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By I. D. Reznik

On blowing nickel matte in a converter without quartz, first the oxidation of metallic iron and a part of FeS occurs without evolving sulfur dioxide, the formed FeO dissolves in a sulphide smelt and form a homogeneous oxysulphide smelt. On further increasing the FeO content, the oxysulphide separates into 2 layers. Based on the laboratory investigation of FeO-(FeS+Fe°) - (Ni3S2+Ni°) ternary phase diagram we have identified the separation region at 1250°C. The boundaries of the separation region have the form of an arc and the composition of the separated oxysulphide layers is defined by the canodes. In the nickel or copper-nickel matte - silicacalcium oxide slag system at 1250°C three layers, namely sulphide, oxysulphide, and slag may be formed. A high slag basicity due to the presence of CaO can serve to enhance the activity of FeO; a low nickel content in the matte corresponds to a high concentration of FeS therein; FeO from slag and FeS from the matte form a homogeneous FeO-FeS solution, i.e. an oxysulphide layer. The investigation on the "Camebaks" apparatus and by the nuclear gamma-ray resonance spectroscopy method of the phase composition in a slowly cooled oxysulphide layer has shown the presence of four phases: wustite, troilite, ferronickel grains, and calcium oxide-silica inclusions. Knowledge of regularities in the oxysulphides formation makes it possible to use them in pyrometallurgy of nickel and cobalt or preventing their formation.

Jan 1, 1997

By Vladimir Mindin

This paper presents results of thermodynamic investigations and experimental' studies of some essential for pyrometallurgy of sulfide concentrates topics. Among them: 1. Thermodynamic simulation and experimental investigations of roasting process, 2. Thermodynamic investigations of sulfur dioxide off-gases treatment technologies. 3. Investigations on "Mind in -Kiknadze" effect of suppression of sulfur dioxide formation during sulfide concentrates roasting in the vapor containing atmosphere. 4. Thermodynamic simulation and experimental investigations of sulfide concentrates and manganese containing materials co-roasting processes. Some essential aspects of thermodynamic simulation techniques are also discussed.

Jan 1, 1998

By Flávia Paulucci Cianga Silvas, Otávio da Fonseca Martins Gomes, Viviane Tavares de Moraes, Denise Crocce Romano Espinosa, Jorge Alberto Soares Tenorio, Guilherme Apostólico Bortolini, Stoyan Gaydardzhiev

"Printed circuit boards (PCB) are particularly problematic to recycle because of the heterogeneous mix of organic materials, metals, and glass fiber. PCBs are found in almost every electroelectronic equipment and their recycling process involves a pre-treatment to separate the products which contain targeted metals. In this work, a physical processing involving sequential shredding and hanuner milling were used to obtain a comminuted sample from scrap printers PCBs. The thus prepared sample was analyzed for particle size distribution and by optical microscopy as well was subjected to pyrolysis, leachabilty and chemical composition determination by XRF. The metals concentration was determined by ICP and AAS. The PCBs have been also analyzed by SEM-EDS (micro-analysis and X-ray mapping). The results show that the studied PCBs are lead free, multilayer with 4 copper layers, have 45% of metals and the copper is present in significantly higher concentration than the rest of the metals.IntroductionThe global generation of e-waste (electrical and electronic equipment waste - WEEEs) grows at a rate of about 40 millions of tons per year [ l].Among this e-waste there are PCBs that are present in almost all electronic equipment. Their composition is heterogeneous and varies according to several factors, including: kind of EEE, when and where it was produced, fabrication technology [2], etc. In printers, the PCBs represent about 6.6- 8 wt.% [3].The PCBs treatment may include physical, pyrometallurgical, hydrometallurgical, ectrometallurgical and more recently bio-hydrometallurgical process. Normally there is a combination between these processes [2, 4, 5, 6, 7, 8, 9, 10].The diversity between the different PCBs composition complicates the recycling process since the composition of metal and others materials can vary according to the models. So characterization is an indispensable step before any processing of PCB to begin. Owing to the above said, the main goal of this work has been set to characterize representative samples of PCBs from printers through physical, chemical and microstructural analyses."

Jan 1, 2014

By L. I. Rosato

A novel hydrometallurgical process for the recovery of silver and gold from neutral leach residue that is based upon leaching with thiourea, is described. Laboratory and pilot plant studies have shown that 80-90% of the silver and 60-70% of the gold can be recovered by:? ( i) leaching zinc calcine with 'Spent electrolyte at pH 2.0-3.0 to generate a precious metal-bearing zinc ferrite residue, (ii) leaching of the thickened zinc ferrite with 3-5 g/L thiourea in a six stage carbon-in-pulp circuit, (iii) elution of silver and gold from the loaded carbon with a thiourea- butanol solution, (iv) thermal regeneration of the stripped carbon and (v) recovery of the precious metals from the pregnant eluate by cementation with zinc dust. The reasons for adopting the thiourea CIP leach and the preferred operating parameters for each process step are presented. The requirements for the destruction of any thiourea transferred to the zinc circuit are outlined, and the results of an integrated one tonne/day pilot plant operation at Canadian Electrolytic Zinc are given.

Jan 1, 1990

By Min Chen, Lei Xu, Weijun Huang, Shuai Zhang

For the purpose of extending the service life of MgO-C bricks used as linings of vanadium-extraction converters, the effect of Fe addition on properties of MgO-C bricks was investigated. The results showed the addition of Fe could effectively improve the sinterability of the oxidized layer of the MgO-C refractory at 1400°C due to the effect of FeO (formed by oxidation of Fe) on formation of MgO-FeOss and modification of the microstructure, and excellent corrosion resistance against vanadium containing slag was also obtained due to the increase of compactness of the oxidized layer and concentration of FeO in the oxidized layer. Consequently, it is considered that MgO-C brick by introducing the new phase of Fe is a favorable substitute of MgO-C refractory to be used as linings of vanadium-extraction converters.

Jan 1, 2015

By K. J. Cathro

A hydrometallurgical process is described for the recovery of copper from chalcopyrite concentrates. The process is based on a cupric chloride leach, the concentrate having first been "activated" by heating it with sulphur at a temperature near 400°C. This activation process converts most of the iron of the chalcopyrite to pyrite, which is insoluble in the cupric chloride leachant. The copper is converted to the mineral idaite, which dissolves readily in hot cupric chloride: at 106°C, 98% of the copper is extracted in a three-stage countercurrent leach, the leaching tirqe being 1 hour per stage. The sulphur of the chalcopyrite appears as elemental sulphur, which is recycled for the activation of further concentrate, the final leach residue consisting of pyrite, plus the gangue present in the original concentrate. The copper extracted can be recovered by electrowinning, using a diaphragm cell. Current efficiency (one-electron basis) is about 70% but the cell voltage is only about 1 V, so that power consumption is three times lower than for the conventional sulphate electrowinning process. The leachant is simultaneously regenerated in the anode compartment. The behaviour of minor elements in the concentrate has also been studied.

Jan 1, 1976

By James C. Barker

Recent investigations of a 55-km long trend of intrusive complexes on southern Prince of Wales Island have identified significant resources of Nb, Y, REE. U, Zr, and a host of potential by-product metals. The northwesterly trend comprises multi-phased sodic alkaline and peralkaline diorite, monzonite, syenite, and riebeckite granite. There are at least three significant deposit types recognized, two of which, 1) pegmatite dikes/vein-dikes that zone laterally from the intrusions and 2) concentrically zoned pegmatites, contain most of the lithophile metals. A third, epigenetic replacement-type mineralization, contains much of the U resource. Other deposit types with minor or unknown resource potential include diatremes, carbonatite, and placers. This report summarizes the deposit evaluations, characterizes the mineralization, and estimates the resources. To date a total of 40.7 million tons of mineralized material is estimated as indicated or inferred. Most of the Y203 plus REO is at a grade exceeding 0.5% and half of the Nb20S exceeds 0.125%. Tonnage estimates would likely be substantially lncreased with additional exploration. Mineralogy is generally fine-grained and complex, and consists of more than a dozen principal REE-Y-Nb-U-Th-Zr phases, the sum of which may compose up to half of the rock. Approximately half of the REE-Y content comprises the heavy yttrium subgroup which is uncommon compared to deposits elsewhere. Although the Alaskan deposits are likely subeconomic at today's metal prices and consumption levels. recent technological advances suggest future demand may increase.

Jan 1, 1988

By Guo Xueyi

The dissolution behaviors of valuable metals, lead and zinc, from secondary fly ash generated in municipal incineration plants were investigated using some lixiviants: sulfuric and hydrochloric acids, acetic acid and some chelating reagents including L-asparaginic-N,N-diacetic acid (ASDA), a biodegradable, and therefore, environmentally benign novel chelating reagent. It was found that zinc exists mainly as ZnO, whereas Pb probably as PbOHCI and PbO, and the easily soluble components in SFA are KCI and NaCl. Suitable amount of HCI can dissolve all of lead and zinc from SFA. Sulfuric acid can selectively extract zinc leaving lead in the residue. Ethylenediaminetetraacetic acid (EDTA) is an effective chelating reagent to extract both zinc and lead. Although ASDA and diethylene¬triaminepentaacetic acid (DTPA) can selectively extract more than half of lead from SFA, it would by no means be regarded as highly effective reagents for the extraction of these metal values. Keywords: Lead, Zinc, Secondary fly ash, Leaching, Dissolution

Jan 1, 2002

By Zhang Chuanfu, Tan Pengfu

"A thermodynamic model is developed to simulate nickel flash smelting process. In the nickel flash furnace, oxidation of concentrate occurs at one end, and reduction of slag occurs at the other. The model makes use two zones, namely the reaction shaft/settler zone and the appendage zone and accounts for 6 phases (matte, slag, silica, magnetite, Cu-Ni alloy and gaseous phase), 13 elements (Ni, Co, Cu, Fe, S, 0, N, C, H, Si, Al, Mg and Ca) and 33 chemical components in nickel flash smelting system. The compositions of matte, slag and gaseous phases in equilibrium are calculated by using the data of free energies of formation and activity coefficients of components. Two nickel sulfide species are used to allow for the modeling of sulfur-deficient mattes. The model predictions are compared with the known industrail data from Kalgoorlie Nickel Smelter, and excellent agreement is obtained. The model can be a very useful tool for monitoring and optimizing the actual industrial operations of nickel smelting process. The distribution behaviors of Ni, Co, Cu, Fe, S and 0 in the nickel smelting furnace depend on the process parameters such as smelting temperature, volumes of air, the content of the elements~ charge and oil.1. IntroductionThe nickel flash smelting furnace essentially consists of a reaction shaft where nickel sulfide concentrate is partially oxidized with air, a settle zone where matte and slag are allowed to separate, and a slag cleaning end where coke is added to provide for the reduction of the oxidized nickel from slag, and electrodes are used to provide heat.The theoretical model to consider a mass balance for copper flash furnace is developed by S. Goto and R. Shimpo[1][2J. However, this can not be true for nickel flash furnace as a whole since oxidation of concentrate occurs at one end (in the reaction shaft/settler), and reduction of slag occurs at the other (in the appendage). Despite these limitations, an acceptable pseudo-thermodynamic description of the furnace can be achieved using essentially two zones, namely the reaction shaft/settler zone and the appendage zone. Compositions of gas, slag and matte in two zones are calculated."

Jan 1, 1998

By William Petruk

Mineralogical and image analysis studies have been performed on four volcanogenic base metal ores that contain 0.01 to 4.5 wt% Pb to determine the behaviour of galena during mineral processing. The galena in these ores is fine grained and is poorly liberated in both the primacy and regrind mill discharges. Consequently, low grade Pb concentrates are produced to obtain relatively high Pb recoveries. The Pb concentrates contain many impurities including high amounts of pyrite and sphalerite, and small amount of CU-, As-, Ag-, Bi-, and Se-sulfides. These impurities need to be rejected from the Pb bullion during smelting. The galena commonly contains up to 1 wt% Ag in solid solution with an average of 600 to 1460 ppu for the deposits studied to date. The Ag in galena accounts for up to 65% of the Ag in some ores.

Jan 1, 1990

By M. Tangstad, H. Mølnäs, J. D. Steenkamp

"Temperature affects several aspects of pyrometallurgical systems, including thermodynamics and reaction kinetics. Reliability of temperature measurements in laboratory and plant applications is thus important from process, safety and financial perspectives. This case study briefly introduces different techniques utilized for temperature validation, and demonstrates temperature validation on laboratory scale utilizing the wire-bridge method. Pt/Ptl3Rh thermocouple hot junctions were constructed by mechanically connecting thermocouple wires through a pure metal bridge consisting of copper, gold, nickel or palladium wire. When heating the wire-bridge thermocouple alongside a regular Pt/Ptl3Rh thermocouple, temperature offsets were quantified as the wirebridge thermocouple short-circuited at the melting points of the pure metals. At the melting points of gold (1064°C) and palladium (1555°C), average measured temperature offsets were -2.1°C ± 2.3°C and 0.2°C ± 0.4°C, respectively. Results from the copper and nickel wire-bridges were inconclusive. The paper concludes with a discussion on the potential industrial applications of the technique.IntroductionThermocouples are probably the simplest of all temperature sensors, but are widely utilized due to simplicity, versatility and ability to handle a variety of experimental conditions and industrial applications. Additionally, thermocouples are often the only option in research laboratories requiring high temperature measurements, and a high level of reliability is usually required from thermodynamic, kinetic as well as safety points of view.The study presented here originated from a test program where the compatibility between different types of carbon-based refractory materials and industrial slag produced in silicomanganese furnaces were investigated on a laboratory scale utilizing the static crucible test[l]. Due to the nature of the silicomanganese production process, the compatibility tests were to be conducted at 1600CC[2]. Details of the experimental set-up utilized for the compatibility tests are discussed in the Experimental Set-up and Method Statement section later in this paper."

Jan 1, 2012

By KNona C. Liddell

The ion interaction model Pitzer proposed twenty years ago is today the most widely used method for calculation of osmotic coefficients and electrolyte and single ion activity coefficients in aqueous solutions. This is due in part to the accuracy of the results that have been obtained for many concentrated electrolytes. An additional factor is that, compared to alternative activity coefficient models, there are many more parameter values available for the Pitzer equations. The important features of this model are reviewed. Published parameter values for Co, Ni, Cu, Zn and Fe are tabulated, and applications of interest in the aqueous processing of these metals are described.

Jan 1, 1993

By Francis Vanbellen

Umicore Precious Metals Refining operates an integrated precious metals smelting and refining plant in Hoboken, Belgium. Once a smelter and refiner of complex concentrates, the plant today?s feed consists exclusively of industrial and consumer recycled products, making it the world?s largest recycling facility for precious metals. Unlike the fairy tale of the Frog Prince, it took much more than a princess? kiss to successfully realize this makeover. A completely renewed plant has been built over the past decade. The most visible technological innovation was the commissioning of the Pb-Cu smelter. Its flexibility towards very different types of feed makes it perfectly suited as main entry to the Hoboken flow sheet. A new Cu-leaching & electro winning plant and precious metals refinery make up the Precious Metals Operations (PMO) whose targets are fast throughput and maximized yields for gold, silver and the platinum group metals. The Base Metals Operations (BMO), flexibly process the by-products from the PMO, valorizing ?impurities? like indium, tellurium, selenium and others. Off gas and waste water treatments ensure compliance with strict environmental standards. Precious metals recycling is an art that goes beyond mastering a unique flow sheet. Umicore Precious Metals Refining offers a complete recycling service, taking care of sampling and assaying, metals management and logistics. The quality of this integral service is recognized through the attribution of ISO certifications for our operational activities, sampling and the environmental care. And it?s an art that follows Michelangelo?s experience: ?Art is 5% of inspiration and 95% of transpiration.?

Jan 1, 2006

By Marco V. Ginatta

Current world production, 60'000 ton/y, is exceedingly too small for titanium's extraordinary combination of favorable properties; it should be 1,000,000 ton/y (7% of stainless-steel). Prices that competitively sustain that sales volume are achievable only with electrolytic production, as it is for all other commercial nonferrous metals. But titanium does not have its commercial electrolytic plants yet, because of producers decisions and strategies, scientists works, industrial problems with chloride process, lack of consumers sponsors. Fluoride high temperature process has the advantages of aluminum electrolysis, plus other favorable characteristics specific to titanium and its feed material. One electrolytic titanium potroom replaces several different plants used for sponge production. Production of titanium ingots with zero defect is achieved. The solidified cathode rectangular slabs are suitable for direct rolling.

Jan 1, 2001

By K A. Pericieous

"Magnetic fields have many actual applications in the metals processing industry. Externally applied magnetic fields give rise to electromagnetic (Lorentz) forces formed by the cross product JxB, between the induced current density J and the magnetic field density B. When the metal is in liquid form, the Lorentz force generates motion in the fluid which in applications of practical interest becomes turbulent. In modelling terms, the Lorentz force appears as a source in the momentum equations. In addition, the induced current generates heat (Joule heating) in the metal that is in proportion to J2, with a corresponding source of heat in the energy equation. Whether as heat or as a force, these effects represent action at a distance - a most useful attribute when dealing with hot metal. The Lorentz force is used to stir solidifying alloys, pump liquid metal in conduits, dampen the flow in the meniscus of a continuous caster, levitate metal drops, induce artificial gravity conditions in suspensions or contain liquid metal. Elsewhere, the Lorentz force may be a by-product of some other operation, so leading to wave excitation in aluminium electrolysis cells, or altering the shape of the weld pool in arc welding. Joule heating is most commonly used with applied AC fields, to melt metal in induction furnaces.The author and his colleagues have been involved in the modelling of most of these processes in the past decade. Modelling is not however straightforward, since most of the examples mentioned represent genuine multi-physics challenges. There is a strong coupling between the flow field and electromagnetic field. The addition of a dynamically varying metal free surface and the moving solidus front means the flow, heat and electromagnetic fields need to be computed simultaneously. In situations involving metal containment, the metal free surface position is governed by the interplay of gravity, Lorentz force, surface tension and fluid inertia. Since all the interesting effects often happen in thin boundary layers at the surface due to the skin effect, mesh generation and mesh control during the computation become non trivial problems that need to be addressed. This paper presents a review of numerical methods used to model droplet levitation, semi-levitation melting and cold crucible induction melting of metals. The first method is based on spectral collocation techniques and the second is the traditional FV approach. Steps taken to validate the computations and typical transient results are also given."

Jan 1, 2001

By Hylton McWhinney, Doanh Tran, Jewel Andrew Gomes, George Irwin, Sameer Pallavkar, Md Islam, David Cocke, Mohammad Rafiqul Islam

"High-performance nickel-based nanocrystalline zinc oxide adsorbents have been prepared adjusting Ni/Zn mol ratio of 1 :5 by thermal decomposition, coprecipitation and sol-gel method for selective adsorption of thiophene in liquid hydrocarbon fuels at ambient temperature and pressure. To understand the nature of reactive adsorption of thiophene (C4H4S) on Ni/ZnO, the effect of preparation techniques, morphological and textural structure on the desulfurization activity was investigated. A model fuel (20 mL) consisting of pentane (C5H12) and thiophene was prepared and adsorption experiments were performed by a batch method under ambient conditions. The physicochemical behaviors of the fresh adsorbents were obtained using X-ray diffraction (XRD) with EDAX, scanning electron microscopy (SEM). The sulfur concentration in the mixture was monitored by UV-vis spectrophotometry. The adsorption reaction confirmed that ZnO played a crucial role in taking up S element to convert it into ZnS. The deposition of nickel on ZnO is an innovative approach which takes advantage of the selectivity of Ni towards S-species and the high adsorptive capacity of ZnO support.IntroductionLow temperature deep desulfurization of fuels via selective adsorption of sulfur compounds keeping coexisting aromatic hydrocarbons and olefins intact is receiving increasing attention in the research community worldwide in order to satisfy the upcoming environmental regulations and fuel specifications. The sulfur compounds in the transportation fuels is a matter of concern when global crude oil slate is becoming heavier and sourer and environmental restrictions on both the refining process and the refined products are becoming more stringent. According to the current refinery technologies, the sulfur content in refinery fuel is typically around 300-500 ppm by weight (ppmw) [1-3]. Starting in 2006, sulfur limits in highway diesel and gasoline were set to 15 ppm and 30 ppm, respectively. During combustion sulfur in the fuel are converted to toxic sulfur oxide (SOx) and contributes to air pollution and acid rains [ 4]."

Jan 1, 2011

By V. Jiricny

There is a growing need to process galvanized steel scrap from automobiles, etc., in order to remove the zinc coating that otherwise causes problems in remelting of the scrap in electric arc furnaces. One approach that has moved to the pilot plant stage is that of Metal Recovery Technologies, Inc., of East Chicago (MRI). That company leaches the zinc fiom the scrap with a sodium hydroxide solution. The leached and washed scrap can then be returned to the steel industry. What is left is a sodium hydroxidelzincate solution which must be processed to recover the zinc and the NaOH. Presently, this is done by MRI using electrodeposition on planar electrodes at moderate current density and the resulting zinc is in the form of fine powder which is hard to process into, say, zinc for galvanizing. MRI has supported an investigation of a novel electrode, the spouted bed electrode (SBE), for zinc electrodeposition. In laboratory cells, zinc particles with low porosity have been grown up to 3mm in size. Microanalysis of the deposited zinc showed low level of impurities. DC energy consumption values were usually in the range of 2-2.5 kWg which is well below the energy consumption of the existing cells (and of present-day cells for electrowinning from acid sulfate electrolytes). These results were achieved at current densities (few thousand A/m2) that are much higher than possible with conventional electrodes. Discussion is provided of the scale-up of the cell to a commercial scale.

Jan 1, 1998

By Thomas E. Weyand

Prior to 1975, lead-based paints were commonly used in protecting steel structures. Because of the toxic effects of lead on human health and the environment, their use has been significantly reduced. However, problems with these paints persist when they are removed during normal maintenance by pneumatic blasting with mineral abrasives. Technologies are developed to contain the spent abrasive and paint during blasting operations. This paper reports on A study to identify beneficial reuses for the spent blasting material. Nine samples were gathered from different projects within Pennsylvania. The samples were thoroughly characterized with regard to composition, morphology, and EP and TCLP leach test performance. Potential reuse applications will be reviewed with regard to technical adequacy, economics, and environmental constraints.

Jan 1, 1992

By Gervais Soucy, François Quesnel, Pierre Hovington, Wen Zhu, Karim Zaghib, Jocelyn Veilleux

The properties of lithium titanates anodes in Li-ion batteries are highly dependent on their secondary constituents. While their main phase is usually constituted of Li4Ti5O12, significant quantity of lithium titanates compounds of various stoichiometry are often present, due to either the processing, usage or aging of the material. These may go underreported, as many of these spectrums overlap or display low signal in X-ray diffraction (XRD). Samples of nanosized lithium titanates synthetized by inductive plasma were characterized by XRD and scanning electron microscopy (SEM), as they provide a regular yet typical crystallite size and shape including multiple phases. A Rietveld refinement was developed to extract the composition of these samples. Mass balance through further annealing and differential scanning calorimetry (DSC) enthalpy measurements from phase transformations were also used as identification and validation techniques.

Jan 1, 2015

By Stephen Chryssoulis, Stamen Dimov

Detection and quantification of precious metals (Au, Pd, Pt, and Rh) in spinels and silicate minerals is important for establishing the maximum attainable recovery by sulphide flotation. To achieve this goal subpart per billion (ppb) detection limits are required plus the ability to quantify results. Existing quantitative microbeam techniques (EPMA, PIXE, SIMS, TOFLIMS) have limits of detection in the O. l-200ppm range. Time-of-flight resonance ionization mass spectrometry (TOF-RIMS) is a microbeam analytical technique that allows for the identification and quantification of atomic species in very small quantities. It utilizes a tunable laser source for resonant excitation and ionization of a particular element of interest and has some unique features: elemental selectivity, linear response over a large dynamic range and very high sensitivity. The analysis consist of three steps: (i) the solid sample is vaporized by laser ablation to form a plume containing neutral atoms, (ii) the neutral atoms of a specific atomic element in the plume are resonantly excited and ionized by another tunable laser, and finally (iii) the ions created are mass analyzed in a time-of-flight mass spectrometer. A TOF-RIMS mass spectrometer was developed at AMTEL for trace element analysis of Au, Pd, and Rh in minerals. The spectrometer was calibrated using homogeneous CANMET and NIST reference samples covering three orders of magnitude in concentration. Attained minimum detection limits (MDL=2cr of the background) are in the low ppb range.

Jan 1, 1999