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By Xuling Chen, Zhiyun Ji, Min Gan, Wenqi Li, Xiaohui Fan, Zhiyuan Yu

"Specularite and vanadium-titanomagnetite are difficult to granulate, and with the increase of their proportions, the permeability of sintering bed is deteriorated together with the combustion velocity of fuel for the shortage of air through the sintering bed, which can lower sintering speed and specific production capacity significantly. The biomass fuel has a higher combustion velocity than coke breeze, therefore the productivity of specularite and vanadium-titanomagnetite ore can be improved remarkably by replacing coke breeze partly with biomass fuel .The results showed that, when the proportion of biomass fuel replacing coke is 40%,the sintering speed and specific production capacity of 35% specularite were improved from 19.06mm/min, 1.33 t/(m2·h)to 21.45mm/min, 1.47 t/(m2·h),and that of 55% vanadium-titanomagnetite were improved from 17.23mm/min, 1.11 t/(m2·h)to 22.80mm/min, 1.44 t/(m2·h). As a conclusion, biomass fuel is effective to strengthen sintering of refractory iron ore.IntroductionThe iron and steel industry of our country has achieved significant development in the recent years. In 2010, the output of steel has reached to 0.627 billion tons. The increasing scale of iron and steel has led to rigorous domestic iron ore environment, and the reserves of hematite and magnetite that have superior sintering characteristics are on the decline with continually exploiting and utilizing [1]. Therefore, the RIO (refractory iron ores) SP (specularite) and VT (vanadium-titanomagnetite) have to be applied vastly. However, the quality of sinters can be deteriorated when utilizing RIO in high proportion due to their poor granulation and metallogenic performances [2, 3]. Generally, the ratio of SP is 3~5%,which should not exceed 10% in our country currently [4]. Though high rate of VT is adopted in PZH steel for a long time, the productivity is obviously low compared with normal sintering [5]."

Jan 1, 2012

By Ivan Imris

The common problem of new and conventional technology of copper production is the copper losses in the slags, which may be divided into mechanical and physico-chemical losses. In the first group can be included particles of mechanically entrained or floated unsedimented matte particles which coexist with slag. On the other hand, the physico-chemical losses are caused by solubility of copper in the slag in the form of sulphide and oxide. The copper losses in the slags from different processes has been predicted by calculation from thermodynamic data and compared with those determined by microscopic examination and quantitative electron microprobe analysis. Depending on the forms of copper losses in the slag the reduction of copper losses in the slag or the slag cleaning process could be suggested.

Jan 1, 2003

By S. Ajima

The Naoshima Smelter and Refinery is the most important copper operation of Mitsubishi Materials Corporation. There are a Mitsubishi Continuous smelter and a conventional type of copper tankhouse. The continuous smelter with 240,000 mtpy of anode production was commissioned in May 19914 replacing two existing smelters, i.e an original Mitsubishi Process line and a conventional reverberatory furnace line. In July 1992, the copper tankhouae was expanded for the purpose to close the gap of production capacity between the smelter and the tankhouse. The cathode production capacity was increased from 13,800 to 15,800 mtpm. By these plant modifications, the distribution of minor elements was significantly changed and the impurities load is getting on increase reflecting recent shortage of clean copper concentrates supply. The paper discusses the distribution of minor elements and the impurity control strategy at the smelter end the refinery.

Jan 1, 1995

By J. C. Yannopoulos

The quest for a continuous copper smelting and converting process, which has been going on for a long time, has not as yet reached its objective. The most recent efforts for the development of a continuous copper?making process started about two decades ago. Among the contending proposed processes, four have been piloted and three of them are currently in operation: the WORCRA process., the NORANDA process, the MITSUBISHI process, the OUTOKUMPU process. The WORCRA process, after some long pilot plant tests, failed to develop as an industrial process: The NORANDA process, as currently operating, is a smelting process and not a continuous copper?making reactor as initially conceived. The MITSUBISHI, although the only continuous process, has not been widely accepted. The OUTOKUMPU process can be applied only to a low iron concentrate feed and co?produces blister and high in copper slag. The thermodynamics of these "continuous" systems and the practical problems of their industrial application are reviewed and discussed. The achievement of efficient and inexpensive environmental control should' be the primary objective of any new process development. A review of the environmental problems of the copper industry indicates that the quest for a continuous smelting and converting furnace should be intensified.

Jan 1, 1983

By Asmo Vartiainen

Background of Direct-to-Blister Flash Smelting is discussed; especially slag chemistry relating to copper solubility, slag fluidity and impurity behavior. In December, 2000, Mini-pilot Flash Smelting test runs were carried out at Outokumpu Research Oy to produce blister copper from Chilean concentrate and white metal and from a mixture of them. Tested slag types were iron silicate slag, ferrous calcium silicate slag and calcium ferrite slag with different slag compositions and different concentrate/white metal ratios. The test runs were successful. The fluxing effect of copper oxide was clearly demonstrated and ferrous calcium silicate slags remained fluid on a very wide liquidus range. The distribution of arsenic between ferrous calcium silicate slag and blister copper is much higher than between iron silicate slag and blister copper. This successful test run with the new slag type offer new possibilities in Direct- to-Blister process design.

Jan 1, 2003

By Asmo Vartiainen

Background of Direct-to-Blister Flash Smelting is discussed; especially slag chemistry relating to copper solubility, slag fluidity and impurity behavior. In December, 2000, Mini-pilot Flash Smelting test runs were carried out at Outokumpu Research Oy to produce blister copper from Chilean concentrate and white metal and from a mixture of them. Tested slag types were iron silicate slag, ferrous calcium silicate slag and calcium ferrite slag with different slag compositions and different concentrate/white metal ratios. The test runs were successful. The fluxing effect of copper oxide was clearly demonstrated and ferrous calcium silicate slags remained fluid on a very wide liquidus range. The distribution of arsenic between ferrous calcium silicate slag and blister copper is much higher than between iron silicate slag and blister copper. This successful test run with the new slag type offer new possibilities in Direct-to-Blister process design.

Jan 1, 2003

By K. Morsi

Titanium-titanium boride whisker (TiBw) composites are emerging as strong candidate materials for advanced applications within the automotive, aerospace and defense industries. Although increasing TiBw volume fraction improves the specific stiffness and wear resistance of titanium, it is usually on the expense of fracture toughness and ductility especially at increased volume fractions of reinforcements where whiskers interlock. This research addresses strategies for microstructural design that may overcome these shortcomings, by generating titanium composites that are locally reinforced with TiBw through in-situ reaction in segregated regions of the microstructure and separated by ductile Ti matrix. The effect of varying composite reinforcement particle sizes (i.e. size of the reinforced regions) on the pressure-less sintering of these dual matrix composites is discussed. Electric current activation was also used to generate high density dual matrix composites and a new simultaneous imaging and modulus mapping technique was used to characterize these unique microstructures.

Jan 1, 2008

By Animesh Jha, Chris Dometakis

"Without the use of a flux, only a poor dispersion of ceramic phase can be achieved. A molten-flux-assisted ceramic phase dispersion technique for producing aluminium alloy metalmatrix composites has been developed. In this paper, we report the physical chemistry for the dispersion of TiB2 in molten aluminium. In particular, aspects of the interfacial energy and the thermodynamics of the dispersion reactions are briefly discussed for enhancing the volume of dispersion phase in the molten metal and for controlling their morphology. This investigation also addresses the role of molten flux in the fabrication of AI-alloy mmc using a casting technique. The morphological aspects of the dispersion are explained on the basis of the classical theory· of nucleation.IntroductionMetal matrix composites (MMCs), have long been recognised as an important class of material due to their greater wear resistance, specific stiffness and temperature capability when compared to conventional monolithic alloys. Particulate reinforced composites produced by melt casting techniques have been amongst the first MMCs to achieve commercial market viability. The advent of melt mixing techniques such as the Duralcan™ process have enabled low cost, easily fabricated composites based on the AI-SiC and AIAlz0 3 systems to be produced. In this process, uncoated ceramic particles with diameters 10ltm and larger, are incorporated into conventional monolithic alloys with reinforcement levels up to 25 volume percent. The AI-7Si-SiC metal-matrix composites have good wear resistance, high strength, low density and high thermal conductivity. The combination of these physical and mechanical properties has become a major attraction for the fabrication of light-alloy composite disc rotor brakes for the automotive sector2. However, in silicon-free alloys, SiC is thermodynamically unstable above the composite melting point and is extensively attacked by the melt to form aluminium carbide3 :"

Jan 1, 1996

By K. J. Martchek

"This introductory presentation will highlight recent efforts to quantify the positive value of recycling metals such as aluminum, magnesium, lead, zinc, nickel and copper in relation to the three pillars of ""sustainable development"" - environmental protection, economic development and improve social consequences.This presentation will provide an overview of life cycle assessment profiles increasingly being utilized by customers, regulators and environmental advocacy groups to holistically evaluate the environmental performance of materials and products. The environmental profiles of prodi.lcts containing recycled metal will be presented based on rules established by the International Organization for Standardization (ISO).Significant to the life cycle profile of metal products is recent confirmation. that recycling has the potential to reduce materials production energy consumption by 95% for aluminum, 80""/o for magnesium and lead, 75% for zinc, and 70% for copper. Furthermore, . ""metals are eminently and repeatedly recyclable, while maintaining all their properties (1 ). "" Their durability relative to many hydrocarbon based materials enhance .their life cycle performance. However, the persistence of metals when dispersed into our natural environmental makes recovery and recycling particularly important Overall, when considering life cycle effects, recycling is critical to a sustainable future for metal products.Finally, regional and international regulations will be highlighted which will effect the efficient recovery and recycle of metals and their overall contribution to environinental protection, economic development and the enhancement of society."

Jan 1, 2000

By Wang Zhi

High-Mg-content concentrates are usually treated in Jinchuan flash smelting Furnace. Because the viscosities of high-Mg-content slag is very high, the operation of flash smelting becomes very difficult. To solve this problem, the viscosities of the semi-synthesized FeO-MgO-Si02 slag of different compositions were measured. The results showed that when in the slag the weight percentage of MgO [m(Mgo)] is 6-10%, the ratio of the weight percentage of iron to that of Si02, m(Fe)/m(SiO2) is 1.1-1.4 and the temperatures are within 1473?1773K, the slag viscosities increased with the increase of m(Mgo) and m(Fe)/m(sio,). When m(Mgo)<6%, the smelting temperature should be controlled at I 300°C in order to to keep the smooth operation. When m(Mgo» 10%, the temperature should be kept above 1633K. When the content of MgO is higher, a lower viscosity slag ean be produced by decreasing the ratio of m(Fe)/m(sio,). The appropriate ratio of m(Fe)/m(sio,) for Jinchuan flash smelting furnace is about 1.2.

Jan 1, 2003

By Warren J. Bruckard, Mark I. Pownceby, Sazzad Ahmad, M. Akbar Rhamdhani

Rutile is the preferred feedstock for producing high-grade TiO2 pigment but due to decreasing resources, alternative materials such as ilmenite is now used to produce a synthetic rutile (SR) feedstock. This requires removal of impurities (e.g. Fe, Mg, Mn) which, for a primary ilmenite is straightforward process. Processing of weathered ilmenite however, is complex, especially when chrome-bearing impurities are present since minor chromium downgrades the SR market value as it imparts color to the final TiO2 pigment, Chrome-bearing spinels are a problem in weathered ilmenites from the Murray Basin, Australia as their physical and chemical properties overlap with ilmenite making separation difficult. In this paper, different sulfidation process routes for weathered ilmenites are analyzed for their applicability to Murray Basin deposits as a mean of remove chrome spinel impurities. Thermodynamic and experimental studies indicated that selective sulfidation of chrome-bearing spinel can be achieved under controlled pO2 and pS2 processing conditions thereby making them amenable to separation.

Jan 1, 2015

By Michael B. Tessieri

With the increasing environmental demands and higher fuel efficiency standards on auto manufacturers, the use of aluminum in automotive applications is expected to show significant growth for the balance of this decade. Cast and wrought aluminum usage is reviewed by auto part, and alloy family for the year 2000 automobile. The analysis addresses the effect of this increased volume on the recycling infrastructure and identifies issues and opportunities, which will face the recycling industry.

Jan 1, 1995

By Saeid Pournaderi, Ahmet Geveci, Ender Keskinkilic, Yavuz A. Topkaya

"This study investigated calcination behavior of one of the Turkish laterite deposits, which was recently found in Sivrihisar region. Representative limonitic laterite samples (1.26% Ni) taken from Yunusemre Karasivritepe and Kucuksivritepe location were first subjected to drying. Removal of chemically bound water and other volatiles were then studied, in detail. In the calcination experiments, temperature and time were the main experimental variables. Thermal treatment was conducted at the specific temperatures in 250 °C - 800 °C range. The weight losses due to elimination of chemically bound water and other volatiles were reported to be approximately 10 per cent of the weight of the ore. For the particle size used in the current work, 700 °C and 40 minutes were determined to be the optimum calcination temperature and time, respectively.IntroductionThe nickel ores that are economically valuable can be grouped into two categories: sulphide type nickel ores and oxide type nickel ores, namely laterites. Over all reserves in the world, 40% are sulphide nickel ores and the remaining 60% are laterites [1]. Pyrometallurgical nickel extraction from sulphide type nickel ores is conducted via matte smelting. More recently, laterite ore bodies have been subjected to nickel extraction. Depending mainly on the chemical composition of the laterite and the process economics, various extraction techniques have been implemented: pyrometallurgical route involves ferronickel smelting. High pressure acid leaching (HPAL) is the commercial method for hydrometallurgical nickel extraction, while ammonia leaching (CARON Process) is a combination of pyrometallurgical and hydrometallurgical processes [2]. With the improvements in these processes, it is predicted that laterite’s share in the world nickel production will rise to 50% in 2012, while it was reported to be 42% in 1,200,000 tons of annual production in 2003 [3]."

Jan 1, 2011

By M. C. Esposito

Seven pyrite samples purified from coal sources and one ore source pyrite (for comparative purposes) have been characterized by chemical and mineralogical analyses, inherent floatability, apparent specific gravity, surface area, semiconductor type, optical anisotropy, dissolution and oxidation rate. The data clearly demonstrate that pyrites from various coal sources differ not only from ore pyrite but from each other as well.

Jan 1, 1987

By A. J. Williams, T. N. Croft, M. Cross

"The computational modelling of extrusion and forging processes is now well established. In this work a novel approach is described which utilises finite volume methods on unstructured meshes. This technique can be used to solve simultaneously for fluid flow, heat transfer and non-linear solid mechanics and their interactions. The approach involves the solution of free surface non-Newtonian fluid flow equations in an Eulerian context to track the behaviour of the workpiece and its extrusion/forging, and the solution of the solid mechanics equations in the Lagrangian context to predict the deformation/stress behaviour of the die. Some preliminary examples of this approach will be discussed.IntroductionThe computational modelling of extrusion and forging processes is now well established. Within the last 20 years the finite element method has become the most commonly used technique to simulate metal forming processes [1]-[4]. The Lagrangian and Eulerian type of formulation have been the two major approaches to this problem.Lagrangian methods are efficient and suitable for handling non-linear problems in which small strains prevail, boundary conditions do not change with the course of deformation, and where mesh distortion is not a critical factor in the analysis. Unfortunately, the above points are essential to any accurate metal forming analysis. The problems of mesh distortion and element entanglement pose a serious drawback on the use of such methods. Some automatic remeshing techniques have been developed for Lagrangian finite element analyses of metal forming problems [5]-[7]. However, these methods are not robust and efficient enough to remedy the mesh distortion problems in general. An alternative is to update the mesh manually but this is not always possible, and even when it is feasible it involves major interaction by the user. In addition, remeshing is usually applied to the whole domain which is not necessary and increases CPU time. The complexities associated with remeshing also affect the ability to parallelise the code."

Jan 1, 2001

By A. E. M. Warner

Inco Limited has long and extensive experience in converting nickel-copper primary smelting mattes over a broad range of nickel/copper weight ratios and combined nickel-copper-cobalt contents. At the Copper Cliff Smelter, the composition of the converter product matte has to meet the requirements of the matte separation process; at the Thompson Smelter, converter matte of a different composition is cast into anodes for nickel electrorefining; and in Soroako, Indonesia, a very low copper product matte is granulated for the Japanese market. Recently, Inco has conducted pilot plant testing of three possible nickel-copper matte continuous converting routes, namely flash converting, oxygen top blowing-nitrogen bottom stirring, and tuyere blowing. This test work has generated substantial new information on nickel-copper matte converting chemistry. This overview paper reviews the metallurgy of nickel-copper matte converting, in particular the behaviour of cobalt and the operating conditions required to meet the iron and sulfur specifications of the product matte. The relevant thermodynamic information is used to discuss the industrial data.

Jan 1, 2003

By C. Takano

The integrated iron and steelmaking industry generates large amounts and many types of solid dusts and sludge, at different phases of the production. Within these are: sludge of the Blast Furnace; coke fines; fine and coarse fractions from oxygen converters; sludge from water treatment at rolling mill unit; and others. In this paper the above dusts and sludge were physically and chemically characterized. The obtained results allowed defining self-reducing pellets using these materials. The high temperature behavior of the pellets were evaluated. Good results, with no decrepitation and swelling, and high yield of reduction, show that it is feasible to recycle them, as self-reducing pellets, in oxygen steelmaking converter.

Jan 1, 2001

By Dieter Neuschiitz, Pengfu Tan

"In order to understand the sintering phenomena during iron ore sintering process, a CFD model of iron ore sintering has been developed, combining with the kinetics of 15 relevant chemical reactions with the aim of describing the temperature fields and the gas flow patterns in the sintering bed. This CFD model can be used to simulate the concentrations of the gaseous and solid species, temperatures of the gas and solid, melting and molten fractions of the mixture, gas velocities, temperature zones and residence times of the gas in each temperature zone. IntroductionThe off-gas analyses clearly revealed that the off-gas of a sinter strand does not have a composition corresponding to thermodynamic equilibrium, for example, the CO, CO2 and O2 concentrations are not the mutually consistent equilibrium values. Apparently the chemical reactions in the sinter bed are controlled kinetically. Therefore kinetic modeling of sintering reactions combined with CFD modeling is necessary to understand the sintering phenomena during iron ore sintering process.Several models of iron ore sintering have been developed since 1970 [l-l 4l, each being more refined than its predecessor. The models were formulated as a series of differential equations to describe chemical and physical changes occurring at a point in the bed. These equations were solved numerically in a vertical plane along the strand. The present CFD model, based on the Nath's model [14], has been published in the reference [15]. In this work, some new chemical kinetic models of gas-solid reactions are incorporated in the present CFD model. The concentrations of gaseous and solid species, temperatures of gas and solid, melting and molten fractions of solid, velocity of gas, and residence time of gas in each combustion zone can be calculated by this model."

Jan 1, 2004

By F. Kongoli

Viscosity is an important parameter of copper smelting and converting processes. It affects the settling of matte or metal droplets in the slag, distribution of elements etc, Despite this importance, confusion exists on the viscosity of copper smelting slags as a result of disagreements found among the measured viscosity data of several authors especially in the slags of high ferric iron content and close to magnetite precipitation. In this work a critical review of the existing data on the viscosity of copper smelting slags has been first carried out and the effect of oxygen potential on the viscosity of copper smelting slags has been clarified through a coupled quantification of viscosity and liquidus temperature. The confusion in the literature has been clarified and the importance of the relation between the viscosity and the liquidus temperature is discussed,

Jan 1, 2003

By Tuula Mäkinen

One of the latest applications of the Outokumpu Flash Smelting Technology is the direct smelting ,of nickel concentrates to metallised low-iron nickel mattes. Compared to the conventional nickel smelting, the new DON process needs a lower number of smelting vessels resulting in considerable economic and environmental benefits. Fundamentals of smelting nickel concentrates in one stage to low-iron mattes are presented. Properties of nickel. smelting slags with an emphasis of the slag fluidity at high MgO-levels are also discussed. Conditions prevailing in DON mattes at high oxidation degrees are presented as well as their influence on the behaviour of such mattes in the settler and on tapping the furnace. Distributions of elements in the direct smelting are presented and compared with the conventional process. A further comparison is made with pilot-plant data and the industrial scale.

Jan 1, 1998