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By Yasuo Ojima

A new copper continuous converting process was investigated to evaluate the possibility of its application in the commercial operation. The tests were performed both in the laboratory and in pilot plant scale. Bath smelting process with the use of the top submerged lance technology was applied in these tests. Furnace shape was modified to a lengthwise eylindrical one with a settling area. The furnace monitor was put in the settling area to check the furnace from inside, FeOx-Si02, FeOx-CaO and FeOx-CaO-Si02 based slag systems were used to check their efficiency, The optimum slag chemistry to have good metallurgical results was discussed and FeOx-CaO system with some Si02 content turned out to be preferable although it has not been practically used, In this pilot plant test feeding rate of I tIH of solid grain matte was charged consecutively for two weeks and continuous converting could be done successively. This process is expected to overcome the problems of existing processes and be easily applied in existing plants.

Jan 1, 2003

By David Roha, Øyvind Mikkelsen

"Significant resources have been spent throughout the years in the investigation of production of aluminum by carbothermic reduction. Due to the technological challenges involved, the efforts have not yet resulted in a commercial process. An initiative to overcome issues that prevented previous attempts to succeed was taken by Alcoa through the Advanced Reactor Process. The research program has resulted in technical developments which have resolved many of the previous issues. The knowledge about the process has continuously improved through physical and computer modeling as well as by experimentation at various scales. The technical achievements together with improved process understanding have resulted in a reactor design able to continuously operate the process for several weeks at the time, with hundreds of kilograms of alloy in every tap.IntroductionThe Hall-Heroult process has since its invention in the late 19th century, been essentially the only process used for commercial production of primary aluminum. The process has so far proved to be superior to all potential process alternatives and has continuously been improved. Although the Hall-Heroult is a reliable process it also has challenges:"

Jan 1, 2012

By Susanne Pignolet-Brandom

Reflected light microscopy, and scanning electron microscope energy dispersive spectroscopic analysis and backscatter electron images were used to determine if a "slick dross" with undesirable handling properties has an assemblage of phases distinct from normal dross. This study has found that in the normal dross the most abundant lead phases are lead sulfide and lead metal and the most common copper phases are copper-iron sulfide and copper sulfide. In the slick dross, the most abundant copper phase is copper-lead sulfide and the most common lead phases are copper-lead sulfide and lead sulfide. The resulting mineralogical information has provided additional insight into the causes of the handling problem and the reaction mechanism for the formation of normal and slick dross

Jan 1, 1988

By Seung-Whee Rhee

Characteristics of ceramic support made by spent foundry sand-loess mixtures are investigated by bulk density, porosity, durability, and compressive strength. And the basic properties of SFS and loess are estimated. The effect of drying time after cutting process, elevated temperature time, sintering temperature, and sintering time is also estimated to obtain the optimal condition in the process of manufacture ceramic supports. From the basic properties of SFS and loess, the content of SiO2 in furan sand is much higher than that in loess but the content of Al2O3and Fe2O3 in furan sand is much lower than that in loess. In order to make ceramic supports cylinder shape is the most desirable to sustain the properties of ceramic support. If annulus shape has a enough compressive strength, however, annulus shape may be decided. For the optimal condition to manufacture ceramic supports, drying time after cutting process is decided to 24 hrs and elevated temperature time is decided by 9hrs. And sintering temperature and sintering time are decided to 900 and 9hrs, respectively in order to prevent solidification of sand materials.

Jan 1, 2006

By Kurt Svens

"As zinc consumption is gradually increasing all the time in the world, many zinc plants are looking for possible expansions. As the sulphuric acid market as well as the fertilizer market in many areas is saturated, the costs for the roasting-acid plant section of the zinc plant will create problems when making feasibility calculations for possible expansions. For solving the customers' situation, two proven zinc concentrate direct leaching technologies are available. A third one, which is possible, does not have any industrially proven applications in the zinc area.IntroductionTime to time, the zinc plants in the world scrutinize their operations with respect to their cost efficiency, the total zinc recovery and the near-by or far-away consumer markets, especially the for zinc and sulphuric acid. Their preliminary profitability calculations can show that a possible total expansion is not economical, when they are looking to expand the whole roasting/acid plant - leaching - solution purification - electrowinning - casting route, as the possible market price for the sulphuric acid is low or the sulphuric acid market is too far away. Based on these facts, their economical study often indicates that implementing a zinc concentrate direct leaching option could be more favourable. Regarding this situation, several aspects concerning three alternative direct leaching methods will be discussed, of which pressure leaching and the atmospheric leaching processes have several industrial applications in the zinc industry, as the ultrafine grinding - conventional leaching process at present has none. As iron is also dissolved during zinc concentrate direct leaching, iron removal processes generally used in the zinc industry are additionally discussed below."

Jan 1, 2012

By Philip Thompson

"Carefully planned laboratory test programs provide valuable data regarding the amenability of low grade gold ores to heap leaching. The most common laboratory test is the column leach test. The overwhelming problem associated with this type of test is the limit on the test column height. Most laboratories use a three (3) meter (10 foot) high column as a standard test due to building ceiling limitations, sample size limitations, etc. This paper presents a case study in which an ore sample was tested in a 1.5 meter, a three meter, and a six meter high column to determine the effect of column height on the test results. Other important factors such as sample preparation protocol, preliminary bottle roll testing to determine appropriate crush size, column diameter requirements, and leach solution analyses, are also discussed.IntroductionColumn leach testing has been used for years by many laboratories to determine the amenability of low grade precious metals bearing ores to heap leaching. However, the test work can be compromised by poor planning, misinterpretation of results, and extrapolation of data beyond the reasonable boundaries of the experiment. Preliminary test work should be performed prior to column testing. This preliminary work provides valuable information regarding the response of the ore to cyanidation and aids in the design of the column tests.The sample should be screened into various size fractions prior to testing. The fractions are assayed to determine the gold content of each size fraction and of the overall sample. The most valuable preliminary test is the bottle roll cyanidation test which is usually performed on five kilograms of coarse sample in a large rolling bottle which can accept material up to 50 millimeters top size. The residue from this test is screened at different sizes to determine the distribution of unleached gold in the residue. Comparison of the gold distribution in the leach residue with the distribution of gold in the feed at the same size intervals provides an indication of the appropriate crush size for the sample. The overall gold extraction from the sample at the crush size tested is also determined from these data. Lime and cyanide requirements can also be estimated from this test. The viscosity of the bottle roll pulp and the size distribution of the feed and leach residue can also suggest whether agglomeration of the ore will be required prior to column testing. Ores which contain significant amounts of clays (greater than 5 percent) will generally require agglomeration to prevent plugging of the test column."

Jan 1, 1997

By Michael F. Kitto

The production of sulphuric acid at base metals smelters is predominantly an involuntary activity and now comprises approximately 17% of all-forms sulphur supply in world terms. The majority of elemental sulphur is also produced involuntarily in response to environmental regulations regarding emissions from hydrocarbon processing plants. The paper examines the points of similarity and difference in the sulphur and smelter acid markets, and reviews their interactions. The reasons for the merchant acid market collapse of 1993 are analyzed, and the prospects of a recurrence are considered.

Jan 1, 1996

By Berger. P.

The accepted definition of the function of an edge protector fails to specify adequately the several tasks which it must perform to be functionally effective: detailed analysis of these tasks leads to the reasoned conclusion that they cannot satisfactorily be fulfilled by the conventional types of "edge-strips". The true cost of edge protector failure is cumulative: renewal costs are dwarfed by the increased operating expenses and production losses which result from but partial or incipient failure of the edge-strip; yet, the several supposedly improved types, for use with starter-blanks, generally were "built down to a price", prolonging the agony, as it were. Clearly, a fresh appraisal of the problem was overdue, and more especially so with the advent of "permanent" cathodes. As a result, new methods of edge .protection have been developed, including the so-called "EDGEWISE" system in which the present author as patentee *) has a vested interest-which he hereby declares. Due mention is made of recent progress in protecting the edges of aluminium "Jumbo" cathodes in zinc electrowinning operations, although the present Paper is more concerned with edge protection of starter-blanks and permanent cathodes in copper ER/EW processes, where most of the "old" problems now may justifiably be claimed to have been overcome, Mention is also made - albeit at this time necessarily only briefly, and confined to edge protection - of "rigidized" metal blanks and permanent cathodes: a most recent development**) which may prove to represent a "breakthrough": time will tell.

Jan 1, 1987

By Xianzhong Hu, Qingbo Yu, Qin Qin

"Oxy-fuel combustion is one promising option among different CO2 capture technologies. The object of this work is to show the effect of CO2 dilution on the laminar flame speed, flame structure and reaction pathway for methane oxidation at O2/CO2 atmosphere. In this paper, kinetic simulations were made using CHEMKIN with GRI-Mech 3.0 mechanism, which was validated by experimental data of laminar flame speeds. The reaction pathway of CH4/O2/CO2 mixture was derived from reaction flow analysis. Results showed that CO2 decreased the flame speeds, lowed concentration of major intermediates and increased flame thickness. The major chemical pathways of CH4 to CO2 have not changed at O2/CO2 atmosphere comparing with O2/N2 atmosphere, but contributions to major intermediates formation from each related elementary reaction have changed a lot. In addition, the secondary chemical pathways of CH3 oxidation became different at O2/CO2 atmosphere.IntroductionNowadays, as the global economy is developing fast and the pollutant levels (especially global warming gases) are increasing, a lot of researches are focusing on new technologies which can cut greenhouse gas emissions [1]. New technologies have been developed, such as high Mild combustion, flameless combustion and Integrated Gasification Combined Cycle (IGCC) technology. Oxy-fuel combustion using carbon dioxide as dilution of oxygen is considered as a promising approach for reducing CO2 emission. The properties of CO2 in flue gas are different from N2 in air. On one side, the transport, thermal and radiative properties of CO2 are different from N2 in air. On the other side, CO2 is not inert but directly participates in chemical reactions and recent researches [2-5] also present the chemical effects of CO2 on oxy-combustion. For these differences above, the characteristics of oxy-combustion are not alike with traditional combustion. It is necessary to develop the investigation of oxy-combustion.In all combustion processes, laminar flame speed is an important parameter, which links to combustion behavior. Analysis of this parameter can provide a better understanding of the effect of CO2 dilution in the process of oxy-combustion. Several investigations of laminar flame speeds of oxy-fuel flame have been improved, including experimental measurements and numerical computations. A.A.Konnov et al. measured the flame speeds of oxy-methane and oxy-ethane mixture using the heat flux method with a flat burner [6-8]. V. Ratna Kishore et al. used heat flux method to measure the adiabatic laminar flame speeds of hydrogen [9] and H2/CO mixture [10]. Adiabatic laminar flame speeds of hydrogen in O2/CO2 atmosphere are much smaller than in O2/N2 or in O2/Ar. The burning velocity of H2/CO mixture decreased with increase in CO2 content in mixture. Jeongseog Oh et al. [11] used Bunsen flame to measure the laminar flame speeds of premixed oxy-methane mixture with angle methods in atmospheric condition (300k, 1atm). The results were SL=29.1cm/s and SL=29.5cm/s respectively derived from oxy-methane from CH* images and Schlieren photos."

Jan 1, 2014

By Ashok D. Dalvi

Production of nickel from laterite ores has occurred for over 100 years beginning with processing of garnieritic ores from New Caledonia. However, until now the world nickel supply has been predominantly from sulfide sources. Going forward, the authors project that the production of nickel from sulfide ores will remain more or less constant. Most of the expansion in nickel production capacity over the next ten years will come from processing of laterite ores. Thus the capital and operating costs of new laterite projects will have significant impact on the nickel supply and therefore price. The authors have reviewed the history and capital and operating costs of various recent laterite projects and capital and operating costs of these projects and those "on the drawing board". The authors have also evaluated the risk associated with such projects. The paper will discuss the impact of this and the recent history on the future development of laterite nickel projects.

Jan 1, 2004

By Huang Chao

The thermodynamics analysis on reducing-matting smelting of sulfide ore of lead, antimony and bismuth which use ferric oxide as sulfur fixed agent is first analyzed. Due to the analysis of reaction mechanism, ferric oxide is first reduced to ferrous oxide, then ferrous oxide produce reducing-matting reaction with sulfide ore and reducing agent as reaction equation: MeS+FeO+CO=Me+FeS+CO2. The reaction thermodynamic calculation shows that the reducing-matting reactions of lead sulfide, antimony sulfide, Jamesonite, and bismuth sulfide are feasible, but is infeasible for zinc sulfide. These conclusion provide a feasible method for solve the pollution which produced in the smelting of sulfide ore of lead, antimony and bismuth.

Jan 1, 2006

By Marilda Macagnan, Rosana de Cassia de Souza Schneider, Valeriano Corbellini, Tiago Bjerk, Mariela de Souza Vieira

The great potential of Brazil for the agricultural production makes our country a generator of agro industrial residues. In this context, the solid-state fermentation appears as a technology that shows alternative ways for those residues, adding values to these raw materials, through the production of substances of industrial interest, besides reducing the possible environmental problems. The main objective of this study was to apply the bovine fat residue associated to the garden grass for the fungal lipase production. Initially, 75 microbial cultures were isolated from garden grass samples after incubation of the mixture with bovine fat. From these cultures were selected the filamentous fungi, whose lipase production abilities were evaluated. The isolation and the selection were accomplished by using a differential culture medium containing Tween 80 as inducer substrate of lipase production. The colonies with lipolytic potential were detected by the presence of white precipitation haloes on the agar. With agro industrial residues the best lipase producer fungus was identified as Penicillium sp in 6 days of solid state fermentation. The crude enzyme obtained was tested in transesterification process for the biodiesel production.

Jan 1, 2008

By Geoffrey S. Plumlee

The Summitville gold mine, located in southwestern Colorado, received tremendous publicity in the 1980's and 1990's for leaks of cyanide solutions from its heap leach facility. As is typical with cyanide spills, real time, geochemically rigorous assessments of the environmental effects were not performed. Past United States Geological Survey (USGS) research used simple mixing experiments to model the influx of alkaline cyanide heap leach solutions from Summitville into a nearby stream, whose waters were highly acidic due to severe acid-rock drainage (ARD) from the mine. These experiments indicated WAD cyanide rapidly degraded due to formation of Fe-Cu-CN solids and lesser HCN volatilization. The alkaline heap leach solutions also precipitated hydrous iron-and aluminum, oxides and hydroxysulfates (iron and aluminum 'supplied by the acid. rock drainage (ARD]), which then sorbed copper and other heavy metals from the ARD. These results indicate that mixing of cyanide heap leach solutions with ARD may be a cost-effective remedial method at mine sites where treatment of both is required. New experiments are currently in progress to further refine a potential remedial process.

Jan 1, 1998

By Bowen Li, Matthew D. Andriese, Jiann-Yang Hwang, Zhiwei Peng

"Magnetic iron sulfide ore particles heat rapidly by microwave (MW) irradiation generating plasma during oxidation of surfaces. The high temperatures produced by the exothermic event decompose local portions of samples forming a differentiated flux of partially melted silicate (si-mt) with entrained metal-sulfide (sul-mt) droplets. The si-mt forms crystals of olivine (01) in Ca-rich pyroxene (Cpx) melt that resorbs a portion of iron sulfide (Po). The immiscible sul-mt droplets of (Fe,Ni,Cu)1-xS contain magnetic subsolidus Ni-pyrrhotite (Ni-Po) with Cr-bearing ferrospinel (Mag). Sub-micron sized flecks of Au are found on the surface of a sul-mt droplet with scanning electron microscope (SEM).IntroductionSulfide ore deposits supply the world's mineral resource in the production of non-ferrous metals. Particularly, Cu-Ni deposits are chemically enriched in metals from high sulfur saturation during magmatic formation that creates the proper geochemical environment for metals enrichment [1, 2]. The sulfur and oxygen fugacity control redox conditions of a differentiated silicate/sulfur magmatic melt with the concentration of iron playing a dominate role in the chemical partitioning of metals in sulfide liquid [3, 4]. The initial magnetic crystallization of (Fe,Ni)i-xS monosulfide solution (mss) from metal-sulfide liquid has an exclusive effect on the fractionation of mineral assemblages (zoning) [5].Phase equilibria of sulfide melt (sul-mt) components are related by a miscibility gap with mss forming Ni-rich pyrrhotite (Ni-Po) followed by the crystallization of (Fe,Cu)1-xS intermediate sulfide solution (iss) [6]. Precious metals form stable chacogenides and are retained in solution until the final liquid solidifies. The redistribution of metals now occurs by subsolidus cooling of mss and iss that exsolve low-temperature Fe-Cu-Ni bearing mineral assemblages [7]. The proper interpretation of ore genesis increases processing capabilities by isolating chemically enriched zones during extraction and should be used to aid in sustainable mine site development [8-11]."

Jan 1, 2013

By Erik Olsson, Gunilla Hyllander, Stefan Schuster, Lena Sundqvist Ökvist, Maria Lundgren, Michael Hensmann, Olavi Antila

"Residual materials from the integrated steel plant itself or other sources often contain valuable compounds of e.g. C and Fe. Dust and sludge have to be agglomerated to be able to recycle to the blast furnace (BF) via top-charging. By injection of the materials, preparation methods in terms of e.g. drying and/or screening only, can be used. Alternative carbon materials (ACM) in terms of BF dust and sludge have been successfully injected up to levels of 60 kg/tHM in the LK.AB Experimental Blast Furnace (LKAB EBF®). Efficiency in recovery of valuable compounds as well as the behavior of undesired elements have been evaluated and are discussed.IntroductionTraditionally, recycling of steel in-plant fines is made via the sinter plant and blast furnace route. Steel plants operating with 100% pellet as ferrous burden and have no sinter plant. There are limited areas for land fill and costs are caused for preparation of landfills and deposit fees. Very fine paniculate dusts or sludges cause decreased productivity and increased coke rate in the sinter plant, and therefore other ways for recycling must be considered. Injecting them into the BF could be an economically and technically feasible alternative. Additionally, as the materials contain valuable compounds of e.g. C and Fe."

Jan 1, 2012

By den Bulck A. Van

In Europe, 50% of the copper originates from recycling. High-Cu containing scraps are regularly rich in impurities like Fe, Ni, Sn and Pb. Many high-Cu containing scraps are fed directly into anode-furnace casting installations or furnaces with limited refining capability. The impurities levels of the anodes produced in these processes should however remain acceptable for further electro-refining. The distribution of Sn between copper and slag has been investigated for conditions relevant to copper converting. Unlike previous studies, this work focuses on the behavior of Sn relevant to fire refining conditions, which are essential for anode refineries.In this study, liquid Cu–1Sn and CuOx–FeOy–SiO2 slag, with CaO additions, were equilibrated at 1300 °C in vacuum sealed SiO2 ampoules. After metal–slag equilibration, the samples were quenched in water. The composition of the slag and Cu metal was investigated with Electron Probe X-ray Microanalysis. The distribution coefficients of Sn between slag and Cu metal were determined as a function of slag composition.

By S. Neven

The smelting of copper anode slimes, a material which contains mostly lead, silver, copper and selenium, has been practiced for many years with a view to recovering the silver and associated small amounts of gold. However, a theoretical understanding of the process has been lacking and this handicaps efforts to improve and intensify smelting operations. In the past few years work has been done in this area and this work will be reviewed in the paper. The underlying thermodynamics of the oxidation of silver-copper selenide mattes has been developed and used as a basis for the construction of a computational thermodynamics model which attempts to predict the composition of all condensed phases during the course of smelting. The model will be outlined and its successes in matching experimental data, as well as its current deficiencies, will be considered. Supporting work on the thermodynamics of silver solubility in slags, on activity-composition relationships in the Ag-Se system and work in progress on the oxidation state of copper in the slags will be reviewed. These projects are designed to provide further detailed data which will improve the robustness of the thermodynamic model.

Jan 1, 1999

By Xiaowen Liu

The thermal decomposition of diaspore was investigated by thermogravimetry (TG),differential scanning calorimetry (DSC), X-ray power diffraction(XRD),infrared (IR)spectrain this paper. The thermal decomposition mechanism of diaspore was discussed according to Coat-Redfer equation. It was found that the decomposition of diaspore was carried out at 500?,and the peak temperature was 530?. The electrovalent balance of diaspore was destroyed. The previous crystal structure was changed. a- Al2O3 was obtained after thermal decomposition. The activation energy is 287KJ/mol.

Jan 1, 2006

By Liming Wang

One of the steps in the extractive metallurgy of lead is a refining process called drossing. Hot dross is mixture of impurity compounds that form on the surface during the cooling of lead blast furnace bullion, and in Missouri, the main impurities are copper and sulfur. The slow cooling of bullion throws out of solution all other minor impurity elements (or their compounds) which are much less soluble at lower temperatures (mainly nickel, arsenic, iron, and zinc). The transfer of bullion from the blast furnace to the refinery and the subsequent hot drossing step cause fugitive emission of lead-containing fume and dust, which creates a plant hygiene problem. One cause of the emissions is the high vapor pressure of lead and its compounds during transmission of = 1000 °C bullion to the drossing kettle. Another cause is the lifting of dross dust during manual skimming of dross. The environmental problems associated with the traditional hot drossing process provided an incentive to investigate a new drossing process that avoids contact between plant air and hot bullion or dross. A key aspect of the process development was a detailed mineralogical examination of dross from two different bullions. The bullion samples were cooled at different rates, and the dross filtered out and examined. The morphology, phase identification, and composition of the dross was examined by optical and SEM microscopy. The principal dross phases were copper and cuprous sulfide, galena, a complex sulfide containing copper, nickel and lead, and speiss (containing nickel, cobalt, iron, copper, lead, and arsenic compounds). The copper was acicular, with nickel and arsenic in solid solution. The cuprous sulfide was largely digenite in a granular or dendritic form. A substantial part of the dross was solidified matte with a eutectic microstructure, consisting mainly of CU2S and PbS. Small particles (some of which had a eutectic microstructure) never floated to the surface of the lead during the slowest cooling rate, thus indicating that flotation of tiny matte droplets and dross crystals is exceedingly slow. The success in separating dross and lead by centrifugal filtration suggests its application in industry as a replacement for traditional hot drossing.

Jan 1, 1995

By Qing Bo

In this study, the cobalt oxide precursor was prepared in open-style reactor in the condition of high reactant concentration, and then the precursor was decomposed to obtain the cobalt oxides (Co3O4). The effects of some factors on the cobalt precipitation, the particle size and size distribution, and the micro-morphology were addressed. The factors studied include cobalt concentration, initial pH of solution, temperature and time for the reaction, the charge amount of urea, and the temperature for decomposition. It is determined that the precursor particle is in the chemical composition of Co2(OH)3Cl with fine crystalline. By calcinations under proper conditions, the mono-dispersed cobalt oxide particles were prepared with fine crystalline, about 2 µ m in particle size and regular shape in morphology.

Jan 1, 2006