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By Baokuan Li, Fang Wang, Meilong Shan

"As the advantage of uniform bus loading, the electroslag remelting (ESR) furnaces with three - phase installation by delta or star connection are mainly used to produce the large or super large ingot. The electrical efficiency is significantly improved as the short circuiting through the molten slag. However, little is found about fiindamental research on the electromagnetic field of the ESR system with three -phase installation. A three-dimensional (3D) finite element model was developed to simulate the current density, magnetic field, electromagnetic force and Joule heating for a system of electrode, slag and ingot in the ESR system with three -phase installation.IntroductionThe metallurgical performance of the ingot is the fundament and precondition to obtain the large forging of high quality, which has a critical role in the producing of forging. The electroslag process (ESR) to product the metal materials of high homogenization and clarity become more and more popular[1].The electroslag process is a special smelting technology of producing small ingots, which originate in 1950[2].At present the three, four or six electrode is used in large scale electroslag furnace. It has been found that the deeper molten pool and the wider of the two-phase zone with only one large diameter of electrode to product large ingot effect the solidification microstructure of ingot[3]. However, the molten pool becomes shallow relatively with several electrodes producing the large ingot, which is benefit to the solidification microstructure of ingot. Three electrodes electroslag remelting furnace take the three phase equilibrium power supply to making the load and electric power network balance, avoiding the distortion phenomenon induced by single phase power supply and saving electric power. It also can uniformize the distribution of heat source."

Jan 1, 2012

By Gjergj Dodbiba, Toyohisa Fujita, Takahiro Kikuchi, I-Chen Wu

"In order to separate molybdenum (Mo) from the high-level radioactive liquid waste (HLLW), Pb-Fe based adsorbents were synthesized. The adsorbents were precipitated by adding sodium hydroxide in mixture of 1 mol/L lead nitrate and 1 mol/L ferric nitrate aqueous solutions. Each precipitate was then filtered, dried and ground to obtain a fine powder, which has been used as an adsorbent. Two main parameters were considered when synthesizing the adsorbents, i.e. the pH value at precipitation of adsorbent precursor and the calcination temperature of Pb-Fe based adsorbent. Moreover, the structures of the synthesized adsorbents were investigated by means of an X-ray diffractometer.The experimental results indicated that the calcination temperature of the Pb-Fe based adsorbent has a great influence on adsorption capacity of the adsorbent for Mo. It was found that when the Pb-Fe based adsorbent was calcinated at 500 oC, the sorbed concentration of Mo was the highest.1. IntroductionThe high-level radioactive liquid waste (HLLW), arising from the reprocessing of nuclear fuel are generally immobilized in an alkali borosilicate glass matrix. Broadly speaking, alkali borosilicate glasses are the matrix of choice for the immobilization of the HLLW, since they permit vitrification of waste stream of variable composition, [1]. Within this frame, the incorporation of molybdenum (Mo) is of particular interest in the vitrification of HLLW. Molybdenum is know to have a low solubility in borosilicate glass compositions and its presence in excess results in the phase separation of a complex yellow molten salt during vitrification, [1]. The formation of so-called “yellow phase” material during the vitrification process is undesirable since it leads to the accelerated corrosion of the inconel crucible liners. Furthermore, the “yellow phase”, which is reported to contain also other fission products, is soluble in aqueous solution providing a potential route for the leaching of radionuclides from the vitrified waste, should it come into contact with water, [1]."

Jan 1, 2008

By T. Takasu

Overall productivity in copper refining is currently determined by the electrorefining process. Previous research showed that forced convection of the electrolyte improves the morphology of the copper deposit on the cathode and suppresses passivation of the anode. In this paper, electrorefining experiments under forced convection were carried out in the presence of As, Sb and Bi impurities, both in electrolyte and in the anode, to determine the effect of the impurities on the electrorefining process. The concentrations of the impurities in the deposit increased with increasing current density without forced convection. An increase in the fluid velocity suppressed the increase in impurity concentration. These concentrations were high, especially in the initial stage of deposition without forced convection, corresponding to a decrease in the cathode potential measured during that period. This indicates that the enrichment of impurities was induced electrochemically. The reason for the decrease in cathode potential was the low concentration of copper ions on the electrode surface because of ion consumption by the electrolysis. The forced convection of the electrolyte enhanced the ionic mass transfer and thus suppressed the polarization and deposition of the impurities. The fluid motion was shown to be effective in achieving electrolysis under high current density conditions.

Jan 1, 1999

By H. Kurokawa

Sumitomo Metal Mining decided to expand copper production capacity of Toyo Smelter and Refinery to cope with the recent copper demand growth in Asia, and to survive by reducing cost. The expansion plan is promoted to increase electrorefined copper production capacity from 270,000 metric tons in 2001 to 450,000 metric tons in 2007. The major changes in smelting section are introduction of the rotary steam dryer, renewal of the feeding system for flash furnace, improvement of the concentrate burner, modification of the flash furnace cooling materials, renewal of the slag cleaning furnace, modification of the flash furnace waste heat boiler, installment of a new converter furnace, enlargement of two anode furnaces. In addition, the gas cleaning system was upgraded and the second acid plant was installed. In the refinery section, the existing tank houses have been operated at high current density of 300A/m2 using the conventional starting sheet cathode technology and moreover a new tank house utilizing the permanent cathode technology was constructed. Although the copper production capacity has been increased, SO2 emission has been kept the lowest in the world through consideration of influence on the environment by expansion project.

Jan 1, 2006

By Florian Kongoli

While calcium ferrite slags have been successfully used in continuous copper converting for the last 30 years, ferrous calcium silicate slag was proposed about 8 years ago as an additional alternative for copper smelting. Although both slags are normal extensions of each other their phase relations have not been completely clarified. In this paper the liquidus relations of both slags have been quantified at various areas that cover both of them. The existing experimental data have been first reviewed and discussed in relation to the solidification procedure. An original physical model is then used to predict various diagrams of the liquidus surface of both slags. It is shown that the ternary liquidus diagrams normally used for FeOx-SiO2-CaO system are not suitable for industrial slags. The new model diagrams of Fe/CaO versus SiO2 and Fe/SiO2 versus CaO as well as Fe/CaO versus Temperature and Fe/SiO2 versus temperature are proven to be much more convenient for ferrite and ferrous calcium silicate slags. Based on these diagrams the effect of SiO2 and CaO on the melting temperature is quantified. The effect of Cu2O is also quantified through the model. Some Fe/CaO versus Cu2O and Fe/SiO2versus CaO at various copper contents are predicted and the results show good agreement with the experimental data. It is also shown that in the presence of liquid copper, Cu2O is dissolved in the slag depending on the oxidation degree of the system and might lower the liquidus temperature. Some discussions are also presented taking into account plant observations and important conclusions are drawn for copper smelting and converting

Jan 1, 2006

By C. Lupi

Zinc chloride electrowinning presents difficulties in obtaining smooth, compact and dendrite free deposits with a high current efficiency due to the presence of undesirable metal ions. However, it is hard to define a level of impurities tolerable in zinc deposition, and despite a lot of research in this field, the reaction mechanisms of the undesired metal ions are still not clearly understood. In this study, the influence of Fe, Cd, Co, Ni and Cu additions were investigated, as well as their synergic effect on the zinc electrodeposition process from chloride electrolytes and on the obtained deposit morphology. The tests were all performed in presence of TBACl which reduces the harmful effect of such impurities on the zinc reduction.

Jan 1, 2003

By P. K. Narasimhargahavan

This paper discusses briefly the major reasons associated with the growth and its impact on the energy requirement and Environmental imbalance. A projection based on the present global Alumina and Al requirement indicate a substantial further growth of at least 30% over the next 10 years. It is indicated that the main factors which are likely to influence investments are the environmental factors such as the Climate Change and global response to the growing energy prices and sustainable development. Each of the developed / developing nations must find response to the GHG emissions which will encourage the Al Industry to make an effective contribution to global warming while preserving the international competitiveness of the industry - a challenging task. The efforts shall concentrate on improving energy efficiency in the industry possibly of the order of 25% over the next 10 to 20 years. The developments in this line are discussed.

Jan 1, 2010

By Kaixi Jiang, Bangsheng Zhang, Lei Zhang, Haibei Wang, Xiaoping Zou

"China plays an important role in the global molybdenum industry; in fact, both China's molybdenum mine and smelter production ranked first in the world. The characteristics of China's molybdenum resources are quite complex, and moly-nickel ores with carbon, coppermoly ores and wulfenite can be only found in China. This paper firstly introduces China's molybdenum resource/ reserve situation. Secondly, the status of molybdenum smelting technologies, especially roasting by rotary kilns and multiple-hearth furnaces, are discussed. The practices and the development of some new technologies, such as pressure leaching, solvent extraction, ion exchange, carbon adsorption for moly-nickel ores and low grade molybdenite concentrates, are also introduced.IntroductionMolybdenum is widely used in special steels, aviation, alloys, chemistry, electronic and medical industries because of its excellent physical and chemical characters [1,2].In nature, molybdenum exists mainly as molybdenite associated with copper ore which are the main material for smelting. About 99% of molybdenum is produced from molybdenite. In addition, wulfenite, molybdenum oxide ore and graphite shale containing Mo-Ni have also industrial value to extract molybdenum and other metals such as Ni, Re, Pb and Zn. The reserves of molybdenum in China are about 8.4 million tons metal; China is ranked as the second largest source in the world. The output in China is more than 40 kt in 2010. Ferromolybdenum is the main product and then ammonium molybdate. The consumption in China is about 20 kt and the rest is exported to overseas.The first molybdenum smelter in China was built in 1963. Today the main producers include Jinduicheng Moly Company, Luanchuan Moly Company and Jiangxi Copper Group Company. Technologies and equipment have changed greatly. Roasting and multi-hearth furnaces are widely used. Several new processes were developed such as pressure leaching, solvent extraction, ion exchange and carbon absorption [3-8]."

Jan 1, 2012

By Akira Yazawa

The composition of ferrous calcium silicate slag is located on the tie line between FeOx and calcium silicates in ternary FeOx-SiO2-CaO system. This slag has never been used as copper smelting slag because of high sulfidic copper solubility. However, when the dissolved copper in slag is just oxidic, as in direct white metal production or in converting process, this slag is quite attractive and can be regarded as the third copper smelting slag after fayalite and calcium ferrite slags. Based on the authors' studies on phase separation thermodynamics and laboratory experiments, it was clarified that the oxidic copper loss in this ferrous calcium silicate slag become the minimum not only %Cu in slag but also the total copper loss when the amount of slag is taken into account. It has been proven that calcium ferrite slag is suitable for continuous converting where the dissolved copper is oxidic, but there exist some drawbacks such as limited solubility of silica, low lead removability and too high fluidity. To overcome these difficulties accompanying traditional slags, ferrous calcium silicate slag is the hopeful alternative. In view of the general trends of modem copper smelting processes, the interesting features of this new slag system are discussed.

Jan 1, 1999

By M. Urda-Kiel

Stainless steel is increasingly used as a cathode starting sheet. It was shown earlier that even when depositing copper on copper, a substrate-influenced zone appears in the deposit structure, followed by a transition zone and finally by the electrolysis-influenced structure. On copper, the substrate-influenced zone has a thickness of twenty micrometers and on titanium, eventually more than fifty micrometers. Initial nucleation and growth have a considerable influence. In this paper, copper was deposited in a channel cell on four different 304 stainless steel substrates: mechanically polished and anodized, respectively, at 0, +400 and +800 mV/SHE in 1M H2SO4 at 20°C. Copper was deposited under electrowinning conditions after solvent extraction (SX) (40 g/l Cu++, 180 gh/l, H2SO4, 20 or 60°C). The results showed that, although Auger surface analyses of the substrates were only slightly different one from another including the oxide thickness, nucleation and initial stages of growth were very sensitive to the surface treatment of the substrate. Potential step and current step methods gave similar results : progressive nucleation followed by 3D diffusion controlled growth. The highest nucleation frequency was observed on stainless steel anodized at 0 mV/SHE, under various electrolysis conditions. The potential influence of these findings on industrial practice is discussed.

Jan 1, 1999

By J. H. de. Visser

The transfer of molten metal in smelting or refining operations is typically performed in open trough-type launders that are constructed of either water-cooled copper troughs or refractory lined steel jackets. This transfer can be either continuous or batch. Batch operations transfer metal through an open launder. The uncovered launder has many operational and environmental drawbacks. In order to improve workplace hygiene, designs have evolved toward ventilated launder covers that .are connected to secondary exhaust systems that use negative pressure under the cover removing fume and hot gases to secondary fume control devices. In smelting operations, a variety of covers have been employed which insulate the launder and contain the fumes and also provide additional heat along the length of the launder through a series of premix or inspiration-type burners that add combustion products to the normal fume load in the launder. Cover designs have proven to be inadequate in that hinged unventilated covers hinder convenient access while heated ventilated covers are costly to maintain. Covers that employ refractory bricks and overhead enclosure-type exhaust hoods have been somewhat successful, but restrict operator movement and require large volumes of exhaust air. An example is given of a cover and off-gas system for launders that is designed to provide superior insulation and heating capabilities, as well: as better control of the fume gases-and ease of maintenance. The cover system must maintain the balance between maintaining launder heat and fume removal. The construction of the covers must be able to withstand high internal temperatures and maintain its structural properties.

Jan 1, 1999

By Nexhmedin Lohja

Macro management of metallurgical industries becomes an important issue in certain situations especially when some government owned metallurgical industries are on the verge or have stopped being feasible. In these cases a government lead macro management in collaboration with domestic institutions and foreign scientific and management expert companies is decisive in order to steer them to a profitable path. This process is not necessary an easy one and incorporates many unknowns and various alternatives. In this paper the macromanagement of the metallurgical industries in Albania will be described as a particular case along with a survey of its mineral deposits, metallurgical facilities and various perspectives for future development. As a country with many mineral resources, the exploration, research, exploitation and processing work of mineral ores before 1990 constituted an important activity of its economy, especially in the exportation of various products of this industry. Since 1990 this activity slowed downs considerably for various reasons and this prompted the necessity of a government lead macromanagement in collaboration with domestic institution and foreign expert companies. This process aims at improving and renewing the technologies in the metallurgical industry in order to transform it into a feasible branch of economy. This goal is being implemented among others through proper geological surveys, rehabilitating and renewing the existing facilities through domestic and foreign investments, the transformation of the ownership or the management from state-owned to local or foreign private companies, etc. Priority is given to the raising of the processing range of the traditional minerals such as chromium, copper, nickel-iron etc. as well as developing new perspective technologies to treat new mineral deposits.

Jan 1, 2006

By P. C. Guillaume

Global plant modernizations or expansions cannot be considered in the same light as any other industrial investment project. Relationships between the partners, relationships and communications with the client, structure and organisation of the teamwork, schedule of the work, and a lot of other tasks and missions devoted to external contractors have to be defined considering one fundamental input: an operating plant. For an engineering company expert in processing, like UM Engineering, such a context requires a specific approach as well as specific procedures able to efficiently challenge the generated constraints. First of all, even if a detailed audit had been conducted at the beginning of the conceptual engineering phase, new elements will be discovered during the preparation and realization of the project, and must be continuously integrated. Consequently, a close proximity to the site is necessary. This is one reason why UM Engineering, most often, works in partnership with a local engineering company. The second important point for the client is that the operation must not be interrupted during the realization. In order to make that possible, UM Engineering has defined a specific project structure and organisation, integrating on a permanent basis the operators (the "users") in the project teams. This paper presents the way UM Engineering copes with this type of "multi-constraints" context with reference to the recent copper cellhouse modernization under realization for the CCR Refinery of Noranda Inc. in Canada.

Jan 1, 1999

By Florian Kongoli

While calcium ferrite slags have been successfully used in continuous copper converting for the last 30 years, ferrous calcium silicate slag was proposed about 8 years ago as an additional alternative for copper smelting. Although both slags are normal extensions of each other their phase relations have not been completely clarified. In this paper the liquidus relations of both slags have been quantified at various areas that cover both of them. The existing experimental data have been first reviewed and discussed in relation to the solidification procedure. An original physical model is then used to predict various diagrams of the liquidus surface of both slags. It is shown that the ternary liquidus diagrams normally used for FeOx-SiO2-CaO system are not suitable for industrial slags. The new model diagrams of Fe/CaO versus SiO2 and Fe/SiO2 versus CaO as well as Fe/CaO versus Temperature and Fe/SiO2 versus temperature are proven to be much more convenient for ferrite and ferrous calcium silicate slags. Based on these diagrams the effect of SiO2 and CaO on the melting temperature is quantified. The effect of Cu2O is also quantified through the model. Some Fe/CaO versus Cu2O and Fe/SiO2versus CaO at various copper contents are predicted and the results show good agreement with the experimental data. It is also shown that in the presence of liquid copper, Cu2O is dissolved in the slag depending on the oxidation degree of the system and might lower the liquidus temperature. Some discussions are also presented taking into account plant observations and important conclusions are drawn for copper smelting and converting

Jan 1, 2006

By L. Z. Villanueva

An investigation and evaluation has been performed to determine the potential utilization of electron beam irradiation technology for sulfur oxides removal from reduced-S02-strength metallurgical gases from copper smelters. These off-gases, though too weak to be converted to usable, concentrated: sulfuric acid by conventional means, are characterized by SO2 content higher than 2,000 ppm and a complex chemical composition, including high oxygen content and its generation occurring in a cyclical, fluctuating pattern. This work was based on information supplied by principal smelter companies in Chile. A laboratory facility with flow rate of 20 Nm3/h and equipped with an electron accelerator of beam energy 8.00 keV, has been used for testing. Influence on SO2 removal efficiency of operational parameters such as gas temperature, water vapor content, ammonia feed ratio and irradiation dose was established. The main conclusion of this work, from experimental laboratory tests as well as engineering studies, is that the Electron Beam Process (EBDS) is a cost-effective, simple and appropriate chemical process means for emission abatement. EBDS can, on a site-specific basis, adequately augment SO2 removal to upgrade overall abatement as required and in an optimal manner.

Jan 1, 1999

By Aly M. Abdel-Rehim

The present work deals with a study of the mechanical activation of processing of Egyptian monazite by its simultaneous ball-milling and pressure leaching in order to improve the recovery of thorium and lanthanides from monazite. Experiments of simultaneous ball-milling and alkaline leaching of monazite contrary to autoclave leaching were carried out in stainless steel ball-mills of cylindrical shape under different conditions of temperature, pressure, time and alkali amount and strength. The ball-mills were heated and mechanically rotated in an electric furnace by means of roll mechanism. The effective rotation speed was fixed at 130 rpm in all tests. The charge of steel balls of different diameters was equivalent to 45% of the total mill volume. Monazite was charged in ball-mill without preliminary grinding. It is found that high rate of monazite leaching by ball-milling leaching method is achieved at lower temperature, shorter time and lower expense of alkali than in autoclaves. The results obtained show that complete recovery of thorium and lanthanides from monazite (99.8%) by simultaneous ball milling and alkaline leaching is attained at 140°C within 2 h. It is concluded that processing of monazite by its simultaneous ball-milling and leaching is mechanically activated and accelerated as a result of grinding action of steel balls that caused the continuous removal of the hydroxide product from reacting particle surfaces. This leads to the exposing of fresh and activated monazite particles surfaces to alkali leach solution and consequently the acceleration of the reaction of monazite processing.

Jan 1, 2006

By Kazuyo Yokoyama

New environmental assessment model based on the Waste Input-Output analysis has been developed and applied for the "Landfill mining activity". "Landfill mining" implies the digging up of the landfilled wastes, the recovery of valuable material and energy resources and, thus, the reuse of the saved space as a new landfill site. In this study, the landfilled wastes are assumed to be treated by the gasification/melting processes. Two kinds of reactors, the fluidized bed type (FB) and the shaft furnace type (SF), have been considered in this work as the typical gasification/melting processes adopted in Japan. In FB, the dug-up wastes are heated in the sand fluidized bed zone under reducing atmosphere, Fe and Al are recovered in the metallic form, and then, the gasification/melting of residues is made in the second zone. In SF, the waste is charged in the high temperature coke bed, and the gas is recovered together with molten metal and slag. Both processes generate electric power by the recovered heat and fly ash as waste to landfill. It has been found in this study that the both processes can reduce the total volume of waste and save the available landfill space. SF seems to have higher potential for decreasing volume of wastes because of less emission than FB while FB has great benefit to recover metallic Fe and Al individually. The results of scenario analysis have also indicated that the landfill mining activity is effective for sustainable management of landfill sites.

Jan 1, 2006

By M. Kawakami

In order to make titanium ingot directly from molten slag, the metal pool was tried to form and used as the cathode. The electro-slag remelting (ESR) unit was used for the purpose. The unit is composed of water-cooled copper mold and the DC power source of 2000 A and 100V. The graphite electrode was used for anode and the base plate was used for cathode. The commercial and re-melted slag of CaO-CaF2 was melted in the mold with the addition of TiO2. The following reactions are expected to occur. Ti4+ + 4e = Ti at cathode 2O2- + 2C = 2CO + 4e at anode During the process, large amount of molten slag splashed out from the mold, showing the CO evolution at anode. The metal deposit was obtained but in the form of block and piled up on the base plate. The metal pool was not obtained perfectly because of shortage of heat supply. The cathodic current efficiency was 60 % at maximum. The metal deposit contained much impurity. In order to reduce the impurity and increase the current efficiency, the effect of electrode distance was examined. The electro-slag re-melting of titanium was tried in order to examine the condition to make metal pool.

Jan 1, 2006

By Henk Dijkman

Existing metallurgical operations can be optimized by implementing engineered bioreactor systems in the process configuration. For instance, metals can be recovered safely and economically from process and waste streams using biogenic sulfide. This paper focuses upon possible applications of high rate biotechnology in metallurgy and mining. Metal recovery from liquid streams (process bleed streams, leach water, waste streams), integrated removal of (fugitive) SO2, treatment of acid blowdown and other options will be described. Practical examples are given. A large-scale application of biotechnology at Pasminco's Budel Zink refinery is described. Here, acid plant blowdown is treated together with electrolyte magnesium bleed. Concentrated zinc sulfide (10 tpd) is produced biologically, eliminating the production of gypsum and closing the refinery sulfur cycle. Recovery of metals from solution at Kovehute Pribram in the Czech Republic is the second practical example. In this case, H2S is produced on-site for metal removal from an alkaline slag dump leachate. At the Caribou mine in New Brunswick, Canada, acid mine drainage is treated with biogenic sulfide. This plant is situated upstream of a lime neutralization plant. As a result, reusable ZnS is produced, the volume of the sludge (gypsum and hydroxides) from the lime plant is reduced by 50%, the sludge is free of heavy metals and the final effluent concentration of heavy metals is in the ppb range. In the second phase of this project, metals will be recovered from stored tailings, resulting in significant revenues.

Jan 1, 2002

By Alain Jardy, Valerio De Felice, Jean-Pierre Bellot, Ismael Lis Alves Daoud, Stephane Hans

"Gas-stirring ladle treatment of liquid metal has been pointed out for a long time as the processing stage mainly responsible for the inclusion population of specialty steels. A steel ladle is a complex three-phase reactor, where strongly dispersed inclusions are transported by the turbulent liquid metal / bubbles flow. We have coupled a population balance model with CFD in order to simulate the mechanisms of transport, aggregation, flotation and surface entrapment of inclusions. The simulation results, when applied to an industrial gas-stirring ladle operation, show the efficiency of this modelling approach and allow us to compare the respective roles of these mechanisms on the inclusion removal rate.IntroductionThe reduction of the weight of high performance materials together with the improvement of mechanical properties and the increase of the recycling of used metal are new challenges which emphasize the importance of metal cleanliness. Ladle treatment of specialty steels has long been described as the secondary metallurgical process mainly responsible for the non-metallic inclusion derived from the deoxidation process. The treatment is accomplished by blowing argon through one or more porous plugs for the purposes of desulphurization, minor composition adjustments, and inclusion removal. Gas injection is applied on routine basis to achieve both the stirring of the liquid bath (thermal and chemical homogenization) and the entrapment of the inclusions by the bubbles (flotation). Furthermore, the turbulence produced in bubble swarms enhances the probability of inclusion collisions and makes aggregation the first mechanism for particle removal. The physical processes involved in gas stirred ladles are numerous and complex owing to the three dimensional and multiphase (metal-gas and inclusions) nature of the reactor. Despite these difficulties, the population balance equations can be implemented in CFD code11'21 and combined CFD-PBM (computational fluid dynamics - population balance method) models are investigated for steel ladle processes13'41 and produce very promising results in terms of inclusion removal efficiency."

Jan 1, 2012