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By S. Ferlay

"The main purpose of the ZIMA VAL project (Label EUREKA EU1367 and LIFE ENV/F/000278) is to demonstrate industrial scale recovery and recycling of the main components of used dry batteries (zinc, manganese dioxide, mercury, and stainless steel) into high added value products. The originality of the ZIMA VAL process resides in:1- the use of hydrometallurgy2- alkaline treatment implementation (highly selective) for zinc and mercury3- electrochemical recovery of high quality products.4- the recycling of all the battery components (zinc, mercury, manganese dioxide, stainless steel) ·5- low operating and investment costs.The process consists of physical classification, mechanical dismantling, hydrometallurgy and electrochemistry. The purpose of the demonstration plant in FALAISE (Calvados - France) is to define the technical and technological parameters of an industrial unit for the treatment of 2400 tonnes per year of used batteries."

Jan 1, 2000

By G. Johnston, J. Greenly, R. G. Buchheit, D. C. McIntyre, R. Muenchausen, D. J. Rej, R W. Stinnett

"Rapid thermal treatment of materials using high energy, high flux, pulsed ion beams can produce modified surface layers with unique microstrutures and properties. High energy ions loose their energy during the slowing down process in the workpiece and thus deposit their energy continuously over a depth of a few microns. The deposition of energy can lead to melting and in some causes ablation of the heated layer. Because the pulse duration of the ion beams is typically only 50-200 ns, steep thermal gradients generated during heating facilitate rapid cooling (107K/sec-108K/sec) of the treated layer by thermal diffusion into the underlying material. Rapid heating and cooling of materials can generate surface layers with non-equilibrium amorphous or nano-crystalline microstructures that exhibit increased hardness, wear resistance, and corrosion resistance. Pulsed ion beam treatment can also lead to surface smoothening or can be used to mix thin « 1 11m thick) coatings into underlying substrates. Pulsed ion beams can be generated using existing ""flashover"" ion source technology which is capable of producing single shot, mixed C, H, and O ion beams with beam cross sections of approximately 100 cm2 and energy fluxes up to 100 J/ cm2. Recent advances in repetitive high energy pulsed power technology and development of magnetically confined anode plasma ion sources have facilitated the development of ion beam systems that generate single species beams that pulse continuously at 120 shots/second. These capabilities will allow rapid treatment of large surface area workpieces at low cost.IntroductionThe rapid solidification of liquid materials can create unique materials and material microstructures that often have properties that can lead to enhanced performance. Rapid solidification processing of the surfaces of materials using continuous and pulsed laser beams (laser glazing) has been explored for over 20 years (1-5). Advances in high energy, pulsed electron and ion beam technologies over the past decade have provided rapid thermal treatment techniques that may be less expensive to impliment than laser surface treatment for many surface modification applications (6). High energy pulsed ion beams have recently been used to harden aluminum(7), copper(8) and tool steel surfaces (6,9), increase corrosion resistance of Al alloys (6), mix coatings into underlying substrates (10), and create amorphous films (11,12)."

Jan 1, 1994

By Issa S. AI-Kharusy

Oxidation/reduction (REDOX) alloy media, as used in wastewater treatment, is founded on the exchange of electrons. Because of this electron exchange, many contaminants are converted to harmless components which require no further treatment. Other types of contaminants are removed from the waste stream by electrochemically bonding to the alloy medium. This paper discusses the REDOX reactions, the role of the alloy medium in various treatment processes, and describes specific applications of REDOX alloy media for the removal and minimization of waste. The characteristics and handling of spent treatment media is also reviewed as a further consideration in waste minimization.

Jan 1, 1996

By A. Slotwinski, R. E. Barry, M. M. Menon, P. T. Spampinato

"A coherent FM laser radar based sensor for remote metrology of plasma facing material surfaces in a fusion reactor is described. The sensor is capable of 3-D mapping of surfaces, based on a series of precise range measurements from large distances (up to 20 m). Other features include the ability to operate under adverse environmental conditions involving very high gamma radiation (3xI04 Gy/hr), ultra-high-vacuum (<I0-5 Pa), and high temperature (200°C). The paper describes the basic principles of the sensor, together with experimental results obtained with the sensor. The ability of the sensor for remote rendering of ""visual quality"" images without the need for any external illumination is also illustrated.IntroductionMeasurement of the features of large area surfaces (-1500 m2) to sub-millimeter accuracy, from relatively large distances (20 m), is necessary in the case of the International Thermonuclear Experimental Reactor (ITER -a 1500 MW fusion reactor that is currently in the design phase). Furthermore, the measurements may have to be performed after the reactor is temporarily shut down. During such shut-downs, the ITER in-vessel environment will be highly radioactive due to neutron activation of the reactor wall (gamma radiation field of 3xl04 Gy/hr), the vessel will be maintained under ultra-clean vacuum conditions (<10-5 Pa), and the plasma facing surfaces will be maintained at elevated temperature (200°C). Therefore, the precision measurements must be conducted remotely, and because of the large dimensions of the fusion reactor and the limited number of access ports, the measurements must be done from large distances. The reactor vessel is a large toroid. Fig. 1 shows the cross section of the toroidal vacuum vessel, and the location of the metrology probe. Because of the very large surface area involved, fast scanning capability is also needed to reduce the reactor down-time."

Jan 1, 1997

By Tim J. A. Smith

Fundicion Refimet S.A. has operated a custom copper smelter at La Negra, near Antofagasta in northern Chile since 1993. From an initial operation based on Reverb smelting and Peirce-Smith, converting, the plant was expanded from 90 000 t/y to 160 000 t/y copper production in early 1997, by conversion to oxy-fuel smelting and use of concentrate injection on Converters. As part of this expansion a novel reverb gas cooling and cleaning system was developed and designed by Kilborn SNC-Lavalin Europe, the London, UK-based mining and metals; Office of Canada&apos;s SNC-Lavalin group. The reverb gas cooler needed to satisfy several very specific requirements including low cost, flexibility, robustness and simplicity of operation. Of particular importance was the requirement to cool and clean the ,oxy-fuel reverb gases and render them suitable for subsequent treatment in a conventional sulphuric acid plant. It was also important to avoid accretion or dust handling problems. This paper describes the key design features and subsequent successful installation, commissioning and operation of the unit.

Jan 1, 1998

By Hideki Yamamoto, Shigeno Matsumoto, Junji Shibata

"Some fundamental studies were carried out in order to produce composite powders comprising of two or three metal oxides ~y using liquid-liquid extraction and to develop the control technology of the particle size. The combination of samarium and cobalt was selected as the two component composite powders. Both stripping and crystallization occurred at the same time by emulsifying the organic phase loading the two metals extracted with Versatic Acid 10 and the aqueous solution containing oxalic acid. The effect of aqueous pH, oxalic acid concentration and agitation speed was examined on some properties such as crystallization percent, particle size and shape of each metal oxide powders obtained in this process. The analysis by using EDX showed that the two metal oxides were distributed uniformly.IntroductionComposite metal and metal oxide powders with high purity are indispensable as industrial materials in the fields of electrical engineering, electronics and metallurgy. It is difficult to mix metal powders or metal oxide powders uniformly for the production of alloy powders. If insoluble metal salts are allowed to collect as crystallization products in the crystallization-stripping process, the conventional melting and crushing process can be avoided. After mixing of the organic phase containing metals in fixed composition, fine metal and metal oxide powders of alloy composition are produced by using a crystallization-stripping method. Versatic Acid 10 and D2EHPA, both acidic extractants, were chosen in this experiment, and the metal oxide powders were produced by using oxalic acid as a crystallization reagent. Mixed metal oxalates containing samarium and cobalt were precipitated from the mixed organic phase containing these metals. Furthermore, the physical properties of the powders, such as particle size, shape and thermal decomposition, were measured in order to evaluate them for industrial purposes."

Jan 1, 2000

By Jesse White, Arlin Olson

"An Engineering Scale Technology Demonstration (ESTD) unit utilizing the THOR fluidized bed steam reforming technology was built and operated by Hazen Research, Inc. for the purpose of denitrating and solidifying various Department of Energy (DOE) radioactive tank waste surrogates into granular products. The ESTD offered the opportunity to investigate the operational characteristics of two fluidized beds in series to test process system designs such as those for fluidization, feeding, and product collection. Operational characteristics that were evaluated included bed attrition rate, particle growth, and elutriation; and the effects that variations in process parameters (e.g., fluidizing gas flow rate, feed composition, feed injection method, and gas distributor design) had upon these characteristics were observed. Testing of the process systems on this scale allowed for design changes to be made where the cost in time and money were significantly less by comparison to those same modifications being made on the commercial scale.IntroductionFluidized bed steam reforming (FBSR) offers a moderate temperature (620-750°C) continuous method by which various liquid wastes can be processed irrespective of whether they contain organics, nitrates, sulfates/sulfides, chlorides, fluorides, volatile radionuclides or other aqueous components. The FBSR technology has exhibited the potential to process these wastes into either a carbonate or crystalline ceramic (mineral) granular product.Pilot scale testing was performed using the THOR Treatment Technologies, LLC (ITT) FBSR process, as it offered the opportunity to evaluate multiple aspects in an environment more conducive to experimentation. Process changes and system modifications could be made faster and with less cost impact as compared with changes to an assembled commercial plant. These aspects include verification of process chemistry and kinetics, evaluation of materials of construction, equipment sizing and design, and the interactions of the systems. Evaluation of process chemistry allowed for the verification of thermodynamic and kinetic models, and was used in conjunction with these models to improve the database and modeling assumptions. It also allowed for the reevaluation of data from earlier bench scale testing with the opportunity for long-term operations. These long-term effects may include the buildup of one or more elements that results in the formation of eutectics leading to the destabilization of a fluidized bed, or the shift in particle size as a result of attrition or agglomeration. The pilot plant also provided an environment to evaluate materials of construction."

Jan 1, 2014

By Robert Matusewicz

Ausmelt Technology has been applied to the recycling of spent pot liner (SPL) generated from primary alnminum production. The process is centered on the Ausmelt furnace, in which the SPL is converted under high temperature, oxidizing conditions to an HF containing gas stream and inert slag. fluorine is recovered from the SPL as HF gas and is concentrated and used to manufacture AIF) for recycle to the aluminum smelters. Approximately 87% of the fluorine can be recovered and converted to AIF), with the remainder being effectively tied up in the by product slag. Cost projections show that the recycling process will be competitive with other processes for SPL. The production and recycling of AIF) provides available credit that significantly offsets the operating cost of the facility. Ausmelt Technology for recycling of SPL is currently being marketed in North America by Ausmelt Technology Corporation in Denver, Colorado, and in the rest of the world by Ausmelt Limited of Dandenong, Australia.

Jan 1, 1996

By Jing Zhan, Gui Li, Wei-feng Li, Li-Hua Jiang, Chuan-fu Zhang, Jian-yang Hwang

Thermodynamics analysis for processing the charge with lead concentrate and lead sulfate-containing materials in bottom blowing smelting furnace was conducted. The results show that the technology of large-scale processing PbSO4- containing materials with PbS concentrate in bottom blowing furnace under the condition of using high-iron slag type, batch heat supplement, high temperature and rich oxygen is thermodynamically feasible. The exploration test and industrial experiment confirm the results. When S content in mixed ore is 16~17% with coke foam content of about 5%, the lead paste amount can be increased up to 40%.

Jan 1, 2015

By Jonathan M. Berkoe

Design engineers and metallurgists have long recognized the need for better methods to calculate a wide range of fluid dynamic effects in smelters and hydro- metallurgical facilities. Examples can range from the capture of fume in the secondary hoods of a copper converter, to controlling the thermal effects of heat transfer resulting from metal and slag flows within a furnace. With the advent of relatively low-cost, high- speed computers and user-friendly, commercially available computerized fluid dynamic (CFD) programs, these calculations can now be made. Use of CFD increased the understanding of both hot gas and molten flows in smelter facilities and has already led to design improvements in converter fume control hoods as well as improved management of heat transfer in electric furnaces. This paper will present two representative CFD applications to metals industry facilities. To date, Bechtel has implemented CFD results on four continents.

Jan 1, 1999

By Tatsuro Ariyama, Michitaka Sato, Atsushi Sakai, Sumiyuki Kishimoto, Ryota Murai

"In order to achieve high pulverized coal injection operation in a blast furnace, optimization of the injection lance arrangement was carried out using an experimental furnace and mathematical models. To increase the injection rate of pulverized coal, it is required to raise the combustion efficiency of pulverized coal. It became clear that multi-point injection and the lance arrangement to avoid interference among the coal streams injected were so effective in increasing combustion efficiency. With these findings, the eccentric double lance arrangement has been newly developed.At NKK, Fukuyama No.4 Blast Furnace, after the improvement of the lance arrangement, the maximum injection rate reached up to 230 kg/thm and an average monthly record of 218 kg/thm was successfully achieved.IntroductionFrom the viewpoints of reducing the production cost of pig iron and prolonging coke oven life, high pulverized coal injection over 200 kglthm is actively pursued by ironmaking industries[1-2].Coal particles injected into the blast furnace are consumed by combustion in the raceway and also in-furnace reaction like solution-loss reaction (C + CO2 = 2CO). The amount of coal consumed by the latter process is determined by the carbon balance in the blast furnace and there is a limit. Therefore, to increase the injection rate, it is desirable to improve the combustion efficiency in the raceway. For these purposes, the optimization of the lance arrangement was examined by a hot model and mathematical models."

Jan 1, 1996

By Carla Lupi, Alessandro Pescetelli

"Spent lead battery recycling still shows few weak points in the achievement of a 100% recycling of different waste matters and by- products arising from the recycling process. Some of said problems are dealing with aqueous streams outgoing the recycling plant, and more particularly, a) the waste waters discarded from the breaking and separation unit, b) purification of the spent electrolyte drained from waste batteries and upgrade to a quality compatible with full re-use by the batteries’ manufacturers, c) purification of the mother liquors discarded in the sodium sulfate crystallization process so to produce a salt of commercial grade. All of the above listed problems have been satisfactorily overcome applying an electrochemical process that, through different process conditions and parameters, is able to remove the harmful impurities that hinder the successful commercialization of such by products, or, at least, that can avoid heavy and expensive treatment plant and operation.IntroductionAlmost 100% of commercial lead and lead alloys produced by secondary lead plants is recycled to the new lead accumulators manufacture. The other by-products and residues produced through the lead recycling process may be classified into two groups:a) matters reusable in the new accumulators production processb) matters produced as a result of various reagents and additives used in the recycling process, to be sold to different market sectorsQuality and saleability of by-products are significant points for the economics of the secondary lead plant operation, because, if said by-products are not saleable, they are just wastes, so offsetting potential revenues, and, at the same time, adding a heavy burden to operating cost, like disposal cost [1]. When looking at a typical, modern lead scrap batteries recovery cycle, it is quite evident that we are still rather far from dealing with a waste-less technology (fig.1).The group a) includes 3 by-products produced through the breaking process: among those matters the polypropylene only usually reaches a standard quality suitable for sale to lead manufacturing sector or to other sectors as well. The other two by-products, electrolyte and separators, do not still reach, through a viable and effective regeneration process, a quality standard sufficient for their re-use in the lead batteries sector ."

Jan 1, 2008

By Tadafumi Adschiri

"Supercritical water can provide an unique reaction atmosphere for synthesizing metal oxide nanoparticles. Due to the drastic change of properties of water around the critical point, including density, dielectric constant and ionic product, the reaction phase with O 2 or H2 gas and the reaction rate and equilibrium can be varied to synthesize new materials or define particle morphologies. In this work, hydrothermal crystallization experiments are performed with several types of flow apparatus that allow convenient manipulation of variables such as temperature, pressure, and residence time. Key features in the flow modes and material preparation are discussed. The proposed supercritical hydrothermal synthesis method has the following desirable features: i) nanoparticles can be produced, ii) morphology of the produced particles can be controlled with small changes in pressure or temperature, and iii) a reducing or oxidizing atmosphere can be applied by introducing oxygen or hydrogen or other gases. An overview of this method is given for functional material synthesis of significant industrial interest including barium hexaferrite magnetic particles, YAO/Tb phosphor fine particles and lithium cobalt fine crystals.IntroductionHydrothermal crystallization, a method of metal oxide formation from metal salt solutions, is typically used at temperatures ranging from 373 K to 473 K. We are developing a new process for hydrothermal crystallizations that uses temperatures in the range of 673 K to 723 K, which is just above the critical temperature of water1 • 8 • In this work, we refer to this process as supercritical hydrothermal synthesis. The supercritical state of water allows one to vary reaction rate and reaction equilibrium by shifting the dielectric constant and solvent density with pressure and temperature. From of our research on material production in supercritical water, we have identified the following specific features of the supercritical hydrothermal synthesis method: (i) ultrafine particles can be produced, (ii) morphology of the produced particles can be controlled to some extent with pressure and/or temperature, and (iii) a homogeneous reducing or oxidizing atmospheres can be provided by introducing gases, such as O 2, H2, H2O 2• and so on.1"

Jan 1, 2000

By B. J. Scheiner

The presence of organic materials in gold ores interferes with gold extraction by cyanidation. The carbon contained in the ore has been shown to adsorb gold cyanide complex from solution. Removal of the carbon content by roasting or chemical oxidation prior to cyanidation results in gold extractions of 85 to 95%. This paper discusses how the mineralogy of the carbonaceous gold ores affects gold recovery by cyanidation. It also discusses the advantages and disadvantages of roasting and chemical treatment to render the ore amenable to cyanidation.

Jan 1, 1987

By Ian G. H. du Preez

It is illustrated how differences in the basic chemistry of individual metal ions can be exploited to develop new or improved separating agents. Factors like coordination number preferred by the specific metal ion, the degree of coordinate saturation reached by the metal ion and its relation to the phase transferability of the complex species, kinetic factors as opposed to thermodynamic factors controlling the success of the separation, the nature and type of the donor atom employed in a separating agent in relation to the preferences of the metal ion, the significance of stereochemical factors and the hydrophobicity of the media are some of the important factors which are discussed and applied for the development of pa1ladiwn(TI) and nickel(TI) specific separating agents, respectively.

Jan 1, 1999

By Irina V. Sokol

Alloyed steel chips and swarf formed during metal processing are looked upon as additional raw material In metallurgycal production. The manuscript presents some new methods for steel waste chips and swarf cleaning. One of them Is swarf and steel chips cleaning In ethylene tetrachloride with ultrasonic assistance and following, solvent regeneration. Thermal cleaning of waste chips and swarf provides exit gas products utilization. Catalyst Influence of metal surface on the process of thermal decomposition of liquid hydrocarbons during cleaning process has been studied. It has been our experience that the efficiency of metal waste cleaning technique depends on the storage time of the swarf. Waste chips and swarf cleaning procedures presented in the manuscript have been proved economically advantageous and environmentally appropriate.

Jan 1, 1995

By Manuel Zamalloa

The outstanding metallurgical performance of the Noranda continuous converter (NCv) in operation since November 1997 has allowed the company to meet production and environmental targets. This achievement positions this new technology as a strong alternative continuous converting technology for copper production. Knowledge of slag chemistry has been important in this respect. The purpose of this paper is to discuss the effect of key parameters including temperature, oxygen potential, slag composition and levels of copper oxide in slag on the conditions leading to magnetite precipitation, as well as on the conditions affecting the liquidus ranges of NCv slag. The above variables are evaluated using industrial data and thermodynamic predictions. Practical implications of customizing operational fluxing procedures to determine optimum operating windows are also discussed.

Jan 1, 1999

By S. M. McDeavitt

Waste form alloys are being developed at Argonne National Laboratory for the disposal of remnant metallic wastes from an electrometallurgical process developed to treat spent nuclear fuel. This metal waste form consists of the fuel cladding (stainless steel or Zircaloy), noble metal fission products (e.g., Ru, Pd, Mo and Tc), and other metallic wastes. The main constituents of the metal waste stream are the cladding hulls (85 to 90 wt%); using the hulls as the dominant alloying component minimizes the overall waste volume as compared to vitrification or metal encapsulation. Two nominal compositions for the waste form are being developed: (1) stainless steel-IS wt% zirconium for stainless steel-clad fuels and (2) zirconium-8 wt% stainless steel for Zircaloy-clad fuels. The noble metal fission products are the primary source of radiation in the metal waste form. However, inclusion of actinides in the metal waste form is being investigated as an option for interim or ultimate storage. Simulated waste form alloys were prepared and analyzed to determine the baseline alloy microstructures and the microstructural distribution of noble metals and actinides. Corrosion tests of the metal waste form alloys indicate that they are highly resistant to corrosion.

Jan 1, 1996

By Maria G. Alves, Alexandre M. Stumbo, Francisca M. A. Pinheiro, Jonas Alexandre, Sergio N. Monteiro, Valdo da S. Marques, Paulo R. N. da Silva

"Brazil is among the few countries with potential for developing all sources of renewable forms of energy. In particular, the country is leading the world efforts of substituting petroleum based fuels for biofuels, such as ethanol and biodiesel. Most of the Brazilian petroleum, which has now achieved self sufficiency, is extracted from offshore wells located at the north region of the state of Rio de Janeiro. In view of the future depletion of petroleum, the State University of the Northern Rio de Janeiro (UENF) has created a Center for Alternative Energies (NEAL) to carry out R&D programs on renewable forms of energy. Today, the main project of the NEAL/UENF is a model park for generation of renewable forms of energy. The objective of this work is to present the structural concept of the park and discuss its contribution in terms of scientific, technological, economical and environmental benefitsIntroductionEnergy is presently a key issue in the world agenda for sustained development and environmental protection. It is of common agreement that the existing status of increasing use of fossil fuels, mainly petroleum, natural gas and coal will not only cause depletion of these resources with a consequent elevation in price but also climate changes, especially global warming. In fact, the humankind may be already facing an irreversible situation of climate alterations as well as reduction of conventional sources of energy. The worse predictions foreseen by specialists, still for this coming century, are dramatic disasters due to catastrophic weather in association with a profound energetic crisis. This scenario may, however, be avoided by actions that could effectively tackle the core of the problem. These actions have been suggested and discussed by scientists and leading authorities, especially in international symposia [1-3]. In particular, the Kyoto Protocol proposed goals for reduction of greenhouse gas emissions as well as a mechanism of carbon credits to allow for decreasing CO2 content in the atmosphere without affecting industrial production [3]."

Jan 1, 2008

By Rumen Markov, Lubomir Kuzev

"The treatment technologies for municipal solid waste (MSW) are effective mainly for components sized over 40 – 50 mm. This fraction is separated by screening in the beginning of the process. Usually the undersized product is deposited without additional treatment. Its quantity is variable from several up to 30 – 40 % of the total MSW. Both oversized and undersized fractions are formed by all types of primary matter. Adapted technologies from mineral processing will provide a suitable technology for treatment of MSW under 40 – 50 mm. The MSW content depends on the geographical location, the degree of urbanization and other factors. The methods can be applied for separations of different components suitable for recycling or other utilization are: • Separation by density; • Separation in thin liquid layer; • Selective grinding and screening; • Flotation, etc. Introduction Municipal solid waste (MSW) represents an integral part of public urbanization. However, there are some drawbacks stemming from MSW, in regard to its collection, transport and elimination. Different approaches exits worldwide for tackling the problems arising from MSW. For a short period of time, the attitude towards MSW has evolved in several levels, each further level being characterized by higher percentage of utilization of MSW components. Thus, the bottom line has been shifted from safety storage towards processing that includes recycling and maximal utilization of MSW components. Technologic processes applied for treatment of MSW have a common feature – that the fine components, having sizes under 20 mm, 30 mm, 40 mm, or 50 mm are excluded from treatment process trough screening, and in most cases diverted without any additional treatment to preliminary prepared storage sites. MSW in Sofia – current situation The amount of MSW collected daily in Sofia as around 1000 t/24 h. It is stored or baled. Baling is a spare alternative of storage, since baling insures only temporal keeping of MSW, till the building of suitable storage site where the bales will be transported and buried. The morphologic composition of MSW in Sofia has been determined several times at different time intervals, from some Bulgarian organizations as well as from the Japanese organization JICA. So far, however, there is still a lack of enough systematical and comprehensive study. Generalized results from the studies on the MSW components, as well as some important parameters are given in Table 1."

Jan 1, 2008