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By S. Stoyanov, M. Cross

"Silicon components containing transistor circuitry are at the heart of electronic products such as computers, mobile phones, etc. These components are connected to printed circuit boards (PCB's) using solder material that acts as the conductor for both electricity and heat. During the lifetime of a product it will undergo many thermal cycles where the chip becomes hot during product operation and then cools when the product is switched off. At the product design stage engineers undertake thermo-mechanical simulations to predict the thermal stress in the solder joints due to this thermal cycle and to ensure that the stress magnitude will not result in early fatigue-type failure. The design engineer's aim is to identify component parameters which ensure that the solder will survive beyond a certain number of thermal cycles.The aim of integrating computational mechanics and optimization tools together is to speed up dramatically the design process. From viewpoint of a design engineer in the electronics manufacturing sector, these tools can be used to quickly estimate key design parameters (i.e. material properties, product dimensions, etc) that will guarantee the required product performance. In this paper a modeling approach coupling computational mechanics techniques with numerical optimization is presented and demonstrated. The integrated modeling framework is obtained by coupling the multi-physics framework - PHYSICA - with the design optimisation tool- VisuaLDOC. Thermo-mechanical simulations are presented that predict the creep strains in solder material. Different numerical optimization procedures: Direct and Response Surface based optimization plus Design of Experiments, are tested as a part of this modeling framework."

Jan 1, 2001

By David R. Jessey

An ore microscopic and geochemical study of the nickel-cobalt occurrence in the Southeast Missouri Mining District has revealed several significant relationships. Siegenite [(Ni,Co)3S4] is the dominant nickel-cobalt sulfide in the ores, however, several other members of the thiospi¬nel group (AB2S4) occur: carrollite (CuCo2S4), nickelean carrollite [(Co,Ni,Cu)3S4], fletcherite [Cu(Ni,Co)2S4] and polydymite (Ni 3S4). In addition, bravoite [(Ni,Fe)S2], vaesite (NiS2), millerite (NiS) and gersdorffite (NiAsS) are present. Thiospinel composition varies dramatically within the district. Paragenetic studies have shown that the stratigraphically lowest thiospinels are the most cobalt-copper-rich. A detailed ore microscopic study of the AMAX Lead Company Buick mine has also shown significant changes in mineralogical association, texture and grain size of the siegenite along the north-south strike of the major ore bodies. Siegenite commonly replaces and veins chalcopyrite and is subsequently replaced by sphalerite. Less commonly, siegenite and chalcopyrite are observed to form linear replacements along sphalerite grain boundaries. The grain size of the siegenite varies markedly, but in a predictable north-south pattern that is consistent with a genetic model formulated from geo-chemical data. The compositional as well as textural trends displayed by the thiospinel mineralization could be exploited to optimize recovery of any or all thiospinels of economic interest.

Jan 1, 1981

By Akira Yazawa

In the field of pyrometallurgy, the equilibrium evaluation has recently become easy by use of thermodynamic software, but it is strongly desired to estimate the amounts of non-equilibrium minor components to simulate practical processes. However, simple physico-chemical technique can not be applied to evaluate practical non-equilibrium components for many reasons. As an engineering solution for postulated equilibrium system, the activity coefficient is modified and introduced as the simulation parameter referred to as the "adjustment coefficient." This modified thermodynamic calculations were adopted to various sulfide roasting processes where many solid phases are participating and the system is not necessarily in equilibrium. Successful simulation was realized by assigning suitable adjustment coefficients for minor components which form a pseudo solid solution in the calcine. Some examples from sulfation roasting and dearsenizing roasting were discussed. In the smelting system, the loss of copper in slag is caused by equilibrium and non- equilibrium reasons, that is, chemical dissolution and entrainment of copper in slag. The total copper content of slag was simulated by use of the adjustment coefficient for entrained copper.

Jan 1, 1998

By Charles L. Richman

The effect of the addition of Silver Sulfide on the rate of Chalcopyrite (CP) of Sulfuric acid (H2SD4 leaching is discussed, Although Ag2S in an expensive addition, a theoretical explanation of it's use will aid in the development of a economic substitution. We have used cyclic voltammography to show the presence reaction species at different potentials. Cyclic Voltammography maps the surface reaction current peaks on CP, to regions on the CP Phorbaix diagram. AC Electro-lmpedance spectroscopy (EIS) models the surface impedance properties, which control the rate of electron and ion transfer, and the surface kinetic reactions, with and with out light. EIS and other measurements show that AgCuS u Photo-reactive material- The EIS results are compared with the SEM and EDXA results to show the presence of diffusion pores, and diffusion controlled reactions during CP leaching without the addition of silver sulfate. We hypothesize that AgCuS is an ionic conductor like Ag2S. EIS shows an imposed negative leaching rate greatly. Our theory shows how the formation of Silver Copper (1) sulfide layer at open circuit potential gives an effect similar to negative potential, that is enhanced with illumination. We verify that AgCuAS is an N-type semiconductor that forms a diode type junction with the electrolyte with the Mott-Schoottly relation.

Jan 1, 2001

By D. Van Dooren

The final goal of the research project is to develop a 3D FEM model that is able to predict the kinetics and micro-structural evolution during the bainitic transformation. The input parameters consist of thermodynamic and atomic mobility data obtained from the ThermoCalc and mCTRA databases combined with structural mechanics data extracted from the stress-strain curves of the fcc and bee phases. In this paper the general principles of the model are outlined and some interesting preliminary results are shown and commented. The full implementation of the model has presently not been achieved yet. In the model the bainitic transformation is considered as a sequence of martensitic (re)nucleation and growth of a ferritic subunit followed by the carbon rejection into the surrounding austenite. The (re)nucleation of the subunits will be described through a non-classical martensitic nucleation criterion. Once a nucleus has been activated at a specific location in the material, a full-sized subunit is instantaneously formed through a displacive mechanism. The stress state in the system that arises due to the transformation strain can be calculated by a 3D FEM programming code. Immediately after the formation of the subunit, another 3D FEM programming code calculates the carbon diffusion from the supersaturated ferrite into the surrounding austenite. The resulting stress state and carbon profiles will be used to determine where and when a new subunit will nucleate based on a renucleation criterion. Keywords: Bainitic Transformation, Modeling, Eshelby, Carbon Diffusion

Jan 1, 2003

By Shadia J. Ikhmayies

SnO2:F/CdS:In bilayers were produced by the spray pyrolysis technique on glass substrates. The structures were characterized by recording and investigating their transmittance curves, I-V plots, X-ray difractograms (XRD) and by observing their scanning electron microscope (SEM) images. From the I-V plots it was found that the SnO2:F forms an ohmic or quasi-ohmic contact with CdS:In. XRD patterns show the polycrystalline nature of the films and show that there is a small shift in the position of the (200) line of SnO2:F without the appearance of new peaks. The morphology of the structures are compared with those of SnO2:F alone and CdS:In alone on glass substrates.

Jan 1, 2009

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 D. Q. Cang, G. Duan, H. X. Li, H. Bai

"Life cycle assessment (LCA) is a valid environmental evaluation method and enterprise environmental management tool used in industrial ecology areas. In this paper LCA was newly used to evaluate the environmental impact of manufacturing of alumina by Bayer process in china from two aspects of logistics and energy flow, GaBi software acted as analysis tools with evaluation model established, and several environmental impact assessment criteria were selected based on the actually typical date of Bayer alumina producing process. Evaluation results show that alumina manufacturing by the Bayer process has a great impact on the global warming and human health of respiration, even roasting process gives rise to the greatest impact of winter fog index. Scenario analysis proposed ways of reducing environmental load caused by Bayer process including: (1) the economic and efficient use of mineral processing technology; (2) optimization of energy use, saving power consumption or the use of new more economical source of energy; (3) actively promote the use of innovated technology and equipment in alumina manufacturing and waste such as red mud utilization process.1 IntroductionSince 2002, China is already the world's biggest producer of aluminium, in 2007, China aluminum production has accounted for above 1/3 all over the world, 2009 for 13 million tons and to the end of 2010, China aluminum production is expected increased to be over 15 million ton [1,2,3]. While as the raw material for producing aluminum the alumina production in china has up to 19.46 million tons of the world's total quarter in 2007, by the end of 2009 China alumina production has achieve to 23.78 million tons [4,5]. China has rich bauxite resources with proven reserves about 23 million tons, but the great majority of china bauxite is hard monohydrate diaspore type with low ratio of aluminium silicon, high impurity content and poor aluminum dissolution performance, that cause high energy consumption, long and complex process, high production costs and heavy environment load[6,7]. Before most used alumina production was sintering process rather than Bayer method in china, over the past decade Bayer method has been widely applied instead of sintering process or combination both forming joint process, premise is improving bauxite quality by mineral processing or adding imported rich bauxite mineral[6,8]. In general each ton production of alumina needs bauxite 1.6~2.20t, limestone 0.7~1.7t, soda 0.250kg, fresh water 12.30 cubic meters, in addition to consume large amounts of energy, and emission waste water over 8.0 cubic meters, dust 2.3~5.7 kg, red mud 0.8-1.5 tons. In china Red mud yield nearly 30.0 million tons every year, accumulated stock is approximately 0.2 billion tons, by 2015 accumulative total red mud is expected to reach 0.35 billion tons [9-13].We know aluminium industry and alumina production have produced large waste, make large energy consumption and its environmental impact could not be ignored. Expecting to optimize production processes and achieve resource recycling for this industrial process the proper environmental assessment is very necessary. Currently Life Cycle Assessment (LCA) is generally recognized as the approved tool to achieve the purpose. The essence of LCA tool is to examine, identify and evaluate a kind of materials, product, process, or a system of environmental impact in their whole life cycle. The life cycle of materials or products includes whole process from raw materials obtained to the final disposal, or more ideal with original or other forms of the whole process of recycling [14-17]."

Jan 1, 2011

By U B. Pal

Downsizing and decommissioning of nuclear facility operations is increasing the stockpile of various different grades of Radioactive Scrap Iron (RSI). Disposal of this material not only represents significant resource and value lost, but also necessitates long term monitoring for environmental compliance. The latter results in additional recurring expense. It is desirable to be able to decontaminate the RSI to a very low level that can be recycled or used for fabrication of containers for RSI disposal instead of using virgin metal to fabricate the container. Electro-Slag Remelting and Refining (ESR) is often used for decontaminating radioactive contaminated sources of scrap iron such as stainless steel. Non-radioactive oxides of cerium are used to simulate the radioactive oxide contaminants of Uranium and Plutonium. The success of the ESR process is strongly dependent on the capacity of the slag to rapidly incorporate the radioactive contaminant (simulant). In this study we have measured the slag-metal partition coefficient for cerium and investigated the reaction mechanism for the dissolution CeO, in the slag.

Jan 1, 2002

By Yichi Lu, Haydn N. G. Wadley, Douglas T. Queheillalt

"Using a 3-D ray tracing methodology combined with laser ultrasonically measured elastic constant data near the melting point, ultrasonic propagation in cylindrical single crystal bodies containing either a convex or a concave solid-liquid interface have been simulated and used to design new sensing concepts. Ray paths, wavefronts and time-of-flight (TOF) of rays that travel from a source to an arbitrarily positioned receiver have been calculated. Experimentally measured TOF data have been collected using laser generated/detected ultrasound on model systems with independently known interface shapes. Both numerically simulated data and experimental results have shown that the solidification (interfacial) region can be identified from ultrasonic transmission TOF data. Since convex and concave solid-liquid interfaces result in distinctively different TOF data. When TOF data collected in the diametral plane are used in a nonlinear least squares algorithm, the interface curvature has been successfully reconstructed and ultrasonic velocities of both the solid and liquid obtained. The reconstruction errors were found to be less than 5%.IntroductionMany of today's single crystal semiconductors are grown by variants of a vertical Bridgman technique in which a cylindrical ampoule of a molten semiconductor is translated through a thermal gradient, resulting in directional solidification and the growth of a single crystal, Fig. 1.1 It has long been recognized that during crystal growth the velocity and the shape of the solid-liquid interface, together with the local temperature gradient, control the mechanism of solidification (i.e. planar, cellular or dendritic), the likelihood of secondary grain nucleation/ twin formation (i.e. the loss of single crystallinity), solute (dopant) segregation, dislocation generation, etc. They thus determine the crystals' resulting quality.2-4 The solidification rate and the solid-liquid interface shape are also sensitive functions of the internal temperature gradient (both axial and radial) during solidification.5•6 This in turn is governed by the heat flux distribution incident upon the ampoule, the latent heat release at the interface, and heat transport (by a combination of conduction, buoyancy and surface tension driven convection, and radiation) within the ampoule. The solid-liquid interface's instantaneous position, velocity and shape during crystal growth are therefore difficult to predict and uncontrolled during growth, especially for those semiconductor materials with low thermal conductivity (e.g. CdTe).4-6 The development of technologies to non-invasively sense the interface position and shape throughout the vertical Bridgman crystal growth process has therefore become a key step toward developing a better understanding of the growth process, for enabling sensor-based process control, and thus ultimately for improving the yield and quality of difficult to grow semiconductor materials like CdTe."

Jan 1, 1997

By Hongxu Li, Pu Liu, Hao Bai, Daqiang Cang, Lihua Zhao

"Coal, as the main energy in ferrous metallurgy, is consumed on a large scale and great amount of CO2 is emitted likewise. In this paper, a model, based on carbon balance, was developed for CO2 emission analysis, with data obtained from a typical integrated steelworks in China. The result shows that, CO2 emissions increase almost constantly with the growth of steel production. However, coals of different classes and product variety in the steelworks exerted an influence on CO2 emissions. Furthermore, three scenarios, including natural gas instead of coal for power generation, EAF process partly replacing integrated steelmaking, and feasible techniques applied to achieve lowest process energy consumption (FLPEC), were assumed to seek possible ways of carbon emission reduction. The result proves that the second scenario is most effective. If 40% of the steel product could be from EAF process, CO2 emissions would be reduced by 45.07%.IntroductionGlobal warming has become a global environmental problem, which is generally caused by excessive emission of greenhouse gases, such as CO2, generated from human activities and industrial processes. It is estimated that about 7% of global CO2 emissions was from iron and steel industry. Further, if the ore and coal’s mining and transportation are included, the CO2 emissions would reach 10%[1]. In general, the relationship between energy saving and CO2 emission reduction is positive correlation. However, in iron and steel enterprises, due to different types of energy resources like coal, heavy oil, natural gas, the consumption of which will generate different amount of CO2, are used, different energy consumption structure in iron and steel enterprises will lead to difference of CO2 emissions.In order to assess the CO2 emission reduction potential of China’s steel industry, Ke Wang etc.[2] developed a model using LEAP software to generate 3 different CO2 emission scenarios for the industry from 2000 to 2030. LEAP is a scenario-based software tool for integrated energy-environment and greenhouse gas mitigation analysis. The amount of CO2 emissions was obtained by the following equation:"

Jan 1, 2011

By Hans von Michaelis

There has been a renaissance in gold and silver extraction and recovery that has taken place over the last fifteen years, since the price of gold was freed from the $3510~ level. Despite major advances in such areas as carbon adsorption processes for gold recovery, refractory gold ore treatment, crushing and grinding, process control, etc., there still remain several gold and silver mineral processing frontiers. Frontiers related to environmental management present significant challenges especially in the USA. More than ever it is appropriate to optimize total economics by adopting a "systems approach" that integrates mining, mineral processing and environmental management.

Jan 1, 1993

By J. B. Winter

The present Inspiration Consolidated Copper Company Smelter/Acid Plant complex located near Miami, Arizona, was designed and built specifically to conform to the ambient air quality standards imposed by the Federal Clean Air Act of 1971. The present plant replaced a facility which had been in operation since 1915. The electric furnace, siphon converters and acid plant complex were commissioned in May, 1974 (1). At that time, the Plant was considered to be one of the most extensively monitored and instrumented facilities of its kind in the world. Several control areas were located in close proximity to the controlled process, in addition to so-called central control rooms in the Smelter and Acid Plant. The control rooms were staffed with officials below the foreman level. Instrumentation consisted of conventional analog devices, except for a computer used in monitoring ambient air environmental conditions and limited use of programmable logic controllers. The harsh service conditions prevalent in the plant rendered a significant portion of the instrumentation unreliable and, in many cases, inoperable. Failure of the facility to obtain the total sulfur collection for which it was designed was, in part, due to serious inadequacies in control system logic and sulfur recovery averaged 79% in the early years. After careful study of the smelting process, engineering hardware and high labor cost inherent in the organizational structure, management made a judgement decision to convert to centralized control of the process with high level supervision 24 hours per day. A distributed digital control system with supervisory arid data acquisition/information reporting computers was selected to satisfy the requirement of central control. Operations are now controlled and coordinated from a primary control room in the Smelter and a satellite control area in the Acid Plant.

Jan 1, 1983

By Roland Loewen

A review of the aqua regia method for the recovery of gold from jewelry shop wastes is given. Also outlined is a specialized procedure for the recovery of the silver that occurs in these wastes. A classic method for the recovery of platinum and palladium is, given. There is a brief review of other gold and silver refining methods. Environmental conditions are discussed and a few perhaps, new and useful processes ,are mentioned. References are by author or editor and are listed alphabetically. Suggestions for further information in the field of precious metals, are given in a final list.

Jan 1, 1989

By W. William Culver

James Douglas became known in the nineteenth century for two reasons fundamental to his mining career: (1) his experimental work with copper hydrometallurgy, and (2) his grasp of the idea that the quantity of copper ore matters more than the quality. On the first reason, there is a moment for any technology that’s critically important—when it moves from an area of scientific interest to one that companies are founded on. This paper examines the original 1869 Hunt and Douglas Copper Process in the context of science and engineering as they were in the 1860 and 1870s. It was a “humid” process, developed at Quebec’s Harvey Hill Mine. Chemically, the Hunt and Douglas vat leaching process succeeded, but not the original companies using it. On Douglas’ understanding of ore quality versus quantity, luck had it that the first company to field test the Hunt and Douglas Copper Process was in Chile. The Hunt and Douglas patent made that transition from experimental model to operational plant in 1870 when the Compañia de Minas de la Invernada was organized in Valparaíso. As a joint-stock company, Invernada spread the risk of investing in the revolutionary, but untested, Hunt and Douglas Process. The company brought Douglas to Chile as a consultant in 1871. His experience with hydrometallurgy, combined with what he learned about the copper business while in Chile, set him off on a career in metal mining that both surprised Douglas and made him wealthy.

By Roberto Javier Santiago

The diferent applications of the Calcium Carbide in the steel plants are described in this paper, trying to give advantages in their use.

Jan 1, 2006

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 David Goodman

The typical operating conditions in Solvent Extraction plants are presented. The various materials of construction used for solvent extraction equipment are reviewed and the history of their use presented. The properties of the materials in common use today, stainless steel, thermoplastics and fiber reinforced plastics, are compared together with cost data. The manufacturing and construction aspects of these materials are discussed.

Jan 1, 2003

By Hong Yong Sohn

On the occasion of this symposium in my name, I reflect upon the contributions of my academic mentors and early associates who helped shape my professional career. I was fortunate to have these people around me during my graduate work and at the start of my professional career. In forming my view of the technical field and career, they represented academia, research institutions, industry, and different parts of the world.

Jan 1, 2006

By Hong Yong Sohn

On the occasion of this symposium in my name, I reflect upon the contributions of my academic mentors and early associates who helped shape my professional career. I was fortunate to have these people around me during my graduate work and at the start of my professional career. In forming my view of the technical field and career, they represented academia, research institutions, industry, and different parts of the world.

Jan 1, 2006