be remediated by using adapted heap and dump leaching technologies, which can be chemical in nature or bio-assisted. The importance of volume reduction by physical separation is discussed. A special attention is devoted to the remediation of soils by leaching (soil washing) to remove heavy metal contaminants, such as chromium, lead, nickel and cadmium. Furthermore, the applicability of biosorption technology in the remediation of heavy metals and radionuclides contaminated industrial waste waters and acidic mining effluent solutions was indicated.

Jan 1, 1996

By John Pilling

The concept of microstructure, its evolution through materials processing and its effect on the properties of the material is, perhaps, the foundation upon which the science of materials is built. PHAUST, a computer aided learning program, attempts to provide instruction in establishing the relationships between phase diagrams, thermal processing and microstructure. Using phase diagrams derived from a database or created by the user, the evolution of microstructure during processing is quantified using the lever rule and/or the Scheil equation and tracked through a doubly linked list (a form of binary tree). Microstructures, in the form of full colour cartoons are then drawn using the quantitative and logical information contained within the linked list using bitmapped templates and logigal operators such as NOT. AND, OR and XOR, giving the student a view of the structure as it would be seen under the optical microscope. The software provides complete diagnostics of student answers, locates errors and misconceptions as well as providing tutoring towards the correct solution method and answer.

Jan 1, 1991

By Tomoji Kawai

"The Pulsed Laser Deposition method using multi-targets is extremely useful for the creation of functional multi-layers and variety of artificial lattices. The topic of the present talk is on the creation of ''Function hannonized artificial lattices by laser ablation"" made of the combined magnetic, ferroelectiric and superconducting layers. The outline of talk is,1. Features of Pulsed Laser Deposition method (Laser Molecular RHEED and S1M/AFM.2. Creation of magnetic, dielectric and superconducting artificial lattices by Pulsed Laser Deposition.3. Novel properties of function harmonized artificial lattices: especially on the magnetic and magnetoresistive artificial The outline of talk is, lattices made of3d transition metal oxides."

Jan 1, 2000

By Dale T. Peters

Conductivity, both electrical and thermal, are attributes accounting for about 70% of the applications of copper and its alloys. This paper presents results of on-going research into two new applications that depend on copper&apos;s excellent conductivity. The Copper Development Association (CDA), together with materials and motor company partners, is working toward a solution to the key problem preventing pressure die casting copper for the conductor bar/end ring structure of the induction motor rotor, i.e., lack of a durable high-temperature mold material. Work is showing that a combination of high- temperature materials and elevated temperature processing gives much improved mold life compared to die steels. Substitution of copper for aluminum in the rotor can result in a 20% decrease in electrical losses in motors consuming 35% of electrical power generated in the U.S. The second development uses the excellent thermal conductivity of several high-strength high-copper alloys to simultaneously improve productivity and part quality in the injection molding of plastic parts.

Jan 1, 1999

By M. I. Kalashnikova

In hydrometallurgical technological flowsheets several methods of target components removal from solution are used. One of these methods is non-ferrous metals removal in the form of rich selective or collective concentrates. In the present work pyrometallugical mattes, thiosulphate containing solutions and pulps, iron powder with elemental sulphur and calcium sulphate were used as the precipitator. It was shown that depending on precipitator compound and process parameters non-ferrous metals precipitate from solution in the different forms with varying content of components including Ni3S2, NiS, Ni3S4, NiS2, (Ni,Co)S2, CuS; Cu1,765S; Cu1,97S.

Jan 1, 2006

By Xi Yun Yang

Ultrafine (0.1µm) spherical magnetite powder was prepared successfully by hydrothermal reaction of ferrous sulfate and sodium hydroxide with activated pyrite as reducing agent in the temperature range 120-140?. XRD and XPS analyses indicate that pH value and pyrite amount have a direct influence on the composition of the product. Stoichiometric Fe3O4 can be obtained only when pH value is 12 and the molar ratio of pyrite/ferrous sulfate is 1:1.8. The hysteresis loop of Fe3O4 shows a ferromagnetic behavior with a saturation magnetization of 75.2 emu/g and a coercivity of 152Oe.

Jan 1, 2006

By Yoshihiko Maeda

It is said that the 21st century will be an era of the remedy of the global environment. In order to reserve natural resources for the future and to avoid the dispersion of heavy metals after usage and to avoid pollution problems, it is extremely important to recycle heavy metals as much as possible by reasonable recovery procedures. The nonferrous metal industry is expected to play a important role in the recycling of heavy metals that are originally their products. From the depressed metal price experienced in Japan in 1980&apos;h due to the sudden change in current exchange rate between US dollar and Japanese yen, one of major nonferrous metal company, Dowa Mining, has diversified its business area not only to the so-called down stream, but also to the environmental business including metal recycling, industrial waste treatment and soil remediation by utilizing technologis and facilities once used or still used for mining and smelting of copper, zinc, lead and precious metals. In this paper some of these applications will be presented.

Jan 1, 2003

By David S. Dolan

To beat capital costs of US$10 per pound of installed capacity has appeared as a major hurdle for the "third generation laterite nickel plants. Forecast costs are escalating. Where can savings come from? Ore beneficiation can reduce the tonnage rate to be processed. High pressure acid leach options include the use of indirect slurry heating and higher operating temperatures to reduce flow rates and residence time. Progress has been reported in atmospheric leaching. High counter current decantation circuit settling rates and high underflow densities reduce CCD costs. Metal recovery options include direct from leach solution to metal production, as used by Bulong and espoused by Goro, and indirect recovery as used by Moa Bay, Murrin Murrin and Cawse. Plant location impacts on the costs of tailings disposal, power and energy costs, supply of consumables and labour costs, among others. Final nickel and cobalt metal production routes are electrowinning, hydrogen reduction or some innovative routes being proposed for Goro. This paper reviews the status in these developments, with particular reference to equipment and processes that offer lower capital costs. Keywords: Laterite, Nickel, Plant, Capital Cost

Jan 1, 2004

By David Tisdale, Phillip Mackey, Nagendra Tripathi, Matthew Kreuh, Pascal Coursol

Xstrata Nickel’s Sudbury smelter operation is based on fluid bed roasting of Ni-Cu sulphide concentrate, followed by electric furnace reductive smelting and Peirce-Smith converting to produce a Bessemer matte for electro refining, along with sulphuric acid produced from smelter gas. While the site dates back to the 1930s, the present smelter configuration has been operational since 1978, and currently has a nominal capacity of about 67,000 tpy of contained nickel and is investigating options to expand in future up to 85,000 tpy. As part of a review of plant capacity options, a new metallurgical model of the plant was developed in order to examine a number of processing alternatives. Based on the METSIM™ platform, the present model includes the ability to examine the impact of a number of plant parameters on potential plant performance including; for example, the following: percent of sulphur elimination in roasting, matte grade, degree of matte metallization, temperature, coke requirements, sulphuric acid production, CO2 emissions and overall energy requirements. The process model also includes a number of special features adopted; for example, approaches to effectively model the complex Ni-Cu-Co-Fe-S-O matte system. This paper provides a description of the model and gives an overview of the results. As well as presenting the results of the present study, the applicability of this modeling approach to pyrometallurgical systems in general is also briefly discussed in the paper.

Jan 1, 2009

By S. Sundarraj

The morphological transition between columnar and equiaxed structures is an important solidification phenomenon frequently observed in castings, especially complex parts with varying cross-section, The mechanical properties and the occurrence of defects such as hot tears are strongly dependent on the structure formed in the casting. Hence, it is important to understand the conditions leading to columnar or equiaxed structures. Although extensive work has been done in modeling solidification systems, almost all of the existing models are based on the assumption that the structure formed in the casting is either purely columnar or purely equiaxed. Prediction of the columnar-equiaxed transition (CET) requires a solidification model which accounts for the formation of both columnar and equiaxed structures, along with related microscopic and macroscopic solidification phenomena. In this paper a CET model is presented which: (i) takes account of both columnar and equiaxed structures, (ii) accounts for macroscopic heat transfer coupled with microscopic phenomena such as nucleation, growth and microsegregation, (iii) satisfies solute conservation, and (iv) is easy to implement in commercial finite element and finite difference software. The proposed model predictions of CET have been validated with available experimental results for a uni-directional solidification of an aluminum-copper alloy. A sensitivity analysis has also been carried out to determine the effects of various parameters on the CET model predictions. The model is being extended to other alloy systems and more complex geometries. This work will be published in due course.

Jan 1, 1996