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By K. D. Mondale

The chemical and physical properties of samples from ten sedimentary zeolite deposits. (representing chabazite, clinoptilolite, erionite and mordenite types), have been determined as a prelude to the development of a wet beneficiation process. The mineralogical composition of each deposit and such properties as morphology, size, apparent density, surface area, pore volume, relative hardness and zeta potential in solution have been determined. Some of these properties, especially apparent density and relative hardness, were found to differ significantly from textbook values. Based on differences in properties between the zeolites and their associated gangue minerals, a wet beneficiation process has been developed which makes use of selective grinding, sizing, sorting and gravity concentration. Additionally, an alternative upgrading process using flotation has been developed for one of the deposits.

Jan 1, 1988

By S. N. Monteiro, C. M. F. Vieira, M. M. Ribeiro

"This work has as its objective to evaluate the effect of incorporation of the powder waste retained in the eletrostatic precipitator of the sintering stage from an integrated steel making plant on the physical and mechanical properties of a red ceramic. Formulations were prepared with incorporation of the waste in amounts up to 20 wt.% into a kaolinitic clay. Rectangular specimens were prepared by uniaxial mold-press at 20 MPa and then fired at 750, 900 and 1050°C. The evaluated physical and mechanical properties were: linear shrinkage, water absorption and flexural rupture strength. The results showed that the waste has a potential to be used into red ceramics. The incorporation of the waste enhanced the properties of the ceramic, decreasing the water absorption and increasing the mechanical strength at all investigated temperatures.IntroductionThe sintering stage of an integrated steel-making plant is dedicated to the agglomeration of a mixture of iron ore, coke or coal, fluxes and water [1]. It is a common practice in this stage to use of solid wastes with great amounts of iron in the form of sludge and powder. One of the atmospheric pollutants generated during the sintering process is the particulate material, which is normally retained in an equipment denote as electrostatic precipitator. This equipment retains very small particulates, present in the gaseous emissions by application of an electrical potential difference in between the plates that the fluid is forced to go through. [2]."

Jan 1, 2011

By ZHANG Ting

In view of the high consumption and contamination of traditional vanadium extraction technology, a new process of leaching the converter vanadium slag without roasting with titanium dioxide waste was proposed. Extraction mechanism of P204 in the leaching solution had been researched and single factor experiments show that after a prereduction of Fe, and under conditions: ambient temperature，leaching solution original pH=2.5, phase ratio (A/O)=1:3, shaking time 8min, the extraction rate of V is more than 98.62% meanwhile the separation rate between V and Fe is up to 135.3 in the 20%P204-10%TBP-Sulfonated kerosene extraction system.

Jan 1, 2015

By Chengyi Ding, Xuewei Lv, Changyang Ji, Rende Zhang, Xiangwei Zheng

Inexpensive and high-quality sinter has an extraordinary position in iron making, and there are many factors influencing the sintering. This research takes the basicity and coal dosage as research subjects to do the experiments based on cost analysis with sinter pot experiment system. Linear program is taken to make the schemes of ore blending. During the experiments of changing basicity from 1.6 to 2.3, the properties and microstructures of the sinter are studied. It comes to a conclusion that increasing the basicity is beneficial to sinter quality but leads to higher cost. To further ascertain the cost of sinter and the potential of saving coke, the work of improving coal dosage is taken on the basis of experiments of changing basicity. Through analyzing the results, a formula (Y=1849+261.1R-130.6C) is proposed which indicates the relation among the cost, basicity and fixed carbon content. And it works well for actual production.

Jan 1, 2015

By Filipe de Menezes Torres, Augusto Pereira de Sa, Itavahn Alves da Silva, Eliana Ferreira Rodrigues, Carlos Antonio da Silva, Varadarajan Seshadri

Top slag eye opening which happens as a result of gas injection is a function of the gas flow rate in addition to other factors such as ladle geometry, porous plug location as well as slag properties. Slag eye opening leads to entrapment of atmospheric nitrogen, oxygen by the steel melt affecting adversely the steel quality. In this work aspects of mixing and eye formation in steel making ladles with inert gas injection have been analyzed through physical and mathematical modeling techniques. Influence of ladle, gas flow rate and distribution and slag properties has been assessed. A correlation for estimating eye opening has been developed. Results from PIV measurements and images of eye opening obtained using a camera have been utilized to validate results from CFD simulation.

Jan 1, 2015

By R. E. Burleigh

'Gold-telluride mineralization was deposited in quartz veins which cut a Late Cretaceous tonalite pluton emplaced near the southern margin of the Peninsular tectono-stratigraphic terrane in south-central Alaska. The gold-bearing veins formed shortly after the development of a widespread Cu-Mo sheeted quartz vein system. Early mineral assemblages consist of quartz, white mica, pyrite, and arsenopyrite (wall rock only). Subsequently, pyrite. sphalerite, chalcopyrite, zoned tetrahedrite and gold precipitated within multiply fractured veins. Late stage galena, tellurides (altaite, nagyagite, coloradoite), and Pb-Sb or Pb-Cu-Bi sulfosalta with gold constitute bonanza ore assemblages that are variably associated with quartz, white mica, ankerite, and calcite. Fluid inclusion evidence coupled with mineral assemblage paragenesis suggests the depletion of volatiles (C02, H2S) and cooling resulted in the precipitation of high grade gold mineral assemblages.

Jan 1, 1988

By Benjamin P. Hay

Complexation of a metal ion to a ligand often results in structural changes that introduce steric strain within the ligand. A design criterior:1 for ligands that will complex metal ions more strongly is to choose Iigar:1d architecture, that minimizes this strain. This paper describes how molecular mechanics models can be used to define the degree of ligand binding site organization in terms of' ,strain energies associated with conformational reorganization and distortion of the binding conformer. This approach yields a method to predict how modifications to ligand structure will affect metal binding affinity.

Jan 1, 1999

By Farouk T. Awadalla

The presence of humic species in spent Bayer liquor causes many processing problems in the production of aluminum hydroxide. Ozonation of spent Bayer liquor was found to be an effective process to destroy the colored humic species. The kinetics of the decolorization in spent Bayer liquor was found to be slower than in the alkaline humic acid solution containing no alumina. However, the reaction kinetics ware enhanced by heating the solution during ozonation above room temperature. Copper ions which are used as catalyst to enhance the ozonation reaction were found to be ineffective due to the presence of large quantities of aluminum hydroxide in the liquor. Ozonation was a more favorable process than membrane separation as it achieved about 92% separation of color and produced lower amounts of organic material. The treated spent Bayer liquor can be recycled to the upstream process without causing any difficulties and the purity of aluminum hydroxide product would also be improved. A comparison of preliminary cost data indicated that ozonation compares very favorably with membrane separation in this application. Key words: ozonation, Bayer liquor, aluminum hydroxide, humic species, copper ions, membrane separation, purity and economic.

Jan 1, 1994

By K. Robinson

Following the longest Smelter campaign in BCL?s history it was planned to completely rebuild the flash smelting furnace in 1987. This was the fourth major overhaul and the most extensive so far attempted. Detailed planning took place over several year$ preceding the shutdown and implementation was completed in 54 days. The key to minimising shutdown time was the method designed for installation of the new uptake shaft and reaction shaft. Major repair work was also undertaken in the waste heat boiler and electric furnaces. Both of these activities had an impact on the critical path of the flash smelting furnace overhaul.

Jan 1, 1993

By Wen Chen, Xinghua Liu, Zeyou Peng, Qiulin Wang

"Limonite is a collective for iron hydroxide argillaceous materials. It is very difficult to be treated due to the wide variation in specific gravity and magnetism and the high argillization rate in the course of grinding and beneficiation. The iron ore in Huangmei, Hubei, China is the typical representative of limonite. If the limonite is processed using conventional physical beneficiation methods (e.g. magnetic separation, gravity separation, flocculation-desliming-flotation, or a combined process of the three), it can only be obtained an iron concentrate grade of 51.98% and an iron metal recovery of 86.64%. However, the technique of flash magnetic roasting-magnetic separation can improve the concentrate grade to 61.03%, iron recovery to 91.17%. This paper describes the tests of recovering limonite by flash magnetic roasting in detail.IntroductionLimonite (mFe2O3, nH2O)[1] is a general designation for hydrous iron hydroxides and argillaceous matters. Limonite is hard to be separated because of its complicated geneses, comparatively weak magnetism, nonuniform grain size and being easily slimed during grinding. So most small and medium enterprises sell deslimed limonite product which was dealt with just by simple methods of washing, magnetic separation or gravity separation and so on. In recent years with the iron ore prices soaring, significant progress was made in mineral processing research of limonite. Laboratory research and industrial test results showed that flocculation-desliming-flotation process and roasting-magnetic separation process are the two best methods to recover limonite till now. To compare these two methods, roasting-magnetic separation process is superior to flocculation-desliming-flotation process in aspects of beneficiation indexes and industrial stability."

Jan 1, 2012

By Christiana Mystrioti

Greece is the only EU country with extensive nickel laterite deposits. Since the 1960s, the Greek laterites are treated for ferronickel production via a pyrometallurgical route, which involves pre-reduction of the ore in rotary kilns and reduction smelting in electric arc furnaces. Due to the rising cost of energy and the decreasing grade of mined laterites, the pyrometallurgical treatment is economically marginal. For this reason, alternative treatment processes are currently under investigation. Potential applicability of hydrometallurgical treatment, using either H2SO4 or HCl, under atmospheric pressure conditions, for Ni and Co extraction from two low grade laterite ores, was examined in the present work. The two samples were selected to represent the different mineralogical composition of the saprolitic and limonitic ore deposits of the Greek laterites. The investigated parameters were temperature (65–90 °C), acid concentration (1–4 N) and solid to liquid ratio (10–30% w/v). The results indicated that HCl was more efficient than H2SO4 for the treatment of the saprolitic ore; Ni and Co extractions were very high for both elements, up to 98% and 96% respectively, while H2SO4 could leach efficiently Ni, up to 100%, but extracted only 34% of Co. Hydrochloric acid was also more efficient for the treatment of the limonitic ore, with Ni and Co extractions up to 98.3% and 87.6% respectively. With H2SO4 the maximum extractions were 71.3% for Ni and 52.1% for Co.

By Joseph Bloch

The hydriding of bulk metals and alloys is a gas-solid reaction in which a hydride product layer is initially nucleated adjacent to the gas-solid interface and continues to grow until a complete transformation of the parent (a) phase into the hydride phase. The combination of measurements of the overall hydriding kinetics of samples having defined shapes and dimensions, together with examinations of partially hydrided samples, enables the presentation of the reaction rate in terms of an appropriate reaction model. A common and important type of topochemical development of the hydride in bulk metals and alloys involves a hydride layer formed on the metallic surface. The continuity of the layer can affect the reaction rate. The rate of hydrogen absorption in a sample, in the presence of a hydride layer, is usually analyzed using a model combining several sequential steps in which the hydrogen is transferred from the gas phase into the reaction site. Coupling the flux equations across the layer under proper steady state conditions, results in a complex rate equation in which the steady state rate of hydrogen absorption (proportional to the hydride layer velocity) is expressed in terms of the pressure, temperature, the rate constants of the sequential steps and the critical concentrations of hydrogen in the hydride. Generally, the rate constants of the individual microscopic processes are comparable in magnitude, so that the overall rate is not controlled by any of the specific sequential steps. However, there are two limit cases related to the first stage, the adsorption, for which the general rate equation is much simpler, namely, the fast and the slow adsorption approximations. Using this limit cases, equations are derived for the steady state hydriding rate of a given system. These equations provide means to anticipate the pressure dependence of the steady state absorption rate under low pressures, close to Peq and under very high pressures. At the low pressure regime both the fast and slow absorption cases yield linear pressure dependence. For the very high pressure range, it is found that the rate become independent of the applied pressure. The rate is given then by a combination of the individual rate constants of the system and the critical hydrogen concentrations. The model is shown to apply in several real cases, such as ZrCo, LaNi5 and titanium.

Jan 1, 2002

By M. K. Mohan

Lead recovery from process solutions contributes not only to the conservation of resources but also clean environment. Zeolites are natural aluminosilicates, which finds applications as catalysts and in wastewater treatment. In the present investigation, studies were taken up on the processing of Pb from process solutions by zeolites. Effects of pH of the solution, time and type of zeolite viz. chabazite, mordenite, erionite and clinoptilolite on the removal of Pb from solutions was investigated. Rate of sorption was found to depend on the pH of the solution and about 99 pct. recovery was observed at pH 6. Optimal conditions were established for the maximum recovery of lead from process solutions. Possible sorption mechanisms were proposed. The calculated adsorption constants calculated from Langmuir and Freundlich equations showed that the adsorption of lead on chabazite was strong.

Jan 1, 1999

By Jun Enriquez

Kennecott Utah Copper aims to extend anode furnace campaigns to more than three years. As part of that goal improvements are sought on anode-furnace tuyere-area refractory performance. Kennecott and Praxair developed high pressure nitrogen refining for the Oxidation Stage which shortened anode furnace fire refining cycles by up to two hours per cycle. Future developments include optimizing the Reduction Stage’s steam-gas reforming and achieving coherent jet tuyereless refining.

By D. Raghavan

In recent years, the environmental issues related to the landfill shortage received considerable importance. Many polymeric solid wastes have high resistivity to chemical and biological degradation, and options are sought by which these wastes can be recycled and reused, or reduced in volume. The present study investigated the biodegradation of polyethylene by Aspergillus niger, and biodesulfurization of rubber by pure and mixed cultures of Thiobacillus thiooxidans and Thiobacillus ferrooxidans. The fungus, A. niger, was found to metabolize portions of polyethylene. Quantitative calorimetric measurements revealed that the amorphocity of the sample decreased during biodegradation. Removal of sulfur from synthetic rubber samples containing 2 to 15% sulfur, was studied in shake flask experiments and the associated oxygen consumption was studied in Warburg respirometers. The mixed bacterial cultures were more effective in the desulfurization of rubber samples than the pure cultures of T. thiooxidans and T. ferrooxidans. The data obtained in these studies may have far reaching consequence for the development of new effective processes regarding the remediation and management of discarded polymeric packaging wastes and car tire rubber materials.

Jan 1, 1993

By Yuanbo Zhang, Zhixiong You, Daoxian Duan, Guanghui Li, Tao Jiang

"Manganese is mainly consumed by steel and battery industries. In recent years, it is essential to utilize the low-grade manganese oxide ores with total manganese grade below 25%, as the high quality manganese ore resources are becoming scarce with the rapid development of the steel industry. Conventional pyro-metallurgical processes for utilizing manganese oxide ores are characterized by high production cost and energy consumption, low productivity, serious environmental pollution, etc. In this study, reduction thermodynamic of MnO2 reduced by sulfur was firstly carried out. Then, a novel process of reduction roasting with sulfur followed by acid leaching was developed to recover manganese from the very low-grade manganese oxide ores. Effects of main factors, including temperature, reduction time and S/Mn mole ratio, were investigated, and a high leaching efficiency of Mn above 95% was obtained under optimal conditions.IntroductionHigh/middle-grade manganese oxide ores are generally used in the metallurgical industries, particularly in steel plants and ferro-alloy units. The consumption of metal manganese in the ferro-alloy industry accounts for 85- 90% of the total Mn demanded [1]. Therefore, high quality manganese ore resources are becoming scarce with the rapid development of steel industry. It is essential to make good use of large quantity of low-grade manganese ores (TMn < 25%) presently available."

Jan 1, 2012

By Guanghui Li

Nickel pig iron (NPI), used as a substitute for electrolytic nickel, is able to reduce the production cost of stainless steel greatly. Aiming for preparing NPI from nickeliferous laterite ore, a pilot-plant scale test of coal-based rotary kiln direct reduction of laterite ore was performed and reported in this study. In this process, the ground laterite sample (18.85% TFe and 1.52% Ni) mixed with additives, pulverized coal and binder was briquetted into briquettes with the size of 40mm×40mm×31mm, laterite ore briquettes and reducing coal were charged into a rotary kiln with the diameter of 1.6 m and the length of 16 m, for a retention period of 6~7 hours, in which reduction section temperature was ranging from 950~1050 oC. The reduced briquettes were water quenched, ball mill ground and beneficated via low intensity magnetic separation. A magnetic concentrate, Ferronickel powder, with 86.9% TFe and 8.0% Ni was obtained, and the corresponding magnetic recovery of iron and nickel are 75% and 96.3%, respectively.

Jan 1, 2014

By Arthur E. Morris

The primary market driver for improving process technology is innovation, which requires a skilled and educated workforce. However, many Materials Science and Engineering departments have eliminated extractive metallurgy and chemical thermodynamics from their curricula, yet these topics contain the necessary fundamentals for process innovation. As a result, most MS&E students are ill-prepared for careers in processing. The dearth of processoriented MS&E curricula has prompted some Universities to develop a “shared” effort to offer distance education between multiple institutions [1]. A target audience for a shared process simulation course would not only benefit students, but also be a basis for an on-line course for practicing engineers faced with new or changing career choices. To fill the gap, the basics of a process simulation course was developed in an abbreviated form as series of eleven articles and Excel workbooks published in Industrial Heating magazine between July 2012 and July 2013.

Jan 1, 2014

By K. Ono

A new process for extraction of titanium metal from its oxide is demonstrated. In this process, row material to be reduced is titanium oxide synthesized from ilmenite. The reducing agent is the Ca+CaCI2 two-phase mixture. TItanium is elaborated in the medium consisted of liquid Ca, Caq and solid TI02 at the temperature range 1200 to l300K by means of mixing mechanically the ingredients in the reactor into a smooth paste. Fluidity of the feed which enables continuous scheme depends on the CaCl2 content. The oxygen level of the reduced titanium is the range 500 to 1000 mass ppm varying with the operational conditions. The Ca+CaCI2 reducing agent is taken out from the electrolysis of CaC12 at 11401(, and this CaCl2 is produced by aqueous chemistry conversion using Cl2 gas recycled from the electrolysis.

Jan 1, 2001

By Kota Nakashima

Residues from titanium smelting tend to contain scandium. The scandiumis discarded because no suitable process exists for its recovery from the residue. Valuable-metal recovery from discharged residue is critical for environmental conservation and to achieve a sustainable society. Since 2015, JXNippon Mining&Metals has been developing a process for scandium recovery from the residue of a titaniumsmelting process. The process consists of the following steps: scandium concentrating by classification or neutralization, selective scandium leaching, impurity removal by neutralization, solvent extraction of scandium by using D2EHPA, purification, and roasting. We optimized the above steps to achieve an effective process to obtain scandium oxide (Sc2O3). In this paper, we introduce results from the bench-scale test of the scandium recovery flowsheet developed by JX Nippon Mining & Metals.