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By Peter Kong

This paper provides a general discussion of atmospheric-pressure plasma generation, processes, and applications. There are two distinct categories of atmospheric-pressure plasmas: thermal and nonthermal. Thermal atmospheric-pressure plasmas include those produced in high intensity arcs, plasma torches, or in high intensity, high frequency discharges. Although nonthermal plasmas are at room temperatures, they are extremely effective in producing activated species, e.g., free radicals and excited state atoms. Thus, both thermal and nonthermal atmospheric-pressure plasmas are finding applications in a wide variety of industrial processes, e.g. waste destruction, material recovery, extractive metallurgy, powder synthesis, and energy conversion. A brief discussion of recent plasma technology research and development activities at the Idaho National Laboratory is included.

Jan 1, 2006

By Norbert Patzeh

The demand for nickel is growing and will continue to do so for the foreseeable, future. This will make the construction of new leaching and smelting plants necessary. This paper described a number of possible alternative processes. The first projects with new technology are currently undergoing trials and feasibility studies. Experience from other industrial sectors and from existing plants is being incorporated into these investigations. The question is, to what extent the old nickel producing concepts will continue to be applied in the future. Keywords: Latcritc, rotary kiln, cyclonc rcactor, dust processing

Jan 1, 2004

By Fei Ruan, Chang Jie, Jieyu Zhang, Jifang Xu, Kuochih Chou

"Viscosity is an important physical parameter of slag in metallurgical processes. Most studies of aluminosilicate and aluminate systems assume that aluminum occurs in tetrahedral coordination. In this case, the O/Al value was utilized to describe the slag structure in terms of the network character of aluminosilicate and aluminate systems. Composition and viscosity data from the literature and the trends were analyzed according to the O/Al value and temperature. It is shown that the O/Al value explains the trends in more than ten systems, containing more than 200 data points. In aluminosilicate system, the trend that viscosity value changed with the O/Al value which implies that alumina works as network modifier such as basic oxides or works as network former. In aluminate system, irrespective of the system and temperature, viscosity decreased steadily when O/Al value increased.IntroductionMetallurgical slags, which are made of oxides and many also contain fluorides, play an important role in metallurgical processes such as iron making, steel making and secondary refining processes. Aluminosilicate slags are applied in a wide range in metallurgical processes. A polymerizing effect of the addition of aluminum and an association of aluminum with low-field strength cations is further supported by the physical variations in aluminosilicate and aluminate systems. The behavior of alumina in silicate melts has been studied by various authors [1-6]. It is generally accepted that Al2O3 is amphoteric [7] because Al3+ ions can behave in profoundly different ways in a silicate melt. When added to a pure silica melt, Al2O3 acted as a network modifier, breaking the bridging oxygen of the pure silica network, thereby decreasing the viscosity in a similar manner to other network modifiers, such as CaO, MgO etc. to form [1/2Ca (AlO4)]4- complexes. However, when added with alkali or alkali-earth metal oxides, some of the Al3+ ions assumed tetrahedral coordination and replaced Si in the liquid network, the missing charge was compensated by Me+ or Me2+ ions. Therefore Al2O3 acted as network former [8, 9]."

Jan 1, 2011

By Batric Pesic

The interactions of mineral-pyrite with T. ferrooxidans were studied by using a cyclic voltametry technique. The interactions with bacteria were carefully examined during the entire growth stage of bacteria (fermentation). Several very important discoveries were made. For example, the pyrite surface invariably drastically changed its properties at the second day of fermentation. Beyond two days of fermentation, the cyclic voltamograms were insensitive to convective diffusion produced by stirring. The SEM study revealed that bacteria populated the pyrite surface at an extremely high density levels. The high density of bacteria, and the solid reaction products formed on the pyrite surface created conditions for pore diffusion which explained why the CVs became insensitive to convective diffusion in solution (stirring).

Jan 1, 1990

By Batric Pesic

Calcium silicate slag (Di-Cal) and magnesium oxide condensate (MgO) are the by-products of magnesium smelting operations, As these oxides have acid neutralizing and metal precipitating properties, it was decided to examine their reactions with (a) individual heavy metals and (b) with a mixture of metals in solution, The resulting solid reaction products were further tested with respect to the stability of the contained metals, The stability of the solid precipitates were examined as a function of the method of precipitation and as function of the solution pH With respect to the method of precipitation, the performance of Di-Cal and MgO was compared to the performance of lime, an industry standard for heavy metal precipitation, Four different pH solutions (4,0, 5,0, 7,0 and 1 LO) were used to study the effect of pH on the stability of the precipitates. It was found that Di-Cal, in most cases, produced the most stable precipitates and thus, outperformed lime, Metal precipitates prepared by the addition of MgO were the most soluble for each metal studied, except for Se,

Jan 1, 2001

The cleaning of copper containing fayalite slag using a CuFe alloy was studied under an oxygen pressure ranging from 10-7 to 5 X 10-11 atm at 1200º c. The reduction of copper from fayalite slags by Cu-Fe alloys was found to be very effective. For example, at a P 02 of 10-7 atm, the copper content in the slag was reduced from 4.1 to 0.402 wt. percent after 90 min. of reaction time using a Cu- 5.27 wt. percent Fe alloy. The copper reduction rates were found to be independent of P02 in the gas phase when using Cu-Fe alloys which exhibit an iron activity of greater than 0.4. A mechanism for slag c1eaning is proposed based on the concept that the Cu-Fe alloy lowers the oxygen potential of the slag according to Eq.1 1, fol1owed by the reduction of cuprous oxide by wustite as shown in Eq.2. Here X represents element X in the alloy phase while (X) represents the element in the slag phase. The copper and iron transfer behaviour obtained in this study are explained by a ?Stepwise equilibrium model.

Jan 1, 1985

By Naiyang Ma

"High oil concentration is one of the major barriers for recycling of mill scale of steel hot rolling mills. It is of vital importance to find cost-effective technologies of reducing oil concentration in mill scale in order to recycle the mill scale without causing detrimental effects on production and environment. This paper discusses in-process separation of mill scale from oil at steel hot rolling mills. Formation of mill scale and status of oily wastewater at hot rolling mills are reviewed in the first place. A mathematical model is then formulated to relate oil concentration in mill scale to physical properties of mill scale, chemical and physical properties of wastewater and interacting parameters between mill scale particles and wastewater. From this model, three approaches of in-process separation of mill scale from oil are derived: (1) avoiding contacts between mill scale particles and oily wastewater, and (2) maintaining low oil concentration in wastewater, and (3) collecting mill scale in upper streams of wastewater flows. In-process separation of mill scale from oil might have advantages of lower capital cost, lower operating cost and less additional environmental concerns, compared to other strategies of separating mill scale from oil.IntroductionHot rolling is an inevitable step in producing finished steel products. Figure 1 schematically shows a steel hot rolling process. Semi-finished steel products, slabs here, are reheated first, and then the reheated slabs are discharged from the furnaces and transported on hot rolling trains to descaling units for removing scale with pressurized water. After being descaled, the slabs are rolled by roughing mills. After treated with cropping and the second descaling, the slabs are finally rolled into finished products, coils here, by finishing mills."

Jan 1, 2012

By R. Luo, R. V. Kumar

"The co-deposition of cobalt and nickel as a binary alloy has been studied by both cyclic voltammetry and long-period controlled-potential electrolysis. Cyclic voltammetry experiments showed that the cathodic current density for the mixed Co-Ni (Co-Ni=1:3) electrolyte is noticeably higher than that obtained on electrolyte containing single CO2+ or Ni2+ (II) salt of the same ionic strength. The onset potential observed for the mixed salts electrolyte was also less cathodic (negative) than that for the single metal salts, respectively. The effects of a number of operational and compositional parameters on the co-deposition of cobalt and nickel were studied. The parameters under investigation include cathode (deposition) potential, temperature, CI-/Sol ratio in the electrolyte, the amount of additives such as H3B03, and acidity of the electrolyte.Optimum operational conditions were established for the deposition of cobalt and nickel binary alloy. These results are discussed with respect to feasibility of reclaiming cobalt, nickel and chromium from mixed superalloy scraps by melt-refining (under nitrogen and/or ammonia), followed by electrorerining of cast anode for co-depositing Co/Ni and thermal decomposition of chromium nitride for recovering chromium metal."

Jan 1, 1997

By Hong Yong Sohn

A novel flash ironmaking technology is under development at the University of Utah under the support of U.S. Department of Energy (DOE) and American Iron and Steel Institute (AISI). The history of the development from the conception of the idea to the current status will be discussed. The flash ironmaking process produces iron directly from fine iron ore concentrates without requiring cokemaking and pelletization/sintering, which will enable the technology to significantly reduce energy consumption and carbon dioxide emissions compared with blast furnace ironmaking. Unlike other gas-based ironmaking processes, this technology will not suffer from the problems of solid sticking and fusion. Current work is focused on the method of supplying the energy required to maintain the necessary temperature, as an intermediate step to determine the scalability for larger, industrial-scale pilot trials.

Jan 1, 2014

By K. Tozwa

The electrical conductivity of electrolytes for copper electrorefining and electrowinning processes has been reported by many researchers since 1911. The experimental results show that the conductivity increases with an increase in sulfuric acid concentration and decreascs with an increase in copper concentration. In pure copper sulfate solution, however, the conductivity increases with an increase in the copper concentration. After confirming the conductivity of pure and acidified copper sulfate solutions experimentally, the concentrations of hydrogen ion and free (not hydrated) water in the electrolytes were estimated and it was found that the relation between the conductivity of acidified copper sulfate electrolytes and the products of concentration of hydrogen ion and free water is linear. Accordingly, the conductivity of acidified copper sulfate electrolytes increases with an increase in sulfuric acid concentration and decreases with an increase in copper concentration.

Jan 1, 2003

By D. Donald Downey

Pilot Testing Ion Exchange Resin (IEX) can go from very simple beaker testing to complicated column testing. Space velocities, regenerant quantities, loading capacities, ion leakage, are all terms that get accumulated together to prove or disprove a resin’s (or resins’) ability to load a single ion (or specific set of ions). Not getting all the resin’s operating parameters correct will disqualify (or at least skew) the results. Laboratory tests for capacity, moisture content, bead size, metals fouling, etc.—what does it all mean? At last count, there were over twenty-five separate ion exchange resin tests (analyses) that were available to end users. Standard testing procedures identify the resin properties but more specific procedures can be used to identify problems with equipment operation. Then, there are the costs to consider; simple cation resin testing (moisture content, total capacity and bead integrity) is in the $200/sample range. However, add to this Chatillon, Russian Ball Mill Test, HIAC particle size, metals and % regeneration test procedures and the lab work can increase to over $1000/sample. In this paper, the author will explain the “must-do” pilot and test procedures and why they are important and the key to understanding how resin performs ion exchange.

By L. Filip

The roast-leach-electrowinning (RLE) process for zinc was modified to treat two typical complex concentrates containing zinc, lead, copper, gold and silver. Laboratory testwork results indicated that the optimum roasting temperature ranged from 700 to 800°C, in order to produce acceptable residual sulfur levels. The calcined concentrate was subjected to a three-stage leach sequence. The resulting leach solution was purified by hematitic precipitation and directed to the recovery of copper and zinc by solvent extraction and electrolysis. Alkaline smelting and subsequent electrolytic purification recovered the lead and precious metals from the leach residue. A flowsheet was developed based on the laboratory testwork results, and demonstrated in a large-scale pilot plant. The recoveries produced during the pilot plant operation ranged from 90 to 92% for zinc and copper, 85% for lead and 90% for gold and silver, respectively.

Jan 1, 1999

By Wenzhou Yu, Cong Zhang, Wenhui Ma, Gang Wang, Kuixian Wei

"A novel technique was successfully developed for nickel further purification by vacuum directional solidification. The removal effect of impurities in nickel was studied based on theoretical analysis and experiments. High removal efficiency of impurities in nickel can be realized according to theoretical analysis. The experimental results show that the vacuum directional solidification treatment could increase the nickel purity from 99.96% to 99.996%. Since vacuum directional solidification could effectively remove the impurities from nickel with low contamination and low cost, it is a potential route to obtain high-purity nickel for commercial application.IntroductionNickel is widely used in metallurgy, machinery, petroleum industry, chemical industry, construction industry, light industry, and other industries for its ductility, medium hardness, ferromagnetism and high chemical activity. Nickel-based alloy is an important material for the key parts of aircraft, tanks, submarines, radars, nuclear reactors and aerospace fields [1-5]. Generally, nickel contains Si, P, S, Fe, Cu, Zn, As, Cd, Sn, Sb, Pb, Bi, Al, Mn, Mg and other impurity elements, which may hinder the commercial application of nickel. Therefore, it is necessary to refine the crude nickel for the high purity nickel."

Jan 1, 2014

By P. Kerr

Iron segregation is pre-dated by copper and nickel segregation processes for which the experimental methodology and reaction chemistry were established. The accepted reaction sequence for segregation involves the generation of hydrogen chloride, the chloridization and volatilization of the metal chloride, and precipitation of the metal from the metal chloride in the vicinity of carbon. Iron segregation roasting offers a potential extraction solution for processing oxide deposits with complex mineralogy or waste streams such as Minette-type iron deposits, nickel laterites, ilmenite, red mud, electric arc furnace (EAF) dust, mill scale and slag. After subsequent magnetic separation, one is left with a high grade metallic iron powder which can be marketed for powder metallurgy or briquetted to serve as a direct reduced iron (DRI) product. The non-magnetic product is typically concentrated oxides including rutile, alumina, or oxides of V, P, and rare earths, etc. that may be economically recoverable with subsequent processing. While operating conditions vary for different metals, they share the requirements of an elevated operating temperature and a mixture of oxide ore, carbonaceous additive and a chloride additive in varying amounts all in a closed reactor to allow for reducing conditions and contain the volatile chlorides. This process is then followed by some form of physical separation. Testwork performed by the authors shows promising results that may aid in future development of the process. Segregation roasting of iron will likely never displace traditional beneficiation and ironmaking technologies; however, it has great potential in niche markets where traditional technologies have failed or current technologies generate substantial waste.

By K. Sanjay

Factorial optimisation technique has been used to develop regression equations at different time intervals for extraction of manganese from precipitated manganese oxide/hydroxide in sulphuric acid using charcoal as the reductant. The three parameters chosen for a 23 full factorial design were : acid concentration, amount of carbon and temperature. The regression equations were used to predict >> 90% extractions as well as kinetic data.

Jan 1, 1996

By Z. Sun, H. A. Davies

"Current understanding of the mechanisms by which glassy and crystalline thin ribbons are formed in high speed continuous casting processes is considered. A computer model of the combined heat and momentum transfer during melt spinning has been developed. The influence of roll velocity and of heat transfer coefficient (between the melt and the roll) on the temperature and velocity distributions within the melt puddle is analysed and the thickness of the extracted ribbon computed. The relative importance of heat and momentum transfer under different conditions is assessed and differences between the casting of crystalline and amorphous strip highlighted.IntroductionHigh speed continuous casting of thin metallic ribbon and strip is currently of considerable interest both to metal processers and to those studying process mechanisms. The practical interest arises both from the potential economic benefits to be gained from a shorter and more energy-efficient production route and from the ability to obtain extended and uniform thin strip having a metastable microcrystalline or amorphous structure with enhanced or unique properties. The latter arise from the rapid solidification associated with the cooling of very thin sections of melt brought into intimate thermal contact with one or two rapidly moving heat sinks.The principal processes for casting thin strip include free jet, chill-block melt-spinning (GBMS) (1), melt drag (MD) (2), planar flow casting (PFG) (3) and twin-roll casting (TRG) (4). For the first three of these, all essentially variants of melt-spinning, melt flows through a nozzle onto the circumferential surface of a rapidly rotating roll, whereas for TRG the melt passes into the nip between two contra-rotating rolls. We shall be concerned in this paper with the single-roll melt spinning processes only. For these, a puddle is established where the melt contacts the roll surface and the length of this puddle l is a function of the process conditions, notably the circumferential velocity of the roll Us and the volumetric flow rate of the melt Q. The contact time between any point on the roll surface and this puddle, or residence time eR(= l /Us) determines the thickness of ribbon t extracted from the puddle. This thickness, in turn, partly governs the cooling rate T and the amount of undercooling in the melt and thus the microstructure of the solidified ribbon."

Jan 1, 1986

By Cassandre Nowicki, Louis Gosselin, Carl Duchesne

"Quebec's primary aluminium production industry consumes roughly 39 TWh of electricity per year and is accountable for roughly 7 million tons of CO2 equivalent. By tapping only a small portion of waste heat and integrating it inside the production facility itself, we can significantly reduce GHG emissions and energy consumption. Although the amount of thermal waste can be adequately estimated by applying an energy balance to production processes, this provides very little information on the quality of waste heat and its potential for integration. A measure of exergy is required. Waste heat streams characterized by high exergy content may generally offer valuable incentives for recovery and integration. More generally, exergy values limit integration possibilities. An exergy analysis is provided for the aluminium electrolytic reduction process. This is meant to guide future heat recovery initiatives and energy efficiency measures.IntroductionCanada is one of the world leaders in primary aluminium production and 92% of its aluminium production capacities are located in the province of Quebec. In 2007, production capacity reached 2,786,000 tons in Quebec alone. Since it is estimated that 2.5 equivalent tons ofCO2 are released for each ton of aluminium produced in Canada, Quebec's aluminium production industry is accountable for roughly 7 million tons of CO2 yearly [1, 2]. Furthermore, with an average electricity consumption of 14 MWh per ton, primary aluminium accounts for 39 TWh of electricity per year in Quebec and this energy consumption represents 350 thousand tons ofCO2 equivalent [3, 4]. Natural gas consumption associated with primary aluminium production accounts for less than 1 TWh, but it represents an additional 350 thousand tons of CO2 equivalent [ 4].This work is meant to provide a tool to guide future efforts towards heat recovery and energy efficiency in the primary aluminium industry. Waste heat recovery and thermal integration can cut down both energy consumption costs and GHG emissions. In a primary aluminium production facility, waste heat represents roughly half of the energy input into the Hall-Heroult process. Tapping only a small portion of this energy could reduce natural gas and electricity consumption significantly. In order to evaluate how much of this energy is actually usable, we propose to apply an exergy analysis to individual transformation processes in an aluminium production facility, such that a potential to do work can be assigned to every waste heat flux. The approach will be described in the next section."

Jan 1, 2012

By Alysson Tadeu Pereira Almeida

Steels with low concentrations of nitrogen, hydrogen and carbon have been in large demand lately. The RH process is a secondary refining process that can simultaneously attain significant levels of removal of these interstitial elements from liquid steel. In the RH process, the melt circulation rate plays a very important role in determining the productivity of the equipment, since it affects the decarburization rate. In the present work, a physical model of a RH degasser in a 1:5 scale of an industrial reactor has been built and used in the study of the circulation rate and of the kinetics of decarburization. The effects of the gas flow rate and of the configurations of the nozzles used in the injection of the gas have been analyzed. The decarburization reaction of liquid steel was simulated using a reaction involving CO2 and caustic solutions. The concentration of CO2 in the solution was evaluated using pH measurements. The experimental results indicated that the kinetics of decarburization can be described by a first order equation. Based on the results, it was possible to determine the contributions of the decarburization in the upleg snorkel and in the vacuum vessel.

Jan 1, 2006

By Hongli Wen, Guangkun Shen, Qiong Deng, Xuling Chen, Min Gan, Xiaohui Fan

"In this research, pyrite cinder which contains 53.51% Fe and 0.54% Pb was processed by magnetic roasting separation to obtain a concentrate with 64.62% Fe and 0.56% Pb. The concentrate was then leached with hydrochloric acid to remove lead. Several technological parameters which may influence the removal efficiency were investigated: the mass fraction of hydrochloric acid, pulp density, the leaching time and temperature. On the conditions that the mass fraction of hydrochloric acid of 5%, pulp density of 30%, the leaching time of 30 minutes and leaching temperature of20°C, the lead content in the concentrate was reduced to 0.19%. The product was suitable for agglomeration and pelletization. Through the analysis of the lead distribution and phase change during the whole process, the mechanism of lead separation from pyrite cinder was analyzed.IntroductionPyrite cinder is rich in iron, which defines its most extensive and effective use as raw materials for iron making. However, some pyrite cinders contain much non-ferrous metals, which is detrimental for the iron making process. Lead, one of the harmful elements, will destroy the blast furnace lining. Besides, it causes pollution of the environment[1]. Therefore it is necessary to remove excessive lead before entering the blast furnace. To separate the lead from pyrite cinder, much research was done, including flotation, high temperature evaporation and leaching. High temperature evaporation consumed too much energy. The flotation was difficult to obtain high- grade iron ore concentrate[2]. Majority of the leaching was direct leaching of pyrite cinder, which was also difficult to get high-grade iron ore concentrate[3]. This article explored the magnetic roasting method to get high-grade iron ore concentrate, acid leaching method of the concentrate to remove excessive lead, providing guidance for the efficient utilization of pyrite cinder."

Jan 1, 2013

By Andres Vikdahl

The Rönnsktär smelter has recently undergone a series of technical and operational changes. This changes are caused by our own will to remain and gain in competivety and to adapt to the ever changing surroundings. To be able to remain competitive in surrounding with high wage costs, high inflation and high environmental standards thorough cost management is needed. The Swedish economic policy in the beginning of the 80'ies consisted amongst other things of two devaluations. The exchange rate of the Swedish Krona was reduced with approximatively 25 %. This boosted the profits of our export industry, some even believed we entered the land of milk and honey ... And working in this promised land where everything turns into profit it is very difficult to be careful and restrictive with your spendings. Apart from some healthy and fruitful investments we allowed ourselves yearly steady increases in salary for ever reduced number of worked hours and we of course employed more people. Inflation rates went up and so did property prices. In 1986 finally reality catched up on us. Reality in the form of too high costs started to hit Swedish export industry 5-6 years after the big devaluations. Furthermore the high inflation rate also hit the domestic industry a couple of years later. Together with other important factors Sweden faced a severe home-made recession in the beginning of the 90'ies. With this background we now report and analyse our smelter's performance and operating results, shown in fig 1 The main constrictions on smelting and refining at Rönnsktär are today: * Income restrictions by governmental production level Limit * Throughput resmctions by governmental emission limit * High capital costs in the aftermath of Swedish high inflation in the recent decade * Low work force turnover Below we will illustrate how we tackled with these issues along the following lines: * People * Quality * Technology

Jan 1, 1993