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By Berger. P.

The accepted definition of the function of an edge protector fails to specify adequately the several tasks which it must perform to be functionally effective: detailed analysis of these tasks leads to the reasoned conclusion that they cannot satisfactorily be fulfilled by the conventional types of "edge-strips". The true cost of edge protector failure is cumulative: renewal costs are dwarfed by the increased operating expenses and production losses which result from but partial or incipient failure of the edge-strip; yet, the several supposedly improved types, for use with starter-blanks, generally were "built down to a price", prolonging the agony, as it were. Clearly, a fresh appraisal of the problem was overdue, and more especially so with the advent of "permanent" cathodes. As a result, new methods of edge .protection have been developed, including the so-called "EDGEWISE" system in which the present author as patentee *) has a vested interest-which he hereby declares. Due mention is made of recent progress in protecting the edges of aluminium "Jumbo" cathodes in zinc electrowinning operations, although the present Paper is more concerned with edge protection of starter-blanks and permanent cathodes in copper ER/EW processes, where most of the "old" problems now may justifiably be claimed to have been overcome, Mention is also made - albeit at this time necessarily only briefly, and confined to edge protection - of "rigidized" metal blanks and permanent cathodes: a most recent development**) which may prove to represent a "breakthrough": time will tell.

Jan 1, 1987

By Xin Zhang, Mengqi Li, Hongxu Li, Xinrong Zhang, Hao Bai, Ning Li

"Organic Rankin Cycle (ORC) is an effective technology to transform low-grade energy resource into electricity. In this paper, based on thermodynamic principle, considering the waste heat resource lower than 120°C, thermodynamic properties of ORC with working fluids ofR245fa, mixed R21/R245fa and mixed Rl52a/R245fa were assessed. The results show that high evaporation temperature contributes to improved system performance. The Rankine Cycle that uses R21/R245fa can increase net cycle output, thermal efficiency and exergy efficiency by 3.02%, 2.35%, and 4.44%,respectively, as compared to that with pure R245fa. When using Rl52a/R245fa as working fluid, the net cycle output can increase by 3.83% at most, while the thermal efficiency decreases by 8.7%. These results indicate that R21/R245fa has a good advantage in improving the cycle thermodynamic performance.IntroductionOrganic Rankine cycle is usually used for low temperature power generation, and is applied to the conversion of geothermal energy, low-temperature solar energy, ocean thermal energy and industrial low-temperature waste heat etc. Traditional Rankine cycle is quite mature already, however, organic working fluids would affect significantly the general efficiency of the entire thermodynamic system. Thus, selection of proper working fluids and development of new highperformance cycle is becoming important."

Jan 1, 2013

By Honglei Zhang, Wuguo Xiang, Xinhao Huang, Guotao Xu, Xilai Chen

"The service behavior of refractories used in hot air pipeline for hot air stoves in a 3200 M3 blast furnace of WISCO was analyzed. The damage factors can be concluded as the poor quality of and alusite based bricks, the severe thermal shock damage, the more porosity in structures, loose bonding capability, and the unreasonable choice of materials and design of bricks. By analysis, the service life of hot air stoves can be enhanced by the measurements such as the reasonable choice of materials and their match, the use of light-weight refractories, the improvement of brick type, etc. Thereafter, the normal production operation of hot air stoves is guaranteed.IntroductionThe No.7 blast furnace of WISCO has been used for about 5 years and it was mid-repaired in March, 2012. The top phenomena of worn hot air pipelines are brick drop, breakage, severely local wear and deformation, existing hidden danger, so the worn hot air pipelines were renewed. Investigations have been done on the stove damage and design [1,2]. In order to clarify the wear mechanism, the used refractories for hot air pipelines were sampled and analyzed, the properties and structures of worn materials and reused materials are relatively studied."

Jan 1, 2013

By J. C. Agarwal

Do large-scale projects in mining and smelting start up and achieve expected capacity on schedule? In most cases not. Regardless of worldwide location, company know-how, or financial backing, unforeseen delays occur. A comprehensive CRA study for the World Bank shows that delays are the rule, not the exception, in most mining and smelting projects. When delays are not factored into analysis and planning, financial projections are, literally, not to be believed. Returns on investment will seldom achieve their targeted level because of startup delays. This paper reviews the results of our analysis of startup of new mines, mills, and smelters; provides a detailed discussion of why delays occur in the smelters and refineries; presents the cash flow implications of startup delays; and discusses preventive measures that should be taken to avoid financial shortfalls,

Jan 1, 1983

A novel process is being developed for metal recovery from waste electrical and electronic equipment involving a leach reactor coupled to an electrochemical reactor. Metals such as Ag, Au, Cu, Pb, Pd, Sn etc. are dissolved from shredded electronic scrap in an acidic aqueous chloride electrolyte by oxidising them with aqueous dissolved chlorine species. In the electrochemical reactor: (i) chlorine is generated at the anode for use as the oxidant in the leach reactor, and, simultaneously, (ii) at the cathode, the dissolved metals are electrodeposited from the leach solution. The extended Butler-Volmer equation was used to provide predictions of the electrode potential dependences of partial current densities and, hence, total current densities, current efficiencies and alloy compositions for acidic aqueous chloride electrolytes containing Ag(I), Au(III), Cu(II), Pb(II), Pd(IV) and Sn(IV) species, together with dissolved chlorine. With judicious choice of kinetic parameters, the predicted total current density ? electrode potential behaviour of such solutions was in good agreement with experimental data for a rotating Pt disc electrode. Reduction of dissolved chlorine at a Pt rotating disc electrode exhibited mass transport controlled behaviour, in agreement with Levich?s equation over the potential range 0.3-0.9 V (SHE). This could form the basis of a linear sensor, possibly using a microelectrode for measurement and control of the dissolved chlorine concentration in the efflux of leach reactors and inlet to electrowinning reactors in the envisaged process.

Jan 1, 2003

By Takahiko Okura

Japanese non-ferrous industry introduced large-scale smelting plants along seashores for overseas concentrates with increasing demand of metals around 1970s. Although serious environmental pollution became obvious, with economic growth, the industry got rid of pollution by installing new processes and improving operation technologies. At present, over 99.8% of sulfur input to smelters is fixed as stable compounds. Through those decades Japan had steep rises of oil prices, sudden change of exchange rate, and inadequate treating charges, we were faced to consider the closure of smelters. The industry has survived by increasing productivity, saving energy and reducing manpower. Furthermore the industry made great effort to recycle valued metals from scraps and wastes for the resources-recycling society. Academic research also contributes to support these individual technologies. Thus the industry has fostered world-acclaimed technologies in terms of efficiency and energy conservation. This paper presents technology development and environmentally-benign sulfide smelting processes.

By John M. Rogers

Risk management has rapidly developed to become an integrated, holistic approach that now encompasses the main risk elements such as product quality control, occupational health and safety, security, environmental liability, social issues and related management information systems. Given the obvious economic benefits, a seamless blend of risk management components has become essential to allowing organisations to sustain a competitive advantage, and is also looked upon as an important attribute in organisational growth. Juxtaposed with this management philosophy is the global trend towards outsourcing, which has seen the emergence of independent, and specialist risk management organisations. The New Millennium will undoubtedly see a shift away from "in-house" risk management practices, and consequently, the selection of a suitable risk management partner - a major vehicle for improving shareholder value - will become an important strategic management decision.

Jan 1, 1999

By K. Morsi

Titanium-titanium boride whisker (TiBw) composites are emerging as strong candidate materials for advanced applications within the automotive, aerospace and defense industries. Although increasing TiBw volume fraction improves the specific stiffness and wear resistance of titanium, it is usually on the expense of fracture toughness and ductility especially at increased volume fractions of reinforcements where whiskers interlock. This research addresses strategies for microstructural design that may overcome these shortcomings, by generating titanium composites that are locally reinforced with TiBw through in-situ reaction in segregated regions of the microstructure and separated by ductile Ti matrix. The effect of varying composite reinforcement particle sizes (i.e. size of the reinforced regions) on the pressure-less sintering of these dual matrix composites is discussed. Electric current activation was also used to generate high density dual matrix composites and a new simultaneous imaging and modulus mapping technique was used to characterize these unique microstructures.

Jan 1, 2008

By Munetaka Iwasaki

Nitrogen strongly affects mechanical properties of steel and therefore we may sometimes modify the various processes for its content. Numerous studies based on the results of chemical analysis of quenched samples were reported with a few exceptions of Hot Sievert method. The technique always poses a risk of uncertainty whether the true content of nitrogen in liquid metal is measured or not. In this study vacuum remelting under relatively low pressure was done to enhance gas phase mass transfer. Total pressure of the melt chamber was about 10-3 pa and electron beam heating was used. Mass spectroscopy was used for the direct observation of the rate of denitrization. Nitrogen molecules or atoms were detected by a mass spectrometer set above the melt. Continuous monitoring of the intensity of the fixed mass number may reflect the transfer of nitrogen from the melt to the vacuum. The results of the new and conventional techniques agree, both technique can be verified.

Jan 1, 1999

By Kristine Bruce Wanderley, Denise Crocce Romano Espinosa, Jorge Alberto Soares Tenorio

Magnesium is present in nickels leach liquor and it is often disposed in waste barriers. However, new technologies with the aim of recuperating magnesium and other metals in the liquor have proven that it is possible to reduce the amount of metal lost during nickel ore processing. In this context, high temperature crystallization removes magnesium, with a concentration of 8 g/L, as MgSO4 H2O from the leach liquor. Kinetic studies of this process are needed to evaluate the thermodynamics of the growth of crystals. Thus, this work aims to study the crystallization kinetics of MgSO4 H2O. Temperatures of 230, 210 and 200 °C were investigated in a batch crystallization system in solutions with pH2. Aliquots were taken at each hour up to 5 h of time residence and analysed by ion chromatography for magnesium concentration. The reaction mechanism as well as rate constant and activation energy for each reaction temperature were obtained

Mar 1, 2018

By Pan Cao

The process of reduction roasting of nickel laterite with rotary hearth furnace combined with magnetic separation becomes a very potential way to prepare ferronickel alloy, especially for the low grade nickel laterite ore. In order to realize this new process, the effect of roasting temperature, time and additive on the reduction degree were investigated in the laboratory experimental. The results indicated that the recovery rate of Ni increased with the roasting temperature increasing to 1500°. Most of nickel and a spot of iron are selectively reduced with adding 25.19% SiO2, 6.42% coal, and roasting for 60min at 1500℃. Then conventional magnetic separation was carried out. The content of Ni and Fe are 7.50% and 59.08% in ferro-nickel nugget prepared by this method. And the recovery rate of Ni is 90.91%, which indicates that a high recovery of ferro-nickel from nickel laterite ore is achieved indeed.

Jan 1, 2014

By P. H. Scaife

The pyrometallurgy industry faces a series of environmental challenges, based on local, national and global issues. While local impacts continue to be important, national and global concerns with Sustainable Development, Greenhouse emissions, Acid Rain and water resources are key strategic drivers for the industry. The environmental problems of the industry are well known: emissions of sulphur dioxides and carbon dioxide, disposal of arsenic wastes, consumption of fresh water, fate and impact of minor components/trace elements in raw materials (whether conventional or complex, or wastes). Solutions to these problems require the application of Cleaner Production principles (waste minimisation, energy conservation, product design to enable ease of post consumer recycling), new technology and scientific studies to assess impacts of discharges. A number of opportunities, driven by environmental concerns, have also been identified

Jan 1, 1994

By E. S. Geskin

New material processing tools should be developed and reduced to the practice in order to meet the challenges facing the contemporary material production industry, One of such potentially important tools is supersonic liquid projectiles. It was shown that at the speed of 1500-1750 m/s the water projectile are able to demolish reinforced concrete plates, forge, to pierce and weld metals, to destroy with no explosion non dischargeable mines, etc. These projectiles are generated by simple, low cost launchers run. It is obvious that these projectiles can be applied to the ore mining and comminution. Thermodynamic considerations show feasibility of the use of these projectiles also for smelting, refining and forming. The presented paper discusses the results of the experimental study of supersonic liquid projectiles as well their potential metallurgical applications.

Jan 1, 2006

By R. W. Lee

The first prototype plant using the Imperial Smelting Process commenced operation in 1950. It is timely therefore to review the developments that have occurred with the process over the past half-century. A major advantage claimed initially for the process was its ability simultaneously to recover zinc and lead from bulk concentrates. This has remained a fundamental advantage, but it has been extended by the increasing treatment of secondary materials containing zinc and lead. This has been facilitated by the development of hot briquetting and tuyere injection. These techniques and their impact on the technology of the operation will be described. The other major advantage claimed for the process was its potential to achieve new levels of productivity in the pyrometallurgical smelting of zinc. This has been realised with operating furnaces producing up to 400 t/d of zinc. The technical developments that have enabled this scale of operation will be reviewed.

Jan 1, 2000

By Corby Anderson

The efficient separation of palladium from the transition metals copper, nickel and iron can be effected by passing a leach solution of these metals through a column of the silica polyamine composite material, WP-1, patented by Purity Systems Inc (PSI), Assignee, University of Montana with exclusive license to PSI. The separation can be done at the intrinsic pH of a nitrogen species catalyzed (NSC) oxidative pressure leach solution (~0) and stripping of the palladium from the composite can be effected with hydrochloric acid/ammonium chloride solutions at 50oC. Batch capacities of the composite for palladium are ~ 1.8 mmol/g resin. The possibilities for isolating the metal from the strip are discussed. Given the proven longevity and rapid capture kinetics of the polyamine composites, this new approach should prove to be an economically viable alternative to the multi-step concentration processes practiced in the PGM industry to date.

Jan 1, 2003

By John M. Rapkoch

In the continuing search for copper matte converting methods, commercially available and feasible choices remain Peirce-Smith Converters, Hoboken Converters, Mitsubishi Converting, Ausmelt converting, and Outokumpu/Kennecott Solid Matte Oxygen Converting (?Flash Converting?). While each alternative improves on Peirce-Smith Converters? limited fugitive gas capturing capability, the Peirce-Smith Converter is relatively easy and economic to operate and has an unmatched ability to accept valuable but difficult-to-handle material such as scrap anodes and purchased scrap copper. Recent experience with designing, building, and starting up an ISASMELT facility, applied in primary smelting of copper concentrates, has led the authors to speculate on how suitable the ISASMELT process would be for copper converting, given its low fugitive gas release and its ability to accept a variety of feed types. This paper reviews the potential metallurgical challenges posed by converting copper matte in an ISASMELT vessel and considers possible engineering and design challenges posed by the inclusion of this technology into a new or refurbished copper smelter.

Jan 1, 2006

By S. J. Kohut

Until recently SX-EW technology has only been used to produce conventional cathode for the cyclical commodity marketplace. Unlike electrorefining, SX-EW lends itself to the integration with the downstream manufacturing technologies for direct mine site production of value added products. The integration of SX-EW and downstream manufacturing results in the elimination of redundant process steps, the cost savings, and the access to value added product markets which can buffer the producer from swings in the cathode market. SX-EW production of copper powder and powder-based products has been demonstrated at the pilot plant level. The SX-EW process has been successfully redesigned to meet the more specific demands of engineered products. Challenges include the solution purity, the cell ventilation, the high current density operation and the product handling. Successful demonstration of mine site production of value added SX- EW products opens up new non-commodity marketplaces to the mining industry.

Jan 1, 1999

By Chai Liyuan

This paper focused on the preparation of porous ceramic pellets for microorganism carriers. A new method for the process was developed using simple gel-casting and bubble-in-water-in-oil type of multiphase double emulsion. The globules, consisting of a foamed sepiolite slurry suspension, were dispersed and consolidated in spherical shape in liquid paraffin as gelation progressed. The green pellets were sintered at 1100°C. The influence of surfactants, extension ratio and impeller revolution rate on the process and characteristics of the pellets was investigated. The pellet size was in the range of 1~4mm and determined directly by impeller revolution rate. The fine cell diameter of porous ceramic was in the range of 100~500m and the micropore diameter was less than 5m. The inner macropores were interconnected and extend to the external surface. It is impossible to analyze a result by SEM micrographs and digital camera.

Jan 1, 2006

By M. P. Bohrer

A closed-loop hydrometallurgical process has been developed for treatment of smelter flue dust generated by copper recycling. The process is a semi-continuous operation in which zinc, iron, and copper are first extracted from the dust with a sulfuric acid solution. The lead and precious metals, initially present in the dust, remain as solids and can be recycled to the copper smelting furnace. Cementation with iron and zinc metal purifies the zinc and iron-rich liquid stream prior to spray drying. The spray-dried product, consisting of a mixture of zinc sulfate monohydrate and iron sulfate monohydrate, is a desirable micronutrient additive for use in animal feeds. Treatment of the smelter flue dust in this manner will generate a positive return on investment, as well as mitigate a potential environmental liability.

Jan 1, 1992

By Jason M. Porter, Douglas L. Porter, David L. Olson, Travis W. Koenig, Van S. Blackwood, Brajendra Mishra, Robert D. Mariani

"Traditional alloy theory models have been applied relative to the three solid phases of uranium: alpha (orthorhombic), beta (tetragonal), and mainly gamma (body centered cubic)[l]. The Darken-Gurry and Miedema models, with modifications based on concepts of Waber, Gschneidner, and Brewer have been used to predict the behavior of four types of solutes: 1) Transition associated with alloying in and containment of the uranium fuel 2) Transuranic elements in the uranium 3) Rare earth fragmentation elements (lanthanides) 4) Transition metals and other fragmentation elements. Using these solute map criteria, elemental behavior have been predicted as highly soluble, marginally soluble, or immiscible (intermetallic phase formers) and have been used to compare solute effects during uranium phase transformations. The overlapping of these solute maps are convenient first approximation tools for predicting alloy behavior.IntroductionAn investigation is in progress to determine the role of various solute elements on size and shape of the 'Y phase field range for uranium to optimize the burning and material processing of nuclear fuel is in progress. Traditional alloy theory models based on correlations to elemental electronic and crystal properties are used to predict solubility and micro structural formation. The effectiveness of this model is based on microstructure property correlations. Darken and Gurry, and Miedema models, with modifications based on concepts of Waber, Gschneidner, and Brewer, models have been used to describe solute solubility with respect to uranium based the on correlation between elemental electronic structure and uranium phases. The alpha (orthorhombic), beta (tetragonal), and gamma (body centered cubic) phases have different solubilities for specific alloy additions as a function of temperature. Using the method of Waber, ellipse diagrams classified those solutes that should have broad solubility in the allotropes of uranium[2]. The predictive diagrams are made from four different correlations:"

Jan 1, 2012