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By Sergio Neves Monteiro

This work had as its objective the characterization of a waste material, steel slag, generated from an integrated steel plant, with a view to its recycling and incorporation into red ceramics fabrication. The characterization was performed in terms of chemical composition by X-ray fluorescence (XRF), particles size distribution, X-ray diffraction (XRD), thermal analysis (DTA/TG) and scanning electron microscopy (SEM). The results indicate that the steel slag presents high amount of Ca, Fe, Mg and Si. The weight loss of the steel slag at temperatures above 800oC is associated with calcium carbonate decomposition. The coarse particle size of the steel slag is inadequate for its direct recycling into red ceramic fabrication. It is necessary to screen or to grind the waste. As a possible solution, it is suggested that screening or grinding the steel slag to a convenient particle size distribution would allow its successful industrial incorporation into red ceramics products.

Jan 1, 2006

By Daniel Bennett

There are few methods currently applied towards on-line bulk mineralogical analysis. Yet on-line knowledge of process mineralogy could potentially provide large benefits, such as increased extraction efficiency or resource optimization. The work described in this paper involves the development of radio frequency methods for bulk mineralogical analysis. Some resonances that occur in the radio frequency spectrum are mineral specific, and potentially allow quantitative estimation of mineralogy in an ore stream. Results will be presented on the specific detection of chalcopyrite. Initial quantitative measurements investigating matrix effects have indicated the feasibility of on-line mineralogical estimation using radio frequency techniques.

Jan 1, 2006

By Pinai Mungsantisuk

Keywords: Pd-Ni alloys, Pd-Fe alloys, Pd-Co alloys, Magnetostriction, Magnetic Properties The presence of congruent melting minima, the occurrence of ferromagnetic transition over a large composition range, and FCC type crystal structure make Pd-Ni, Pd-Co, and Pd-Fe based systems attractive candidates in our search for materials with no rare-earths, large low-field magnetostriction, and good mechanical properties. The presence of paramagnetic-ferromagnetic transition over a broad range of composition also provides opportunity for fundamental studies. In this work, we have examined the magnetic and magnetostrictive behavior of Pd-Ni, Pd-Co, and Pd-Fe alloys over the entire composition range. Alloy sample rods were prepared by arc melting and casting. X-ray diffractometer was used to obtain lattice parameter data. Magnetostriction was measured along the rod axis using strain gages. Magnetic properties were measured using a vibrating sample magnetometer.

Jan 1, 2005

By Sayavur Bakhtiyarov

Keywords: Rheology, Viscoelastic, Oil In this paper we present the results of the rheological property measurements on viscoelastic composite materials used in oil industry. Laboratory experiments were carried out to determine important thermophysical, rheological and mechanical properties of the test materials using both the standard commercial and in-house made equipment. The composites with the paramagnetic particles (?-iron oxide) are exhibited a significant magnetic memory after magnetic treatment. The measured value of the yield stress after the magnetic treatment increased almost twice in comparison with the yield stress value of the magnetically untreated composite. The yield stress of the composite material exponentially decreases with time and reaches its magnetically untreated value after 15 hours. The yield stress also increases with the amount of the paramagnetic powder additive, and it reaches a maximum value at 8 wt-% of this additive. The obtained results provide valuable information for computer modeling of the viscoelastic fluid flow in pipes of complex geometry.

Jan 1, 2005

By Elaine Araújo

Since the ancient times, clays were used as decolorant material for various types of oils. These clays were called ?decolorant clay?. They have the property to decolor dye materials present in mineral oils, plants and animals. Biofuel is a fuel derived from biomass of live organisms. As biodiesel is produced from renewable sources, the generation of employment due to industrial scale production may cause a reduction in the dependence on foreign diesel importing, as well as the reduction of air pollution by the addition of biodiesel to diesel. This study aimed to develop a technological process to decolor post- consumption oil to be applied as biofuel. The results were characterized by techniques of XRD (X-ray diffraction), X-ray fluorescence and FTIR (Fourier Transform Infrared). It was observed that the post-consumption oils presented a higher decoloration result after treatment with the Brazilian clay.

Jan 1, 2009

Sm-Co alloy is a kind of magnetic material with high power and has been applied in modern industry widely. In this study, the wet chemical co-precipitation was developed for synthesis of the Sm-Co alloy oxide precursor. The thermodynamic analysis of the studied system was done to clarify the solution behavior theoretically based on the thermodynamic equilibrium and simultaneous equilibrium. Then, the experiments were done to address the various effects on the wet chemical process, including solution pH, reactant concentration, dispersant, reaction temperature and time, etc. It is found that by precise control of the process, the Sm-Co alloy oxide precursor was synthesized with fine crystallization and special size & size distribution.

Jan 1, 2005

By M. N. H. Khan

CSIRO has been experimenting with supersonic flows as a method of rapidly quenching metallic vapours. Cooling rates above 106 °C/s have been achieved. The supersonic flow conditions are achieved by adiabatic expansion of the vapour through a Laval nozzle into a vacuum chamber. This paper will describe the basic physics of the process, outlining computer fluid dynamic (CFD) modelling of flow in the nozzle, the effects of different flow conditions on the condensation process and discuss the practical design issues associated with operating supersonic nozzles. Results obtained from a CFD model of the nozzle, which compared two methods of incorporating condensation, showed that inclusion of condensation substantially changes the conditions in the nozzle. Most noticeably, the effect of condensation produces a region in the nozzle where the temperature remains almost constant.

Jan 1, 2006

By Zeljka Pokrajcic

Crushing and grinding, or comminution, circuits are the most energy intensive process of a mineral processing plant. Comminution involves the physical size reduction of an orebody to a particle size sufficient for recovery of the mineral values. However, the comminution process remains inherently inefficient. The inefficiency is a result of the operating nature of comminution devices such as grinding mills, where transfer of energy between grinding media and particles in unconstrained and completely random. New comminution circuit design strategies are presented in this paper. The aim of the new strategies is to improve the overall efficiency of the comminution process and reduce the total energy consumption of a comminution circuit. The energy efficient strategies include the: ? rejection of coarse size liberated gangue from the comminution circuit and further downstream size reduction ? use of more efficient grinding and crushing equipment ? the selection of coarser particle product sizes to alleviate the increased energy intensity required to achieve finer product sizes Singularly and when combined, these energy efficient strategies can significantly decrease the overall energy consumption of a comminution circuit. This paper also explores the financial impact of certain energy efficient strategies using an analysis tool called EcoNomics?. It shows that substantial financial gains can be made by including more efficient technologies and methods in comminution circuit design.

Jan 1, 2010

By Carlos Frias

The lead-acid battery recycling is a major industrial activity (more than four million tonnes recycled lead per year) that generates large amounts of toxic wastes such as lead slag, mattes and acidic sludge, besides airborne emissions. This is a waste-producer industry that needs a definitive solution to avoid its negative environmental impact and getting a sustainable lead production. That is the principal target of the CLEANLEAD technology, which properly combines both hydrometallurgical and pyrometallurgical routes aiming to get zero-waste production, reducing the use of energy and resources in all phases of battery reprocessing, and consequently, greatly decreasing the operating cost. There will be no toxic emissions to land, water or air, and obtained products are pure lead metal or pure lead oxide, and commercial gypsum instead of waste sludge.

Jan 1, 2006

By Emma Arakelova

?2?2 (98 %) vapour passed through a reactor at 25Pa where a Zn? target was placed at 273K- 373?. Experiments were carried out on a flow- type vacuum device. ?2?2 decomposition on Zn? surface accompanied by formation of a Zn-containing volatile complex which transferred to the gas phase, and Zn? deposited on a substrate at condensation. As the substrate, five sequentially located quartz cylinders were used at 293K- 423 K (?n). Decomposition of the Zn-containing complex on quartz substrates carried out as a first- order reaction. ?The complex decomposition constant (??) increased with the substrate temperature (?n=293 K, ??=7.05 sec-1;?n = 373 K, ?? = 87 sec-1;?n = 423 K, ?? =158 sec-1). ?The complex decomposition constant did not practically vary when the target temperature increased; the complex formation rate increased slightly.

Jan 1, 2006

By Anat Deepatana

Bioleaching of nickel laterite ores is the extraction technology based on the use of heterotrophic micro-organisms and their organic acid products to dissolve metals from oxide minerals. This study examined the chemical leaching kinetics of limonite and nontronite ores with metabolites including citric, lactic and malic acids. The leaching process was found to follow the chemically controlled model. The leaching kinetics was found to be significantly influenced by the acid strength or dissociation of acids in solution. Although increasing the acid strength increased the rates of leaching, this trend was not indefinite. An optimal acid concentration that defined the fastest leaching rates was identified for each acid. The amenabilities of the minerals hosting the nickel and cobalt in limonite and nontronite to organic acid leaching were also established.

Jan 1, 2006

By Pietro Navarra

Cooling of critical furnace equipment to produce freeze lining is of particular interest as many metallurgical processes are intensified while attempting to prolong campaign life. This idea was combined with high-capacity heat pipes in the design of a copper slag launder. The design methodology of the launder and heat pipe cooling system is examined in this paper. With reliable material properties and operating conditions, CFD was used to quantitatively predict the skull thickness and the corresponding heat load applied to the slag launder. The operational limitations of heat pipe technology were considered and an appropriate cooling system was incorporated into the model. Parametric modeling was used to simulate several launder and heat pipe configurations. The generated results were then used to optimize the design of the launder, which was built and tested in August of 2005. The experimental performance of the cooling system is evaluated and compared with the model results.

Jan 1, 2006

By Andrey V. Tarasov

To carry out a physicochemical substantiation of a transition to ?soft? modes of reduction of calcine obtained by desulfurizing roasting of nickel concentrate produced as a result of copper-nickel converter matte separation in a nickel anode production circuit, an analysis has been conducted of the macrokinetic behavior of actual calcine samples in the presence of gaseous H2-CO mixtures and solid reductant additives. Within a temperature range of 900°C to 1100°C the main regularities typical of the calcine reduction process with individual gases (H2, CO) also take place when using a gaseous mixture. Under the conditions of low-temperature (900°C to 1000°C) nickel oxide reduction with products of fuel oil conversion in the presence of coke, the role of the latter is insignificant from the technological viewpoint. As a result of the present investigations, we have obtained analytical expressions of macrokinetic parameters of the reaction interaction within the [NiO] calcine-H2-CO-C-CO2-H2O-O2-N2 system.

Jan 1, 2005

By Emma Arakelova

An increase in concentration of a Zn-containing volatile complex for synthesis of ZnO films was investigated when processing their target by ultraviolet radiation emitted by mercury lamp. The experiments were carried out using a flow-type quartz reactor. ZnO tableted target was preliminarily irradiated during 2 to 7 hours. H2O2 (98%) vapor at 25Pa passed through the reactor with ZnO target at 373K. As substrate material, five subsequent quartz cylinders were used at 423K. The experiment lasts 4 hours. H2O2 decomposition on ZnO surface was accompanied by formation of a Zn-containing volatile complex which passed in gas phase and decomposed on the substrates with isolation of final ZnO. The concentration of the Zn-containing volatile complex (N) in gas phase increases with UV pre-irradiation time (t) (without irradiation N = 1.05 1011 particles/cm3; after t=2 hours, N = 5.19 1011 particles/cm3, after t=4 hours, N = 9.95 1011 particles/cm3; after t=7 hours, N = 1.86 1012 particles/cm3.

Jan 1, 2006

By Carlos Maurício Fontes Vieira

In the present work a ceramic body, fabricated using a mixture of clays and sand, for roofing tiles, produced in Campos dos Goytacazes, north of the State of Rio de Janeiro in Brazil, was characterized. Characterization was performed by X-ray diffraction, thermo analysis, chemical analysis, particle size distribution determination and plasticity. In addition, technological properties related to water absorption, linear shrinkage and flexural rupture strength were determined in samples fired at 700, 900 and 1100oC. The results showed that the investigated ceramic body has satisfactory plasticity and presents a refractory behavior during firing due to the predominantly kaolinitic nature of the clays.

Jan 1, 2006

By Jacques J. Eksteen

Metallurgical accounting around toll treatment smelters pose a number of challenges. This paper reviews the requirements for good sampling practice, and how conflicting requirements for good furnace operation and design often makes reliable closure of the metallurgical balance tenuous at best. Typical physical causes of variance and bias will be identified. The propagation of error (in the form of variance) will be discussed for a copper smelter.

Jan 1, 2006

By Juliana Gutiérrez-Paredes

Keywords: Slag, chromium oxide, recovery, stainless steel Experimental and theoretical work was performed to estimate the effect of slag basicity and amount of reducing agents on the reduction of chromium oxide from the slag which interacted with molten steel at 1600°C. The slag system contained CaO, MgO, SiO2, CaF2 and Cr2O3 together with Fe-alloys (Fe-Si and Fe-Si-Mg). The CaF2 and MgO contents in the slags were 10 mass % each; Cr2O3 was 25%. The amount of the ferroalloys ranged from 12.5 to 50 g per 100 g of slag. The (CaO+MgO)/SiO2 ratio was held at 1 and 2. The Cr yield was determined using both Fe-alloys as reducing agents. Some estimations were made to determine the theoretical effect of temperature, slag basicity, (CaO+MgO)/SiO2, and amount of reducing agents in the slag on the chromium recovery. The FACT (Facility for the Analysis of Chemical Thermodynamics) computational package is used to determine the equilibrium between the slag and molten steel.

Jan 1, 2005

By Pengfu Tan

A thermodynamic model of KIVCET lead smelting process has been developed. The model has the capability to predict the distribution behaviors of Pb, Zn, Fe, S, O, As, and heat balance in KIVCET direct lead smelting furnace. The compositions of lead bullion, matte, slag and gaseous phases, and heat balance are calculated. The effect of the ratio between oxygen and feed on the chemistry of the smelt and heat balance of the coke checker has been simulated and discussed. The thermodynamic model also helps to understand the tapping issue of the lead bullion. In this paper, some applications of this model in the industry have been presented.

Jan 1, 2006

By A. Deepatana

Bioleaching of nickel laterite ores is based on the use of heterotrophic fungi organisms and their metabolites (organic acids) to dissolve nickel and cobalt from oxide minerals to form metal-organic complexes. Metal recovery from this process using an aminophosphonic acid based chelating resin (Purolite S950) was investigated as a function of metal concentrations, complexing agent including citric, dL-malic and lactic acids. Batch adsorptions were conducted using synthetic leachate solutions of nickel and cobalt with concentrations from 15 to 2000 mg/L prepared in 0.01 and 0.1 M organic acids. Adsorption equilibrium data were interpreted using the Langmuir, Freundlich and Dubinin-Kagner-Radushkevich (DKR) models. The results showed that equilibrium adsorption data for nickel-organic complexes followed the Freundlich model and those for cobalt agreed with the Langmuir model. It was observed that the maximum adsorption capacities of nickel and cobalt were 3.26 and 10.48 mg/g resins respectively. These were achieved in metal complexes prepared from 0.01 M lactic acid. Metal elution was conducted using 2 M nitric acid. High metal recoveries were achieved from low metal concentrations but were found to decrease with increasing metal concentration. The results suggest that effective recovery of nickel and cobalt from low concentration of metals, such as those generated from bioleaching operations, can be achieved suitably using chelating resins.

Jan 1, 2006

By M. Hochenhofer

Due to economic aspects and environmental regulations recycling of slag and waste from ferroalloy production became a very important issue for the companies during the last years. The treatment of slag depends prior on the composition, especially on their content of valuable metals and impurities. The final aim should be a total re-use of these materials in the industry e.g. cement industry, pig-iron production etc.. Therefore, to reach the required physical and chemical properties for a further use, possibilities of a metallurgical treatment have been investigated. The conditioning of slag with a high V-, Mo- and P-content via reducing metal bath showed to be one alternative. To determine the optimal process parameters, practical investigations with different slag compositions and thermodynamic calculations were carried out.

Jan 1, 2006