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By Lztok Peruš, Goran Kugler, Matevz Fazarinc, Milan Tercel

"Hot deformability of M42 tool steel additionally alloyed with cobalt and molybdenum was investigated. Hot-compression tests were carried out in the temperature range 850 °C -1200 °C, at strain rates range 0.001--6s-l up to strain of0.9. Field-emission scanning electron microscope and optical microscopy were used for characterization of microstructure of deformed samples, which revealed a very complex precipitation of carbides that strongly depends on the soaking temperature, the soaking time, the stress state, the deformation temperature as well as on the strain rate. Gathered data was used to calculate the processing parameters such as process maps, apparent activation energies and strain hardening exponents. For better understanding of thermodynamical properties of the studied steel a simultaneous thermal analysis was conducted. Furthermore the analysis of phase equilibrium was calculated using Thermo-Cale software. On the basis of these studies the optimal soaking temperature and process windows were determined.IntroductionHot workability ofledeburitic tool steels is important economic factor. This means that for each tool steel individuallysafe range of hot working parameters should be revealed. Publications in the literature with regard to the hot workability of tool steels are rare and therefore more information from this research area is desired.The relatively low hot workability of ledeburitic tool steels, i.e. steels in which the solidification is completed by a eutectic transformation of the residual interdendritic liquid to austenite and various alloy carbides (ledeburitic carbides), is usually characterized by the production of surface and internal cracks during the hot deformation."

Jan 1, 2013

By Daniel Kim, Ari Rantala

Efficient on-line monitoring of electrolytic cell performance in copper electro-refining has been challenging due to the need for complex electrical measurement systems and the management of the enormous volume of data. Based on Kennecott Utah Copper's innovation Outotec has developed a novel and innovative electrolytic cell monitoring system called CellSense™ System. As the system is based on self-powering from bus bars, wireless communication, on-line adaptive modeling and easy to access information and alarming, traditional obstacles of electrolytic cell monitoring are eliminated. With cell voltage and electrolyte temperature measurements, CellSense System enables real-time cell performance discovery and early reaction to critical production or quality disturbances such as short-circuiting, flow blockages, cold cathodes or electrolyte temperature excursions. During the past few years the system has been delivered to over 3500 commercial cells. In this paper the largest CellSense™ System ever delivered and recently adapted by Kennecott Utah Copper with 1412 cells monitored on-line for high tankhouse performance, cathode quality and optimized operator work flow is presented. Early results and benefits are discussed.

Jan 1, 2012

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 Z. Zak Fang, P. Fan, S. Middlemas

"Titanium dioxide (T1O2) has been widely used as pigment in paints, paper and cosmetic products, as well as high-tech applications such as PV Cells, semiconductors, biomedical devices and air purification. T1O2 pigment is primarily produced by the high temperature chloride process, resulting in considerable CO2 emissions. A novel hydrometallurgical process for making T1O2 pigment without direct CO2 emission is investigated. The new method promises to eliminate direct CO2 emissions, consume significantly less energy, and produce minimal environmental waste. The novel process involves molten salt roasting of titania slag, with subsequent washing, leaching, solution purification, hydrolysis, calcination and post-treatment stages, resulting in high-purity anatase or rutile pigments while realizing significantly reduced environmental impacts. Pigment whiteness is critically sensitive to trace amounts of discoloring impurities such as iron and chromium. Several methods for reducing the levels of these impurities are investigated. Energy consumption and emission models are also developed.IntroductionTitanium dioxide (T1O2) is one of the most commonly used minerals in the chemical manufacturing industry. It has been commercially processed since the early 1900's, and has a wide variety of applications. Pigment is used in paints [1], plastics and paper [2], sunscreen [3], cosmetics and even as a food additive [4]. T1O2 has also been used in photovoltaic cells [5], biomedical devices [6], and in air purification [7]. T1O2 pigment has a refractive index of 2.7, which imparts a high level of opacity (and hence whiteness) to whatever material it is added [8]."

Jan 1, 2012

By XUEWEN WANG, Xingming Wang, Xuehui Liu, Mingyu Wang

The Panzhihua titanium concentrate contains high contents impurity of Mg and Al, and it is difficult to prepare high grade titanium slag. To solve this problem, a sodium salt roasting-acid leaching process was proposed for removing the impurities in titanium concentrate. Na2CO3 and titanium concentrate were mixed with the proportion of 1:4, and then the mixture was roasted at 700 for 2h. After roasting, the calcine was leached with HCl solution. The experimental results showed that the removal rate of silicon and aluminum can reach more than 85% and 80%, respectively, at leaching temperature of 70 , leaching time of 4h, HCl addition of 5ml and liquid-solid ratio of 4:1.

Jan 1, 2016

By Daniel C. McLean

Extraction data for Cu, Zn and Fe were obtained from 4.5" and 10" columns using massive sulfide ore and natural acid mine water. The purpose was to determine if recycling of solution through the column would produce leach liquors of 4 g/l Cu and Zn at extraction rates of 1 g/l per pass at typical flow rates of 0.002 to 0.006 gpm/sq.ft. Test results exceeded expectations. Cu and Zn concentrations of 4 g/l were obtrained within 4 to 6 cycles. Concentrations greater than 6 g/l Cu and 8 g/l Zn were reached within 10 cycles. Concentrations of greater than 40 g/l of Fe and free sulfuric acid were obtained with no decrease in biological activity being observed. No reagents were used.

Jan 1, 1995

By Teruo Tanabe

The hydrogen-absorbing materials are expected to have the following properties at moderate conditions, (a) a large capacity of hydrogen absorption, (b) the absorption rate of hydrogen is large and (c) hydrogen-absorbed materials can easily desorb hydrogen. Thus the three concepts of capacity, rate and reversibility seem to be indispensable to clarify the mechanism of hydrogen absorption by the materials. In this work, the amount of absorbed hydrogen, the absorption rate and the reversibility of hydrogen absorption- desorption reaction were measured for binary R-M systems (R = Y, La, Ce; M = Co, Ni). These experimental results were discussed by the following three physical properties that were calculated by the extended Hückel method, i.e. the density of states unoccupied by electrons, the cohesive energy and the energy fluctuation. The major results are as follows: (a) the amount of absorbed hydrogen increases with the density of states in the energy range between -9 and -4 eV, (b) the R-M compounds of which energy fluctuations are large show a large value of rate of hydrogen absorption, and (c) when the cohesive energy is large, the compound has a tendency not to easily desorb hydrogen, i.e. its reversibility is poor.

Jan 1, 2006

By M. O. Lai

"Metal matrix composite (MMC) with composition of Al-4.Swt.%Cu reinforced by IOwt.%TiB2 or ISwt.%SiC particulate has been successfully fabricated using powder metallurgy technique. Disk, compression and beam specimens were prepared with (a) layered structure containing ductile Al-4.Swt.%Cu with brittle Al-4.Swt.%Cu/TiB2 or Al-4.Swt.%Cu/SiC layers, and (b) homogenous constituent with composition of Al-4.Swt.%Cu/lOwt.%TiB2' The specimens for the fracture toughness measurement were built through three ductile-brittle-ductile alternating layers. For the beam specimens, the layers were built through brittle-ductile-brittle sequence. The brittle layer consisted of Al-4.S%Cu with fixed amount of reinforcement. Fracture toughness testing revealed an increase for layered composites although the total amount of the reinforcement was the same for all disk specimens. The increase in fracture toughness is due to the existence of ductile layers which manifests a strong influence on delaying the occurrence of fracture. It acts as a barrier to resist the propagation of crack and hence increases the fracture toughness of the layered MMC specimens, Delamination in the beam specimens was observed to be due to shear stresses. Fracture surfaces of both disk, compress and beam specimens were characterized using the SEM. IntroductionMechanical and thermal properties can be achieved by the incorporation of refractory secondary phases to constrain the plastic flow of the matrix in a metal matrix composite (MMC). The size of the reinforcement particulate incorporated must be in the range larger than the dislocation cell size and strongly bonded to the matrix (I). Particulate reinforced metal matrix composites hence provide high modulus, improved wear resistance and strength (2-4). Because of the incorporation of refractory phases which are generally brittle, the major limitation in the mechanical properties of MMCs is their limited ductility in comparison to their base metals. Cracks normally initiate from the reinforcement and voids (4, 5). Due to the lack of ductility, cracks propagate rapidly with increase in load. As a result, the interactions between reinforcement particles and propagating cracks have recently been of great research interest (6). In addition, volume fraction of reinforcement and aging condition of the matrix significantly affect the mechanical behaviour of MMCs. In the case of AI-3.5%Cu reinforced with varying volume fractions of SiC particulate, it has been found that the probability of particle fracture increased with increasing volume fraction of reinforcement (7)."

Jan 1, 1996

By C. A. Silva

The kinetics of chlorination of titanium-bearing raw materials has been investigated. For comparison purposes pellets of controlled macro-porosity, made of analytical grade TiO2 and anatase concentrate (Brazil) , have been exposed to different combinations of gas composition - CO, CO2, C12 -, gas flowrate and temperature. A thermogravimetric technique and an adapted grain model have been used in order to assess the influence of the several experimental parameters upon the chlorination behavior.

Jan 1, 1997

By Ximena Diaz

Mercury is one of the most undesirable contaminants in gold bearing ores. During cyanidation mercury cyanide compounds accompany gold in all the extraction and recovery processes. Of course mercury in the carbon eluates creates environmental problems in subsequent refining steps. One possible process alternative for the separation of gold from mercury in such concentrated alkaline cyanide solutions is the selective solvent extraction of gold by undiluted Dibutyl Butyl Phosphonate (DBBP). In order to describe the behavior of mercury during extraction by DBBP, the results from a preliminary research program are presented. In this study, temperature and cyanide concentration have been found to be the most significant variables which influence the separation of gold from mercury by solvent extraction using DBBP. It was found, using plant eluate from a carbon strip, that excellent separation of gold from mercury can be obtained at 60' C with 98% gold recovery and complete mercury rejection in a single stage of extraction. The influence of pH is also discussed in terms of the extraction chemistry. These results complement previous research which described the DBBP solvation extraction of an aurocyanide ion pair. In addition, these results extend our understanding of the alkyl phosphorous ester extraction systems by illustrating that neutral ionic species such as Hg(cN)02sq, can be extracted at low cyanide concentrations, a phenomenon which had not been observed previously for other cyanoanions.

Jan 1, 1993

By Damien Wagner

To reduce the emission of greenhouse gases by the steel industry, particularly for ironmaking, the production of DRI (Direct Reduced Iron) using hydrogen as the reducing gas instead of carbon monoxide is being considered. In this context, the reduction of pure hematite by hydrogen was studied at the laboratory scale, varying the experimental conditions and observing the rate and the course of the reaction. All the reduction experiments were performed in a thermobalance and supplementary characterization methods were used like scanning and transmission electron microscopy, X-ray diffraction, and Mössbauer spectrometry. The influence of rising temperature in the range 550-900°C is to accelerate the reaction; no slowing down was observed, contrary to some literature conclusions. A series of experiments consisted in interrupting the runs before complete conversion, thus enabling the characterization of partially reduced samples. Interpretation confirms the occurrence of three successive and rather separate reduction steps, through magnetite and wustite to iron, and illustrates a clear structural evolution of the samples. Finally, the influence of the sample type was revealed comparing a regular powder, a nanopowder and a sintered sample. The regular powder proved to be the most reactive despite its larger grain size, due to a more porous final structure.

Jan 1, 2006

By Marshall Khan

The Goodfellow Expert Furnace System Optimization Process (Goodfellow EFSOP?) is a proprietary process that uses real-time and continuous off-gas analysis, along with process monitoring to optimize the operation of electric arc furnaces (EAF) for steelmaking. With the exception of off-gas composition, dynamic process measurements within the EAF are not possible due to the harsh operating environment. The Goodfellow EFSOP? system provides a dynamic indication of the operating conditions within the EAF. Continuous measurement of furnace off-gas composition, along with other furnace operating parameters is used to elucidate the fate of chemical energy usage within the EAF including: the evolution of carbon from the molten steel bath; the in-leakage of air into the furnace; the extent of combustion above the molten steel bath and the occurrence of dangerous water-leaks from the furnace cooling system. The ability to measure the process reliably and continuously enables Techint Goodfellow Technologies Inc (TGTI) to implement dynamic process control of combustion within the electric arc furnace and to optimize the overall operation through adjustments to the EAF process based on off-gas measurement. This paper discusses the methodology and results achieved from several recent Goodfellow EFSOP? installations in South East Asia.

Jan 1, 2006

By Victor Bredykhin

The report is devoted to the investigation and improvement of processes taking place at contact of large quantities of water insoluble liquid and particles of solid phase in a pulp. Theoretical analysis and simulation of acting conditions have allowed to determine that after attaching of oleophilic particles on the «water-reagent» separation surface the break of a formed complex is taking place according to the reagent volume and for oleophobic minerals along the «solid-reagent» separation surface. As a result particles are selectively treated if the magnitude of the reagent adhesion to the surface of solid phase in water is great. The results of dispersion are influenced significantly by availability of sharp edges on the surface of real particles. They keep tree phase perimeter of moistening. It is possible to fix reagent in the form of lens whose contact angle is significantly smaller in comparison to the thermodynamic angle. In adhesion dispersion the reduction of reagent volume, covering the equal area of particles surface is possible when the reagent is in a pulp in the form of thin films on the «water-gas» separation border. The process is tested in laboratory conditions as well as at pilot concentrating mills in flotation of sulfide ores, non-ferrous metals (copper-molybdenum ore), native sulfur and coal.

Jan 1, 2006

By M. Vijayalakshmi, S. Saroja, C. Sudha, T. N. Prasanthi

"Ti-5Ta-2Nb alloy and 304L austenitic stainless steel were joined by explosive cladding process. Investigations on 'as received' explosive clad revealed high hardness very near the interface due to martensitic transformation of 304L steel base plate. To improve ductility, explosive clads were heat treated in the temperature range of 823 to 1073 K for 1 to 20 h. Consequent change in the microstructure and microchemistry of the clad interface was studied. No change in the interface microstructure was observed for heat treatment at 823 K. Increase in temperature lead to the formation of various reaction zones at the interface, their number and width increase with temperature and time of thermal exposure. Growth kinetics of the reaction zones was monitored and activation energy required for formation was calculated. From elemental redistribution profiles, effective inter-diffusivities of alloying elements were calculated as a function of concentration and activation energy required for inter-diffusion was evaluated.IntroductionFor engineering components exposed to highly oxidizing and corrosive environments, a titanium based alloy i.e Ti-5Ta-2Nb (Ti-Ta-Nb) is often chosen as a structural material [1,2]. For economic consideration, vessels and piping exposed to non-oxidizing conditions are fabricated from 304L austenitic stainless steel (304L SS). Hence, dissimilar joint of Ti-5Ta-2Nb alloy and austenitic stainless steel becomes unavoidable. Fusion welding processes are not suitable for joining Ti and Fe based alloys due to the propensity for the formation of intermetallic phases and subsequent reduction in the bond strength [3,4]. Hence, explosive cladding, a solid state welding technique, was used to achieve high integrity, corrosion resistant joints between the two alloys."

Jan 1, 2012

By Karel Verscheure

Reliable furnace cooling technology is a domain of increasing concern to the pyrometallurgical industry as it can significantly increase process intensities, productivity and campaign times of furnaces. Although there are many advantages in using cooling systems, they also impose a variety of problems mainly related to safety, heat losses and sustainability of the operations. The choice of cooling system is hence a matter of trade-offs and differs for every metallurgical application. This paper gives a review of different cooling designs used in the ferrous, non-ferrous and alloying industries. Additionally, the paper systematically reviews aspects of materials selection, manufacturing, installation, water quality and furnace monitoring when using water cooled refractories.

Jan 1, 2006

By Beatriz Amarai Campos, Jorge Alberto Soares Tenorio1, Denise Crocce Romano Espinosa, Adriana Johanny Murcia Santanilla

"The aim of the present work is to investigate the recovery of nickel from obsolete cell phones printed circuit boards. The printed circuit boards were firstly submitted to a grinding process and then leached in sulfuric acid. Nickel was extracted from aqueous solution using Cyanex 272. Aqueous/organic ratio was 1/1. The effect of both pH and modifier addition on selectivity of extraction was investigated.IntroductionCurrently, electric and electronic equipments (EEE) have become a necessity to the modern life. Associated with this necessity comes the continuous and increasing replacement of those equipments by new ones. The accelerated technology advances are responsible for the generation of electric and electronic waste. This waste can be dangerous not only to human health but also to the environment. Waste of electric and electronic equipments (WEEE) has a variety of components and metals in its composition becoming a potential pollutant to the environment when not properly discarded. Its wrong disposal causes a loss of materials that could be recovered and reused. Therefore WEEE treatment is an important matter because it can assist the reduction of waste generated and the recovery of valuable metals.Printed circuit board (PCBs) is an essential component of EEE and is typically very complex from a chemical point of view. Several metals may be present in its composition, such as cooper, nickel, iron, zinc, lead, tin and silver1''. This characteristic hinders the development of a simple treatment, making it necessary the application of chemical and mechanical processing for their recycling'4'. The UN estimates that approximately 20 to 50 million of tonnes of WEEE are generated worldwide each year."

Jan 1, 2011

By F. Begazo

The most common approach to increase production in copper refineries is to increase current densities. However, if these increases are not well thought out beforehand and are not properly and effectively controlled, the end results could be reduced plant performance and a deterioration in cathode quality. Both of these factors result in lower efficiencies and increased costs. At the Ilo Refinery of Southern Peru Copper Corporation, a modernization and expansion program was implemented shortly after the Refinery was purchased from Minero Peru, in 1994. This program was intended to increase production from 195,200 mtpy of cathode to 227,000 mtpy over a 3-year period. Part of this production increase would come from increasing current density. During the period from 1994 to 1997, current density at the Ilo Refinery was increased from 218 A/m2 to 230 A/m2, while plant efficiencies were maintained at consistently high levels. The current efficiencies were maintained at >97.5% and time efficiencies were maintained at >98%. During 1998, additional increases in current density were implemented while the high plant performance was maintained at the same levels. By the end of 1998, the current density was 241 A/m2, while current efficiency and time efficiency of 98% were maintained. This paper describes the control processes used at the Ilo Refinery to maintain high plant performance levels while increasing the current density. Additionally, expected plant performances from extended test programs at current densities up to 280 A/m2, for future production increases, are reviewed and discussed.

Jan 1, 1999

By Hideki Yarnarnoto

The simultaneous removal for NH4+ and PO43- in aqueous solution was carried out by using Ca type zeolite synthesized from coal fly ash. The effect of pH on the cation exchange capacity and adsorption properties of the obtained zeolite, the simultaneous removal of NH4' and ~04'. in various solutions and the mechanism of simultaneous removal were investigated respectivel? ,The Ca type zeolite used in this study can simultaneously remove NH4+ and PO43- In aqueous solution without releasing counter ion, and this method gives great advantage over the other ordinary removal methods.

Jan 1, 2002

By Anjali Talekar

Low temperature heat capacities of pentaerythritol [PE: C(CH2OH)4], pentaglycerine [PG: (CH3)C(CH2OH)3], and 2-amino-2-methyl-1,3-propanediol [AMPL: (NH2)(CH3)C(CH2OH)2]have been determined by adiabatic calorimetry from 3 K to 300 K. To the best of our knowledge, this is the first reported heat capacity measurement below 280 K for PE and AMPL. The Debye temperatures for these organic crystals have also been determined and compared with other alcohol derivatives of neopentane.

Jan 1, 2006

By Emil H. Geus

A process has been developed to recover aluminum from dross which does not require the use of salt flux as commonly employed, This results in a salt-free residue which has potential industrial uses or alternatively can be safely land-filled. The dross is first heated by an air-fuel or oxy-fuel burner in a sealable rotary furnace. At a suitable temperature the burner is turned off and the temperature of the dross thereafter controlled by means of an atmosphere of oxidative and inert gases. When the free metal has agglomerated it is first discharged from the furnace, followed by the residues.

Jan 1, 1995