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By Guo Xueyi

The reaction mechanism for the manganese dioxide reductive dissolution in acidic chloride media in the presence of ferrous/ferric ions are based on theoretical delineation and dual cell experiments. In terms of the Buttler-Volmer equation and chemical kinetic principles, a electrochemical kinetic equation was deduced, which successfully provided a theoretical basis for describing the role of Cl-, Fe2+, Fe3+ and H+ in solution, as well as their interrelationship in manganese dioxide reductive dissolution. Dual cell experimental studies indicate that the increases of Cl- and Fe2 in solution are helpful to accelerate the couple process; while, Fe3and Mn2+ hinder the coupled reaction to some degree. Higher acidity in solution is beneficial to the dissolution of MnO2. All the dual cell experimental results are consistent with the theoretical deduction. This study will be useful to understand the mechanism for the leaching of manganese nodules from the deep ocean, as well as the leaching of manganese dioxide ore from land.

Jan 1, 2003

By Shunichi Ajima

PT. Smelting Co. was established in February, 1996 to construct and operate the Gresik Smelter and Refinery. The construction work of first Copper Smelter and Refinery in Indonesia was completed in the end of August, 1998 and it was put into the integrated test operation in December, 1998. Gresik Smelter and Refinery is designed to produce 200,000 tpy of copper cathode from copper concentrate supplied from Grasberg Mine of PT. Freeport Indonesia Company in Irian Jaya, Indonesia. As by product 592,000 tpy of sulfuric acid, 382,000 tpy of slag, 31,000 tpy of gypsum and 480 tpy of slime will be produced in the full operation. Major processes applied at Gresik Smelter and Refinery are: Smelter: Mitsubishi Continuous Copper Smelting and Converting Process ( Mitsubishi Process ) Anode Casting: Continuous Casting of Copper Anodes with the Hazelett Twin Belt Caster Refinery: ISA Process Acid Plant: Lurgi Mitsubishi Double Contact Process

Jan 1, 1999

By S. H. Castro

In 1997 Chile was the world's largest copper mine producer with around 3.4 million metric tomes of copper. Conventional technology (conminution-flotation- smelting-converting-electrorefining) for copper sulfide ores was used. For copper oxidized ores hydrometallurgical processes (heap leaching-solvent extraction- electrowinning) were employed. Consequently, the most important waste effluents include flotation tailings, gaseous emissions, smelter slags, acidic and alkaline wastewater, electrolytic sludges, solid residues from leaching, etc. The introduction of stricter environmental regulations are forcing the Chilean industry to minimise the generation of waste and promote cleaner production. Gas emissions such as SO2 and arsenic from smelters and process wastewater are the major problems at this stage. The environmental impact assessment of gas emissions in all six largest smelters namely Chuquicamata, Caletones, Potrenllos, Ventanas, Paipote and Chagres led to design a "decontamination plan." The implementation of this plan resulted in (i) the installation of sulfuric acid plants for SO2 abatement and (ii) the installation of electrostatic precipitators to remove arsenic oxides condensed from cooling gases. The aim of this paper is (i) to describe the type of waste associated to the various stages of the metallurgical processes and (ii) review the main abatement technologies used in medium and large size companies.

Jan 1, 1999

By Peng Fan

Liquid phase tends to migrate from an aggregate of solid particles immersed in a liquid phase into another aggregate composed of the same solid particles and liquid but with smaller particle sizes and/or lower volume fraction of the liquid phase. This type of liquid migration in a two phase system can be attributed to the driving force for the system to decrease its total interfacial energy. With liquid migration pressure as a convenient measure for the total interfacial energy of a solid-liquid two-phase system, liquid migration can be attributed to the existence of liquid migration pressure gradient in the two-phase system. The kinetics of liquid migration is of great practical importance for many industrial processes, one of which is the liquid phase sintering of functionally graded WC-Co composite materials. During liquid phase sintering, WC-Co composite forms a typical solid-liquid two-phase system where solid particles of WC are immersed in liquid Co. For a sample composed of two layers of WC-Co with the same Co content but different WC particle size, Co gradient will be formed during liquid phase sintering; while for a sample composed of two layers of WC-Co with the same WC particle size but different Co content, the Co gradient will be eliminated during liquid phase sintering. The formation and elimination of Co gradient are controlled by the liquid migration pressure gradient. This paper describes a numerical simulation of the kinetic process of the formation and elimination of cobalt gradient.

Jan 1, 2006

By Manolete Mena

WC-Co nanocomposite powder is among the first group of materials with a promising potential for nanocrystalline-materials application. A chemical vapor synthesis (CVS) process that has previously been used for preparing the aluminides of titanium and nickel, and other metallic and intermetallic powders has been applied to the preparation of WC-Co nanocomposite powder. This CVS system was designed so that a tungsten precursor (WCl6 powder) and a cobalt precursor (CoCl2 powder) were separately fed into each evaporator in a reactor by means of specially designed powder feeders. The reduction and carburization of the vaporized chlorides by methane-hydrogen mixtures produced nanosized WC and Co composite powder. The product is a very uniform mixture of the constituent powders, which is important to ensure a high quality of the bulk cemented tungsten carbide product after consolidation. In the present work, the effects of reaction temperature, CH4 to WCl6 ratio, CH4 to H2 ratio, residence time, and Co content on the powder composition and particle size were determined. The products were characterized using XRD, carbon analyzer, and TEM.

Jan 1, 2006

By L. Z. Villanueva

An investigation and evaluation has been performed to determine the potential utilization of electron beam irradiation technology for sulfur oxides removal from reduced-S02-strength metallurgical gases from copper smelters. These off-gases, though too weak to be converted to usable, concentrated: sulfuric acid by conventional means, are characterized by SO2 content higher than 2,000 ppm and a complex chemical composition, including high oxygen content and its generation occurring in a cyclical, fluctuating pattern. This work was based on information supplied by principal smelter companies in Chile. A laboratory facility with flow rate of 20 Nm3/h and equipped with an electron accelerator of beam energy 8.00 keV, has been used for testing. Influence on SO2 removal efficiency of operational parameters such as gas temperature, water vapor content, ammonia feed ratio and irradiation dose was established. The main conclusion of this work, from experimental laboratory tests as well as engineering studies, is that the Electron Beam Process (EBDS) is a cost-effective, simple and appropriate chemical process means for emission abatement. EBDS can, on a site-specific basis, adequately augment SO2 removal to upgrade overall abatement as required and in an optimal manner.

Jan 1, 1999

By Anurag Tripathi, J. K. Saha, S. K. Ajmani, J. B. Singh

"The quality of steel is a major concern in the metallurgical industry. The control of liquid steel temperature can enhance the level of cleanliness in steel. Ladle is one of the major vessels used to transfer liquid steel between different stations. The heat transfer phenomenon taking place in this vessel needs to be monitored for controlling the liquid steel temperature. A CFD model was developed for prediction of liquid steel temperature during complete process cycle of ladles in direct heats. The model was validated with liquid steel temperature measured at on-line purging station and tundish during teeming from one of the actual steel plant. The accuracy of model was 96 %. The results obtained show insignificant effect of slag thickness, tapping temperature and ladle life on liquid steel temperature in the ladle. However, the importance of initial refractory temperature was noticed. The CFD model developed in present work can generate the thermal history of liquid steel and refractory walls of any ladle at any stage.1. IntroductionThe control of liquid steel temperature is desired to achieve required steel quality. The low casting temperature is detrimental and may result in nozzle blockages due to premature solidification in the tundish. The phenomenon of heat losses taking place in ladles needs to be understood for prediction of liquid steel temperature. The assessment of thermal profile of liquid steel from BOF converter to caster can be done through consideration of heat losses at all points. Hlinka and Miller [1] showed that the ladle pouring temperature varies due to heat losses from molten steel into surrounding refractory layers. The phenomenon of thermal stratification was numerically simulated by Ilegbusi and Szekeley [2]. The effects of slag cover on heat loss and liquid steel flow in ladle before and during teeming to a continuous casting tundish was numerically simulated by Chakraborty and Sahai [3]. Investigators also developed some simple models to predict the steel temperature for some of the processes taking place in ladles [4-9].The present work is an effort to generate the full information about the temperature drop taking place in any ladle throughout its process cycle. This information can be used to predict liquid steel temperature and to take decisions to minimize heat losses."

Jan 1, 2012

By Keizo Uematsu, Kumiko Sanda, Nozomu Uchida

"Full understanding of mechanical properties is the most important assignment in ceramics. Establishment of defects-property relationship is crucial for fulfilling the assignment. This study reports detailed characteristics of defects and their relevance to the mechanical properties for alumina ceramics made through a typical industrial processing. Novel characterization methods were applied to evaluate their defects. A very simple direct correlation was successfully found between defects and properties in ceramics. This result is a great epoch in the field of ceramics. IntroductionThe ceramic materials are used in refractoriness, corrosion resistant materials and structural materials. The low fracture toughness and scatter of strength are very important problems in ceramics. The toughness of ceramics is lower than metal and polymer materials, and the allowed defect size is small. Very small internal defects (pore, crack, huge particle) can be a fracture origin in the brittle fracture. The characteristics of defects such as size, distribution and shape change markedly by process condition, which cause the scatter of strength. This study conducts quantitative evaluation and direct observation of the sizes, shape and a number of internal defects with a light microscope, and discusses the relationship for mechanical properties and defect sizes"

Jan 1, 2000

By M. C. Flemings, S. B. Brown

"Metallurgy, as all of material science and engineering, rests on the intellectual foundations of processing-structure-property-performance relationships. Today it is widely recognized that processing has been too long neglected and presents exciting opportunities for exploitation. New processes, many of them already in the laboratory, will be exploited in the year 2000 and beyond, for near net shape forming and for achieving-new metallurgical structures and composite structures. Process modelling will alter the way we think about process and product design. Processes themselves will increasingly be automated and controlled by computers, altering the nature of the workplace and the tasks of the metallurgical engineer of the future. IntroductionInnovations in metal processing is hardly a new phenomenon, with the field thousands of years old. Nonetheless, the next few decades offer particularly important opportunities to improve our ability to process these materials. We appreciate today the variety of processing paths available to us, including vapor-, plasma- and electro-deposition, multiple phase and casting technologies, and non-equilibrium processes, and how these affect structure at the atomic level and at higher levels of aggregation. We understand the basic physical mechanisms involved far better than even before and have remarkable new abilities to predict, control, and simulate the kinetics underlying processes, and the processes themselves.The following sections describe these new opportunities in greater detail. First, we examine developments in the modelling of metal processing. We then consider some implications associated with process control and automation. Finally we present what we consider to be particularly promising metal processing technologies, and conclude with a few summary comments."

Jan 1, 1988

By James J. Reilly

This paper recounts a history of the contribution of Dr. Gary Sandrock to the science and applications of metal hydrides from 1974 to 2006. It includes a bibliography that cites selected publications over the course these years and which constitutes an important public record.

Jan 1, 2006

By Bora Derin

Optimization of slag composition has great importance on effective and clean metal production technologies. Reddy-Blander (RB) model, a priori, is very useful tool for prediction of impurity capacities of industrial slags. In this study, sulfide capacities (Cs) of 19 lead smelter slags indicated in the literature were calculated and effects of Cs values on sulfur content of lead bullions were discussed.

Jan 1, 2006

By Larry G. Stolarczyk

The development of geosteering technology for geothermal reservoirs is challenged by the integration of electrically small antennas in small-diameter metallic drill rods. To be useful, the antenna pattern must achieve sufficient back-lobe suppression, preferably with a forward-looking pattern. Forward-looking capability requires an antenna array with phase control. The phase-controlled antenna pattern enables imaging of geologic structures ahead of and surrounding the well bore. This paper describes the development of electric and magnetic dipole arrays for small-diameter drilling pipe.

Jan 1, 2006

By Hong Yong Sohn

On the occasion of this symposium in my name, I reflect upon the contributions of my academic mentors and early associates who helped shape my professional career. I was fortunate to have these people around me during my graduate work and at the start of my professional career. In forming my view of the technical field and career, they represented academia, research institutions, industry, and different parts of the world.

Jan 1, 2006

By Todd S. Fayram

The Gordonsville Operation of Pasminco US Inc. along with the Center for Advanced Mineral and Metallurgical Processing (CAMP) at Montana Tech studied, developed and implemented a pilot scale hydrometallurgical facility for the industrial recovery of germanium and gallium. This paper describes the joint testing and engineering program that culminated in this successful process.

Jan 1, 2003

By J. Peter, S. E. James, J. L. Watson

A survey of operating zinc smelters and refineries throughout the world has been done in conjunction with the Lead-Zinc 2000 Symposium. This survey follows the examples set by the Japanese Mining Industry Association in 1985 and 1995. Questionnaires were sent to operating zinc plants that covered feed materials, process details, energy consumption and labor requirements. The voluntary responses to the survey were tabulated. Key operating parameters including feed grade, production capacity, quality of the intermediate products and quality of the final products have been compared for both hydrometallurgical and pyrometallurgical processes.

Jan 1, 2000

By Cashman R. S. Mason

Removal of halides (fluoride, chloride) from metallurgical solutions can reduce corrosion rates and improve hygiene from decreased anodic chlorine evolution. This is particularly true for zinc sulphate electrowinning solutions. This paper describes the chemistry of a new process for the removal of halides from such solutions by solvent extraction ? the Teck Cominco Halogon? process, for which patents are pending. In this process, the halides are loaded directly from commercial zinc sulphate solutions and are stripped into a form suitable for disposal. Sulphate extraction efficiency is variable while maintaining halide extraction efficiency. The method of optimizing the solvent composition is demonstrated.

Jan 1, 2003

By R. Gordon Bloomquist

The economic benefits of the co-production of minerals from geothermal brines far exceeds the potential revenue stream from the sale of marketable by-products such as silica, zinc, manganese, lithium and a number of rare earths. Extraction of silica can avoid scaling problems often associated with many geothermal power projects and may allow for additional power production through the use of bottoming cycles or the use of the brine in direct use applications now impractical due to scaling problems. An additional benefit of silica removal is the opportunity to use the geothermal brine as a source of water for enhanced evaporative cooling ? a technique that can significantly improve the summer power output from binary power plants employing air cooling for condensing the working fluid.

Jan 1, 2006

By Kang-In Rhee

Nonferrous metal recycling not only provides energy saving and environmental benefits but also is a significant factor in the supply of various types of metals used in our society. Recycling plays an important role in establishing the sustainability of materials. The total amount of recycled nonferrous metals by weight accounts for less than 5% but their value is larger than 50% compared to ferrous metal recycling which consists of about half of the total metal recycling in weight. This paper describes trends and typical achievements in nonferrous metal recycling and overviews the present and future of nonferrous metal recycling technology and business in Korea.

Jan 1, 2006

By Neil E. Izatt

The use of Molecular Recognition Technology (MRT), a selective separations technology using specifically designed ligands, has been established as an effective process for removal of metal ions found in many hydrometallurgical, chemical, and wastewater streams. The MRT process has been proven to be highly efficient and effective for indium extraction and recovery from zinc acid leach, electrolyte, chemical process and waste streams. A high percentage of the indium is recovered in a solid product format. MRT has also proven effective for germanium extraction and recovery from similar feed streams. This paper provides the indium and germanium metal recovery flow sheets and analytical results of the metal load and recovery steps.

Jan 1, 2006

By Li Rongxing

A general regular solution model put forward in this paper defines a general interaction parameter that includes both composition and temperature dependence. On the basis of this model, analytic express of solution excess properties was obtained by least square fit using the composition and temperature relations in binary alloy phase diagram. After some solution excess properties analytic expresses of correlated binary alloy system obtained, the analytic express of ternary alloy system could be obtained by superposition of general geometrical model. The ternary alloy system Pb-Sn-Zn has been predicted in terms of this method and the result was very in agreement with actual measured value.

Jan 1, 2006