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By R. Parada

A real-time dynamic simulation model has been developed to characterise the flash furnace operation at the Chagres smelter. This model permits the operators to plan the process to meet the Peirce Smith converters' schedules and feed the acid plant with gases that satisfy its best operating efficiency range. Essential control parameters for the furnace (process air enrichment, oxygen coefficient and supplementary heat) are calculated to satisfy process targets such as matte grade, slag silica and matte/slag temperatures. These calculations are carried out with a real-time simulation. Flash furnace control and operational stability permits setting up control strategies that streamline the flow of copper to converters and of sulphur to the acid plant.

Jan 1, 1999

By N. Krishna

The utilization of Electrochemical Impedance Spectroscopy (EIS) in conjunction with Atomic Force Microscopy (AFM) is a powerful surface characterization technique to study the role of sulfur formation during acidic oxidation of chalcopyrite. It has been established that the chalcopyrite dissolution kinetics is controlled by the formation of passive sulfur layer during leaching. The objective of the study was to characterize the intermediate sulfur layer formation at different oxidation conditions in acidic solution. The chalcopyrite samples were subjected to anodic oxidation and the oxidation process was analyzed using impedance spectroscopy. The sulfur growth on the chalcopyrite surface during oxidation was further analyzed using Atomic Force Microscope for sulfur roughness and grain size, peak height and sulfur growth.

Jan 1, 1999

By Nagy El-Kaddah, T. T. Natarajan

This paper describes a novel approach for modeling three-dimensional electromagnetically driven flow in inductively stirred systems, and its application to modeling electromagnetic and flow phenomena in sub-mold rotary stirring of billets. It is based on a new T-\jf potential formulation of electromagnetic field, which does not require the calculation of the field in free space. A finite element algorithm has been developed for solving the electromagnetic field and Navier-Stokes equations in the fluid flow domain. The computed results have shown that the electromagnetic force field generates a strong rotational flow within the vertical section covered by the stirrer, and a relatively strong secondary flow beyond the stirrer. It has also been shown that the rotational and secondary flows were driven primarily by the vorticity of the force field at the billet corners. The induced flow in the molten pool was found to be turbulent and the effective mixing region in the molten pool was about three times the length of the stirrer. The mathematical approach presented in this paper provides the theoretical framework for quantifying these effects for any given stirrer configuration and operating parameters.

Jan 1, 1999

By P. E. Donaldson

Since 1992, Falconbridge has made available to the international copper industry, Kidd Creek's licensed refinery process technology under the name of the Kidd Process. This has resulted in the supply and installation of permanent cathodes and associated product handling equipment to refineries in Canada, the United States, South Korea, Chile and Mexico. These installations accommodate both electrorefining and electrowinning processes. The growth and industrial acceptance of the Kidd Process has generated technical advancements in the areas of product random sampling, corrugation, marking, labeling, product tracking and data acquisition. In a different area, the expanded development of custom materials processing at Kidd created a need to advance technologically. The process-related problem of high nickel concentrations in refinery electrolyte compromised an increase in current density to >300 A/m2. The need for nickel removal resulted in Kidd Creek's newly developed Nickel Recovery System. The effective and economical extraction of nickel, along with reduced antimony and bismuth levels, reduces bleed stream volumes and/or neutralization costs and simultaneously produces a marketable nickel carbonate product.

Jan 1, 1999

By Wenbo Luo, Kang Liu, Jilai Xue

"Coal fly-ash(CFA) from thermal power plants is rich in Al2O3, which has great potential as an alternative resource for alumina production. In this work, Alz03 contained in the coal fly-ash was extracted using an acid sintering-leaching process. This process was enhanced by aid of power ultrasound during the leaching. The recovery rate of Al2O3 was increased with ultrasound, compared with the similar process without ultrasound under the identical operation conditions. Leaching temperature can be lowered by about 10-l5°C and the processing time reduced by about 50%. The process kinetics were investigated in details for a better understanding of the fundamentals on the effects of power ultrasound. The obtained results demonstrate the potential application in reducing processing energy and increasing production rate.Introduction Coal fly ash is a typical solid waste generated from coal combustion in thermal power station. Vast amount of CF A accumulation lead to serious environmental problems such as air and water pollution, cropland occupation, radioactive contamination, etc. However, CFA is rich in Al2O3 and SiO2 content, so that it has a potential use as recourses for alumina and silica production [1]. Aluminum industry, especially in China, has made a rapid expansion in recent years accompanying with a large amount of bauxite consumption, resulting a urgent demand to develop secondary alumina resources like CF A to maintain a sustainable development of aluminum industry that faces grim challenge [2].Acid leaching is an efficient technology to use in alumina extraction from CF A. Since the particle of CF A is not naturally existed mineral but was formed in molten state at high temperature, the internal Al-O-Si bonds are so strong to separate alumina from the ash particle. Because of this reason, the direct acid leaching [3-6] operated at ambient temperature has low extraction efficiency, approximate 30% to 40%, which is attributed to self inhibition effect from CaS04 generated by reaction between CaO and H2S04 [7-8]. High pressure leaching can efficiently decompose mullite to release A12O 3 content in the fly ash particles, but this requires autoclave material having strong acid corrosion resistance, high temperature (100°C-300°C) and pressure (1.0MPa-2.SMPa) resistance while its operating security is low and its acid consumption is large [9]. Concentrated acid boil process is conducted at near acid boiling point (200 °C - 300 °C) in 4 mouth flask wrapped by electric heating jacket with high mass ratio of acid and ash to achieve high Al203 recovery rate from CFA. Its disadvantages are similar to the high pressure leaching technology except no-pressure, and also the operating solution at nearly boiling point acid may easily spill and splash with additional acid loss and potential safety hazard [10]."

Jan 1, 2014

By M. D. Crites

As part of a multi-year program for assessing the viability of chrome-free refractories in copper smelting, converting and refining furnaces, dynamic corrosion tests have been conducted on a series of refractories from the magnesia-alumina system, using a ferrous silicate slag. The corrosion rates of the test refractories are compared with those of a reference mag-chrome brick, and recommendations are made for more in-depth evaluations of the more corrosion-resistant materials.

Jan 1, 1999

By Pekka Taskinen, Hannu Johto

"Copper sulfide concentrates often contain impurities such as lead and iron. The phase stabilities of the sulfide impurity systems in metallurgical process conditions are in many cases unsatisfactorily known. Thermodynamic information of a system gives better understanding of its behavior of metal making processes, but also has effects on the economic and environmental factors of the production process. In this study, isothermal equilibrium and quenching experiments of the stable phases of the system Cu2S-FeS-PbS at 700 and 900 °C were carried out and based on the experimental results, Gibbs triangle of equilibrium phases of the system was outlined.IntroductionThe knowledge of stabilities of phases and the thermodynamic properties of many sulfide systems in the temperature range of 500-1200 °C are quite limited. Especially, the knowledge of liquidus surfaces of multicomponent sulfide systems is essential for making many metallurgical processes more environmental friendly and allowing the utilization of complex concentrates. In this work, the aim was to investigate the phase stabilities of the quasiternary system CU2SFeS- PbS using evacuated silica ampoules. Of greatest interest were the properties of the liquidus surface in the system, in order to be able to predict better the formation of a liquid phase in metallurgical processes."

Jan 1, 2012

By Sylwia Zymankowska-Kumon, Rafal Danko, Józef Danko, Mariusz Holtzer

"Burning of ceramic materials is carried out at temperatures 900+ 1300°C, in dependence of the required functional properties. The Faculty of Foundry Engineering together with the Faculty of Material Engineering and Ceramics developed the technology of production of burned ceramic materials with using spent moulding and core sands. The mentioned above waste materials of the foundry industry fulfilled -in plastic masses intended for obtaining ceramic materials -the role of the addition weakening clay raw materials. The laboratory investigations were fully verified by the results of industrial tests. It should be pointed out that none negative effects were observed at the stage of mixing raw materials and preparation of plastic masses. The measurements of exhaust gases emissions performed during burning the products containing spent moulding sands as well as during the normal production did not exhibit any significant differences, which could have indicated the harmful impact on the natural environment.IntroductionSands are used by the foundry industry to make metal casting molds and are a mixture of silica sand, bentonite clay and carbonaceous additives or resins. During the casting process, the molten metal cause thermal decomposition of carbonaceous additives or resins, which results in the formation of potentially hazardous organics, that are emitted to the atmosphere and condense in the molding sand. Each year the U.S. foundry industry landfills about 10 million tones of sand because it is no longer suitable to make metal casting molds. A large high-silica sand content in spent foundry sands (SFSs) generates rational premises for their reuse in other than foundry practice fields. Efforts to divert the SFSs from landfills and encourage their beneficial use in manufactured soils, geotechnical applications, the construction industry (road construction, highway construction), the building materials industry (cement, bricks, limestone manufacture), in the filling of mining cavities or in landfill construction (roads on landfills, permanent covers) are make [1-7]."

Jan 1, 2013

By Yonggang Liu

Microstructure and precipitates in hot rolled low carbon steel sheet by CSP were investigated in this paper. It is pointed out the precipitates in low carbon steel sheet by CSP are different with that by traditional hot rolling. The bainites were found in CSP hot rolled steel sheet by TEM testing and these bainites could maintain in the sheets even after batch annealing. The selected area electron diffraction analyzing indicated that there were many CrB2BN and FeB4BN phases precipitated in hot rolled steel sheet and no AlN grains precipitated. The nitrides forming can limit AlN grains precipitating during the batch annealing processing, and this could do harm to the texture pipeline along orientation line forming with formed properties.

Jan 1, 2006

By Zviad Kovziridze

Structure of celsian ceramics in BaO-Al2O3-SiO2system is studied with electron microscope in the entire temperature region of baking interval. The process of the pores filling and the full consolidation of material growth at comparatively high temperatures of baking intervals are described.

Jan 1, 2006

By Merete Tangstad, Lars Klemet Jakobsson

"Slag refining is a promising refining method for boron removal from silicon as a part of a metallurgical route for production of silicon for solar cells. There is, however, limited data on the distribution of impurity elements between silicon and different types of slags. In the present study, the distribution of boron and calcium between silicon and slag were determined at 1600 °C for calcium silicate slags with a CaO/SiC>2 ratio between 0.65 and 1.3. An almost horizontal linear trend was found for the distribution of boron between silicon and slag, and the borate capacity was found to follow the relationln(CB0, ) = 30.8 + 2.96-V (1)where V\s the CaO/SiCh mass ratio within the range of the experiments.IntroductionSolar grade silicon feedstock contributes significantly to the total cost and energy required to make crystalline silicon solar cells. A less expensive and less energy requiring method of solar grade silicon production is therefore needed in order to make crystalline silicon solar cells more viable as an energy source. Silicon is an abundant element and the manufacturing cost of solar grade silicon is therefore mainly determined by costs related to purification of metallurgical grade silicon. The Siemens process is the most common process today, but it is an expensive and highly energy requiring process that gives silicon with a higher purity than is needed for crystalline silicon solar cells. A cheaper and less energy requiring method for production of solar grade silicon can either be achieved by modifying the Siemens process or by using a new production method. Purification of metallurgical grade silicon through a metallurgical route is a promising method that is already in use industrially. It has however proven to be hard to lower the boron content to 0.3 mg/kg or less, which is the requirement for most p-type crystalline silicon solar cell manufacturers. Slag refining is seen as one of the most promising approaches that can be used to bring down the boron content to the required level, but there is not much data on how boron is distributed between silicon and binary calcium silicate slags [1-4]. The distribution of boron between silicon and calcium silicate slags at 1600 °C has been studied in this work, and the obtained data has been used to calculate the borate capacity of binary calcium silicate slags."

Jan 1, 2012

By Shun Myung Shin, Dong Hyo Yang

Cobalt is recovered from square type of spent lithium ion batteries (LIBs) containing 5~20 % Co, 5~7 % Li, 5~10 % Ni, 15% organic chemicals, and 7% plastics together with Cu, Al, Fe, and Mn. The waste LIB was prepared by physical treatment. After screening, the crushed LIBs were separated to +8 mesh, -8/+16 mesh, and -16 mesh powder. Among these, -16 mesh powder was selected for leaching. The leaching test was investigated at 2 M H2SO4, 6 vol.% H2O2, reaction temperature 60 ?, agitation speed 300 rpm, solid/liquid ratio 50 g/ 500 ml, reaction time 1 h. The leaching efficiency of cobalt was more than 99 % and its concentration was 24.9 g/L. For removing of impurities such as copper, iron, and aluminum in the leaching solution before cobalt solvent extraction, the impurities were eliminated by pH control with alkali solution. For selective extraction of cobalt, the aqueous phase removed impurities was equilibrated with different volumes of 0.4 M Cyanex 272 saponified of 50 %. Extraction efficiency of cobalt was about 80 % at first step. Separation coefficient (ßCo/Li) of cobalt and lithium extractions was 206.5. Over 9.0 % of pure cobalt sulfate solution was obtained after stripping with H2SO4 solution.

Jan 1, 2008

By Kiichiro Hayashi

"Indonesia is one of the world leaders in palm oil production. Palm oil industry is an industry to be considered when it comes to environmental impacts. This paper utilizes three step approaches. First, a material flow analysis of palm oil related industry was conducted in Indonesia. Second, a factory visit survey was conducted for getting information on environmental impacts of plantation and CPO mills. Third, a LCA study was made for a model Indonesian CPO mill in several bio-waste treatment options. Main findings were that, first; over 70% of FFB was bio-wastes generated from CPO mills. Second, some mills introduced a zero emission bio-waste policy. However, untreated bio-wastes in the zero emission policy, such as, CH4 from POME ponds, may have potential to reduce more impacts on the environment. Introduction Indonesia is one of the world leaders in palm oil production with approximately 12.4 million tons of crude palm oil (CPO) production in 2005 and with the plantation area 5.6 million ha spreading out in 19 provinces [10]. The expansion of palm oil cultivation in Indonesia and its export oriented industry heavily relies on the strong world market demand for food. Currently, there are 320 CPO industries in Indonesia [10]. These include plantations and palm oil related factories. Among them, there are six biggest players in CPO business in Indonesia: PT. Perkebunan Nusantara (PTPN) consisting of 9 PTPN, Sinar Mas, Raja Garuda Mas, Astra Agro Lestari, Minamas Plantation and Indofood. They are managing more than 50% of plantation estate in Indonesia and are leading the Indonesian palm oil business.Palm oil industry is an industry to be considered when it comes to environmental impacts. Unfortunately, there is not so much available information related to the performance of each CPO on environmental impacts. There are reports which provide information on environmental impacts of CPO mills in South East Asian countries, but are limited to, for instance, Thailand’s cases [4 and 5] and Malaysia’s cases [1, 3, 6, 7, 9, 11 and 12]. On the other hand, similar studies on the Indonesian’s case are not well established in academic literatures. And also there is limitation on Indonesian palm oil industrial information from plantation to consumption and disposal in academic articles. There is no literature related to material flow analysis focusing on the whole Indonesian palm oil related industry. One way to describe and present the environmental impacts is through a life cycle assessment (LCA). The LCA could be used to estimate the impacts of CPO production including the stages of plantation, transportation and milling [5, 8 and 11]. However, studies on Indonesian CPO production process were not well established in academic articles. The purpose of this paper is thus to clarify environmental impacts of palm oil industry in Indonesia especially by focusing on plantation and CPO mills with consideration to various bio-waste treatments."

Jan 1, 2008

By Xiping Chen, Wangxing Li

"Spent potlining is unavoidable solid waste from aluminum smelters. About thirty kilograms spent potlining is discharged in China to produce per ton primary aluminum. Spent potlining has high level soluble fluorides and cyanides so that it brings heavy pollution to environment. It is prohibited to keep a large amount of spent potlining in open air because it will lead concentrated pollution to local soil and water source due to hydrated reactions between spent potlining and rain water/moisture in air. Landfill may solve pollution of spent potlining provisionally, but it is difficult to be accepted by aluminum smelters because of its high investment, troublesome monitoring and perennial maintenance. Detoxifying of spent potlining not only can remove deleterious fluorides and cyanides in SPL, but also can make fluorides in SPL recycle and return to aluminum electrolysis cells, at the same time benign SPL solid residue can be recycled and ready for cement production.IntroductionChina became the largest primary aluminum manufacturer in 2001. In the past few years, its aluminum output increased by twentyfive percent every year and reached 12.56 million metric tons in 2007. The whole world was very surprised and focused attention upon Chinese aluminum industry. It is more and more important to keep sustainable and steady development with the rapid development of Chinese economy. Aluminum industry is an important base industry and does a great contribution to Chinese economy. But aluminum industry is high energy-consumption and heavy-pollution industry. The government has paid more attention to aluminum industry in recent years. Nowadays the bothersome problem which counterworks Chinese aluminum industry is pollution from solid wastes. Main Solid wastes from aluminum industry are red mud from alumina refineries and spent potlining (short as SPL) from aluminum smelters. Spent potlining are waste lining materials from aluminum electrolysis cells. During production of aluminum, due to reactions between melted electrolyzer and pot lining as well as penetrating of fluorides into pot lining, newly-formed compounds inlayed in pot lining, destroyed the lining structure and brought pot lining cracking. Melt rushed out of lining cracks, cells have to be stopped running and ready for heavy repair. Cell life generally varies from 1500 to 2000 days. Spent potling is an unavoidable solid waste from aluminum industry."

Jan 1, 2008

By Mohamad Omarei, S. M. Sadrameli

"The aim of this research work was to produce biodiesel (fatty acid methyl esters, FAME) from canola oil using KOH loaded on y-Al203 support as a heterogeneous catalyst. Different parameters such as effects of the molar ratio of methanol to oil, catalyst amount and reaction time on the yield were investigated. Scanning electron microscope (SEM) and X-ray diffraction (XRD) were used for characterization of the catalysts. A biodiesel yield of 86.67% was obtained under catalyst preparation and transesterification conditions of calcinations temperature of 773 K, 4 h of reaction time at 338 K, and using 3.5 wt% catalysts and molar ratio of methanol/oil of 15:1. The leaching of potassium species in the spent catalyst was observed.1. IntroductionBiodiesel is an eco-friendly and alternative energy source for diesel engines that can be synthesized by transesterfication of vegetable oil or animal fat with alcohols [1 ]. There are four principal approaches to the synthesis of biodiesel involving the transesterification of the triglycerides of the plant oils and animal fats: base catalysis [2], acid catalysis [3-5], employing supercritical alcohol conditions [6] and enzyme catalysis [7]. The commonly used homogeneous catalysts are NaOH, KOH and their alkoxides. Homogeneous alkali-catalyzed transesterification is much faster than acidcatalyzed transesterfication [8]. However, a large amount of water is required to transfer the catalysts from the organic phase to a water phase after the reaction. Therefore, it is considerably more costly to separate the catalyst from the produced solution [9]. These disadvantages could be removed by use of a heterogeneous catalyst [10]. The use of heterogeneous catalysts eliminates the neutralization step, hence it results much easier to separate from liquid products. Also, they can be designed to give a higher activity and selectivity and to have longer catalyst lifetimes [11]. A large number of different heterogeneous catalysts have been synthesized for biodiesel production. For example, calcined Mg-Al hydrotalcites [12], zeolite and metal catalysts [13], metal oxides such as calcium oxide (CaO) [14], magnesium oxide (MgO) [15], zirconium oxide (Zr02) [16], and supported catalysts [17] have been investigated as heterogeneous catalysts. CaO and MgO are most frequently used heterogeneous catalysts for biodiesel production [18]. In this present work, we aimed at developing an efficient catalyst for transesterification of canola oil. We have prepared KOH/ Al203 by impregnation and applied to determine the optimum conditions for biodiesel production. Three different variables including reaction time , alcohol to oil molar ratio and catalyst loading with may influence the quality of the produced biodiesel were optimized. Moreover, SEM (scan electron microscope), XRD (X-ray diffraction) and XRF were used for characterization of the catalysts."

Jan 1, 2012

By Rauf Hurman Eric

In this review paper the effect of composition and temperature on electrical conductivity and viscosity of the slags encountered in electric smelting of PGM-containing sulfide concentrates is described along with their liquidus temperatures. Optimization of slag composition is attempted on the basis of opposite trends of viscosity and electrical conductivity. Metal losses to slag, matte-slag separation and matte settling are also discussed in conjunction with interfacial and surface tension concepts. The electrode immersed in the slag phase is the main factor in the design and operation of the furnace. The most important electrode parameters are the size and the positioning in the slag phase which are determined by the slag resistivity, furnace resistance, cell constant and power input. The flow of heat generated by the electrode current determines the energy distribution and furnace dimensions creating viscosity profiles within the slag phase which in turn affects the flow conditions. Thus the flow of slag is discussed together with furnace geometry, stirring action, buoyancy and electromagnetic effects and the action of the electric furnace as a settler is emphasized. A discussion on the design d production capacity of the furnace is provided which are based on considerations derived mainly from slag properties.

Jan 1, 2006

By Hans Jürgen Maier, Gregory Gerstein, Florian Nürnberger

Microstructural analysis to support the development of material models provides valuable information to design complex forming operations. Damage models such as e.g. by Gurson consider spherical voids only. However, investigations of bcc steels by scanning electron microscopy reveal that voids exhibit an ellipsoidal shape with progressing deformation. The material’s weakening in the Gurson model is taken into account by the void volume fraction. Therefore, a three-dimensional characterization of the void shape offers important data for modelling. Thus, information on the anisotropy of the process of void evolution and accordingly, about the anisotropy of the deformation process is provided. Application of the information regarding the void shape anisotropy within the Gurson model is discussed.

Jan 1, 2016

By M. I. Kalashnikova

In hydrometallurgical technological flowsheets several methods of target components removal from solution are used. One of these methods is non-ferrous metals removal in the form of rich selective or collective concentrates. In the present work pyrometallugical mattes, thiosulphate containing solutions and pulps, iron powder with elemental sulphur and calcium sulphate were used as the precipitator. It was shown that depending on precipitator compound and process parameters non-ferrous metals precipitate from solution in the different forms with varying content of components including Ni3S2, NiS, Ni3S4, NiS2, (Ni,Co)S2, CuS; Cu1,765S; Cu1,97S.

Jan 1, 2006

By Leonid M. Lerner

High temperature aluminum Alloy 8009 is a rapidly solidified/powder metallurgy aluminum-iron-vanadium-silicon alloy. This alloy in combination with hard oxide aluminum film has unique engineering properties which may recommend its use in compressors and impellers for aerospace applications. Various anodizing processes (including Sanford Low Voltage DC+AC Process) for these task will be evaluated and normal chemical composition, physical properties, and macrostructures of 8XXX aluminum alloys will be presented.

Jan 1, 2006

By Corby G. Anderson

Laboratory testing, interpretation and application of metallurgical technologies can be tedious, time consuming and costly. This paper outlines the use of proven statistical design of experimentation software for rapid optimization of laboratory testing and operating plants with limited representative sample utilization. This results in less costly required testing, a more thorough understanding of results and the ability to simultaneously optimize several variables and outcomes at once. At the Center for Advanced Mineral and Metallurgical Processing, this testing methodology has been used successfully in many metallurgical development and plant optimization projects thereby confirming its real world utility and application. Accordingly, several applied examples in flotation and hydrometallurgy will be outlined in this paper. This will include flotation testing of a copper gold ore, flotation testing of a copper, cobalt and gold ore, optimization of an industrial hydrometallurgical jarosite circuit and optimization of industrial nitrogen species catalyzed pressure leaching of a copper enargite concentrate.

Jan 1, 2006