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By Kazuya Koyama

We are studying the hydrometallurgical recycling process of indium from an Indium-Tin-Oxide(ITO) target. For this process, it is necessary to remove Sn(IV) ions from the aqueous hydrochloric acid solutions containing In(III). In this study, the removal of Sn(IV) ions by a potentiostatic electrolysis method was examined. The polarization measurements and potentiostatic electrolyses were carried out under a nitrogen atmosphere. In the Sn(IV) solution, current begins to rise at the cathode potential of -0.26 V vs. SHE, and increases with a reduction in the cathode potential. In the In(III) solution, current begins to rise at a cathode potential of -0.43 V vs. SHE. Metallic tin was electrodeposited without indium electrodeposition at the cathode potentials of -0.30 and -0.40V vs. SHE. More than 98% of the Sn(IV) was removed at the cathode potential of -0.40 V after the electrolysis for 3hrs. Both tin and indium were electrodeposited at the cathode potential of -0.50V vs. SHE.

Jan 1, 2006

By G. Mark Aylmore

Various processes have been developed using a combination of elevated temperature and chemical treatment processing to recover Li from silicate minerals. To facilitate further process development, a comprehensive understanding of the deportment of Li and associated minerals in ore bodies is essential to allow the industry to predict the response of ore reserves to metallurgical treatment options. This paper describes results from the integrated use of the John de Laeter Centre’s state of the art analytical and mass spectrometry techniques to characterise a selection of Li bearing ore bodies and determine their amenability to potential processing options for the extraction of Li. The mineralogy, mineral associations, and liberation characteristics of ore-bearing and gangue minerals were characterised using a combination of the TIMA and XRPD studies. The Li content and distribution within minerals were defined using LA-ICPMS and field emission scanning electron microscopy techniques (EBSD, ToF-SIMS) and atomic probe microscopy.

By Ari JokiIaakso

Three different sulphidic raw materials were treated in a laboratory scale laminar flow fur-nace simulating suspension smelting conditions. The materials were a pure chalcopyrite concentrate, a high-antimony concentrate (tetrahedritic), and crushed copper mattes. The gas preheating temperatures were 500 -1 100°C ana the atmospheres ranged from N2 to N2 -75 % O2, Two particle size fractions were used for the concentrates with x = 20 -38 um and x = 62 -74 um, and three for the granulated copper mattes with x < 37 um, x = 62 -88 um, and x = 125 -177 um. Scanning electron microscopy combined with energy dispersive analysis and backscattered electron analysis was used for determining the morphology and the mineralogy of the reacted particles. Fragmentation of the particles were observed in all materials during the flash oxidation, the conditions depending on the iron and sulphur content and the original particle size fraction of the material. The melting and/or reaction stages of the particles in different conditions were studied from powder samples. Polished sections were examined in order to follow the development of porosity and the mineralogy of the particles.

Jan 1, 1989

By J. Daniel Bryant

Deformation processing of rapidly solidified powder alloys presents a technical challenge different in several ways from the processing of ingot based alloys. The metastable phases formed during planar flow casting of aluminum alloy 8009 (FVS0812) must be safe-guarded from high temperature excursions during processing to avoid decomposition; this restriction prohibits liquid phase sintering of particles during consolidation. The development of strong particle-particle adhesion, therefore, relies on the imposition of very large strains during forming operations to insure sufficient mechanical meshing of the aluminum particles and break-up of prior particle oxide boundaries. These strains are generally much greater than those required for metallurgical transformations in ingot based alloys. In an attempt to quantify the deformation required to improve interparticle bonding, the finite element method (FEM) was employed. Preliminary results which predict the metal flow and strain distribution in several workpiece configurations are discussed. These predictions are then correlated to measurements made on experimental subscale forgings. Lastly, experimentally measured quantities which reflect the degree of interparticle bondingg are related back to FEM model predictions.

Jan 1, 1992

By V. I. Lakshmanan

Wastes when produced can be reused or recycled prior to disposal. Industries that cause environmental concerns during manufacturing include primary materials and primary metals. Pollution prevention mechanisms to achieve waste reduction require new separation, reclamation, control and process simulation technologies. Substituting recyclables for virgin resources will reduce energy use, water pollution, air pollution, water use and mining wastes. Shrinking landfill space will spur new technologies for waste treatment and recycling. These situations hence offer opportunities for innovative flowsheets with appropriate separation technologies. Development of innovative flowsheets to treat recyclables offer unique opportunities for process/product development, obtain green products and hence market advantage. The paper will illustrate with selected innovative flowsheets to treat recyclables.

Jan 1, 1996

By Charles H. Bucknam

A gold sampling optimization study was carried out in support of open pit gold mining operations for the Newmont Gold Company Bootstrap-Capstone deposits in Northeastern Nevada. Six bulk samples were tested using fire refining techniques at field particle size, to determine coarse particle heterogeneity of the ores, and by gravity .concentration methods at 10 mesh particle size, to observe any particulate gold liberation. An overall sampling model is presented for the deposit based on the pooled test information, to reconcile the results of coarse particle heterogeneity testing and the fine particle 'liberation testing. The sampling model is used to recommend procedures to control the variability of gold grade estimation due to the fundamental error (nugget effect) during sampling, sample preparation and assaying of the ores and other fundamental variances. The technique of simplified quantitative risk analysis (SQRA) is used to provide an economic justification for implementation of. recommended improvements to field sampling practices.

Jan 1, 1999

By Simon N. Lekakh, D. G. C. Robertson

A new integrated CFD-combined reactors approach is proposed for the description of processes in metallurgical vessels. CFD simulations were used to obtain the melt flow pattern in the vessels (ladle, tundish, and continuous caster mold). From these simulations, the characteristic curves were derived: (i) the residence time distribution curves (RTD) for flow-through systems (at tundish exit or at dendrite coherency surface in the mold) and (ii) the mixing curves for closed systems (ladle). In the next step, the melt flow was represented in a “combined reactors” system consisting of a combination of unit reactors (Plug Flow, Mixer, and Recirculated Volume). An inverse simulation was used to define the volumes of the reactor units and the melt flow rates between them by fitting to the characteristic curves from both methods (CFD and combined reactors). The suggested approach is demonstrated for multiple designs of Ar-stirred ladles, tundish, and SEN. This methodology can be used to enhance traditional post-processing CFD analysis and also as a tool for on-line process control.

Jan 1, 2014

By A. W. Bryson, S. P. Fox, S. A. Godorr

"This work is an extension of a previous investigation on the development of surface roughness during electrodeposition of copper. A comprehensive model based on diffusion and migration in a force field together with surface diffusion and sticking probabilities is used to generate profiles which are compared to those produced experimentally. The roughness is characterized by using the technique of fractal geometry which is shown to describe both qualitatively and 9uantitatively the development of surface morphology during electrodeposition.The work is extended to the deposition of copper in the presence of various concentrations of thiourea. The development of roughness is observed experimentally on the edge of a thin copper disc mounted between two glass plates. This enables photographs to be taken at various stages during growth. The surface outline is digitized using an image analyzer which enables the fractal dimension to be determined as growth proceeds. As expected, the presence of thiourea at low concentrations produces a fractal dimension which is closer to unity (i.e. the surface becomes smoother).IntroductionThe development of surface morphology during electrodeposition has far-reaching implications for copper plating in the electrowinning and electrorefining processes. Short circuits as the cathode surface grows unevenly require operator intervention in a dangerous environment and imply processing delays, and the inclusion of electrolyte in small gaps in the plated cathode have implications in downstream processing of the cathode. Higher current densities are obviously desirable, as they result in greater production rates, but as shown by Ettel et. al.(l), Harvey et. al.(2), Cook (3), and Harvey et. al.(4), it is not possible to operate near the projected economically optimum conditions because the electrodeposition of copper from sulphate and acid solutions is a mass transfer controlled process. It has been shown (Ettel et. al.(l), Harvey et. al.(2)) that the closer a system operates to mass transfer limiting conditions, the poorer the resulting cathode quality. One solution is to use agitation techniques to increase the limiting current density. Another is to add surface active additives to the electrolyte which has been shown by Ettel et. al.(l), Harveyet. al.(2) and Afifi et. a1.(5) to allow higher rates of production without decreasing cathode quality. The second proposed solution is of interest in this work, since there is very little knowledge of the conditions under which these additives operate effectively, and little fundamental understanding of the mechanism by which they operate. The current work seeks to contribute to this field by correlating a simulation model with experimental results to describe the development of surface morphology in the electrodeposition process."

Jan 1, 1997

By Xu Zhang, Xuewei Lv, Guibao Qiu

Slag foaming phenomenon is of vital importance to the mass and energy transfer in metallurgical processes. A considerable extensively studies carried out via out-gas in the past cannot simulate well the foaming phenomenon formed in the blast furnace where high TiO2 iron ore is used. A gas reaction was designed in the water-glycerol system to simulate the inner-gas system. This study investigated the influences of solution viscosity, particle concentration and particle size on foaming caused by endogenetic gas. The results show that the foaming height decreases with the increase of solution viscosity, which means reduced foaming ability, more difficult foaming elimination process and prolonged time for natural defoaming. With increasing the solid particle content, the foam height presents a trend which increases firstly and then decreases. Under a certain solid particle content, foaming height decreases with the increase of solid particle size, indicating a weak foaming ability.

Jan 1, 2015

By Deepu Philip, Pratik Agarwal, Ajay Kumar Shukla, Ishani Shukla, G Rajesh

Steel plants generally employ static BOF end point control models to arrive at a given temperature and chemistry at the end of blow. These end point models have now been supplemented with chaos control models to steer the blowing process in the right direction while the blow is in progress. Merely arriving at the correct end point temperature is however not adequate because in the subsequent stages as well the temperature variations can be large and unpredictable. The present paper deals with an integrated model to take into account the effect of all parameters affecting temperature and composition from tapping to the start of casting to minimize the use of LF or aluminum heating, and also minimize grade mixing. The application of lean operations strategy is explained in which the previous “Push System’ is changed to a “Pull System”, minimizing the use of ladle furnace or aluminum heating during steelmaking.

Jan 1, 2014

By W. S. Kirk

World cobalt production in 1987 was estimated to be about 26,600 metric tons (MT) of which Market Economy Country (MEC) production was estimated to be about 22,000 MT. Zaire and Zambia produce about 80 percent of the primary cobalt produced among Market Economy Countries (MEC). Production cutbacks. lowering cobalt grades and mining curtailments in Finland and Zambia in 1987, resulted in lower production than that of 1986. The trend is expected to continue through 1988. Cobalt production from Canadian ores and from Botswana is expected to increase significantly in 1988 as a result of increased nickel production. MEC production in 1988 is estimated to be 22,100 MT, only slightly higher than that of 1987. There are currently no primary cobalt mines. Virtually all cobalt is recovered as a byproduct of copper and/or nickel mining. Zaire, which produces cobalt as a byproduct of copper, is the worlds largest cobalt producer, with over 50 percent of total estimated world cobalt production and nearly 65 percent of MEC production. Zambia follows with about 14 percent and 17 percent, respectively. Zambia&apos;s cobalt production also results from copper production.

Jan 1, 1988

By Batric Pesic

Solvent extraction of nickel and cobalt from the real leach solutions was studied by using a novel extraction system. The extraction system was a mixture of 2,6-bis-[5-n-nonylpyrazol-3¬y]] pyridine (BNPP) and dinonylnaphthalene sulfonic acid (DNSSA). The BNPP represents a novel molecule, which was designed and synthesized in our laboratory. Real solutions for the study were prepared by leaching of two different cobalt-nickel bearing concentrates, cobaltite [CoAsS] concentrate from Blackbird Mine, Idaho, and siegenite [(Ni,Co)3S4] concentrate from Missouri Lead-Belt. The major strength of the system was the selectivity of extraction toward nickel and cobalt from iron containing solutions. Other metals such as Mn, Mg, Ca, Al and As were not extracted. Due to the irreversibility of copper extraction, its removal from solution was required prior to the extraction of nickel and cobalt. Zinc was not as strongly extracted (i.e. its stripping was readily achieved) as was copper . Flowsheets for the recovery of nickel and cobalt were also developed.

Jan 1, 1997

By S. Ozbilen

"Al-Li binary alloys with nominal Li contents of0.15, 1.1and2.8 (in wt%) were aged naturally at room temperature for two months, aged at low temperatures ( 65 and 1 OOEC) for up to 2 months and aged artificially at 190EC for 4 days after water quenching to 25EC following solutionizing at 530EC for 20 minutes. Ageing behavior of these binary alloys were studied by Vicker's Hardness measurements and DSC thermal analysis. Thermal analysis results indicate the formation of GP zones of Al-Li system in Al-2.8wt%Li binary alloy. In the same alloy, rapid quenching from one phase region (a) gives rise to precipitation of small o' particles in a matrix (a) with still high supersaturation. During ageing of this alloy below lOOEC an additional transformation, i.e., GP zone formation occurs proceeding at a very high rate which is described on the basis of the theoretical analysis for the quenched Al-Li system proposed by Khachaturyan et al [6]. Ageing at temperatures below 11 OEC takes place slowly by the formation of small d' particles of lower thermal stability than the quenched-in d precipitates in addition to GP zones resulting in an increase in hardness compared to water quenched samples. During artificial ageing, GP zones transform by dissolution to d' precipitates while d' particles already in the microstructure coarsen during under aged condition at which hardness increases with time till peak aged condition.IntroductionIn binary Al-Li alloys the d' (Al3Li) fully coherent internally ordered inetastable phase of Li2 structure with a=0.4038d [1-5] forms homogeneously between 120 and 190EC before the formation of stable d' (A!Li) phase and cause the superior mechanical properties. This is due to an appreciable age hardening effect resulting because of the d' precipitation during ageing [1]. The response of d' to decomposition and its formation kinetics have been studied previously and it is believed that the decomposition of the a-supersaturated solid solution occurs in a two stage process; i.e., a 6 d' (Al3Li) 6 d(A!Li). Khachturyan et al [6] theoretically investigated precipitation of the d' phase and gave an interpretation of the transformation paths of the quenched Al-Li alloys. They predict that the disordered supersaturated solid solution congruently orders, and then the uniformly ordered solution decomposes into ordered regions that differ in Li-content. Finally, ordered d' phase forms in the disordered matrix."

Jan 1, 1998

By Herbert Pöllmann

Waste disposals are needed for safe deposition of different kinds of materials which can not be used as secondary raw materials. Often high contents of heavy metals must be bonded tightly to cristalline compounds to protect the environment from contamination. Therefore it is important. to find minerals which are capable to incorporate different heavy metals and protect the ground water. The power of resistance against leaching out effects of highly water-soluble salts can be increased. Mineral groups of metal hydroxy salts, ettringites, apatites, sodalites and calciumchlorosilicates and their hydrates are recommended for their formation in mineral reservoirs. Different wastes as red mud, gasification ash, garbage combustion ash and fluidized bed ashes were included in this study. The formation of different new compounds and their properties were determined.

Jan 1, 1991

By William D. Riley

The U. S. Bureau of Mines has developed technology to recover by-product materials from aluminum scrap using engineered scavenger compounds (ESC). ESCs are structural oxides with a channel or tunnel structure that allows them to hold ions of a specitksizes and charges. The scavenging reaction is easily reversible allowing the ESC to be recharged for continued use and the ion is recovered as an electro deposit. Key features of this novel technology are; a) ESC ,systems are designed to have a high degree of selectivity for a desired ionic species. b) The recovered mater.ial requires little or no additional reprocessing prior to reuse. Two current uses for the ESC technology that are described in this paper are the removal and recycle oflithium (Li) from lithium aluminum (Li-AL) alloys; and, using ESCs as a replacement for the conventional demaging (magnesium removal) technology used by the secondary casting industry. Research indicates that the ESC technology proposed for both these applications has either &apos;distinct economic and/or environmental advantages over previously employed methods of recovering. metal values from aluminum scrap.

Jan 1, 1995

By A. Kontopoulos

Refractory sulfide gold ores or concentrates require an oxidation pretreatment step to yield the contained gold amenable to the subsequent leaching step. The process options for oxidation pretreatment can be broadly classified as follows: roasting, high or low pressure oxidation bacterial oxidation, chemical oxidation, each with a number of alternative suboptions. Roasting and high pressure oxidation are being applied on an industrial scale; the stage of development of the other options range from preliminary laboratory to advanced pilot plant- In this paper, the major technical, environmental and economic aspects of the above processes are being discussed. Future industrial trends will also be considered. Particular emphasis will be placed on the treatment of arsenical ores and concentrates, where safe plant operation as well as, handling and disposal of the arsenic containing products and/or effluents &apos;and residues is of paramount importance.

Jan 1, 1990

By A. Vahed

The Goro Nickel Project is situated in the Southern Province of New Caledonia. Inco Limited and Goro Nickel S.A. have developed a process that features the use of pyrohydrolysis to produce nickel oxide. The process treats a blend of laterites by Pressure Acid Leaching followed by solvent extraction of nickel and cobalt using Cyanex 301®. Purified nickel chloride solution is converted to high purity NiO product and 6M hydrochloric acid, which is recycled back to the SX circuit. In co-operation with Andritz AG, spray roaster and fluid-bed pyrohydrolysis technologies were examined for this purpose. Tests were conducted at the Andritz AG pilot plant in Vienna, Austria, and at Goro in larger scale installations. The latter served to establish process engineering design parameters for scale-up. Several process variables were investigated in both technologies and the off-gas characteristics were established. Fluid-bed pyrohydrolysis was selected for the Goro commercial plant, primarily because it produced a granular nickel oxide. The main focus of this paper is to outline the results obtained in pilot plant studies of liquid fueled fluid bed pyrohydrolysis for the Goro Project. Keywords: lnco Goro Nickel, Fluid Bed Pyrohydrolysis, Pilot Plant Tests

Jan 1, 2004

By Kiyoshi Shibata

A new assessment model has been proposed for metal production and its recycling system. The model consists of three processes, smelting of ore, cascading and upgrading of metal scrap. The present approach is to assess the total energy consumption of the system, by introducing two equations for describing the relationships between critical impurity content and the mass of production or scrap recycling. The total energy consumption in the system can be described as a function of recycling rate and performance of the upgrading process. The present model suggests that the impurity removal efficiency and yield in the upgrading process are essential to reduce the energy consumption in the systems. Especially, such points should be explicitly controlled in recycling of aluminum. The potential capability of this model was also discussed by obtaining several quantitative information required for the process design and the operational control of beneficial recycling of metals.

Jan 1, 1998

By Anish Kumar

Keywords: Ultrasonic velocity, Poisson?s ratio, Elastic constants A new correlation has been established between two independent elastic properties, ultrasonic shear wave velocity and Poisson?s ratio, in a wide variety of isotropic solid materials, such as pure metals, ceramics, polymers and intermetallics. It has been shown for the first time that Poisson?s ratio decreases with increase in elastic moduli, E & G and ultrasonic velocities. This new correlation between two independent elastic constants may lead to the reduction in independent elastic constants for isotropic solid materials from two to one, at least for a given alloy system with different microstructural conditions.

Jan 1, 2005

By Patricia A. Wells

In the remelting of scrap, the ultimate goal is to produce clean aluminum while minimizing metal losses. Recently, it has become more difficult to make significant recovery improvements in Reynolds&apos; Reclamation Plants since metal recoveries were nearing the theoretical maximum. In an effort to gain a better understanding of the factors impacting Reynolds remelting process, a series of experiments using a Taguchi-type design was performed. Specifically, the critical variables and interactions affecting metal recovery of shredded, delacquered Used Beverage Containers (UBC) melted in a side-well reverbatory furnace were examined. This furnace was equipped with plunger-style puddlers and metal circulation. Both delacquecing and melting processes operated continuously with downtime only for necessary mechanical repairs. The experimental design consisted of an orthogonal array with eight trials, each using nominal 500;000 lb shred charge volumes. Final recovery results included molten output and metal easily recovered from dross generated during the test.

Jan 1, 1995