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By Dirk Verhulst

The Altair process employs digestion of ilmenite ore in concentrated hydrochloric acid, solvent extraction to concentrate Ti in a purified stream and spray hydrolysis to produce a TiO2 hydrate, followed by final calcining and milling. HCl gas is regenerated by pressure-swing distillation and reinjected in the leaching solution. All chloride streams are recycled. Chromium compounds generally remain in the residue. Solvent extraction provides flexibility for the removal of naturally occurring radioactive elements (NORMs) present in some ilmenites. The process was previously tested at a 5 t/day feed scale. Recent work at pilot scale (40 liter reactor) led to further improvements. Recovery of Ti in solution is now at least 90% with ilmenite ores, while crystallization at lower temperature lowers the amount of Fe in solution to about 5 g/l and improves solvent extraction, which is now conducted in columns. Higher Ti and lower Fe concentrations in the SX eluate improve the economics. A new formula for pigment production via spray hydrolysis produces a pigmentary base with a narrow particle size distribution.

Jan 1, 2003

By N. J. Tannyan

Laboratory bath smelting tests were conducted to determine the feasibility of smelting nickel- copper concentrate directly to a low iron matte in one step. Concentrate, air/oxygen and a silica flux were fed to a matte-slag bath kept in MgO crucibles at I 300°C. Various oxygen enrichments and smelting rates were used to maintain 0.5 to 2 wt% iron in the product matte. The slag losses are comparable to those obtained under similar industrial conditions. Due to the highly oxidizing conditions required to produce mattes with low iron contents, it is not recommended to target iron contents below about 2% in the matte. The specific bath smelting rates were equal to or higher than those in various industrial bath smelting processes.

Jan 1, 2003

By Kexin Jiao, Huichang Song, Zhijia Zhang, Jianliang Zhang, Zhengjian Liu

A clear understanding of iron carburization reaction occurring between molten iron and carbonaceous materials is of great importance in blast furnace, and it is one of the hot spots that ironmaking workers pay close attention to. Although carburization rates between iron and coke have been studied, the factors directly controlling it have not been clearly identified. This study focused on the kinetics analysis of iron carburization reaction. Sulfur content was determined as having positive influence on graphite carburizing reaction rate in the range of 0.02% - 0.06%. The values of apparent activation energy calculated by the experiment are consistent with the existing literature, which in turn proved the reliability of the experimental data.

Jan 1, 2015

By S. H. Amini

The effects of CaF2 and ilmenite on dissolution rate and diffusivity of CaO in calcium alumino-silicate based slag in a temperature range of 1500 ? 1600 ºC were studied by using the rotating disk/cylinder technique. The effect of rotation speed on the rate of dissolution in the base slag indicated that mass transfer in liquid slag played a significant role in controlling the dissolution. At a constant rotation speed, the effect of 5 wt% addition of fluxes tothe slag on the dissolution rate was investigated at various temperatures. While CaF2 had the highest effect, addition of ilmenite increased the rate of dissolution significantly. The diffusivity of lime in these slags was quantified using the dimensionless mass transfer correlations for rotating disk/cylinder in the melt. The diffusivity values were deduced using the data on dissolution rate and solubility of lime in the slags. The measured diffusivity in base slag at 1500 C was found to be about 1.32 10-5 cm2/s and increased to 3.07 10-5 cm2/s at 1600 °C. Addition of 5wt% CaF2 increased the diffusivity by a factor of 3 to 5, while 5wt% ilmenite increased the diffusivity by a factor of 2 to 3 in the temperature range of 1500 to 1600 ºC. The two examined fluxes reduced the activation energy of diffusion.

Jan 1, 2006

By Vaughan R. Voller

"Numerical methods for dealing with a temperature dependent conductivity are discussed. An approach based on a local application of a Kirchhoff transformation at the discrete level is presented. The application of this transformation - that does not require any inversion- is demonstrated on solving a two-dimensional test problem.IntroductionMuch is said in the recent literature on the modeling necessity of obtaining appropriate thermo-physical properties; in particular the requirement to account for properties that are ""strong"" functions of the depended variables, e.g., Temperature. Of course obtaining appropriate thermo-physical properties serves no purpose unless they can be accurately integrated into a discrete numerical calculation. The purpose of this paper is to examine how temperature dependent conductivities that exhibit discontinuities or rapid changes can be handled in a numerical code.The discussion will be made in the context of a control volume finite element method [1]. After a brief outline of control volume finite element fundamentals basic methods of dealing with discontinuous or rapidly changing thermal conductivity are discussed. This is followed by the presentation of the recently proposed local Kirchhoff method [2,3], The paper concludes with an investigation of the performance of the various conductivity schemes in solving two dimensional problems. This testing clearly shows the advantages (accuracy and implementation) in using the local Kirchhoff method."

Jan 1, 2001

By Kimio Itagaki, Torn Matsumoto, Makoto Ohtsuka, Kentarou Harada

"The structure and hydrogen-absorption properties of LaNis thin films were investigated in the present study. LaNis thin films were prepared by a sputtering method with a radio-frequency power, Ws, of 50 -400 Wat substrate temperature, Ts, of323 -573 K. Nickel content of the films decreased with increasing Ws, however, there was no dependence on Ts. At low Ws and low Ts, amorphous films were deposited. In other conditions, the films were polycrystalline. The films prepared at high Ws and low Ts, or at low Ws and high Ts, exhibited only a (h k · 0) peak in the X-ray diffraction profiles. This indicates that the c-axis of crystalline films was oriented parallel to the substrate plane. At high Ws and high Ts, the films with columnar structure were obtained. Hydrogen-absorption capacity of the thin films increased with increasing Ws. The pressure plateau did not appear on the pressure-composition isotherms. The films deposited at high Ts represented a higher equilibrium pressure.IntroductionThin films of hydrogen storage alloys can be applied for an electrode of rechargeable battery or fuel cell, a filter for H1 purification and various kind of sensor. Some studies on the preparation of the thin films of LaNi5 intermetallic compound, which is a typical hydrogen storage material, have been done hitherto. Adachi et al. , 2) and Sakaguchi et al. 3) prepared amorphous and crystalline LaNi5 thin films using flash evaporation of alloy powders and measured the pressure-composition isotherm for the prepared film utilizing a quartz crystal mass monitoring (QC:MM) method. It was found that the prepared amorphous film absorbed hydrogen without disintegrating into the powders and the hydrogen-absorption capacity of the films increased with the degree of crystallinity. Sakai et al. 4) reported that the maximum hydrogen storage capacities of amorphous and crystalline LaNi5 thin films, fabricated by a RF sputtering method using combination targets, were about 40 mA h g-1 (LaNisHo.7) and 160 mA h g-1 (LaNi5H2.6), respectively. Uchida et al. 5, 6) prepared LaNi5 thin films using flash evaporation of alloy powders and measured volumetrically the pressure-composition isotherm for the prepared film. It was reported that the hydrogen-absorption capacity of the films changed by the annealing treatment."

Jan 1, 1998

By Donna M. Noel

Bacterial strains have been cultivated from solids previously exposed to cyanide that will tolerate 300 ppm sodium cyanide under anaerobic conditions. In selected solid samples, these bacteria have been shown to reduce the level of cyanide from approximately 300 ppm to essentially zero in about 50 days under anaerobic conditions. Various media were investigated, and the nutrients providing maximal growth were ?established .. Degradation of cyanide in sterilized solids was determined for comparison with degradation obtained in bioactive solids. All experiments were conducted at ambient temperature and initial pH of approximately 10.5.

Jan 1, 1991

By Andrey Dmitriev

The solution of set of equations for the bottom zone presented by a condition of a thermodynamic equilibrium, namely, an equilibrium constant of wustite reduction by carbon oxide, material and thermal the balances, supplemented by the equation of the heat balance for the top zone, allows to calculate the base indices of blast furnace smelting. The calculated indices are extreme accessible at the given parameters of charge and blast. Application of actual degrees of the use of gas instead of equilibrium allows the calculations of actual indices of the blast furnace smelting process.

Jan 1, 2006

By M. M. Swan

A stratiform gold occurrence of Precambrian age located 20 miles southeast of Prescott, Arizona, within the Agua Fria Mining District, displays chemical, mineralogical, structural and lithological patterns indicative of a distal, exhalative volcanogenic environment. Metavolcanic and metasedimentary rocks of the Proterozoic Yavapai Series (1775-1820 m.y.) host the mineralization and are'characterized by greenschist grade metamorphism, steeply-plunging penetrative folds and steeply-dipping schistosity. Mineralization is confined to a 100m thick stratigraphic section that is comprised of a series of thin auriferous massive sulfide beds and intercalated schist .containing disseminated sulfides. The mineralization extends more than 4km along strike. Coincident with, and largely confined to the mineralized strata, are anomalous amounts of As, Sb, Cu, Pb, Zn and Ag and associated silicification, sericitization and carbonatization. This exhalative mineralized system is interpreted to have been deposited in a paleo topographic low on the distal flank of a submarine rhyolite dome and to represent the final episode of a Precambrian volcanic cycle.

Jan 1, 1981

By Yun Li

An innovative lead recycling process from scrap lead-acid battery paste is presented. The novelty in the process is avoiding SO2 generation and emission by using reductive sulfur-fixing technique. Iron-bearing secondary wastes produced from metallurgical industry were utilized as sulfur-fixing agent to capture sulfur in the form of FeS (s) instead of generation of SO2 (g). Na2CO3 molten salt was added to the smelting system to speed the reactions and improve valuable metals’ recovery and sulfur-fixation efficiency. Furthermore, this process can simultaneously co-treat various lead and iron-bearing wastes. At the same time, some precious metals, such as Au and Ag, contained in iron-bearing wastes can be recovered. The feasibility and reliability of this process was investigated thermodynamically and experimentally with the help of HSC 9.0 database and XRD and SEM-EDS analysis. A possible reaction mechanism and path in PbSO4–Fe2O3–Na2CO3–C smelting system was also clarified.

By Nils Eivind Kamfjord, Halvard Tveit, Ingeborg Solheim

"Because of its negative environmental effect the attention towards NO emissions increases. This again leads to new demands from the authorities for better surveillance and control of emissions. Earlier and recent industrial measurements towards FeSi- and Si-metal furnaces reveal quite high NO-emission. The NO is believed to be produced in the combustion zone above the furnace surface, mainly as thermal NO.In order to expand the knowledge on NO-formation in silicon metal production, a pilot scale experiment in a 440 kVA silicon furnace has been carried out. The experimental set-up was designed with a view to be able to copy and manipulate the formation mechanisms for NO by controlling the flow of false air into the off-gas system.The resulting NO-values corresponding to the different air inlet to the furnace top, show significantly differences between the different air inlet geometries.IntroductionNOx is the common notion for the two gases nitric oxide (NO) and nitrogen dioxide (NO2). Since combustion of fuels, such as gasoline, diesel, bio diesel, propane, coal, and ethanol, forms NOx the dominating contributors to NOx emissions are the on-/offshore transportation industry and power generation based on fossil fuels [1]."

Jan 1, 2012

By Guo Chang Jiang

In order to improve the IIAZ toughness of X-60 pipe steel, the intragranular ferrite plate (IFP) technology was used. The characteristics of IFP is claimed to be much fine ferrite plates appear inside the original austenite grains. By means of suitable Re, Zr, Ti additions in a bath with a higher initial oxygen potential, a good control of the peak temperature and the cooling rate during welding simulation, one can get a %IFP in volume over 50%, and the toughness gets up from 55 J to 160 J. It was found that the inclusions most effective in nucleating IFP are some deformable complex silicates which either entrap Re, Zr, Ti oxides or contain these elements. The greater the number of the evenly distributed and effectively nucleating inclusions, the more the %IFP in volume, and the finer the microstructure of the HAZ, so the better the relevant toughness. Generally, these silicates bahave as fine spheres along a line. The present authors revealed that these fine spheres result from the remelting of the shuttle- like silicates due to heating in the process of welding simulation. These silicates used to get a higher sulphur capacity, so MnS deposits might be observed on the periphery of the silicates. IFP was proved to be directly rooted in the [Mn] depleting zone which locates beside MnS deposits.

Jan 1, 1997

By Natasa Mitevska

The statistical analysis of the slag composition influence on copper losses to discard slag in the reverberatory furnaces No.1 and No.2 in the RTB BOR, Copper Smelter and Refinery (Yugoslavia) is presented in this paper. The model for the slag basicity calculation is determined, and connected to the copper distribution coefficients between the matte and slag phase. The influence of all components on the slag structure is also illustrated.

Jan 1, 2003

By T. Ahokainen, J. Pitkälä, J. L. Xia, A. Jokilaakso, J. Vaamo

"The aim of the present paper is to use the two CFD codes to model the two phase flow in a water model ladle with central gas injection. The codes examined are CFX and Phoenics. An Eulerian two phase model is used and predictions are compared against the experimental data available. The results show that the codes can reasonably well predict the gas-liquid plume in the ladle, and predictions are generally in a good agreement with experimental data. However, differences do exist in predicting the gas volume fraction and velocity profiles. The results should be interpreted most carefully and cautiously, because they are very sensitive to the boundary conditions and dependent on the models for the physical phenomena involved. IntroductionSubmerged gas injection has widely been used in the metallurgical industry for more than a century. At the present, the use of gas is most effective in steelmaking industry where the advantages of the gas injection have already been long well understood. Effective mixing, large contact area between reactants, easy modifications and flexibility of the processes are the most important advantages. Disadvantages include refractory wear, blocking in the tuyeres, and splashing. These disadvantages can be reduced and advantages further improved by studying the flow phenomenon in process vessels. However, it is difficult to study flow in a real vessel because of the high temperatures and physical and mathematical modelling is therefore increasingly used in the process development work."

Jan 1, 1999

By N. Panagiotopoulos

A low-grade (1.06% Ni, 0.06% Co) hematitic type lateritic ore from Triada, Euboea Island, Greece, has been leached with sulfuric acid at atmospheric pressure for the extraction of the contained Ni and Co values. The effect of various parameters, including reaction time and leaching temperature, acid strength, pulp density, etc., on Ni, Co extraction and Fe dissolution was determined. By leaching at 95°C for 4h with a 3N sulfuric acid solution at 25% pulp density, Ni and Co extractions were 82 and 75% respectively, and Fe co-dissolution 28%, yielding a pregnant solution containing 2.7 g/l Ni, 0.16 g/l Co, and 33 g/l Fe. Overall acid consumption was 850 kg/t ore (or 100 kg/kg Nil. Preheating of the laterites at 600°C before leaching resulted in much faster leaching kinetics for Ni, but the final extraction and acid consumption remained unaffected; Fe extraction was not influenced. Three-stage counter-current leaching at 9S°C, using 2N acid strength at each stage and 35% pulp density, reduced acid consumption to 350 kg/t ore (41 kg/kg Nil, and yielded 81% Ni recovery. Percolation leaching of -10 mm laterite at ambient temperature with 3N acid for 7 days resulted in 58% Ni extraction.

Jan 1, 1988

By Brian Lightfoot

Ausmelt technology is a versatile bath smelting technology with application in many waste treatment fields at low capital and operating cost. Heavy metals extracted from wastes may be recycled to mainstream use and the slags produced will be inert and suitable for use as aggregate, shotblasting grit or other applications.

Jan 1, 1994

By Shantanu Chakrabarti, Khursid Alam Khan

"Globally, the use of metallic coated steel sheets in the automobile industry is increasing. The sheet should have excellent formability, weldability, paintability and corrosion resistance. Since bare cold rolled steel sheets have certain limitations, application of galvanized steel sheets is steadily expending. Galvannealed steel sheet fulfills all requirements and has become of major interest in the automobile industry.The success of Galvannealed (GA) steels in the body-in-white depends upon material design and parameters of various processes involved, like cold rolling, continuous annealing, hot dipping and galvannealing. In the present work, powdering resistance, one of the important product characteristics of GA, has been studied and a relation is established between the process parameters and the powdering value. The product obtained through optimization of the process parameters have been successfully used by major automotive producers without any powdering problem, for internal as well as external automotive applications.IntroductionThe present automotive industry demands that steel for the auto components should have excellent formability, weldability, paintability, corrosion resistance etc. In addition to this there is specific requirement for some particular components like high surface quality for skin panels. Corrosion resistance of panels is important requirment which determines the life of the particular component and brand value of the automotive. Among all the zinc based steel coating used in the automotive industry coating produced by Galvannealing process has received most attention because of its excellent weldability along with superior corrosion resistance and better paintability."

Jan 1, 2012

By M. F. Hochella

Transmission electron microscopy (TEM) and energy dispersive X-ray (EDX) analysis have been used to study the mode of occurrence and mineral associations of gold in partially oxidized high grade gold ore from the Carlin sediment-hosted deposit. Rounded.gold particles have been observed that range in size from 0.03 to 0.1 p.m (300 to 1000 A) in diameter. The gold is associated with maghemite h-Fep3l and a K-Al-Si-bearing phase that is suspected to be illite. Detailed descriptions of gold and its mineral associations in 'Carlin-type' gold deposits are critical not only to understanding the mechanism of fluid transport and precipitation of gold, but also to developing improved metallurgical techniques for the recovery of gold from refractory ore. Direct observation of gold in unoxidized ore is rare due to its relatively high degree of dissemination and low average bulk concentration which averages 9 ppm according to Radtke (1). Hausen and Kerr (2) observed 1 to 5 p.m grains of gold directly in oxidized ore but these microscopically visible particles account for only a small percentage of gold present in the ore. The samples used in this study were selected from individual beds of high grade, partially oxidized ore (4.55 oz/ton or 156 ppm gold) that were collected in the Main pit of the Carlin mine. The samples were collected from several thinly laminated carbonate micrite beds within the top 50 meters of the Roberts Mountains Formation. The carbonate micrite has been altered by hydrothermal fluids to a calcite-absent, moderately silicified rock referred to as alteration zone #3 by Bakken and Einaudi (3). Based on petrographic and SEM studies, the samples contain carbonaceous matter, and both pyrite and iron oxide pseudomorphs after pyrite. The oxidation of pyrite may be a pro-duct of deep weathering, in which case limited remobilization of gold may have occurred. TEM sections of the rock were prepared by first embedding small chips in low viscosity epoxy. The epoxy blocks were cut with a Reichert Ultracut E ultramicrotome, producing thin sections less than 0.1 p.m thick. The sections were examined with a Phil-lips 400ST TEM at 120 keV in both imaging and selected area diffraction modes. Native golci*was easily detected in TEM bright field images due to the large electron density contrast between gold and all other phases that are present (Figs. 1 and 2), Gold was positively identified with high spatial resolution EDX analysis in the transmission electron microscope, although selected area diffraction of individual grains was not successful EDX analyses of the platy and massive minerals immediately surrounding the gold particles typically indicate the presence of Si, AI, K, and Fe, However, the d-spacings derived from selected area diffraction of these polycrystalline masses (as, for example, in Fig. 2) give an exact match for maghemite. As a result, there is no diffraction information to identify the K-AI-Si-bearing phase(s). The lack of a diffraction pattern could be due to either electron beam damage or to a poorly crystalline phase(s).

Jan 1, 1987

By Yong J. Kim, J. M. Park

"Solid/melt interface shape during continuous casting process has a strong influence on the resulting microstructure of the ingot. The interface shape is primarily governed by the heat flow condition between the molten metal and mold (or container). The roll of the microstructural transition resulting from various solid/melt interface shapes is discussed using the Sn-22.6wt%Pb alloy. Three different types of mold such as cold mold, resistantly heated mold, and electromagnetically heated mold were used to generate those interfaces having different curvatures. Experimental measurements of complete temperature profile along the axis and surface of the ingot during downward continuous casting are presented to determine the solid/melt interface geometry. The results provide an explanation of the ingot property with emphasis on microstructure.IntroductionA large scale of continuous casting process of alloys often has a rather deep V channel type of solid/melt interface resulting from a limited heat flow condition. As a result, the deep V type solid/melt interface shape entraps defects such as pores and inclusions and also creates canter segregation. In order to reduce the defects concentration, electromagnetic stirring(EMS) mechanism has been applied to the melt in the channel[l]. Speith and Bungeroth introduced first experimental EMS device to the continuous caster in 1952.[2] Today, with wide ranges of benefit, a large variety of such technique is available. Electromagnetic field on the melt can be divided into three aspects. First, eddy current is induced on the metal surface by alternating magnetic field with high frequency, which results in heating the metal. Second, electromagnetic body force which is generated by the magnetic field and the eddy current reduces the melt pressure on mold or support the melt not to contact with the mold[3,4,5]. This force is used for electromagnetic casting process(EMC). Finally, it causes stirring in the melt. Many research efforts have been done on the EMC process to improve surface quality of slab[6] and control meniscus shape where three phases such as melt, solidified metal, and mold powder coexist[7,8]. However, the eddy current heating effect on the surface of the ingot was less considered. It is worth noting that induced eddy current on the surface of slab melts the solidified shell and thus changes the heat flow condition between the mold and melt. Mold heating effect was first proposed by A. Ohno[9] and its processing conditions were identified in details[ 10, 11]. The so-called Ohno process is based on the fact that by keeping the mold temperature slightly above the melting temperature of the liquid, no grain can be nucleated on the mold wall[12]."

Jan 1, 1998

By G. Brooks, J. Naser, M. A. Sattar

CFD models have been developed and numerical simulations have been carried out to predict the formation of foam in oxygen steelmaking. Foam was considered as a separate phase comprising a mixture of gas and liquid. Bubble break up and coalescence models have also been incorporated in a CFD model to predict the number density of individual bubble classes. A population balance equation was used to track the number density of each bubble class. Decarburization with heat generation from chemical reactions was integrated in the process. User subroutines were written in FORTRAN to incorporate the foam formation, the bubble break up and coalescence rate and decarburisation in the main program. The model predicted the foam height, bubble number density, velocity of phases, decarburization, and turbulence. The result from the model has been compared with available data from literature and found to be in reasonable agreement with the experimental and plant data.

Jan 1, 2014