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By G. Cifuentes

When the applied current is interrupted in a copper electrowinning plant, and then is back in operation, the lead anodes tend to corrode. In order to decrease the corrosion, the damage protective ("back up") anodic currents are applied during the period of interruption. The current work aims to establish the effect of the concentrations of sulphuric acid, copper and cobalt on the anode corrosion, to quantify the effect of various anodic protection levels on the anode corrosion and to propose a method to select the appropriate protective current density value.

Jan 1, 1999

By Kent D. Peaslee, Lifeng Zhang, Edith Martinez, Yufeng Wang

The current study investigated the multiphase fluid flow, heat transfer, solidification of the steel, and the motion and entrapment of inclusions during the centrifugal casting process using FLUENT software. User-defined functions (UDFs) were developed to add velocity with a value related to the rotation speed and radial distance to the solidified steel, to exert a centrifugal force to the motion of inclusions, and to add the entrapment condition of inclusions at the solidifying shell and export the entrapment locations of the inclusion. The calculation shows that there are two peaks of inclusions along the thickness of the produced tube: one at close to outer surface and another one close to the inner surface of the tube. With a larger rotation speed, inclusions tend to be entrapped more towards the inner surface. The calculation agrees well with the industrial measurements.

Jan 1, 2012

By S. D. Prosser

The earliest record of slag in the world was the discovery of the remains of a copper blast furnace in Southern Israel, which has been carbon dated at 3500BC, nearly 6,000 years ago. Slag in Australia is a much more recent phenonenum with the first iron blast furnace commencing operations in 1848. The early days of metal smelting in Australia were marked with many company failures due to a variety of reasons. This paper traces the progress of metal and slag production from those early days up to the present times

Jan 1, 1994

By Johan Sundström

Anhydrous DyC13 was prepared by dehydration of DyCl3?6H20 in a fluidized bed using both batch- wise and continuous feeding. A gas mixture with varied composition of argon and HCl was used. The productivity was high, reaching values of 0.25 mol H20/m2-st during the reaction step 6- 1 and 0.062 mol H2O/m2.s during the reaction step 1-0. The product was free from hydrolytic compounds, such as DyOCI, if control of inlet gas composition versus temperature was achieved. From the results of various experiments, some relations between HCI-concentration and temperature in order to avoid hydrolysis have been deduced. The fluidization process efficiency decreases drastically after the dehydration has proceeded down to about 10 mol% of remaining water. Therefore, in a final treatment the last traces of water were removed by slowly purging gas through a packed bed. The water content could thereby be reduced to less than 1 mol%.

Jan 1, 1997

By W. L. Dalmijn, E. A. Schokker, N. Fraunholcz, P. C. Rem

Many processes developed for the mechanical processing of Automotive Shredder Residue (ASR) suffer from high processing costs. We offer a distinct concept for low-cost mechanical processing still allowing high value-added recycling of the recovered materials. The basic idea behind this approach is to produce saleable pre-concentrates at the lowest possible costs that can be further processed in existing separation facilities. Our process includes screening, size reduction and magnetic separation. Preliminary studies showed that fibers in ASR are magnetic due to adhering rust particles allowing separation into a fiber fraction and a non-magnetic rigid fraction by high-intensity magnetic separation. The fiber fraction is most suited for thermal processing. The rigid fraction mainly consists of plastics and rubbers with up to 10 wt.-% of non-ferrous metals, some inert material and copper wires. This fraction is very well suited for mechanical processing by, e.g., sink-float separation in existing metal separation plants. The non-metal fraction can be processed further to recover the plastics and rubbers. The process proposed in this study is expected to be substantially cheaper than full thermal processing. In addition, as it mainly relies on existing separation facilities, it can be applied in the short term.

Jan 1, 2000

By K. Osseo-Asare

Rate laws for the hydrogen reduction of metal ions are typically of the form: [r = -d[M(II)]/dt = k[M(II)]xPy2H] where k is an apparent rate constant, [M(II)] and PH2 represent dissolved metal concentration and hydrogen pressure respectively, while x = 0 - 1 and y = 0.5 - 2. Half-order dependences have been reported for some M(II)/H2 systems; however, no satisfactory explanations have been offered. In an effort to bridge this gap in our understanding, the published precipitation rate data (for M(II) = Cu(II), Ni(II), and Co(II)) are reviewed (with emphasis on the reported reaction orders) and compared with the corresponding but limited electrochemical polarization data. Based on the available literature on the electrochemical kinetics of the M/M(II) and H2/H+ systems it is demonstrated theoretically that, under certain conditions (e.g., in the presence of electron-conducting solids), the rate of the M(II)/H2 reaction can be expressed as: [-d[M2+]/dt = k[M2+]2/1P2/12H] It is concluded that electrochemical processes probably play an important role in the hydrogen reduction of metal ions, especially for systems that involve heterogeneous catalysis.

Jan 1, 2003

By N. Lohja

Metallurgical industries are generally big producers of solid residues of various kinds. In contrast with the past where environmental sensibilities were not so elevated and the accumulated mass of these residues were not considerable, these days the solid residues are everywhere scrutinized among others in term of their harmful environmental impact and as possible materials for valuable elements extraction or secondary utilisation. As a case study, the present paper gives an overview of the solid residues discharged by the metallurgical industry in Albania for the last tens of years. The results of two monitoring study on the solid residues of copper, iron and ferrochromium producing industries are also summarized. The first deals with the origin, quantities and chemical composition of these residues and the second one with the impact of harmful ingredients of these residues in the environment. Some methods for the processing of these solid residues are also proposed in order to ensure a clean environment and to make not just possible but also economically viable their secondary utilisation. This work is part of a bigger cooperation project among local institutions and foreign expert companies such as Flogen Technologies Inc and other in various countries that will not only monitor the situation but will also develop appropriate technologies for treatment of these specific residues.

Jan 1, 2006

By Dirce H. Jacomo, Jaciele G. Teixeira, Anibal Y. Abreu Castillo, EsperidianaA. B. Moura, Yalquiria A. Silva, Rene R. Oliveira, Michelle G. Gomes

"Composites consisting of poly(vinyl alcohol), starch and sugarcane bagasse ashes, using glycerol as plasticizer agent, were prepared by solution casting method. Composites prepared were subjected to electron-beam radiation treatments, at radiation dose of 50 and 80 kGy using a Dynamitron electron beam accelerator, at room temperature in the presence of air. The composite samples obtained were evaluated for their water absorption, mechanical and morphological properties.1. IntroductionThe potential of biodegradable polymers and more specifically of biocomposites obtained from agro-resources have long been well established [1-3]. Starch, derivate from variety of botanical sources (cereals, legumes, and tubers) is widely available raw material and one of the most studied and promising agro-resources for the production of biodegradable polymers as matrices for biocomposite applications. However, starch itself is very brittle, hydrophilic and its mechanical properties are very poor for many applications [3 - 5]. The blending of starch with conventional polymers is a promising approach to improve its drawbacks. Recently, many efforts have been made to blend starch with biodegradable synthetic polymers [5, 6]. Polyvinyl alcohol (PYA) is a particularly well-suited synthetic polymer for the formulation of blends with natural polymers, as it is highly polar and can also be manipulated in water solutions, and depending upon its grade, in functional organic solvents as well [3, 7]. PY A has been reported to be an option to blend with starch. Most of the starch/PY A composites have been prepared by casting. However, it is well known that starch/PY A composites has poor in water resistance and mechanical properties after absorbing water [3,8]. Attempts to improve the mechanical properties and to decrease the water absorption property of the starch/PY A composites are made by adding the cross-linkers and plasticizers. Park et al. prepared starch/PY A/citric acid films by the casting method. They also studied the effect of (spell out) citric acid on the mechanical properties and water resistance of composites [9]. Zhai et al. prepared the starch/PY A hydrogels using electron-beam radiation [10]. Different kinds of lignocellulosic fibers have been investigated in blends for formulation of biocomposites."

Jan 1, 2013

By Mokka N. Rao

In this experimental investigation, the principal operating parameters of the spirals HC 1870 and HG 8/7 are determined for the hydrogravimetric separation of the friable siliceous iron minerals of the Piar Distric, Venezuela. Mineralogical characterization including optical microscopy of feeding materials and the products after separation are presented. Comparative analysis is made of effectiveness of productivity between the two spirals.

Jan 1, 1999

By John L. Uhrie

Oxide stockpile leaching operations can realize increased copper recovery and decreased acid consumption from in-situ generated acid resulting from the oxidation of intentionally introduced pyrite recovered from mill tailings or other sources. While all oxide leach ores can benefit from pyrite addition, low acid consuming ores can show remarkably increased recovery and net acid generation; however, more highly acid consuming ores will show benefit more exclusively through increased copper recovery. Additional work shows that the value of highly acid consuming ores can be optimized by balancing copper recovery against acid consumption.

Jan 1, 1999

By Z. S. Wronski

In rapidly solidified Fe-Nd-B permanent magnet alloys, the content and distribution of Nd-rich intermetallic and Fe-phases determine coercivity Hc and remanence Br. Consequently, microstructure plays a crucial role in deter- mining the (BH) max-product of permanent magnets fabricated from these alloys. A study has been initiated to investigate changes in microstructure and the effects on magnetic properties as the material is processed from arc-melted ingot to melt-spun flakes and finally to a product consolidated by hot-forming. Anisotropic magnetization behaviour has been observed in rapidly solidified flakes after low-temperature annealing.

Jan 1, 1989

By Shunichi Ajima

PT. Smelting Co. was established in February, 1996 to construct and operate the Gresik Smelter and Refinery. The construction work of first Copper Smelter and Refinery in Indonesia was completed in the end of August, 1998 and it was put into the integrated test operation in December, 1998. Gresik Smelter and Refinery is designed to produce 200,000 tpy of copper cathode from copper concentrate supplied from Grasberg Mine of PT. Freeport Indonesia Company in Irian Jaya, Indonesia. As by product 592,000 tpy of sulfuric acid, 382,000 tpy of slag, 31,000 tpy of gypsum and 480 tpy of slime will be produced in the full operation. Major processes applied at Gresik Smelter and Refinery are: Smelter: Mitsubishi Continuous Copper Smelting and Converting Process ( Mitsubishi Process ) Anode Casting: Continuous Casting of Copper Anodes with the Hazelett Twin Belt Caster Refinery: ISA Process Acid Plant: Lurgi Mitsubishi Double Contact Process

Jan 1, 1999

By Gregor Mori

Niobium electrolysis has been performed in a NaCl-KCl-NaF-NbCls electrolyte. By means of electrolytic .refining the average valency of the niobium ions was determined as well as the crystallization behaviour. In electrowinning runs the influence of the main parameters such as temperature, RF (mole ratio F/Nb), chemical prereduction, niobium content of the melt and current density has been determined with respect to low specific energy consumption and high purity of the deposit.

Jan 1, 1995

By R. Upadhyaya

Aluminium alloy matrix cast composites have been synthesised by incorporating fine graphite powders (0.5 - 20 µm size) and chopped carbon fibres (6.5 pm P). 3-6 mm length) by liquid metallurgy technique. Incorporation of these second phase materials exceeding 6-8 wt% invariably resulted in agglomeration of the dispersoids and sometimes leading to even total rejection. It was found that small additions of mischmetal (1-3 wt%) during dispersion resulted in better incorporation without much agglomeration of the dispersoid as evident from the macro and micro structures of the composites. Further, the additions of mischmetal increased the volume of the effective incorporation of the dispersoid even to the extent 50- 60%. The mischmetal addition results in a significant increase in the power factor of the stirrer motor indicating an apparent increase in the viscosity of the system. The higher viscosity of the melt increase the shear transmission conditions within the melt during stirring thereby breaking the agglomerates of the dispersoids. The increased viscosity of the melt seems to be due to the formation rare earth - aluminium inter metallics precipitation, as observed in the metallographic studies, thereby making the process a "pseudorheocasting? technique. A provisional patent has been filed based on this work.

Jan 1, 1989

By D. N. Collins

A sampling program was conducted in which both spoon and isokinetic sampling techniques were used to collect samples from the reaction shaft. The samples were then characterised by chemical, XRD and mineralogical analysis. Further information was acquired by measuring the oxygen potential and temperature at the bottom of the shaft using disposable probes. Comparison of the results of the two sampling methods showed that the spoon samples were devoid of material less than 25 m. Sulfur analyses on the samples provided information on the extent of reaction, plume shape and recirculation patterns. Disposable probe measurements showed the measurable particle temperatures ranged from 1150 to 1700 °C and that the material falling into the bath had a normalised oxygen potential similar to the slag. These latter measurements combined with the sulphur elimination and mineralogical analyses provided further information on the extent of reaction and enabled the reaction sequence to be ascertained.

Jan 1, 1999

By G. P. Chaudhari, F. Warchomicka, M. Dikovits, V. Pancholi, C. Poletti

"The hot formability of a microalloyed steel with 0.16 wt-%C modified with N is studied by using processing maps. Compression tests of cylindrical samples are carried out using a Gleeble®3800 simulator in the range of temperature between 750 -1000°C and strain rates between 0.01-100 S-1. For this alloy, an Ar3-temperature about 740°C is determined by means of dilatometry. Processing maps are calculated using the modified dynamic material model developed by Murty and Rao for different logarithmic strains. For the instability map, the parameter Kj developed by the authors in previous works is used and compared with other instability values. Softening in the flow curves provoked by induced ferrite during deformation at low temperatures and low strain rates is reflected in the n-value. Light optical microscopy (LOM) and electron back scattered diffraction (EBSD) measurements are used to study the microstructure of the hot deformed samples to determine the deformation mechanisms active and to verify the processing maps.IntroductionProcessing maps offer a good possibility to optimize thermomechanical process parameters and to avoid defects in the products. Prasad et al. [1] developed the processing maps using the dynamic material model (DMM) and Murty & Rao [2] modified it. Processing maps consist of two superimposed maps: the dissipation efficiency and the instability map. The processing maps can be used to detect areas with a good hot formability, which are normally related to restoration of the material by dynamic recovery/recrystallization. For a high dissipation efficiency value and no instabilities, a good hot formability is predicted. In the DMM no storage of energy takes place and so the material is considered essentially dissipative, this is only true for high temperatures and high strain rates [1]."

Jan 1, 2012

By Tuula Mäkinen

In 1959 Outokumpu started up an integrated nickel smelter and refinery at Harjavalta. The flash smelting ? Peirce-Smith converting route was applied, and the high-grade converter matte was further refined to nickel cathodes by leaching and electrowinning. In 1995 the production capacity was increased from 17 000 mtpa to 52 000 mtpa, based on the Direct Outokumpu Nickel Smelting Process. The additional refinery capacity is based on hydrogen pressure reduction, producing nickel powder and briquettes. The smelting operation is currently part of Boliden Group and the nickel refinery part of OM Group. In the DON technology, high-grade nickel matte with low iron content is produced in the flash smelting furnace directly without subsequent converting. The metal values in the smelting slag are recovered in an electric furnace as an iron containing Ni-matte. The mattes produced differ from the conventional nickel mattes in many respects, and therefore focused R&D efforts have been made in order to cope with their melting points, fluidities and settling properties. When developing and operating metallurgical processes it is crucial to manage and control the characteristics of the products as well as by-products generated in different steps of the process chain. The low melting points of the high-grade nickel mattes produced in the DON furnace, particularly those low in copper, have pointed out challenges in the furnace design, in particular in the hearth and its thermal engineering. Also key issues of the DON technology are smelting of high-magnesia concentrates, the recoveries of nickel and copper, as well as those of PGM`s and cobalt. These factors can be affected by a proper selection of the process concept, and the operational conditions in the processing vessels. This paper deals with the experience of the DON technology gained over the first ten years of operation, including the significant environmental impacts. Selected results of the thermo-dynamic modelling of DON and EF mattes and high-magnesia slags are reviewed, with the reference to the mattes produced. Also the design principles of the FSF and EF will be discussed.

Jan 1, 2006

By Vladimir Lobanov, Vladimir Skorohodov, Andrew Evdokimov, Ural State Technical University 19, Boris Radionov

"The bulk of raw materials in metallurgy of secondary platinum metals are the wastes such as multilayered ceramic-metal systems, e.g. the spent catalysts of the chemical and petrochemical industry, automobile catalysts, etc. Due high chemical resistance of a ceramic basis the extraction of platinum metals by leaching even at very fine crushing is poor. The study of sorption leaching of platinum and a palladium from the spent automobile catalysts are carried out. The average content of PGM is 0.5%. A few methods of raw materials sampling were compared: 1) direct hydrometallurgical leaching of platinum metals from the fine-grained catalyst and atomic absorption analysis of the obtained solutions; 2) fusion to a metal or sulphidic collector of precious metals with the alloy analysis by direct spectrometry; 3) fusion with dissolution of a precious metals collector and atomic absorption analysis of PGM in solutions. Leaching allows detecting out no more than 90% of a palladium and 80% of platinum. Fusion to a collector gives the best results at the chemical ending. Researches on sorption leaching are executed. Under optimum conditions the extraction of platinum metals to concentrates is comparable with similar indicators of collector fusion.The large part of raw materials in metallurgy of secondary platinum metals are the multilayered or tridimensional ceramic-metal systems, in particular the spent catalysts of the chemical and petrochemical industry, automobile catalysts, ceramic-metal condensers, etc. The content of the sum of PGMs can be from hundreds grams per ton to several percent. For processing of such materials the hydrometallurgical methods of platinum metals leaching by various reagents are used commonly. High chemical resistance of the ceramic basis covering the metal particles causes low recovery even at very fine grinding. Other fundamentally different method of catalysts opening includes dissolution of the ceramic basis in the solutions of hydrofluoric acid and the subsequent recovery of platinum metals from insoluble residue. Application of this method is associated to use of corrosive medias and appropriate equipment. Fusion of the specified materials with collecting of PGM by copper, nickel or lead at the specialized enterprises provides higher extraction in semiproduct. At the same time, complexity and duration of the subsequent extraction of platinum metals concentrates causes high total cost per unit. Thereby this method is economically acceptable only for rather poor raw materials (no more than 0,1%). Undoubtedly, that the raw materials with the high content of PGM are reasonable to process by individual technology. In the present work the processing of some kinds of ceramic-metal raw materials, particularly automobile catalysts (neutralizers) with various collectors at the conditions of a target fusion are investigated."

Jan 1, 2008

By Zhang Hengzhong

Ni-P-Fe slag is the by-product in the production of phosphate fertilizer in blast furnace with nickel contained serpentine ore as the raw material. It contains nearly 5-7% Ni, 65-7( Fe, and 10-12% P. The slag is very hard to process, it neither dissolves in aqueous ammonia, nor in sulphate acid. In the stiff the technique to treat the slag in order to extract valuable nickel was developed, it essentially consisted of the processes of roasting, leaching, separation and purification. Nickel sulphate was prepared with this method.

Jan 1, 1993

By G. Roderick Eggert

Material criticality reflects the degree to which a raw material is both necessary and subject to supply-chain risks. This study compares the criticality of selected raw materials from the differing perspectives of the manufacturing sectors of China, the European Union, Japan and the United States.