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By Osarnu Inoue

In Mitsubishi Continuous Copper Smelting and Converting Process, smelting, slag-matte separation and matte converting are continuously carried out in series in three furnaces connected by launders. As a result of this operational configuration of the furnaces, influence of the change in operating condition in upper stream, such as variation of feeds in the smelting furnace, propagates to down stream with some delay. In order to achieve stabler operation, process control algorithm based on the dynamic characteristics of each furnace would be very effective. In this study, the dynamic process simulation model was developed for the smelting furnace. The model consists of two mathematical modules, i.e. the thermodynamic module and the mixing module. The calculation results using operating data obtained at Naoshima Smelter showed good agreement with the actually observed change in temperature, composition and flow rate of matte and slag at the outlet of the furnace. In addition, operation parameters such as reaction efficiency of oxygen and coal, dead volume of melts were estimated.

Jan 1, 1999

By Taiping Lou

The coarsening process of precipitates in non-equilibrium systems was studied, and then a physical model of coarsening was proposed. The coarsening process of CaO'TiO2 in MgO-TiO2-Al2O3-SiO2-CaO-CaF system was investigated. It is shown that the coarsening process by the model predicting is agreed with the experimental results.

Jan 1, 2000

By Tullio Corsini

Scrap battery recovery process, developed by Engitec Impianti S.p.A., is improved transforming batches operations in continuous. Benefits expected: constant and better quality of the products; easier and more reliable control of the operating parameters, reduction of manpower requirements. Paste will content less sulfate, particularly in soluble form. Sodium sulphate is obtained with higher and constant purity.

Jan 1, 1993

By Yang Cui

The partition ratios of lead and antimony between liquid copper and MgO saturated Cu2O-CaO-SiO2 flux and their removal rate by using CuCl-based flux were measured between 1423 K and 1573 K. For Cu2O-CaO-MgOsatd. system, the partition ratio of Pb was not affected by the CaO content at 1573 K, while that of Sb increased with increasing CaO content. The maximum value was 160 at the CaO content of 15.4 mass%. For Cu2O-CaO-SiO2-MgOsatd. system, two liquid phases of calcium silicate rich phase and Cu2O rich phase were observed at 1573 K. The partition ratios of Pb and Sb between calcium silicate phase and liquid copper depended on the (mass%CaO)/(mass%SiO2) ratio. When the (mass%CaO)/(mass%SiO2) ratio increased, the partition ratio of Pb decreased and that of Sb increased. For CuCl flux, the removal of Pb from liquid copper at 1473 K was possible, and a relatively low concentration could be reached. Moreover, most of lead as metal chloride vaporized from flux. For the removal of antimony from liquid copper at 1423 K, it was difficult by CuCl flux, and the removal ratio was approximately 20% for 75 minutes. However, the addition of CaO or Na2CO3 to CuCl flux was relatively effective to remove antimony, and the concentration of antimony reached a relatively low value after 15 minutes by using CuCl-CaO or CuCl-Na2CO3fluxes. Moreover, a small part of antimony as chloride vaporized from flux.

Jan 1, 2006

By Frank L. Marley

Mexican silver mining operations have existed prior to the sixteenth century. Recovery processes throughout the centuries were developed at the many mining localities and have progressed through smelting, the patio amalgamation process to cyanidation and flotation. A study of the present silver mining zones is reported in which the ores are evaluated in terms of the mineralogical constituents, their state in the matrix and the effects these are noted to impose upon the efficiency of recovery. Silver mineral identifications were by quantitative ore microscopic and scanning electron microscopic energy dispersive X-ray analysis.

Jan 1, 1982

By Marie-Aline Van Ende, In-ho Jung

A thermodynamic database for the oxyfluoride system CaO-MgO-Al2O3-SiO2-Na2O-K2O-Li2OMnO- FeO-F has been developed based on the critical evaluation and optimization of all available experimental thermodynamic and phase diagram data. The developed database can be used for phase diagram and equilibrium solidification calculations for multicomponent systems and for understanding the solidification behavior of mold fluxes. Based on this thermodynamic database, a simple kinetic model was developed to simulate the interactions between the mold flux and molten steel using effective equilibrium reaction volumes combined with the thermodynamic database.

Jan 1, 2014

By Andrew A. Fyfe

The start-up and operating results obtained at Zia Technology Inc.'s first commercial operating facility at Caldwell, Texas are described. The operation which stated in early 1991 is the first to employ the patented Inclined Rotary Reduction System (IRRS') with the associated 'all-metallic retort for the recovery of all metallics contained in EAF dust.

Jan 1, 1992

By Baokuan Li, Qiang Wang, Zhu He

"A mathematical model has been developed to investigate the magnetohydrodynamic (MHD), thermal, and solidified behavior in electroslag remelting process. Based on the finite volume method, a multiphase coupling MHD approach is employed to investigate the droplet formation as well as movement in molten slag under the action of an alternating current. The VOF formulation is adopted for interface tracking. The electrical potential method is adopted for the electric current and magnetic field. The Electromagnetic force and Joule heating are recalculated at each time step and then is implemented in the momentum and energy equations as a source term, respectively. Moreover, solidification of the metal is described by an enthalpy-based formulation, while the mushy zone is treated as a porous medium with porosity equal to the liquid fraction. The model is used to investigate the effect of electrode tip shape on MHD, thermal, and solidified behavior and provide valuable information.IntroductionElectroslag remelting (ESR) process has been used widely to produce high-performance alloys dedicated to critical application, such as hot work tool steels, nickel base alloys, the manufacture of components in aerospace and landbased turbines, etc. Figure 1 shows a schematic diagram of ESR process including a consumable electrode, a molten slag pool, a liquid metal pool, a solidified ingot, and a water-cooled mold. Alternating or direct current flows from the electrode to the water-cooled baseplate through the high resistivity calcium-fluoride-based molten slag which result in Joule heating and Electromagnetic force (EMF). Part of the Joule heating melts the electrode and the droplets travel through the slag and accumulate the liquid metal pool. The electrode is continuously advanced into the slag as it melts to build up an ingot of improved structure and composition by controlled solidification and chemical refinement. The metallurgical properties of the remelted ingot are really related to the solidification structure, which strongly depends on magnetohydrodynamic, thermal, and solidified behavior in the molten slag, liquid metal pool, and mushy zone."

Jan 1, 2014

By Masanori Harata

A fundamental study was conducted on a new process for producing scandium (Sc) metal or aluminum-scandium (Al-Sc) alloy by the calciothermic reduction of scandium oxide (Sc2O3). In this study, aluminum (Al) and calcium chloride (CaCl2) were used as the collector metal and flux for the reduction, respectively. A mixture of Sc2O3, Al, and CaCl2 in a tantalum crucible was placed inside a stainless steel reaction container, and the feed mixture was reacted with calcium (Ca) vapor at 1273 K for 6 h. After the reduction experiment, the reaction product (CaO), CaCl2 flux, and excess Ca reductant were removed from the obtained alloy sample by leaching with an aqueous solution. The formation of Al3Sc in the Al matrix phase of the alloy was confirmed by X-ray diffraction (XRD) and electron microprobe analysis (EPMA). This result indicates that Sc2O3 was successfully reduced to metallic Sc and alloyed in situ to form liquid Al-Sc alloy during the reduction. When Al was not used in the reduction experiment, a complex oxide (CaSc2O4) was formed, and the reduction was incomplete. This study demonstrates that the Al-Sc alloy can be directly produced by calciothermic reduction using CaCl2 flux and Al collector metal.

Jan 1, 2006

By Luis W. Pommier

The developed processes, the subject of this paper, extract the hydrocarbons, halogenated organic compounds and metal contaminants from hazardous soils, rendering them non-hazardous and ready to be placed back on the ground. The processes first segregate a non-contaminated fraction from the contaminated soil. This initial task is performed using available minerals processing technology: sizing, gravity separation, magnetic separation, froth flotation, etc. The remaining contaminated fraction, is submitted to two leaching operations for the removal of organic and metal contaminants, whenever both are present or to a single leaching operation if only one type of contaminant is present. The decontaminated soil fraction is mixed with the non-contaminated fraction and is placed back on the ground. The leaching liquors, used at neutral pH, are non- hazardous. After decontamination the liquids are processed to extract the contaminants, now valuable materials, for commercialization. Organic contaminants are removed by distillation of the solvents. The metal contaminants are precipitated in their oxide form. In both cases the regenerated solvents are recycled. The decontamination processes are economically competitive with transportation and disposal of the soils to permitted facilities for hazardous materials, and most importantly the developed processes remove the liabilities from the Responsible Parties. The law establishes that these liabilities do not disappear with either fixation nor with transportation and disposal since the environmental liabilities are of the ? cradle to grave? type.

Jan 1, 1994

By Y. Moriya, Y. Sadayoshi, Y. Nonogaki, Y. Takeda

"Preparation and growth processes of CaF2 on Si(111) and of . InxGa1-x,As islands on CaF2 by molecular beam epitaxy (MBE) are described. It was found that first of all the Si(111) surface treatment process to obtain the 7x7 reconstructed structure was necessary to ensure the cleanness of the surface and to grow a flat and high quality CaF2 on it. Growth of InxGa11-x,As islands on CaF2 was tried by droplet heteroepitaxy using the same MBE reactor. In,GaxGa1-xAs islands were successfully grown epitaxially, and the size and density of the islands dependent on the In composition were investigated.IntroductionThough semiconductor/semiconductor heterostructures are widely used for many device applications, small band off-sets of the conduction bands and the valence bands restrict the utilization of the intra-subband transitions to far-infrared regions. With InAs as the quantum well and fluorides as the barrier layers, we can design three-electronic-level systems in the infrared region, which is the low loss transmission window of the silica optical fibers. To realize those structures, we have grown InxGa1-xAs islands on CaF2 thin films that were epitaxially formed on Si(111) substrates by molecular beam epitaxy. By the droplet heteroepitaxy that we invented, the InxGa1-xAs islands with height of -10 nm have been obtained successfully. Optimum processing to obtain atomically smooth surfaces of Si and CaF2 and high quality InxGa1-xAs islands is reported.ExperimentsMBEMachineCaF2 was grown on Si(111) and InxGa1-xAs islands were grown on CaF2 successively by MBE. The MBE machine consisted of a growth (or reactor) chamber and a loading chamber. The reactor chamber was equipped with Ga, In, As and Er metal source cells and CaF2 and BaF2 source cells. Cell materials were P-BN for Ga, In and As metals, and were graphite for CaF 2, BaF 2 and Er to avoid reaction with BN cells. The electron gun and screen were attached to the reactor to observe the RHEED pattern during the substrate surface treatment and the growth of CaF2 and InxGa1-xAs islands. The substrate manipulator was designed to heat up the Si substrate up to 1,200°C for the surface cleaning. The QMS was also equipped to analyze the residual gas species in the reactor chamber. The base pressure of the reactor chamber was 2-5x10-11 Torr, being pumped by ion pump and the liquid nitrogen shroud"

Jan 1, 2000

By Guo Xueyi

The electrochemical couple behavior of manganese dioxide with ferrous/ferric ions in acidic chloride medium was investigated, It was proven that the dissolution of Mn01 is due to the electrochemical couple reaction between MnO2/Mn2+ and Fe2+/lFe3+ in the solution, The driving force for the process originates from the rest potential difference of the two couples. The reduction of Mn02 is controlled by clectrochemical kinetics, whereas the conversion of F e2+ to Fe3+ is limited by diffusion, The factors such as the Mn2+, Fe2+, Fe3+, Cl concentration, pH of the solution and the temperature, have much influence on the kinetics of the couple process, This study will be useful to elucidate the mechanism for the leaching of manganese nodule from the deep ocean as well as manganese dioxide ores in land,

Jan 1, 2003

By Hui-Gai Li

The fine Ti oxide inclusions precipitated during solidification are favorable for intragranular ferrite nucleation. The oxygen content before solidification affects the composition and size of inclusions. The composition of precipitated inclusions in Mn-Ti alloyed steel was studied by means of thermodynamic calculation and experiment in this paper. The micro-segregation of Mn, Ti and O during solidification was considered in calculation and unidirectional solidification apparatus was employed in experiment to ensure that alloy elements diffused along solidification direction. The results showed that: inclusions are mainly Ti oxide when oxygen content is 10ppm; they are Ti oxide and Mn-Ti oxide when it is 20ppm; Mn-Ti oxide dominates when it is 30ppm. With the increase of oxygen content, the size of inclusions increases. The maximum oxides size is about 3µm from statistical results of experiment.

Jan 1, 2008

By J. D. Sloop

This paper discusses the current state of EAF dust recycling at AmeriSteel's Dust Processing Division in Jackson, Tennessee. Included are a brief history of the plant, a description of the facility, a description of the process, and operating data.

Jan 1, 2000

By Min Chen, Cui-huan Huang, Zhen Tian, Jian-hong Dong

"The present work studied the production of Fe-Si-Mn alloy from adjusted converter slag by thermodynamic analysis. The results showed that solubility of SiO2 in the molten slag increased with increment of temperature, and it is about 80% at 1800 ?. With increment of SiO2 content, a(MnO) and a(CaO) decreased, and a(FeO) increased to the maximum when w(SiO2) is about 30%. As a result, the reduction of the slag was in the order of Fe?Mn?P before SiO2 reduction, the reduction order was Fe?P?Mn?Si when SiO2 content in the slag was from 46.4% to 54.2%, and changed to Fe?Si?P?Mn when SiO2 content exceeded 54.2%. The mass fraction of Si in the alloy phase increases with increasing of w(SiO2) in the slag, and the mass fraction of Si in the alloy reached to 62.2% at 1800 ?.IntroductionFerroalloy production is a high energy consumption and high pollution industry[1-2]. If ferroalloy production could be produced from molten slag by addition of carbon-reducing agent, the valuable metal and oxide in the slag can be recycled, most importantly, if the high-temperature resource carried by molten slag can be made full use in the field of ferroalloy production, the power consumption of ferroalloy production could be cut down greatly.Converter steel slag is a kind of byproduct in steelmaking processing increasing rapidly with the increment of crude steel, but the utilization ratio is low. Most heat recovery research is still in the experimental stage except the heat recovery of blast furnace slag by water quenching method, at present[3-4]. It is of great significance for enterprises to energy saving and emission reduction if the molten steel slag could be utilized directly. Not only the reuse methods of liquid steel slag material can be promoted, but also the use of heat carried in the slag could be achieved. The basicity of converter slag is high and the activity of SiO2 is low so the reduction of SiO2 in the slag is little. The compositions of slag and metal phases were calculated by Factsage program on different conditions to explore the reduction of converter slag for recovery of valuable metals and an efficient new way to use the high-temperature heat combining with the current reuse and research status of converter slag. Further, the improvement of components activity in slag and the increase of Si concentration in the metal were also dicussed."

Jan 1, 2012

By Jitka Jandová

A laboratory process based on simple and environmental friendly operation, aimed at recycling of spent Li/MnO2 batteries, is described in this study. This process involves roasting Li/MnO2 batteries in a vacuum furnace at 650°C, followed by selective leaching Li2CO3 from calcined electrode material in distilled water at ambient temperature and controlled crystallization of pure Li2CO3.

Jan 1, 2006

By C. Alexandru Sonoc

Donnan Dialysis uses ion exchange membranes to extract and separate cations. The driving force is provided by differences in chemical potential, rather than by electric fields or pressure. A Donnan Dialysis based process to recover lithium, nickel, cobalt, manganese, and organic acid lixiviant from recycled lithium ion battery cathodes is under development. In this paper we present a model of Donnan Dialysis and results of simulations of the aforementioned process. The simulations show that 170 m2 of membranes can process 1000 L of leachate ([Li+] = 0.285 M, [Co2+] = [Ni2+] = [Mn2+] = 0.095 M, pH 2) in two days and recover 94.1% of the lithium (as lithium carbonate), 99.4% of the transition metals (as mixed sulphates ready for solvent extraction), and all of the organic acid using 423 mol of H2SO4 and 268 mol of KHCO3.

By Liwen Hu, Jianxun Song, Hongmin Zhu, Qiuyu Wang, Shuqiang Jiao

The subchloride titanium was prepared by sponge titanium and titanium tetrachloride in the CaCl2 at 1173 K. The species were detected are mainly titanium dichloride, and the average valent in the melt are 2.05. The accurate equilibrium constants were obtained for the reaction 3Ti2+ = 2Ti3++Ti after the accurate activities of titanium chloride were evaluated with emf method, and the observed deviations from ideal behavior are discussed.

Jan 1, 2015

By Sung-Mo Jung

Experiments were carried out on a system with artificially prepared slags in a graphite crucible, in order to examine the possibility of recycling BOF slags produced in the steelmaking process. More than 80% of FeO and P2O5 was reduced within 20 minutes and the FeO reduction rate was greater than that of P2O5. P2O5 reduction began after more than 60% of FeO was reduced. Increasing slag basicity enhanced the reduction of FeO and P2O5. Temperature also improved slag reduction. The overall reduction rate was controlled by the chemical reaction at the slag/carbon interface. The reduction rates of FeO and P2O5 were second and first order with respect to their respective contents. Most of the reduced phosphorous is believed to vaporize in the form of P2 gas.

Jan 1, 2006

By Paul B. Queneau

U.S. plants solely devoted to recovering values from metal-rich wastes have established market niches based on one or more competitive advantages: superior process technology, access to key feedstocks, unique equipment, special knowledge of markets, and an appropriate exit for outfall water. Plant methodology, competitiveness, environmental factors, and economics are examined, with particular attention to feedstocks, technologies, products, and outputs.

Jan 1, 2003