Search Documents

By U .. C. Rojas, J .. C. Gomez

"Fire Refined Copper (EI Teniente Three Stars) has been produced at Caletones Smelter of Codelco Chile since almost the beginning of its operations.Due to changing features of the copper market, together with the targets on technical efficiency and productivity, it has become more and more relevant for copper industry to reach both, good final product quality and a proper environmental control.At present, copper refining process at Caletones Smelter takes place in two cylindrical tilting furnaces, where solid fluxes are injected through horizontal tuyeres into the molten bath. (Fig. N2 1)Solid reagents are pneumatically conveyed and injected into the liquid copper bath attaining excellent solid - liquid contact, so the impurities removal efficiencies are found to be high. Same injection tuyeres are used to introduce both oxidising agent (normal air) and reducing agent (reformed gas) into the molten bath. Air or nitrogen is used as conveying gas for solid reagents, depending on the process stage.This pap~r gives a fundamental description of the process and industrial results related to the injection of blend of sodium and calcium carbonates to remove arsenic and antimony, silica and granulated reverberatory slag to remove lead and a mixture of calcium carbonate and mineral coal to reduce the selenium content of the fire refined copper."

Jan 1, 1996

By Hoda Emami

In this study, a combined pyrometallurgical and hydrometallurgical technique has been designed and used to recover rare earth mixture elements (REE) and cobalt from a NdFeB magnetic waste. while addressing the cost of reagent and process facility. This process can be adjusted to different magnetic wastes regardless of their compositions. Prior to the leaching, the magnet scrap was pretreated by two rounds of roasting (750°C in air) and a mechanical grinding in between, to convert iron metal to ferric oxide. Subsequent leaching was performed using optimized conditions (pH, temperature and retention time) where the extraction ratio of REE to Fe III is the highest. After removing iron content from the leachate (pH ≈ 3), REE was precipitated selectively and purified further. The produced REE concentrate reaches 99% purity with 85% recovery in a single run. The cobalt oxide was isolated from the PLS as a by-product with 99.8% purity.

By Yanhui Liu, Xuewei Lv, Pingsheng Lai, Chenguang Bai

The purpose of this paper is to study the effect of slag basicity on the Si content in stainless steel master alloys prepared by smelting reduction of Fe-Ni-Cr sinters. Theoretical analysis focusing on the gas, slag and alloy phases of the smelting reduction process at 1600°C was carried out by thermodynamic calculation software----FactSage, showing that the increase of CaO within the slag can result in the decrease of Si within the master alloy. Experiments were also carried out in vacuum melting furnace at 1600°C , and chemical analysis method was used to detect Si content in the alloys. When the MgO content is 9.00%, the experimental results were consistent with the calculated values. However, when the MgO content rises up to 14%, the content of Si in the alloy reaches the maximum when SiO2 equals to 22.81%.

Jan 1, 2016

By M. D. Strachan

Technical & Procurement Services Limited (TECHPRO) in Ashford, Kent, UK, have been appointed as Project Managers for the major rehabilitation of the Copper Smelting complex of Nkana Division, Zambia Consolidated Copper Mines Limited, (ZCCM) Zambia. In outline, the overall scope covers three main areas: a) Transfer and implementation of new technology into Zambia for the production of primary copper. b) Replacement of gas collection and gas treatment circuits to guarantee high quality feed to the acid plants. c) Completion of a number of minor projects in the copper smelter and associated utility plants to complement changes in the primary smelting technique. This paper describes the Project Management methodology and style used by TECHPRO to tackle typical problems that arise in retrofit projects of this type. Reference is made specific aspects of the smelter projects to illustrate solutions to the problems. The subjects. addressed highlight the complexities not only of having a -Client 5,000 miles from the Project Office, but also the difficulty of co-ordinating and controlling the performance of min sub-contractors who are also geographically distant.

Jan 1, 1991

By Axel Hoppe

Although Tantalum is not usually regarded as a precious metal, its pricing structure is very similar to that of Silver. Different from precious metals, Tantalum has only industrial applications and its use is about 1000 metric tons per year. The intrinsic value of Tantalum already in .the past was a driving force for its recycling. Based on these facts the Tantalum industry world-wide is approaching the closed-loop concept of its recycling. A detailed material flow of Tantalum processing as well as recovery of residues and used products will be discussed.

Jan 1, 1995

By P. Chris Pistorius

An example is presented to illustrate the joint effect of local reaction equilibria and mass transfer limitations, for reactions during ladle refining of steel. The example relies on some of the kinetic principles that David Robertson has employed to quantify many metallurgical processes. In calcium treatment of alumina inclusions in aluminum-killed steels, solid CaS forms as an intermediate reaction product. During subsequent reaction, CaS disappears and calcium aluminate forms; at the same time, aluminum and sulfur dissolve in the steel. Kinetic analysis shows that the rate of this reaction is not limited by mass transfer of dissolved aluminum and sulfur away from the reacting inclusions. The reaction rate is likely limited by transport of dissolved calcium. This example also illustrates the use of FactSage macros for kinetic modeling.

Jan 1, 2014

By Naixiang Feng, Shaohu Tao, Zhihui Wang, Yuezhong Di

"A novel vacuum aluminothermic reduction lithium process was developed in present work which used lithium carbonate, alumina and calcium oxide as raw material. The process mainly contained three steps. The first step is that LiA102 clinker is prepared in ambient environment, then metal lithium is vacuum extracted from LiAl02 clinker with aluminum power as reducing agent, and the last step is that alumina is leached from the reduction residue with a mixture of sodium hydroxide and sodium carbonate. The results show that the lithium reduction ratio can be over 95% under the conditions of reduction temperature 1423K, reduction time 3h, and aluminum excess 20%. The main components of reduction residue are CaO· Al203 and 12Ca0·7Alz03. The alumina leaching rate of calcium aluminate in residue is over 80%. High-whiteness aluminum hydroxide can be obtained by carbonation precipitation of the reduction slag leaching solution.IntroductionWith a density about half of water, lithium is with the lowest density of all solids, mere 0.5 g/cm3 at 20 °C [l]. Lithium is widely used in aerospace, aviation, nuclear-generated power and electric battery industry. Nowadays, over 90 % of the world's primary lithium is produced by molten salt electrolysis [2-4]. But the development of molten salt electrolysis will be effected by some factors: cost, environment, and so on. Vacuum thermal reduction may be used extensively in future because of its low-energy consumption, high-purity and short-cycle."

Jan 1, 2013

By G. C. Gullo, H. Wabusseg, P. J. Uggowitzer, H. Kaufmann

"The basic concept of New Rheocasting (NRC) is described and the application of wrought alloys with this process is discussed. Practical experiments with the aluminium alloy AIMgSi I are explained. For this alloy the proper NRC - casting temperature was determined by using Thermo Cale - computer software and DT A and the essential processing conditions are shown. In the experiments the melt was taken from an aluminium holding furnace and cast into NRC steel cups. After controlled cooling the resulting slurries were cast into a 4-step die on an UBE HVSC 350 Squeeze Casting machine. The characteristic microstructural values such as grain size and shape factor were measured and compared with classical casting alloys. The influence of the wall thickness of the step part (6 mm, 10 mm and 14 mm) on the microstructure is described. Tensile properties in different heat treatment states are compared with characteristic prope1ties of the same alloys in forged condition. The ew Rheocasting - process CNRC)The NRC process is a recently developed new semi-solid processing method which allows the production of pore-free, pressure tight components.In the NRC process a fu lly liquid, but only slightly superheated melt is taken from a holding furnace and poured into specially designed steel crucibles, which are placed on a carousel next to the Vertical Squeeze Casting machine. In this ,NULL,slurry maker'· globul ar a-Al grains grow, following forced homogeneous nucleation at the cup wall [ 1, 2]. In the few minutes during which the melt is cooled to sem i-so lid processing temperature, a stable ske leton of a-Al phase forms. The resulting slug keeps a cylindrical shape during its slide into the sleeve of the Vertical Squeeze Casting machine, where it is cast into shape."

Jan 1, 2000

By Cheng Pan, Xuewei Lv, Guibao Qiu, Chenguang Bai, Meilong Hu

"Physic-chemical properties of slag at high temperature play an important role in the pyrometallurgical process of production of ferronickel alloy. It determines the operation efficiency, metal recovery ratio, energy consumption and the distribution of elements like S and P between the slag and metals. In the present work, the effect of MgO content in the slag on melting features and viscosity of the slag was investigated. The MgO content in the SiO2-CaO-MgO-Al2O3 -FeO in the quinary slag system varied from 14.5% to 22.5%. The results shown that all slag samples begin to softening at the same temperature, the softening temperature, melting temperature, flowing temperature decrease with the increase of MgO content when the MgO content is in range of 14.5 and 20.5 pct mass, and when MgO content up to 22.5 percent, the temperatures increase sharply. Besides the inflection point temperature of viscosity-temperature curve increase with the increase of MgO when the MgO content is in range 16 and 22.5 pct mass.IntroductionNickel is very important to modern society, without it, we would not be able to share many things in our daily life, such as airplanes, computers and many stainless steel appliances in our homes and workplaces1.. It is the essential element of the stainless steel making, and about 65% of the nickel consumed in the world is used to make stainless steel2., so with the increase of stainless steel, the nickel production and demand has continued to increase3.Nickel is produced from two distinct ore types: nickel sulfide deposits and oxide nickel laterite deposits. The great majority of world’s known nickel resources are contained in laterite deposits3.. The laterite ores are normal classified into two groups: the high-iron laterite ore and high-magnesia laterite ore1. Typical composition of high-magnesia laterite ore is in the range 1-3%, and these ores are suitable for pyrometallurgical process to produce ferronickel4."

Jan 1, 2012

By Richard D. Hangi

Process mineralogy techniques are uniquely applicable to industrial problems related to the extractive metallurgy of nickel, cobalt, and associated metals. Reflected 1ight microscopy, together with selected determinations by scanning electron microscopy-energy dispersive spectrographic analysis and electron probe microanalysis, provides the means to identify the ore minerals cobalt and nickel ores, determine the abundance of each ore mineral, assess the extent of intergrowth between the cobalt and nickel minerals and other ore and gangue minerals in the ores and concentrates, and predict the potential success of cobalt and nickel extraction by grinding, flotation, pyrometallurgical, and hydrometallurgical treatments. In addition, the extent of locking of the cobalt and nickel minerals with each other and with the gangue minerals can be directly observed by reflected light microscopy. Where ores have been treated by hydrometallurgical procedures, reflected light microscopy can serve to determine the causes of excessive leach consumption. Finally, the partitioning of cobalt and nickel between high-temperature synthetic phases produced by pyrometallurgical treatment can be precisely determined by process mineralogy techniques. Case histories from cobalt and nickel deposits illustrate the value of applied mineralogical techniques in the study of cobalt and nickel ores, beneficiation, hydrometallurgial, and pyrometallurgical products.

Jan 1, 1993

By Ki Joo Sim, Sung Beom An, Joonho Lee, Minsoo Shin

Valorization of the electrical arc furnace oxidizing slag by coke was carried out by the reduction of iron oxide in the slag. Since the reduction of iron oxide by solid carbon is an endothermic reaction, supply of heat energy is required. In addition, slag has a low thermal conductivity; traditional fuel injection is not suitable for this reaction. Microwave can be used to supply heat energy to the system. Commercial oxidizing slag was reduced by coke under the microwave irradiation (1.7 kW, 2.45 GHz). The maximum recovery ratio of iron was 87%. In addition, slag composition modification was attempted to use the remaining slag for a mixture in cement clinker. Free-CaO in the slag was successfully suppressed, and the use of the remaining slag as a potential mixture was confirmed.

Jan 1, 2014

By Paponetti B. . A.

Gold is usually recovered by cyanidation, thiourea leaching and amalgamation, however the efficiency of these technologies, in the case of refractory ores, is low ever when fuie grinding is practised. For example, .if the gold particles are included in sulphide minerals, the leachant cannot reach them, so they are often lost in the tailings. Hence .it is first necessary to break the sulphide crystals by preliminary treatment such as roasting, nitric .acid oxidation, pressure leaching and bacterial oxidation and then apply a conventional extractive technique for satisfactory gold recovery. This paper describes the effect of biological pre-treatment with Thiobacillus ferrooxidans) on the? extraction ? and? recovery of gold by conventional cyanidate. leaching from; a refractory arsenopyrite ore from Golcuck (Turkey).

Jan 1, 1991

By J. K. S. Tee

Using a novel method, zinc has been selectively removed from galvanized steel scrap on a laboratory scale. The separation is based on thermodynamic principles: during chlorination in air-chlorine (10:l) mixtures at 800 OC, zinc forms a volatile product (zinc chloride) while iron does not chlorinate as its oxides are more stable than the respective chlorides. As much as 92 % of zinc is removed from the surface of steel within 10 minutes. This process overcomes tedious and costly preparatory stages associated with leaching - electrowinning methods.

Jan 1, 1999

By V. P. Bystrov

Vanyukov process has been developed and investigated in Russia over the last 25 years. It has been established that various kind of material could be treated in Vanyukov process. The results of the pilot plant trials as well as industrial experience are presented in this paper.

Jan 1, 1993

By Tadashi Aiura, Yasuhiro Miura

"A small amount(0.2mass%) of Scandium(Sc) was added to the 7.NOl and 5083 Al alloys as a refiner and stabilizer of microstructure, and the resulting microstructures were discussed in comparison with the effects of the conventional additives. The followings are summarized: 1) in the as-solidified structure, a ·decreased tendency of constitutional supercooling and increased solubility of Mg were recognized for the Sc-added 5083 alloy. Sc is a -better microstructure refiner for the 7N01 alloy than Zr, in a sense that it does not suppress the favorable effect of· coexisting Ti. 2) Sc effectively suppresses recrystallization both in the 5083 and 7N01 alloys. 3) The rod like primary Al3Sc crystals formed during solidification, as well as the fine dispersion of Al3Sc precipitates formed by subsequent heat treatment, can act as a strong recrystallization suppresser. IntroductionThe 7N01 and 5083 alloys are the most popular industrial Al alloys and they are widely' used for various structures because of their superior properties. Fine macro and micro structures of the materials are required for obtaining acceptable sec resistance,consistent appearance of anodized surface and good weldability, as well as good mechanical properties. In order to produce fine grain structures, transition metals, such as Cr, Zr, and Mn, have been conventionally added.It has been reported that Sc is an efficient refiner [l, 2] and can be an alternative for the conventional and also suppresses recrystallization in Al alloys [3,4]. Scandium is the lightest transition element and forms an equilibrium intermetallic phase. The equilibrium phase, Ll2-Al3Sc, is coherent with the matrix, and of _spherical shape. A fine dispersion of the spherical precipitates is obtained by quenching and aging after solutionizing annealing. The authors have already reported a part of the experimental results on the effect of Sc on the as homogenized microstructure of the 5083 alloy [5]. In the present study, the effects of Sc on the macro and micro structures of the industrial high strength Al alloys(7N01 and 5083) for extrusion are investigated, and the superior role of Sc as a grain refiner is shown"

Jan 1, 2000

By Filiz Sahin

This paper presents a synthesis of TiB2 via carbothermal reduction method using a mixture of TiO2, B4C and C prepared in molar ratio of 2:1:3. Reduction experiments were carried out in a high temperature graphite furnace in a graphite crucible under argon atmosphere at different time (0, 15, 30 and 60 min.) and temperatures (1400, 1500 and 1600 °C). The products obtained were investigated using XRD technique.

Jan 1, 2008

By Zhang Libo, Li Wei, Peng Jinhui, Guo Shenghui, L. Jing

Partially stabilized zirconia ceramics (PSZ) were prepared by microwave sintering using natural baddeleyite which was obtained by flotation of baddeleyite ore as starting materials. Because of using natural baddeleyite as raw and the process producing no waste, it realized shorter process, energy savmg, environmentally-friendly and non-damage processing. In this work natural baddeleyite stabilized with 3.8wt.% CaO were sintered at 1300°C for 60min in a multi-mode 2.45GHz microwave furnace. Microwave sintering could fast heating and sintering. Besides that, microwave sintering could heat materials wholly, low the sintering temperature, improve the materials properties and save energy. X-ray spectrum displayed the product composed by the tetragonal phase and monoclinic phase that also showed the product was PSZ. Fine and uniform microstructures were observed in the product through scanning electron microscopy. PSZ which was with high density was confirmed by the method of the Archimedes technique.

Jan 1, 2011

By N. Tsuneyama

Sumitomo Metal Mining Company has been operating Waelz Kiln at the Shisaka Works for 12 years to recover zinc and lead from electric arc furnace (EAF) dust. To increase the capacity and cut down the operating cost, some improvements have been carried out resulting in the capacity of 60,000 t/ y of EAF dust as compared with 32,000 t/ y in 1977. The current capacity is equivalent to 20% or EAF dust generated in Japan. The number of workers has been decreased by the introduction of an automatic control system, and the productivity per worker is now twice as much as 10 years ago. This paper will describe the progress of the operation at the Shisaka Works after the previous? paper reported in "Zinc' 8 5? and summarize the status or EAF dust recycle in Japan.

Jan 1, 1990

By Tiejun Chun, Jian Pan, Deqing Zhu, Zhiyong Ruan

"In this paper, the desulfuration of pyrite cinder pellets was carried out. Phase analysis shows that most sulfur of pyrite cinder exists in the form of elementary sulfur. Most sulfur was removed in preheating stage. 81.25% sulfur was removed and the average SO2 concentration of exhaust gas was 1365ppm when the pellets were preheated at 950oC for 9 min. The final product, assaying 62.42wt%Fe and 0.02wt%S content at 96.88% desulfuration was achieved under the conditions of preheating at 950? for 9 min and roasting at 1200? for 15 min, which can be used as the burden for blast furnace.IntroductionPyrite cinder, as a subsidiary product of sulfuric acid production by roasting of pyrite ores, was solid waste in sulfuric acid enterprises. According to the statistics, the annual production of pyrite cinder is about 15 million tons in China. Besides, there is lots of pyrite cinder deposited for many years [1-3]. The pyrite cinder consumed in the cement and other industries as auxiliary additives only accounts for less 30% of its total discharge and the left is stored in waste pond, occupying much land and polluting environment in China [4-5]. Moreover, pyrite cinder contains iron between 30-63% which can be utilized as a cheap raw material for ironmaking by sintering or pelletizing processes, which can not only prevent pollution but also provide cheap raw materials for ironmaking [6-7]. However, compared to traditional iron ore concentrate, pyrite cinder possesses higher sulfur content."

Jan 1, 2012

By Nobuo Kikumoto

Recently, the treatment of industrial waste materials has been a serious social problem here in Japan. Filling them in ponds is now strictly prohibited due to a limited land area and incineration method is also regulated as not to generate DXN. In these conditions, Onahama Smelter has begun to treat shredder dusts (SD) of car at reverberatory furnaces to recover various metals such as copper, gold, silver and palladium without generation of DXN. The total volume of these dusts is expected more than 1 million metric tonnes a year in Japan. Onahama Smelter is now planning to treat about 20% of them in the near future by using tonnage oxygen. In this paper, the heat balance, control method of DXN and treatment of these dusts in reverberatory furnaces are described. DXN : Dioxin (The generic term of PCDD and PCDF)

Jan 1, 2000