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By I. C. Knight

The current levels of copper smelter by-product acid production are reviewed on a regional basis, together with the possible changes in the future. There will be increasing pressure for all smelters to achieve a sulphur capture level of at least 95% by the end of the decade.

Jan 1, 1996

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

Reducing electricity cost is important for energy intensive industries such as the iron and steel industry. With the implementation of time-of-use (TOU) electricity price, plenty of attention has been paid to the optimal management of byproduct gases. The time-of-use (TOU) electricity price is the practice of implementing different prices for different times of use. It is possible to reduce electricity cost by adjusting the amount of product gases stored or used for power generation throughout the day. In this paper, a novel mixed integer linear programming (MILP) model concerning the TOU electricity price is proposed to optimize byproduct gas use. Compared with previous models, this model considers the optimal load shift between gasholders and boilers under TOU electricity price. The case study of a steel plant demonstrates that the electricity purchase cost can be reduced by more than 30% after optimization.

Jan 1, 2016

By Wei Yin, Bin Xu, Qian Li, Yongbin Yang, Tao Jiang

Copper anode slime is an increasingly significant resource for precious metals such as Au, Ag and Pd. The extraction of Au, Ag and Pd from decopperized anode slime by different pretreatments and different lixiviants including cyanide, chloride, thiourea and thiosulfate have been investigated. When oxidizing roasting pretreatment was carried out under the conditions of roasting time 120min and temperature 625 ℃, the removal ratios of S and Sb could reach 82.18% and 98.52%, respectively. And the following alkaline leaching of calcine could result in the dissolution of 46.40% Cu and 98.48% Pb. The optima leaching ratios of Au, Ag and Pd reached 99.48%, 97.69%, 94.79% by cyanide leaching, and 95.01%, 79.84%, 96.59% by chloride leaching, and about 95.21%, 95.66%, 48.79% by thiourea/thiosulfate leaching.

Jan 1, 2015

By Patrice Chartrand, Halvor Dalaker, Philippe Ouzilleau

A size-dependant thermodynamical model for the carbon-hydrogen previously developed by Ouzilleau et al. [1] has been expanded here to include chemisorption of methyl groups. Gibbsenergy minimalisation calculations using FACTSAGE software on this model indicates that hydrogen bonding through methyl groups is energetically favoured as an intermediate between bonding as monoatomic hydrogen to edge hexagons (which is more favourable) and as monoatomic hydrogen to corner hexagons (which is less favourable). The model has also been applied to methane decomposition and oxide reduction using natural gas. A C-H solid solution as a thermodynamic description of the solid carbon phase influences calculations of carbon activity in metastable methane, and gives different results than when using graphite.

Jan 1, 2015

By Chao Lian, Hongxu Li, Hao Bai, Wei Wei

"Application of high-emissivity coating on inner walls in industrial furnaces increases the furnace thermal efficiency. The coating with high emissivity strengthens radiation heat transfer in the furnace, however, according to Wien's displacement law and Planck's radiation law, under heating temperature, the wavelengths of the radiation transfer are mostly between 1-5 µm, implying that increasing emissivity of the coating in near infrared band is more effective for higher thermal efficiency. In this paper, a new CuO-ZnO-based coating material sintered at 1600K was developed. The emissivity of the samples were measured and the result shows that, in near-infrared band, the emissivity of the sample reaches 0.98 at 773K with 13at.% of CuO doped in ZnO. In addition, the effects of CuO doping and use temperature on emissivity were also discussed. Furthermore, crystallization behaviors of ZnO-CuO sintering were investigated by DTA,XRD and SEM-EDS etc., which offered information for possible optimal design of the material.1. IntroductionIndustrial furnaces are widely used in various industrial heating. For example, the metal smelting furnace, ore sintering furnace in metallurgical industry; the distillation furnace, cracking furnace in petroleum industry etc,. The research on efficient energy saving technology has important significance. High emissivity coatings are widely used in many high temperature applications to effectively transfer the heat by radiation [ 1]. The theoretical calculation and experimental studies have shown that, coated high emissivity coating in the heating surface is an effective method to enlarge the infrared radiation power [2].At present, the infrared high emissivity coating has been widely used in China, and have been achieved remarkable energy saving effect. According to Wien' s displacement law and Planck' slaw, most energy of the black body at high temperature is radiated in the wavelength range of l-5µm; however it happens that many materials have the low emissivity within this range. Thus, it is important to improve the near-infrared band emissivity of materials [3]."

Jan 1, 2013

By Katsutoshi Inoue, Shafiq Alam

Several novel types of chemically modified chitosan were prepared by immobilizing functional groups of EDTA and DTPA onto polymer matrices of chitosan in order to investigate their potential for mutual adsorptive separation among rare earths. Following the batch wise adsorption tests to elucidate their basic adsorption characteristics for rare earths, mutual separation was carried out using a column packed with the chemically modified chitosan. The separation between Sm(III) and Y(III) was tested using a column packed with EDTA-type chitosan while mutual separation among 4 light rare earths, La(III), Ce(III), Pr(III) and Nd(III) was tested using a column packed with DTPA-type chitosan. In both cases, satisfactory mutual separation was achieved by the chromatographic operation using these chemically modified chitosan.

Jan 1, 2014

By Y. Huang, P. B. Prangnell

"An Al-0.1Mg alloy was firstly deformed at room temperature by ECAE to a true strain of 10, where a steady state deformation was established and further processing had little effect on grain refinement. The ECAE samples, with an average grain size of ~0.55µm, were then compressed in a channel die at 77K- 473K to various reductions. Microstructures were characterized by electron backscatter imaging and EBSD in a FEGSEM. Grain refinement to the ECAE submicron structure occurred during deformation at cryogenic temperatures of 77 – 213K, whereas coarsening took place during deformation at elevated temperatures. A steady state deformation was observed at all temperatures where a constant grain structure was developed and maintained upon further straining due to dynamic recovery. The mechanisms of dynamic recovery during steady state deformation at cryogenic temperatures are discussed.IntroductionSevere deformation processing (SDP) has been successfully used to produce submicron grain structures, and in some cases nano-scale crystallite sizes, in a wide range of alloys. However, the rate of grain refinement becomes increasingly inefficient at high strains as a steady state grain structure is approached [1-3]. Steady-state grain sizes have also been reported in other ultra-high strain deformation processes, like cryogenic ball-milling [4]. There is thus a minimum grain size achievable in a material by a given SPD process under constant deformation conditions.It is well documented that a steady state subgrain size is observed in warm deformation of metals due to dynamic recovery (e.g. [5]). In severely deformed alloys a constant grain size at ultra-high strains has similarly been attributed to dynamic recovery [1-3]. Mechanisms have been proposed, for rapid deformation induced grain growth including stress driven boundary migration and breakaway from solute pinning [2]. However, as pointed out by Humphreys et al. [2] the restoration processes are currently poorly understood, particularly at low temperatures, where the boundary migration rates required to maintain a constant grain size are orders of magnitude higher than can be satisfactory explained from diffusion controlled migration. Similar to the subgrain size, the steady state grain size obtained during SDP is generally related to the temperature compensated strain rate [2, 6]. Thermally activated restoration processes are thus expected to be suppressed by lowering the deformation temperature and a smaller steady state grain size can be achieved."

Jan 1, 2012

By Jian-Xun Fu, Hong-Qiang Liu, Si-Yu Liu

The production of zinc-bearing solid dust is up to 4%~8% of total crude steel in steel plant, which is difficult to be recycled in traditional methods. To fully utilize the resources and reduce environmental pollutions, Chinese steel plants are using rotary hearth furnace (RHF) process to recycle solid dust. A consequential life-cycle inventory was carried out to assess the impact of dust recovery on greenhouse gas emissions based on the local production status. In the study system, the selected steel plant named which have 10.5 million tons of Crude steel productivity and 0.48 million tons solid dust come out meanwhile. To research, a RHF production line of 0.3 million tons directly reduced iron (DRI) a year was established to recycle the solid dust. The DRI will be obtained from RHF and sent to the blast furnace as raw materials to reduce the demand for iron ore and coke in steelmaking processes. By researching on the life-cycle inventory in the system, the steelmaking process with RHF was 2299.3kgCO2/ton steel. It’s a little higher while compared with the process without RHF, which data is 2297.0 kgCO2/ton steel. The small production of DRI make a small difference to reduce the carbon footprint of steelmaking process, the added carbon footprint of RHF process is more than BF and other steelmaking processes reduced. It is concluded that dust recovery has no contribution to the greenhouse gas emission reductions in the technic condition of Chinese steel plants currently.

Jan 1, 2016

By Elli Nurminen

Sulphate decomposition was studied in the conditions of a typical copper flash smelting heat recovery boiler. The aim was to determine the kinetics of the copper sulphate decomposition reactions and to find out if they are likely to take place in the process conditions prevailing in an industrial HRB. The information is essential in CFD-modelling of the reactions taking place in the boiler and for optimising the process. Thermal decomposition of sulphates was studied by thermogravimetry. The experiments were conducted with a commercial copper sulphate, a partially sulphated copper oxide and an actual process flue dust. The main variables studied were temperature and gas composition of a N2-O2-SO2-mixture. The samples were characterized with SEM, optical microscope and XRD. Temperature affected the decomposition rate strongly but the gas composition had a minor effect on the kinetics. The decomposition was fastest in the partly sulphated oxide and slowest in commercial copper sulphate. Keywords: Sulphate decomposition, flash smelting, heat recovery boiler, flue dust

Jan 1, 2004

By Roberto Javier Santiago

This paper tries to make a study about the use of calcium carbide during the tapping in replacement of part of the aluminum used in the furnace tapping, analyzing theoretical consumptions and then transfering the practice to the plant.

Jan 1, 2006

By Rajesh K. Mishra

In secondary precious metals refining, the feed to the plant itself is a waste generated in manufacturing processes. Constant changes in manufacturing processes produce ever changing feed materials to the secondary PGM (platinum Group Metals) refineries. After extracting the precious metals, secondary wastes are generated. The discharge of effluent is dictated by both the PGM losses in wastes and the regulatory mandates. This paper will discuss some. of the conventional as well as some newer approaches to face both the challenges.

Jan 1, 1995

By Ross McClelland

This paper provides a technical overview on the installation and commissioning of the Ausmelt lead smelting, slag reduction and slag cleaning operations at the HZL Chanderiya site in India. It also discusses theoretical concepts behind the process practices currently in place at HZL.

Jan 1, 2006

By Larry G. Stolarczyk

The development of geosteering technology for geothermal reservoirs is challenged by the integration of electrically small antennas in small-diameter metallic drill rods. To be useful, the antenna pattern must achieve sufficient back-lobe suppression, preferably with a forward-looking pattern. Forward-looking capability requires an antenna array with phase control. The phase-controlled antenna pattern enables imaging of geologic structures ahead of and surrounding the well bore. This paper describes the development of electric and magnetic dipole arrays for small-diameter drilling pipe.

Jan 1, 2006

By Patrick R. Atkins

Energy issues will have increasing impacts on decision making in all facets of society over the next few decades. Industrial users of energy and producers of products that affect energy use must be fully aware of the implications of their processes and products on the energy situation. This paper describes a model that has been developed for the aluminum industry that allows scenarios to be evaluated to gain improved understanding of possible implications for our businesses. A brief overview of the model is provided.

Jan 1, 2006

By Todd S. Fayram

The Gordonsville Operation of Pasminco US Inc. along with the Center for Advanced Mineral and Metallurgical Processing (CAMP) at Montana Tech studied, developed and implemented a pilot scale hydrometallurgical facility for the industrial recovery of germanium and gallium. This paper describes the joint testing and engineering program that culminated in this successful process.

Jan 1, 2003

By Pragna Bhakta

The use of microbes for sulfide oxidation was investigated as a potential treatment option for low-grade refractory gold ores at Newmont Mining Corporation. The resulting patented technology for heap biooxidation maximizes oxidation rate by distributing the microbial population on the ore before placement on a heap. This paper presents data on global oxidation rates based on oxygen uptake in a 50-kg column for sulfidic refractory ores from the Gold Quarry mine. The oxygen uptake data was converted to a global oxidation rate. The calculated global oxidation rate was used to determine heap cycling times for Newmont?s commercial heap biooxidation facility.

Jan 1, 2003

By L. A. Kazanbayev

The Chelyabinsk Electrolytic Zinc Plant (CEZP) was commissioned in 1935. Over the elapsed years the Plant capacity has been increased from 10 thousand tons of zinc (1935) to 150 thousand tons of zinc (2005). The paper describes the Plant main achievements in production updating for the last 10 years.

Jan 1, 2006

By H. Kurama

In this paper, utilization of fly ash as a value added product in areas such as novel materials, waste management, fillers and agriculture is reviewed with the aim of helping the expand of the usage of fly ash and reduce the environmental and economic impacts of disposal. The used unburned carbon benefication/treatment methods such as low temperature combustion, froth flotation, partical size classification and electrostatic separations to remove unburned carbon particles from fly ash are also discussed.

Jan 1, 2006

By Patrick R. Atkins

Energy issues will have increasing impacts on decision making in all facets of society over the next few decades. Industrial users of energy and producers of products that affect energy use must be fully aware of the implications of their processes and products on the energy situation. This paper describes a model that has been developed for the aluminum industry that allows scenarios to be evaluated to gain improved understanding of possible implications for our businesses. A brief overview of the model is provided.

Jan 1, 2006

By Kliment Y. Hakobyan

A new technology for treating molybdenum sulfide concentrates has been developed. It includes roasting the concentrate in a special regime with water vapor, cooling and neutralizing exit gas, oxidation roasting of rhenium containing MoO2, and the extraction of rhenium from exit gases. This technology allows economically efficient and environmentally safe processing of molybdenum concentrates: The degree of molybdenum extraction is 98.8%, rhenium-90%, sulphur-98.4%. The technology also ensures high extents of extraction of selenium and tellurium as well as the fixation of sulfur in the form of sodium sulfide or elemental sulfur.

Jan 1, 2006