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By Zhenyang Wang, Yiran LIU, Xiangdong Xing, Jianliang Zhang, Zhengjian Liu

Basic characteristics of marine placer were systematically studied by chemical analyze, scanning electron microscope and X-ray diffraction in this paper. It could be found that the marine placer mainly consists of titanomagnetite and titanohematite. A series of experiments were performed to investigate reduction-magnetic separation for Fe and Ti from the marine placer. Effects of reduction temperature, reduction time, carbon ratio, magnetic density, and grinding fineness on the reduction-magnetic separation process were investigated. And the optimal process parameters were obtained as follows: the reduction temperature 1300, the reduction time 30 min, the carbon ratio 1.1, the magnetic density 50mT, and the grinding fineness of 0.074μm 86.34%. Under such conditions, the metallization rate, iron grade of magnetic substance and iron recovery reached to 94.23%, 97.19% and 90.28% respectively, and the titanium grade in non-magnetic substance and recovery of was 57.94% and 87.22% respectively. The effective separation of iron and titanium could be achieved in reduction-magnetic separation process.

Jan 1, 2015

By Sebastião Ribeiro, Leonardo Carneiro Sardinha, Alline Sardinha Cordeiro Morais, Carlos Maurício Fontes Vieira, Sergio Neves Monteiro

The glass tube of spent fluorescent lamps is contaminated with mercury, which might be a serious hazard in the case of conventional recycling by melting with other glasses. A possible solution could be its incorporation into a clay body to fabricate common fired ceramics such as bricks and tiles. The objective of this work is to characterize a type of fluorescent lamp glass waste to be incorporated into a clayey ceramic. The characterization was performed in terms of wettability tests to evaluate the interaction between the surface of the clayey ceramic and glass waste as a function of the firing temperature. The results showed that the contact angle decreased with increasing temperature, reaching a value of 79°, at a temperature of 1100°C, but not sufficient to completely wet the ceramic. However, compatible chemical composition and reduction of porosity by the flow of soft glass waste between the clay particles favor the consolidation of the ceramics structure above 900°C.

Jan 1, 2015

By Yang Wang, Xiancong Zhao, Hao Bai, Qi Shi, Zhancheng Guo

Linz-Donawitz converter gas (LDG) or basic oxygen steelmaking gas (BOSG) is one of the most important secondary energy sources in iron and steel industry, whose effective use plays a vital role in energy saving and emission reduction. However, the generation of LDG suffers from great fluctuation with respect to the production status of steel making. Therefore, a long term prediction model of LDG generation would be essential in gas system balancing and optimization. In this paper, a long term prediction model for the generation volume of LDG was proposed based on the steelmaking production estimation from Gantt chart and k-means clustering algorithm. Compared with the previous model, this model considered the influence of different steel type on LDG generation. The experimental results of a steel plant demonstrate that the proposed model exhibits high accuracy and can provide an effective guidance for balancing and scheduling of byproduct gases.

Jan 1, 2016

By Hyun Soo Kim, Joon Soo Kim, Myong Jun Kim, Jyothi Rajesh Kumar, Jin-Young Lee

Rare earth materials have an ever growing variety of applications in the modern and hitech technology. They apply to many an industry with crucial materials and they provide numerous a customers with benefits. Rare earth materials utilization increasing day-by-day in the worldwide, at the same time the resources is very limited in many countries like Korea. The present general article divided four sorts such as 1) mineral processing of Korean ore deals the gravity, magnetic separation and froth flotation, 2) decomposition and leaching of concentrates included sodium hydroxide fritting, sodium hydroxide hot digestion, hydrochloric acid leaching, 3) separation and purification of rare earth elements in mixed rare earth chloride solution consists reduction and oxidation method, solvent extraction, 4) preparation of rare earth oxide compound from purified elemental rare earth chloride solution having oxalate salt precipitation by reaction crystallization. The last part consists of a summary of the present study.

Jan 1, 2015

By John W. Graydon

Incineration is an attractive alternative to the disposal of MSW in landfill sites. However, the process of incineration generates fly ash which contains significant levels of leachable heavy metals - particularly cadmium, lead, and zinc - and it is essential to manage this fly ash in an environmentally sound manner. The compositions, phases, textures, morphologies and size of fly ash particles have been studied by light microscopy, scanning electron microscopy, X-ray microanalysis, and X-ray diffraction. The detailed spatial relationships and speciation of the environmentally significant constituents have received particular emphasis. The information obtained is useful in understanding how fly ash is formed during incineration, in understanding the leaching behavior of untreated fly ash if it is disposed of in a landfill and, most importantly, in guiding the development of the best treatment strategies for fly asti to mitigate its environmental impact.

Jan 1, 1992

By Paul E. Queneau

The QS (Queneau-Schuhmann) copper converter is a gently sloped, stepped, horizontal kiln-type tilting reactor in which desired bath oxygen activity, compositional and temperature gradients are created by countercurrent flow of matte and slag phases through a series of controlled bubble plume, mixer-settler configurations. Flow of gas and slag is normally concurrent. Copper sulfide concentrates are top-fed, employing oxygen flash burners. Oxygen and oxygen-carbonaceous fuel mixtures are bottom-blown into the smelting bath through judiciously located, independently regulated submerged injectors. Composition and mass flow rates of injector inputs are controlled to produce bubble plumes of desired character, without jetting through and out of the bath. The mixer-settler pattern can be reinforced if desired by employment of suspended shallow baffles. State-of-the-art instrumentation provides timely information required to govern key process variables. The outstanding capabilities of the QS converter for coppermaking have now been indicated by the current success of industrial QSL (Queneau-Schuhmann-Lurgi) leadmaking reactors. Modified converter designs are employed for leadmaking, nickelmaking and steelmaking.

Jan 1, 1993

By Yasuhiko Ito

"This talk is concentrated on the topics of compound film formation on the substrate electrode by interdiffusion of substrate element and electrochemically deposited species and/or by direct electrochemical implantation of the component element of the film into the substrate. As a typical example, electrochemical implantation of nitrogen atom into Ti metal to form TiN surface film is described. Another example is the formation of various kinds of intermetallic compound films including Ni2Y, Ni2Dy and Pd3 Y by the electrochemical implantation of lanthanoid elements into transition metal electrodes. By combining these two methods, Sm-Fe-N ternary material film also could be formed. The principle and application of the ""electrochemical implantation"" are discussed in detail.IntroductionGenerally speaking, surface film formation by molten salt electrochemical process can be divided into the following three categories:(i) single element film formation on the electrode by electrodeposition,(ii) compound film formation on the electrode by electrocodepostion of more than two elements, and(iii) compound film formation on the substrate electrode by interdiffusion of substrate element and electrochemically deposited species and/or by direct electrochemical implantation of the component element of the film into the substrate.This talk is .concentrated on the topics of category (iii), especially on the electrochemical implantation. Typical example can be seen in the electrochemical implantation of nitrogen atom into Ti metal to form TiN surface film. Another example is the formation of various kinds of intermetallic compound films including Ni2 Y, Ni2Dy and Pd3 Y by the electrochemical implantation of lanthanoid elements into transition metal electrodes. By combining these two methods, Sm-Fe-N ternary material film also could be formed. The principle and application of the ""electrochemical implantation"" are discussed in detail with examples above as well as other experimental results also obtained very recently in the author's laboratory."

Jan 1, 2000

By Ben Q. Li

An efficient numerical algorithm for solving steady state heat transfer and solidification problems is described. The algorithm is of boundary integral type and is based on the formulation of the field variables along the boundary of the domain of interest. Compared with the familiar domain-based methods, such as the finite element and finite difference (or finite volume) methods, this boundary-based method has an advantage of solving fewer unknowns and hence has a potential for reducing computational time significantly. Another and yet more important advantage of the present algorithm is that it is a stable scheme and is not prone to numerical oscillations resulting from convective effects, as often encountered in the domain-based methods. Therefore, no numerical or artificial diffusion (such as streamline upwinding) is necessary. Numerical examples are presented that are drawn from processing systems for producing aluminum-based materials.

Jan 1, 1994

By S. Gopalan, J. D. Milshtein, S. N. Basu

Production of syngas is proposed utilizing the W/W03 redox system and employing a solarpowered two-step thermochemical cycle. Three chemical reactions occur in two chambers. Assisted by a solar concentrator, a high temperature reaction reduces W03 powder to metallic tungsten in both chambers. Subsequently, the temperature in one of the chambers is lowered and H2(g) is produced via re-oxidation of the tungsten powder using steam. The temperature in the other chamber is simultaneously lowered to an intermediate temperature and CO(g) is produced via oxidation of the tungsten powder using C02(g)· The gas streams coming out of the two chambers result in the syngas production. A complete thermodynamic analysis of the system is described. The W/W03 redox cycle offers greater gravimetric fuel productivity compared to previously proposed systems, and the entire cycle can be operated below 1273K.

Jan 1, 2013

By Baozhong Zhao

Experimental results have shown that fluxing with soda ash (Na:zC03) can remove As and Sb from molten copper at the rate of As>Sb, but is relatively ineffective in removing Hi. The rate of impurity removal is controlled by impurity mass transfer in the metal phase. In this paper, a mathematical model was developed to describe the impurity removal phenomena. The model incorporates the effects of molten bath mixing intensity, soda ash feeding rate, oxygen content in the molten copper and soda ash fluxing by surface addition and injection. The model predictions are in good agreement with experimental results and may be used in designing large scale tests.

Jan 1, 1996

By Sanaz Mosadeghsedghi

The feasibility of the application of electrodialysis in separation of light and heavy rare earth elements (REE) in synthetic solutions was investigated. The experiments were carried out using single and binary solutions of a light (cerium) and heavy (ytterbium) REE. The effects of electrical voltage, electrical current, and the addition of complexing agent (EDTA) to increase the separation selectivity were investigated. Separation of Ce and Yb was achieved in binary solutions with and without the addition of EDTA. Higher degrees of separation were seen at higher voltages. Ce–Yb separation was more significant in the presence of EDTA. The separation factor of Ce–Yb and Ce–Yb-EDTA were 1.44 and 2.60, respectively.

By W. D. Cho

Fast dissolution of nonmetallic inclusions such as alumina particles in molten slags has been required in secondary steelmaking -ladle and tundish - to minimize the amount and the size of nonmetallic inclusions in steel products. In the present work, the dissolution behavior of alumina particles in molten CaO-A12O3 and CaO-A12O3-SiO2 slags at the temperatures between 1450 and 1550°C have been investigated in terms of kinetics and mechanism. Alumina particles were added directly into the slags and the variation of the particle size with time was determined using optical and electron microscopies. The conventional types of slag for ladle and tundish were included in the dissolution study. The effects of Al2O3, Siq, CaF2 and MgO contents on the dissolution rate of alumina particles have also been determined. The diffusion boundary layer between alumina particle and bulk slag phase has been observed and analyzed using SEM and EDS. Based on the analysis of kinetic data and the boundary layer, the dissolution mechanism has been discussed.

Jan 1, 2002

By Natasa Mitevska

The statistical analysis of the slag composition influence on copper losses to discard slag in the reverberatory furnaces No.1 and No.2 in the RTB BOR, Copper Smelter and Refinery (Yugoslavia) is presented in this paper. The model for the slag basicity calculation is determined, and connected to the copper distribution coefficients between the matte and slag phase. The influence of all components on the slag structure is also illustrated.

Jan 1, 2003

By Nolberto Moreno Borjas

This paper outlines the detrimental impact that unblended ore can have on the Ni and Co recoveries and the ore slurry density with real data from the Caron low-pressure ammonia leaching process for the Punta Gorda ore. The author briefly discusses the reason for the decrease in slurry density that the process experiences. The lower metal recoveries in the process that are caused by the unblended ore chemical characteristics and variations are shown with a data base statistical analysis drawn from the results obtained from a pilot test, designed with different ore bypassed from the normal process flow and a similar ore from a similar metallurgical treatment. Keywords: Ni-Co Laterite, Caron Process, Ore Blending, Slurry Density, Metal Recovery

Jan 1, 2004

By Xiaobing Yang, Abhishek Lahiri, Animesh Jha

"In the FFC-Cambridge process, the cathodic dissociation of oxide and CO/CO2 production on carbon anode is the basis for metal production in a CaCl2 bath. By using an inert intermetallic anode, the CO2 evolution can be eliminated altogether with acceleration in the electro-reduction kinetics. At present the process suffers from slow reduction kinetics of TiO2 to Ti metal, which can be enhanced significantly by the incorporation of alkali species in the TiO2 pellet at the cathode and in the CaCl2 bath in the presence of an intermetallic inert anode. Nearly full metallization with greater than 99% of Ti metal containing 1500 ppm of oxygen is possible to achieve in less than 16 hours of electro-reduction. Analyses of phase composition and the microstructures morphology in fully metallized pellets revealed the presence of localized solidified Ti layer, indicating that fast reduction process also involved formation of liquid phase as middle stage reaction. In addition, in situ creation of porosity and maintain higher current level during electrolysis process were two key factors to fully reduction of TiO2.IntroductionDuring cathodic dissociation of TiO2 in a CaCl2 bath and anodic evolution of CO2 on a carbon anode, which is the basis for the FFC Cambridge process [1], the rate of metallization slows down due to the formation of CaTiO3 at the reaction interface. Calcium and alkaline earth perovskites are known for their poor electrical conductivity which adversely affects the overall electro-reduction. One of the ways to increase the porosity is via the addition of polyethylene precursors in the pellet or by directly starting from perovskite [2, 3]. The experimental evidences shown in the literature confirm although the speed of reaction increases, but a complete or near complete metallization is not possible by enhancing the in-situ porosity alone, as the insulating perovskite is very slow to decompose under the equilibrium that prevails in the cell. Plethoric evidences on carbon anode show with the current decrease gradually, and finally stabilize at a very low value between 0.2 and 0.4 A, which is a testimony of the presence of perovskite insulating barrier in the current path. Our aim in this paper is to demonstrate the mechanism of enhanced electro-reduction when alkali ions are present in the oxide pellet at cathode and in the bath. We also show for the first time the use of an intermetallic anode for Ti-metal production using the FFC Cambridge process."

Jan 1, 2009

By R. W. Smith

A microorganism will function as a mineral flocculant if it is to some degree hydrophobic and can attach itself in some manner, such as through electrostatic interaction, to the fine mineral particles to be flocculated. The present paper concerns the use of a hydrophobic bacterium, Mycobacterium phlei, as flocculating agent for phosphate slimes. Experimental work on the flocculation of phosphate slimes and of dolomite and clay mineral suspensions was performed. It was found that M. phlei functions as an excellent flocculant for a dolomitic slime but does not function as well for mineral suspensions where large quantities of the solids are finer in size than the approximately 1 µm size of the bacterium.

Jan 1, 1992

By Jean-Christophe Gebelin, Mark Jolly, Samantha Jones

"The de-waxing process in investment casting is truly a black art which is carried out in a black hole - the autoclave. The process involves exposing wax, coated by a porous ceramic shell, to steam at a pressure of 10 bar and a temperature of about 180°C. The processes which then occur are truly multi-media and multi-physics. Steam condenses in the porous ceramic, wax melts and flows, the shells expand and sometimes crack. Why the shells crack is one of the most difficult questions asked in the industry.Modelling and validating the de-waxing process is not simple. The IRC at the University of Birmingham is attempting to model this process using Physica+ a code developed in the UK. This paper will present the latest results in this attempt to model one of the casting industries most intractable problems.IntroductionThe de-waxing process using an autoclave involves the following physical phenomena:· Flow of the steam in the autoclave;· Heat transfer from the steam to the wax, possibly through the shell;· Melting and flow of the wax.At the same time, other phenomena may occur, such as the flow of the steam through the shell, the condensation of the steam on the shell surface and on the wax pattern surface, the flow of wax the through the shell, etc ...This shows how complex the de-waxing process is from a physical point of view. The main defect that appears during this process is the cracking of the shell. Previous modelling work carried out by Snow [1] has shown that it is possible to predict the stress in the shell, making numerous assumptions. In this paper, the modelling to predict the state of stress in the shell that is currently in development at the University of Birmingham is presented together with the presentation ofthe physical phenomena to model and the assumptions used. The parameters that are needed in such models will also be discussed, and some experimental work undertaken at the moment presented."

Jan 1, 2001

By H. Masuda

The lijima Zinc Refinery started operation in 1972, and has today an annual capacity of 200, 000+-Zn. The hematite process was employed for the first time and the ideal of waste-free refinery has been pursued for 30 years. In recent years, however, only half of the hematite produced would be sold to the cement industry and hence a reduction of arsenic level has been necessary in order to sell the entire amount produced, The arsenic cementation process with zinc powder, developed through a long time laboratory research was found among some options as the best for the hematite process. The construction work started in 2000 and the facility was put into operation in 200 I. As a result in the same year all hematite were sold to the cement industry. The outline of this project, present operations and technical issue are reported in this paper.

Jan 1, 2003

By Michael F. Kitto

The production of sulphuric acid at base metals smelters is predominantly an involuntary activity and now comprises approximately 17% of all-forms sulphur supply in world terms. The majority of elemental sulphur is also produced involuntarily in response to environmental regulations regarding emissions from hydrocarbon processing plants. The paper examines the points of similarity and difference in the sulphur and smelter acid markets, and reviews their interactions. The reasons for the merchant acid market collapse of 1993 are analyzed, and the prospects of a recurrence are considered.

Jan 1, 1996

By Hani Henein

"Heat transfer between droplets/particles and a gas phase plays an important role in the transport of numerous materials processing operations. These include rapid solidification operations such as gas atomization and spray forming, as well as chemical systems such flash furnaces. Chemical reaction rates and solidification are dependent on the rate of gas-particle or gasdroplet heat transport. Using a heat transport model validated using single fluid atomization of molten droplets; the effect of process variables on heat losses from droplets was examined. In this work, the effect of type of gas, droplet size, gas temperature, gas-droplet relative velocity on the heat transport from AA606 l droplets was examined. The most critical of these process variables to heat transfer is identified and will be presented.IntroductionIn materials processing, droplets are often encountered and used in processing a wide range of liquids and slurries. The small size of the droplet enables high reaction rates or high solidification rates in many systems. In order to capitalize on these high rates of transport processes, sprays are· also developed to maximize throughput. The design of these sprays, however, does not account for the transport steps and rate limiting mechanisms at the droplet surface. Rather, spray design focuses on maximizing the break-up of a stream or slurry into small size droplets or controlling the spread of the spray. Spray systems in industrial use typically generate droplets of wide size distribution leading to a wide range of reaction times for each of the droplets. Often the generation of a spray involves a number of coupled phenomena such as stream break-up, droplet-gas transport, droplet size distribution and spray geometry. Using gas generated sprays, it is not possible to identify how individual process variables contribute and control each of these coupled phenomena. While many mathematical models have been developed of sprays and they attempt to simulate coupled droplet transport, they do not provide insight into the contributions of different mechanisms in heat transfer. This is primarily because the basic fundamental heat transport between droplet and gas cannot be isolated from other gas spray phenomena experimentally such as two-way thermal coupling [l]. Thus, experimental validation of heart transfer of large and complex industrial spray models is not carried out. Hence, the validity of spray models remains in question and the approach required to optimize spray processes cannot be clearly identified"

Jan 1, 2004