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By H. H. Law

Large amounts of waste material in the form of flue dust are generated in the operation of copper smelter furnaces. As a result of increasingly stringent disposal, it has become important to develop methods for treating such metallurgical wastes to extract metals and convert them into salable products. A two-step closed-loop hydrometallurgical process, has been developed: (1) extraction with sulfuric acid removes about 90% of zinc and decreases the dust volume by 50%; (2) extraction with hydrochloric acid dissolves the lead and further decrease the dust volume by 75%. A process scheme for generating salable products is proposed.

Jan 1, 1992

By Xi-Shan Li, Qian Li, Yong-bin Yang, Li-na Cui, Tao Jiang, Jie Ge

"With regard to control environment pollution in the roasting pretreatment of sulfur & arsenic-bearing gold concentrate, roasting of double-layered pellet was proposed. In the paper, the characteristics of double-layered pellet roasting were studied. Removal and solidification rates of sulfur and arsenic were investigated as primary factors. The result indicated that the removal and solidification rates of arsenic reached up to 95.91 % and 98.95% while the sulfur was 97.19% and 97.90% respectively on the premise of adopting slaked lime as solidified agent at temperature of 6000, the package proportion of 2.14 and roasting time of 3h. However, pyrite and arsenopyrite were transformed to hematite and magnetite and product of solidification mainly consisted of calcium sulfate, calcium arsenate and calcium sulfite within optimum roasting parameters.IntroductionUtilization of refractory gold resources has been gradually concentrated on with the depletion of the gold resources which are easy to deal with in the world [1]. Sulfur and arsenic-bearing gold ore is a typical refractory gold one, in which ultrafme gold is encapsulated in the structure of metal sulfide minerals [2,3], so it gives poor recovery through direct cyanide leaching. These refractory ores need pretreatment before the process of cyanide leaching to undermine lattice structure of pyrite and arsenopyrite containing gold [4] so that the gold could touch with cyanide solution [5]. Among various methods of pretreatment, conventional roasting method is most effective, but this process generates gases such as S02 and As203 harmful to environment. Therefore solidification roasting was proposed to solve this problem occurring in the conventional roasting at the end of last century."

Jan 1, 2013

By L. Klinger, T. Werber, LA Levin, A Katsman

"The process of catastrophic carburization known as ""metal dusting"", whereby a solid metallic material is converted into fine particles in a carburizing atmosphere, was analyzed. It was shown that this conversion is the result of plastic deformation and subsequent fracture accompanying diffusional phase formation in the near-surface layer. The process is controlled by internal stresses arising during phase transformation. Competition between stress generation and relaxation may result in the attaining the ultimate strength in the near-surface layer and its fracture. Such a mechanism of metal disintegration may occur in a certain temperature interval depending on the kinetic and geometrical parameters of the system - the diffusivities of the alloy's components, the ratio between specific volumes of the new and the old phases, and the ultimate plastic strain. The temperature interval for disintegration of carbon steel, the rate of disintegration, and the period of the disintegration cycle, were evaluated and compared with experimental data. IntroductionCatastrophic carburization, known as ""metal dusting"", consists in conversion of a solid metallic material into fine particles. The process occurs in a carburizing atmosphere at elevated temperatures. The corrosion product, usually named ""coke"", consists of metallic particles dispersed in a loose carbon matrix. Under industrial conditions metal dusting takes place, for example, in a gas mixture of CO and H2 or in hydrocarbon environments. Steels, nickel- and cobalt alloys are susceptible to this kind of wastage in the temperature range 400-800°.A mechanism of metal dusting in steels was proposed by Hochman [1] and later developed by Grabke and coworkers [2-5]. According to the proposed model, the process consists of the following reaction steps:"

Jan 1, 1996

By Jian Wang, Hongyang Cao, Binxiu Wu, Junhong Li, Jimin Wang

"The enrichment and separation of scattered metal indium component in the pressure leaching solution with sulfuric acid from vacuum furnace germanium slag were studied by iron substitute and P204 extraction, which is supplied by shaoguan smelter. The experimental results show that the extracting power of P204 for indium from pressure leach solution is powerful. The optimal technological condition were the ratio of P204 and sulphonating serosene 3:7, phase ratio 1:3, solution pH 1.2, and extracting 5 minute. The enrichment indium solution of 21.7 g/L In at 95.2% recovery ratio was obtained by three-stage counter flow extraction and four- stage counter flow stripping.IntroductionScattered metals, such as Indium and germanium, were inriched as intermediate product or by-product during the metallurgy process of other non-ferrous metals, such as lead, zinc, copper and tin. For example, the indium and germanium were inriched in vacuum furnace germanium slag, which is the by-product of zinc vacuum distillation operation from hard zinc. It is difficult to recovery the indium from the vacuum furnace germanium slag, because the indium content is low, and the chemical composition and phase compositon were complex.Recovery indium from bearing indium zinc slag was researched extensively, such as pressure acid leaching, high temperature evaporation, solvent extraction method[l-7], acid leaching method has the advantages of high leaching rate, which can be separated hydrochloric acid, sulfuric acid and silicon fluoride acid systems. Solvent extraction method has the advantages of low production cost, fast reaction speed, high enrichment ratio, and simple operation."

Jan 1, 2013

By Lijuan Li, Xin Xia, Junjun Huang, Qijie Zhai, Xiang Jiang

"Some experiments with different temperatures (1173, 1223, and l273K) and different annealing times (3, 4, 5, 6min) were carried out on cold-rolled plate of Fe-36Ni invar alloy. The microstructure and the mechanical properties were observed and tested respectively, and the fracture morphology was observed by SEM. The results show that with increasing of the temperature and the annealing time, the austenite grains gradually grow up accompanied by a small amount of annealing twin crystals, meanwhile, its plasticity and toughness are improved, and it is typical ductile fracture under the condition of tensile failure. After annealed at l223K, the invar alloy has better comprehensive properties than that at the other annealing temperatures, and the grains size is more uniform. Furthermore, when the annealing time is 4min, the invar alloy has the best comprehensive properties.IntroductionAs we known, most metals and alloys expand with increasing temperature. More than one hundred years ago (in 1897), Guillaume observed that Fe-Ni alloy with face-centered cubic (fcc) crystal structure, consisting of36%Ni, showing a very small thermal expansion coefficient below the ferro-to-paramagnetic transition, the thermal expansion coefficient around room temperature( <2 X 1O-6K-1 compared to most metallic materials which have a thermal expansion coefficient of 10-20 X 1O-6K-1) [1,2]. Since then, the subject has attracted many researchers, and various alloys with low thermal expansion coefficients have been developed. These alloys, generally known as ""invar alloys"", are in demand where dimensional changes due to variation in temperature must be minimized and where high stability is required [3, 4]."

Jan 1, 2012

By Cameron Harris

With the consolidation of the copper industry in the second half of the 20th century resulting in fewer plants treating ever increasing quantities and qualities of feed, the enormous flexibility of the Noranda Process gives it significant advantages over many competing technologies for the production of matte. Toll smelting, recycling, and secondaries treatment will become the cornerstone of profitable operations for all but the lucky few who have large captive mines associated with the smelter. Consequently, the ability to respond to changing market conditions without significant metallurgical or operational upsets will be of considerable commercial advantage. The inherent stability of this bath-smelting process leads to tight matte grade control, while the bath turbulence leads to rapid consumption of feeds with widely varying physical characteristics. Low capital and operating costs combined with a layout suitable for retrofit into existing converter aisles makes it a sensible choice for parts of the world still experiencing the aforementioned consolidation, which is essentially complete in fully developed economies such as the United States of America and the European Union. This paper will discuss features of the Noranda process compared with other technologies and its place in the future global copper production industry, which is set to become increasingly competitive and aggressive.

Jan 1, 2002

By K:-I. Rhee

The recovery of tellurium from Te-cement obtained during the processing of copper anode slimes was carried out by a series of hydrometallurgical processes, i.e. leaching Te-cement in NaOH solution, precipitation of impurites with the addition of Na2S followed by direct electrowinning of tellurium in NaOH solution. The optimum conditions for each process were determined and discussed in terms of various parameters associated with each step to maximize the recovery and purity of tellurium. The final purity of tellurium from electrowinning in alkaline solution was found to be more than 99.9 %.

Jan 1, 1997

By Wenbo Luo, Jilai Xue, Tiepeng Li, Jun Zhu

Sodium silicate solutions for producing silica have been ultrasound treated to enhance the precipitation process in laboratory scale. Higher precipitation rate was found with ultrasound treated solutions than those without ultrasound. The obtained SiO2 powder products were characterized using XRD, SEM, BET and laser particle size analyzer. The particle size distribution and the specific surface area of the powder products varied with the power input level and the processing time of the ultrasonic treatment. The results indicate that the efficiency of the precipitation process can be improved optimally when the ultrasound is conducted into the solutions before the nucleation stage.

Jan 1, 2015

By A. Valenzuela

During the last years, Chile has been the largest copper producer, either as concentrates or cathodes. Copper obtained via pyrometallurgy is produced by seven smelters, which have carried out modernization plans to increase smelting capacity or to achieve environmental regulations established in the Chilean legislation. Thus, the present work updates technological innovations in smelters, environmental regulations and presents solutions for SO2 handling, particulate matter and arsenic. Also, the authors emphasize the important role of CODELCO Chile, the most important state-owned copper company, in developing technologies such as EI Teniente Converter and EI Teniente Slag Cleaning Furnace,

Jan 1, 2003

By J. M. Toguri

The viscosity of the molten FeO-Fe2O3-Si0z system in the composition range of interest to copper smelting has been investigated using a rotating cylinder technique. The silica content of the slag was varied from 20 to 35 wt percent while the oxygen pressure of the system was varied from 10-7 10-11 atm. The temperature range investigated was from 1200 to 1350°C. It was found that the viscosity of the slag generally decreased with increasing temperature and increasing oxygen pressure. As the silica content was increased, the viscosity was found to increase.

Jan 1, 1976

By M. A. Rabah, F. E. Farghaly, M. A. Motaleb

"Wastewater from industrial galvanization industry was reclaimed under current flow stream conditions. Results showed that the raw water contains 0.7 % by weight total suspended solids (TSS) causing turbidity amounting to 30. Measurements of Zeta potential as a function of pH revealed that solid separation takes place at pH 9. Addition of H2O2 to the polmer solution helps to oxdize ions of iron and zinc metals toinsoluble ferric oxide and zinc hydroxide to a higher state of oxidation. Addition of 5 mg/L of cationic magna flocculants polymeric solution helps the rapid separation of the turbidity. Separation of floccules so formed takes place by filtration. Addition of peroxide ions to the turbid wastewater confirms the physical stability of the flocs so formed. Impurity flocculation takes place in few seconds. Maximum temperature for safe solid removal was <30°C. The treated water was pure and safe for recycling or use in domestic purposes.IntroductionStocks and et. al. [1] show that the galvanizing process introduces spent pickling acid waste production, but its major constituent, could be used. Survey of the operational procedures adopted and the acid wastes produced by UK Galvanizers are reported. Various methods to recovery spent acid of suitable composition and to eliminate zinc contamination was considered. Application of the Kleingarn acid management system reduces waste volume, saves hydrochloric acid (HCl) and increases component throughput whilst, in conjunction with zinc elimination, could allow recycling of the majority of galvanizer’s acid wastes.Dahab [2]; Kerney [3] reported recycling of galvanizing products, including pickleliquor. Kerney suggested a mobile treatment plant for recycling pickling acids. Dahab found that pollution reduction could be achieved by relatively simple operational changes to the process that gave fairly short payback times.Rozenblat and et. al.[4] studied the extraction of zinc (II), iron(III) and iron(II) with Tributyl phosphate (TBP) from hydrochloric acid solutions containing high zinc(II) concentration. Two technological approaches for the separation are considered. Firstly, the selective extraction of iron(III) (iron(II) is oxidized to iron(III)) over zinc(II) with TBP deficiency. Secondly, iron(III) reduction to iron(II) followed by zinc(II) selective extraction with an excess of TBP. Prior stripping, the organic phase was washed with small amounts of water. Scrubbing of TBP solutions containing iron(III) contaminated with zinc(II) gives always a mixture of zinc(II) and iron(III) which must be recycled to the extraction step in continuous process. The following technological concept is proposed: reduction of iron(III) to iron(II), extraction of zinc(II) with 5-10 volume excess of TBP, washing of TBP phase contaminated with iron(II) with small volumes of water and recycling of the scrubbings and stripping of zinc with water."

Jan 1, 2008

By M. Arenas

A corrosion study of a bonded NdFeB permanent magnet materials alloyed with titanium carbide additions has been undertaken. The materials were produced by rapid solidification by melt spinning. Commercial epoxy was used as a bonding medium. The corrosion results were compared with those of a near stoichometric unalloyed NdFeB. Anodic polarization and potentiostatic techniques in 0.9 M Na2SO4 solutions were used to characterize corrosion behavior. It was found that the addition of 6 a10 Tic resulted in superior corrosion resistance, as indicated by lower corrosion currents and less iron dissolution at fixed potential.

Jan 1, 1997

By Akira Yazawa

Oxidic dissolution loss of metal in slag is discussed thermodynamically in terms of oxygen potential, activity coefficient and equilibrium constant. To understand basic principle, regular solution model is applied for model calculation of the activity behaviour of metal oxide in FeO-SiO2-CaO slag, and effects of slag composition, temperature, and basicity of oxide on dissolution loss are demonstrated. As: a simplified but practical conclusion, the dissolved metal loss in slag is inversely proportional to activity coefficient of metal oxide, and also to FeO content in slag when amount of slag is taken account.

Jan 1, 1994

By Zviad Kovziridze

It is stated that the specific character of SPHTS specimens of TiCx consists in crystal lattice strength reflecting the condition of synthesis in ?burning wave?. The use of roentgenographic and other methods of analysis allow to estimate the effect of the conditions of synthesis causing the carbon sablattice defect on the grinding intensity of TiCx -phases. The study of the kinetics of vibratory grinding of TiCx -phases in ethanol and benzene medium allows to establish high grinding intensity of the phases close to stoichiometry and the possibility of producing high dispersion powders (Ssp 4.5-6 m2/g).

Jan 1, 2006

By B. G. Belew

Recent operating improvements at the Phelps Dodge Chino Smelter, coupled with intensive capital expenditures since 1987, have resulted in a safer, higher quality, more productive smelter. This paper briefly reviews the flowsheet of the Chino Smelter with emphasis on recent capital expenditures. The main focus of the paper is to provide case studies of how operating functions have been improved. Case studies presented include: (1) safety, (2) anode quality control, (3) flash furnace cross-over build-up control, and (4) flash furnace temperature control. Most of these accomplishments have been achieved by providing specific measurable goals and subsequent feedback to operating crews.

Jan 1, 1993

By Christian M. Sagedahl

The stringent environmental regulations for air pollution regarding emission control, along with the need of dry concentrates to feed autogenous smelting processes, are enhancing the development of cleaner technologies. Indirect drying of concentrates by a Kvaemer steam dryer is a technology with promising results, reducing dust entrainment to the exhaust gas stream and leading to smaller dust separation units. The Kvaemer dryers are designed for a very high availability, a high-energy efficiency, low amount and velocity of exhaust gases, no SO2, CO or CO, emissions combined with a wide range of satisfactory operating conditions and low total operational costs.

Jan 1, 1999

By Kliment Y. Hakobyan

A new technology for treating molybdenum sulfide concentrates has been developed. It includes roasting the concentrate in a special regime with water vapor, cooling and neutralizing exit gas, oxidation roasting of rhenium containing MoO2, and the extraction of rhenium from exit gases. This technology allows economically efficient and environmentally safe processing of molybdenum concentrates: The degree of molybdenum extraction is 98.8%, rhenium-90%, sulphur-98.4%. The technology also ensures high extents of extraction of selenium and tellurium as well as the fixation of sulfur in the form of sodium sulfide or elemental sulfur.

Jan 1, 2006

By Mary Cunningham

The EPA and DOE have collaborated on a series of studies to evaluate the effectiveness of treatment technologies at stabilizing bulk elemental mercury and wastes containing high concentrations (i.e., with greater than 260 mglkg total mercury) and multiple forms of mercury. The data from these treatment demonstrations are intended to help EPA to determine if regulatory revisions to allow a stabilization alternative for high-mercury subcategory wastes are warranted. In addition to mercury-contaminated wastes, the disposal of bulk elemental mercury is of concern because of the excess quantity of mercury in the Defense Logistics Agency (DLA) stockpile, as well as other potential sources of excess elemental mercury. The studies evaluated the effectiveness of several technologies at: I) stabilization of mercury in a "hard-to-treat" matrix; and 2) conversion of elemental mercury into a stable waste form for disposal. A surrogate waste was designed for the study on high-mercury wastes, which included an organic form of mercury, elemental mercury, and several mercury salts in an inorganic matrix. The surrogate waste and the bulk elemental mercury were treated by the vendors, and the treated waste forms evaluated for mercury Icachability, using both the TCLP and an automated, constant-pH leaching protocol. Constant pH leaching was conducted at pH 2,4,6,8 10 and 12 for 14 days at each pH. The leaching data demonstrate that the stability of the mercury in three treated waste forms varies widely across the pH range tested. Clearly, the stability of mercury in these treated waste forms will be highly dependant on the disposal conditions. The combination of site-specific disposal conditions and appropriate treatment technology must be considered as decisions are made about disposal of high-mercury wastes.

Jan 1, 2003

By M. Rubinstein, N. C. Koon, B. N. Das, V. G. Harris

"Copper and gold - based alloys having giant magnetoresistance properties were produced by melt spinning from arc melted and cast rods. The ribbon width varied between 1 and 2 mm and the ribbon thicknesses were in the range of 30 to 50 11m. The uniform microstructure of the cast rods indicated the composition homogeneity in the starting material. The ribbons showed composition uniformity across the cross section from EDX analysis. However, the spun ribbon microstructure changed from a 'frozen in' region near the wheel side to a nanosize spherically precipitated phase towards the freely frozen surface. The evolution of the microstructure from the spun ribbon state to the annealed ones was studied by optical microscopy, SEM and TEM. The structural information of the spun and annealed specimens was obtained from X - ray, electron diffraction, electron microscopy and ferromagnetic resonance. Magnetoresistance was measured by the four point probe method.IntroductionRecently. Giant Magnetoresistance. GMR. has been observed in sputtered thin films alloys of Ag. Au and Cu with Co and Fe [1. 2. 3]. The sputtered films are produced by condensation of the alloys from the vapor phase. These Ag. Au and Cu alloys are miscible and homogeneous in the vapor and liquid phase (except Ag alloys which exhibit phase separation even in the liquid phase) but immiscible and heterogeneous in the solid phase. In our work we have produced thin ribbons of the Cu and Au alloys about 30 µm thick from the miscible state in liquid phase by rapid solidification melt spinning. The microstructural development of the ribbons was investigated in the as - spun condition and on annealing. The other properties such as magnetization. GMR and Mossbauer Spectroscopy were also investigated in the various microstructural conditions of the ribbons."

Jan 1, 1994

By Biswadeep Saha, Meenakshisundaram Ramanathan, Chai Ren, Sivaraman Guruswamy

"Fe-Ga alloys have a large low-field magnetostriction and these alloys are attractive candidates in energy conversion and harvesting applications. Small additions of W also increase the magnetostriction of Fe. In this paper changes in magnetostriction by W substitution for Ga in various Fe-x at.% Ga alloys are presented. Fe-Ga-W single crystals were grown using vertical Bridgman Growth technique. [001]-orientated single crystal samples were prepared with faces within 1 degree off <100> orientation. The samples were annealed at 1150 °C in the alpha-phase region and water quenched. The magnetostriction coefficient (3/2)A-100 measurements were made on these Fe-Ga-W single crystals. The result on the effects of W substitution and annealing on the magnetostrictive behavior of these alloys are discussed.*Support of this work by NSF-DMR under the award DMR-0854166 is gratefully acknowledged.IntroductionMagnetostrictive materials changes their dimension exhibit reversible strains and changes in elastic properties in the presence of an applied magnetic field or the reciprocal effect of changes in the magnetic properties with the application of stress [IJ and are very important in sensor, actuator device, linear motor, magnetomechanical devices, microelectro- mechanical devices, active vibration dampening devices application areas. The discovery of an order of magnitude enhancement in the magnetostriction of Fe with Ga addition coupled with low saturation magnetic fields, and excellent mechanical properties opened up the possibility of obtaining larger magnetostriction values in other low-cost ductile a-Fe phase based alloys with alloying additives that are less expensive than rareearths such as Tb and Dy [2·4l_ The magnetostriction values observed in Fe-Ga single crystals are sensitive to thermal history and composition. The formation of second short range ordering phases and local defects inside crystal structure can also cause a dramatic change to this alloy's magnetostriction behavior [5-9l_"

Jan 1, 2012