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By Ryan Walton

The Flash Converting Furnace at Kennecott Utah Copper converted over 465kmt of high-grade matte in 2002 but was restricted due to low matte production to 395kmt in 2003. This paper presents updated operational performance data and describes improvements implemented since the mid 2001 rebuild. Matte burner feed distribution, silica and arsenic impacts on settler lime-based slag operability, blister laundering, uptake/boiler accretion control, and dust sulfation will be discussed, as well as current development requirements dictated by operational imperatives and furnace modification plans.

Jan 1, 2005

By F. Z. Utyashev

The present work considers the essence of fragmentation: on the level of a simple model as a material response to the curvature accumulated by it at large deformations. It is on this basis that the correlation between curvature and fragment sizes is determined. It is shown that at deformation the area of curvature center inevitably changes. It is revealed that a specific value of variation of center surface area, i.e. ^As parameter, is numerically equal to the value of curvature acquired by a material. Minimum sizes of fragments and grains depending on ^As have been estimated, and the dependence of this parameter on strain has been established. Besides, the present paper considers the effects exerted by curvature center geometry, material distortion, directions of deformation and thermal warming up in the localization zones on structure refinement when various techniques are applied.

Jan 1, 2006

By Oliver Zach

To know as much as possible about the condition of the refractory material (lining thickness, slag layer, build ups, ...) in an high temperature furnace is very important due to the safety and economic impacts. The new CONSCAN system offers the possibility to measure the inner surface of an furnace, and based on this results to calculate the thickness of the refractory lining, slag layer, build ups,.... The CONSCAN System provides this results as figures and graphics. This system is also working under hot conditions so it is not necessary to cool down the furnace. Based on these results the process control and the refractory lining concept could be optimized for maximum campaign life of the furnace.

Jan 1, 2006

By Anat Deepatana

Bioleaching of nickel laterite ores is the extraction technology based on the use of heterotrophic micro-organisms and their organic acid products to dissolve metals from oxide minerals. This study examined the chemical leaching kinetics of limonite and nontronite ores with metabolites including citric, lactic and malic acids. The leaching process was found to follow the chemically controlled model. The leaching kinetics was found to be significantly influenced by the acid strength or dissociation of acids in solution. Although increasing the acid strength increased the rates of leaching, this trend was not indefinite. An optimal acid concentration that defined the fastest leaching rates was identified for each acid. The amenabilities of the minerals hosting the nickel and cobalt in limonite and nontronite to organic acid leaching were also established.

Jan 1, 2006

By Jacques J. Eksteen

Metallurgical accounting around toll treatment smelters pose a number of challenges. This paper reviews the requirements for good sampling practice, and how conflicting requirements for good furnace operation and design often makes reliable closure of the metallurgical balance tenuous at best. Typical physical causes of variance and bias will be identified. The propagation of error (in the form of variance) will be discussed for a copper smelter.

Jan 1, 2006

By Pengfu Tan

One copper Isasmelt furnace has been operated in Xstrata Copper at Mount Isa in Australia since 1992. A thermodynamic model and computer program, CuModel, has been developed to model the distribution behaviors of Cu, Fe, S, O, Ni, Co, Sn, Pb, Zn, As, Sb, Bi, Au and Ag, copper loss in the slag, and heat balance in copper smelting process, matte converting process and copper continuous smelting process. The thermodynamic model has been used to model the key parameters in the control of the copper Isasmelt furnace. The effects of the process parameters on the control of the copper Isasmelt furnace have been predicted and discussed. These process parameters include SiO2/Fe, matte grade, coal, temperature, spec air of feed, oxygen enrichment, and MgO contents in slag.

Jan 1, 2006

By Elaine Araújo

Since the ancient times, clays were used as decolorant material for various types of oils. These clays were called ?decolorant clay?. They have the property to decolor dye materials present in mineral oils, plants and animals. Biofuel is a fuel derived from biomass of live organisms. As biodiesel is produced from renewable sources, the generation of employment due to industrial scale production may cause a reduction in the dependence on foreign diesel importing, as well as the reduction of air pollution by the addition of biodiesel to diesel. This study aimed to develop a technological process to decolor post- consumption oil to be applied as biofuel. The results were characterized by techniques of XRD (X-ray diffraction), X-ray fluorescence and FTIR (Fourier Transform Infrared). It was observed that the post-consumption oils presented a higher decoloration result after treatment with the Brazilian clay.

Jan 1, 2009

By H. Antrekowitsch

Nowadays, the pyrometallurgical treatment in copper smelters is the common process for the recycling of metals from the electronic scrap. Furthermore the European Directive on the Waste from Electrical and Electronic Equipment (WEEE) and the Directive on the Restriction of Hazardous Substances (RoHS), increase the importance of electronic scrap recycling. Besides these a high amount of plastic and inert components in these materials leads to problems at the processing. An optimisation concerning the internal recovery and the high amount of plastic is necessary to reach the recycling quota of the European directive. The majority of the scrap is treated mechanically in order to separate in a first step plastics from metals, iron from nonferrous metals and harmful substances from valuable materials. But the quality of the different fraction often rather low and further treatment leads to higher costs. Therefore an interaction between mechanical treatment and metallurgical processing should be realised. The Christian Doppler Laboratory for Secondary Metallurgy of Nonferrous Metals at the Institute of Nonferrous Metallurgy at the University of Leoben carried out investigations concerning the optimisation of the metallurgical recycling and the treatment of the input materials especially of printed circuit boards.

Jan 1, 2006

By C. J. Newman

In January 1999, a redesign of the Kennecott Flash Converting furnace settler was initiated to enhance furnace integrity and extend furnace life. This furnace uses Kennecott-Outokumpu Flash Converting technology to produce copper directly from copper matte. A detailed assessment was made of all technology available around the world before making a decision on the design features to be incorporated in the new design. The new design includes the following: redesign of all sidewall cooling elements to include the latest cooling element technology; redesign of the furnace hearth to include a stadium hearth at the reaction shaft end of the furnace; redesign of the furnace hearth to include a stepped hearth design adjacent to the furnace sidewalls; addition of flat settler roof cooling elements .around the reaction shaft; replacement of reaction shaft transition elements with an improved design and improvements to the furnace cooling element monitoring systems. The Flash Converting furnace was shut down on a planned basis in July 2001 to implement these improvements after 29 months of operation, converting more than 1,000,000 tonnes of matte. During the 30 day shut down, the improvements were successfully completed, with furnace start up in August 2001

Jan 1, 2002

By Zengjie Wang

Kinetic study of hydrochloric acid leaching of Panzhihua ilmenite from China is presented. Both temperature and concentration of hydrochloric acid have significant effects on the rate process of Fe dissolution from ilmenite ore, while the ratio of liquid to solid has little effect on the Fe dissolution. The Fe dissolution is found to follow the spherical model f (??) =1-(1- ??)1/3 and the apparent activation energy is calculated as 47.21 KJ/mol, suggesting a chemical reaction controlled mechanism. The dissolving behaviors vary at different kinetic stages. At the beginning the amount of the dissolved Fe and Ti increased monotonically with leaching time, while about 15 minutes later the dissolved Ti in the form of TiOCl2 began hydrolyzed into TiO2 fines reunited on the ilmenite ore surface, as observed by SEM and EDS technique. For the unreacted ilmenite particles covered by a layer of hydrolyzed TiO2, the leaching seemed to be as a selective leaching of iron and because Ti dissolved from and hydrolyzed rapidly again into the unreacted ilmenite particles. The leaching process can be ended 4 hour later when almost of Fe has dissolved into the solution and TiO2 remains as solid residues. The effects of acid concentration and leaching temperature were also investigated.

Jan 1, 2009

By Pengfu Tan

A thermodynamic model of KIVCET lead smelting process has been developed. The model has the capability to predict the distribution behaviors of Pb, Zn, Fe, S, O, As, and heat balance in KIVCET direct lead smelting furnace. The compositions of lead bullion, matte, slag and gaseous phases, and heat balance are calculated. The effect of the ratio between oxygen and feed on the chemistry of the smelt and heat balance of the coke checker has been simulated and discussed. The thermodynamic model also helps to understand the tapping issue of the lead bullion. In this paper, some applications of this model in the industry have been presented.

Jan 1, 2006

By Emmanuel N. Zevgolis

Energy required for roasting and smelting of a nickeliferous laterite ore by the rotary kiln - electric furnace process is investigated. From this work it comes that thermal energy is about 65% of the total energy needed and the rest is electrical. Also, 61.3% of thermal energy input in the roasting step (of all combustibles fed into the rotary kilns) is used for pre - heating, 11.6% for pre - reduction and the rest (27.1%) corresponds to the energy of the remaining carbon in the rotary kiln products (i.e., calcine, dust and coatings). Carbon entering the system is used as follows: 57.9% for combustion, 37.1% for reduction and the rest (5.0%) remains unburnt. Exploitation of energy from gases of both furnaces, as well as the higher possible reduction degree, the optimum temperature of the calcine and also elimination of the excess air in the rotary kilns, improve significantly energy balance and economics of the process.

Jan 1, 2006

By Andrey V. Tarasov

To carry out a physicochemical substantiation of a transition to ?soft? modes of reduction of calcine obtained by desulfurizing roasting of nickel concentrate produced as a result of copper-nickel converter matte separation in a nickel anode production circuit, an analysis has been conducted of the macrokinetic behavior of actual calcine samples in the presence of gaseous H2-CO mixtures and solid reductant additives. Within a temperature range of 900°C to 1100°C the main regularities typical of the calcine reduction process with individual gases (H2, CO) also take place when using a gaseous mixture. Under the conditions of low-temperature (900°C to 1000°C) nickel oxide reduction with products of fuel oil conversion in the presence of coke, the role of the latter is insignificant from the technological viewpoint. As a result of the present investigations, we have obtained analytical expressions of macrokinetic parameters of the reaction interaction within the [NiO] calcine-H2-CO-C-CO2-H2O-O2-N2 system.

Jan 1, 2005

By Wang Shulan

The synthesis process of BaTiO3 from TiO2 and BaCO3 in the molten NaOH-KOH at 350oC was studied by the A.C impedance technique. The A.C. impedance of molten NaOH-KOH (xNaOH = 0.36) and the variation of the conductivity of the salt with time during the synthesized process were measured. The synthesized reaction of the BaTiO3 and the decomposition reaction of BaCO3 are fast and were finished in 10min. The interaction between TiO2, BaO and BaTiO3 and the molten salt was confirmed by the variation of the conductivity.

Jan 1, 2005

By Chuanlin Fan

The process of flotation separation and recycling of spent potlining (SPL) was described. On the basis of the laboratory investigations, the effects of influencing factors in froth flotation process, such as grain size, flotation agent dosage, pH value, pulp density, and dissolved components concentration, etc, were carefully studied. And the influence on environment of the process was also discussed. It was found that flotation separation can be used as an environment-friendly method for treatment of SPL residue. Carbon and other compounds (include cryolite, sodium fluoride, calcium fluoride and diaoyudaonite, etc.) from SPL were separated and recycled as flotation products respectively.

Jan 1, 2009

By Scott A. Shuey

Keywords: E-Waste, Pyrometallurgy Many might think addressing the issue of e-waste is a new area of study. Electronics disposal has been discussed in some circles for at least the past 25 years. The recycling of electronic waste (e-waste) tends to be a rather complex undertaking when considering the intimate bonding of materials in the average printed circuit board. The development of a recycling process is further complicated when considering the wide variety of products being generated under the heading of ?electronics.? Focusing only on the primary constituents (polymers, Cu, Al, Fe, etc.) tends to lead one to fairly simple flowsheets. Ignoring trace elements, and the various halide species generated, will lead process engineers down a development path that is sure to cause material handling issues. Researchers at Colorado School of Mines are modeling the complex chemistry that exists within the body of e-waste?comprising 39 of the known elements. An understanding of the systems thermodynamic behavior will result in the development of a more robust, long-term process for the recovery of valuable materials from the e-waste stream.

Jan 1, 2005

By Carlos Maurício Fontes Vieira

In the present work a ceramic body, fabricated using a mixture of clays and sand, for roofing tiles, produced in Campos dos Goytacazes, north of the State of Rio de Janeiro in Brazil, was characterized. Characterization was performed by X-ray diffraction, thermo analysis, chemical analysis, particle size distribution determination and plasticity. In addition, technological properties related to water absorption, linear shrinkage and flexural rupture strength were determined in samples fired at 700, 900 and 1100oC. The results showed that the investigated ceramic body has satisfactory plasticity and presents a refractory behavior during firing due to the predominantly kaolinitic nature of the clays.

Jan 1, 2006

By M. Hochenhofer

Due to economic aspects and environmental regulations recycling of slag and waste from ferroalloy production became a very important issue for the companies during the last years. The treatment of slag depends prior on the composition, especially on their content of valuable metals and impurities. The final aim should be a total re-use of these materials in the industry e.g. cement industry, pig-iron production etc.. Therefore, to reach the required physical and chemical properties for a further use, possibilities of a metallurgical treatment have been investigated. The conditioning of slag with a high V-, Mo- and P-content via reducing metal bath showed to be one alternative. To determine the optimal process parameters, practical investigations with different slag compositions and thermodynamic calculations were carried out.

Jan 1, 2006

By Z. Sun

Magnetic fields have been used for inclusions removal from melt and preparation of materials with gradient compositions. Fundamental in these applications is that the induced magnetic forces on the particles/melt can enhance migration and change the interaction behavior. In the present paper, migration and interaction behavior of electrical-insulating particles in a conductive melt under strong magnetic field are theoretically analyzed. It is found that the migration can be considerably enhanced for micrometer sized particles by applying a strong magnetic field. In addition, two forces are involved in the interaction between two particles: the interparticle magnetic dipole-dipole attractive force due to magnetization and the repulsive force induced by flow of the melt. This theoretical analysis renders a better understanding of recent experimental results. Additionally, a new method by using strong magnetic field can be proposed to control the particle size distribution for the preparation of metal-matrix composites.

Jan 1, 2009

The purpose of this study was to investigate the immobilization as a host for metallic pollutants (Cr, Cu, Pb, and Zn) by ettringite phase. Ettringite phase is produced through hydration reaction of calcium aluminate with gypsum. From the XRD patterns, it is known that the distance between spaces in 010 planes in ettringite crystal increase with an increase of ionic radius of heavy metal except Pb; no big difference is shown. For this reason, the d-value of 010 planes in ettringite crystal increased with the substitution of Cr, Cu and Zn having a big Al ironic radius. But in case of Pb, because the substitution occurred at calcium site, it does not influence to increase d-value of 010 planes.

Jan 1, 2006