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By S. Agatzini-Leonardou

The objective of this work was to prove repeated loading capacities and investigate the selectivity of physically stabilized algal biomass from Spirulina platensis and Chlorella sp. for the removal and recovery of cobalt, nickel and chromium from laterite heap leach liquors. The testwork was carried out on a bench scale in small glass columns and proved that it was possible to immobilize the biomass on the highly porous surface of pumice stone (kissiris). Nickel and cobalt could be removed from pure aqueous solutions of each metal by the immobilized cyanobacterial biomass. Nickel and also cobalt biosorption was sensitive to the initial solution pH. Cobalt recoveries up to 80% were achieved after 5 loading cycles, from low concentration solutions, at pH 6.0. Nickel removal was complete under the same conditions, whereas chromium sorption was ineffective. Desorption of the metal loaded columns was effected by dilute sulfuric acid. The algal species giving the best adsorption capacities for the metals under consideration was selected for further experimental work with real laterite heap leach solution produced by column leaching. A statistical analysis of all obtained results was conducted using the fraction of metal removed as response. The ratio "mass of metal removed to mass of protein contained in the immobilized cells" was determined as well. The described method might be applicable for recovery of cobalt and nickel from diluted laterite heap leach solutions, such as heap wash waters, or for their removal from waste streams of a hydrometallurgical extraction process.

Jan 1, 1997

By R. D. Lrwin, W. M. Mullins, S. Venugopa, J. C. Malas

"Physical models for acoustic emission (AE) are introduced and expressions are derived to predict AE activity from such parameters as applied stress, strain and strain-rate. These models are then incorporated into a visco-plastic finite-element simulation program, and the acoustic emission event rate generated during metal forming operations are predicted. Simulation results are presented for upsetting operations on a typical C-Mn type steel for various friction and die geometry conditions. The AE model predictions compare well with the limited available experimental results reported in the literature and demonstrate that AE signatures can be reliably simulated. The signatures predicted for metal forging are fairly insensitive to processing parameter changes. This suggests that AE event rate monitoring may not be well suited to process monitoring for forging. However, the size of the features is conjectured to influence the frequency content of the AE signals. Thus, since current simulations include only the ability to predict the number of events for a set of processing conditions, future work is required to simulate the duration and magnitude of acoustic events. Fourier analysis techniques may then be applied to investigate correlation with microstructural features.IntroductionThe open loop control system method for deformation processing design, as described by Malas et al. [1 ], consists of several steps in series to achieve the final design. The first step uses microstructure development models to determine the optimum deformation path to achieve the desired final microstructure. The second step, the process model, calculates the processing parameters required to achieve this deformation path. Finally, the metal-working system uses the required processing parameters to produce the part. Figure 1 shows this in block diagram form"

Jan 1, 1997

By Bin Xu, Qian Li, Yong-bin Yang, Tao Jiang, Jian-jun Hu

It could significantly increase the leaching rate of refractory gold concentrate containing sulfur and arsenic by roasting pretreatment with adding certain amount of sodium sulfate, and the mechanism of that was systematically researched with DSC, XRD and SEM in this paper. Results indicated that the mechanism of Na2SO4 on double refractory gold concentrate at roasting pretreatment can be summed up in the following three aspects：Firstly, Na2SO4 can react with SO2 and SO3 which is produced by the oxidation of sulfides and generate Na2S2O7(l), which plays buffer effect on sulfides exothermic oxidation, avoiding the secondary-encapsulated of gold. Secondly, the liquid phase of Na2S2O7 can cover mineral particles' surface that possesses a sintering effect, it leads to internal cracks of the particles. Finally, mineral particles will gather with sodium sulfate particles as the center that can improve the permeability of the layer.

Jan 1, 2015

By Chonghun Han, Tae-Hwa Choi, Young-Hwan Chu

"A statistical optimization method is proposed to maintain stable operation in a blast furnace with stave coolers. The objective of this study is to find the operating condition which maximizes productivity as well as minimizes the heat load on the stave coolers. In this method, we first analyzed historical data and calculated the heat flux of stave coolers and the burden distribution by mathematical models. In this approach, we determined the variables to optimize and manipulated variables to adjust these response variables. Next, we collected the necessary data for the data variables after preprocessing such as removal of noise and outlier. Finally, we constructed empirical models describing the patterns of response variables in terms of manipulated variables by partial least squares regression method, and then these models were used as objective functions for entire optimization problem. By using appropriate optimization algorithm, we determined the compromised optimum operating condition considering all response variables from the past operating conditions.IntroductionBlast furnace operation which is accompanied by complex physical and chemical phenomena is an essential process for steel industry. In this process, iron ore which is charged into the blast furnace from the top goes downward. It is reduced to iron by CO gas and is melted by the heat of combustion of coke and pulverized coal. The pig iron is tapped at the bottom in liquid phase after removing the slag, which floats on the pig iron.The cooling equipment of the blast furnace wall is changed from the plate type to the stave cooler recently. In order to cool the shell uniformly and eliminate shell spray cooling, Pohang No.2 blast furnace of POSCO (Pohang Iron & Steel Company) was equipped with 11 rows of stave coolers. These staves are only 350mm-thick including the 170 mm-deep refractory on the hot face."

Jan 1, 2001

By Krishna Parameswaran

This paper discusses sustainability considerations in primary copper smelting using selected examples of practices at ASARCO LLC, an integrated U.S. primary copper producer. Using the classic Brundtland Commission definition of sustainable development, i.e., “development that meets the needs of the present without compromising the ability of future generations to meet their own needs,” the paper discusses how copper mining and smelting practices can be made sustainable. The examples used to illustrate sustainability considerations include: (1) adoption of flash smelting; (2) emission reduction and process improvement associated with anode refining of blister copper and the converter retrofit project, and (3) preliminary research findings on alkali treatment of copper smelting slags and copper mine tailings.

By E. G. Noble

The potential for using heterotrophic microorganisms to solubilize manganese from low-grade domestic ores is being assessed at the Reno Research. center, U.S. Bureau of Mines. More than 90 pct of the manganese has been extracted from a variety of oxide ores in shake-flask tests using molasses as a source of .. nutrients for the microorganisms. It has also been demonstrated that high recoveries of manganese can be obtained from a domestic wad ore using column bioleaching. 'l'he isolation and identification of organisms responsible for manganese extraction is discussed, as are the mechanisms responsible for manganese solubilization.

Jan 1, 1991

By W. K. Choi

Stainless steel exposed to wet environments at ambient temperature is subject to the formation of a surface biofilm. Depending upon the prevailing environmental conditions (dissolved oxygen, pH, Eh, concentration of cationic/anionic species), the biofilm may stimulate corrosion through formation of differential aeration zones and concentration cells. Corrosion significantly impacts the United States economy, since on a yearly basis, corrosion induced losses are estimated to be over $200 billion. A large portion of this corrosion is imputable to bacterial activity, and basic information is needed for a better understanding and control of the biocorrosion phenomenon. The present study has investigated the influence of Thiobacillus ferrooxidans in the corrosion of American Iron and Steel Institute (AISI) 304, 316 and 416 stainless steel samples. The formation of biofilm and microstructural changes on the surface of stainless steel samples and their weldments were assessed by microscopic examination, and the changes in the mechanical properties by stress-strain measurements. The significance of the results will be discussed.

Jan 1, 1993

By Norbert Steiner

For the desulfurization of weak SO2 gas streams, Degussa developed a process using dilute H2SO4 solution containing H2O, instead of conventional gas scrubbing with all solid absorbent medium (limestone, MgO). The process is based on fast reaction of H2O, with SO2 yielding H2SO4 up to 70% strength, depending on off-gas temperature. Compared to the conventional systems with typically < 95% efficiency, independent on the raw gas SO2 concentration, residual SO2 concentrations of less than 20 mg/Nm3 can be easily achieved, corresponding to nearly 100% removal. These features render the H2O, process a very attractive, low capital cost technology to retrofit existing conventional desulfurization plants.

Jan 1, 1996

By Qingchun Yu, Bin Yang, Yong Deng, Heng Xiong, Fei Wang, Minxiu Chen

"Metal aluminum produced by non-electrolysis process received much attention due to its lower energy consumption. In this paper, carbothermic reduction and carbothermic-chlorination of alumina in normal pressure and vacuum were studied. The products were examined by means of XRD, EDS and SEM. During the carbothermic reduction process using carbon reductant in normal pressure, no metal aluminum was found. However, when coal was used as reductant, a mixture containing metallic aluminum, A14C3, and silicon was obtained, but metallic aluminum couldn't be separated from the mixture. During the carbothermic-chlorination process in vacuum, Al404C and Al4C3 were produced by the reaction between alumina and carbon, and Al Ch gas reacted with Al404C and Al4C3 to produce Al Cl gas. Metallic aluminum was produced due to the disproportionation of A!Cl gas and condensed on the collecting plate. Meanwhile, the initial temperature of carbothermic reduction of alumina reduced in vacuum compared with that in normal pressure.IntroductionIndustrial production of primary aluminum is carried out in alumina cell by the so-called Hall- Heroult process, necessitating the use of very high currents of low voltage. The alumina from which metallic aluminum is gained must be chemically pure, otherwise impure metal results. The main drawbacks of the electrolytic production are its very high energy consumption, the release ofperfluorocarbons, and the high specific C02 emissions [1]. During the past years, there were a lot of attempts to produce metallic aluminum by carbothermic reduction of A1203 [2, 3]. Cox [4] determined the vapor pressure over the A1203-C system and performed X-ray diffraction analysis of condensed products. It was demonstrated that an increase in the carbon content in the system leaded to the sequence of transitions: A1203~Al404C~A1zoc~A14C3 ~AI [5]. In any carbothermic reduction process for aluminum, extremely high temperatures (2000 °C ) were required [6]. In spite of considerable effort, the carbothermic reduction of alumina to aluminum remains a formidable technical challenge, due to the high temperatures required, and to the formation of aluminum carbide and oxycarbide byproducts [7]."

Jan 1, 2013

By T. T. Chen

Raw anode slimes consisting primarily of PbSO4, AgCuSe, Cu3Se2, Cu2-x Se, Cu2O, CuSO4.5H2O, Sn arsenate and Sb-Bi-As oxide are batch-leached with electrolyte-O2 to dissolve Cu. During this process, Cu2O and CuSO4.5H2O are solubilized and the Cu in the selenides is leached with the formation of Ag2Se and Se. A small amount of Cu remains in the Ag2Se, Sn arsenate and Sb-Bi-As oxide. The decopperized slimes are repulped in Na2CO3 solution to convert most of the PbSO4 to NaPb2(CO3)2(OH). The Sn arsenate and Sb-Bi-As oxide partly react, but the Ag2Se is not significantly affected by the Na2CO3 solution. The NaPb2(CO3)2(OH) intermediate phase is dissolved in acetic acid to leave a final product consisting of Ag2Se, Se, Sn arsenate and Sb-Bi-As oxide, together with small amounts of PbSO4, NaPb2(CO3)2(OH) and various gangue constituents.

Jan 1, 1993

By L. A. Mills

After three years of experience in operating the pilot plant for the Noranda Continuous Smelting Process, the decision was made, in March 1971, to build an 800 ton per day commercial plant at Noranda, Quebec. The de- sign and layout of the plant is discussed and the installed equipment described. Experience previously gained in the pilot plant is mentioned when it has been used in the choice of equipment or plant layout. The full- scale reactor was started up in March 1973 and the operational datacollected and the experience acquired during the first 30 months of operation are described. This includes operation to produce both high grade matte and copper. Areas discussed include refractory wear, fuel consumption and throughput of copper concentrates. Changes made to original equipment and methods of operation are discussed, together with the reasons. The ad- vantages of using solid fuels to handle inert materials and to maximize converting air flowrates and concentrate throughputs are described. Relative efficiencies of oil and natural gas are compared. The addition of oxygen from a 94 ton per day oxygen plant to the reactor converting air was started in August 1975 and the initial operating results are included.

Jan 1, 1976

By Neale R. Neelameggham

"Most chemical process plants and metallurgical production facilities have some sort of cogeneration to minimize process energy costs. Use of Alternative Energy Production from sun and wind power with storage can become an integral part of a process plant utility. This will facilitate reduced fossil fuel usage and help minimize thermal emissions. This will be similar to Pollution Control equipment, which have become an essential part of process plants in the past four decades. Conceptual flow sheets of such Process Utility schemes are presented.IntroductionPower is supplied to industries, commercial and residential users. Over the past decade, Electric Utility companies have made major inroads, in introducing alternative energy resources in an attempt to somewhat reduce fossil fuel use in power generation. Now, on a much larger scale than in the early 1980s, residential users, motivated by government provided tax credits, have started installing alternative energy generators such as roof top wind mills or roof-top photovoltaic generators. This will minimize future energy costs, help control thermal emissions etc. This alternative power generation is typically connected to the existing power grid with two way power metering. However, the use of alternative energy generation has not been seen at large industrial sites yet.Paul Scherer Institute, Switzerland and the NREL laboratories in Colorado, are two of the several institutes which have been developing how solar thermal power can be used to supply the endothermic input energy in chemical and metallurgical processes. The theme of this present symposium addresses the above as well as the energy storage needs for such events to become continuous. This paper emphasizes the concept of how alternate energy can be used in the production of materials on a generic sense wherever there is a need for input energy – beyond endothermic process energy - while addressing how to reduce the thermal and carbon emissions.The alternative energy generation using wind or solar source is discontinuous due to the nature of the energy source. They are not only discontinuous but also variable. This necessitates storage of generated power for close to continuous use with variable loads. C Smith, et al pointed out in 2006, that 'the electric power industry has taken notice of the expansion of wind and its potential' in a summary article on integrating wind generation into utility systems.1 In 2009, the 1000 MW wind generation project in Texas had to be postponed to 2013 for lack of transmission.2 There are only a few large MW solar generation units in the US; the projects being slow mainly from lack of adequate storage and redistribution."

Jan 1, 2010

By Sh. Najisi, O. Lashkari, M. R. Ghomashchi, A. Charette

"One of-the important parameters in casting and foundry technology is the fluidity of molten metal. This parameter becomes particularly important when casting thin wall parts. Therefore, understanding and controlling fluidity plays a major role in fabricating sound and defect-free cast components.Semi-Solid Metai SSM, slurry is a mixture of solid and liquid, mushy zone, with solid volume fractions of 0.1-0.5 and apparent viscosity close to oil viscosity at room temperature. It flows easily under pressure and capable of making complicated shapes with high degree of die filling and integrity.In this study, the ability of the semi-solid slurry to continue to flow is investigated through the effect of different fraction solids and holding temperatures. The results show that in mechanically stirred, MS, semi-solid 356 Al-Si alloy, increasing fraction solid reduces fluidity. Furthermore, the results of MS-alloy are compared with a newly patented Rheocasting route, i.e. SEED, Swirl Enthalpy Equilibrium Device to highlight the differences of the two processes. In addition, the interrelationships between microstructural evolution and fluidity are discussed."

Jan 1, 2004

By R. W. Charles

The Los Alamos National Laboratory, under the sponsorship of the U.S. Department of Energy; is involved with laboratory and field experiments to assist in development of the Hot Dry Rock concept of geothermal energy. The field program consists of experiments in which hot rock of low permeability is hydraulically fractured between two wellbores. Water is circulated from one well to the other through the fractured hot rock. Our field experiments are designed to test reservoir engineering parameters such as heat-extraction rates, water-loss rates, flow characteristics including impedance and buoyancy, seismic activity, and fluid chemistry. Laboratory experiments were designed to provide information on the mineral-water reactivity encountered during the field program. Two experimental circulation systems tested the rates of dissolution and alteration during dynamic flow. SOlubil ity of rock in agitated systems was studied. Moreover, pure minerals, samples of the granodiorite from the actual reservoir, and Tijeras Canyon granite have been reacted with distilled water and various solutions of NaCl, NaOH, and Na.CO.. The results of these experimental systems are compared to the observations made in field experiments done within the hot dry rock reservoir at a depth of approxi-mately 3 km where the initial rock temperature was 150 to 200°C.

Jan 1, 1981

By Petrus Christiaan Pistorius, Ming Tang

Magnetite concentrate is pelletized and then hardened by elevated-temperature oxidation to hematite, to produce pellets for ironmaking. Previous work showed that the rate of oxidation is under mixed control of gaseous mass transfer of molecular oxygen through the pellet pores, and solid-state diffusion into the oxidizing grains. Because of the partially limiting role of solid-state diffusion, concentrate size distribution strongly affects pellet oxidation. Previously, a simple mixed-control model was formulated to describe isothermal oxidation. In that model, the main effect of concentrate size distribution was on the plateau level of oxidation which is reached at a given temperature. However, the extent of plateau oxidation increases with increased temperature, requiring a more complex model for non-isothermal oxidation. In this paper, predictions of the non-isothermal model confirm the strong effects of concentrate size distribution and oxygen enrichment. In particular, a greater fraction of coarse magnetite particles would be beneficial, decreasing the size of the macroscopic unoxidized pellet core.

Jan 1, 2015

By Itsuki Uehara, Hiroyuki T. Takeshita, Tetsuo Sakai, Nobuhiro Kuriyama, Hideaki Tanaka

"AB5 type hydrogen storage alloys (A: rare earths, B: transition metals) are extensively applied to a negative electrode of a nickel metal hydride (Ni-MH) rechargeable battery for portable electric equipments, electric vehicles, hybrid vehicles etc. Performance of a hydrogen storage alloy electrode is affected by various factors, microstructure and surface composition of the alloy and structure of the electrode as well as composition of the alloy. Control of those factors enables us to commercialize the Ni-MH battery in various field.IntroductionA Nickel-metal hydride (Ni-MH) battery has been extensively developed because of (1) good compatibility with a nickel cadmium (Ni-Cd) battery, (2) high energy density (1.5-2 times higher per unit volume than a Ni-Cd battery) and high dischargeability, and (3) low environmental pollution. The charge/ discharge reactions can be written as [l, 2,3]:(+) Ni(OH)2+OH- = NiOOH+H2O+e· (E=+0.490V NHE),(-) l/6LaNi5+H2O+e-· = 1/6LaNi5H6+OH- (E=-0.828V NHE),where E° is a standard potential of an electrode vs. normal hydrogen electrode (NHE). Because of the above advantages of a Ni-MH battery, the battery have been widely used as a power source of portable computers, cellular phones, electric vehicles (Toyota ""LAV4L EV"", Honda ""EV Plus"" etc.) etc. Some hybride vehicles (Toyota ""Prius"" and Honda ""INSIGHT"") and fuel cell vhehicles (Toyota ""FCEV"") are power-assisted by a high-power Ni-MH battery. In 1999, the production of Ni-MH batteries reached 870 million cells in Japan. Most of commercialized NiMH batteries are incorporated with rare-earth-based AB5-type hydrogen storage alloy as a negative_ electrode. The production of rare-earth-based alloy is estimated to be approximately 8000 tons.The battery performances of the Ni-MH battery, for example, capacity, durability (cycle life), dischargeability (kinetics) and selfdischarge, ate closely related to the metal hydride· (MH) electrode, especially, the hydrogen storage alloy in the electrode. Substitution of alloy components, heat treatment, and surface treatment in order to change surface and bulk structure of hydrogen storage alloys have been examined by us and many reseachers in order to improve the performances of MH electrodes. This paper is a review of our and their efforts to improve performances of MH electrodes."

Jan 1, 2000

By Ikuhiro Sumi

A new steelmaking process, in which manganese ore was intentionally reduced, was developed to achieve a higher manganese Yield using a combined blowing converter. In this study, manganese behavior was discussed through the introduction of a model. Apparent reduction rates of manganese were calculated by the two terms that were determined experimentally, with SOkg and 2S0ton combined blowing converters. The model calculated manganese changes during the operation. We applied the model to the actual operation and found that manganese behavior was predicted fairly well by this model.

Jan 1, 1996

By S. Viswanathan, Q. Han, A. S. Sabau

"In spite of recent advances in the mathematical modeling of fluid dynamics for materials processing applications, no significant advances have been made in the numerical discretization of these equations. In this work, the application of two-step projection methods for the numerical simulation of interdendritic flows is discussed. Unlike previous methods, the methods presented here are constructed for the exact equations which are characterized by variable density and volumetric fraction of the liquid. The drag terms, which describe the momentum loss due to the flow around and through the dendrite structures, are treated implicitly. Numerical examples for shrinkage-induced flow during solidification of an Al-4.5% Cu alloy bar is used to illustrate the effectiveness of the proposed algorithm.IntroductionLiquid contraction during solidification plays an important role in the formation of casting defects such as shrinkage voids, microporosity, and macrosegregation. Owing to their importance, the study of transport processes during solidification have received considerable attention during the past years [1, 2]. By the use of volume-averaging techniques, the mass and momentum equations for flow through a stationary dendritic structure were derived [3]. By using the volume-averaging techniques for multi-phase systems, two-phase transport equations for solidification problems were derived [4]."

Jan 1, 1999

By Gennady I. Gulyayev

A mathematical model of plastic deformation occurring in cold plug drawing of mother tubes with initial cross-sectional wall thickness variations (CSWTV) has been developed. The main provision of the model is that eccentricity em is of such value that projection of all forces acting upon the plug in the deformation zone along the axis perpendicular to the drawing axis equals to zero. Calculations have proven that with other conditions being equal increase in the die cone angle and the deformation cycle number reduces CSWTV. Theoretical findings were confirmed by practical results. Keywords: cold, drawing, plug, die cone, plastic deformation.

Jan 1, 2003

By Bruno Augusto Batista Ribeiro, Felipe Terra Elias, Wagner Moulin Silva

In the pyrometallurgical production of copper from its sulfides, converting in the Peirce Smith (P-S) Converter is still the most widespread method to obtain white metal and blister copper from the matte. Despite the fact of being a century-old process, it is still possible to achieve improvements in the process, by the use of modern tools, one of the most valuable being numerical calculation and computer-aided simulation. The present study presents three cases in which the angle for the gas injection and the number of working tuyeres are changed during the slag blow phase of the converting process. It was noticed that a decrease of the number of tuyeres, followed by an increase in the injection gas velocity, results in improved reaction volume and less stress to the refractory lining. However, an increase in the amount of copper lost to the slag as oxide is likely to occur.

Jan 1, 2014