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By T. Malvik

Norway is a big producer of ferrosilicon and silicon metal. The raw material is quartz and quartzite and large quantities from both Norwegian and foreign sources are used. The demands maade on both the chemical purity and the thermomechanical qualities of the quartz/quartzite have increased in recent years in an attempt to reduce energy consumption and to improve utilization. Control of the chemical quality of the raw material is relatively easy by means of routine analysis, but it is more difficult to find a suitable method for testing the thermomechanical properties. A rapid test method to define high quality quartzite deposits for use in the metallurgical industry has been developed. The method is based on a combination of chemical analysis, dilatometry, thermosonimetry and cathodoluminiscence.

Jan 1, 1989

By Martin E. Nelson

Several heavy metal separation techniques are currently being developed for soil remediation at various Department of Defense and Department of Energy (DOE) Facilities. The majority of these techniques involve a wet process using water, PH modifiers or other compounds. The United States Naval Academy (USNA) has developed a dry process for heavy metal separation. The process uses air classification technology to concentrate the metal contaminant into a fraction of the soil. The advantages of this dry process are that it creates no contaminated by product and uses commercially available technology. The USNA process is based on using a Gayco-Reliance air classifier. Tests have been conducted with the system at the Naval Academy and the University of Nevada-Reno (UNR). The USNA tests used soil from the Nevada Test Site mixed with bismuth at a concentration of 500-1000 ppm. The UNR tests used soil from four DOE sites mixed with uranium oxides and plutonium at an activity level of 100-700 pCi per gram. Concentration of activities and volume reduction percentages are presented for the various soils and contaminants tested.

Jan 1, 1995

By V. I. Lakshmanan

Crown ethers are gaining importance in separation technology specifically for rare earth elements (REE, La to Lu plus Y) and precious metals (Au, Ag, Pt, Pd, Rh and Ir) due to their specific binding ability, metal complex stability and high extraction efficiency. The selectivity of crown ethers in extraction of these metals depends on different factors, including the cavity diameter and nature of a donor atom of the crown ether, size and charge of the metal ion, diluents and counter ion. Demand for strategic REE and precious metals are consistently increasing in the world while the separation of these metals is most challenging tasks. In this paper, the use of crown ethers in separation of REE and precious metals, reaction mechanisms and simplified process flowsheets will be elucidated. New reagents with high selectivity for the separation of these metals are further expected to produce high purity metals.

By V. D. Tathavadkar

Natural chromite mineral is a solid solution of spinet end members namely: chromite (FeCr2O4), hercynite (FeA1204), magnetite (Fe3O4), magnesio-chromite (MgCr2O4), (MgA12O4), and magnesio-ferrite (MgFe2O4). A phase transformation in chromite minerals occurs in oxidising conditions during the soda-ash roasting reaction. This phase transformation plays an important role in improving the extraction efficiency of Cr3+ from mineral phase. The extraction efficiency of chromium (Cr3+) from chromite to a water¬soluble sodium chromate (Cr6+) salt depends upon the decomposition kinetics of the spinet phase. An investigation of the phase changes in chromite ores in the absence of sodium carbonate was carried out in air, argon, and in argon +5 % hydrogen gas mixture. The thermodynamics of phase transformation reaction in chromite solid solution phase is discussed using the solution model proposed by Sack and Ghiorso [1]. The microstructural changes and the changes in elemental compositions of different phases were examined by SEM and electron probe microanalysis (EPMA) respectively. The experimental results indicate that the solid solution spinet phase in chromite mineral undergoes spinodal decomposition under the influence of oxygen partial pressure and temperatures. The structure of phases formed and their morphologies suggest that the phase decomposition may be similar to those observed by Burkert et. a]. 121, although the scale of phase separation in chromite appears to be strongly dependent on oxygen partial pressure.

Jan 1, 2001

By Adam Powell

A Cahn-Hilliard phase field model is formulated to describe transport-limited electrochemical reactions coupled with fluid flow in a metal reduction cell. When the reaction is limited by mass transfer of metal ions from the electrolyte to the cathode, the metal-electrolyte interface at the cathode exhibits a Mullins-Sekerka instability, leading to the growth of dendrite-like "streamers" of liquid metal into the electrolyte, which in turn significantly enhance the apparent mass transfer coefficient there. Model results for iron reduction from ferrous oxide in slag show formation of these streamers. Although the double-layer is not included in this model, the related phenomenon of electrocapillarity can be represented by a gradient penalty term which includes the electric potential gradient, such that interfacial energy is a function of the electric field normal to the interface.

Jan 1, 2003

By Pengfu Tan

In order to understand and control the formation of dioxins and furans in iron ore sinter plants and to possibly avoid expensive end-of-pipe removal stages, thermodynamic calculations on the stability of PCDD/Fs have been combined with sinter process modeling by means of kinetic simulations and computational fluid dynamics. Three thermodynamic databases of PCDD/Fs, derived using the Group Additivity approach and two computational molecular modeling methods, MNDO and PM3, respectively, combined with the SGTE database have been used to model the PCDDIF formation and the PCDD/F isomer distributions in iron ore sintering. The results show very similar conditions for the PCDD/F formation using the different databases. Concerning the isomer distributions of toxic PCDD/Fs, the calculated data derived from the MNDO method showed optimum agreement with measured values from industrial furnaces. The thermodynamic calculations also proved that the isomer distributions found in combustion processes are equilibrium values, while the concentration ratio of PCDDs and PCDFs in the wind boxes does not represent an equilibrium state. A CFD model of iron ore sintering was developed including the kinetics of 15 relevant chemical reactions with the aim of describing the temperature fields and the gas flow patterns in the sintering bed. On the basis of these information and experimental observations reported in the literature possible pathways for the PCDD/F formation in sinter plants have been identified: PCDD/Fs are formed in the critical temperature region of 250 to 450 °C below the combustion zone, are then carried downwards with the gas and condensed close to the bottom of the sinter bed. Transported to the discharge end with the solid mixture, they are again released into the gas phase when the flame front approaches the bottom. PCDD/Fs are also formed in the last wind boxes when the hot off-gases cool down and reach the critical temperature range. Consequently, methods to reduce the dioxin formation reactions are proposed including inhibitor addition to the sinter feed and off-gas quenching.

Jan 1, 2003

By Matthew John M. Krane

"The macrosegregation patterns and convective behavior of a Pb-5wt%Sb-35wt%Sn alloy are studied using new numerical treatments of solid particle motion and of transport phenomena occurring during the solidification of ternary metal systems. At this composition, the solidification which occurs while the local liquid composition is in the (Pb)-(SbSn) binary eutectic trough has a significant effect on these phenomena. The effects of this solidification path on fluid flow and macrosegregation are compared to the more familiar binary alloy patterns and the effect of solid particle transport is evaluated. The final predictions of macrosegregation are compared to measured composition profiles. IntroductionThe macroscopic maldistribution of alloy constituents during solidification, commonly called macrosegregation, is a defect which occurs in real metal processing systems. This nonuniformity of species distribution, especially when it forms a high composition gradient or a poor distribution of secondary phases, can lead to areas of high stress concentration, which contribute to cracking during extrusion or forging of wrought alloys or when an as-cast piece is severely loaded in service [1, 2]. Macrosegregation studies in binary systems have become quite common since the introduction of single-domain numerical models which feature one set of conservation equations and boundary conditions for an entire, fixed computational domain containing solid, liquid and multiphase regions. A complete review up to 1995 has been presented by Prescott and Incropera [3]. However, most commercial alloys generally have more than two species in amounts significant enough to affect the convective flows which lead to macrosegregation and other defects. The formation of secondary solid phases, including eutectic and peritectic reactions, also may occur in commercial metal alloys and should be treated using appropriate thermodynamic models."

Jan 1, 1999

By T. Fujita

The removal of phosphorus is essential 1n order to increase the recycling of steelmaking slags for their manganese, iron and lime contents. This study aims at establishing the phosphorus mineralogy and its distribution in steelmaking slags, the effect of slow cooling, and the methods of phosphorus removal. A series of steelmaking slag samples was prepared at different cooling rates, and the mineralogy, chemistry and grain size of the samples were investigated with SEM/EDS and x-ray diffraction. The test results using high gradient magnetic separation are discussed.

Jan 1, 1988

By Yin Zhang, Xiaoyu Huang, Mi Wang, Bencheng Du, Youduo He

"Burners are important facilities for blast furnace stoves to raise hot-blast temperature up to 1200°C. Common types of two-ring ceramic burners have very long flames so that part of combustion occurs in the upper part of the chequers and will cause damage to the refractory materials. Using computer simulation to analyze the turbulent diffusion flame in the combustion chamber, some good results were obtained. A new type of ceramic burner will be installed by Anshan Steel Complex in stoves of blast furnace number 4. A pilot experiment was done on the new burner. The experimental data have shown that the mixing condition was improved and the length of flame was shorter with the new type of ceramic burner.IntroductionPulverized-coal injection can give significant operating saving, reducing coke rate in blast furnace(BF) operation. However, during high rates of coal injection, extra heat must be compensated in hearth to maintain certain raceway adiabatic flame temperature. One of the effective methods for heat compensation is to raise hot-blast (HB) temperature up to 1200°C. Nowadays, since the fuel being combusted in stoves is BF gas only, in which the calorific value is down to round 3000 kJ/m3 , to increase the combustion ability and to provide a suitable length of flame in combustion chambers of stoves becomes more important. In other words, designing a good ceramic burner which will affect to HB temperature and stove lifetime is drawing more attention."

Jan 1, 1999

By M. Nishikawa

The Hachinohe Smelter employs the Imperial Smelting Furnace (ISF) for production of zinc and lead and handles a large number of concentrates and recycled materials. In recent years, recycled materials such as zinc-bearing materials, lead sludge and Waelz oxide have provided up to 30% of the feed materials at the plant. To allow for a satisfactory operation using such a wide range of recycled materials, the Hot Briquetting Plant was built in 1986 and started its operation in January 1987. In April 1988 the zinc production capacity of the ISP was increased from 81,000 to 101,000 tonnes per year. The additional production in the ISP has been attributed to the utilization of the hot briquetting process. This paper describes the various facts of the smelter, concentrating on hot briquetting operations and treatment of hot briquettes in the ISF.

Jan 1, 1991

By Keiji Toyabe

Several purifying techniques have been developed for controlling the impurity levels in the copper electrolyte at Niihama Copper Refinery. These have been carried out as follows; i ) the study of the reaction in liberation made it possible to raise the current efficiency for arsenic removal by more than 50% and to decrease generation of arsine sharply. By applying this method, a good performance was attained at commercial operation. li) the antimony in the electrolyte can be successfully removed by contacting it with activated carbon. This procedure is applicable particularly when there is a large amount of antimony in the copper anode. lli) for the nickel sulphate recovery from the electrolyte, an electric evaporating system was developed. The characteristics of this process are, capability of continuous operation with less manpower, the high recovery ratio of nickel sulphate (more than 85% as nickel) and no black acid formation in the treated solution.

Jan 1, 1987

The concepts of capacity and basicity have proved extremely useful in dealing with a wide range of solute species in metallurgical slags, and as a result have been widely applied. These two concepts are reviewed, and it is suggested that the Lewis approach to basicity has much to commend it. In some cases, it appears that the term capacity has been used without due consideration being given to the nature of the solution being formed, or even to whether a true solution was being formed at all. This paper proposes a rigorous definition of capacity, based on the true nature of the solution process in slags and glasses, and briefly reviews the repercussions of this approach on data available in the literature and the limitations which it may impose on future investigations in this area.

Jan 1, 1994

By P. M. Swash

The determination of the heavy minerals in beach sand samples is highly dependent on the preparation technique used. In this paper a simple reproducible method for the quantification of "recoverable" ilmenite, zircon, rutile and leucoxene by magnetic separation, is described. The procedure recommended yields information relevant to the metallurgical processing of the ore rather than to the total heavy minerals present in the samples. Finally the determination of mineral reserve estimations and grade assessments is greatly facilitated when this "mineral assay" method is employed. An assortment of other mineralogical methods are described including SEM, EMPA, XRD, XRF, Image analysis, Mossbauer. clerici and perm roll separations. The methods are briefly examined and the practical information that can be gained by using such techniques are reviewed. Experience has shown that an understanding of the relationship between the physical and chemical properties of the heavy minerals can contribute to the prediction of mineral particle behaviour. Such information may ultimately help reduce the prospect evaluation period and minimise expenditure on metallurgical testwork.

Jan 1, 1991

By C. Beckennann, C. Y. Wang

"Computer simulations of structural and compositional development in equiaxed dendritic alloy solidification are performed using a recently developed multi phase model. The model not only accounts for the transport phenomena occurring on the macroscopic (system) scale, but includes also the grain nucleation and growth mechanisms taking place at various microscopic length scales. In this paper, a numerical technique consisting of a fully implicit control-volume based finite difference method and a multiple time step scheme is developed for accurate and efficient simulations of both micro- and macro-phenomena. Sample numerical results are presented to reveal the effects of liquid now and crystal sedimentation on segregation and the final grain size distribution. In particular, the importance of the interplay between the dendrite microstructure and multiphase now patterns is shown.IntroductionIn recent years, modeling of equiaxed dendritic solidification without convection has experienced considerable progress (1,2]. Nucleation and growth kinetic laws have been coupled with transient heat conduction calculations to determine the solidification microstructure. However, modeling of equiaxed dendritic solidification with melt convection and solid movement has not been attempted so far, largely because of the complications associated with the transport of free equiaxed crystals in the melt. The gravity-induced transport of free crystals is fundamental to the development and extent of the equiaxed zone and also greatly affects the columnar to equiaxed transition. Another possible effect of crystal sedimentation or floatation is to cause severe macrosegregation as well as structural inhomogeneities. The only study available in the literature that accounts for both liquid convection and solid transport is by Ni and Beckermann (3], but deals with globulitic structures (as opposed to dendritic)"

Jan 1, 1994

By E. Açma

Sivas-Divrigi flotation plant has a capacity of 90,000 tpy. Beneficiation of the tailings of iron ore magnetic separator seems to be attractive, because of its Cu, Co, and Ni contents. In the experimental work, sulfidic flotation concentrate is produced from these tailings. A roasting-leaching-H2S precipitation procedure is used to treat this concentrate, containing 0.55% Cu, 0.51% Co, 0.74% Ni, and 0.027% Zn. Sulfatizing roasting is carried out in a rotary furnace at 690°C. Roasted product is leached with 10 gpl HzSOl at 70°C and 30% pulp density. For the precipitation of desired metal, H2S is bubbled through the concentrated solution of repeated leaching, under controlled temperature and pH. Final metal recoveries of 91% Cu, 91% Co, and 50% Ni, and 92% Zn are attained. Roasting gases with their 13% SO2 content are suitable for H2SO4 production and the leach residues can be integrated with the iron ore processing plant as they contain 57.4% Fe and very low non-ferrous metals.

Jan 1, 1993

By R. G. Reddy

To better understand the behavior of bacterial-mineral interfacial reactions, a thermodynamic model based on the- studies of bacteria adhesion on mineral surfaces has been evaluated. The bacteria adhesion to the mineral surface would be increased by l ' d1;1creasing the change in Gibbs free energy of adhesion and it would be reduced if the change in Gibbs free energy of adhesion of the system is increased. From the combination -of Young's equation and equation of state, the change in Gibbs free energy of adhesion -for bacterium-mineral system- was calculated. Influence of liquid surface tension, mineral surface tension on the change in Gibbs free energy of adhesion and consequently bacteria behavior on mineral systems- has been discussed.

Jan 1, 1991

By Alex Probst

With low metal prices and increasing value placed on plant water and tailings disposal areas, it is becoming essential to maximize the efficiency of solid-liquid separation processes. Since its inception over 25 years ago, the use of flocculants has grown exponentially. While flocculants play a crucial role in the sedimentation process, they are also a major operating cost. Recent innovations are revolutionizing the industry once again. New thickener designs are doubling thickener-loading rates while reducing flocculant consumption. The feedwell, as the heart of the thickener, is undergoing many significant metamorphoses. With CFD and other advanced computational analysis, feedwell technology is being examined more thoroughly than ever before, The result is that the thickener previously thought of, as a "Black Box" is now being mapped and controlled with state-of-the-art technology. This paper will examine recent design improvements in all aspects of thickeners in order to project the look of the thickener of tomorrow.

Jan 1, 1999

By R. G. Reddy

The Margules .equation is used for interpreting excess Gibbs energy of several ternary systems. In the present study activity coefficient of 'a dilute solute, 2, in a binary solvent 1-3 was derived. The derived expression is used to interpret logarithmic activity coefficient of oxygen and sulfur in several metallic systems. Self interaction parameter of the solute is derived from the partial function of solute using constant compositional path. An expression for logarithmic activity coefficient and self - interaction parameter of solute is also derived using Maclaurin infinite series. The derived equation is based on Maclaurin infinite series used successfully to deduce thermodynamics of self interaction of oxygen as a interstitial atom in two metallic systems. The predicted thermodynamic parameters values using Maclaurin infinite series and Margules. equations, are in excellent agreement with the experimental data and also our predictions are far more accurate than the predictions made by other models.

Jan 1, 1996

By Y. K. Rao

Relatively pure crystalline lead sulfate (PbSO4) can be produced by chemical vapor transport from an impure source such as the lead-acid battery paste or the roast-ore-leach-residue from a hy¬drometallurgical process-route. In a closed-reactor, transport of matter is induced by a tempera¬ture-gradient and the steady-state transfer rate can be calculated using the data on the standard free energies of formation for the species present and the pertinent binary diffusion coefficients. The present work focusses on chemical vapor transport in a tubular reactor (1.4-cm inner diameter x 10-cm long) with the source- and deposition-ends held at 850°C (T,) and 750°C (Td), respectively; PbC12(g) is the 'solvent' or 'transport agent' and NiSO4(s) placed in the source-zone -serves to maintain a sufficiently high S0,-potential such that the stability of the lead sulfate species is ensured. For the purposes of analysis, the gas-phase in the reactor is assumed to consist of eight species: H2O, PbC12, SO3, SO2. O2 HO, C12, and PbC14. The reaction between C12(g) and PbSO4(s) in the high-temperature source-zone produces PbCl2, SO2, and 02; four more reaction-equilibria in the same zone yield other species. In the low-temperature deposition-zone, reaction equilibrium involving PbC12, H2O, and SO, leads to the nucleation and growth of PbSO4 crystals; three other reaction-equilibria occur in this zone. By employing the virtual equilibrium state for the end-zones and coupling it to the Stefan-Maxwell diffusion equations for each of the gas species, the respective partial pressures for these, in the source- and deposition-zones, are computed at steady-state. From these data, the molar fluxes of PbCl2. PbCl4, and so forth, are determined. Allowing for the transport-enhancing effects of thermal convection, the net transport rate of lead (or PbSO4) is duly calculated for specified initial conditions. The predicted rates show very good agreement with measured rate data reported in the literature [ V. Plies, T. Kohlmann and R. Gruehn: Z. anorg. allg. Chem, 568, 62 (1989)

Jan 1, 1995

By Jari Aromaa, Olof Forsen

"Oxygen evolution by decomposition of water is the main anodic· reaction in sulphuric acid solution. Traditional anode materials have been relatively low-cost lead alloys, though the active lead dioxide layer has a high oxygen evolution overpotential. This causes a significant increase of cell voltage. To lower total energy use in metal production, electrocatalytical properties or corrosion resistance to decrease replacement costs must be improved. Addition of an catalyzing ion will decrease oxygen evolution potential. The effective area of an anode increases by calcium additions and by producing anodes with fine microstructure. Remelting and rapid quenching is possibly a method that is economically feasible and technically simple enough to be adopted.IntroductionPermanent anodes are widely used in several electrochemical processes and cathodic protection applications. The permanent or ""inert"" anodes can be either massive or coated anodes. The massive anodes are metals, like lead alloys, or non-metals, like magnetite, graphite or ferrite. The coated anodes are made of a valve metal base (titanium, niobium or tantalum) coated with an electrochemically active coating. The purpose of anodes is to supply current to the electrochemical cell. A vast number of materials and their combinations are electrical conductors and may hence be used as anode materials. However, good anode materials must survive in aggressive environments and also be able to pass high current densities. These opposite requirements restrict the amount of possible materials. Generally, an useful anode material must meet three requirements, electrical conductivity, electro catalysis and stability. Good electrical conductivity is essential for energy efficiency. Good electrocatalytical properties are essential to improve product yield. Long term stability is also an important property, because electrode wear and corrosion may cause product contamination, increasing energy consumption and material and labor costs due to need of periodical maintenance. Electrical conductivity and electrocatalytical properties are more widely studied subjects than long term stability of anodes, and a good amount of information about these two subjects can be found in the open literature. Wear and corrosion mechanisms of the anodes vary depending on the operational conditions, i.e. concentration of different species, temperature and operating current density."

Jan 1, 1997