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By Nickolas J. Themelis

Nearly thirty two million tons of municipal solid wastes (MSW) are combusted annually in over one hundred U.S. Waste-to-Energy (WTE) power plants, thus reducing the use of fuel oil by about 1.6 billion gallons of fuel oil One of the advanced WTE processes is the 0.9-million ton/y SEMASS facility at Rochester, Mass. Most of the combustion in the three giant combustion chambers occurs while the injected shredded wastes are in suspension, i.e., in flash combustion mode. The velocity, temperature, and concentration profiles in the SEMASS combustion chamber were simulated by representing the combustible fraction of MSW by the simplified formula C6HIO04 and using the CFD program Fluent to solve the turbulent energy and mass transport equations. After validation against plant data, this model will be used to examine options for increasing the productivity of WTE combustion chambers, such as optimum distribution of primary and secondary air and oxygen enrichment.

Jan 1, 2003

By M. E. Coleman, G. Money

"Clyde Materials Handling is an established customer-driven solutions provider, which utilizes its knowledge, expertise and technologies to transform the production processes of its customers, who operate in the ferrous and non-ferrous metals industries.With over 30 years experience in the process improvement industry, Clyde Materials Handling has helped their global customer base transform the way in which they operate their processes, which has enabled them to generate sustainable economic benefit and maintain their positions as leaders in their respective markets.Clyde Materials Handling has supported operators within the metals market by developing and deploying pneumatic conveying and pneumatic injection technologies. These environmentally supportive and sustainable solutions have been used to transport raw materials within operating facilities, from storage to silo, as well as injecting these materials directly into the heart of production processes.Clyde Materials Handling has worked closely with their customers, such as Codelco in Chile, where their pneumatic solutions have been used to inject a consistent, pulseless and accurate flow of copper concentrate into a bath smelter, which has helped to fuel the operational capacity, availability and productivity.This paper will discuss and highlight the ways in which pneumatic injection technologies, created by Clyde Materials Handling, and applied in partnership with their customers, have helped to improve the operational performance of the production processes of operators across the non-ferrous metals markets with specific reference to applications in the Peirce Smith Converter.Clyde Materials Handling has applications injecting Electronic Scraps, Dusts, Reverts, and other additives to the Peirce Smith Converter. They also have experience of modified PS Units used for Slag Cleaning. There experience with the Codelco Teniente Converter is also directly related to this area of operation."

Jan 1, 2009

By C. S. Simons

This paper presents a review of the extractive processes used in the production of nickel, with emphasis on developments since the beginning of the Second World War. Attention is given to the factors, many outside the nickel industry itself, which determined the direction of process research and strongly influenced the ultimate commitments to industrialize the resulting developments. An example of such a factor is the sudden surge in demand, far exceeding the then available nickel production capacity, that was caused by the advent of World War II; the result was the first serious consideration ever given to low- grade laterites as a viable source of primary nickel. Other factors discussed include such items as process development in the extraction of other metals - particularly copper; the availability of increasingly sophisticated materials of const- ruction; the advent of the "environmentalist" and related political developments; the massive escalation in the price of energy - particularly oil. The paper concludes with an attempt to forecast the nature of the most effective nickel process of the future, based on extrapolation from the economic and political situation that exists today.

Jan 1, 1988

By Nickolas J. Themelis

Nearly thirty two million tons of municipal solid wastes (MSW) are combusted annually in over one hundred U.S. Waste-to-Energy (WTE) power plants, thus reducing the use of fuel oil by about 1.6 billion gallons of fuel oil. One of the advanced WTE processes is the 0.9-million ton/y SEMASS facility at Rochester. Mass. Most of the combustion in the three giant combustion chambers occurs while the injected shredded wastes are in suspension, i.e .? in flash combustion mode. The velocity. temperature, and concentration profiles in the SEMASS combustion chamber were simulated by representing the combustible fraction of MSW by the simplified formula C6HIO04 and using the CFD program Fluent to solve the turbulent energy and mass transport equations. After validation against plant data. this model will be used to examine options for increasing the productivity of WTE combustion chambers, such as optimum distribution of primary and secondary air and oxygen enrichment.

Jan 1, 2003

By Anna Wasilkowska

The study concentrates on the effects exerted by microstructure, deformation history and uniaxial stress conditions (temperature, stress state, strain rate) on the mechanical properties offerritic TRIP-aided steels for automotive applications. In low-alloyed TRIP-steels it is quite difficult to separate the effect of the austenite to martensite phase transformation from the influence of the ferritic matrix contributing to the yield stress and uniform elongation. Investigation of transformation kinetics of retained austenite as a function of the deformation temperature show that using the parameter k to characterize the retained austenite stability allows to identify regious of different temperature sensitivity separated by a transition temperature of 10±5°C. The observed low strain-rate sensitivity of the flow stress is an intrinsic property of the ferritix matrix and points to defomtation governed by slip. The ultimate tensile strength is much stronger affected by temperature than the yield stress. The influence of the temperature on the elongation is complex, because of the heating of the specimens by 60-l20°C at moderate and high strain rates. The increase of the total strain can be understood in terms of thermal softening of the ferrite. On the other hand, the steep increase of the stress during dynamic testing is an effect of accommodated elastic and plastic strains in the matrix. The strain- hardening exponent is dependent on the conditions imposed during testing. The martensite transfomtation rate is lower and the critical stress for martensite nucleation is much higher under compression compared to tensile loading. In secondary tensile tests, the yield stress increases steeply, and the ultimate tensile strength and the total elongation depend linearly on the amount of pre-straining. The results confirm that in the range of 8=10-4 s-l the TRIP-effect governs room temperature plasticity. Keywords: TRIP-steels, mechanical properties, strain rate sensitivity, temperature sensitivity, austenite stability

Jan 1, 2003

By Alan M. Russell

In recent years, several rare earth intermetallic compounds with the B2-type structure have been reported to exhibit high tensile ductility and high KIC fracture toughness at room temperature. These materials retain considerable ductility even at 77K. These are noteworthy findings because most intermetallics possess poor room temperature ductility and low fracture toughness unless one or more special contrivances are applied (e.g., doping with small additions of interstitial elements, offstoichiometric compositions, testing in ultra-dry atmospheres, etc.). This paper summarizes recent findings on rare earth B2 intermetallics. These include the determination of the active slip systems; the strain rate sensitivities; yield strength maxima at elevated temperatures; the search for possible twinning and stress-induced phase transformations; ab initio calculations of their defect energies and the anisotropy of dislocation line tension. Potential applications of these materials and the possibilities that this study may suggest strategies for increasing ductility in other intermetallic compounds are discussed.

Jan 1, 2008

By Kenichi Moriyama

The Sumitomo Toyo Copper Smelter started operation in 1971, as an epoch-making smelter at which 9996 of the charged sulfur could be captured. In the past ten years, the amount of treated copper concentrate has-been increased from 1,300 l/ day to 1;900 t/ day by the extremely effective application of the oxygen enrichment for a flash smelting furnace and converter furnace. The sulfuric acid production capacity at the acid plant has also been increased up to 1,900 t/ day corresponding to the increase of copper concentrate smelting rate without installing an additional acid plant. Furthermore the sulfur fixed ratio is kept at a high level, more than 99.996. despite the SO. strength fluctuation of the wide range of 596 to 1396 which is attributed to the combination of flash smelting furnace and, P.S. converter. These -operational results at the? acid plant were achieved by several modifications. and two examples are briefly described as follows; (1) Converter modifications in order to cope with the high SO, strength -gas (2) Introduction of the anodically protection shell and tube type acid coolers In addition. the quality of sulfuric acid has been positively increased. For example, the concentration of iron and arsenic, which were the main Impurities in ?sulfuric acid, was successfully .reduced.

Jan 1, 1995

By Won C. Park

Experiments showed changes in the mineral content of dolomitic oil shale at temperatures and exposure times which bracket conditions encountered during in situ retorting. Laboratory results correlate with cores from a spent in situ retort at Occidental's Logan Wash test site at Garfield County, Colorado. Dolomite, CaMg(CO3)2, decomposes rapidly to form periclase, MgO, calcite, CaCO3, and CO . Both calcite and periclase are intermediate products that can be stabilized by CO atmosphere at lower temperatures, while steam accelerates the formation 2 of silicates. The decarbonation of calcite appears to involve a direct reaction with both quartz and periclase in forming these silicates. Decarbonation preceeds the formation of akermanite, Ca2 MgSi 207, and diopside, CaMgSi 206, within several hours of heating and is followed by the nucleation of forsterite Mg2SiO4, and monticellite, CaMgSiO4. Under in situ retorting conditions, akermanite and diposide are the major minerals above 800°C. Equilibrium is not attained within 200-300 hours. In situ retorting temperatures above 800°C for extended periods of time should reduce potential ground water leaching by the formation of silicate minerals. These silicates are less soluble than free lime, magnesium or alkali oxides. There is a corresponding decrease in the natural pH of these silicates from approximately 12 down to 7.5 to 9:

Jan 1, 1981

By F. Baldini, M. S. Borges

"The proposed method emphasizes the optimization of waste management with regard to the exploitation of raw materials incorporated in the remains of industry, as well as the economics of natural resources as an environmental impact assessment. This system [tool] allows: (a) the conversion of an environmental liability into an asset by finding a line of appropriate research for each type of waste and the development of new materials applicable to other industries, (b) the performance of internal control of the waste generated (production, storage, final destination) as well as legal conformity.Objectives:1.1 General objective:To design a collaborative system for socio-environmental management of industrial waste.1.2 Specific objective:Develop evidence of concepts;Evaluate the deployment of the inventory of waste in an industry;Enable the conversion of an environmental liability into an asset by finding a line of research appropriate to the waste: a case study;Evaluate the environmental legislation in the legal mechanisms that influence company decisions.IntroductionThe global economy is undergoing major changes, among these changes; it should be highlighted those related to technological progress and environmental quality.While the industrialized countries and higher levels of economic growth dominate modem technology, developing countries are identified by a different growth pattern, using the annual growth rate of Gross Domestic Product per capita [3, 18].Growth is when the GDP grows, in percent, over the previous year. Development, on the other hand, is when the countries change their technologies and improve their internal structure. Thus, the growth considers the accumulation of wealth, while the development is concerned with the distribution of wealth, improvement of the quality oflife and environmental quality [3, 18].As the UNESCO report shows (1999), the biggest problem is between consumption and development, what is produced and the end that is given to the product. Therefore, product and by-product have equal importance in the quantity produced [29].On one hand there is a positive relationship between indicators of economic growth and technological progress, however, on the other hand, these transformations are a paradox, confirmed by the dramatic use of environmental resources and the lack of technologies for recycling of industrial scrap."

Jan 1, 2011

By K. Robinson

Following the longest Smelter campaign in BCL?s history it was planned to completely rebuild the flash smelting furnace in 1987. This was the fourth major overhaul and the most extensive so far attempted. Detailed planning took place over several year$ preceding the shutdown and implementation was completed in 54 days. The key to minimising shutdown time was the method designed for installation of the new uptake shaft and reaction shaft. Major repair work was also undertaken in the waste heat boiler and electric furnaces. Both of these activities had an impact on the critical path of the flash smelting furnace overhaul.

Jan 1, 1993

By G. Lindkvist

Roasting of concentrates with high impurity levels is normally done in multiple- hearth furnaces where the concentrates are heated with oilfired burners in order to remove As, Sb and Bi before the final sulfide oxidation. Although it is a countercurrent heat exchange process it uses a lot of oil. In order to develop an energy saving, and from a working environmental point of view a less harmful process than the multiplehearth process, pilot-plant tests have been done in a two-stage fluidized bed for partial roasting. The test materials have been As-rich concentrates with 8-25 % As some 5b and Bi. The Cu-content was 0-28 %. The tests have been successful with <0.3 % As,in the calcine and with an elimination of 5b between 80 and 90 %. In order to achieve the proper conditions for good impurity removal, 1.e. right temperature,residence time and sulphur potential, the tests were performed in a special designed roaster. The roaster consists of two beds with the facilities for recirculation of calcine, preheating of the blast, and possibility to use oxygen enrichment. The construction makes it easy to control the reactions that generate the heat in the bed and reduce the amount of dust that passes through the cyclones. As two roasting steps are used, the possibility to obtain optimal conditions for impurity removal is improved and the calcine can either be smelted to a normal matte, or after being dead-roasted in the second stage, be leached in the normal way for gold extraction. The calcine was smelted with slag. The matte and the slag obtained had low quantities of impurities in the matte and a favourable distribution of impurities to the slag.

Jan 1, 1983

By Xuemei Zheng, Aiyuan Ma, Chao Liu, Guojiang Li, Chenyu Sun, Jinhui Peng, Libo Zhang, Yongguang Luo

In this paper, the removal of fluorides and chlorides from blast furnace dusts by water vapor enhanced microwave roasting was investigated, combined with the advantages of microwave selective heating and based on a thermodynamic analysis of zinc and lead halides. According to proposed reactions in the process, detailed experiments were systematically conducted to study the effect of roasting temperature, holding time, air flow, water vapor flow rates, and stirring speed on the efficiency of the removal of F and Cl. The results show that 97.26% of F and 64.23% of Cl could be separated when the condition of the roasting temperature of 650°C, stirring speed of 80 rpm, holding time at 60 min, air flow of 350 L/h and water vapor flow rate of 8 mL/min was optimized.

Jan 1, 2016

By M. M. Kim

Zn-27% Al was pressure infiltrated into a column of 20 micron diameter abrasive grade SiC particles to give billets with particle loading of 50 voli.une %. Some billets were heated to a temperature where they became semi-solid and diluted with liquid Zn-27% Al alloy to give billets with particle loadings of 12 and 16 volume %. Some of these billets were then extruded into wire with an area reduction of approximately 98%. Tensile properties of the as-cast billets were always inferior to those of the matrix alloys; however, the extruded composite samples showed at 37% improvement in ultimate tensile strength compared to their extruded conventional counterparts. The fracture surfaces of these samples are described.

Jan 1, 1990

By D. S. Barr

Mineralogical, lithological, and metallurgical studies were conducted on various gold ore deposits currently controlled by Freeport-McMoRan Gold Company. Ore samples were first lithologically and mineralogically categorized, then subjected to chlorination, roasting, and autoclaving pretreatments to determine their effects on gold recovery in a subsequent alkaline cyanide carbon-in-leach extraction. The studies indicate that, while organic carbon and sulfide sulfur are the primary refractory components, their effect on process response must be interpreted with respect to the deposit&apos;s geology and mineralogy. This approach has proven to be an effective method for evaluating metallurgical alternatives and fore-casting future mill performance.

Jan 1, 1987

By Dave Tahija

"Many investigations are being performed with the goal of removing carbon dioxide from the atmosphere and permanently storing it in geologically stable settings. At the same time, carbon dioxide in the form of dissolved carbonate is steadily accumulating in the world's oceans. Both carbon dioxide sequestration and oceanic accumulation are constrained by the aqueous thermodynamics of the carbonate system. These constraints are illustrated using the STABCAL computer model to generate potential-pH and aqueous distribution diagrams of seawater in contact with various pressures of carbon dioxide gas. STABCAL diagrams and titration simulations are also used to model some potentially useful cation-carbonate sequestrationsystems.IntroductionAtmospheric carbon dioxide concentrations have risen dramatically in the past couple of centuries and are rising still, primarily as a result of human activities, especially the burning of fossil fuels. Increased atmospheric carbon dioxide concentrations have been implicated as a main cause of global warming but have other effects as well.Rising levels of atmospheric carbon dioxide result in increased concentrations of dissolved carbonate complexes in water, including the oceans. These dissolved carbonates interact with other dissolved substances, altering overall seawater chemistry, most noticeably causing lowered pH levels.Some of these chemical changes are observed directly, for instance the general drop in oceanic pH, [1], while others can be inferred and predicted using thermodynamic modeling. The chemistry of dissolved carbonate in seawater is not especially intricate, as such chemical systems go, but neither is it simple enough to be worked out on the back of an envelope. Interactions between the several simple carbonate species and all the major dissolved cations in seawater should be considered, as well as the effects of competing anions, especially chloride and sulphate, since they are much more abundant than carbonate in seawater."

Jan 1, 2011

By Z. Q. Chen, M. H. Loretto, Y. G. Li

"As-cast, As-forged, as-solution-treated, and solution treated and aged microstructures of Ti-15Mo (IMI205) with and without carbon were examined using optical microscopy, scanning electron microscopy .and transmission electron microscopy. Tensile testing was carried out at room temperature. It was found that carbon acts primarily as a titanium carbide former: Titanium carbides increase slightly the tensile strength, but decrease the ductility of IMI205. These observations are interpreted in terms of the titanium carbide morphology observed using SEM and TEM and the phase diagrams of Ti-Mo, Ti-C, and Mo-C.IntroductionIn a recent study on the development of a burn-resistant 13-Ti alloy, carbon was introduced· into the Ti-V-Cr system in order to optimise the mechanical properties. Research results[1, 2] demonstrate that carbon addition can refine the 13 grain size and improve the stability of the 13 phase in Ti-V-Cr alloys. The most attractive result is that carbon addition produced a marked improvement in the ductility of alloys when the carbon content is over 0.1 wt.% in this alloy system. Even after long exposure, the alloy with carbon addition maintains good ductility. One of the main reasons for the ductilising of the alloy is that titanium carbides can getter the oxygen from the 13 matrix.In view of the success of carbon addition in improving the properties and the stability of the Ti-V-Cr alloy, it is of interest to investigate the behaviour of carbon addition in other beta Ti-base alloys. The objective of the present work was, therefore, to assess the microstructures and mechanical properties of IMI 205, a metastable beta titanium alloy, with and without carbon addition using optical microscopy (OM), scanning electron microscopy (SEM), transmission electron microscopy (TEM), wavelength dispersive X-ray (WDX) analysis, room temperature tensile testing."

Jan 1, 2000

By S. Viswanathan, Q. Han, A. S. Sabau

"In spite of recent advances in the mathematical modeling of fluid dynamics for materials processing applications, no significant advances have been made in the numerical discretization of these equations. In this work, the application of two-step projection methods for the numerical simulation of interdendritic flows is discussed. Unlike previous methods, the methods presented here are constructed for the exact equations which are characterized by variable density and volumetric fraction of the liquid. The drag terms, which describe the momentum loss due to the flow around and through the dendrite structures, are treated implicitly. Numerical examples for shrinkage-induced flow during solidification of an Al-4.5% Cu alloy bar is used to illustrate the effectiveness of the proposed algorithm.IntroductionLiquid contraction during solidification plays an important role in the formation of casting defects such as shrinkage voids, microporosity, and macrosegregation. Owing to their importance, the study of transport processes during solidification have received considerable attention during the past years [1, 2]. By the use of volume-averaging techniques, the mass and momentum equations for flow through a stationary dendritic structure were derived [3]. By using the volume-averaging techniques for multi-phase systems, two-phase transport equations for solidification problems were derived [4]."

Jan 1, 1999

By M. E. Huckman

In this paper, we review the equations needed to construct an ion exchange column model. These models contain three major components: 1) a differential material balance around the colunm, 2) a differential material balance around an ion exchange particle, and 3) a constitutive equation for diffusive flux We then examine the ability of a fairly simple mathematical model to predict ion exchange column experimental data. This model contains the traditional absorption theory equations and is used to predict the behavior of a column filled with a hydrous crystalline silico-titanate and which is removing trace amounts of Cs+ from a high pH, complex electrolyte solution. Finally, we propose replacing Fick&apos;s law with the Nernst-Planck equation as the constitutive equation for diffusive flux We use a Nernst-Planck type model to predict batch experimental data, then evaluate it by comparing it&apos;s ability to predict experimental data to that of a more traditional Fick&apos;s law type model? The data from this comparison suggests that the Nemst-Planck type model yields better results.

Jan 1, 1996

By Cajsa Samuelsson, Theo Lehner

Converting and refining play a central role in the extraction of metals. Sweden has a long tradition as an experimental play ground for metallurgists, chemists and alchemists, developing new methods and technologies. Presenters of papers are usually happy in recording successful developments. But reporting failures can be as great a value as the former. In the paper experiments and experience in process development are illustrated, differences between ferrous and non-ferrous developments are highlighted and industrial learning curves are discussed. 53

Jan 1, 2009

By Noel A. Warner

Modern steelmaking is based on direct use of oxygen in high intensity batch reactors. A totally new approach is proposed in this paper, based on the view that pursuit of high intensity is unlikely to lead to successful coal-based continuous steelmaking. By substituting carbon dioxide and water vapor as the oxidants rather than using oxygen directly, the intensity is greatly reduced. Accordingly. subsurface formation of carbon monoxide bubbles can be avoided by careful manipulation of the three participating rate processes, gaseous diffusion, interfacial chemical kinetics and liquid phase mass transfer. Steelmaking can then be carried out without explosive ejection of molten droplets and the generation of micro-spray but rather in a controlled and fumeless fashion. The vital component is the introduction of generic melt circulation technology. Three melt circulation loops in series are envisaged. Starting with a composite feed of iron ore fines, pulverized coal and lime flux, a metallized solid raft floating on molten iron is propelled out of the ironmaking loop onto the first of two downstream steelmaking loops. In the first, a liquid slag is formed, primary decarburization is undertaken not with oxygen but rather with CO2 and H2O and the melt is desulfurized. The semi-product stream enters the third melt circulation loop, where open-channel decarburization is effected along with dephosphorization to yield a low carbon steel product. Alternatively, the melt leaves the last loop to irrigate a packed tower countercurrent to argon at around 100 mbar to continuously produce ultra-low carbon (ULC) steel.

Jan 1, 2003