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By Jirí Faltus

The paper deals with studying the impact of structural properties and anodizing of surface on the corrosion properties of extruded rods from commercial aluminium alloys: AA6082, AA6262, AA6012, AA2007 and new lead-free aluminium alloys AA6023, AA2015 and AA2111B. Samples were exposed to the corrosive atmosphere NSS, AASS in the chamber by EN ISO 9227. Surface of samples were either in the original state or anodizing by selected mode. The depth of corrosion attack and the form of corrosion attack are evaluated depending on the type of alloy, the metallurgical condition and surface treatment of the samples.

Jan 1, 2015

By D. Paul Bishop, Kevin P. Plucknett, Hung-wei Liu

"Spark plasma sintering (SPS) process has been evaluated for producing the commercially pure (CP) Ti, TiAl and a TiAl-B4C composite. Comparisons were made between the materials in terms of the sintered density, resultant hardness and microstructures. In the present work, the titanium aluminide powders (Ti-48Al, producing a mixture of y-TiAl/a2-Ti3Al) were synthesised „in-house? using a simple reaction-sintering and mechanical attrition approach. This allowed various size distributions to be generated. The powders were then blended with a fine boron carbide (B4C) powder (up to 6 wt.%), and the resulting mixtures were consolidated using spark plasma sintering (SPS) under vacuum in graphite dies. An applied stress of 50 MPa was used for all SPS runs. The SPS parameters were varied in terms of the ultimate sintering temperature (up to 1300°C) and hold time (up to 10 minutes) for each material. It is demonstrated that high densities can be achieved this approach (exceeding 95% of theoretical, with optimised samples close to full density). Microstructural characterisation was conducted using optical microscopy, scanning electron microscopy, and X-ray diffraction. The B4C additions were seen to partially react with the TiAl to form reinforcements, such as TiCx and TiBx. Preliminary mechanical property assessment will also be briefly discussed.INTRODUCTION Titanium- and titanium aluminide-based alloys possess many unique properties, such as excellent corrosion resistance and high temperature strength, respectively (Cardarelli, 2001; Leyens & Peters, 2003). Compared to many other competing materials (e.g. stainless steel or Ni-based alloys), Ti- and TiAl-based alloys also have relatively low densities (~4.5 and ~3.9-4.1 g/cm3, respectively), which is critical for performance in aviation and automobile applications. However, the manufacturing cost is high, due to the expensive raw Ti material and difficulties in machining. TiAl-based alloys are particularly difficult to produce because of their limited ductility (Lütjering & Williams, 2007). To overcome those problems, powder metallurgy (PM) technologies have shown great potential as near-net shape processes for Ti- and TiAl-based alloys. The general PM process largely avoids laborious post-machining and minimises material use. In industrial production, the PM approach has been successfully utilised to manufacture aluminium- and iron-based alloys (Huo & Heath, 2008)."

Jan 1, 2017

By H. Sato, Y. Sato, T. Ooishi, K. Sakamoto

"Sumitomo Metal Mining Co., Ltd.(SMM)'s Niihama Nickel Refinery(NNR) produces high quality Nickel cathode, Cobaltcathode and other by-products using hydrometallurgical refining process called “MCLE”(Matte Chlorine Leach and Electro-Winning). In 2005,NNR started to use nickel and cobalt mixed sulfide (MS) produced by one of the SMM’s subsidiaries Coral Bay Nickel Corporation(CBNC)’s HPAL plant in Philippines, although its main and the only raw material until then was nickel matte. With start-up of the second HPAL plant at Taganito in 2013, NNR expanded its production capacity of nickel cathode from 41,000 to 65,000 tpa and finally achieved its target in 2015 by producing 65,980 tpa. SMM developed the technologies to improve poor reactivity of MS and installed new facilities to cope with increased Cobalt and Sulfur production at that time. This paper describes the technical approach to increase MS treatment with high efficiency.INTRODUCTIONThe Sumitomo Metal Mining Co., Ltd.(SMM)Niihama Nickel Refinery(NNR) produces Nickel cathode, Cobalt cathode and other by-products using Matte Chlorine Leach and Electro-Winning (MCLE) process technology. SMM uses nickel matte and nickel & cobalt mixed sulfide (MS) as raw materials for the MCLE process. Table 1 shows typical composition of these raw materials. Nickel matte had been only raw material until 2005, and with start-up of Coral Bay Nickel Corporation (CBNC) operation in the Republic of the Philippines, MS became major part of it. In 2009, when CBNC doubled its production capacity, NNR also expanded its plant capacity of electrolytic nickel from 36ktpa to 41ktpa, keeping an eye on the possibility of 65ktpa with oncoming SMM’s second HPAL in Philippines. Poor reactivity of MS was the prime concern at that time because our intention was to increase production with MS. Nickel extraction rate deteriorated with increasing usage ratio of MS in raw materials. To keep high nickel extraction rate under high ratio of MS, NNR developed a new leaching technology. Another concern arising from treatment of MS was Cobalt and Sulfur contents that are much more than those of nickel matte as shown in Table 1.NNR introduced new technology of solvent extraction process as to Co/Ni separation process in order to keep cost competitiveness instead of the conventional cobalt oxidation–neutralizing method. As to sulfur products, new sulfur productive facility was installed to improve the exposure to sulfur dust and the hot working conditions for workers. As a result of process development and installation of new facilities against the problem with MSusage,65 ktpa production was achieved in 2015."

Jan 1, 2017

By Daan Maijer, Wade Marquardt, Robert MacKay, Steven Cockcroft, Farzaneh Farhang Mehr

"To comply with the new Corporate Average Fuel Economy (CAFE) standards, the automotive industry is aiming to reduce weight and increase the power and efficiency of small displacement engines through the application of forced induction technologies. As an example, there are now several 2.0 litre turbocharged engines in production, producing in excess of 240 hp. To meet the need for improved fatigue properties in the engine blocks used in these high-output engines, a new water-cooled chill technology is under exploration at UBC in partnership with General Motors and Nemak. A series of experimental techniques were used to assess the capability of the new chill to extract heat from an A319 casting in the vicinity of the main bearing bulk head. The results show that this method has the potential to achieve a reduction in secondary dendrite arm spacing thus meeting the new microstructural specifications for these engines.INTRODUCTION The automotive industry is working to meet the stricter efficiency requirements laid out within the CAFE (Corporate Average Fuel Economy) regulations (Bastani, 2012; Cole, 1995; Mackay, 2011; Miller, 2000), while at the same time not sacrificing performance. One approach is to increase the use of lightweight materials, which leads to a decrease in the overall vehicle weight and fuel consumption (Cole, 1995; Mackay, 2011; Miller, 2000). Other approaches include smaller displacement engines and gas-electric hybrid drivetrains. However, one trend that is becoming clear, is a greater emphasis on force induction gasoline engines. This allows for weight reduction to be achieved with smaller displacement engines without sacrificing performance. One consequence of this approach is that the engine block materials are subject to higher in-service thermal and mechanical cyclic loads (Cole, 1995; Miller, 2011; Heysler, 2001) The fatigue properties of an alloy are strongly affected by a number of the, as-cast, microstructure features including, Secondary Dendrite Arm Spacing (SDAS), porosity and eutectic lamella spacing (including intermetallic ß-Al5FeSi platelets) (Mackay, 2010a; Mackay, 2010b; Viet-Duc, 2015; Casellas, 2005). It is generally accepted they can act as fatigue initiation sites and that a reduction in their size will result in an improvement in fatigue performance. For a given alloy chemistry, one of the key parameters affecting the length scale of all three is cooling rate (Mackay, 2000)."

Jan 1, 2017

By L. Magne, M. Maldonado, R. Varela

Real-time optimization of flotation circuits demands for accurate and reliable measurements to support the decision making process. The collection zone gas holdup is an important variable in this context as integrates the effect of machine and chemical factors on the bubble size and velocity distributions. It has been demonstrated that gas holdup not only correlates with bubble surface area flux, which defines the particle collection rate and recovery in the collection zone, but also with water overflow, a variable which has been related to the froth zone recovery. Therefore, on-line gas holdup measurements provide a reliable alternative to judge efforts leading to the optimization of flotation cells and columns. Estimation of gas holdup in flotation from electrical conductivity measurements has been proposed and extensively used in lab and industrial installations. The approach is based on the application of Maxwell's model, which relates the concentration of a dispersed phase in a continuous medium to measurements of the conductivity of the liquid medium and of the mineral pulp with and without air bubbles included. These measurements require a conductivity cell which covers a representative volume of the flotation cell, and creates a homogeneous electric field throughout this volume that ideally is not affected by the conductivity of the medium. The development of such a cell in the limiting space and geometry of a laboratory flotation cell has been problematic, but a multi-electrode arrangement offers a promising alternative. Electrodes were installed in the flotation cell of a Denver unit; the results of preliminary testing are discussed with a focus on its performance in the measurement of two- and three-phase dispersion conductivity.

Jan 1, 2015

"SART technology is a useful tool for improving the economics of gold recovery from certain types of complex gold ores. SART liberates cyanide consumed by base metals such as copper, zinc and nickel, and enables the newly freed cyanide to be recycled to precious metals leaching while producing high-grade base metal sulphide concentrates for sale. The benefits of SART include the reduction in cyanide consumption, avoidance of cyanide destruction costs, minimization of risks of environmental non-compliance due to residues of cyanide destruction reporting to mine effluents, and generation of extra revenue from the sale of base metal concentrates. Concerns with SART typically include uncertainties around capital and operating costs and proper integration of SART into the overall metallurgical flowsheet. This paper presents two case studies addressing these concerns. The first involves actual costs of the full scale SART integrated into a gold heap leach operation and treating up to 500 m3/hr of leach solution at a mine in Mexico. The second involves field pilot testing and a preliminary cost estimate for integrating SART into a silver mine in Peru using Merrill Crowe.INTRODUCTION One of the current trends in the gold industry globally is the increasing importance of complex polymetallic gold deposits as discoveries of large Carlin type gold deposits become increasingly rare (Sceresini, 2005). The presence of cyanide soluble copper and zinc in complex gold deposits necessitates changes in traditional gold extraction metallurgical flowsheets. One of the tools available to the industry to help deal with interferences of cyanide-soluble base metals in gold extraction is the SART (sulphidization-acidification-recycling-thickening) process. SART breaks the weak acid dissociable (WAD) base metal-cyanide complexes, precipitates the metals as high-grade sulphide concentrates and makes the freed cyanide available for recycle. Although SART is a commercially available technology, it is still relatively new to the industry. Fewer than ten (10) full scale plants have been constructed in the past couple of decades. Some of these SART plants are small, most are located at remote sites, and the majority have not operated on a continuous basis. This has resulted in a general lack of information in the industry about the true costs, operability and metallurgical performance of SART. BQE Water has been involved in the design, construction, commissioning and operation of large scale SART plants in Mexico, Turkey and Chile and has conducted field testing programs as part of the technical assessment of SART integration into various metallurgical circuits. Having built and operated numerous plants utilizing selective sulphide precipitation of heavy metals, BQE Water has gained unique insight into the design and control of the sulphidization stage of SART to minimize costs and ensure high efficiency in cyanide recovery."

Jan 1, 2017

By Afshin Sadri, Wai Lai Ying, Brycklin Wilson, Zoe Coull

"Although there have been great steps forward to integrate corrosion engineering into operations, there is still an underlying tendency for maintenance tasks to be performed in a reactive manner. This is especially true when strategies focus on lagging indicators such as visual inspections, RCA (root-cause analysis), and FMECA (failure mode, effects and criticality analysis). This trend to “reactive maintenance” can be avoided by utilizing more inspection and monitoring methods to identify leading indicators of failures. Prevention is generally less costly than repairs; moreover, when paired with appropriate monitoring techniques, intervention of corrosion protection can be more effectively timed and based on more accurate data. Hatch asset reliability studies show nearly 80% of defects are introduced through operations and maintenance. Therefore, proactive corrosion management can provide the necessary feedback to optimize operations and maintenance strategies preventing costly corrosion losses. Understanding corrosion risks gives a clear picture of the benefits of a proactive approach to asset performance. Monitoring techniques (Non-Destructive Testing, field testing, sampling, etc.) by nature are a more effective means of improving maintenance efforts and preventing corrosion losses than other methods (RCA, FMECA). This paper will outline the importance of proactive corrosion management and demonstrate its benefits through industry examples.INTRODUCTION Over the past few decades, with the growth of technology and awareness of sustainable development many studies have shown the benefits of a proactive approach to maintenance strategies. However, in practice there is still an underlying tendency for maintenance tasks to be performed in a “reactive manner”. This is especially true when strategies focus on lagging indicators such as visual inspections, RCA (root-cause analysis), and FMECA (failure mode, effects and criticality analysis). This trend to “reactive maintenance” can be avoided by utilizing more inspection and monitoring methods to identify defects and leading indicators to failures."

Jan 1, 2017

By Vicken Aprahamian

"The Royal Canadian Mint (RCM) operates a gold and silver refining toll operation in Ottawa, Ontario, Canada. The silver refining line is a recent addition and was commissioned in 2005. One source of silver in the refinery is from gold doré which undergoes Miller chlorination before electrorefining to 99.99% cathode gold. Treatment of the Miller salt or silver-copper chloride produced consisted of a 2-stage high temperature reduction process step using soda ash prior to 2005. Copper-rich silver bars were produced and shipped offsite for further refining.The copper-rich bars could not be blended into sufficient high grade silver doré to dilute the copper and allow electrorefining in a silver nitrate medium. A new wet process was developed and commissioned to replace the high temperature reduction and allow removal of bulk copper. Thus upgraded impure silver produced was cast into anode for electrorefining to 99.9% purity silver flake. The 2005 RCM Hydromet Slag process is presented as well as its more current version. In addition, mention is made of a novel processing scenario for the introduction of Miller chlorination silver into the electrorefining circuit."

Jan 1, 2015

By I. Caraconcea, M. Cousineau, S. Gariepy

"Several base metal plants operate in low grade/high tonnage conditions which impose strict cost control on all fronts for their operations to remain profitable. This leads to decisions regarding plant design, procurement, operations and maintenance that often favor cost minimization over value optimization. This may hinder the representativeness of the metal accounting systems while this should be a priority in a low margin environment. Such poor representativeness not only creates confusion in plant scheduling but can also hide suboptimal metallurgical performance. Furthermore, this situation can run undetected for a while since one dominant feature of a poor metal accounting system is its poor self-awareness. During their practice, authors have particularly identified measurement bias and reproducibility, as well as their impact on metal recoveries as areas of concern. These issues have not been extensively reviewed in the specific context of precious metals in base metal plants. Pragmatic solutions are proposed either at the design stage for a new project or to retrofit an actual operation. These solutions should be based on a business analysis that set a value of information matching the contribution of precious metals as well as the potential to use such information to act toward increasing plant profitability. Conclusions are that trade-offs are an inherent part of the design/audit/retrofit of any metal accounting system in any plant processing either base or precious metals. However, compromises must be evaluated on economic/technical ground.INTRODUCTION Every mineral processing plant must produce metal accounting reports (Morrison, 2008) where estimated saleable metal flows and inventories are published. These metal accounting reports are delivered to a variety of stakeholders who use them for internal management purposes (day-to-day plant production planning, plant operation optimization, capital spending, etc.) as well as for external management (royalty settlements, tolling agreements, etc.). Hence, there should be no doubt that state of the art metal accounting is instrumental for mining companies to reach and sustain high-quality corporate governance (Gaylard, Randolph, & Wortley, 2014). However, producing a metal accounting report involves much more than just printing it (Lachance, Leroux, & Gariépy, 2015a). The underlying metal accounting system (Figure 1) is responsible not only for the reliable production of the metal accounting reports but also for the quality of the outcome. As such, the crucial tasks of its design/audit/retrofit should neither be seen as ancillary nor be left as an afterthought."

Jan 1, 2017

By Y. Thibault, L. Morin, R. Cameron, D. Gould

"There are an estimated 50 to 100 million dry metric tonnes of low-grade nickeliferous pyrrhotite tailings in the Sudbury area alone, with an average nickel grade ~0.8% (plus cobalt). Pyrrhotite is a highly reactive sulphide mineral that has the potential to generate acidity; consequently, it is stored in large tailings ponds that require perpetual treatment to avoid the production of acidic drainage. Re-processing this material using bioleaching technologies has the potential to recover valuable metals, while reducing the toxicity, reactivity, and acid generating potential of the remaining residues. CanmetMINING is currently developing a stirred-tank bioleaching process to recovery nickel and cobalt from pyrrhotite-rich tailings. Stirred-tank experiments have been conducted with one tailings sample over a range of pH and temperature conditions, resulting in 80 to 90% and 70 to 80% leaching of nickel and cobalt respectively in 10 days.INTRODUCTION Sulphide tailings may represent a significant financial liability for mining companies as these wastes may produce acidic drainage under some disposal conditions. As a result, the companies must post financial bonds large enough to ensure there are sufficient funds for perpetual management of these wastes. At the same time, there are billions of dollars in metals incorporated into these mining wastes waiting to become valorized. Many sulphide tailings are amendable to bacterial oxidation for metal extraction. Re-processing of tailings using bacterial leaching has the potential to recover valuable metals from waste; and reduce the toxicity, the reactivity, and the acid generating potential of the remaining residue. By reprocessing these wastes there is an opportunity to significantly reduce liabilities and financial assurance bonds, while recovering metal values. There are an estimated 50 to 100 million dry metric tonnes of low-grade nickeliferous pyrrhotite-rich tailings in the Sudbury area alone with an average nickel grade ~0.8% (Peek et al., 2011) plus cobalt and copper. Pyrrhotite is separated from pentlandite concentrates by magnetic separation and flotation. It is already finely ground and has often been segregated from other tailings material, making „mining? relatively inexpensive. This represents roughly (> $100/ton) in contained value, with negligible mining costs. This paper reports on the development of a stirred-tank bioleaching process for recovering nickel and cobalt from pyrrhoitite-rich tailings, which is currently underway at Canmet MINING."

Jan 1, 2017

By ByongPil Lee, Changkyu Lee, Jin Gyun Park, Hyung Sub Eom, Sung-Koo Jo, Jae-Young Lee, Gilsoo Han

"A new hydrometallurgical process for nickel extraction from a low grade laterite ore such as limonite has been developed by RIST and POSCO. This POSCO Nickel Extraction Process (PosNEP) consists of five main processes: ore reduction using hydrogen as a reductant; acid leaching at atmospheric pressure and temperature; cementation by the use of reduced-ore seed; production of the main product such as ferronickel or a high purity nickel compound; and production of by-products such as cobalt and iron in the forms of cobalt sulfate and iron oxide. In addition, hydrogen produced in acid leaching and hydrochloric acid regenerated in pyrohydrolysis for iron oxide production can be reused in the process, which makes PosNEP more cost-effective. The performance of PosNEP has been proven through pilot tests, showing that this process is economically and technically viable. In this paper, basic concepts and detailed test results of PosNEP are shown.INTRODUCTIONNickel has been extracted from two types of ore, sulfide and oxide ore. Nickel and cobalt usually occur together in the ores. The principal ore mineral of the sulfide is pentlandite, (Ni,Fe)9S8, which is easily beneficiated to produce sulfide concentrates(Moats & Davenport, 2014). These concentrates are usually treated by smelting and converting to make a matte. The produced matte is then purified through either hydrometallurgical or pyrometallurgical processes to produce high-purity nickel. In general, this process for sulfide ore has been known as a more cost-effective process than that for oxide ore.The oxide ore is laterite comprised of two different ore types, saprolite and limonite. The main nickel-bearing mineral of saprolite is nickeliferrous garnierite,(Mg,Ni)6Si4O10(OH)8, and that of limonite is nickeliferrous goethite (Fe,Ni)O·OH ore (Moats & Davenport, 2014). Since the saprolite has high contents of nickel and slag formers (MgO and SiO2) and a low content of iron, it tends to be treated by a pyrometallurgical smelting process such as calcination and electric furnace techniques to produce ferronickel for use in stainless steel. In this process, the cobalt in the ferronickel does not have any economic value."

Jan 1, 2017

By Alessandro Navarra, Kristian Waters

Mineral concentrators are designed from preliminary geological data, and are therefore subject to geological uncertainty. This uncertainty has a demonstrable impact on the mining lifecycle, and has motivated stochastic strategic mine planning algorithms. The current paper describes how these algorithms may be extended to consider mineral processing operations in conjunction with open-pit mining operations. In particular, the paper describes an effective way to incorporate variable concentrator feed grade into these algorithms, which is the first step toward more elaborate representations of mineral concentrators. The resulting framework will be able to connect geological data to alternate configurations of the downstream resources, hence comparing the benefit of each configuration, and the corresponding capital investments. Sample computations are presented, comparing the NPV and utilization for several different mineral processing capacities.

Jan 1, 2015

By G. T. Lapidus, A. Garcés, O. J. Restrepo

"Colombian nickel laterites have historically been processed by pyrometallurgy. However, due to the depletion in ore grades, alternative processes are required. Hydrometallurgical processes, such as pressure acid leaching, have been proposed as alternatives to extract nickel from deposits with suitable characteristics. Such a leaching process requires high concentrations of acid to achieve acceptable extractions, and is not selective. In this study, an alternative aqueous alkaline glycine system has been employed to evaluate the leaching behaviour of a Colombian nickel laterite which contains 1.15% Ni, 0.12% Co and 41.1% Fe. Additionally, the effect of the addition of chloride ions, the use of a reducing agent and the application of a pre-treatment to improve the extraction of nickel were evaluated. Extractions of 4.63% Ni, 42.16% Co and 0.33% Fe were obtained using a 1M solution of glycine at pH 9. In addition, an increase in nickel extraction from 4.63% to 25.68% was achieved by applying a pre-treatment to the sample. The results show that even though nickel dissolution was much slower than in acid leaching, it was selective over other metals such as iron, proving the proposed method to have potential as a process for the extraction of nickel from Colombian laterites.INTRODUCTION Before 2010, most of the industrial operations used pyrometallurgical processes for the extraction of nickel, mainly in saprolitic regions of deposits, with greater contents of the metal. Nevertheless, due to the gradual depletion of such deposits, different hydrometallurgical processes have been studied as alternatives to process those nickel laterites with low grade and those which present problems of refractoriness due to the presence of acid consuming materials (McDonald & Whittington, 2008; Oxley & Barcza, 2013; Wang et al., 2012). However, such leaching processes require high concentrations of acid to achieve acceptable extractions and they are not selective. Facing lateritic nickel ore deposits containing high levels of acid consuming materials, an alkaline leaching medium becomes an advantageous alternative over acidic media, due to the increase in selectivity and decreased corrosiveness and reagent consumption (Tanda, Eksteen, & Oraby, 2017). Unlike conventional acidic reagents used for metal recovery, alkaline reagents can selectively dissolve the desired metal, leaving in the solid residue other elements such as iron, magnesium and aluminum, which are problematic in subsequent stages of metals separation and recovery. Furthermore, there are no serious corrosion problems associated with alkaline leaching, even at higher reagent concentrations, or at elevated temperature and pressure (Ntumba Malenga, Mulaba-Bafubiandi, & Nheta, 2015)."

Jan 1, 2017

By L. Tafaghodi, A. Hosseinpour

"Silicon is considered as the most appropriate semiconductor material for manufacturing solar cells because of its natural abundance and being nontoxic. The transferable knowledge and technology from the electronics industry and the long history of silicon-based semiconductors are also assisting the domination of silicon as the most common semiconductor material. Developing an environmentally and economically viable process for producing solar grade silicon has been one of the main challenges in the silicon industry in the past few years. Metallurgical refining processes have received significant attention because of their high productivity and low cost. Slag refining is one of the purification methods which is based on oxidation of the impurity elements, followed by its dissolution into a slag phase. This article presents a review of various slag refining processes that have been employed for purification of silicon and silicon alloys. SiO2, CaO, CaF2, CaCl2, Al2O3, MgO and Na2O are the major components of the slags used for silicon refining. These slags can be classified into three main categories including binary, ternary and quaternary slags.INTRODUCTION Silicon can be categorized into three different grades based on its application or purity: metallurgical grade silicon (MG-Si) with purity of ~98 %, solar grade silicon (SoG-Si) with purity of ~99.99999 % and semiconductor grade silicon (SeG-Si) which has the purity of 99.9999999 % (Johnston & Barati, 2010; Krystad, Tang, & Tranell, 2012; Tang, Øvrelid, Tranell, & Tangstad, 2009). Producing SeG-Si is carried out through an energy-intensive and complicated process named Siemens. This purification process is relatively slow and involves using toxic and corrosive reagents (e.g. Trichlorosilane). At present the majority of SoG-Si is produced via Siemens or Siemens-like processes and there is very limited production via processes dedicated to SoG-Si. Because of the difference in silicon specifications required in microelectronics and photovoltaic industry, and the cost and energy associated with the Siemens process, an interest has emerged to develop technologies dedicated to producing low cost SoG-Si (Istratov et al., 2003; Johnston, Khajavi, Li, Sokhanvaran, & Barati, 2012; Mitrašinovic, D'Souza, & Utigard, 2012; Wu et al., 2012)."

Jan 1, 2017

By John Shirokoff, Ladan Khaksar

"Cyclic polarization technique and also potentiodynamic measurements were applied to study corrosion behavior of 13% chromium steels in chloride containing environment. Potentiodynamic measurements were performed at 25 and 75 °C with 0, 10 and 20 g/l NaCl in 0.01 M hydrochloric acid solution. At the same time, the significant pitting parameters such as corrosion potential (Ecorr), pitting potential (Epit), protection potential (Epro) and passive current (Ipass) of cyclic polarization curves with various NaCl concentration were analyzed and compared to describe the corrosion behavior of 13% chromium stainless steel. Surface measurement techniques such as SEM and EDS were used for morphology and analysis of corrosion products. The results showed that both temperature and Cl- concentration had significant effects on corrosion behavior of 13% chromium stainless steel in acidic solution.INTRODUCTION Of all the corrosion resistant alloys (CRA) used in oil and gas developments, martensitic stainless steels (MSS) are some of the most common ones these days. These steels not only have the advantages of normal steels: high strength, cost-effective, easy to manufacture, available in a wide variety of product forms, but they also have good CO2 corrosion resistance at higher temperatures as a result of their 11% minimum chromium content. One of the most common types of MSS used in the oil and gas industry is 13% chromium steel. NACE and API standards both reference several different varieties of 13% chromium steels for use in oil and gas projects(“Corrosion Resistant High Cr Steel for Oil and Gas Wells,” 2013). All types of 13% chromium steels have about 12 to 14% chromium and other minor alloying additions, and can be placed into two general groups: conventional and modified. Conventional 13% Cr steels (13Cr) are those most common in oil and gas, some of which are CA6NM (UNS J91150), AISI 410(UNS S41000), and AISI 420 (UNS S42000). These alloys have excellent corrosion resistance when compared to carbon steels up to about 300°F (150°C) and are used for a variety of wellhead, tubular, and downhole components however they have very limited resistance to cracking in H2S (Vallourec Group, 2015). Modified 13% Cr (M13Cr) steels came from the need for increased corrosion resistance at higher temperatures, increased H2S cracking resistance, and increased yield strength above 85 ksi (586 Mpa) primarily for tubular goods and other downhole equipment. These features were developed by taking a conventional 13Cr steel and adding nickel (Ni), molybdenum (Mo), copper (Cu), and other alloying elements. M13Cr provides better corrosion resistance than 13Cr up to about 350°F (177°C), yield strengths up to 110 ksi (758 Mpa), and also improved H2S cracking resistance(“Corrosion Resistant High Cr Steel for Oil and Gas Wells,” 2013)."

Jan 1, 2017

By G. R. Waters

"The technology behind industrial applications such as Hydrometallurgy continues to evolve, as do the corresponding regulations and specifications that ensure the safety of workers and the environment. Valves make up key aspects of this technology, and often represent the single point of failure for entire operations. More often than not, the valves being used in Hydrometallurgy applications are known as Severe Service Valves (SSVs) due to their ability to withstand the extreme conditions. Most experts agree that SSVs are identified by applications, and that these applications are challenging to the valve’s ability to provide a minimum acceptable level of performance over a minimum acceptable duration. The Manufacturers Standardization Society (MSS) of the Valve and Fittings Industry has designated Ross Waters, President of CGIS, as Lead to the Task Force put in place to determine the minimum requirements a valve needs to be able to perform to when faced with extreme conditions, whether from pressure, temperature, toxicity, solids, or usage. This paper serves to determine what the minimum requirements are for SSVs in Hydrometallurgy applications. It will draw on five decades of industry experience from one of Canada’s leading valve experts.INTRODUCTION Severe Service Valves Severe Service Valves (SSVs) mean different things to different people. Until today, defining SSVs had little if any global agreement or recognition. That is about to change as the Manufacturers Standardization Society (MSS) has accepted an application to produce a Standard Practice so defining them. This paper provides information about the selection of SSVs in all industries but focusses on metallurgical processes and applications and offers examples to illustrate the successful and unsuccessful use of these valves. All of this with the purpose of raising the awareness of the industry on all sides, from the suppliers and manufacturers, specifiers and to the users and owners of them. It also supplies tools to understand where and why to separate SSVs from general purpose or commodity valves (GPVs). SSVs are often identified by applications, and these applications are challenging to the valve’s ability to survive. Within these applications the elements that make the service severe are being analyzed, quantified and qualified. From this, we expect to offer objective and repeatable definitions and guidance to improve the experience of SSVs, reduce unnecessary costs, provide longer service life and process runs, improve safety and reduce environmental issues."

Jan 1, 2017

By S. Usui, Y. Shinohara, C. Tokoro, K. Horiuchi, S. Owada

Process optimization of heating and physical separation for Cobalt (Co) recycling from spent lithium ion battery (LIB) was investigated. LiCoO2 in spent LIB was transformed to LixCoO2 which was more easily decomposed than LiCoO2 by heating. Coexisting materials of aluminum and carbon, and sealed atmosphere of the LIB promoted LixCoO2 decomposition. In an atmosphere of Argon, 95 % of LixCoO2 in the spent LIB was decomposed to 76 % of Co oxide and 19 % of Co metal in 10 min at 823 K; a lower temperature than the theoretical value for LiCoO2. The Co oxide and Co metal exhibited magnetic properties and could be recovered by wet magnetic separation. Furthermore, slow heating was effective for grain growth of Co oxide and Co metal. At 2 K/min rate of heating, average grain size of Co oxide and Co metal were 239 µm and 28 µm respectively, whereas at 30 K/min they were 190 µm and 15 µm respectively. Therefore, separation efficiency for Co recovery by wet magnetic separation was increased when spent LIB was slowly heated at 2 K/min.

Jan 1, 2015

By K. Horikawa, S. Kitahata, H. Kobayashi

"It has been clarified that the Al-5%Mg alloys containing 200 mass ppm of sodium showed grain boundary (GB) fracture, even when tested at room temperature, as well as at high temperatures (~500°C). SEM/EDX study revealed that the GB fracture was associated with the segregation of sodium on grain boundaries of the Al-Mg base alloys. Differential scanning calorimetry (DSC) revealed that the GB fracture at room temperature of Al-Mg alloys was caused by sodium segregation in the solid state. It was also shown that the tendency of the GB fracture strongly depended on the heat treatment; the alloys after the solution heat treatment showed severe GB fracture compared with the alloys after the homogenizing treatment. Moreover, it was shown that the GB fracture at room temperature by sodium segregation was suppressed by the addition of bismuth or indium. The suppression of the GB fracture by the additional elements was believed to be the scavenging effects by forming the sodium bearing compounds in grains.INTRODUCTIONIt is widely known that Al-Mg base alloys containing high amount of magnesium(~5 mass%)show better workability at room temperature, while that the alloys show grain boundary (GB) embrittlement at higher temperatures ranging from 200 to 500°C, depending on grain size(Otsuka, 1984), sodium impurity level(Ransley, 1959, Okada, 1997, Horikawa, 2001)and testing strain rate(Yamada, 2012). In the case of coarse-grained Al-5%Mg alloys (~300 ?m), 2 mass ppm of sodium causes severe GB fracture around 300°C, however, the Al-5%Mg-2ppm alloy does not show GB fracture at room temperature. It has also been shown that the GB embrittlement caused by 2ppm of sodium was suppressed by the additional elements, such as bismuth (Talbot, 1995), antimony (Ueda, 1997) and indium (Horikawa, 2012). Basedon these facts, we have concluded that the GB embrittlement at higher temperatures of Al-Mg alloys is attributed to the synergy effects of GB segregation of atomic sodium and GB sliding. For the GB embrittlement mechanism of Al-Mg alloys, involvement of low melting point metallic phases has been pointed out (Lynch, 2002),since the GB embrittlement appeared only at high temperatures. Up to date, the effects of high amount of sodium addition more than 2 ppm on GB fracture were not fully investigated in Al-Mg alloys. In the present study, the effect of 100 ppm ordered sodium impurity on GB fracture of Al-5%Mg alloys was examined, together with the effect of another additional elements."

Jan 1, 2017

By Ozdemir. O.

Magnesium additions to aluminum enhance strength and hardness, lowering density, and improving corrosion resistance. However, during melting and casting processes, significant amounts of magnesium are lost due to selective oxidation. Preventing these losses would reduce the production cost and improve the quality of the final product. The effects of strontium addition on the oxidation behaviour of aluminum-0.5% and 1% magnesium alloys were investigated by monitoring sample weight gains with time with a thermogravimetric balance at 750°C. Sample cross sections have been examined using Field Emission Gun Scanning Electron Microscope.

Jan 1, 2004

By Alessandro Navarra, Amir Arash Rafiei, Kristian Waters

Mathematical programming (MP) is fundamental to systems engineering and operations management, but has not been widely adopted by mineral processors. The current paper presents an interdisciplinary approach, using MP to incorporate basic notions of mass balancing into an optimization framework. The optimization is typically related to economic profitability. Two- and three-product formulas are extended to give formal descriptions of alternate modes of operation, and a global representation of the concentrator. At this global level, the framework may assist plant managers to make tactical decisions based on incoming feed data. The MP framework is demonstrated through sample calculations describing a lead-zinc concentrator.

Jan 1, 2015