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By Miao Tian

Large quantities of copper complex resources are produced globally and urgent to be cleanly processed. This article presents a thermodynamic analysis of mixed smelting process including low-grade polymetallic copper sulfide concentrates, high copper content sulfide concentrates, metallurgical by-products (copper removal slag from lead metallurgy), and copper powder from electronic waste. A top blown smelting reactor to simulate mixed smelting process is developed using a metallurgical process simulator, METSIM. Reactor parameters, heat loss and phase distributions are estimated from actual plant data. The proper proportion between complicated primary and secondary copper resources is determined by analyzing the influence of the feed rates of various resources, oxygen, silica flux and revert on the smelting performance. Autogenous smelting process is built by optimized matching materials of copper complex resources, in terms of the reactor temperature, copper content in matte and slag, and the percentage of magnetite in slag.

By Tapani Järvinen

Non-ferrous metals and metals in general are considered as being non-renewable natural resources. Metals are needed because of their excellent and irreplaceable properties. The consumption of metals, with the exception of carbon steel, is steadily growing by 1-3 % annually, and that of stainless steel as much as 3-6 %. This is a general trend, which is periodically disturbed by cyclical variations. In recent years so-called "New Economy" has become prominent in the public media and the market value of the traditional industry has been well below its real value and importance. Nevertheless, the modem society requires metals today and also in the future, and the companies using the most modern technology in a responsible way and innovative solutions not only in technology, but also in everything they do will survive. This paper describes the role of Europe as a producer of primary base metals and as a supplier of technologies in the base metals industry. It concentrates on the development and commercialization of technologies and project implementation in the metallurgical industry. As one example ofa European approach to these matters the paper presents Outokumpu's response to the future challenges in the base metals industry. Outokumpu Oyj is one of the leading metals and technology companies in the world of stainless steel, copper, zinc, and sales of technology in metals and minerals businesses. Outokumpu applies its knowledge of metals and processing to generate value for its customers and shareholder. Everything we do, we do in an economically, environmentally and socially responsible way.

Jan 1, 2003

By J. W. Lyman

Nickel-metal hydride (Ni-MH) battery electrodes have been developed as a substitute for cadmium-containing negative electrodes. Use of Ni-MH electrodes offers enhanced electrochemical properties in many instances as well as reduced environmental toxicity. Rechargeable batteries using Ni-MH electrodes are also strong candidates for electric vehicles. During the production and secondary reclamation of these battery types, recycling procedures will be needed to prevent environmental impact caused by these wastes as well as to recover the value inherent in the scrap. The U.S. Bureau of Mines (USBM) is investigating hydrometallurgical technology that separates and recovers purified metallic components from Ni-MH battery scrap of two types, AB, and AB,. An investigation of acid dissolution and metal recovery techniques has determined several processing alternatives that may be used to promote the successful recycling of much of the battery fabrication scrap and eventual secondary scrap. Although recovery techniques have been identified in principal, their applicability to mixed battery waste stream and economic attractiveness remain to be demonstrated.

Jan 1, 1995

By Neil E. Ryan

Because of their chemical reactivity and affinity for oxygen, rare-earth elements are difficult to extract, and due to their close chemical similarity, it is an exacting task to separate one from the other. Nevertheless, these same characteristics can be used to benefit other metals by enhancing their resistance to high-temperture oxidation/corrosion and by inhibiting their corrosion in aqueous environments. This paper gives an overview of the use of rare-earths: [a] as alloy additions, [b] in coatings, and [c] when added to hostile environments, to retard rates of high- temperature oxidation and inhibit aqueous corrosion.

Jan 1, 1992

By Taegong Ryu

A thermal plasma process was used to synthesize nanosized tungsten carbide -cobalt composite powder, in which ammonium paratungstate and cobalt oxide were reacted with a gas mixture containing CH4, H2 and Ar. The reduction and carburization of vaporized precursors produced nanosized tungsten carbide (WC1-x) - cobalt composite powder, which sometimes contained small amounts of W2C and/or W phase. The effects of gas composition, plasma torch power, and the flow rate of plasma gas on the product composition and grain size were investigated. The grain size of synthesized tungsten carbide powder was less than 20 nm. The synthesized composite powders were also subjected to a hydrogen heat treatment to fully carburize WC1-x, W2C, and W phases to the WC phase as well as to remove excess carbon in the product. Finally nanosized WC-Co composite powder of grain size less than 50 nm was obtained.

Jan 1, 2009

By Yunnen Chen

In the present study, waste materials like pine sawdust and spent grains were investigated to assess their potential for removal of cobalt ion from water by the process of biosorption. The effects of solution pH, reaction time and initial concentration were studied in batch experiments. The removal efficiency of Co(? ) by spent grains was higher than that of pine sawdust. The initial removal was rapid and equilibrium was established in less than 90 min. Equilibrium data all agreed well with both Langmuir and Freundlich isotherm models for the two metal-biomass sorption processes. Good correlation coefficients were obtained for the pseudo second-order kinetic model. Pine sawdust and spent grains were shown to be promising biosorbents for Co(? ) removal from aqueous solutions.

Jan 1, 2010

Roasting treatments were investigated to remove arsenic from a nickel concentrate. The main arsenic minerals and their proportions in the concentrate were niccolite (NiAs)-50%, gersdorffite (NiAsS)-40% and arsenopyrite (FeAsS)-10%. Thermal analysis showed that gersdorffite and niccolite began decomposing when heated above 640 and 830°C respectively. The maximum roasting temperature was limited by agglomeration of the concentrate above 900°C. A small vibrated bed reactor was used to investigate the effects of temperature and gas flowrate, the latter to sweep away evolved arsenic. At 900°C, 24% of the original arsenic remained in the concentrate. SEM examination of the calcine showed that the residual arsenic was associated with the calcium in the gangue minerals. Additions of sulphur (either as elemental sulphur or from pyrite) facilitated the decomposition of the arsenic-containing minerals, decreased reaction with calcium in the gangue and produced calcine containing 4-6% of the original arsenic. Treatment with chlorine during roasting was effective in reducing the arsenic content to similar levels. Generation of chlorine in the bed by sulphation of CaC12 also produced encouraging results. Arsenic, Nickel Concentrate, Roasting, Chlorine, Sulphur, Gersdorffite, Niccolite

Jan 1, 2005

By Amir Rehmat

The Institute of Gas Technology has developed a fluidized-bed process for recovering direct reduced iron from blast furnace flue dust a material currently considered to be a waste from the iron and steel industry. In the process, a portion of the carbon in the flue dust is combusted to supply energy for the endothermic reaction between carbon and steam. The reaction produces reducing gases comprised of carbon monoxide and hydrogen both of which react with iron oxides to produce reduced iron. Up to 95 percent of the iron oxides contained in the waste stream can be reduced to elemental iron. The vitiated reducing gases emanating from the process can be used as fuel in the plant. The yield of iron depends upon the quantity of iron oxide present in the flue dust and generally ranges from 20 to 30 percent of the waste stream. The investment cost estimated for a single processing train dedicated to one steel plant can be recovered in less than one year.

Jan 1, 1996

By James C. Barker

Near Rainbow Mountain in the east-central Alaska Range an ultramafic complex forms a sill-like intrusion composed of dismembered bodies exposed along the south side of the Denali Fault and Broxson Gulch Thrust. The complex comprises dunite and peridotite with lesser gabbro, which together exhibit poorly defined, steeply-dipping compositional layering. The complex hosts four types of copper-nickel occurrences which have characteristic platinum-group elements (PGE), gold, and cobalt distributions. Three of the occurrence-types are considered to have formed as a result of primary mineral segregations which developed during intrusion of the complex. The fourth type of copper-nickel occurrence formed as a result of post-magmatic hydrothermal fluids at intrusive contacts. Scanning electron microscope examination indicates that PGE occur as micron-size telluride and arsenide minerals.

Jan 1, 1987

By Jr. Loper, M. H. Kim, H. H. Jo, C. S. Kang, T. S. Song

"An investigation has been conducted to describe the effect of grain refiner (e.g.,Ti) or modifier (e.g., Sr) on the microstructure of an Al-11.3wt%Si alloy produced by the Ohno horizontal continuous casting process using a heated mold so as to obtain directional solidification at high cooling rate of 300 to 2000°C/s. Experimental results demonstrated that the directionality of the primary a grain was promoted by the addition of0.2 to 0.4%Ti or by the addition of0.02%Sr, whereas the addition of0.6%Ti suppressed this directionality. Feathery a grains were promoted by the addition of 0.2%Ti, while these feathery a grains were suppressed when over 0.4%Ti (grain refinement) or when 0.02%Sr was added. The addition of Ti also resulted in increased coarsening of the eutectic Si in these Al-1 l.3wt%Si alloys.IntroductionThe mechanical properties of conventionally cast Al-Si alloys can be enhanced through judicious control of the casting parameters, by the addition of grain refiners (e.g., Ti) and by the addition of eutectic modifiers (e.g., Sr).[1-3] The Ohno continuous casting process[4-5] uses a heated mold (maintained at a temperature above the alloy liquidus temperature) to produce a casting with a mirror surface free of shrinkage defects. The process is especially suitable for the production of high quality and non-deformable rods of small diameter. This study was conducted at investigate the effects of Ti and Sr on the microstructure of Al-1 l .3wt%Si rods cast by the 01).no process."

Jan 1, 1998

By Ting Liu, Qian Li, Peng Deng

The wastewater containing Hg2+ and Pb2+ does great harm to the environment and human bodies. Traditional wastewater treatment cannot fundamentally put a stop to heavy metals pollution for producing secondary pollution. In this paper, Hg2+ and Pb2+ in wastewater were removed and recovered by sulfide precipitation- flotation. Sodium sulfide was used as precipitant and butyl ammonium aerofloat was used as collector. Results indicated that Hg2+ and Pb2+ could be reduce to less than 0.03mg/L and 0.16mg/L respectively by both coprecipitation- floatation and fractional precipitation- floatation. In these two methods, fractional precipitation flotation could not only remove Hg2+ and Pb2+ from wastewater, but also could recover mercury and lead effectively. The infrared spectrograms showed that the adsorption between butyl ammonium aerofloat and mercury precipitate or lead precipitate is chemisorption.

Jan 1, 2015

By Musa Karakus

In an attempt to explain the phenomena of lead entrainment during Cu drossing of lead bullion, two different synthetic lead bullions were heated to 1050°C, cooled slowly to various temperatures, and then quenched. The morphology and composition of dross particles that form when Mn is used to desulphurize bullion also were examined. Polished sections of these pyrometallurgical products were examined by process mineralogical techniques to identify the impurity phases, determine their chemical compositions, examine the morphology of the impurity phases and evaluate the potential for lead entrainment in such crystals, and characterize pre-quench and quench-generated phases. The phases crystallized were metallic lead, metallic copper, galena, chalcocite, albandite, Cu14.4Pb2S9. and 5.5Pb2S3.5. Metallic copper formed isometric skeletal crystals, chalcocite formed platy and skeletal crystals, and 1formed crystals and eutectic intergrowth with chalcocite and Cu14.4Pb2S9 or Cu5.5Ph2S3.5. The pre-quench crystals are larger and usually exhibit skeletal forms; the quench-generated phases are only a few micrometers across and disseminated throughout the lead matrix. Skeletal crystals of metallic copper and chalcocite form three dimensional networks that entrain large amounts of metallic lead.

Jan 1, 1989

By Sylvain Gouttebroze, Mohammed M'Hamdi

In a previous work, a small scale Bridgman furnace has been used to study silicon bi-grain crystallization at different cooling rate. This work expands the analysis by studying the mechanical interaction between the crucible and ingot during the solidification and cooling. The thermal model is based on a 2D-axisymetric heat-transfer model. The flux histories are then transferred to the ingot-crucible 3D-model. Anisotropic Elastic and Crystal Plasticity model are used to model the silicon deformation. Four different assumptions are applied to model the mechanical contact crucible-ingot and three grain misorientations are considered. The results show the strong impact of the alumina crucible contraction on the stresses and deformations in the silicon ingot.

Jan 1, 2015

By N. Menad

. Electronic wastes are heterogeneous mixture, with mainly copper, aluminium and steel attached to or mixed with various types of plastics and ceramics. In general, small amounts of precious metals are incorporated in this mixture. Today, these components constitute an environmentally problematic fraction in disposal. Their physico-chemical characteristics have been investigated through chemical, x-ray diffraction, infrared spectroscopy, scanning electron microscopy and thermal analysis.

Jan 1, 2000

By J. C. Agarwal

Do large-scale projects in mining and smelting start up and achieve expected capacity on schedule? In most cases not. Regardless of worldwide location, company know-how, or financial backing, unforeseen delays occur. A comprehensive CRA study for the World Bank shows that delays are the rule, not the exception, in most mining and smelting projects. When delays are not factored into analysis and planning, financial projections are, literally, not to be believed. Returns on investment will seldom achieve their targeted level because of startup delays. This paper reviews the results of our analysis of startup of new mines, mills, and smelters; provides a detailed discussion of why delays occur in the smelters and refineries; presents the cash flow implications of startup delays; and discusses preventive measures that should be taken to avoid financial shortfalls,

Jan 1, 1983

By W. Petruk

The behaviour of galena, chalcopyrite and tetrahedrite during floration of a fine-grained base metal ore from New Brunswick was investigated by image analysis study of the mill concentrates and tailings. The minerals were analyzed to determine the grades and recoveries as related to free and unliberated mineral grains and their size distributions. The results show that only 37 wt % of the galena was liberated but 88 wt % of the free galena was recovered, indicating good mill performance for the lead. The lead recovery was 65 wt %, with the main loss due to unliberated galena. Most of the unliberated galena lost to mill tailings is so fine-grained that galena liberation and Pb recovery would not improve significantly by re-grinding. Chalcopyrite liberation was 56 wt % but only 75 wt % of the free chalcopyrite was recovered. Copper recovery was 45 wt %, with the chalco-pyrite loss in the mill tailings being both as large free grains, and as small and large unliberated grains. It was calculated that copper recoveries could be improved about 8 to 10 wt % by changing the concentrator operations and by regrinding. Concentrator operations hive already been modified and copper recoveries have improved about 5 wt %. About 29 wt % of the silver was lost to tailings mainly as both free and unliberated, large and very small, Silver-bearing tetrahedrite grains. It was calculated that about 25 wt % of the silver in the tailings might be recovered by improved milling conditions and by regrinding.

Jan 1, 1981

By Guy Xueyi

The environmental impact assessment of the Imperial Smelting Process for metallic zinc and lead production in Shaoguan Smelter, China, was carried out by the life cycle assessment method. The detailed inventory analysis of the Input/Output in the process during 1998-2000 was conducted and the allocation was done among the main products of zinc, lead and sulfuric acid, according to the system expansion and substitution principle, The environmental impacts were assessed by using the following five Eco-indicators: Gross Energy Requirement (GER), Global Warming Potential (GWP), Acidification Potential (AP), Heavy Metal Toxicity' (HMT) and Solid Waste Burden (SWB). The results from this study are useful to address the environmental situation of the technology practice in this smelter, and provide a scientific basis for the further improvement.

Jan 1, 2003

By Joseph Sofra

It has become increasingly evident that sustainable metals production in the 21st century requires producers to balance the needs of cost effective, high value production with that of responsible plant operation. This is becoming more difficult as lower grade and more complex feed materials, including recycled scrap and residues, are being processed to reduce production costs and decrease exposure to primary metal market fluctuations. One particular facet of the metals industry facing these challenges in the 21st century are copper producers, The recent steady decline in the copper price has seen the industry cut expenditure, tighten control on income streams and focus on high returns on capital investment. For these reasons copper producers are looking towards flexible technologies that can deliver high value products, with minimal environmental impact at low capital and low sustainable operating costs. Ausmelt's Top Submerged Lancing (TSL) technology for copper production is a low cost, proven technology for the processing of both primary and secondary copper materials. Both the smelting and converting operations introduce significant advantages in environmental performance, improved process efficiencies and high rates of metal recovery, Ausmelt has made significant gains in the past 4 years in establishing a strong market position for its copper technology, New installations in China, South Africa and India as well as existing operations in Zimbabwe and China have demonstrated its effectiveness. This paper reviews the application of Ausmelt Technology for both smelting and converting of primary and secondary sources, It discusses Ausmelt's design and implementation philosophy, and how this philosophy meshes with the needs of the end user.

Jan 1, 2003

By Felipe Perissé Duarte Lopes

The tensile properties of DGEBA/TETA epoxy matrix composites reinforced with different amounts of curaua fibers were evaluated. Tensile specimens with up to 35% in volume of long, continuous and aligned curaua fibers were room temperature tested in an Instron machine. The fracture was analyzed by SEM. The results showed significant changes in the mechanical properties with the amount of curaua fibers. This was compared to other bend-tested composites with distinct matrices. The fracture analysis revealed a weak fiber/matrix interface, which could be responsible for the comparatively low performance of some properties.

Jan 1, 2010

By Zhihe Dou, Zimu Zhang, Guozhi Lv, Yan Liu, Xiaoli Jiang

"Cyclic heat stewed slag washing water carries high content of alkali and calcium and may cause serious tube scaling and impose an adverse impact on normal production. This study proposes a solution to utilize washing water by absorbing and mineralizing CO2, potentially restraining scaling and being able to create calcium carbonate powders. Effects of water flux on water quality, utilization ratio of CO2 and yield of calcium carbonate powder have been investigated; meanwhile, features of calcium carbonate powder are also represented. On the other hand, effects of factors such as as injection flux, pressure of CO2 on utilization ratio of CO2, morphology and purity of calcium carbonate are also investigated. The results show unambiguously that after soften injection of CO2, calcium ions were removed effectively via precipitation, alleviating the scaling problem. High purity yet fine carbonate powder could be achieved.IntroductionNowadays, 0.34 tons of blast furnace slags will be produced when producing 1 ton of pig iron; ensuing that, 0.12 tons of steel slag will be generated with 1 ton steel production while 1.57 billion tons of steel output all over the world in the year of 2012. It is therefore a critical issue to realize zero discharge of steel slags to achieve sustainable development and cyclic economy of iron and steel industry. In recent years, research institute of MCC and China JINGYE engineering company developed a heat stewed steel slag self-decomposition technology GENERATION III to solve the problem of instability of steel slags and realize the zero discharge. However, the problem of circulation line scaling which may cause the clogging, even exploding, need to be solved. The principles of the technology are: directly spraying water to the high temperature steel slag when it is poured into the hot closed pot, realizing the selfdecomposition via utilizing the waste heat of steel slag. The washing water is recycled to achieve a cyclic utilization. The process is shown in Figure 1."

Jan 1, 2014