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By Marc Verhaege

The effluent under investigation results from a catalic oxidation unit in which paraxylene is oxydised to terephtalic acid. The solution contains cobalt and manganese as their acetates in a concentration range of 0,4 - 1,2 g/I of cobalt and 0,8 - 2,4 g/l of manganese. Before being fed into the main waste stream treatment unit of the plant it is advisable to apply a petreatment step in which both metals are eliminated to a great extent from this effluent. Conventional treatment is done by precipitation of both metals either through pH increment with a base or by adding a suitable reagent producing insoluble species. The aim of this study was to look for a treatment (elimination of both metal species) in which no sludge or precipitate is formed.

Jan 1, 1995

By J. R. Hartin

Traditionally, many of the advances in casting technology have been made by expensive and time consuming trial-and-error methodology. Modeling of the complex solidification process promises production of castings which are made "right the first time." Even though several models are available for simulation of conventional casting processes, none of them address this relatively new technology of investment cast titanium aluminides. In this paper, modification and application of a transient, three-dimensional, fully coupled fluid flow and heat transfer solidification modeling computer program to the analysis of centrifugally cast titanium aluminides is discussed. The predictive results of the program are compared to qualities of actual cast parts for validation.

Jan 1, 1992

By Zachery Zanetell

Flotation circuit performance has become increasingly more challenging due to the complexity of available ore sources. To optimize value mineral recovery, the mineralogical composition of the ore should be evaluated and understood. Utilizing a variety of mineralogical and analytical tools, flotation processing challenges can be overcome and potential limitations understood. In this paper, several case studies will be discussed in terms of the value that has been provided through the use of mineralogical analysis to optimize flotation performance.

By Animesh Jha

The carbothermic reduction of chalcopyrite has been studied in the temperature range 1073 to 1273K in presence of lime. The role of lime during the reduction process is explained and the phase equilibria leading to the metallisation of copper and iron are discussed. The effect of coal and carbon monoxide on the reduction process have been studied and the rate governing steps are identified. This investigation also cites examples of possible mechanisms of physical separation of metallic Cu from iron during the reduction process.

Jan 1, 1992

By J. D. McCain

Magma's San Manuel smelter has adopted new operating techniques resulting in 21% increased productivity and 87% reduction in lost time accidents. Reverberatory furnaces were converted to coal firing from expensive natural gas and fuel oil. Slag and matte flow problems and safety were improved by implementing hydraulic slag stopping and matte tapping machines. Coordination of furnaces, converters and acid plant was improved by using a computer-aided converter controller/scheduler function. Manual mudding of converter lips after each collar pull was replaced with a gunning system for coating the mouth castings. One converter punch car was automated using robotic technology. An automatic anode take-off was installed with fewer moving parts and a mechanism for ear twisting one cell contact. Anode copper refining was improved by replacing propane/hydrogen mixtures with high pressure/velocity natural gas tuyeres. Improved converter scheduling increased acid plant production 43% with more autothermal operation time. Six dedicated computers/microprocessors are utilized for automation, data acquisition, process monitoring and on-line air quality information for the Supplementary Control System.

Jan 1, 1983

By R. Kola

Since more than 15 years the Waelz process at "Berzelius" in Duisburg has proved suitable for reprocessing the zinc and lead containing dust and .sludge which inevitably occur in making steel in EAF-plants. The produced Waelz-oxide is agglomerated in a hot-briquetting plant and charged to an Imperial Smelting Shaft Furnace to recover the valuable elements in form of metallic zinc and lead. In view of the actual importance of the dumping problems of the EAF wastes a description of the "Berzelius" treatment route is given but also the situation in Western Europe is illustrated. Dust from stainless steel production is successfully treated in the Scan Dust Plasma Process in order to recycle Chromium and Nickel, while the resulting Zinc-Dust is treated via the Waelz-ISF-Route. For treatment of low Zinc-containing dust, sludge and fines from integrated steelworks, pilot scale tests have been carried out successfully in the Circulating Fluid Bed in order to recover metalized iron and .zinc/lead fume. A 30,000 tpy Demonstration Plant is planned?.

Jan 1, 1990

By Chang Wei, Zhigan Deng, Minting Li, Cunxiong Li, Xingbin Li

A direct hydrometallurgical process of extraction molybdenum and nickel from molybdenum-nickel ore by pressure water leaching without reagent was studied. The extraction of Mo and Ni from molybdenum-nickel ore by oxygen pressure leaching, which exploit the characteristic of molybdenum-nickel minerals contain high concentration amorphous sulfide which has highly active, and make the most of easily oxide to sulfuric acid and sulfate at low temperature and excess oxygen presence of the amorphous sulfide. Under oxygen pressure conditions, considerable molybdenum and almost all the nickel were extracted into solution in the leaching process. The results show that with the leaching time for 3~4h, temperature at 150o C, liquid-to-solid ratio of 2mL/g, mineral granularity of 0.074mm, oxygen partial pressure of 0.4~0.5MPa without other reagent, molybdenum leaching percentage can be over 80% and nickel leaching percentage can be more than 97%. Furthermore, about 80% sulfur in the Mo-Ni ore has been transformed into sulfuric acid.

Jan 1, 2014

By George Grandy

Kvaerner experience is being used to develop software to design or simulate crushing and screening plants. The model techniques discussed are presently being used for open-circuit plants and are being extended to closed circuit plants. The program contains a library of routines, each representing a piece of equipment or unit operation, which are assembled into one of several open-circuit plant configurations. Routines include gyratory primary crushers; standard secondary and shorthead tertiary cone crushers; single, double or triple deck screens; and stockpiles, feed bins and belt conveyors. The program uses steady-state models to simulate the performance of crushers and screens that have small residence times and quickly reach equilibrium when operating conditions and/or parameters are changed. The dynamic aspect of the total circuit model concerns the storage units within the circuit, i.e. stockpiles and bins, and, in the closed circuit configuration, circulating loads and size distributions. In many cases, just vendor's catalog data are necessary for a pre-feasibility simulation; in other cases, actual plant test data are required to obtain more accurate simulations. The entire plant is shown in a single graphic screen so the user can see all the relevant information he might want, and soft-keys are provided for the user to make on- line parameter changes and observe the effects on storage elements, equipment feed rates and the final product size distributions. The model also reports equipment utilization in percentage, power consumption, and other related operating information, and soon, will be able to report estimated capital and operating costs.

Jan 1, 1999

By Shadia J. Ikhmayies

"Cadmium sulfide thin films were prepared on glass substrates by the spray pyrolysis technique at a substrate temperature of 490°C. Some of the films were etched by HC1 in distilled water, others were heat treated in nitrogen atmosphere, and another set of films was first etched by HC1 and then annealed. Room temperature impedance spectroscopy measurements on the films were performed using coplanar geometry in the dark and in room light in the frequency range 20 Hz to 1 MHz. The experimental data were represented by complex plane diagrams and showed one well-defined semicircle in the high frequency region. Hence the equivalent circuit that models the CdS: In thin films was found to be a single RC circuit, which indicates the bulk conduction through the grains. The influence of treatments on the electrical properties was investigated.IntroductionCadmium sulfide (CdS) is a brilliant II—VI semiconductor material with a direct band gap of 2.42 eV at room temperature. It has many outstanding physical and chemical properties, which have promising applications in multiple technical fields including photochemical catalysis, gas sensor, detectors for laser and infrared, solar cells, nonlinear optical materials, various luminescence devices, optoelectronic devices and so on [1]. There are different methods to prepare undoped and doped CdS films, such as rf sputtering [2] chemical bath deposition (CBD) [3], pulsed laser deposition (PLD) [4], and spray pyrolysis (SP) [5-11]. Of these methods, spray pyrolysis represents the less expensive option, and can produce large area high-quality low cost thin films [12]."

Jan 1, 2012

By Jan Smit

Sulphidic copper concentrates are generally processed by pyrometallurgical means; while oxidative pressure leach processing of such materials has been shown to be technically feasible, there has traditionally been little incentive to choose this route in favour of a smelting option. However, for concentrates with elevated arsenic levels, oxidative pressure leaching offers distinct advantages, as smelter air emission standards and restrictions on concentrate importation have tightened. The current state of pressure leach technology allows for high copper extractions from arsenical copper concentrates, while producing an environmentally stable process residue, without atmospheric emissions of sulphur dioxide or arsenic. In its studies on pressure leaching of copper concentrates, Sherritt has shown that arsenical feed materials can be converted into environmentally stable residues, with excellent copper extractions. The results of recent batch and pilot plant test work are discussed, including the deportments of copper, arsenic and precious metals.

By T. V. Jayaraman, Kranti Kumar, Paul Praveen J., Dibakar Das, A. R. James

"Lead free piezoelectric ceramics with high piezoelectric coefficients are in great demand for sensor and actuator applications. Synthesis and characterization study of one such lead free system, barium zirconate titanate - barium calcium titanate [xBZT-(1-x)BCT] (x = 0.5), via solgel method have been carried out. X-ray diffraction (XRD) and transmission electron microscopy (TEM) confirmed the formation of single phase BZT-BCT nanoparticles (<50 nm). The as-synthesized powders were calcined at 1000°C and the powders were pressed into cylindrical pellets. Solid-state sintering of the green pellets at 1550°C for 2 hrs resulted in single phase perovskite structure. Hysteresis loops were obtained which indicates the ferroelectric nature ofBZT-BCT. The bulk ceramic samples with the highest sintered density (~93%) were subjected to electrical poling and the piezoelectric properties ( d33, kp, & i:,) were measured. The structure and piezoelectric properties were investigated and correlated for the given composition of the BZT-BCT system.IntroductionPiezoelectric ceramics are widely used in various sensors and actuators and most of the piezoelectric ceramics, which are presently used, are lead based, which contains at least 60% lead (Pb) by weight. The critical disadvantage of these lead based piezoelectric ceramics is their hazardous effect related to the toxicity of lead, which poses a serious environmental concern starting from their processing to the disposal stage[l]. It is well known that a material to be a good piezoelectric it requires a morphotropic phase boundary (MPB) i.e. the composition induced phase transition between any two ferroelectric phases."

Jan 1, 2013

By Luiz A. Teixeira

A process is described whereby worn, deffective or crystallized photoconductive Se-As layers can be stripped off from aluminium photocopier drums, using hydrogen peroxide solutions in conditions such that the aluminium substrate is preserved from chemical attack. The process allows the stripped drum to be recoated with a new photoconductive layer, and to be put again in use.

Jan 1, 1990

By Dalene Joalet Steenkamp

Excavation of industrial-scale furnaces allows for the systematic study of reaction sequences by identifying the different reaction zones within the furnace. In 2013, Transalloys excavated a 48 MVA submerged arc furnace that was used for silicomanganese production using the ore-based route. The excavation method was reported elsewhere as was observations made in terms of refractory wear and modes of electrical energy dissipation prior to excavation. The paper presented here, reports on the process reaction zones observed during the excavation and subsequent phase chemical analyses of a number of process samples obtained during the excavation. The zones identified were a loose burden zone, a dry coke-bed zone, a wet coke-bed zone, a hard build-up zone, and an alloy zone. The results are compared to observations made in the excavation of an industrial-scale SAF and a pilot-scale SAF in Norway. The presence of the hard build-up zone below one of the electrodes and absence of a slag zone below all three electrodes are unique features of the SAF excavated at Transalloys.

By C. E. Abbey

Cobalt, iron and manganese play various roles in copper electrowinning using lead–calcium–tin alloyed anodes. Cobalt catalyzes electrochemical water decomposition resulting in lower anode potential and reduced corrosion rates. Iron reduces cathodic current efficiency, but is used to reduce higher oxidation states of manganese that oxidize organics in solvent extraction. Manganese also produces anode scale and is generally considered a problematic impurity. The effect of the combined interaction of these three metal ions on the anode potential has not been quantified yet. The current work used a three factor, two level, three replicate central composite design of experiments to analyze the effects and potential interactions among cobalt, iron and manganese. The experiments consisted of chronopotentiometric analysis to assess anode potential after 24 h of operation. Higher [Co], lower [Mn] and either high or low [Fe] yielded lower anode potentials. Two regression models were developed to predict anode potential as a function of [Co], [Fe] and [Mn]. A method to estimate electrical energy consumption for copper electrowinning is also presented.

By Makiko Takahashi

A tool is being developed to predict and visualize the microstructural evolution of steels during quenching. This tool utilizes experimental data and reference data that are stored in a database to predict the microstructural development. The visualization tool animates qualitative representation of two- dimensional microstructure drawings as well as the quantitative volume fractions of phases present as a function of time. This is achieved by superimposing the Jominy End-Quench test results over the Continuous Cooling Transformation diagram of the alloy. The predicted microstructure is presented through the web browser to maximize the ease of use. In addition, a parallel coordinate system is used to aid in identifying similarities within the data set by presenting the large number of data at a glance. The results for 4140 steel that was quenched in a wide variety of quenchants will be presented to illustrate the prediction and visualization tools. Keywords: Quenching, Microstructure Prediction, Simulation, Data Visualization, Database, Applet, Animation

Jan 1, 2003

By Ali Nadir Khan

Depleting copper resources and advancing technologies have challenged industries to develop more viable, adaptable and cost efficient processes using also secondary raw materials in copper production. This study is targeting to that goal by dynamic modelling of flow and heat transfer coupled with chemical kinetics in an industrial scale flash smelting furnace settler using commercial CFD software ANSYS Fluent. First, different physical phenomena occurring inside the settler, for example, settling and separation of the matte/slag phases, and heat transfer between slag/matte phases and settler walls are studied. Secondly, reaction kinetics between matte and slag, and between slag/matte and settler walls, and impurity element distribution will be studied. This would also include phase changes phenomena due to these reactions and the flow of the reaction gases inside the settler. Settling of polydispersed droplets, their coagulation, breakage, and WEEE particle behavior are further targets of the modelling work.

By Katie Schumacher, Greg Roset, Dayle Flynn

The Columbus Processing Complex of the Stillwater Mining Company began operations at Columbus, Montana in 1990 based on electric furnace smelting treating a precious metals concentrate from the nearby Stillwater mine and mill. Since that time, the smelter plant has been expanded in stages in order to treat recycled materials in addition to the concentrate. This paper describes a number of changes made at the plant to effectively handle recycled materials.

Jan 1, 2014

By Heikki K. Jalkanen

Thermodynamic properties of copper-iron mattes and slag-matte distribution of copper and some minor matte constituents (Ni, Co, Mo, As, Sb and Bi) are discussed on? the basis of equilibrium measurements: a change from. oxidic to sulfidic solubility as the predominant form of dissolution of copper takes place as matte grade decreases. Distribution coefficients of minor matte constituents are complex functions of sulfur and/or oxygen potentials?. The distribution behaviour of different? metals can be qualitatively derived from their affinities to copper and stabilities. of their sulfides and oxides. The equilibrium results are compared with commercially observed values. from Outokumpu.Oy flash smelting furnace.

Jan 1, 1983

By K. S. Kawatra

In recent years, there have been several efforts to develop binder mixtures for iron ore pelletization. Some efforts have been fruitful, while others have encountered failure. For example, adding corn starch to bentonite is effective, while adding fly ash to bentonite is not. When binders are made with fly ash, a pozzolanic reaction occurs, but no such reaction occurs when bentonite and corn starch are used together. The authors analyzed which binders can be mixed, and which binders will succeed. The authors confirmed this analysis with several laboratory and plant studies. This paper presents this critical analysis, along with various combinations of binders for making Iron Ore Pellets.

By A. Erçin Ersundu

In the present work, three different domestic iron ores; Sivas Divrigi B Head high grade hematite lump ore, Malatya-Hekimhan-Hasançelebi medium and low grade magnetite lump ores reduced with Soma-Kisrakdere lignite coal to investigate their suitability for sponge iron production. A laboratory scale box furnace was used to carry out the reduction experiments. In the experimental studies different operation parameters were selected being Cfix/Fetot. ratio, temperature in the range of 1100 - 1250 oC and time, to determine their effects on metallization. Metallization degree up to 90 % was found in the reduction experiments realized by using Sivas Divrigi B Head high grade hematite lump ore, whereas for Malatya-Hekimhan-Hasançelebi medium and low grade magnetite lump ores 60 - 65 % metallization degrees were obtained.

Jan 1, 2008