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By Helena Byrdziak

Polish Copper Industry, located in the Lepica-Glogów region and operated since the 1970's, includes four mines and two smelters, "Legnica" and "Glogów", the latter consisting of "Glogów" I" and "Glogów II" both having different technologies. The "Legnica" and the "Glogów I" smelters using shaft furnaces, so sulfur elimination largely takes place during batchwise converting, resulting in fluctuation SO2-concentration between less than 1% up to 10% in the converter pas W the sulfuric acid plants. The ensuing difficulties of the past have now largely been overcome. Introduction of flash smelting at "Glogów II" with subsequent acid making by double SO2-conversion from the stable process gas, contributed significantly to further reduction Of SO2-emission. In 1994 a new double conversion sulfuric acid plant was installed at "Glogów l" as well as a "Solinox" desulfurisation plant at "Legnica", further reducing SO2 emission considerably, The next step towards this goal under consideration is a semi-dry desulfurization system for the "Glogów I" power station, SO2- abatement measures by KGHM and the results thereby achieved are presented.

Jan 1, 1996

By M. K. Alam

Chemical Vapor Deposition (CVD) processes are currently attracting special attention in materials processing. CVD processes are now used to produce special materials in the form of thin films, coatings, composites, and optical fibers. This process produces material of high purity, in complex shapes, and in a variety of microstructures. It is a capital intensive process, involving use of high cost raw materials. Modeling simulations have the potential of reducing the time for CVD . process design, and the need for experimentation. Modeling would, therefore, appear to be an attractive option for producing a product of acceptable quality. At Ohio University, progress has been made in modeling of CVD processes, specially in the areas of optical fiber preform fabrication, and fiber coating.

Jan 1, 1990

By P. Myllykoski, J. Nylander, A. S. Korhonen, J. Larkiola

The coefficient of friction and the deformation resistance have been determined from the measured rolling parameters by applying the Bland-Ford-Ellis rolling force model and the artificial neural network model (ANN). The dependence of friction on the parameters such as reduction, rolling speed, front and back tensions, contact pressure and deformation resistance have been studied by the ANN model. Measured data of over 10 000 coils have been used in the training stage. Various dependencies have been examined and the results show that the friction coefficient does not depend much on the rolling speed. The reduction and deformation resistance seem to have the strongest effect on the friction coefficient. A friction model based on neural computing has been included into the existing rolling force model.

Jan 1, 1994

By Ross R. Bhappu

Anticipating a major power cost increase in 1990, Cyprus Copper Company decided to modernize the Miami Smelter at a cost of $92.5 million. The modernization project included the addition of an Isasmelt vessel for use as the primary copper smelter and the modification of the existing electric furnace to a slaglmatte separating vessel. The project was completed in June of 1992 and is currently operating at close to its design capacity. This paper provides a summary of the decision making process, a description of the project, a summary of start-up problems and solutions and the current status of the smelter operation.

Jan 1, 1994

By Yoshihiko Maeda

It is said that the 21 st century will be an era of the remedy of the global environment. In order to reserve natural resources for the future and to avoid the dispersion of heavy metals after usage and to avoid pollution problems, it is extremely important to recycle heavy metals as much as possible by reasonable recovery procedures. The nonferrous metal industry is expected to play a important role in the recycling of heavy metals that are originally their products. From the depressed metal price experienced in Japan in 1980th due to the sudden change in current exchange rate between US dollar and Japanese yen, one of major nonferrous metal company, Dowa Mining, has diversified its business area not only to the so-called down stream, but also to the environmental business including metal recycling, industrial waste treatment and soil remediation by utilizing technologies and facilities once used or still used for mining and smelting of copper, zinc, lead and precious metals. In this paper some of these applications will be presented.

Jan 1, 2003

By Jinxing Ji

Several fundamental aspects related to the nickel electrowinning from chloride electrolytes have been addressed in this paper. The thermodynamic study includes the activity coefficient of the hydrogen ion and the speciation diagram of NiCI2 solutions. The activity coefficient of the hydrogen ion (YH+) was calculated and estimated experimentally using a combination glass pH electrode. It was found that YH+ was greater than one in concentrated NiCl2 solutions and increased significantly with increasing NiCl2 concentration. The speciation diagram for NiCl2 solutions was plotted with YH+ and the effect of the ionic strength on the equilibrium constants being taken into account. It was discovered that the predominant nickel species in the acidic region were Ni2+ and NiCI+ in 0.937 M NiCl2 solution at 25°C. Electrodeposition tests demonstrated that higher Nit' concentration in the electrolyte improved the current efficiency of nickel electrodeposition (CENi). The additions of H3BO3, and NH4Cl increased very little the current efficiency of nickel electrodeposition at pH 1.5 and temperature 60°C. However, the addition of sulfate decreased the current efficiency of nickel electrodeposition. Nickel electrodeposition was also found to be a steady-state process since the amount of acid added to the electrolyte at a constant pH increased linearly with time during galvanostatic electrodeposition. The cathode surface pH during nickel electrodeposition was measured using a flat-bottom combination glass pH electrode and a 500-mesh gold gauze as cathode. The cathode surface pH was found always to be higher than the pH in the bulk electrolyte, and if the current density was sufficiently large, it would eventually reach a level causing precipitation of insoluble Ni(OH)2(s) on the cathode surface. Rotating disc electrode studies revealed that the rate of nickel electrodeposition was first order with respect to the activity of nickel ion and zero order with respect to the activities of chloride and hydrogen ions. The rate of hydrogen evolution was found to be first order with respect to the activity of hydrogen ion and to be zero order with respect to the activities of nickel and chloride ions. These findings indicate that nickel deposition and hydrogen evolution proceed independently.

Jan 1, 1995

By A. Rios

ENAMl's Paipote Smelter commenced operations in 1951. At present, it processes 230,000 tonnes/year of green feed in a conventional smelter, which comprises one reverberatory furnace, two Hoboken, one Peirce-Smith converters and one rotary anode furnace. The feed is composed of 83% copper concentrate and 17% metallic copper precipitates, which results in a feed average grade of 32% of copper content. The final products are 75,000 tonnes/year of copper anodes and 48,000 tonnes/year of sulphuric acid. At present, the plant is undergoing a modernization to expand the smelter capacity to 300,000 tonnes/year of green feed and increase the sulphuric acid production to 100,000 tonnes/year. This will be achieved with the installation of an El Teniente Converter and an expansion in the acid plant. The work began in November 1991 and is scheduled to be in operaton by March 1993. The paper provides an overview of the modernization plans and results achieved to-date.

Jan 1, 1993

By S. A. Davis

In July of 1996, the Kroll process began production again at TIMET's Henderson, NV, manufacturing facility. This, after being shut down for several years due to low market demand for titanium. Faced with limited pond capacity and increasing costs for water and wastewater disposal and storage; process changes were made to recycle water used to wash Kroll titanium sponge back into the sponge leaching process. This idea was revisited from 1992-93, when three consecutive attempts to recycle water for this application were unsuccessful due to early pump failure. Since it was uncertain why previous attempts failed, a complete understanding of the existing system was first sought. This included reviewing piping and flow diagrams; taking field measurements for all the piping, valves, and fittings; analyzing the wastewater composition; and modeling the fluid dynamics and control of the system. The fluid dynamics of the system were modeled by breaking the piping network up into nodes and applying the Bernoulli equation to each segment. The fluid flowrate control valves were modeled for this purpose also and the models were used to help specify the required processing equipment and control ranges and tolerances. Once the project was completed, an operating procedure was prepared for operation, startup, and shutdown of the washer water recycle system.

Jan 1, 1999

Hazardous waste has often very complicated chemical compositions in a variety of physical forms and is normally processed in rotary kiln incinerators. Due to large variations in waste types and difficulties in feed characterization, the complex transport processes within the incinerator are not well understood, and the incineration process meets challenges in a smooth operation, and expects various uncertainties in the process chemistry and emission control. For better understanding of the incineration process, simulation was carried out by using Computational Fluid-dynamics (CFD) to characterize temperature and species distribution in the incinerator. In order to catch certain aspects of thermal and chemical behavior, a novel approach is proposed to represent approximately the waste streams and the subsequent combustion process. Hazardous waste in various forms from an industrial-rotary-kiln waste incinerator is firstly converted to a hydrocarbon-based virtual fuel mixture with approximately the same HIC molar ratio and calorific value. The simulation of the combustion process of the simplified hazardous waste was proceeded with a combustion model. The distribution of temperature and chemical species especially the remaining CO in the system is preliminarily investigated. Distribution of CO concentration, as a good indicator of emission level for the incineration process, could be used to evaluate the emission control. The predicted temperature distribution has been compared with available measurement data from an operating rotary kiln waste incinerator at AVR-Chieme, in the Netherlands. Reasonable agreement has been reached between the measured and predicted temperature data. In the next step, measurement of species distribution in the system is planned to further validate the combustion model.

Jan 1, 2003

By K. Mansfield

Spent Pot Lining (SPL) is an unavoidable waste product of the electrolytic process in the smelting of aluminium. SPL is considered to be a hazardous waste in various countries because it contains significant quantities of absorbed fluorides along with traces of cyanide. In 1995, Portland Aluminium undertook the investment of AUD$26,400,000 to construct a Research and Development processing facility at Portland, Victoria, Australia, to treat SPL. Extensive research, development and design were carried out over 5 years prior to the investment decision. This study led Portland Aluminium to install an Ausmelt pyrometallurgical furnace to combust and melt the SPL producing a hydrogen fluoride (HF) laden gas, which was cooled and then converted to aluminium fluoride (AlF3). Both the cooling and AIF3 manufacture were processes developed by Portland Aluminium. Many commissioning, equipment reliability and process problems have been encountered that had not been experienced in the trials at Ausmelt or in the developmental process for the treatment of the furnace offgases to form AlF3. Designs based on anticipated process expectations have had to be re-engineered by the SPL team to ensure plant and operational success. In June 2001, the installation of the final major component - a slag granulation process - was completed. This has produced a vitrified (glassy) slag that is expected to have leachability qualities acceptable to the Victorian Environment Protection Authority (EPA) to allow commercial end uses of the slag material to be developed. Today (September 2001), the smelter has successfully used the fluoride product, namely 65- 70% AIF3, in aluminium production and the SPL plant has significantly increased throughput with expectations to be at annual design rates of 12,000 tonne of SPL in early 2002. "The Alcoa Portland SPL Process" has been technically developed and is a proven process for the treatment and recovery of valuable components from SPL materials.

Jan 1, 2002

By T. Wang, R. G. Reddy, D. Mantha

"A new eutectic LiN03-NaN03-KN03-KN02 quaternary molten salt system was calculated using thermodynamic modeling. The eutectic temperature was predicted to be 100°C. The melting point and heat capacity of the salt eutectic composition were determined using DSC. The experimentally determined melting point is in excellent agreement with the predicted value. The melting point is more than 124°C lower than that of the KN03-NaN03 solar salt. The density of the molten salt was experimentally determined as function of temperature. Using the density, heat capacity and the melting point, thermal energy storage density and gravimetric storage density of the quaternary molten salt were calculated and compared with that of solar salt. The larger storage density value of this molten salt indicates that this salt has a better energy storage capacity for solar power generation systems.IntroductionMolten salts have been used as thermal energy storage media for solar energy applications. Nitrates are being used in the solar energy applications for their low melting point, low unit cost, high heat capacity, high thermal stability, negligible vapor pressure and high energy storage density [l]. Solar salt (NaN03/KN03: 60/40) is the most popular thermal energy storage medium which is currently being used with the freezing point of 221 ·c [2]; another ternary system HITEC® which contains NaN03, KN03 and NaN02 has freezing point of 141°C [3]. Newer nitrate salt mixtures are being studied and projected as potential candidates for thermal energy storage (TES) and heat transfer (HT) applications. Based on these favorable features, molten salt can work directly as the energy storage medium below 500°C [l]. Development and synthesis of newer molten salt mixtures with freezing point lower than those currently used for thermal energy storage applications is necessary for sustained utilization of solar energy. The approach to develop lower freezing point molten salt mixtures is by the prediction of new eutectic mixtures and also by the development of new nitrate compounds."

Jan 1, 2012

By Roberto Parra

The classic criteria of the preparation of the charge for the smelting of copper concentrates in at flash furnace considers the mass and energy balance from the chemical and mineralogy composition of the concentrates. The operation parameters fixed with this method don't assure the stability of the operation and the critical problems of the slag quality and dust formation occurs very often. This paper presents the results of a laboratory test that allows the prediction of the behavior of concentrates blends in the view of the minimization of the dust formation and the magnetite control in the slag. The combustion of different copper concentrates and blends were done in a drop tube furnace The results show that the magnetite and dust formation don't have a linear behavior with the weight proportion of the blend and some optimal blends of 2 or 3 types of concentrates can be identified. From the reasonable hypothesis that the qualitative behavior of blends in the drop tube represents the real behavior in the burner, the preparation of the charge with this approach could help to solve those operational problems.

Jan 1, 2003

By Stephen R. Brown

Current conditions in the copper market demand that mine and plant operators make budgeted production targets at the lowest possible unit costs. For those companies bringing new production capacity on-line, achieving budgeted production levels as quickly as possible after start-up is vitally important to minimize unit costs and to begin a positive cash flow. Whether the objective is to simply improve unit costs or successfully start-up a new, complex plant, success will be strongly influenced by .the skill levels of the operators :and supervisors. The only way to assure return on plant investment, and to survive during depressed metal prices, is to ensure that plant operators have the knowledge to effectively run the plant. Technology available in computer-based, multimedia training systems, including: interactive animation, videos, voice-overs, schematics, and text can now be used to train operators at their own pace using plant-specific information. Additionally, it has been shown that learning through multimedia provides a higher degree of long term retention than more traditional learning methods.

Jan 1, 1999

By M. Hamamoto, S. Tanaka, K. Noda

"Tamano Smelter or Hibi Kyodo Smelting Co. Ltd. is operating with the Tamano Type Flash Smelting Furnace method which is a flash smelting furnace without slag cleaning furnace but which can discharge a slag equivalent to that from the slag cleaning furnace and with the development or coke combustion technology which is the basis of this world's only one type flash smelting furnace process, the smelter exhibits a low operation cost under high productivity operation. Utilizing this experience and improving it we have developed and put to practice an operation guide system using a general purpose computer in order to further establish s stable operation. In this paper these improvements are described. Background of System DevelopmentWith the recent rapid progress of general purpose computers and improvements in their performance an environment for the use or computer in process simulation at low cost and simple operation has been established. If an accurate operation simulation can be done with the Tamano Type Flash Smelting Furnace the merits would be very great and thus we started development of the system. The official name of this system is Computer guide system for Coke Combustion in the T-FSF and taking the initial letters we call it CCCT. We aim to achieve operation with stable mane grade, temperature and slag loss in the furnace by maintaining the most suitable combustion conditions of concentrate and coke in the flash furnace with the assistance of CCCT to the flash smelting furnace operators.Through several production expansion projects clone in the past by oxygen enrichment the copper concentrate treatment quantity and matte grade have increased step by step as shown in Figure I. Following this increase the difference between the operation calculation results al the initial stage of coke combustion and the actual behavior of furnace (matte grade. temperature in the furnace. etc.) gradually became bigger. Further operation procedures taken by different operators against the same phenomenon were sometimes different depending on each individual, which from time to time caused the operation to become unstable. Prior to the development of the system we checked out thoroughly the weak points of operation calculation procedures which were in practice until that time. The results were analyzed and study was carried out to establish a most suitahle operation calculation procedure and finally we reached this system"

Jan 1, 2000

By Messias dos Santos Machado, Renato B. Godoy, Roberta Lima, Andressa Silva, Francisco Valenzuela-Díaz, Rene R. Oliveira, Esperidiana Moura

This work aims to incorporate the Bof White Clay, from Boa Vista, Paraiba State, Brazil, as natural nanofiller in Ehylene vinyl alcohol copolymer (EVOH) and obtain flexible films. Nanocomposite was obtained using a twin-screw extruder, and film formed using a blow extruder machine. The flexible film nanocomposite was characterized, by tensile tests, XRD, DSC and their properties were evaluated. The results showed a good interaction between the clay and the EVOH resulting in an increase of properties of films nanocomposites as compared to films neat polymer.

Jan 1, 2015

By Ivo André

Sorption of copper ions from aqueous solutions by dried biomass of the aquatic plant Potamogeton luscens was studied at laboratory scale. The aquatic plant was collected in water resources in Brazil, washed, dried at 60°C and ground in a bladed mixer. Sorption experiments were conducted in agitated flasks and in a packed bed column. Maximum copper removal was obtained between pH 5.0 and 6.6 when copper was present in the ionic form Cu'. Sorption followed the Langmuir isotherm with saturation attained at 35 mg/g. Free energy of sorption was found, to be of the order of -25 kJ/mol. Sorption kinetics data were better described by a second order reaction and rate constants were calculated in 0.030 1/(min.mg) for - 4.0 mm particles and 0.081 1/(min.mg) for - 0.59 mm particles. Removal of metal ions in a packed bed column showed that Potamogeton luscens biomass can be used in several sorption/dessorption cycles. After sorbent saturation, copper ions can be recovered from the loaded biomass by elution-with H2SO4, solution. Main mechanism responsible for heavy metal uptake was found to be ion exchange. Results are discussed in terms of the surface properties of the biomaterial, solution chemistry of copper ions and thermodynamics parameters.

Jan 1, 1995

By Glenn C. Miller

Cyanide is the most common lixiviant for extraction of precious metals, and its efficient use in open pit mines has contributed to the increase in world production of gold during the previous two decades. With this expansion of precious metals mining using cyanide, public concerns have developed in response to the inherent public perception of cyanide as a tox-in as well as a series of environmental problems that are directly or indirectly related to cyanide use in open pit mining. Some of these have technical or regulatory solutions, while others will require additional investigation before they can be resolved. The following discussion will summarize some of the public concerns regarding the use of cyanide in precious metals mining. The issue of cyanide use in large scale precious mining is controversial, and recent banning of cyanide use in open pit mines in Montana, or complete banning of cyanide in Hungary has reflected those international concerns. The underlying basis for some of the bans (e.g. Montana) reflect a general concern of the environmental impacts of mining, rather than specific issues related to risk of cyanide use. The human safety record for cyanide use, particularly in the developed countries is good, and cyanide is clearly the most efficient lixiviant for precious metals. Indeed, the relatively short lifetime for cyanide in the environment renders it one of the less problematic chemicals used for extraction of gold from ore. Mercury amalgamation or use of bromide as a lixiviant are certainly much more problematic. What, then, is the basis f~r the international concern about precious metals mines that use cyanide. Ifuse of cyanide for gold recovery is to continue, what additional infom1ation needs to be developed that will allow a better management of the risks of cyanide? Which of the concerns are directly related to cyanide, and which are indirect concerns that more related to effects of open pit mining. Under what conditions should use of cyanide be discouraged? DUl::ing June of 2000 the United Nations Environmental Program conducted a two-day workshop on cyanide use in mining that was attended by persons from the mining industry, regulators and environmental community. Support and attendance at this workshop reflected concerns by all three groups on further restrictions for cyanide use and the emerging potential for guidelines for better management of the catastrophic release of cyanide-containing mining waste. The following discussion is meant to focus-on those risks and explore the basis for an often negative reaction to precious metals mining using cyanide. It is presented in the format of a statement, followed by a discussion. While admittedly provocative, the statements are meant to express the concerns? of the public regarding cyanide and the mining industry.

Jan 1, 1998

By Ryokichi Shimpo, Akio Fuwa

"The process-measurements of copper smelters in Japan were investigated for the summary of the latest technique and for the fundamental study of process control. The smelters investigated are those employing flash smelting furnace and P.S. converter, one reverberatory furnace and P.S. converter, and one continuous smelting converting furnace (M.I. process). Respective process is then considered, consisted of several reactors of different functions. The measurement methods were summarized in each reactor, including the measurement points. The methods of chemical analyses of the samples in each reactor were also investigated.IntroductionAn investigation on the process measurements, chemical analyses, and system control in copper smelters in Japan were carried out for understanding and summarizing the technique of the pyrometallurgical copper smelting operations. The typical seven processes in six copper smelters were investigated in the period from 1985 to 1987. The smelters investigated were Touyo Smelter of Sumitomo Metal Mining Co., Ltd., Kosaka Smelter of Dowa Mining Co., Ltd., Saganoseki Smelter of Nippon Mining Co., Ltd., Tamano Smelter of Hibi Kyodo Smelting Co., Ltd., Ashio Smelter of Furukawa Co., Ltd. and Naoshima Smelter of Mitsubishi Metal Co., Ltd. They include five flash smelting furnace and P.S. converter systems, one Mitsubishi continuous smelting and converting process (M.I. process), and one reverberatory furnace and P.S. converter system.The investigation was performed by making inquiries about the measurements, chemical analyses, system control, and their future prospects to the engineers in each smelter and by summarizing up in each item. The system control and future prospects were summarized in another paper titled ""Process Control Scheme of Copper Smelting Processes in Japan and Future View."

Jan 1, 1989

By Shigeatsu Nakazawa

Activities of Bi and In in the Bi-In liquid alloy were measured over the whole range of eomposition at the temperatures from 850K to 1050K. An alloy was vaeuum-sealed in a quartz cell and heated at the temperature of interest. The absorption for 307nm radiation from Bi lamp was measured for Bi atom vapor in the cell. By heating a pure metal as a standard and measuring the absorbance as a function of the temperature, an analytical curve for Bi atom vapor was constructed and used for conversion of the absorbance to the vapor density. Bi activity was determined as the ratio of the Bi atom vapor density over the alloy to that over a pure metal. The same procedure was applied to the In 304nm radiation from In lamp and In activity was determined independently of Bi. Results showed that the liquid Bi-In system behaves like a regular solution.

Jan 1, 2003

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