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By Jilai Xue

Experiments with various industrial cathodes ranging from 35 wt.% to 100 wt.% graphitic and fully graphitized carbons were carried out in a laboratory aluminum electrolysis cell. Sodium and cryolite bath penetration into the cathode samples was measured by XRD and SEM-EDS analysis. For a higher cryolite ratio in the bath, the cathodes with lower graphitic carbons exhibited more sodium penetration than the fully graphitized. The increased graphitization in the cathode materials can reduce Na, NaF and Na3AlF6 penetration. SEM-EDS inspection reveals that the sodium and fluorides penetration within the cathode samples has different patterns for varying graphitization of the carbon materials. XRD quantitative analysis indicates that there is a large percentage of Na3AlF6 in the penetrated bath. The results can provide useful information for quality evaluation of the industrial cathode products.

Jan 1, 2010

By Pietro Navarra

A great deal of effort has been expended on how to optimize conventional water cooling circuits in furnace cooling elements, and the results have been largely satisfactory. However, there is a general agreement that the proximity of high-pressure water passages to the flow of molten furnace products is a safety concern. Nonetheless there exists little alternative to the formula: increasing furnace integrity implies the incorporation of more extensive forced-convection water cooling systems. Recent developments in evaporative cooling technology have resulted in the development of a high-capacity heat pipe capable of operating under the thermally intense environments of a metallurgical furnace. The system functions using several kg of a working fluid (water) in total, has no moving parts, and allows for a significant reduction in cooling water requirements. Full-scale pilot tests of a copper tap hole and slag launder were done in 2003 and2005, with detailed results given in this paper.

Jan 1, 2006

By Hebi Yin

A two-dimensional multi-scale solidification model was developed to study the heat transfer, fluid flow, and grain growth occurring in the molten pool during the laser engineered net shaping (LENS) process. This model coupled the finite element method to calculate mass, energy and momentum transport in the macroscale with the cellular automaton technique to calculate liquid/solid phase change at the microscale. The validation of the model was performed by comparing the simulation results with experimental data from previously published works, showing good agreement in temperature distribution and the dendrite morphology (size and shape). The simulation results showed that Marangoni convection, caused by the temperature gradient along the pool surface, played a critical role in determining the flow pattern in the molten pool and exerted influence on the pool size and shape. It was also found that columnar dendrites can be formed, with dendrite arm spacings as fine as a few microns due to the high cooling rate during the LENS process. In addition, the influence of fluid flow on the dendrite growth in the pool was discussed.

Jan 1, 2010

In this study, the method of chemical co-precipitation?reduction?diffusion was developed for the preparation of magnetic SmCo5 alloy. In the chemical co-precipitation process, the effects of solution pH, the reactant concentration, the dispersant on the process were investigated. The optimum conditions of the process were determined, and the SmCo5 alloy oxide precursor particles with fine crystalline structure, narrow size distribution was obtained. Then, by reduction-diffusion treatment of the precursor particles, the SmCo5 alloy with high quality was produced. It is anticipated that the co-precipitation-reduction-diffusion is a novel method available for SmCo5 alloy production.

Jan 1, 2006

By C. M. F. Vieira

In the county of Campos dos Goytacazes, north of the State of Rio de Janeiro, Brazil, there is a large production of red ceramic, mainly perforated bricks. A percentage of these bricks are damaged during the firing processing and become a red ceramic waste. This work investigates a possible solution to this environmental problem through the mixture of fired brick wastes, up to 20 wt.%, with clay bodies to produce red ceramics. Cylindrical pressed bodies were fired at temperatures varying from 500 to 1100ºC. After firing, samples were then tested for linear shrinkage, water absorption and mechanical strength. The results showed that brick waste addition did not changed the workability of the clay and that up to 5 wt.% of waste no detrimental effect occurred on the fired properties at all temperatures.

Jan 1, 2010

By Sergio N. Monteiro

Natural lignocellulosic fibers are successfully replacing synthetic fibers in many engineering applications. In addition to well-known conventional lignocellulosic fibers, others with promising properties are now being considered. The present work investigated the mechanical and structural characteristics of a relatively high strength fiber, curaua (Ananas erectifolius) from the Amazon region of Brazil. The results obtained from tensile tests confirmed the superior strength while scanning electron microscopy (SEM) analysis displayed features that justify the possibility of using the curaua fiber as an effective reinforcement for polymeric composites.

Jan 1, 2006

By Hui Lu

The structural changes in solutionized AA2618 during natural aging and their effects on subsequent artificial aging were investigated by hardness measurements, X-ray diffraction, differential scanning calorimetry and transmission electron microscopy. The changes in lattice parameter and hardness during natural aging indicate that copper-enriched clusters form in the earliest stage, followed by the formation of magnesium-enriched clusters and coppermagnesium co-clusters. Prior natural aging consistently weakened the hardening during subsequent artificial aging at 180, 200 and 230 °C but had no effects on artificial aging at 150 °C. The decreased age hardening was attributed to the reversion of small clusters/zones that formed during prior natural aging. The lattice parameter exhibited erratic changes with increasing artificial aging time, reflecting the complex sequence of the reversion and precipitation.

Jan 1, 2006

By Xiang-yang Zhou

Keywords: Low-Grade Dolomite, Low CaO Content, High Specific Surface Area, MgO. A low energy consumption preparation technology of magnesium oxide with low calcium oxide content and high specific surface area from low-grade dolomite has been investigated. The optimum technical conditions for the preparation of magnesium oxide are the followings: dolomite is partially calcined at 750-800° for 2 h; the optimum solid-liquid ratio range in calcined dolomite slurry is 20-30 g?l?1; carbonation temperature, carbon dioxide pressure and end point pH value of carbonation are less than 40°, 0.4-0.6 MPa and 7 respectively during carbonation process; decomposition temperature of Mg(HCO3)2 solution is near 100°; calcination temperature of the precursor (i.e. precipitated basic magnesium carbonate) is less than 850°. More than 90% of magnesium can be extracted by the technology. The MgO product (CaO < 0.38%) with a specific surface area of near 50 m2?g?1 also can be obtained by the technology.

Jan 1, 2005

Sm-Co alloy is a kind of magnetic material with high power and has been applied in modern industry widely. In this study, the wet chemical co-precipitation was developed for synthesis of the Sm-Co alloy oxide precursor. The thermodynamic analysis of the studied system was done to clarify the solution behavior theoretically based on the thermodynamic equilibrium and simultaneous equilibrium. Then, the experiments were done to address the various effects on the wet chemical process, including solution pH, reactant concentration, dispersant, reaction temperature and time, etc. It is found that by precise control of the process, the Sm-Co alloy oxide precursor was synthesized with fine crystallization and special size & size distribution.

Jan 1, 2005

By Licheng Zhou

The use of aquatic plants for the removal of heavy metals from wastewater has gained high interest. In this study, batch experiments were conducted to evaluate the adsorption of copper ions in aqueous solution by P. pectinatus L. under various conditions of contact time, initial pH of the solution, metal concentration and adsorbent dosage. The results showed that the maximum adsorption amount of copper ions by P. pectinatus L. was 22.60 mg/g when the initial copper ions concentration was 98.41 mg/L at pH 4.5. The Langmuir and Freundlich models were used to describe the adsorption equilibrium of copper ions on P. pectinatus L. and the adsorption followed the Langmuir isotherm. The adsorption kinetic was well-fitted with pseudo-second-order sorption equations.

Jan 1, 2009

By Rashmi Ramesh

Zinc oxide nanoparticles and nanostructures form an active area of research in the recent years. It can be doped to modify electronic, optical and other properties. Synthesis and characterization of zinc oxide is of extreme importance in order to understand the structure property relationship in this material which is now being considered of importance next to carbon nanotubes. Microstructure of zinc oxide nanomaterial is extremely sensitive to the preparation conditions. Nanocrystalline pure and Mn and Mg doped zinc oxide samples were prepared by wet-chemical method under different growth conditions. The samples were investigated for crystalline phase, microstructure, morphology and luminescence characteristics. The effect of Mn and Mg doping on the characteristics of ZnO have been discussed.

Jan 1, 2010

By Orhan Gokce Goksu

It has been shown that metallic tungsten powder can be obtained by electrochemical reduction of solid CaWO4 in molten CaCl2-NaCl eutectic mixture at 600oC. In this study, constant and pulse voltage electrolysis experiments were performed to optimize reduction kinetics and obtain information about the mechanism of above process. It was found that pulse voltage applications yield faster reduction rates when average voltage of pulse voltage application was the same as constant voltage application. In addition, analysis of the current vs. time graphs of constant and pulse voltage electrolysis studies showed that reduction occurs at potential differences higher than about 2.2 V between CaWO4 cathode and graphite rod anode.

Jan 1, 2010

By José Carlos D?Abreu

The Tecnored process is a new ironmaking technology, developed on a unique approach that combined empirical and theoretical knowledge backed by extensive tests carried out in a dedicated pilot-plant and with close support of universities and research centers. Campaigns in the pilot-plant focused on operate different reactors of different sizes, including a full size slice of the industrial furnace. This approach provided actual conditions to develop the main features of the process such as the internal dimensions, raceway pattern, thermal and gaseous profiles, etc, besides provide reliable data to feed and calibrate a specific mathematical process modeling. This paper presents the first computer model used by the Tecnored technical staff, focusing the behavior of a self reducing agglomerate in the upper shaft of the furnace (zone of solid state reduction). Some results of this model are given and discussed.

Jan 1, 2006

By A. M. Ramalho

In the synthesis and sintering processes to obtain superhard materials, such as diamond and cubic boron nitride, deformable ceramic capsule is used as gasket to transmit and support the required high pressures and high temperatures, HPHT. The ceramics materials for these capsules should have special physics and chemical characteristics such as refractoriness, shear strength and compressibility. In this work, Bridgman?s anvil made of hard metal or speed steel was used to characterize some ceramics materials in terms of their maximum compressible thickness. Tests were also performed with different resin polymers used as binding mixture with ceramics powder. Chemical analyses and investigations through scanning electronic microscopic (SEM), X-ray and real tests for the synthesis of diamond were also performed. The results showed that local Brazilian calcite can be successfully used in the manufacture of HPHT gaskets.

Jan 1, 2006

By Wilhelm Wendt

About five years ago we showed that it is possible to use the spectral in- formation in the light emitted by the off-gas flame of a PS converter for on-line production control. Very recently measurements have been performed using improved optical equipment and data evaluation software, resulting in both improved accuracy and the establishment of new optical process parameters. Using the optical signals the slag heats could be stopped at a predetermined Cu content of the white metal with an accuracy of +0.2% Cu m the range 74-78% Cu. A good correlation was found between the slag composition and optical data, providing a possibility for on-line monitoring of the SiO2 content of the slag. The measurements indicate the possibility of predicting the optimum end-point of the copper-making stage and having real time information on the impurity removal. Factors influencing the optical parameters, such as blowrate, Pb content, temperature etc. will be discussed.

Jan 1, 1993

By Theo Lehner

Turning matte into anodes continues to be an area to watch: for visitors to see pyrometallurgy in action; for metallurgists to keep up with modern smelting furnaces and ever increasing production rates; for management to remain profitable using more tools than taught in school; and for environmentalists to detect the last small clouds from the ever cleaner smelter. Current converting practices have been screened and analyzed, and today, converting and casting is a modern industry. An impressive, though typical learning curve of converter productivity may be detected. Local conditions such as availability and type of raw materials, products extracted, cost factors, etc., have stimulated the development of add-ons or even alternatives to the still dominant method of converting by Peirce-Smith technology. Turning blister copper into anodes follows a similar path, namely increased productivity and improved quality. We dare to predict that development will continue.

Jan 1, 2005

By Seong- Rin Lim

Light-emitting diodes (LEDs) are regarded as environmentally friendly light sources due to their high energy efficiency and lack of mercury content. LEDs are used for a variety of domestic and commercial lighting systems, where they are replacing incandescent and fluorescent lamps at a rapid rate. Incandescent lamps inefficiently consume energy because electricity is mostly converted to heat rather than light. This causes unnecessary environmental impacts and energy consumption associated with power generation and transmission from a life cycle perspective. Although fluorescent lamps are more energy-efficient than incandescent lamps, their disposal at end-of-life presents special challenges because of the presence of toxic mercury. Despite the seemingly apparent advantages of LED, very few studies have rigorously addressed potential environmental consequences of their disposal. Specifically, LEDs are designed with III-V semiconductors that presumably consist of toxic and rare materials, including arsenic, gallium, and indium. We hypothesize that, depending on their concentrations and leachability, these constituents may also contribute to render LEDs as hazardous waste at the end of their useful life.

Jan 1, 2010

By S. Tanaka

The Tamano Smelter of Hibi Kyodo Smelting Co. Ltd. was commissioned in 1972. Since start up, the anode production capacity has increased from 101,000 tpy to 290,000 tpy, as a result of the application of continuous improvements at each phase of the expansion projects. The Tamano Smelter had developed several innovations, including the original coke combustion technology for Flash Smelting Furnace operations (T-FSF), and has also been able to extend the operating life of the Peirce-Smith converters. This paper will present several improvements implemented at the Tamano Smelter, and will discuss relevant P-S converter operation.

Jan 1, 2005

By Xiangjun Zuo

This paper firstly reviewed the state of the art in the recycling of used Printed Wiring Boards (PWB), and then presented part of the authors study on the combustion of PWB powders with and without the addition of catalyst. During the combustion of PWB powders without catalyst addition, there were two obvious exothermic reactions, one at 300-380oC, the other at 450-500oC. With the addition of catalyst during PWB combustion, there were no obvious exothermic reactions, indicating that dehalogenation reactions are not exothermic: The results showed that NaHCO3 and CaCO3 were very efficient to control the emission of Br2 and C6H6, lowering 80% compared to the case without catalyst, Na2CO3 can slightly control the emission of Br2 gas but not for C6H6 gas mission, and NaOH has no any effect of the control of both gases.

Jan 1, 2009

A modified Cuprex Metal Extraction Process (CMEP) leach process was used to extract Cu. Ni and Co from a complex sulphide concentrate. The standard leach was modified to a two-stage countercurrent leach which provided emf control of the copper SX feed and minimized iron dissolution. A flowsheet was developed to recover the base metals and silver from the leach solution and gold and platinum group metals from the leach residue which was predominantly elemental sulphur. Techniques required to maintain an iron balance in the system including pressure oxidation and solvent extraction are described.

Jan 1, 1996