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By P. R. Taylor

Titanium carbide and titanium diboride powders have been successfully synthesized by direct treatment of ilmenite concentrates in a non-transferred arc thermal plasma reactor. Methane gas was used as the reducing agent and boron oxide was used as the boron source in these processes. Free energy minimization plots were used to predict the behavior of each system under different molar ratios and operating conditions. Products were characterized by XRD, SEM and chemical analytical techniques. The average size of the ceramic product is in the submicron range. Metallic iron apparently is finely deposited on the surface of the titanium carbide or titanium diboride particles. Minor impurities such as silica, manganese and zircon were converted to the carbide form.

Jan 1, 1995

By Masayuki Kudoh, Tohru Maruyama, Yohichi. Ito

When hypo-peritectic carbon steel is quenched during unidirectional solidification, the region of fine columnar grain is observed. It is classified into two coexisting phases. One is coexisting phases of liquid, delta and gamma in the upper part of the region, and the other is coexisting phases of delta and gamma in the lower part of the region. To form the coexisting part of the three phases means that solidification in this experiment proceeds in non-equilibrium state. The size of the narrow side of one fine columnar grain coincides with the arm spacing of a primary dendrite and this result is the same as the hyper-peritectic carbon steel. However, the boundary of the fine grain in the hypo-peritectic carbon steel is formed in different location from that of the hyper-peritectic carbon steel. The former is formed in the skeleton of the dendrite, while the latter is formed in the interspacing of the dendrite. The region of the fine grain changes suddenly to that of the coarse grain when the delta phase in the coexisting part of two phases disappears completely. Therefore, the delta phase in the hypo-peritectic carbon steel might prevent the growth of gamma grain. In order to recognize it, ferrite formers such as Mo, V and Ni are added in the sample. Then, the longitudinal length of the fine columnar grain extends in the sequence of the no addition, Mo, V and Nb.

Jan 1, 2000

By Takashi Fujii

In the OG (Osaka Gas) process which includes a fusion process of sewage disposal sludge in coke bed knowledge of molten and fluid properties of the sludge are most important to controll the process in good condition. Thus, the softening and melting temperatures and viscosity were measured by the sessile drop technique and a rotating viscometer. Obtained results are summarized as follows: Melting character of sludge slag is varied according to their composition, but closely related to CaO/SiO2 ratio in ordinary sludge and to CaO/(Cr2O3,+Al2O3+P2O5) ratio in Cr2O3 containing sludge. Fluid property of sludge slag has a correlation with optical basicity or Riboud parameter, However, the correlation is poorer than that of metallurgical slags. Especially, chromium oxide containing sludge shows high viscosity and behaves somewhat different manner from ordinary sludge.

Jan 1, 1992

By Yuanbo Zhang, Yongbin Yang, Guanghui Li, Zhengwei Yu, Yufeng Guo, Tao Jiang, Xiaohui Fan, Youming Hu

"Composite agglomeration process (CAP), as an innovative method for preparing blast furnace burden, was developed and has been put into operation in China. CAP is different from traditional agglomeration processes of iron-bearing materials involving sintering and pelletizing. Compared to the traditional agglomeration processes, CAP is characterized by several strengths such as permission of diverse iron-bearing materials in production, obvious improvement of permeability in the feed bed, decreasing the fuel consumption and remarkably increasing the productivity of sintering machine. Furthermore, the use of the composite agglomerates prepared with CAP is capable of obviating the negative effects caused by the differences in quality of sinter and pellets on the operation of blast furnaces. This paper mainly presents an overview of the principle and applications of CAP.Development Background and Principle of CAPhe traditional agglomeration processes including sintering and pelletizing have been the two predominant methods for preparing ironmaking burden from iron-bearing materials. Sintering is a way for agglomeration by heating the coarser fine ores (general granularity 0~10mm). The mechanical strength of irregular porous sinter is obtained by the solidification of molten phase at high temperature process. It has been shown that the production of high basicity sinter (R=1.8~2.2) is characterized by low energy consumption and high efficiency compared to low basicity sintering. Meantime, the finished high basicity sinter is characterized by good mechanical strength and metallurgical performance. Pelletizing is another way for agglomeration by firing wet green pellets, which are balled from the fine grained iron ores or concentrates. Based on the differences of chemical compositions, the finished pellets can be divided into acidic oxidized pellets, fluxed pellets, magnesium-bearing pellets, and so on. The acidic oxidized pellets are the dominant products of modern pelletizing."

Jan 1, 2012

By Baozhong Ma, Yonglu Zhang, Yongqiang Yang, Chengyan Wang, Yongqiang Chen

During the past decades, slurry electrolysis (SE) has been implemented commercially for the processing of bismuthinite and complex Pb-Cu bearing gold concentrates. Recently, SE was proven effective for the treatment of As-rich antimonic gold concentrates. Laboratory test results suggest over 98% of the antimony was extracted, while the extraction of arsenic and gold was less than 0.5%, and that of iron was less than 6%. Moreover, the cathode antimony contained over 98% antimony and less than 0.3% arsenic. Considering the disadvantages of traditional 3 kA slurry electrolysis baths, such as smaller electrode area, reduced capacity, and greater electrode deterioration, the authors have developed an innovative 12 kA slurry electrolysis bath equipped with mesh and fence type titanium alloy electrodes. Furthermore, the technique was successfully used within a pilot scale plant yielding results similar to those observed in the laboratory. The technique yielded ametallic antimony ingot of 99.9% purity after arsenic removal via the addition of Na2CO3.

Jan 1, 2014

By W. Zhao

Several years ago, Reddy and Blander presented upriori model for calculating the sulfide capacity of binary silicate melts. It is modified now to apply to CaO-AlO 1.5 melts at different temperatures and compositions. Our predictions are in very good agreement with the available experimental data. From a comparison of binary calcium aluminate and calcium silicate systems, higher sulfide capacities are obtained in aluminate systems. The sulfur can be removed from hot metal more effectively by adding aluminate melts.

Jan 1, 1995

By Jinjing Dua, Jun Zhua, Kuiren Liub, Bin Wang, Xiaolei Wua

V-Ti-Fe as hydrogen storage alloy was prepared by reducing metal oxides with a metallothermic reduction method. The deoxidation process of the V-Ti-Fe alloy was performed by electro-deoxidation and vacuum induction melting method, respectively. The results showed that the content of oxygen impurity can be controlled at about 0.2wt% after electrolyzing for 240min. Both the maximum values of hydrogen absorption capacity and the effective hydrogen desorption capacity are 2.65wt% and 1.01wt%, respectively. The deoxidization effect of vacuum induction melting process is more remarkable, with Ce as the reducing agent. It is found that Ce addition is beneficial for reducing the componential segregation, promoting the hydrogen absorption activation of V-Ti-Fe alloy. When m(Ce)/m(alloy) is up to 5%, the oxygen content has been reduced to 0.05wt% and the maximum hydrogen absorption capacity and the effective hydrogen desorption capacity are up to 3.36wt% and 1.85wt%, respectively.

Jan 1, 2015

By P. F. Stratton, M Huggahalli, N Saxena

"Several studies have been carried out to determine how the optimum atmosphere conditions in the heat treatment of metals can be established for a given product by using different gas injectors and varying atmosphere flow rate and composition. The most common approach taken to gain insight into furnace atmospheres has been to use commercial computational fluid dynamics codes and examples of their use are shown. However, the complexity of these codes, the difficulty in establishing boundary conditions, their cost and computational demands limit their usability in solving day-to-day production problems.A simplified, web-based model of a furnace atmosphere is described where the conservation equations are solved to determine the composition profiles of the atmosphere in the furnace. Although the model is restricted in scope to certain types of furnace, it is shown to give better results than CFD when boundary conditions are uncertain. The application of the model to the understanding of existing furnace conditions and to determining ways of optimising the use of gases are discussed. IntroductionThe important role of protective atmospheres during heat treatment of metals, furnace brazing of assemblies and soldering of printed circuit boards is well established. The atmosphere in the furnace prevents air ingress and oxidation of the parts, helps flush away any flux or binder from braze and solder pastes and provides an important mode of heat transfer [1]. In a batch furnace having typically one or two gas injectors, the gas utilisation and process can be optimised by minimising air leaks and mantaining atmosphere homogeneity with fans or other atmosphere circulation techniques. In a continuous furnace, however, atmosphere optimisation is more difficult as furnace inlets and exits can also let in air. The atmosphere requirements of different stages of heat treatment, brazing or soldering vary [2]. Achieving these atmospheres in different sections of the open-ended furnace is a relatively complex task. Methods such as atmosphere zoning and the use of physical curtains and gas injectors have evolved with time, though it is hard to predict how effective these techniques will be for a given furnace and process. Experts in the field tend to rely on experience and rules-of-thumb rather than scientific method to achieve the required results."

Jan 1, 2001

By Hideo Nakae, Hideki Yamaura, Toshiaki Kimura

"In 1968 J. N. Reding et al. suggested processes for fabricating composites. According to their patent, decompression atmosphere, which occurs during the reaction between magnesium and oxygen and/or nitrogen in the closed system, causes the spontaneous infiltration of melt into narrow spaces such as ceramic preforms. However, they did not report the proof of this phenomenon or the industrial manufacturing method. Therefore, this research measured the pressure change among SiC particles surrounding molten aluminum. As a result, the pressure reduction during the Mg reaction was identified. Moreover, the existence of Mg3N2, which improves the wettability between Al alloy melt and SiC particles on the interface, was observed on the surface of particles. Applying these two phenomena, a new process for the manufacturing of cast discontinuously reinforced aluminum composites (DRA) was developed. This new method is expected to produce DRA without additional pressure.IntroductionWith the increasing demands for light-weight materials in the automotive and aerospace industry in recent years, ceramic particulate reinforced aluminum matrix composites called DRA (Discontinuously Reinforced Aluminum Composite) have been receiving significant attention because of its lightness, superior abrasion resistance, high heat conductivity and low thermal expansion [1-3]. Consequently, DRA was considered for electronic parts such as heat-sinks or a base for power semiconductors, and began to be applied for automotive parts including brake drums, discs, cylinder liners, pistons and so on [4- 6]. However, high machining cost is one of the significant barriers to widespread use ofDRA. One solution to this problem is the adoption of cast DRA that can be produce to near-net shape, reducing machining cost."

Jan 1, 2000

By Jorge Alberto Soares Tenório, Denise Crocce Romano Espinosa, Kellie Provazi

"The purpose of this paper is to study metal separation and recovery from a sample composed of a mixture of the spent household batteries main types, using liquid-liquid extraction and metals electroplating. The electrolytes preparation consisted: grinding the waste of mixed batteries, reduction and volatile metals elimination using electric furnace and acid leaching. From this solution were studied the liquid-liquid extraction using Cyanex 272 [bis(2,4,4-trimethylpentyl) phosphoric acid] with tributyl phosphate as extracting agent. After study of solvent extraction and stripping has been recover and separate the metallic ions and with electroplating was recovered the manganese, copper, nickel and cobalt in their metallic forms.IntroductionCurrently has increased the consumption of electronics devices such as mobile phones, laptops, wireless phones, comcorders, etc., especially portable devices that use batteries as a power source, and consequently has increased the disposal of such material.Increased consumption of this devices is caused by several factors including increased popularity of consumer electronics devices, has become essential of modem life. Therefore, recycling of batteries is important because its reduces the waste of raw materias and nonrenewable resouces used in manufacturing these materias and help prevent potential environmental risks associated with improper disposal of these products together with household garbage.The batteries have a very diverse composition, containing metals such as zinc, lithium, nickel, lead, mercury, cobalt, cadmium, iron, copper, manganese and rare earths. Some components may contain hazardous materials such as cadmium, mercury and lead, and can contain acids or bases.This research line is a pioneer in dealing with a single process for recycling a mixture with all batteries types, for only processes that exist in the world are based on the recycling a mixture with all types of batteries, for only processes that exist in the world are based on the recycling of one or two types of batteries [1-4]. This process necessitates the previous separation of the batteries by type."

Jan 1, 2012

By Darryl Lovato, Ramiro Pereyra, Daniel S. Schwartz

"During an annual inventory of nuclear material, a plated steel container which contained plutonium oxide failed. The container had been packaged for temporary storage but had been overlooked and remained in storage for more than 23 years. Although it was determined that the failure occurred through the slip-top rim, a metallurgical evaluation was requested to help to determine the integrity of the container.Optical metallography and scanning electron microscopy were used to analyze the character and degree of corrosion in the container. The depth of corrosion, measured at approximately 10 µm, did not pose a threat to the integrity of the container. However, the corrosion morphology and chemistry did suggest that a galvanic cell had developed between the tin and steel from the condensation of water. The morphology also suggests that the attack of the steel took place over a series of cycles due to changes of the environment.IntroductionMetallographic analysis was requested as part of the investigation into the mechanism of the failure of a slip-top container (#38621) containing plutonium oxide (PuO2) powder. The container had leaked during a special nuclear material (SNM) annual inventory causing contamination and closure of the vault. A photograph of the container and interior container is shown on the right in Figure 1. An initial investigation established that the source of contamination was the consequence of the failure of multiple layers of containment. Initially by the deterioration of the interior plastic bottle and polyvinyl chloride (PVC) bagout bag, and finally through the lid and steel container interface at a location where tape had not adhered properly [1]. Although the source of the breach was established, it was determined that metallographic analysis was important to establish the extent of deterioration of the steel container."

Jan 1, 2008

By Xiaojian Zuo, Yihua Han, Qingguo Xue, Jingsong Wang, Lintao Wang, Rongzong Lan

"Using the facility of reduction experiment, the low temperature reduction pulverization and reduction behavior of sinter in oxygen blast furnace (OBF) were studied. Through analyzing the results, the difference of pulverization and reduction behavior of sinter in OBF and conventional blast furnace (BF) were discussed. Furthermore, the effect laws of reduction temperature and the content of CO and H2 on reduction behavior of sinter were studied. Also the controlling step of iron oxide reduction was discussed. Compared with BF, the low temperature reduction pulverization of sinter became serious at 773 K; reduction rate became faster at 1173 K; reduction time became less and final reduction degree was increased in OBF. With increasing of H2 and CO contents, the reduction of sinter was promoted. The reduction process was controlled by interface chemical reaction at the earlier stage and by interface chemical reaction and internal diffusion at the final stage.IntroductionThe new ironmaking technology of Oxygen Blast Furnace (OBF) is most likely to be used in large-scale application process. The concept relies on the removal of the CO2 contained in the top gas of the blast furnace. Therefore the useful components, i.e. CO+H2, can be recycled back into the furnace and reused as reducing agents. In addition, injecting oxygen (O2) into the furnace instead of preheated air, removes unwanted nitrogen (N2) from the gas. Under the pressure of CO2 emissions in iron and steel making, the growing international shortage of coking coal resources and the rising price of coke, OBF has attracted attentions of both domestic and foreign researchers, because it has so many advantages such as high productivity, high PCI rate, low coke rate, high gas reducing capability and high top gas calorific value, etc [1-7]. As a result of recycling most of the top gas after CO2 removal and injecting oxygen into the furnace, the reduction capacity of blast furnace gas will be increased, so the metallurgical behavior of OBF's iron burden is different from traditional blast furnace. Therefore, it is one of the keys to develop this technology, which studies the metallurgical behavior of sinter in OBF. The purpose of this paper is to study the low temperature reduction pulverization and reduction behavior of sinter at the atmosphere of OBF, which includes the difference of low temperature reduction pulverization and reduction behavior of sinter in oxygen blast furnace and conventional Blast Furnace (BF). It will provide theoretical basis for the development of OBF."

Jan 1, 2012

By N. Choi

The distribution behavior of selenium and tellurium in nickel sulfide smelting was investigated in the temperature range of 1250-1300 °C under an inert gas atmosphere and various oxygen partial pressures. The distribution coefficients of selenium and tellurium between nickel-copper-iron matte and silica-saturated iron silicate slag were detennined in terms of matte and slag compositions, temperature, and oxygen partial pressure. The effect of slag additives such as CaO, MgO, and Ah03 on the distribution coefficients of those elements was also investigated. It was observed that the distribution coefficients of selenium and tellurium increased with increasing matte grade and temperature. The solubility of selenium and tellurium in the slag decreased with increasing the partial pressure of oxygen within the range investigated in this study. The distribution coefficients of selenium and tellurium increased with the amount of CaO and MgO. Tellurium distribution coefficients also increased by the addition of Ah03. Meanwhile, the addition of Alz03 decreased the distribution coefficients of selenium at high matte grade.

Jan 1, 1996

By Z. Smieszek, J. Botor, Z. Miczkowski, S. Sobierajski

"From 1978, the direct process for the smelting of chalcocite concentrates in a flash furnace by the Outokumpu method has been applied at the Glogów II copper smelter. The chemical composition of these concentrates make it necessary to control the process very strictly. In this paper, the method for controlling and measuring the main technological parameters of the copper production by flash smelting is being presented. It includes the determination of the chemical composition of the concentrate, its grain structure, the temperature of liquid products of the process, oxygen content in process gases, as well as lead concentration in copper and copper concentration in slag.The main process parameters are determined from the mass and energy balances. The relations between parameters, such as an effect of grain structure of a concentrate on oxygen and oil consumption, and dependence of chemical composition of a concentrate on capacity and products quality are discussed. 1. IntroductionThe Polish copper concentrates, as most concentrates occurring worldwide, contain from 18% to 30% Cu, and less sulphur (7-11%) and iron (2-5%). The main copper-bearing mineral contained in the concentrates is chalcocite, while bornite and chalcopyrite are present in smaller quantities. Moreover, the organic carbon (5-7.5%), arsenic (0.05-0.3%) and lead (1.2-3.0%) are also contained in the concentrates. The gangue consists mainly of silica, aluminosilicates, calcium carbonate and magnesium carbonate. Their proportions make the addition of slag-forming agents unnecessary.The composition of Polish concentrates, especially their low iron content, allows their application in the direct flash smelting process for blister copper production. Low sulphur content is the factor which determines the necessity of oxygen application in this process."

Jan 1, 1989

By W. D. Cho

The slag chemistry in steel processing plays an important role in terms of the removal of impurities including alumina particles. In the present study, the dissolution of solid alumina particles in CaO-based fluxes at the temperatures between 1450 and 1550 °C has been investigated to determine dissolution kinetics and mechanism. Alumina particles were added directly in the slags and the size of alumina particles was measured as a function of time using optical and scaru;ling electron microscopes. The dissolution rate has also been obtained as a function of Si02, CaF2, MgO and MnO contents in the slags. The diffusion boundary layer between alumina and bulk slag phase has been observed and analyzed using SEM and EDX. In addition, some experiments have been performed for the dissolution of alumina in BaO-based fluxes.

Jan 1, 2003

By C. F. Feng, L. Froyen

"In-situ processes have emerged as new and promising techniques for metal matrix composite fabrication. They offer significant technical and economic advantages over conventional processing. One of the in-situ processing routes that have been used is reactive free sintering of a mixture of powder reactants. However, materials synthesised via this route are always porous because of density differences between reactants and products. An example are the porous Al/(TiB2+Ah03) MMCs obtained by heating powder mixtures of Al+ Ti02+B with Ti02 and B in stoichiometric ratios for forming TiB2• In this study, porous Al/(TiB2+Ah03) composites were further processed by hot-pressing at temperatures above 600°C. This processing cycle was designed so that the composites could be densified. Furthermore, the reaction kinetics of the in-situ processing are studied by means of DSC analysis measured at different heating rates. The activation energies of the three intermediate steps that are involved in the reactive processing for preparing AV(TiB2+Alz03) MMCs are determined to be 923 kJ/mole, 241 kJ/mole and 235 kJ/mole respectively.XRD proved that the hot-pressed products consist of Al, TiB2 and Al203- Properties of the products are assessed by microstructural characterisation (LOM, SEM and EDS), microhardness, Young's modulus and bending tests. The results show that good microstructures, elastic properties and strengths, as well as acceptable ductilities were achieved. For the composition 79.74wt% Al-15.95wt% Ti0z-4.31wt% B, after the reactive free-sintering and hot-pressing cycles, Young's modulus is 105 GPa, bending strength is 509 MPa and maximum strain is 5.0%; for composition 88.73wt% Al-8.87wt% Ti0z-2.40wt% B, they are 89 GPa, 311 MPa and 8.2% respectively. It can be seen that the properties of products can be tailored by adjusting the relative amounts of reactants in green samples. Furthermore, for comparison reasons, Al and a binary system Al-Ti02 were identically processed as the ternary systems. Their microstructures and properties were studied."

Jan 1, 1998

By Kuo En Chang

Many rare earth - transition metal (RE-TM) compounds absorb/desorb hydrogen reversibly at room temperature and atmospheric pressure. For LaNi5 which is used as a battery material, the electrochemical nature of this process is well known. In the case of Nd-Fe-B which has found wide application as a powerful permanent magnet, the absorption of hydrogen has both significant advantages and disadvantages. However, a fundamental understanding of the hydrogenation process at ambient temperatures and its effect on subsequent corrosion behavior is currently lacking. This paper reports the results of the hydrogenation of NdFeB two alloys, (NdDy)15Fe78.3A10.7B6 and (NdDy)15Fe67Co5V4A12B7, which are compared with that of LaNi5. Results show that hydrogenation can be accomplished by either electrochemical methods or immersion in dilute sulfuric acid. For the latter method, the change in lattice parameter indicates that the level of hydrogen absorbed by the NdFeB particles corresponds fairly closely to an overall composition of Nd2Fe14BH2.7. Cyclic electrochemical charge/discharge experiments show that the maximum hydrogen discharge capacities of the NdFeB, NdFeB-Co-V, and LaNi5 are 40, 60, and 210 mA?h?g-1, respectively. Anodic potentiodynamic polarization measurements and calculated values of icon reveal that absorbed hydrogen in NdFeB-Co-V and the NdFeB may lead to significant increases in corrosion rates.

Jan 1, 1995

By H. V. R. von Rhaden

Systematic quantitative X-ray diffraction analyses performed on diamond-drill cores originating from the Aandenk formation at the Loraine Gold Mine, located in the Welkom goldfield, Orange Free State, South Africa, have revealed the presence of a number of phyllosilicate mineral assemblages which have not hitherto been reported from this region. Rectorite, a regularly interstratified 1:1 mica-montmorillonite "swelling clay", is found to occur together with paragonite, muscovite, pyrophyllite, kaolinite, and chlorite in highly-altered friable rocks. The presence of rectorite in mill feeds may have potentially serious implications with respect to gold recovery. Quantitative X-ray diffraction analysis for phyllosilicates can be used as an aid to correlation, and also to guide the widths of stopes in underground mining. Rectorite has a unique mode of origin, which is discussed.

Jan 1, 1991

By W. D. Cho

The slag chemistry in steel processing plays an important role in terms of the removal of impurities including alumina particles. In the present study, the dissolution of solid aluimina particles in CaO-based fluxes at the temperatures between 1450 and 1550 °C has been investigated to determine dissolution kinetics and mechanism. Alumina particles were added directly in the slags and the size of alumina particles was measured as a function of time using optical and scanning electron microscopes. The dissolution rate has also been obtained as a function of Si02, CaF2, MgO and MnO contents in the slags. The diffusion boundary layer between alumina and bulk slag phase has been observed and analyzed using SEM and EDX. In addition, some experiments have been performed for the dissolution of alumina in BaO-based fluxes.

Jan 1, 2003

By Michael B. Tessieri

With the increasing environmental demands and higher fuel efficiency standards on auto manufacturers, the use of aluminum in automotive applications is expected to show significant growth for the balance of this decade. Cast and wrought aluminum usage is reviewed by auto part, and alloy family for the year 2000 automobile. The analysis addresses the effect of this increased volume on the recycling infrastructure and identifies issues and opportunities, which will face the recycling industry.

Jan 1, 1995