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By A. M. Strachan

The arising and behavioural pattern of polonium-210 in the Capper Pass & Son Limited non-ferrous metal smelting and refining circuit is briefly discussed. The process developed for the removal of polonium from lead, solder and bismuth is discussed in detail, together with the essential personnel safety and environmental protection precautions which must be taken during the refining and subsequent storage of the active dross.

Jan 1, 1992

By Tae-Hyun Kim, Shun Myung Shin, Jin-gu Kang, Jeong-Soo Sohn

We investigated about synthesis of Mn-Zn ferrite with spinel structure using sulfuric acid leaching solution of mixed spent zinc-carbon batteries and spent alkaline batteries. The waste batteries were prepared by physical treatment such as crushing, magnetic separation, and screening. After screening, the crushed batteries were separated to +8 mesh and -8 mesh powder. Among these, under 8 mesh powder was selected for leaching test. The leaching test was investigated at 2 M H2SO4, 4 vol.% H2O2, reaction temperature 60 ?, agitation speed 250 rpm, solid/liquid ratio 50 g/ 500 ml, reaction time 1 h. The leaching efficiency of zinc, manganese and iron were 99.0%, 98.9%, 58.5%, respectively. For co-precipitation of zinc, manganese and iron, 5M NaOH solution was used for pH control. Then in order to synthesize Mn-Zn ferrite powder, it was investigated according to reaction temperature, agitation speed and O2 partial pressure. We could synthesize about 20 nm of Mn-Zn ferrite with spinel structure.

Jan 1, 2008

By W. Petruk

The silver-rich cobalt-nickel arsenides ores of the Cobalt area in Ontario, Canada were mined for silver from about 1904 to 1985. The ores contained about 8 oz to 100 oz Aglt and about 1 wt% Ni and 2 wt% Co. They were processed by gravitational techniques, screening and flotation to produce separate silver and Fe-Co-Ni arsenide concentrates. The silver concentrate was smelted, and in some cases the arsenide concentrate was sold to custom smelters which recovered silver and other metals. The ores display a wide variety of textures and contain many minor and trace elements. This paper presents an evaluation of mineral characteristics that have a bearing on extractive metallurgy and smelting of this type of ore.

Jan 1, 1993

By Dengfu Chen, Huabiao Chen, Yunwei Huang, Mujun Long, Youguang Ma, Lintao Gui

In the current work, a three-dimensional model coupling turbulent flow, heat and solute transport was developed to investigate the solute transport and redistribution in the mold of slab continuous casting where the Reynolds number is very high and the molten steel flows strongly. The conservation equations of momentum, energy and species for a multicomponent system which includes solute element C, Si, Mn, P, S were solved with the commercial software ANSYS Fluent. The parameters used in the model are based on the actual continuous casting. The fluid flow, temperature distribution and solute elements distribution were analyzed. Results showed that negative segregation occurred near the strand surface, and the species concentration reached a peak value at the solidification front during solidification. The segregation degree of solute element S is higher than the other solute elements because of its lower equilibrium partition coefficient. The species concentration in the liquid pool is homogeneous because of the turbulent flow effect.

Jan 1, 2015

By Geir Wedde, Anders Sorhuus

"Vast quantities of energy are released as heat to the environment from industrial operations. Many countries target waste heat recovery to mitigate CO2 emission. Exhaust gases from industries such as primary aluminium smelting, carry a substantial portion of the waste heat generated. For a cost efficient capture of more valuable heat (higher exergy), heat exchangers should operate on the exhaust gases upstream of the gas treatment plants. Heat exchange surface would be exposed to dust laden gases with risk of fouling. Heat exchangers of innovated design and operation have overcome the potential of excessive fouling rates. Heat exchangers of the ""shell and tube"" design have been demonstrated for exhaust gases from ferroalloy as well as primary aluminium smelters. In addition to the heat recovery, gas cooling results in smaller gas treatment plants with lower costs and reduced emission. The aluminium experience is exampled in the paper.IntroductionIndustrial usage of energy continues to grow as a result of increasing volumes of production, a trend that is likely to continue in the coming decades as living standards keep rising globally. World energy consumption (Figure la) is to grow 49 % by 2035 (ref. 2010) as reported by EIA [1]. The industrial sector consumes somewhat more than 50% of the total world energy consumption predominantly the energy increased demand comes from non-OECD countries in Asia. The industrial consumption by production of metals iron and steel accounts for 14 % and for non-ferrous metals 3 % mostly for aluminium production (Figure lb). Aluminium production will be discussed in this paper as an example of an industry with large quantities of waste heat to recover"

Jan 1, 2012

By Ray Y. Lin

Chemical vapor deposition of tungsten carbide on the surface of steel has been investigated at temperatures between 400 and 550C in an atmosphere containing tungsten hexafluoride, hydrogen and benzene. The tungsten fluoride flow rate was maintained at 20 ml/min. The hydrogen flow rate was at 100 ml/min. The benzene concentration varied from 1.15 to 5.56% in the reaction gas. It was observed that the higher the temperature, the faster the deposition rate for tungsten carbide. But the dependence of the deposition rate on the benzene concentration was not systematic. From the x-ray diffraction analysis, it was observed that W, W2C and WC are all presented in the coating. The amount of each phase presented in the coating depends on the temperature and, to a less extent, on the benzene concentration. The microhardness measurement has also been done for all CVD carbide coatings obtained in this study.

Jan 1, 1992

By René Winand

The paper gives a synthesis of research work performed in the department during the last ten years and dealing with cobalt , copper and manganese electrodeposition in chloride aqueous solutions. Special emphasis is given to electrocrystallization. For copper, properties of the electrolyte such as solubility limits, electrical conductivity and complex ions stability are discussed in connection with leaching, purification of the electrolyte, and metal recovery. When possible, kinetic parameters and probable electrode mechanisms are given. Problems that are still to be solved are also listed.

Jan 1, 1985

By Jae-Ho. Lee

Mercury is a toxic contaminant encountered in the extraction of gold from mercury-containing ores. It is found in the leach solution of CIP circuits and in the cathodes of the electrolyte cells used to electrodeposit the gold. The research conducted has examined the potential for selective removal of mercury from synthetic Au-Hg-CN electrolytes containing only gold, only mercury, and both gold and mercury. Cyclic voltammograms were obtained for mercury- coated copper electrodes with these cyanide electrolytes. Exchange current densities were determined from the voltammograms in the low overpotential region. Laboratory scale batch- electrolysis at constant current was also conducted for the electrolytes containing only mercury and both mercury and gold, at 20 and 50°C and from which the kinetic behavior associated with the process was analyzed. The surface of cathode before and after electrolysis was also characterized and a copper mercury intermetallic (CyHg,) was identified. Gold codeposited with mercury during the later stages of electrolysis. The results of this work corroborate that the mercury-amalgam copper electrode offers a viable electrochemical technique for the selective removal of mercury, however a high-surface-area cathode-cell would have to be utilized to provide for the desired selectivity.

Jan 1, 1994

By Cyro Takano

An alternative use for recycling of waste from bag house of iron ore sinter plant was tested by producing and evaluating" at laboratory scale, the self reducing cold bonded pellets. This waste was characterized and the self-reducing pellets were produced using anthracite coal fines as reductant and Portland cement or hydrated lime/Blast Furnace slag as binder. It was used the molar ratio of Fe2O3/C (fix) equal to 3. Evolution of cold strength with curing time, for different contents of binder, was evaluated. Cold strength of 200N/pellet was obtained, for sinter dust, after 10 days of curing. Suitable hot strength was also presented and no decrepitation and swelling were observed. Good fractional reduction was obtained at 950°C and 1137°C. These results show that this material may be used by the Self-Reducing Processes for hot metal production, as an alternative route for this dust destination.

Jan 1, 1996

By Uday B. Pal

In the electrochemical vapor deposition (EVD) process, gaseous cation precursors are passed over one side of a porous substrate, and oxygen is passed on the other side of the substrate. The gases diffuse and react within the porous substrate, and the pores get filled with the desired solid oxide. Subsequent solid state electrochemical transport through the solid oxide in the pores continues the reaction, and the film grows over the porous substrate. The EVD process has been used to deposit lanthanum chromite interconnection films and yttria stabilized zirconia electrolyte films over porous air electrodes. The EVD growth of these solid oxide films is found to be parabolic in nature, which indicates that the solid state transport (diffusion) of ions through the film controls the growth. This solid state transport can be analyzed using Wagner's treatment of the electrochemical transport. Conductivity measurements and the information on the defect structure of the oxide can be combined with the EVD growth rate measurements to calculate the solid state transport properties (transport numbers and partial conductivities) of the rate-controlling minority species in the oxide. Using this approach, the EVD growth of other electronic, mixed conducting and ionic solid oxide films can also be analyzed.

Jan 1, 1992

By T. I. Arbuzova

The present work presents the original data concerning using a high pressure torsion method and a shock wave loading technique to produce compact oxide nanomaterials and investigations of the effect of severe plastic deformation on a microstructure, crystal lattice and stability of these compounds. This allowed us to compare two ways of deformation action that can be characterized as quasi-static and dynamic effect, correspondingly. Particular attention was paid to a stoichiometry and surface composition changes upon severe plastic deformations. A procedure for studying chemistry of the oxide nanomaterials by means of nuclear microanalysis and Rutherford back scattering has been worked through. For surface studies the X-ray photoelectron spectroscopy has been used. It was shown that both distortion methods permit to produce massive nano-scale oxide materials from the coarse-grained powder during a single technological cycle. Bulk nanocrystalline materials based on LaMnO3, TiOy and ZrO2:Y2O3 were obtained by the quasi-static deformation technique. Nanoscaled ceramics of CuO, Mn3O4 and LaMnO3 were produced by the dynamic deformations. The density of the nanoceramics comes to 99%. Size effects and specific imperfection of the nanoceramics obtained lead to a set of particularities of physical properties.

Jan 1, 2006

By R. Escalera-Lozano, M. Herrera-Trejo, M. A. Pech-Canul, J. López-Cuevas, A. L. Leal-Cruz, M. I. Pech-Canul

"The use fly-ash (FA) and rice-hull-ash (RHA) offers the potential for the manufacture of hybrid Al/SiCp/spinel composites via reactive infiltration, both with recycled aluminum. The main reason behind this statement is the beneficial role that both waste materials play in preventing the degradation of SiCp reinforcements when the composites are processed with aluminum in molten state. Experimentally, MgAl2O4 is formed in situ during the infiltration of SiCp-preforms in the temperature range 1050-1150 oC for 50-70 min in argon atmosphere at a pressure slightly above to that of the atmospheric pressure. Results reveal that both FA and RHA help in preventing SiCp dissolution and the subsequent formation of the unwanted Al4C3; and although FA-composites still might be susceptible to corrosion via Al4C3 -by the interaction of native carbon in FA with liquid aluminum- a proper FA treatment significantly mitigates its deleterious effect. Primary corrosion mechanisms and strategies to overcome the potential degradation effects are outlined.IntroductionOwing to inherent materials characteristics and post-processing complications –such as corrosion damage- development of metal matrix composites (MMCs) from recycling/waste sources might be a challenging task. Fly-ash (FA) and rice-hull-ash (RHA) are two primary waste materials that offer excellent opportunities for the development of Al matrix composites. Due to its singular hollow-spherical shape and low density, FA has attracted the attention of many researchers. For this reason, most of the efforts to develop Al-based composites from waste materials have been centered on the use of fly ash. Extensive research efforts in the use of FA for Al-based composites have been undertaken by Rohatgi and coworkers [1-4]. In addition to lowering costs, incorporation of fly ash into aluminum has been proved to decrease the materials’ density, increase their hardness, abrasion resistance and stiffness [1]. One of the major outcomes from the mechanical evaluation of aluminum composites prepared with fly ash is that related to their compression characteristics. Typical compressive stress-strain curves form A356/hollow fly ash composites show a linear elastic region followed by a plateau (associated to the collapse of the hollow particles), and then an increase in stress, representing densification of the foam. The crushing of the cenospheres in the composites has been related to an enhancement in the energy absorption capabilities of the material and to a better damage tolerance [4]."

Jan 1, 2008

By Sheng-hai Yang

The electrochemical synthesis was conducted in anhydrous ethanol solvent mixed with conductive reagent when tantalum plate was used as anode and stainless steel plate as cathode. The effects of different conductive reagents (such as NH4Br, (CH3)4NCl, (C4H9)4NCl), conductive reagent concentration and the space on the cell voltage and the current density were investigated. The current efficiency of electrosynthesis was more than 95%. The electrolyte, a mixed solution was then undergone air distillation and vacuum distillation to get the final product which was characterized by Fourier Transform Infrared(FTIR) spectroscopy, Raman spectra, 1H-Neclear Magnetic Resonance(1H-NMR) spectroscopy. Carbon and hydrogen contents in the product were determined by elemental analysis instrument. Results consistently show that the product was tantalum penta-ethoxide.

Jan 1, 2006

By Jiechao Liu, Lijian Luo, Yubao Ma, Bo Zhang, Yanfeng Yang, Xin Hong, Luming Liu, Jienan Liu

Reduction kinetics of stainless steel slag in iron bath smelting reduction was studied at the temperature of 1500℃ ~ 1650℃. It was concluded that the reduction process consisted of two parts. That is to say smelting reduction was controlled by stainless steel slag melting initially and by interface reaction later. In order to increase smelting reaction rate, the melting point of slag should be decreased at the first stage and adjust the liquidity of slag at later stage. Smelting reaction rate will be accelerated by means of optimize the slag content. The optimal reduction result that all most all of the chromium in slag been recovered was obtained in temperature was 1500℃, basicity of slag was 1.0~1.2, the value of Al2O3+MgO was 25%.

Jan 1, 2015

By Mike Adams

A comprehensive pre-feasibility study has been conducted by Companhia Vale do Rio Doce CVRD) for Niquel do Vermelho nickel laterite deposit. Within this study, five integrated flowsheet options were evaluated via batch and pilot campaigns at Lakefield Oretest, over an intensive six-month period from receipt of ore to final reporting. Key technical objectives set by the client included demonstrating the technical viability of the beneficiation of several ore types, processing through integrated pressure acid leach/mixed hydroxide precipitation (PALIMI-IP) and mixed sulfide precipitation (PALIMSP) circuits, and the treatment of barren liquors to meet stringent environmental requirements. Refining of the MHP was by ammonia re-leach and solvent extraction (SX) to produce LME-grade nickel cathodes, NiCO3, NiO and CoS. LME grade nickel and cobalt was also produced by oxidation of the MSP and hydrogen reduction on the leachate. The database and data acquisition system, along with web-based reporting, enabled rapid turnaround on both daily and more comprehensive run reports, making it possible for speedy and confident decisions on operating conditions of the complex flowsheets. The high value of developing such data is emphasized and discussed as pivotal in the successful progression of laterite projects through to sustainable commercial viability. Keywords: Flowsheet, CVRD, Nickel, Piloting, Pressure, Leach, Refining.

Jan 1, 2004

By Hector M. Henao

There is an increasing trend in the copper smelters to recycle electronic materials, which contain relatively high concentration of precious metals. As a consequence, the amount of precious metals lost in the slag phase is increasing. To determine the portion of the precious metals chemically dissolved and that associated with the mechanically trapped matte in the slag will be a key factor to improve the recovery of those metals. Thus, an experimental study was carried out to determine the distribution of precious metals (Au, Pt, Pd, Rh, Ru) between the equilibrated copper matte and iron-silicate slag phases. The experiments were made in a magnesia crucible at 1573 K and a fixed partial pressure of SO2 of 0.1 atm for the matte grades between 40 and 70 mass% of copper. It was found that the distribution ratios (defined as mass% X in slag/mass% X in matte, where X represents the precious metal) are around 10-2 for Ru, 10-3 for Au, Pt and Pd and 10-4 for Rh. The distribution ratios show a tendency to increase when the grade of matte is increased.

Jan 1, 2006

By A. Haxhiaj, E. Haxhiaj

"The paper has as a studying object the issue of effective management of gasses’ heating and dusts in reductive melting process in lead (Pb) metallurgy. It also analyses the issue related to the usage and recycling of dusts and gasses in all pyro-metallurgical processes of technical lead production. The paper contains the analysis of technological process of separation of humidity, gasses, and dusts of valuable remainders in “Trepça” plant. Paper has the results of theoreticalexperimental studying, analytical and graphical of gasses thermal balance depending on height and composition of load, and the coke quantity on load for reductive melt in “Water-Jacket” furnaces. With thermal balance, having into consideration all parameters of heat in entry and exit depending on aforementioned factors we aimed to optimize the parameters of the process, keeping the attention to the minimization of energy consumption, and the overall influence on environment.1. IntroductionThe upper part of the furnace which is the study point of this paper lies from the reactions zone of Water-Jacket furnace and it also includes the furnace neck. In this zone has been elaborated the zonal material balance referenced third in the row. The separation of humidity, dusts, gases and lead with gases depends on many parameters like temperature, load composition, and height of load inserted in the furnace, and also the height of preheating zone in Water-jacket furnace. Lead oxidizes in reaction zone of the furnace and exhales with gases like dusts and small particles after which falls in worthy storage of Trepça plant and has negative effects in environment, and economic stability of reductive melting process of Water-jacket furnace. Thermal balance of gases in this zone depends on many factors; height and load composition, coke quantity in a load. The calculation has been done as the standard methodology of thermal calculation is done; moreover, by using a computer for mathematical models which enables very accurate results. We must emphasize that acquired and used heat in reaction zone and melted materials is calculated in others studies, so their influence in preheating zone is assumed."

Jan 1, 2010

By T. Alboussiere, O. Paireau

"We have designed an experiment to simulate natural convection in a direct-chill aluminium ingot. In this experiment we induce natural convection within a hemisphere filled with liquid-metal (mercury). The device consists of a copper hemispherical bowl closed by a copper plate. The top is maintained at superheat temperature while the boundary is cooled. While the temperature measurements were found using thermocouples, the velocities were obtained using an original technical procedure that relies on MHD properties. By applying a steady local magnetic field, we measure the velocity. The distribution of temperature and velocity can be separated into a thermally stratified core bounded by thermal wall jets. These wall jets greatly influence the degree of macrosegregation in ingots.1. Natural Convection in Aluminium CastingIt is well known that the quality of the final product in aluminium casting depends on the movements within the liquid metal such as forced or thermogravitational convection. Strong buoyancy-driven flows are known to occur in the liquid metal pool of an aluminium ingot caster. These flows have a significant influence on the metallurgical structure of the ingot through the redistribution of heat, fragmented dendrites and segregated material within the pool. Macrosegregation mechanisms depend on favourable temperature and flow distributions in the sump, and these factors will determine the pattern and degree of macrosegregation. Moreover, for many years, the importance of thermally-driven natural convection in casting has been underlined (Cole & Bolling, 1965). In this way, a precise determination of the velocity and temperature fields is required in order to improve understanding of the macrosegregation mechanisms. That is precisely the aim of this paper, which provides experimental data of the flow and the temperature distributions in a natural convection experiment. We intend, with this laboratory experiment, to determine accurately the velocity field, particularly within the thermal boundary layer where the effects of the flows may have an important role in the transport of crystals."

Jan 1, 1999

By Mamoru Kuwabara

A high-power sound which can transmit through any continuous elastic medium with less attenuation, particularly in liquid allows us to externally control the system of concern by using the acoustic radiation force or the cavitation phenomena. These functions may eliminate gravitational and/or atmospheric constraints which are often encountered in conventional operations for producing clean and advanced materials. This paper outlines the recent development in the field of sonoprocessing of materials. Cold model experiments in some vessels have been performed to simulate ultrasonic operations such as inclusion removal from liquid, degassing of melt, emulsification of two liquid phases, solidification processing, and decomposition of chemical species in waste water. High speed visual imaging is carried out for better understanding of the cavitation phenomena as well as the followed microjets during the processing. The radiation force acting on fine suspending objects in a fluid can be utilized for eliminating or rearranging/orienting the objects in the fluid. Acoustically induced cavitation phenomena in liquid can be utilized as an effective dynamic means to control interfacial phenomena as well as micro- and macro-mixing of liquid. Sonochemical and thermal effects in cavitation multi-bubble can be also useful in a waste water treatment.

Jan 1, 2006

By Pascal Gardin

The purpose of the paper is the mathematical modelling of flows inside steel continuous casting mould. For CFD validation of flow oscillation prediction, unsteady calculations with a realizable k- model were performed in a billet caster with rectangular section. Self sustained and regular oscillations were obtained. Calculated flapping frequency is very close to what is mentioned in literature. For slab caster configuration, flow oscillation is influenced both by lower roll, which creates very small frequency oscillation (0.012 Hz for our water model), and upper roll, which creates slightly higher frequency oscillation (0.05 Hz). The two rolls interact and it is possible to detect both frequencies in the nozzle jet region. Numerical results are in good agreement with measurements for fluctuating velocity spectra and provide explanation for interaction of rolls. To improve flow stability inside the mould, it is established that gas injection in the nozzle has a very positive effect.

Jan 1, 2006