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By P. H. Chang, J. E. Gould

"Solidification structures and austenite decomposition in some spot welded O.05%C - O.3%Mn steels have been studied with the aid of a numerical thermal model. The model is a one dimensional finite difference formulation, and accounts for melting, temperature dependent thermal properties, effective heat transfer in the liquid, and contact resistances. The model was used to predict solidification conditions during resolidification of the nugget. These solidification conditions were correlated with the primary dendrite spacing using available primary dendrite spacings modelling. The model was also used to predict cooling rates in the temperature regime for austenite decomposition. These cooling rates were used to interpret the underlying microstructure.INTRODUCTIONThe metallurgical transformations which occur during the spot welding of low carbon steels have traditionally been characterized only in the most general of fashions. This is most probably due to the similarity of spot welded microstructures to other welded microstructures, and that the mechanical integrity of spot welds has not been a concern. In addition, little information about the particular thermal cycles experienced during spot welding has been available. The introduction of HSLA (microalloyed) sheet steels has, however, raised new concerns about the integrity of spot welds. These steels have on occasion shown irregular weldability, as well as brittleness in the weld nugget on destructive testing l - 4 .In response to these concerns, considerable work has been done attempting to characterize thermal cycles in spot welds 5-12. This has largely taken the form of thermal modelling, with the end purpose generally to estimate the size of the nugget formed. This work uses the thermal model developed at Inland Steel 13 ,14 to try and understand, in a more fundamental way, microstructural evolution in spot welds. Two facets of this microstructural evolution are examined in detail:"

Jan 1, 1986

By A. Navarra

Peirce-Smith converting (PSC) is applied for roughly 50% of primary nickel and 70% of primary copper production. PSC cycles produce batches of ironfree sulfide matte (or blister copper, in the case of copper smelters), that are subject to further processing. However, the number of cycles that can be performed simultaneously is limited by the offgas handling system. Moreover, PSC suffers from variation in the yield and duration of the cycles. This variation is managed by conventional smelter designs, in which the upstream smelting capacity exceeds the nominal converting capacity; PSC is thus a major bottleneck in conventional nickel and copper smelters. Stabilization and standardization of PSC operations can therefore increase smelter throughput. The current paper presents a discrete event simulation (DES) framework to assist in smelter debottlenecking. It features random number generation to represent cycle variability, and time-adaptive finite differences to represent thermochemical complexity. Preliminary computations are presented.

By I. M. Ritchie

Cyanide owes its great success as a lixivant for gold to the great strength of the Au-CN bond. A replacement for cyanide must similarly be a strong complexant for gold (I) or gold (III). The various alternatives are briefly considered and it is concluded that only thiosulfate has a reasonable chance of replacing cyanide as a relatively non-toxic lixivant at the present time. However, there are considerable technical problems to be overcome before thiosulfate can be considered to be a realistic alternative to cyanide. Firstly, the leaching of gold using aerated ammoniacal thiosulfate with copper as a catalyst is a complex process which needs to be understood and controlled carefully in order to achieve maximum recoveries with minimum reagent losses. Secondly, there needs to be an option similar to the CIP process for recovering and concentrating the dissolved gold thiosulfate complex from pulps produced in the processing of low grade gold ores. The prospects for overcoming these technical' challenges are evaluated and discussed.

Jan 1, 1998

By N. Y. Ma

Solid wastes produced in ironmaking and steelmaking off-gas cleaning systems often contain zinc. The zinc level in these solid wastes is generally too high to recycle the wastes for iron through blast furnaces, but too low to economically treat the wastes for zinc through zincrecovery facilities. The behavior, status, and distribution of zinc in the ironmaking and steelmaking off-gas cleaning systems have been analyzed from three aspects: thermodynamics of zinc condensation, oxidation and deposition, correlation of zinc concentration with particle size and density, and aerodynamics of dust particles in the off-gas cleaning systems. Theory and supporting data show that spontaneous separation of zinc from iron-bearing dust occurs in the ironmaking and steelmaking off-gas cleaning systems. Dry off-gas cleaning systems provide the most favorable conditions and environments for zinc to separate from the dust. If highefficiency dry separators were applied and appropriately arranged in the off-gas cleaning systems, zinc would be concentrated, and the majority of the solid wastes could be recycled for iron recovery through blast furnaces.

Jan 1, 2008

By Tao Zhang, Wen-tao YU, Hai-bin ZUO, Jian-Liang Zhang

Sintering-pot tests and metallurgical performances of sinter with 4 kind of different Al2O3 contents are experimented in this paper. Results show: when the Al2O3 contents increase from 2.0% to 3.5%, acicular calcium ferrites in mine phase will be gradually replaced by plate-like iron calcium. The increase of Al2O3 contents will lead to the addition of liquid viscosity and the reduction of permeability of sinter bed. Sintering time will be prolonged. The rate of yield is stable basically but production is low; besides, the increase of liquid viscosity will decrease of drum strength. The change of permeability of the material layer will make RDI +3.15 decrease first and then increase when Al2O3 contents changed from 2.0% to 3.5%. RI of sinter shows a contrary trend because many open voids are formed by deterioration of liquidity first and then pores closed.

Jan 1, 2015

By Mingchun Lu, Zhe Wang, Mingming Cao, Xiangdong Xing, Shan Ren, Jianliang Zhang, Zhengjian Liu

"The effect of reduction temperature on the vanadium titano-magnetite carbon composite pellets was investigated by X-ray diffraction (XRD) and scanning electron microscopy (SEM), and the discussion has put emphasis upon the enhanced reduction mechanism of additives containing CaF2 and NaF in this paper. The results showed that the reduction temperature of 1350°C was needed for the generation, mergence and growing up of metallic iron as well as monomer dissociation between metallic iron particles and slag phase in the vanadium titano-magnetite metallization pellets. The iron compound was completely reduced into metal iron, and Fe2Ti04 was mainly transformed into metal iron, (Fe,Mg)Ti205 and FeTi03 at 1350°C. The maximum metallization ratio was only 88.5% at 13500 for 30 min without any additive. However, with the addition of 3.0% CaF2 or NaF, the metallization degree of pellets could reach up to 94.8% and 92.5%, respectively.IntroductionVanadium titano-magnetite which is mainly distributed in the area of Panxi, Chengde and Maanshan in China is a kind of complex iron ore which contains various valuable metal elements such as iron, vanadium, titanium, etc. Among the above areas, Panzhihua (Sichuan Province in China) area possesses the largest deposits of vanadium titano-magnetite and the future reserves are more than 100x108t, and the reserves of Ti existing as Ti02 reach to 8.7x108t which occupy over 91% of the whole nation and ranked No.1 in the world[1]. Lots of researches on the comprehensive utilization of vanadium titano-magnetite have been conducted in the world. And many technological processes have been applied successfully in industrial production. Among these processes, the process of rotary kiln-electric furnace is employed to recover iron and vanadium in South-Africa, while the process of blast furnace-rotary furnace is widely used in Russia and China. Besides, many researchers have made efforts on employing new direct reduction process to realize the effective comprehensive utilization of vanadium titano-magnetite[2-4]. However, the direct reduction process is only researched in laboratory and it has not been used in industry."

Jan 1, 2013

By S. E. Khalafalla

A method for preparing ferrochromium alloys containing less than 2 pct carbon has been devised in a single vacuum furnace reactor. This method can conserve chromium and should reduce the capital and energy requirements relative to chromite electrothermal reduction. Reduced products containing less than 2 and as low as 0.01 wt pct carbon were obtained by reacting pellets of chromite and carbonaceous reductant mixtures at pressures of 0.1 to 1 ton and temperatures of 1,230° to 1,320° C. The extent of reduction increased with increased temperature and decreased pressure; however, operating conditions were limited due to the onset of significant chromium vaporization at higher temperatures and lower pressures. Foundry coke, anthracite, and carbon black were found to be superior to graphite as reductants. The reduction of chromite to metallics was found to proceed via the carbide intermediates Fe3C or Cr3C2. Lime accelerates the. rate of solid state reduction of chromite and can shorten the furnacin1r time at 1,3000 C under vacuum from 13 hours to less than three hours. Additional lime and silica are added to the hot reduced chromite after releasing the vacuum and raising the furnace. temperature to 1, 700° C. Soaking the charge for about 20 minutes gave a button of low carbon ferrochromium alloy beneath a well-defined slag layer.

Jan 1, 1985

By Volovik A. V. Ivtan, Shelkov E. M. Ivtah

"One of the most power consumption Industrial process is production of Al from bauxites (about 45000KWt.hour electrical energy for production of 1 ton. of technical Al). This process is based at the low efficiency and productivity electrolysis technology.Last years IVTAN investigations give to .us information about possibility to use of high temperature shaft- furnaces for efficiency production of alumina (AL2O3 ) technical. aluminium and some all.oys on the base of the high temperature carbon- thermal reduction process. At this case power consumption for production of unit of last, product will be less at the 3-4 times.The carbon-thermal method is allow produce alumina (Al203 ), technical Al and its alloys not only from deficient bauxites, but practically inexhaustible reserve of other types of Al-contain row materials (cianite, sillimonite and so on/The thermal-chemical economical analises of fulfilled at the IVTAN, production of alumina. Base on facts of production and technical technology are especially for ones arguments at the high temperature shaft-furnace technical Al and its alloysIn the last decades of the 20-th century, the discharge into atmosphere of high temperature and. combustion gases places . problems before humanity more and more sharply and becomes of great importance task.But at the same time, as production of material values increases, intensity of pollution of environment increases all time. And the value of new processes and. technologies of material production, aimed at reducing the expenditure of power and pollution of· the environment, also increases."

Jan 1, 2000

By William Petruk

Mineralogical and image analysis studies have been performed on four volcanogenic base metal ores that contain 0.01 to 4.5 wt% Pb to determine the behaviour of galena during mineral processing. The galena in these ores is fine grained and is poorly liberated in both the primacy and regrind mill discharges. Consequently, low grade Pb concentrates are produced to obtain relatively high Pb recoveries. The Pb concentrates contain many impurities including high amounts of pyrite and sphalerite, and small amount of CU-, As-, Ag-, Bi-, and Se-sulfides. These impurities need to be rejected from the Pb bullion during smelting. The galena commonly contains up to 1 wt% Ag in solid solution with an average of 600 to 1460 ppu for the deposits studied to date. The Ag in galena accounts for up to 65% of the Ag in some ores.

Jan 1, 1990

By I. Iwasaki

Platinum group elements (PGE) are often found in arsenide and sulfarsenide minerals as inclusions in copper-nickel bearing gabbroic rocks. Major losses of platinum in flotation have been attributed to the poor recoveries of the arsenic minerals. Flotation characteristics of a synthetic nickel arsenide and arsenopyrite were studied through rest potential and oxidation rate determinations, surface analyses, and micro-and batch-flotation tests. The use of nitrogen during grinding and flotation together with copper activation improved the PGE recoveries from Duluth Complex ores. The flotation behaviors of the sulfarsenide minerals are still unresolved. The role that electrochemical interactions play among arsenides, sulfarsenides, sulfides and grinding media on their f10atabilities is discussed.

Jan 1, 1988

By Tao Zeng, Jianchao Li, Chang Jie, Jieyu Zhang, Jifang Xu, Kuochih Chou

"The densities of the selected quaternary Ca0-5%Mg0-Alz03-Si02 slag with low silica were measured by the Archimedean method in a wide temperature range from l 723K to 1823K. Slag compositions were chosen based on five different levels of Si02 content between 0.00 pct and 11.40 pct. The MgO content was equaled to 5.00 pct. The mass ratio of CaO/Alz03 was varied from 0.67 to 2.14. The effects of temperature, Ca0/Alz03 ratio and optical basicity were studied. It is shown that density decrease approximately linearly with an increase in temperature. With the same Si02 content, the density decreases with increasing of CaO/Alz03 ratio and optical basicity. Based on the experimental data as the boundary of the homogenous phase region predicated by F ACTSAGE software, the mass triangle model is used to calculate the density of selected limited homogenous phase region. The results showed that the mass triangle model is working well.IntroductionIt is of great importance to measure density of slag melt not only to the theory research for melt, which that is directly amenable to the structure correlations of molten slags, but also to the industrial application. Many metallurgy phenomena such as inclusion formation in molten melt and its removing, slag foaming, slag-metal reaction are closely related to the density of slag. Density is also required to estimate other fundamental properties, like surface tension, viscosity, and thermal conductivity from thermal diffusivity so that a relatively complete picture in regard to the behavior of high-temperature molten oxides could be made."

Jan 1, 2013

By Baokuan Li, Fang Wang

"Comparing with the single electrode in electroslag remelting processes, two series-connected electrodes have the advantage of little inductance, lower power consumption and higher melting rate, which was widely used to produce superalloys and specialty steels. Detailed understanding of the electromagnetic field distribution is essential for both improving ingot quality and saving electric energy. In the present work, a 3D finite element model was developed for the magnetic field, electromagnetic force, current density and Joule heating field of electro slag remelting processes (electrode, slag and ingot) with two series-connected electrodes using Maxwell equation, Lorentz law and Joule law. The results show that the maximum current distribute occur at the middle of electrode, due to the interaction of selfinduced and mutual-induced of two series-connected electrode; associated magnetic flux density on the inner side of electrode increase and the outer decrease; The maximum joule heating is at the interface of slag and electrode. The parameter study shows that if the current frequency is greater than 35Hz, the current density in inner electrode tend to linear distribution; with the increasing of original current, The maximum current density near the wall in electrode will increase linearly; with the increasing of electrode innnersion depth and decrease of slag cap thickness and the maximum of the joule heat in slag will increase.IntroductionElectroslag remelting processes(ESR) are widely used to produce superalloys and specialty steels [l-3l_Two pair, four pair or six pair electrodes in electroslag remelting processes is common in casting large scale ingot, which has the advantage of little inductance, lower power consumption and higher melting rate, comparing to singe electrode. They have the same essence with two electrodes in ESR.Compared to the single electrode ofESR, the other electrode is added which can decrease the reactive resistance and power consumption in the two electrodes of ESR. It is a complicated metallurgy process with a series physical and chemistry phenomenon from the molten of steel to the solidification of ingot [4-71_ These physical and chemistry phenomenon originated the effect of alternating current of high intensity. The rule of the alternating current of high intensity which revealed the law of physical and chemistry phenomenon in ESR is the precondition of improving ingot quality and saving electric energy. Jihe Wei and Yongli Ren[S-9lstudied the distribution of electromagnetic field in single electrode ofESR with Maxwell equation and relative electromagnetic theory. It had the limitation that take the electrode and mold as infinite conductivity. A detail analysis of Electromagnetic fields in ESR had been conducted by Patel A D [JO-llJ using general stream-function formulation. It is difficult to extend to three dimensions which could not be used widely. Daniel V [lZJ and Kharicha A [BJ only analysis the current density associated magnetic flux density field and temperature field without the whole irlformation of electromagnetic field. Maopeng Geng [l4J considered the current density and temperature field of the real and fake electrodes in ESR without skin effect. As to the complication of the two electrodes of ESR, it is rarely reported the electromagnetic field and Joule heating field of the two electrodes in ESR. The rule of effect of electromagnetic and modification of numerical simulation should be studied in depth."

Jan 1, 2011

By J. A. Brierley

A biooxidation-heap pretreatment process was field tested to evaluate enhancing gold recovery from a preg-robbing sulfidic carbonaceous ore. Newmont Gold Company&apos;s Gold Quarry sulfidic carbonaceous ore was inoculated with an iron-grown culture of Thiobacillus ferrooxidans to form a 495 ton test heap. Biooxidation was conducted for a period of 100 days. The most active period of biooxidation occurred during the first 40 days of pretreatment? About 35 to 40% of the sulfide was oxidized. The extent of biooxidation was considered good as the ore particle size was relatively large 58% >1?9 cm (&apos;/< inch). The larger particle size ore limited the extent of bacterial activity. The field test demonstrated the ability to conduct biooxidation in a small pilot test heap. Thiourea was evaluated for extraction of gold from the biooxidized preg-robbing ore.

Jan 1, 1995

By Michael L. Sorokin

The various methods of converter slag cleaning operation are analysed from the thermodynamk point of view: cleaning using coal, cleaning using combustion products of natural gas and cleaning in presence of matte. All calculations were done, applying the developing computer procedure based on the free energy minimisation algorithm. Three-suffix Margules equations were used to calculate thermodynamic properties of melts; The calculations resulted in recommendations for the practical appliance.

Jan 1, 1995

By Muhamad Firdaus

There is a growing interest in Magnetoelectric (ME) materials in view of both fundamental understanding and novel desirable applications. The application potential for multiferroic materials with the possibility of reversing the magnetization by applying an electric field (or vice versa) is quite promising especially in data storage application. The rare earth ortho-ferrites (REFeO3), such as NdFeO3, have been studied extensively in recent study in the context of discovery of magneto-electric (ME)/multiferroic nature materials. In this paper a potential high temperature recovery of rare earth elements in the form of REFeO3 from waste permanent magnets using direct oxidation in air was investigated. It was found that REFeO3 (NdFeO3) phase can be separated from the other oxide phases by thermal treatment of NdFeB magnet waste at 1100 °C in air atmosphere. The REFeO3 also found to have different physical characteristic (density) from the other layers and can be separated physically. This paper will include a proposed flowsheet to recover Nd as NdFeO3 through powder separation. The technique can be beneficial and favourable for RE recycling and recovery from waste permanent magnets.

By Mingming Zhang, Mallikharjuna R. Bogala, Ramana G. Reddy

Steelmaking desulfurization slag samples were characterized using chemical, X-ray diffraction (XRD), scanning electron microscopy (SEM) and energy dispersive spectrometry (EDS) methods. The objective of this work is to investigate the occurrence of sulfur and phosphorus components in the slag samples and to identify their origin and associations with the iron phases. Thermodynamic calculations results confirm the presence of phosphorus and sulfur components in the slag sample at high temperatures (1400 to 1800oC). The main constituents of slag include Ca3SiO5 (28.1%), MgO (9.31%), Ca3(PO4)2 (9.18%), CaS (8.39%) and CaO (5.68%). The major phosphorus and sulfur components of the slag are Ca3PO4 (99.2%) and CaS (79.3%) respectively. Characterization studies indicate the presence of microparticles of different sizes and shapes in the slag sample. Elemental analysis of these particles confirm the presence of major elements (O, Mg, Al, Si, S, Ca and Fe) in the slag sample.

Jan 1, 2015

By Björn Saxen

Outotec atmospheric Direct Leaching has so far been implemented for zinc production capacities of around 100,000 t/a. Lately, there has been growing interest for small scale direct leaching plants, producing circa 30,000 t/a of Zn. Such small leaching plants can provide extra front-end capacity in existing roaster-based plants and enable treatment of feed materials not suitable for roasting. In small scale plants the proven OKTOP® 9000 Direct Leaching reactors are not readily applicable, due the large size. For smaller installations a modular approach is proposed providing multiple advantages, such as reducing the construction time and amount of the site work required causing less disturbance to regular plant operation with reduced cost. In this paper, we present advantages that can be achieved by using modular OKTOP®C reactors and discuss also process design when connecting a small scale direct leaching process to an existing zinc plant. Also benefits of direct leaching expansion are presented.

By Bora Derin

This work deals with the recovery of valuable metals from the ancient copper smelting slags located in Küre-Turkey. In this process, copper and cobalt were recovered in metallic form and/or as their compounds, whereas iron was recovered as magnetic oxide or pigment. Abrasive grit material was produced using reduced final slag. The process stages involved carbothermal reduction in a DC arc furnace, granulation, leaching, chemical precipitation, selective sulfidizing roasting and product preparations. In this paper, the process stages were described as theoretically and experimentally whereas slag and products were characterized in detail.

Jan 1, 2003

By José Carlos Abreu

This work presents a kinetics study covering the effects of temperature over the reduction rates of a carbon composite briquette, aiming its use as burden in some of the new alternate ironmaking technologies, such as the Tecnored process. It is reported that increases in the temperature increases the reaction rate. Additionally, the morphology of the iron phase generated during the reduction of these briquettes is presented. It was possible to verify that three types of iron morphology occurred during the process: an external, dense and continuous iron layer, the presence of iron globules at the center of the briquettes and whiskers at the briquette&apos;s core. The measurement of the carbon content on the globules and the external iron layer is also presented.

Jan 1, 2003

By D. Mishra

Electric arc furnace dust (EAFD) generated during the recycling of steel- scrap is classified as a hazardous waste for landfilling. This is because it contains leachable heavy metals such as zinc, lead,... Recovery of these metals could result in both resources conservation and resolving waste disposal problems. A study of the thermal reduction of a sample of EAFD was carried out in an inert gas atmosphere using coke as a reducing agent. Preferential volatilization of zinc and lead was achieved during the reduction process at about 800 "C. More than 96 % of both zinc and lead were removed from the dust and were recovered in the condensates. The treatment residue was essentially composed of iron oxides and almost free from heavy metals.

Jan 1, 2002