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By Michael J. Nicol

This paper summarizes some of the results of a study of the reactions involved in the Caron leaching process and identifies the roles of the major dissolved species in the kinetics of dissolution of iron alloy particles formed during reductive roasting. Using rotating disk electrodes and synthetic leach solutions, the reduction of water with the evolution of hydrogen was found not to occur on a dissolving iron surface under typical leach conditions. It has been established that the oxidative dissolution is governed primarily by a reaction involving reduction of Co(III) to Co(II) ions. The reduction of oxygen was also found to make a significant but largely indirect contribution to the kinetics of the dissolution process. The dissolution rates of various iron-nickel-cobalt-copper alloys which simulate the dissolving alloy particles in a Caron plant were measured in synthetic leach solutions under aerobic and anaerobic conditions. The initial dissolution rates of iron, nickel and the iron alloys were found to increase in the presence of thiosulphate, whereas the thiosulphate had a negative effect on the dissolution rates of cobalt and copper. It is shown that the eventual passivation of the iron occurs sooner in solutions rich in Co(II) ions. Whilst these conditions are present in the quench slurry, on-site measurements have shown that due to the very high concentration of reduced dissolved species, passivation does not occur until the slurry is strongly aerated. In the light of these fundamental findings, options for optimizing the rate of dissolution and minimizing the extent of passivation of the iron and iron alloys are discussed. Keywords: Ammonia, leaching, alloy, kinetics, passivation.

Jan 1, 2004

By D. E. Larson

In cooperation with the National Institute of Environmental Health Science and the National Institute for Occupational Safety and Health the U.S. Bureau of Mines conducted grinding research on non-asbestiform tremolite. The goal of this effort was to prepare ground tremolite samples containing a considerable percentage of acicular grains with aspect ratios (approximately = 8um long with widths = 1 um) similar to those of asbestos particles suspected of causing cancer, Optical-and electron-microscopic examinations were used to monitor the size and shape of the grains in the ground products. Although customized milling techniques do have noticeable effects in producing acicular grains, the prismatic nature of fracturing in the non-asbestiform tremolites limited the number of acicular grains that could be purposely produced, and indicates that the likelihood of high concentrations of acicular particles occurring under normal mining and milling conditions is small.

Jan 1, 1991

By Roderick I. L. Guthrie, Donghui Li, Mihaiela Isac, Luis Calzado

The HSBC is an ideal process for the production of BMG strips. The purpose of the present work was to investigate the casting of Ca-based, bulk amorphous strips. The possibility of casting three Ca-based alloys (60Ca-20Mg-20Al, 60Ca-15Mg-10Al-15Zn and 55Ca-15Mg-10Al-15Zn- 5Cu (at.%).) was investigated, using the HSBC simulator. Numerical simulation and mathematical modeling were used to predict temperature variations and cooling rates, under different interfacial gaseous atmospheres (helium and air) near the meniscus region. Given the critical cooling rates and glass temperatures needed to be reached for the vitrification of the respective alloys, this leads to predictions of the critical thicknesses possible with this novel casting process. To validate our predictions, these alloys were then prepared and cast onto the sand-blasted, solid copper substrate mould of the HSBC simulator. The possibility of producing Ca-based metallic glassy strips via the HSBC processes was confirmed, using optical microscopy, X-ray diffraction and Scanning Electron Microscopy, to characterize the glassy properties of the cast strips. It was found that the HSBC process would be able to provide sufficient cooling to form amorphous strips for the 60CA-15Mg-10Al-15Zn and 55Ca-15Mg- 10Al-15Zn-5Cu alloys, but not the 60Ca-20Mg-20Al alloy.

Jan 1, 2014

By D. J. Burkhardt

Newer copper SX/EW facilities often incorporate hot water heating for the cell feed electrolyte to obtain the necessary plating temperatures of 40 to 50°C. Heating is most necessary in oxide heap leaching, however it may also be required in bioleaching of secondary sulphides in colder climates or higher altitudes where most of the heat gain in the heap is lost to the environment. Given that the solution flows in the leach, organic circuit and electrolyte circuit are circular in nature, and the fact that the hot lean electrolyte is often exchanged with cooler rich electrolyte, it can be difficult to access the heating requirement for the cell feed. There are energy losses in piping, tankage, raffinate, and energy gains through the PLS and electrowinning process itself; some of these are significant and others are not. This paper discusses the overall heat balance, the relative significance of the various energy gains and losses, and describes a methodology to develop a heat balance to assist the engineer in sizing the heating equipment.

Jan 1, 2003

By N. A. Warner

To filly secure the environmental and social acceptability benefits of making a sulphide smelting facility and its ancillary sulphuric acid plant or other means for fixing sulphur, a virtually zero gas emission operation, it will be necessary to utilise exclusively technically pure oxygen. The strategy proposed for preventing the smelter from overheating involves highly efficient energy transfer by promoting sulphur trioxide formation at a relatively higher temperature than normal. A closed-loop gas circuit uses an eductor system actuated by the process oxygen to recirculate sulphur trioxide and unconverted sulphur dioxide back to the smelter, the endothermic dissociation of sulphur trioxide becoming a major contributor to the removal of excess heat. The only gases leaving the system relate to the bleed of nitrogen impurity introduced in the tonnage oxygen.

Jan 1, 1998

By Stuart D. Miller, Clayton L. Rumble

"A field net acid generation (NAG) test procedure has been utilized on-site to identify, classify and map potentially acid forming overburden at the PT Kaltim Prima Coal (K.PC) mining operation situated in the tropical equatorial region of East Kalimantan, Indonesia. The field procedure involves routine use of a calibrated, site specific NAG test (rapid oxidation test using hydrogen peroxide) which has a tum-around time of less than 24 hours and requires minimal sample preparation. It is used on geological drill-hole samples, for forward planning and overburden management; blast-hole samples, for day-to-day operational control and overburden scheduling; and final dump surface samples, for verification testing. This operational monitoring program has been in use at KPC for the past four years.Calibration and implementation of the field procedure has involved validating the NAG test using conventional acid-base accounting techniques, producing an overburden geochemical classification scheme, optimizing laboratory and sample preparation procedures, and ongoing quality management. This paper presents background theory and practical application in a case study format."

Jan 1, 1999

By Shenghui Guo, Ying Lei, Wei Li, Jinhui Peng, Libo Zhang, Yu Li

"Abstract: In this work, low temperature carbothermic reduction of Panzhihua low grade ilmenite after ball milling were investigated. The ball milling of ilmenite and graphite were processed in a ball mill. The milling process can attenuate the particle of ilmenite, and the ilmenite characteristic peak were broadened and weakened. The reduction temperature and behaviors are studied on the thermo gravimetric apparatus; lower temperature and higher reaction rate were obtained for the reduction of ilmenite with graphite after milled. The reduction temperature and times of ilmenite decreased to 1000-1025°C and 40-60min via milled for 4 or 8h; Low down the reduction temperature can eliminate the solution of Mg2+ and FeTi03 in a certain degree; the reduced ilmenite has an obvious loose structure, can favored the subsequent procedure such as leaching.1 IntroductionThere is about 9.66 billion tons of Vanadic Titan-magnetite deposited in Panzhihua, China. In this reserve, there is about 8.73x108 t ofTi02, Accounting for 90.54% of the Chinese reserves, and 35.17% of the international reserves and ranking first in the world. [JJ Titanium mineral deposits major classified into Rock type and Placer type. Rock type is the igneous mineral, which have great content of FeO (Relative to Fe20 3) and gangue. The rock textures are compact and almost are complex ore. Rock type Titanium mineral major are ilmenite and titan magnetite ore, difficult to separate the metal ore and gangue. l.21 Thus, the Ti02 grade of Rock type ilmenite much lower than the Placer type (Table land 11). Panzhihua ilmenite are the typical Rock-type, due to the higher contents of MgO, CaO and Si02 and the complex mineralogy in ilmenite in Panzhihua region, making its direct reduction progressively more difficult. Mechanical activation, usually carried out by energetic milling or ball milling, was reported to significantly decreased the reduction temperature and accelerate the reaction rate of reduction of ilmenite with carbon, silicon and Magnesium. f3·(>J It reported that the process temperature were decreased to 600-1000°C and the annealing time were reduced to 30-120min after milled for 50-400 h. Shorter milling time involved was imported for else procedure such as direct leaching. 171 Hardly any research had referred to the carbothermic reduction reactivity of ilmeite milled for a short time as 1-1 Oh. In the present work, the aim is to investigate the reactivity and reaction temperature of carbothermic reduction of Panzhihua ilmenite. The Phase composition and micro morphology of samples are characterized."

Jan 1, 2011

By Klaus Gamweger

"This paper introduces an innovative solution to open and close the tap hole of different furnace types in the copper industry with a slide gate system. Two plates with defined drilled holes are slid against each other, which enables effective starting and stopping of the copper flow as well as throttling. Typically, the copper is poured via a tap hole into a launder system by rotating the furnace into an appropriate position. Control of the casting rate is also performed in this manner. Or, in case of stationary furnaces the tap hole is opened by oxygen lancing and closed manually with a clay- or copper-cone. These procedures show a lot of disadvantages including splashing, oxygen pick-up, and energy losses as well as a severe danger for the working staff. All these problems can be overcome with an appropriate slide gate system.IntroductionThe control of the casting rate of a copper anode furnace usually is performed by rotating the furnace into an appropriate position. This implies that the taping starts with the tap hole at a very high position. Copper splashing and an uncontrolled oxygen pick up are - with several more disadvantages - the consequences. RHI AG has developed an innovative solution for copper applications to open and close the tap hole with a slide gate system which allows also an accurate control of the flow rate. By using this system it is possible to start the casting procedure with the tap hole at the deepest position, directly above the launder. This paper presents this new slide gate system in detail and shows the advantages in production and safety issues."

Jan 1, 2012

By João M. S. Rodrigues

The use of sandblasting as a treatment method for conditioning anodes for zinc electro-winning was investigated and compared with conventional fluoride preconditioning. The anodes were made from two different lead-based alloys (Pb-Ag-Ca and Pb-Ag). Laboratory results showed that sandblasting and preconditioning both minimize lead contamination in the zinc and sludge generation. Sandblasting was found to have no aggravating effect on the anode corrosion. The sandblasting treatment was tested on Pb- Ag-Ca anodes on an industrial scale in the celJhouse of a local zinc producer. An unexpected finding of the large-scale tests was that the sandblasting appeared to strengthen the anodes, resulting in reduced warping during handling and operation.

Jan 1, 1996

By Jing Zhan, Gui Li, Wei-feng Li, Li-Hua Jiang, Chuan-fu Zhang, Jian-yang Hwang

Thermodynamics analysis for processing the charge with lead concentrate and lead sulfate-containing materials in bottom blowing smelting furnace was conducted. The results show that the technology of large-scale processing PbSO4- containing materials with PbS concentrate in bottom blowing furnace under the condition of using high-iron slag type, batch heat supplement, high temperature and rich oxygen is thermodynamically feasible. The exploration test and industrial experiment confirm the results. When S content in mixed ore is 16~17% with coke foam content of about 5%, the lead paste amount can be increased up to 40%.

Jan 1, 2015

By Christian Redl

"The Lattice Boltzmann Method (LBM) solves fluid dynamics problems based on a discrete mesoscopic approach. It is based on the Lattice Boltzmann equation which is a special discretisation of the continuous Boltzmann equation. Its principle advantage is that it can handle complex physical phenomena (like interaction between different components and surface effects), complicated boundary and initial conditions very well, free from many gridding and stability constraints that plague conventional numerical methods used for fluid flow simulations. Complex structures like porous media can be resolved directly. The LBM algorithm has a simple structure and acts locally, which is favourable for parallel computing. Its potential for metallurgical process simulation is demonstrated in the present study which is concerned with the simulation of the fluid flow in a copper winning electrolysis cell. The electrolyte is modelled as the carrier fluid and the oxygen is considered via a so called active scalar equation. The modelling of buoancy, momentum exchange and the free surface requires special effort. The results of the simulation are validated against experimental data obtained by Laser-Doppler-Anemometry. Despite the simplifications made, good agreement between the simulation and the experiments was found.IntroductionThe hydrodynamics in an electrometallurgical cell is a complex, highly non-linear phenomenon. It includes the simulation of a two component system with high density ratio, gravity driven flow and a free surface. A general solution to this problem is currently unknown.The flow field is a result of the combination of various hydrodynamic effects [18]. Metal deposition at the cathode yields in a decrease in the ion concentration, which reduces the density of the electrolyte. At the anode molecular oxygen is formed as a consequence of the oxidation of water molecules. The oxygen is solved in the electrolyte and again the electrolyte density is decreased. Both effects lead to a free upwards directed convective flow, refered to as natural convection."

Jan 1, 2001

By W. D. Cho

Fast dissolution of nonmetallic inclusions such as alumina particles in molten slags has been required in secondary steelmaking -ladle and tundish - to minimize the amount and the size of nonmetallic inclusions in steel products. In the present work, the dissolution behavior of alumina particles in molten CaO-A12O3 and CaO-A12O3-SiO2 slags at the temperatures between 1450 and 1550°C have been investigated in terms of kinetics and mechanism. Alumina particles were added directly into the slags and the variation of the particle size with time was determined using optical and electron microscopies. The conventional types of slag for ladle and tundish were included in the dissolution study. The effects of Al2O3, Siq, CaF2 and MgO contents on the dissolution rate of alumina particles have also been determined. The diffusion boundary layer between alumina particle and bulk slag phase has been observed and analyzed using SEM and EDS. Based on the analysis of kinetic data and the boundary layer, the dissolution mechanism has been discussed.

Jan 1, 2002

By S LeClair

Intelligent manufacturing involves intelligent, product-directed systems that facilitate the on-line, real-time generation of an improving product process cycle. A first step in the journey relates to self-directed systems which have the ability to reason and create their own processing paths in response to varying product and process conditions encountered during the process. This paper discusses an application of self-directed process control in the manufacture of graphite-epoxy laminated composites. An Air Force team involving researchers and production personnel have caused the development of a system now in use at the Air Force Logistic Center at McClellan Air Force Base in Sacramento CA. The paper discusses results and lessons learned in the process of trying to speed the implementation of research efforts which show significant potential of improving the product quality in less time and at less cost

Jan 1, 1992

By Mahmood Alemrajabi

When LKAB processes their iron ores in northern Sweden, they generate apatite as a by-product. The apatite has been recovered by flotation and the concentrate contains about 0.4 wt% rare earth elements (REE). Both phosphate rock and REE are listed as critical raw materials for the European union. In the present study, the recovery of REE within the nitrophosphate process of fertilizer production has been studied. In the first stage, the REE are precipitated and isolated as a phosphate concentrate. For further purification and individual separation of REE by solvent extraction, removal of phosphorous from the concentrate to enhance the dissolution of REE in mild acidic solutions is essential. In this study, thermal treatment of the concentrate with sodium hydroxide at elevated temperatures followed by water leaching has been studied in order to separate the phosphorous and thereby facilitate dissolution of the REE. The results show that 95% of total phosphorous initially present in the REE phosphate concentrate is removed after thermal treatment with NaOH 1:1 mass ratio, at 400 °C.

By C. J. Lewis

This presentation concerns calcium oxide-better known as high calcium quick lime High calcium quicklime is produced by calcining high calcium limestone, mostly in the many rotary kilns located throughout the United States and Canada. This paper presents suggestions on the handling of lime based on field experience. The subjects covered are chemical analyses, transporta¬tion, lime storage, lime slaking to form a water slurry of calcium hydroxide solids, slurry transportation, slurry viscosity, and scaling of lime slurries. It is hoped that the comments on the foregoing areas will be of use to those designing or operating lime systems.

Jan 1, 1992

By Jennifer Mager, G. P. Martins, Dean Mussatti

"The role of lead, at low concentrations in high pH cyanide-electrolytes, on the dissolution behavior of gold, has been a topic of scientific and industrial concern for well over a century. The recent paper by Kondos et al [1] at CANMET (1995) this continuing interest and apparent importance. Nevertheless, the mechanism(s) by which this (and other heavy metal) component influences the electrodics of this electrochemical system has still not been unequivocally demonstrated. Instead, several plausible hypotheses, by pioneering researchers in this field, have been advanced and reiterated OVer the ensuing years. While it is generally accepted, based on equilibrium elctrode-potential calculations, that reduction (or co-reduction when oxygen is present in the electrolyte) of lead on the gold surface may occur due to cementation (contact reduction), the cemented lead has never been characterized. The work presented has reexamined the role of lead in this system, by delineating the species distribution of these system components and by interpreting the results of potentiodynamic studies in conjunction with SEM analyses of a gold electrode.1. INTRODUCTIONThe leaching of gold ores in cyanide electrolytes has been practiced for well over a 100 years. Research conducted on this topic has been primarily focused on the effects of operating parameters such as concentrations of oxygen and cyanide, and the pH of the electrolyte; or the leaching behavior of carbonaceous and sulfitic gold-bearing materials.Mechanisms by which pure gold is leached in alkaline cyanide media, with oxygen serving as the oxidant, have been subjected to continual examination and re-examination in the published technical literature during this century. Recently, it has been speculated that without the presence in the electrolyte of trace heavy metals, such as lead or mercury, that gold would not be leachable. Researchers who have tackled this topic, have either considered heavy metals to be a natural occurrence in these systems and ignored the role they may serve in the leaching process, or they have deliberately focussed on controlling their concentrations in the system to undetectable limits. As a result, conflicting findings have been reported for what would appear - depending on the details provided in these reports - to be identical systems."

Jan 1, 1997

By Yavuz Ali Topkaya, Aydin Rusen

"In this study, zinc and lead recovery from zinc plant leach residue obtained from Çinkur using hydrometallurgical methods have been investigated by laboratory scale experiments. Considering more than one million tons leach residue (LR) rich in Zn (12.43%) and Pb (15.51%) in the stockyard and environmentally hazardous, it is essentially necessary to process Çinkur LR. Zinc and lead have been recovered in two main stages. As a first step, Çinkur LR was releached by using hot sulphuric acid for zinc recovery. About 72 % Zn was recovered by using 150 g/l H2SO4 at 95 oC in 2 hours with a pulp density of 200 g/l. Secondly, for lead recovery brine (NaCl) leaching tests were performed on the secondary Çinkur LR obtained after acid leaching process. In brine leaching while lead recoveries up to 95 % could be attained at a low pulp density, the maximum recovery obtained was 84.9 % at a high pulp density (200 g/l) with 300 g/l NaCl concentration in 10 minutes at 95 oC. Introduction Zinc and lead have been known and used by humans since ancient times and also they are important nonferrous metals [1]. Zinc and lead have different properties thus they are used in various application areas, ranging from automobiles to construction, from batteries to textile. Zinc and lead deposits are widely distributed in the Earth’s crust. The principal ore mineral for zinc is zinc sulfide, Sphalerite (ZnS), and lead sulphide, Galena (PbS), is the main source of lead in the world [2].Although zinc is generally produced from sulphidic ores (ZnS) or concentrates by Roast – Leach – Electrowinning (RLE) in the world, in Turkey, zinc production is based on zinc carbonate ores (ZnCO3), and at the Çinkur plant zinc was produced from zinc carbonate from its establishment to 1997 due to high reserves of zinc carbonate in that region. Çinkur is the only plant in Turkey that produces Zn from primary ore containing ZnCO3 by Waelz – Leach - Electrowinning route [3]. However, due to depletion of local high grade ores, oxidized ore concentrates were imported from Iran after 1997, until this plant was shut down. Therefore, there are two different leach residues (LR) which are Turkish LR (TLR) and Iranian LR (ILR) in Çinkur stockpiles. It has been estimated that the total amount of leach residue is more than one million tons of which the major part is Turkish leach residue (TLR)."

Jan 1, 2008

By P. Balachandran

The paper outlines the existing facilities and working practices at the Khetri electro-refinery of Hindustan Copper Limited. Plans have been drawn up to mechanize some key operations to improve the quality of cathodes and the working environment as well as economize the refinery operations. The economic analysis for determining various optimum operational parameters under conditions existing in India have also been outlined. The impact of capacity utilization and mechanization under different sets of conditions on operational costs have been highlighted.

Jan 1, 1987

By Yusuke Kimura, Ken-ichi Yamaguchi

"Secondary materials have long been processed at the S-furnace of the Mitsubishi continuous copper smelting and converting process at Naoshima Smelter and Refinery. Intensive recycling in the recent years has formed concerns that impurities in the secondary materials may cause drastic changes in the chemical properties of the CL-slag, which is separated from matte in the smelting stage. Among various impurities included in secondary materials, the authors have studied the influences of sodium oxides in the CL-slag because the behavior of sodium oxide has scarcely been studied with respect to the copper smelting slag. The examinations have been applied experimentally on the distribution between slag and matte of arsenic whose acidic characteristics suggest strong affinity to sodium-oxide of basic characteristics in silicate melts. The results have been discussed by thermodynamic evaluations and the results of pyro-tests at the commercial furnace.IntroductionAt Naoshima Smelter and Refinery, the existing line of the Mitsubishi continuous copper smelting and converting process has been operated since 1991. The Mitsubishi Process consists of three furnaces namely the S-, CL- and C-furnace as shown in Figure 1. In the S-furnace, copper concentrate and powdery secondary materials (scraps, sludges, etc) are charged through the top lances with oxygen enriched air. The other secondary materials of lumpy shapes are charged through the chute installed on the furnace roof. Charged materials are smelted by the reaction heat in accordance with the oxidization of copper concentrate. The mixed melt of matte and slag overflows through the launder into the CL-furnace, where the melt is separated into slag and matte by the difference of their specific gravity. Matte is siphoned out and sent to the C-furnace and converted to blister copper continuously. The CL-slag overflows continuously through the slag outlet to be water-granulated. Granulated slag is sold as a raw material used for the cement production and so on. Various secondary materials have been processed at the S-furnace of Naoshima Smelter and Refinery. Intensive recycling in the recent years has formed concerns that the chemical properties of the CL-slag may change drastically due to impurities originating from secondary materials. Among various impurities included in secondary materials, the authors have studied the influence of sodium oxide in the CL-slag because the impact of sodium oxide has scarcely been studied with respect to the copper smelting slag. The examinations have been applied experimentally on the distribution between slag and matte of arsenic whose acidic characteristics suggest strong affinity to sodium-oxide of basic characteristics in silicate melts."

Jan 1, 2012

By H. P. Wang, E. M. Perry

"Analytical solutions for investigating the solidification of casting problems with initial superheat and natural boundary conditions have been derived using an integral method. There are two moving interfaces in the solution field, one for the phase change line and the other for the superheat line. Two coupled nonlinear differential equations, representing two moving layers, were calculated by the Runge-Kutta numerical integration scheme. The solutions are in terms of six dimensionless parameters: phase change number, two Biot numbers for interfaces, diffusivity ratio, and dimensionless superheat temperature and time. Parametric studies on these parameters have been conducted to provide generic information about this phase change problem. This analytical information is extremely useful for validating numerical solutions. A simplified I-D finite element model was constructed for the purpose of comparison. The excellent agreement between the analytical and finite element solutions has proven that they are mutually validated.This validated finite element modeling tool was then used for modeling an investment casting process of a super-alloy with a simple geometry: a two-step plate. The nonlinear latent heat release, a common property of alloy materials, was approximated by several piecewise linear segments. The transient temperature response of this 2-D finite element solution, including a metal/mold gap resistance, shows excellent agreement with experimental data.This fundamental work provides a solid basis for further work on the development of a process modeling tool for the complex investment casting process.IntroductionAt present, the investment casting process is used in a variety of industries. In the aircraft engine industry, in particular, investment casting is used to produce parts ranging from turbine blades to engine frames. Because a large single casting can replace many component parts that require machining, fabrication, and assembly, this one-piece casting approach becomes a very cost-effective manufacturing process.The main constraint in using this process for mass production is the long design-to-production lead time. The standard rigging design is still an art, based on the experience of casting experts, rather than on scientific methods. Many trials are often required before making a sound final casting. In order to .reduce the number of expensive casting trials, the development of computer-aided tooling technology is needed.The fundamental physics describing this manufacturing process can be simply described. They reduce to a solid/liquid phase change problem, with two parts - first, the thermal balance of the initial superheat temperature of the molten metal and the preheat temperature of the ceramic shell through heat conduction, and second, the energy release from the mold surface to the ambient by radiation."

Jan 1, 1986