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By Pietro Navarra

Cooling of critical furnace equipment to produce freeze lining is of particular interest as many metallurgical processes are intensified while attempting to prolong campaign life. This idea was combined with high-capacity heat pipes in the design of a copper slag launder. The design methodology of the launder and heat pipe cooling system is examined in this paper. With reliable material properties and operating conditions, CFD was used to quantitatively predict the skull thickness and the corresponding heat load applied to the slag launder. The operational limitations of heat pipe technology were considered and an appropriate cooling system was incorporated into the model. Parametric modeling was used to simulate several launder and heat pipe configurations. The generated results were then used to optimize the design of the launder, which was built and tested in August of 2005. The experimental performance of the cooling system is evaluated and compared with the model results.

Jan 1, 2006

By M. Hochenhofer

Due to economic aspects and environmental regulations recycling of slag and waste from ferroalloy production became a very important issue for the companies during the last years. The treatment of slag depends prior on the composition, especially on their content of valuable metals and impurities. The final aim should be a total re-use of these materials in the industry e.g. cement industry, pig-iron production etc.. Therefore, to reach the required physical and chemical properties for a further use, possibilities of a metallurgical treatment have been investigated. The conditioning of slag with a high V-, Mo- and P-content via reducing metal bath showed to be one alternative. To determine the optimal process parameters, practical investigations with different slag compositions and thermodynamic calculations were carried out.

Jan 1, 2006

By Pengfu Tan

Converter slag chemistry control has played an important role in optimizing converter operations. A thermodynamic model of copper P-S converter has been developed to predict the behavior of magnetite in the converter slag. Predictions of bath temperature, slag and matte compositions, and magnetite content in the slag have been validated by industrial data. The effects of fluxing strategy, returns and skim charges, oxygen enrichment, and temperature on the magnetite formation in the slag have been predicted and discussed. Some improvements of the industrial operations have been presented.

Jan 1, 2005

By Othon do Rêgo Monteiro Neto

[The present study has investigated the extraction of copper from a chalcopyrite flotation concentrate using an adapted strain of Thiobacillus ferrooxidans and shake flasks, tank leaching and Warburg respirometer techniques. From the shake flask experiments, the activation energy and the frequency factor have been determined to be ?ka = 59.4 kJ and A = 3.3 x 105 S-1, respectively. The temperature coefficient was found to be Q10 = 2.2 in the range of 20 to 35°C. It was suggested that the reaction mechanism of chalcopyrite leaching by T. ferrooxidans involves the formation of an activated complex. whose thermodynamic values have been calculated to be ?G? = 92.1 kJ, ?S? -148.8 J K-1 and ?H$ = 47.8 kJ. The maximum volumetric oxygen mass transfer coefficient for the reactor leaching was found to be achieved by using an optimum air flow rate of 1970 cm min l at a rotational frequency of 1000 min-1. The highest copper extraction in tank (reactor) leaching experiment was 86.8% after 17 days of leaching, while in the sterile runs the corresponding copper extraction was only 40.1%. The copper extraction was suggested to be diffusion controlled. The power requirement of the aerated reactor was calculated to be Pg = 2.02 watts. During leaching, the oxygen saturation concentration was found to be C* = 6.70 mg dm-3. Using the gassing out method the critical oxygen concentration was assessed to be CCrit 0.05 mg dm 3. From the Warburg experiments, the kinetic parameters of the Monad equation were derived with a new evaluation technique to be Vmsp = 9.0 µm3 02 min-1 mg protein-1 and K = 7.4% pulp density for the effect of substrate concentration. The order of reaction and the overall reaction rate constant were determined from the modified van't Hoff plot to be n = 0.0 and k = 1.49 p dm3 02 min-1 mg Protein -1 for the chalcopyrite concentrate oxidation by T. ferrooxidans. On the basis of this experimental work, a preliminary flow sheet has been proposed for the bioextraction of copper from flotation concentrates.]

Jan 1, 1985

By J. R. Donald

For processing copper, continuous converting has been successfully employed in a variety of locations, but for nickel, there has yet to be a successful commercial implementation of continuous converting technology. At Inco?s Copper Cliff smelter, there are specific requirements for the production of Bessemer matte relating to downstream processing that makes continuous converting for nickel mattes even more challenging. The nickel carbonyl refineries require very low iron levels in the matte, and the sulphur deficiency must be carefully controlled such that the appropriate quantity of PGM-rich metallics are produced from matte separation. The present paper outlines continuous converter technologies that have been implemented in copper, and evaluates their potential for nickel converting. The challenges of producing a Bessemer matte to the required specifications are discussed. The economic and environmental driving forces, and the challenges of justifying a novel technology in place of productive existing equipment, are discussed.

Jan 1, 2005

By Vijaya Thangavelu

Biological leaching of low-grade nickel laterite is based on a non-traditional leaching of oxide minerals using heterotrophic micro-organisms. The organisms solubilise metals by excreting organic acids; these acids then form complexes with heavy metals. High salinity of water supplies and soils in the vicinity of nickel laterite ore bodies is a major abiotic stress to fungi and represents a major challenge in the application of bioleaching process in-situ. Salinity exposes fungi cells to Na+ toxicity and osmotic stress. This study examined the salt tolerance development of Aspergillus foetidus based on gradual acclimatization of organism, its salt threshold and the salinity effect on its metabolism. The biological leaching of weathered saprolite ore with the resulting halotolerant organism under saline conditions was assessed. It was observed that salinity stress affected the organism?s growth and energy utilization

Jan 1, 2006

By Kim Fagerlund

Boliden Harjavalta Oy operates a copper smelter in Finland, which is based on flash smelting together with Peirce-Smith converting of copper matte. This paper reviews a case study when a high arsenic feed mixture was successfully eliminated in order to guarantee the anode quality. Based on theoretical and practical knowledge in slag chemistry at Outokumpu Research, the CaO-fluxing practice was introduced. Description of a thermodynamic simulation using MTDATA and implementation of the results into converting practice is given. Results showed that the impurity fluctuations in raw materials could be effectively controlled by efficient utilization of different slag chemistry.

Jan 1, 2005

By Andrew Wessman

Keywords: Recycling, Electrodeposition, Recovery, Dilute, Dissolved Metal Ions In order to facilitate the recovery of pure metals from solutions containing a mixture of dissolved metal ions, a pulsed electrodeposition method was developed. Using this method, it is possible to selectively remove metal ions from solution based upon the electrochemical potential of the particular ion desired. The use of pulsed electrodeposition rather than direct current electrodeposition creates an electrodeposited material with better morphology, increases electrical efficiency of the process, and avoids problems with short circuiting between electrodes. Using this method, it is possible to recover dissolved metal ions in a purified form in one simple step, and therefore maximizes recovery of the metal ions while obtaining them in a saleable form. This method is likely to be useful in improving the recycling process for numerous complex metal mixtures and alloys.

Jan 1, 2005

By Qingzhu Li

The brewing industry byproduct, spent grain (SG), was evaluated for its ability to adsorb Ag(I) from aqueous solutions. Ag(I) adsorption was dependent on solution pH, contact time, adsorbent dose, initial Ag(I) concentration and temperature. The kinetic data were well described by pseudo-second-order kinetic model, indicating that chemical adsorption was the rate-controlling step. The equilibrium data followed Freundlich isotherm rather than Langmuir isotherm, suggesting heterogenity of the adsorption sites on spent grain. Ag(I) desorbed from Ag(I)-loaded spent grain was also evaluated in this study. HCl, NaOH, Na2S2O3 and ultrapure water were chosen as eluants and desorbed Ag(I)-loaded spent grain for 30min, Ag(I)-loaded spent grain desorbed in 0.1M Na2S2O3 exhibited higher elution efficiency as compared with other eluants. The results indicated that application of spent grain for adsorption and recovery of silver from aqueous solutions was feasible.

Jan 1, 2009

By Yavuz Ali Topkaya

Rare earth ferrosilicide is a versatile alloy mainly used to control the detrimental effects of sulfur in steel and to modify graphite structures in cast iron. The aim of this study was to determine the optimum conditions to make rare earth ferrosilicon alloy using a preconcentrate produced from a bastnasite type of ore present in the Beylikahir-Eskisehir region of Turkey. This concentrate contained 23.5%REO, 41.37% CaF2, 10.69% BaSO4, 8.50% CaCO3, 4.18%Fe2O3, 2.83% Al2O3, 2.74% SiO2, 1.20% P2O5 and small amount of other oxides. The initial metallothermic reduction of this concentrate using ferrosilicon and aluminum in a graphite crucible placed in a muffle furnace gave very low recoveries due to the difficulties encountered in adjusting the slag composition, temperature and amount of additives. Therefore, two batches of rare earth oxide concentrate containing 61.1% and 81.7% cerium oxide, respectively, that were procured from a Turkish glass producer, were used to optimize with respect to temperature, duration, slag-making additives and amount of reducers. In these experiments, smelting and reduction was done in an induction furnace with graphite crucible, and, ferrosilicon and aluminum were added after melting the charge. As a result, there was no difficulty in obtaining a rare earth ferrosilicon alloy containing 35-55% RE, 5-25% Fe and 20-40% Si, with about 80% metal recovery. When the optimum conditions were applied to the preconcentrate, alloys of similar compositions were obtained with 70-80% recovery. Experiments were also done with mixtures of preconcentrate and rich concentrate, and, recoveries as high as 95% were obtained. Only in this case, to increase the recovery, mixtures had to be charged to the empty graphite crucible after heating the crucible to the required temperature.

Jan 1, 2006

By Melissa L. Trapani

Keywords: Copper, Taphole, Flow Instability. ?Blister spitting? is a flow irregularity where the molten blister copper stream ? or part thereof ? sprays from the taphole exit rather than following a regular flow profile to the collection box. As well as being a general ?housekeeping? issue, the unpredictable nature of the flow is a threat to operator safety. Also, the aggressive flow pattern may contribute to the mechanical wear of the taphole refractory, compromising the integrity of the taphole. This paper brings together a collection of first-hand observations and reports from process personnel, and suggests some theories as to the causes of blister spitting.

Jan 1, 2005

By Luciano R. G. Santos

Keywords: biosorption, cadmium, copper, biomass, spent zeolite. The majority of the industrial activities produce some kind of solid wastes. In this work two industrial residues (spent zeolite and wood sawdust) were chemically modified to increase their heavy metals sorption capacities. Manilkara longifolia (a Brazilian plant known as parajú) sawdust was first treated with NaOH and modified with different citric acid concentrations (0.6-1.2 mol/L) at 120°C, for 90 min. Infrared spectroscopy confirmed the presence of carboxylate groups in the wood structure as result of their mixing. Similarly, spent zeolites were also submitted to a chemical treatment (NaOH) to remove carbon deposited during oil cracking and to recover its sorption capacity. Batch experiments carried out at ambient temperature showed that both materials present sorption capacity for copper and cadmium comparable to weak acid ion exchange resins. A maximum of 78 mg-Cd/g and 59.7 mg-Cu/g as well as 29.9 mg-Cd/g and 14.6 mg-Cu/g were observed for the sawdust and the zeolite, respectively. The results were modeled according to the Freundlich and Langmuir equilibrium isotherms and compared with results of other studies.

Jan 1, 2005

By Eun-young Kim

Electrogenerated chlorine leaching of waste printed circuit boards was investigated in hydrochloric acid solutions. The pulverized printed circuit board contained about 37.6% of metal component, in which copper was about 83.6%. The leaching rate of copper was greatly affected by current density and agitation speed. The leaching of copper up to 98% was achieved at 20 mA/cm2, 50?, 180 minutes, and 600 rpm in 1M HCl solution. Increasing agitation and lowering current density enhanced utilization efficiency of electrogenerated chlorine. Leaching of copper was suppressed at initial stage, while the minor metal elements, such as aluminum, lead, and tin, were dominantly leached out.

Jan 1, 2006

By Z. Sun

Magnetic fields have been used for inclusions removal from melt and preparation of materials with gradient compositions. Fundamental in these applications is that the induced magnetic forces on the particles/melt can enhance migration and change the interaction behavior. In the present paper, migration and interaction behavior of electrical-insulating particles in a conductive melt under strong magnetic field are theoretically analyzed. It is found that the migration can be considerably enhanced for micrometer sized particles by applying a strong magnetic field. In addition, two forces are involved in the interaction between two particles: the interparticle magnetic dipole-dipole attractive force due to magnetization and the repulsive force induced by flow of the melt. This theoretical analysis renders a better understanding of recent experimental results. Additionally, a new method by using strong magnetic field can be proposed to control the particle size distribution for the preparation of metal-matrix composites.

Jan 1, 2009

By Masaki Imamura

A novel hydrometallurgical process for copper concentrate treatment has been developed by Niihama Research Laboratories of Sumitomo Metal Mining Co., Ltd. The process has numerous advantages with respect to the operational and environmental aspects. For example, copper is leached effectively from chalcopyrite concentrates by chlorine gas under atmospheric pressure. The copper in the leach solution is then separated from iron and silver by solvent extraction and undergoes electrowinning for its recovery as a highly pure copper metal; this does not require any further purification. Moreover, iron metal can be produced from the purified raffinate by electrowinning without generating a large volume of goethite or hematite, which are solid wastes generated due to iron rejection in common hydrometallurgical processes. This process can also realize the efficient recovery of precious metals. The results of batch testing and continuous-operation testing are presented in this paper.

Jan 1, 2006

By Yunnen Chen

This work concerns the removal of zinc(II) and COD by means of sawdust obtained as a by-product from locally used wood. The zinc(II) and COD removal study has been carried out batchwise where the influence of physico-chemical key parameters such as tree species, pH value of solution, temperature and contacting time and dosage of adsorbent have been considered. The maximum percent removal was attained at pH 9 all for Zn(II) and COD after about 60 min. The adsorbent can be effectively desorption using 0.1 M HCl. The experimental results showed that ion exchange maybe the major adsorption mechanisms for binding the divalent metal ions to the sawdust. Sawdust was a potential adsorbent for the removal of Zn(II) from the effluent of electroplating industry.

Jan 1, 2009

By Esher Hsu

In Taiwan, around 8,000 tons of batteries are consumed per year but only 17% of which were collected and transported to oversea for recovery. The dumping used batteries have become a potential environment problem. How to increase the collection efficiency of used batteries is an important issue for EPA in Taiwan. Besides, some treatment plants are on process to get permission for recovering used batteries. The objective of this study is to estimate the recycling cost of spent consumer battery and explore the feasibility of recovering used consumer batteries in Taiwan based upon the principle of cost-efficiency. The recycling cost including collection cost and recovery is estimated based on a survey. Results would provide some suggestions to Taiwan EPA regarding feasibility of recovering used batteries in Taiwan.

Jan 1, 2006

By Godwin Beene

During recent years, copper and acid production from Nkana Smelter has formed a significant proportion of ZCCM's total output, but a number of problems affecting the smelter over the last decade have only been recently overcome. This paper discusses recent developments in the smelting practice, highlighting some of the operational problems experienced and associated solutions. The smelter performance over the decade is discussed and the innovations in the smelting technology employed to sustain production in the wake of limited re-capitalization are dealt with in detail.

Jan 1, 1999

By Pengfu Tan

The control of converter slag chemistry and slag viscosity has played an important role in optimizing converter operations. A thermodynamic model of copper P-S converter and a viscosity model of converter slag have been used to predict the chemistry and viscosity of converter slag. The effect of oxygen potential, SiO2/Fe in slag, detection of slag blow endpoint, and temperature on slag viscosity, liquidus temperature of converter slag and skimming operation has been discussed. Some applications of the industrial operations have been presented.

Jan 1, 2006

By He De-wen

The influence of wastewater containing benzene from chemical industry by technology combined blow-off with Fenton reagent oxidation was experimentally studied. The present results suggest that the technology combined blow-off with Fenton reagent oxidation can effectively remove benzene pollutant in wastewater. The main factors that influence the removal benzene such as temperature and blowing time and volume, pH and reagent dosage of H2O2 and Fe2+ are studied and the optimal experimental conditions are as follows: time 20min, temperature 40i, air-blowing volume 0.4L/min, pH value 5, and H2O2 and Fe2+ dosage 2mL/L and 200mg/L respectively. Under the above conditions, benzene pollutant can be removed up to 97%. Compared to other removal ways of wastewater containing benzene, the technology combined blow-off with Fenton reagent oxidation is more effective and has the advantage of high speed.

Jan 1, 2009