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By Sudhir C. Dhara

An attempt has been made on the concentration of Platinum Group Metals (PGM) from the converter matte material by microbial .leaching. Biological oxidation of base metal sulfides such as iron, copper, nickel and free sulfur present in the matte material using Thiobacillus ferrooxidans is an alternative method to concentrate the PGM-and gold. The method which produces a platinum group metals concentrate is comparable to chemical processes and electrochemical process.

Jan 1, 1995

By J. Fraser Forbes

"The meaning of the term ""process control"" has evolved significantly since its widespread use began in the manufacturing industries in the 1940s. Further, the scope of process control applications has drastically increased both in terms of the breadth of industries using process automation technologies and the vertical integration of these technologies within a single industry. This evolution and integration of process control technologies within the manufacturing industries has proceeded to such an extent that process automation is an integral part of modern business practices.This paper will examine the current status of process control technology from simple process regulation through process performance optimization to business planning. Each layer of the operations automation hierarchy will be discussed both in. terms of the current state-of-the-art and the directions in which these technologies are evolving. The key tools and tasks necessary for success at every level of the automation hierarchy will be introduced. Finally, the critical challenges that must be faced in accomplishing the goal of complete Computer Integrated Manufacturing (CIM) will be described.Finally, although this paper addresses issues of practical importance to any manufacturing company, the discussions will be framed in terms of the particular challenges facing and the opportunities available within the materials manufacturing industries."

Jan 1, 2000

By S. Malinov, J. J. McKeown, W. Sha, S. McShane

"A model is developed for prediction of fatigue stress life S-N diagrams for Ti-6Al-4V alloy at different conditions, using Artificial Neural Network (ANN). Different factors which have influence on the S-N diagram are involved as input parameters of the NN, namely microstructure, environment, texture, test/work temperature, surface treatment and stress amplitude. As the output the S-N fatigue diagram is simulated and plotted.The model is based on standard multilayer feedforward neural network. The NN is trained with a comprehensive data set collected from the literature, using Levenberg-Marquardt training algorithm in combination with Bayesian regularisation. A very good performance of the trained Neural Network is achieved. Good correspondence between ANN"" prediction and experimental S-N diagrams is observed. Using the model S-N diagrams for different conditions are predicted and analysed. Graphical User Interface is developed for use of the model. We believe that the model will be important for practical applications in solving various problems on fatigue behaviour of the titanium alloy.IntroductionTitanium and its alloys have an increasing range of applications due to their very good combination of mechanical properties, corrosion and erosion resistance. They are currently finding widespread applications in many industries due to their desirable and versatile properties. Most important among the alloys is Ti-6AI-4Y. Jet aircraft manufacturers are the principal 'consumers of Ti-6Al-4V and it is often specified for critical parts, the failure of which could result in the loss of an entire system. A generic class of Ti-6AI-4V has been developed over the past years and it has become the best understood of all the titanium alloys. The advantages of titanium alloys include: (i) low densities, giving very attractive strength to weight ratios allowing lighter and stronger structures; (ii) superior corrosion and erosion resistance in many environments; (iii) high temperature capability. Although the titanium materials are still considered as expensive materials, for many applications the cost of titanium alloys can be justified on the basis of their desirable properties."

Jan 1, 2001

By Cao rong-jiang, Tang Xin-he

"In ordinary manufacture process of tungsten powder, a preferable intermediate product used is ammonium paratungstate (APT). The particle size of tungten powder made from it through W2OO58 is larger than 1. 0 um. In order to obtain ultrafine tungsten powder with narrow size distribution, a new type of tungstate, hydraziniull tungstate, was studied. Its formula is 5(N2H5)2O·12 WO.s , with tetragonal crystal structure of a=5.821 , c=18. 468. Three methods for preparing hydrazinium tungstate (ART) were set up and ART can be produced by current industrial APT process with little modification of operation and without any change of equipment.Under certain PH and operation condition of the solution from which ART was produced, an autoreduction of tungsten occured, which produced a lower valency tungstate with blue color when ART was heated at different temperatures, in N atmosphere, tungsten bronze, tetragonal W0290 and W02.7E could be obtained respectively. They all have the superiorities, in the production of tungsten powder, of superfine size and narrow size distribution [average size of 0.5um or even smaller.The rate of autoreduction of ART is very fast at elevated temperature. The reduction reaction, which gaves tetragonal WO290, could be handled smoothly without explosion. To research their behaviors at autoreduction temperatures and the products of autoreduction will be new advances of tungsten chemistry and may also serve tungsten industry with new processes and materials."

Jan 1, 1988

By Niels Verbaan

NioCorp is developing the niobium/scandium/titanium Elk Creek carbonatite deposit. The probable reserve announced by the company in 2017 indicated significant niobium (0.79% Nb2O5), titanium (2.81% TiO2), and scandium (71 g/t), and is composed predominantly of calcite, dolomite, and ankerite. Niobium is mostly (80%) contained in pyrochlore with the balance in various Fe-Nb-Ti oxides, which also host most of the titanium. Scandium is primarily deported in dolomite, with lesser quantities in pyrochlore and biotite. The process flowsheet recovers separate niobium, titanium, and scandium products. Scandium is extracted from whole ore hydrochloric acid leach solutions using solvent extraction and is further refined through a re-leach and precipitation process. Scandium leach residues are treated in a sulphuric acid sulphation process to recover separate niobium and titanium precipitates as well as to solubilize the remaining scandium. Both hydrochloric acid and sulphuric acid reagents are recycled within the flowsheet. This paper will discuss key bench and pilot test results of the niobium extraction and recovery circuits and will present a conceptual flowsheet developed by the project team for NioCorp at SGS Minerals.

By J. N. Hartley

Samples of ash from the May 18, 1980, eruption of Mt. St. Helens Were collected from several locations in eastern Washington and Montana. The optical microscope and the combined scanning electron microscope with energy dispersive x-ray microprobe were used to determine the composition and mineralogical characteristics of the samples. In addition, a quantitative image analyzer was used to examine the particle size distribution, and x-ray diffraction was used to identify major minerals. Both polished sections and ultra thin sections (less than 5 ~m in thickness) were prepared to study the mineralogical characteristics. The use of ultra thin sections provided access to microstructural detail. Mineralogically, the samples ranged from almost totally glassy to almost totally crystalline. Crystal-line samples were dominated by plagioclase feldspar (andesine) and ortho-pyroxene (hypersthene) with smaller amounts of titaniferous magnetite and hornblende. Nearly all the samples contained from less than 1 to 3 wt% free crystalline silica (quartz, trydimite, or cristobalite).

Jan 1, 1981

By Antoine Allanore, Luis A. Ortiz, Donald R. Sadoway

"The steelmaking industry has drastically reduced its energy consumption in the last fifty years, and today’s technologies are considered to operate at their optimal efficiency with respect to energy needs. To cope with new constraints related to greenhouse gas (GHG) emissions, a change of paradigm is necessary. One of the promising technologies that could be deployed to help reach CO2 mitigation targets relies on the intensive use of electricity: molten oxide electrolysis (MOE). This paper presents the key process parameters that need to be tuned to address the practical needs for both high productivity in a steelmaking reactor and for an energy efficient process. Herein we show that contrary to common perception, the electrolysis process for ironmaking requires less energy than today’s chemical reduction route. Furthermore, we prove that most of the energy that must be provided to operate the electrolytic iron production cell is thermal energy which is readily generated by joule heating during electrolysis due to large currents being passed through the electrolyte. The energy consumption of the electrolysis cell is therefore shown to be highly dependent on the cell configuration and the chemistry of the electrolyte. As a consequence, the CO2-impact of the technology strongly depends on both the power production mode and the technological choices for design of the process, including cell configuration. Surprisingly enough, even when the electricity generation is not carbon-free, MOE still appears to be viable from the perspective of reducing GHG emissions providing sound reactor design considerations are made.IntroductionIn the context of greenhouse gas (GHG) emissions mitigation, the steelmaking industry is considering several techniques that could sustain the efforts and progress achieved by this sector in the last decades [1]. A recent report [2] on potential routes for low-CO2 steelmaking highlighted for all techniques both the strong dependency of CO2 emissions on electric power production mode and the need for a decrease in energy consumption per tonne of steel. Incited to innovate with respect to this last criterion, the steel industry considers electrolysis to be a promising technological solution, and in particular the molten oxide electrolysis (MOE) process. This process conducts electrolysis in a mixture of oxides that dissolve the iron oxide feed, which by the action of electric current is decomposed into liquid iron and oxygen gas. The opportunity for reduction in energy consumption during steelmaking by MOE is commonly attributed to the “direct” pathway from iron oxide to liquid metal offered by the use of a molten oxide melt and operation at a temperature above the melting point of iron, ideally 1600°C, to provide enough superheat for tapping the molten iron product:"

Jan 1, 2011

By Pertti Koukkari, Nagendra Tripathi, Karri Penttilä, Justin Salmine

ChemSheet is a thermodynamic multi‐phase multi‐component simulation software, which is used as an Add‐in in Microsoft Excel. In ChemSheet, the unique Constrained Gibbs free energy method can be used to include dynamic constraints and reaction rates of kinetically slow reactions, yet retaining full consistency of the multiphase thermodynamic model. With appropriate data, ChemSheet models can be used to simulate reactors and processes in all fields of thermochemistry. The presentation will cover off‐line modeling of Cu‐flash smelters and advanced thermochemical simulation coupled with on‐line process control of Cu‐Ni smelting. The presentation will describe an off‐line model of Cu‐smelter based on critically assessed properties of the Al-Ca-Cu-Fe-O-S-Si –system (slag, matte and liquid metal) by using the quasichemical model. A four‐stage reactor model (shaft, settler, uptake and bath) is used for optimizing process parameters and feed particle distribution. As a second example, an advanced thermochemical model of a Ni-Cu sulphide smelting plant will be given. The on‐line model covers the operation of treating Ni-Cu-S concentrate via roasters, electric furnace and converters, producing a high grade Bessemer matte product for further refining. The model integrates the thermochemistry of the roasters and electric furnace, and predicts important process parameters such as degree of sulphur elimination in the fluid‐bed roasters, matte grade, iron metallization, slag losses and the iron to silica ratio in the electric furnace slag. Both models can be used to assist process engineers and operators in calculating the addition rates of coke, flux and air for different feed scenarios.

Jan 1, 2014

By S. G. Kumar

The performance of nickel based high temperature materials is directly related to their microstructure, which is controlled by the various processing steps. Nickel base alloys are melted and refined by a variety of processes that include Vacuum Induction Melting (VIM), Vacuum Arc Remelting (VAR) and Electroslag Remelting (ESR). The limitation of VIM is that the metallrefractory reactions lead to the disintegration of the crucible and hence contamination of the product due to macrosegregation. This macrosegregation is alleviated to some extent by controlling the solidification in VAR. The main attraction of ESR is its ability to produce a clean product by controlling the deleterious inclusions. In recent years Electron Beam Melting (EBM) is emerging as an alternative to the VIM, VAR and ESR. This paper reviews the current status of these processes and outlines the scope for further improvements in the processing technology.

Jan 1, 1993

By Pengfu Tan

Electric arc furnace (EAF) dust from the steel industries is listed by the United Sates EPA as a hazardous waste under the regulations of the Resource Conservation and Recovery Act due to the presence of lead, cadmium and chromium. The disposal of the approximately 650,000 tons of EAF dust per year in the U.S. and Canada is an expensive and unresolved problem for the majority of steel companies. The Waelz process has been considered as the best process for treating EAF dust. A process model, combined thermodynamic modeling with heat transfer calculations, has been developed to simulate the chemical reactions, mass and heat transfer and heat balance in the kiln. The injection of air into the slag and the temperature profile along the kiln has been modeled. The effect of (CaO+MgO)/SiO2 on the solidus temperature of slag has been modeled also and discussed. Some optimizing results have been presented in this paper.

Jan 1, 2005

By I. Gaballah

Jarosite contains up to 15 % of heavy metal compounds 'HMC'. The current waste disposal methods will not be allowed in the near future due to new environmental regulations and pollution risks. For these reasons, thermal treatments of raw or decomposed jarosite, in controlled atmospheres, were investigated. The aim of these treatments is to decontaminate the jarosite and/ or to recover the HMC for recycling. According to physico-chemical characteristics of the samples, the thermal treatments in controlled atmospheres N2, CO+N2 and C12+air lead to the extraction rate that vary from 93 to 98 %. Heavy metal compounds were separated by cooling the gaseous phase. The treatments' residue was almost free from HMC. Between 700 "C and 800 "C, the chlorinating treatment was successful of eliminating more than 97 % of HMC contained in four different samples.

Jan 1, 1999

By R. Cavanagh

Studies relating to the fixation of sulfur by reaction of 4 to 8 mm diameter cylinders of calcined limestone or dolomite with high strength sulfur dioxide in the temperature range 880°C to 1020°C were undertaken. Dolomites are far superior in sulfate capacity and reactivity than dense limestones even at high strength SO2. The sulfation reaction was first order with respect to SO2 concentration below 100 percent. Zero reaction rate at 100 percent SO2 concentration indicates that sulfate was the exclusive reaction product and that sulfite had no role in the reaction. At relatively low SO2 concentrations gaseous diffusion through the reaction product layer has a marked effect on the rate. As SO2 concentrations were increased up to 100 percent more complex rate controlling mechanisms unfold. By sectioning partially reacted dolomitic limestone pellets a moving interface was observed. Reaction ceased because of pore plugging for dense non-porous limestones at 30% conversion. With dolomitic material virtually complete sulfation of the calcium was observed. S.E.M. analysis showed that the average atom ratio Ca:S was 1.01, thus supporting the argument that little if any of the magnesium was sulfated.

Jan 1, 1996

By Jan A. Aune

The paper describes a number of electric furnace equipment modules especially developed or modified for slag furnace applications. Both the resulting design concept for a modern electric sulfide smelter and some of the changes in traditional process-concepts made possible are outlined.

Jan 1, 1983

By Florian Kongoli

Converters have been playing an important role in the extraction and processing of metals ever since the first type of converter was invented about 100 years ago. Historically their operation has been mainly based on the experience of talented operators rather than on strict control and optimization technologies. However, in the new realities of unavoidable necessity to increase productivity and in the conditions of diversification of primary materials from various geographical areas, improving control and optimization techniques have become indispensable. In this paper a review of the authors? previous work in terms of improving control and optimization of converter operational practices related to magnetite content and precipitation, slag and metal blows, problematic and dangerous elements such as As, Sb etc. has been described by highlighting the advantages that the new control and optimization methods and tools bring to everyday converter practices. Several examples are given and future work is underlined

Jan 1, 2005

By E. A. Werner, A. Pichler, A. Spalek, G. Reisner, P. Stiaszny

"Interstitial free (IF) sheet steels are used for complex shaped parts because of their excellent formability. If a deep drawn part is subjected· to a impact deformation at low temperature brittle fracture of the part may occur. This phenomenon\ is called secondary work embrittlement (SWE). One possibility to characterize this material/structural behavior is the drop-weight test. The result of .this .test is a temperature at and below which a crack can initiated in a deep drawn part under the investigated set of parameters. This paper addresses the influence of the preforming process on the sus- . . ceptibili.ty of IF steels to SWE.IntroductionInterstiiial:free (IF-) steels are frequently used in the automotive industry for complex· shaped p·arts because of their excellent deep drawability. The microstructure of the steel consists of a highly ductile ferritic matrix with embedded precipitates of nitrides and/or carbides. Brittle fracture can occur in deep drawn parts, if they are subjected to a high speed deformation at lo""w temperature. This phenomenon is called ~econdary Work gmbrittlement (SWE) [1-11]. Up to now there are no standardized testing procedures available to quantify the sensibility of IF-sheet steel to SWE. Neveitheless, a reasonable testing procedure which allows to quantify the tendency of a predeformed part to SWE is necessary for further material development. A commonly used test method is the drop-weight test performed at low temperatures. In such ·tests a cone-like drop weight expands a deep drawn cylindrical cup [l-3, 6, 8, 9, 11]. From this expansion experiment the temperature is determined at and below which a brittle crack can be initiated in the deep drawn cup under the investigated impact test parameters. The highest measured temperature at which a deep drawn cup fails by brittle fracture is called frack appearances !emperature (CAPT). The lower the value of the CAPT the lower is the sensibility of a deep drawn part of IF-sheet steel to SWE. This paper aims to clarify the role of the preforming process on the impact behavior of an IF steel. For this purpose a numerical analysis of the deep drawing process and cup expansion tests are conducted."

Jan 1, 2000

By Emmanuel N. Zevgolis

After the Krupp-Renn process was shown to be unsuitable for treatment of the Greek nickeliferous laterites, the LM process was developed. It involved roasting reduction up to metallic iron in a Rotary Kiln (R/K) and smelting in an Electric Furnace (E/F). Ferronickel (with 15% Ni) produced in the E/F, was upgraded to 90-95% Ni in an 02 converter. Raw Ni was then electrolyzed to pure Ni. The LM process was not applied for very long however, due to various problems. So, the Larco process was developed, i.e., pre-reduction in R/Ks, smelting of the calcine in E/Fs for ferronickel production (15% Ni) and enrichment to 20% Ni, in an O2 converter. Until now, many technological improvements have been invented and applied or adjusted to the process, which have made it a fully reliable and competitive one. sohe of the improvements were the invention and application of a new granulation process for liquid ferronickel, the modification of the existing R/Ks, E/Fs and converters and the design of new ones, and others that are described in the paper. Keywords: Ferronickel, metallurgy, laterites, LM process, Larco process

Jan 1, 2004

By Paul Van Negan

During the last decade, MHO has continued to diversify the feed. of its Hoboken smelter. The range of feed materials including larger proportions of precious metals has been extended and the production of minor metals has been developed. These diversifications have required further improvements at the smelter. Attention has been particularly focussed on an increase of productivity, compliance with emission standards and achievement of the highest recoveries of valuable elements. The assaying and sampling facilities have been considerably expanded and the different processing steps of the smelter are now also systematically controlled and managed by simulation models. The charge preparation at the sinter plant, returns handling, sinter conditioning and corresponding ventilation systems have been completely renewed. The annual smelting requirement is now achieved with two blast furnaces instead of three. This is the result of rebuilding and enlarging one of the furnaces and, of a completely new concept of the charge proportioning and charging systems, together with oxygen enrichment and blast air preheat. Ventilation capacity has also been drastically increased. A 7 MVA electric furnace for cleaning the slag from both blast furnaces. contributes to improving the overall metal recovery.

Jan 1, 1990

By Huimin Lu, Min Li, Jinghua Zou

"Zeolitic imidazolate frameworks (ZIFs) are new type of porous materials, form inerratic polyhedral in three-dimensional with large cages and small apertures, and appear structural diversity. Their hole size can be adjusted. These materials have high selective adsorption capacity to carbon dioxide. In this paper, zeolitic imidazolate frameworks were synthesized by solvothermal synthesis method with dimethylformamide (DMF) as solvent and structuredirecting agent, divalent metallic ions as cation, and imidazole as ligand. The crystals were characterized with XRD, SEM for their crystal structures and physical properties, the adsorption of the crystals for carbon dioxide was also tested, and the result suggests that these porous materials have a capacity of 1.35ml/g for storing carbon dioxide at 273 Kelvin under ambient pressure.IntroductionGlobal warming caused by the increase of carbon dioxide in the atmosphere has become one of the main environment problems, contemporary research has focused on ways to slow or stop this trend. CO2 capture has attracted attention due to the potential to trap and sequester large amounts of CO2 from concentrated sources such as power plants [1]. Traditional technologies in capturing CO2 include absorption by aqueous amines [2]. However, utilization of this process is energy intensive and expensive. Carbon dioxide storage materials investigated so far can be divided into two categories: chemical storage adsorbents and physical storage media [3]. The first kind of materials can chemically adsorb carbon dioxide within their structures and need thermal energy to release the adsorbed carbon dioxide. The examples of the chemical adsorbents include aqueous amines, gas-hyperbranched aminosilicas [4]. The physical adsorbents store carbon dioxide by physical adsorption of carbon dioxide at elevated pressure and release the adsorbed carbon dioxide at low pressure. The physical adsorbents that have been investigated for carbon dioxide storage include zeolites, carbonaceous materials and other porous materials. Until recently, a new type of microporous material, known as zeolitic imidazolate frameworks (ZIFs), has been reported as promising adsorbents for carbon dioxide storage [5 ~ 10]."

Jan 1, 2010

By Renato G. Bautista

The solvent extraction separation of nickel, cobalt and their associated metals have been considered for industrial application since the early 1960's. This review of the solvent extraction processes is limited to the industrial applications, pilot plant and the more extensive bench scale studies reported in the literature. The processes with their significant chemical and technological contributions are discussed in detail whenever the information are available. The application of solvent extraction to the nickel-cobalt processing has so far been limited to the secondary separation of nickel-cobalt containing feedstocks derived from other primary nickel-cobalt separation methods.

Jan 1, 1993

By B. R. Baldock

The converting of high-grade nickel matte for production of low-sulphur matte or nickel metal is a process which has eluded metallurgists in the past because of the limitations of conventional converting furnaces. The high temperatures required and the refractory nature of nickel oxide has prevented practical success in a process which has been known to be theoretically feasible for a long time. The Ausmelt top submerged lancing system is capable of operating under close control of the smelting conditions. High temperatures and both rapid oxidation and rapid reduction can be achieved. These features have provided the basis for successful pilot plant trials of the desulphurisation of high-grade matte from the Kalgoorlie Nickel Smelter. Sulphur level in product was lowered from 20 to 25% to as low as 0.2%, with iron levels in matte in the range of 1.0 to 3.5%. The theoretical background of matte desulphurisation is surveyed and the pilot plant operations described. The implications of the results in relation to commercial plants and possible refinery operations are summarised.

Jan 1, 1993