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By V. M. Paretsky

The basic work conducted by Prof. A.Yazawa has demonstrated that in order to ensure single-stage white metal production by autogenous smelting of copper sulfide raw materials, it is most favorable to use highly basic slags, in particular oxide systems CaO-FeO-Fe2O3-Sio2. he special studies have been conducted in the Gintsvetmet Institute to investigate the composition and structure of slags produced on a semi-commercial scale when testing the KFP and FBP processes for white metal smelting, as well as the slag obtained in a full-scale KFP furnace at the Almalyk copper smelter. The investigations conducted have demonstrated why production of high-grade matte or white metal is associated with lower loss of copper in slag in a series: silicate slag I silicate-calcium slag I ferrite-calcium slag.

Jan 1, 2003

By Minna Rämä

Iron containing leach residues like jarosite and goethite from electrolytic zinc production contain many valuable metals and harmful substances. These metals and substances should be removed in order to obtain an acceptable, stable and reusable product, and maximize economic feasibility as well as minimize environmental footprint. In this work, the processing of jarosite leach residue was studied in laboratory scale experiments under oxidizing and reducing conditions at high temperatures. First, the pretreated material was melted and oxidized to produce a melt of metal oxides. Second, the oxide melt was reduced in CO–CO2 atmosphere. Target after the reduction step was to obtain a clean slag and a liquid metal or speiss phase that collects the valuable metals, such as silver. The kinetics of the thermal processing were studied for determining optimal times and conditions for the aforementioned process steps. The preliminary results show that the process is thermodynamically feasible, and the desired phases can be obtained in the experimental conditions investigated.

By Minjun Tang, Jianfeng Zhou, Feng Chen, Linjiang Qing, Xiaolei Song, Yufeng Guo, Tao Jiang

"Reduction swellability index (Rsn and low temperature reduction disintegration index (RDI) of vanadium-titanium magnetite oxidized pellets are harmful to the processing of ironmaking, for example, causing serious gas permeability, decreased yield, higher coke ratio and more furnace dust. Thus, the improvements of RSI and RDI of vanadium-titanium magnetite oxidized pellets were investigated in this paper, including the pretreatment of raw material, additives of dolomite or boric acid, pellets treated in chloride solution and so on. The results showed that damp milling as pretreatment and boric acid added in pelletizing were conducive to the RSI which decreased 5% and 7% respectively, while they were not efficient enough in improving RDI. Dolomite was efficient in improving RSI, but had negative effect on RDI. There was no evidence to show that RSI and RDI would be improved when pellets were treated in chloride solution. Pursuing this further, the mechanism of those improvements were investigated.IntroductionIn the world, vanadium-titanium magnetite utilization is investigated around how to recover iron, titanium, vanadium, and divided into blast-furnace method and non-blast-furnace method according to respective characteristics. Blast furnace method [1, 2] can recover iron and vanadium effectively, but Ti02 cannot be recycled. Non-blast-furnace methods include rotary kiln-electric furnace method, pre-reduction electric furnace method, reduction- grinding method and sodium vanadium-rotary kiln-electric furnace method and so on. [3-7]Comparing to the Non-blast-furnace method, the method of blast furnace smelting has been put into industrial applications. And it has the following advantages: First of all, effective recycling iron and vanadium; Second, technical problems of high titanium slag in blast furnace smelting; Third, it has mature technology in blast furnace smelting."

Jan 1, 2013

By W. Kunda

A laboratory study was carried out on the treatment of sulphidic copper concentrates in aqueous chloride systems under elevated temperatures and oxygen overpressure. Exploratory tests showed that chalcopyriteoxidizes with various chloride salts to form, depending upon the pH of the system, soluble copper chloride or insoluble copper oxychloride salts; the copper can then readily be recovered from the solution or residues respectively. During the leaching, iron was oxidized to iron oxide and remained in the leach residue while the bulk of the sulphide sulphur was oxidized to the elemental form with a minor portion oxidized further to sulphate. The presence of metal chloride salts in the system increased the oxidation rates of chalcopyrite and depressed the solubilization of iron in the system. A systematic oxidation leach study carried out in (1) ammonium chloride and (2) sodium chloride systems showed that the former system required little or no HC1 addition while the latter required 2 mol of HC1 per mol of dissolved copper (plus zinc). The copper was recovered from the cuprous or cupric chloride leach solutions by cementation with iron. Extractions of 99% copper and zinc, 97% silver, and negligible iron were obtained. Sulphur was oxidized to the elemental or sulphate form; the relative proportions of the total sulphur were 60 and 30% for system (1) and 80 and 10% for system (2). A flowsheet for a conceptual process with minimal reagent requirements was proposed.

Jan 1, 1976

By J. E. Dutrizac

The mineral forms of silver, lead and cadmium in the zinc concentrates and the various roaster products made by the Kidd Creek Division of Falconbridge Inc. have been elucidated. In the concentrates, all three elements occur mainly in sulphide form, either in solid solution in the principal ore minerals or as discrete mineral grains. During roasting, Ag, Pb and Cd are preferentially concentrated in the hot cyclone and ESP dusts of the roaster train. Silver is converted to <0.5 µm grains of silver metal and to Ag2S04 which dissolves in or impregnates silicates. Lead is converted to Pb-bearing silicates or to PbS04 and PbO which are present either as tiny free grains in ZnO or as an intergrowth with lead silicate. Lead is also a minor constituent of the ferrite phase. Cadmium occurs mostly as cadmium-bearing zno and ZnFe2o4 , but a significant amount also reports as Cd-bearing silicates or zinc sulphate.

Jan 1, 1990

By Ivan Imris

The iron production has generated many tonnes of very fine residues with high concentration of iron. In addition, during the recycling of galvanised steel scrap in the steel making processes the zinc and lead are largely concentrated in the dust. These kinds of dusts are usually dumped beside the metallurgical plants and cause environmental problems. Therefore the metal recovery from the metallurgical residues has become a major interest not only from the viewpoint of metals recycling but mainly from the viewpoint of environmental land protection. The thermodynamic analyses and laboratory experiments suggested that the metals could be recovered from metallurgical wastes by reduction roasting and by plasma smelting processes. The iron rich pellets with very high metallization may be obtained from metallurgical wastes by the reduction roasting and the inert slag and pig iron could be produced by plasma smelting processes. In both cases the iron rich products are suitable for the steel production. During the reduction roasting or plasma smelting the high volatile zinc and lead metals were removed and enriched as a secondary dust, Zn-Pb concentrate, which is suitable for processing in zinc and lead smelters. Suggested processes are commercially feasible and environmentally friendly without any solid or liquid waste.

Jan 1, 2003

By R. G. Robins

The effective removal of arsenic(V) from process streams and waste waters by precipitation with excess iron(II1) is sometimes attributed to the formation of basic ferric arsenates. The authors have investigated this system extensively using a variety of techniques and conclude that the solid phase produced is iron(II1) oxyhydroxide (ferrihydrite) with arsenic(V) adsorptively bound to the 2-3 nm particles.

Jan 1, 1992

By G. Diáz

A basic technology coping with a wide range of secondary zinc sources has been developed. The process combines an electrowinning stage, a solvent-extraction unit and a leaching procedure. The acidity generated in zinc electrowinning, transferred by the organic solvent to the aqueous raffinate, is reused to leach the zinc secondary materials. The basic process recovering zinc is described in detail. The route recovering other valuable metals such as copper, cadmium and lead associated with zinc is also described. This non-ferrous metals recovery route is advisable for either ecological and/or economical reasons. Main results of an experimental program aiming at the demonstration of the suitability of the process for several feed materials are summarized. Waelz oxides, galvanizing ashes and EAFD coming from different sources were tested in laboratory and continuous pilot plant campaigns. High zinc recovery, low reagents and utilities consumption, and effluents meeting environmental regulation were confirmed. The paper also includes the main results of a feasibility study of an industrial "base case". A mixed raw material and Spanish EAFD and 20,000 ta of zinc ingots production were chosen. The SGH zinc recovery from secondary raw material by means of the clean, safe and profitable Modified Zincex Process has been demonstrated. This reliable technology is ready for industrial application.

Jan 1, 1995

By Simon Lekakh, Von Richards, C. Hank Rawlins, Kent Peaslee

"Batch aqueous leaching and carbonation tests were conducted using industrial steelmaking slags to determine the effect of carbonic anhydrase enzyme as a catalyst. Calcium leaching is a strong function of particle surface area, and the extent can be expressed as a function of time and particle size. Carbonic anhydrase did not affect the calcium-leaching rate, however, it did catalyze calcium carbonate formation to achieve a neutralization time near the theoretical rate. Additionally, carbonic anhydrase modified the precipitate morphology due to accelerated particle nucleation. Time controlled tests in which the pH dropped to ~6 decreased the amount of carbonate produced, and this effect was exaggerated by carbonic anhydrase, while pH controlled tests (>8.5) exhibited the highest rate of carbonation. Because the leaching rate was ~50% faster than the carbonation rate, a further increase in the amount of carbonation may be realized by using carbonic anhydrase however pH must be >10.3.IntroductionSteelmaking slag contains high fractions of alkaline earth oxide based phases (i.e., CaO and MgO) that exothermically form carbonates. Thus, it is being considered as a means of permanent carbon dioxide sequestration. At current U.S. steel production rates, approximately 13-17 million tons/year of slag are generated from basic oxygen furnace (BOF), electric arc furnace (EAF), and ladle metallurgy furnace (LMF) processes [1]. BOF and EAF slag is used as high quality mineral aggregate or cement clinker, while LMF slag, produced at ~15% the rate of BOF and EAF slags, has limited use as blast furnace flux or acid mine neutralization with the majority going to landfill [2]. Based on slag’s chemical nature and immediate availability as a co-product from steel production, the steel industry initiated a project to investigate hydrous carbonate formation in steelmaking slag as a method of sequestering carbon dioxide emitted in steelmaking offgas [3]. The goal of this project is to determine the reactor parameters suitable for the design of an industrial system for treating steelmaking offgas with raw or minimally processed slag."

Jan 1, 2009

By P. N. Anyalebechi

"The effects of solidification rate, initial melt hydrogen concentration, and grain refining on porosity formation in aluminum alloy 2024 have been investigated with unidirectionally cooled laboratory-size ingots. The ingots were prepared from melts containing hydrogen concentration of 0.059-0.27 cm3/100 g and solidified at 0.2-37 °C/s. As expected, the amount of porosity, average pore size, and pore number density increased with increase in melt hydrogen concentration and decrease in solidification rate. However, the effect of solidification rate was greater at the very low melt hydrogen concentration (0.059 cm3/100 g). These results are consistent with reported effects of solidification rate and melt hydrogen content on porosity formation in other aluminum alloys. Interestingly, addition of grain refiner slightly increased the amount of porosity and the average pore size, especially at solidification rates above 1°C/s. IntroductionIn shaped castings and wrought products fabricated from ingots, billets, bars, or slabs of aluminum and its alloys porosity formation is a problem. This is because it compromises their tensile strength, fracture toughness, and fatigue properties [ 1-18]. The pores are usually the crack initiation and propagation sites [6,8,9] and the largest pores tend to dictate the fatigue life of the aluminum products [9,10,14]. Porous regions within an aluminum product probably yield first due to the reduced tensile load bearing capacity, causing the concentration of the strain near the voids which subsequently results in premature fracture. In aluminum alloy ingots, billets, bars and slabs porosity formation is particularly problematic because of its persistence through fabrication and potential for reappearance or exacerbation during subsequent thermal treatment processes before and/or after fabrication [19]. In fact, persistence of microporosity is a serious problem in large thick plates of wrought aluminum alloy products that must be rolled from correspondingly large direct-chill or electromagnetic cast ingots. Some of these thick plate products are machined into large aircraft components that are required in service to withstand multi-directional stresses and to possess high fatigue strength, fracture toughness, resistance to stress corrosion cracking, and strength in the short-transverse direction [1,20]."

Jan 1, 2011

By Jewel Gomes

Produced water (PW) is salty water trapped in the reservoir rock and brought up along with oil or gas during production. It subsists under high pressures and temperatures, and usually contains hydrocarbons and metals. Therefore, it must be treated before being discharged to surface water. Different techniques are being used to treat PW through phase separations, system control and design, and chemical treatments. In this paper, we discuss our experimental results on treating PW through electrocoagulation (EC). The performance of EC was investigated for the reduction of chemical oxygen demand (COD) and metal ions. Effects of different electrodes, residence time, current density, and pH were also studied to optimize the treatment conditions. Different kinds of cleansing agents, such as lime and borax were used to break the buffering effect encountered during treatment. FTIR, SEM/EDS, and XRD were used to characterize the EC-floc and thus to elucidate removal mechanisms.

Jan 1, 2009

By Albert F. S. Seboukens

A 5;6 MVA pyrometallurgical demonstration-scale pilot plant was commissioned at Mintek, South Africa, in 1994, using lead blast-furnace slag and coke as raw materials. The plant included a.d.c. power. supply, two plasma-arc furnaces&apos; and an ISP lead-splash condenser. Slags containing typically 12 per cent zinc oxide and 3 per cent lead oxide are produced as a waste during the smelting of lead in a blast furnace. These slags are a potential: resource for the recovery of lead and zinc. During 1994, about 600 t of lead blast-furnace, slag was proceced through the pilot plant using the Enviroplas process. Zinc and lead oxides were reduced to their respective metals, volatilized, and collected in an. ISP lead splash condenser. Prime Western grade zinc and slags disposable in accordance with current US legislation, were produced. Zinc condensation efficiencies of about 80 per cent were achieved.

Jan 1, 1995

By Richard A. Heckman

Destructive Thermal Technology (DTT) is used in the management of various waste streams. DTT includes Destructive Distillation, Pyrolysis and Classical Incineration. Recent work has more clearly defined the differences in these technologies based upon a more rigorous thermochemical approach. The U.S. Environmental Protection Agency (EPA) has chosen Classical Incineration as the Best Developed Available Technology (BDAT) for the management of hazardous organic wastes. Municipal Solid Wastes (MSW) and Sewage Sludges (SS) are also managed using Classical Incineration. Three environmental problems plague the use of Classical Incineration. Destructive Distillation, on the other hand, avoids these problems. It is an environmentally benign DTT for managing a wide variety of organic waste streams, including hazardous wastes. Thermochemical analysis of the available data on the performance of three types of DTT will be discussed.

Jan 1, 1994

By Malti Goel

"The cost-effective capture of carbon dioxide (CO2) from the point sources for its reduction the atmosphere offers many challenges in materials science. Novel CO2 capturing approaches using chemical, physical and biological methods are in the research stage and are aimed to minimize the cost. Appropriate materials development , which can withstand required temperature or pressure as the case may be for CO2 emanating from coal gas or industrial waste gases form the minimum condition. Other requirements are reclyclability of material and cost of separation. Nano-material composites can be more effective in selective capture of CO2 and can offer solutions for large-scale separation process. Nano-porous material catalysis can enhance the reaction rate of CO2 with other chemicals and thus help in capture of CO2 and convert it into value added products. This paper reviews recent industrial scale developments. In the Indian context, R&D priority areas in CO2 capture process development with a focus on energy industry are presented.IntroductionScience of Climate Change is growing at an enormous pace. With the ultimate goal of stabilization of greenhouse gases in the atmosphere, new scientific approaches are being researched worldwide. A shift in policies from low carbon and no carbon energy sources to fossil fuel sources with capture of carbon and its permanent storage is taking place. The process of carbon capture is both energy and materials intensive and the cost of power generation may increase up to 40% when carbon capture and storage (CCS) technology is implemented. Development of cost effective R&D technology therefore remains the greatest challenge before the scientific community."

Jan 1, 2009

By Huimin Lu, Liyuan Zhao, Zhijiang Gao

The aluminum matrix composite reinforced by graphene was successfully fabricated using high pressure torsion (HPT). With only 0.5wt% graphene, the grain size was reduced to 100nm while that of pure Al was about 500nm. The hardness of the composite increased from the center (64HV) to the edge (120HV) of the sample. Moreover, the tensile strength of this composite reached 197MPa, while that of pure Al was 157MPa. The enhancement in mechanical properties was induced by grain refinement, load transfer from the matrix to the reinforcement and dislocations piled up at the grain boundaries.

Jan 1, 2015

By Evgueni Jak

Pyrometallurgy is an important sector of modern industrial society actively participating in solving current environmental, economic, materials scarcity and other challenges. Recent advances in analytical methods, experimental techniques, thermodynamic, phase equilibria and process modelling tools provide new opportunities to increase the productivity of pyrometallurgical reactors, the treatment of complex feeds and metal recoveries. Fundamental theoretical models can now be used to make a significant next step towards the development and implementation of computerised models describing real industrial processes—Virtual Reactors, and computer-aided smart-decision-making systems that may be called Pyro-GPS by analogy to GPS; these developments can facilitate knowledge-based improvement and optimisation strategies. The implementation of these improvements require ongoing collaboration between researchers, industry and government.

By K. Kalgraf

The motion and stability of the metal/electrolyte interface is determined by Navier-Stokes equation. The equation may be decomposed into two independent equations by taking the divergence and curl of Navier-Stokes equation. The divergence determines the motion and stability of magneto-gravitational waves. The curl of Navier-Stokes equation gives an equation containing only velocity and magnetic field, and states that the magnetic field is driving a circulation pattern in the cell, and this magneto-flow has its own stability conditions. The waves are called Alfven waves, and their stability properties are related only to magnetic field and geometry.

Jan 1, 2001

By J. S. Becker

Technology developed and first implemented in the United Kingdom enables very low grade aluminum scraps containing oils, organics, plastics and ferrous metals to be directly charged, without pretreatment, into a unique melting furnace. The system has been in full scale production for four years. The oxy-fuel-based furnace design incorporates internal afterburning in the furnace&apos;s hot zone, producing excellent thermal efficiency and very low emissions. The furnace is inherently low in NOx. This paper will provide both theoretical background and extensive operating results for this new melting concept. Applications describing both purpose built new furnaces and retrofits of existing reverberatory furnaces will be presented. Extensive operating emissions data will be presented.

Jan 1, 1997

By Heikki Tuovinen

The total utilization of raw materials and energy is the most important criterion when planning. industrial processes. The main goal is clearly to use the raw materials and energy as effectively as possible in order to make the desired products directly in the primary process itself&apos;, or to recycle unused materials and energy either as such, or after cleaning back into the process. However, few industrial processes are so straightforward. Most processes generate by-streams of materials and energy, which cannot be recycled directly and it is namely these by-streams which tend to remain as wastes. These by-streams are slags, dusts, vaporized metals, liquids, slurries, sludges, gases etc. Most base metal processes produce all these by-products. Waste water and gas emission controls and regulations are tightening all the time, so new processes must be developed to keep pace with these requirements. These processes generate more solid wastes, which must be utilized or at least processed into a harmless form landfilling. Municipal and hazardous wastes also contain valuable materials and energy, which must be used to minimize landfilling. The development of processes for these purposes places even greater demands on research and development. The same principles and methods developed for mining, ore dressing and metal refining processes can also be adapted for research and development work on processes for waste minimization. However, the problems encountered are much more complicated and less familiar, demanding more versatile and accurate tools and equipment. This paper presents principles, examples and some references of R & D work on processes for waste minimization.

Jan 1, 1992

By O. Forsén

A new cell construction was designed for the study of the electrochemical behaviour of additives in conditions that simulate real copper, electrorefining. The behaviour of gelatine and thiourea was studied by applying different electrochemical methods, i.e. polarization resistance and voltametric measurements. In this study, individual galvanostatic electrolysis experiments were carried out for 120 hours. The organic additives were introduced to the electrolyte at certain intervals and their concentration was varied in the range &om zero to four ppm. An optical microscope was applied for the examination of copper cathode deposit microstructures. The results show that gelatine has a polarizing effect on the deposition potential of copper whereas even small amounts of thiourea depolarize the electrodeposition of copper. The maximum inhibitor efficiency of gelatine was obtained at a gelatine concentration of slightly lower than two ppm. When both gelatine and thiourea were present in the electrolyte, the depolarizing effect of thiourea exceeded completely the polarizing effect of gelatine. If chloride ions were added to gelatine and thiourea containing electrolyte, the electrochemical behaviour of the system was altered drastically. Chloride ions resulted in the prevailing of polarization effect caused by gelatine while the depolarizing effect of thiourea disappeared in this system. The polarizing effect of gelatine increased until chloride ion concentration of 30 ppm was reached. Also, the above electrochemical phenomena could be detected in the optical examination of copper deposit microstructure.

Jan 1, 1995