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By Jian Zhang

From the standpoint of quality, surface cracks normally pose more of a problem than internal cracks. Hypo-peritectic (HP) steel grades are well known for their proneness to surface longitudinal cracking (SLC) during continuous casting. This study analyzed the influences of chemical composition, technique parameter and secondary cooling on the surface longitudinal cracks. Based on the optimized the first and secondary cooling zone water distribution in the process of continuous casting, low cooling water distribution at solidification initial stages and uniform cooling at secondary cooling zone were suggested, which can be used to effectively control the surface longitudinal cracks.

Jan 1, 2010

By AIME AIME

LAST month we published (p. 440) the first half of the L discussion by O. E. Kiessling of the paper on copper by Mr. Vogelstein that appeared in the same-issue, but lack of space made it necessary to hold the remainder for this number. Mr. Kiessling now asks to have the last " sentence of the part already published revised to the form given in the first sentence which follows, and also asks that the two parts, though necessarily published separately, be read together, as a mistaken impression may be derived from the first Dart unless it is read in connection with the statement of the Bureau of Mines policy respecting secondary metals which is here published. .

Jan 1, 1931

By J. W. Furness

THE utilization and collection of waste materials have gone on for centuries, and have become a habit of the human race. The degree to which the salvaging of waste plays a part in a nation's industry depends largely on the availability of raw materials within the political confines of the country itself, or its ability to purchase such material from outside. When purchase is necessary careful economical use of the raw materials results. These economies, as a rule, are represented by lengthening the life of the given article as well as much re-use. For many years the steel industry of Italy and Japan has depended largely on importations of scrap, yet both are important. As long as the expenses incident to the conditioning and marketing of materials manufactured from salvaged waste are less than the cost of virgin material, the salvaged material will be re-fabricated and in many cases will compete with primary materials. One of the most obvious methods for furthering the efficient utilization of our limited mineral resources is the salvaging of mineral wastes. This method, moreover, in¬creases the available supply of a given material. If the price depends on a balance of supply and demand and the recovery from wastes enlarges. the supply, there can be no question but that it influences the sales price of primary.

Jan 1, 1931

By LUDWIG VOGELSTEIN

WE are indebted to Mr. Barbour for his valuable contribution to the literature on copper statistics; it is to my knowledge the only intelligent attempt to throw light on a much misunderstood subject. If I should appear to criticize some of his findings and arguments, I do not want to leave the impression that I do not appreciate the article; I think Mr. Barbour has been painstaking, and even where one might not agree with his conclusions, he has opened our eyes and stimulated us in our search for the truth.' It might be well to define the term "secondary copper" and to make a few remarks about the origin and the reasons for the variation of the supply. Mr. Barbour has touched on these points, but not sufficiently to make them clear to those not in the business.

Jan 1, 1931

By J Wood

Steady depletion of the world’s primary copper reserves coupled with a meteoric rise in electronic waste (e-waste) generation has led to secondary copper processing assuming an ever-increasing importance within the global copper industry. Treatment of secondary copper feeds at existing smelting operations has traditionally been performed in the Blast furnace, Peirce-Smith converter and/or anode furnace. In the past decade or more, bath smelting technologies have been preferred for the processing of these materials due to their superior environmental performance and flexibility to operate under a wide range of conditions. This paper focuses on the pyrometallurgical processing of copper secondaries in the Outotec Ausmelt TSL Furnace and some of the unique issues facing secondary copper smelters and downstream gas handling/cleaning equipment.

Aug 8, 2011

By Faustino G. Prado

In the, quest for an economical and environmentally friendly reclamation of metallurgical dusts generated during pyrometallurgical operations, our goal has been the separation and recovery of most of the components, as well as the complete recycle of all the reagents. Effluents have been avoided, within acceptable economic parameters. This presentation, which can be applied to a large spectrum of dusts and other residual-materials-, has focused on the dusts generated by the operation of Secondary Copper Smelters. Those dusts show a wide range of components, including zinc, lead-, copper, cadmium, tin, chlorine and-alkalies. Our present work deals with the use of ammonium salts in the separation and recovery of-the above mentioned elements in a marketable form. Most of the chemistry and techniques involved have teen already confirmed in commercial scale operations. Others have gone through pilot scale tests or bench scale tests. The recycle of reagents has also been- confirmed at the same operating levels. A preliminary evaluation indicates that the chosen route, in addition to a viable economy, offers a complete and safe reclamation within the most strict environmental regulations.

Jan 1, 1995

By B. Karnath, K. Guha, S. Tandon

At Jhagadia Copper Ltd (India), Copper is produced through secondary route using Top Blown Rotary Converter (Kaldo Furnace). The basic raw material being treated includes Matte-slag Reverts, Copper Cakes, dross & Cement, Oxide Ore, Low S bearing Concentrates & various metallics along with high grade copper scraps. The plant has capability to refine & produce Blister grade copper from Kaldo furnace as well as PS Converter . Blister is fire refined in Anode furnace & electro refined in Refinery to produce cathode copper. Our product , Copper Cathode , has already been established in the market as its quality is better than 'LME Gr'. The paper deals with the experiences encountered during commissioning & stabilization of the plant.

Jan 1, 2007

By W. R. Opie

Fundamentals of blast furnace smelting of low grade copper and precious metal scrap and residues are reviewed with emphasis on emission control, by-products produced, slag cleaning for high recovery of metal values and the evolution of an off-gas system to eliminate hydrocarbons that result from decomposition of plastics in the blast furnace- charge. Problems with tin, antimony and nickel in the smelter-refining cycle are discussed.

Jan 1, 1985

By A. P. Svenningsen

DURING the work at the test mill in Morenci, it was determined that a suitable feed for the ball mills could be made by a single pass through a short-head cone crusher. These crushers did not require a closed circuit delivering only a screen product to the mills, such as is the practice in some concentrators. By no means does this mean that the practice in these other concentrators is wrong, but just that the Morenci ore can be most economically crushed and ground in this manner. Therefore, the design of the secondary crushing plant was simply a problem of taking 25,000 tons of ore per 16 hour day from the primary crusher, this ore ranging in size from fine particles to 10 or 12 in., and reducing it to minus 3/4 in. Inasmuch as outages must be contended with in any crushing plant, it was assumed that the crusher would operate at full capacity for approximately only twleve hours per day, which is three-quarter capacity for the 16-hour shift. With this in mind, it was necessary to design a crushing plant which would average approximately 1600 tones per hour for the 16-hour day, or 2000 tons per hour for slightly over 12 hours per day.

Jan 1, 1942

By Peter L. Siems

Humid tropical environments pose many problems for mineral exploration. The problems result from thick lateritic soils, dense vegetation, seasonally heavy rains, deep chemical weathering, few outcrops and thick saprolites. Although geochemical exploration should be potentially a useful technique in these environments, it appears from the scarcity of reports in the literature that insufficient attention has been paid to developing procedures that are specific to the needs of humid tropical areas. For this reason, the authors believe that this account of a geochemical study in a tropical coastal area on the edge of the Brazilian shield is of general interest and importance for potential geochemical exploration surveys in similar areas within the tropics. The objective of the geochemical study was to develop a practical technique of reconnaissance geochemical prospecting for copper deposits in Brazilian tropical coastal lowland areas. In order to achieve this objective, information concerning the secondary dispersion of copper in these areas was required. Consequently, an orientation survey was designed to provide this information. The present account contains details of the geochemical study and the information about the secondary dispersion of copper that was acquired during the course of the orientation survey. Location and Climate The field area is on the Atlantic coastal lowland of Brazil at latitude 13°S. It lies approximately 10 kilometers south of Maragojipe, a city of 15,000 inhabitants; this city is on the western side of the Bay de Todos os Santos about 45 airline kilo¬meters northwest of Salvador. (See Fig. 1) A good gravel road from Sao Felipe to Sao Roque do Paraguay crosses the southern part of the field area. The climate of the area is hot and moist, and is without prolonged dry periods. The mean annual rainfall is about 1600 mm (63 in.) and the greatest precipitation occurs during the winter months of May and June and the summer months of December

Jan 1, 1972

By W. Lo, M. Brothers, G. Oprea, G. Richard, T. Troczynski

Magnesia-chrome and chrome-magnesia are the most used refractories in contact with iron-rich non-ferrous smelting slags. The corrosion by slag always brings chromium oxide into the slag, causing the precipitation of crystalline phases at the process temperature. This secondary effect of the chromium-bearing refractory dissolution was studied in this work, emphasizing the effect of the other chemical components of the slag at various temperatures. The experimental results showed that the presence of chromium and lead contribute, although in different ways, to the formation of complex spinel phases and their precipitation at temperatures in the range of 1250-1400°C. The XRD and SEM/EDS results were discussed for refractory-slag mixes containing 0-20% Cr2O3 and 0-11% PbO.

Jan 1, 2004

By R. P. Thomas

Secondary fertilizer minerals are the mineral materials used to supply directly and indirectly the secondary and trace plant food nutrient needs of a fertilizer. Since few soils contain sufficient availability of all plant nutrients for their proper growth, man has prepared mixtures of plant food materials to correct these nutrient deficiencies. These mixtures or fertilizers, when added correctly to a soil, make it possible for abundant and economic crop growth. Many kinds of materials are used as sources of these needed nutrients. They come from natural and synthetic materials and minerals including many beneficiated byproduct compounds. A fertilizer consists largely of carriers of one or more of the three major plant foods, namely nitrogen (N), phosphorus-phosphorus pentoxide (P2O5) and potassium-potash (K2O). Many other nutrients are just as essential for plant growth as the three major plant foods. In fact, the efficient use of fertilizers today depends upon an adequate supply of all these other nutrients. Since these additional materials are usually removed from the soil by plants and supplied in fertilizer in less quantities than the major nutrients, they are called secondary and minor nutrients. In the early days these special nutrients were contained as impurities in the primary nutrient carriers. Today, fertilizers are made primarily from concentrated and synthetic materials which carry very few of these other essential nutrients. Consequently, many secondary and trace nutrient carriers, as salts, byproduct compounds and even minerals have to be added to fertilizers. Secondary Nutrient Carriers The secondary plant foods in fertilizer are next to the major nutrients in abundance. They are calcium, magnesium, sulfur, chlorine, silicon and sodium. Although many of these elements are added to a fertilizer as part of the major nutrient carriers, they are also added in special carriers. The large tonnage of these secondary nutrient carriers used in fertilizers represents only a small percentage of the total production of these materials. A fertilizer producer thinks in terms of materials which supply nutrients instead of minerals. Therefore, these materials will be discussed by elements. CALCIUM Soils need calcium to supply the nutrient needs of plants and maintain the desired physical and biological conditions in the soil. The available calcium is usually 40 to 80 pct of the exchangeable bases. (These bases are ones which can be displaced by other cations and determined quantitatively. They are then expressed as milliequivalents per hundred grams of soil-me.) Direct applications of lime materials such as burnt, ground or hydrated limes are the important sources of calcium for the soil. Most crops, especially legumes, have a high requirement for calcium. The average farmer does not use enough lime to maintain the proper level of available calcium. Hence, it is necessary for many fertilizers to contain soluble calcium materials for efficient use of the major nutrients. The following major nutrient carriers supply some calcium: calcium nitrate, ammonium nitrate mixtures and cyanamid, and many of the phosphates. Both synthetic and natural gypsum are used in fertilizer production. Some crops such as peanuts require a large amount of soluble calcium. Gypsum is the important supplier of this soluble calcium. It is not applied with the fertilizer

Jan 1, 1960

By J. W. Turrentine

SECONDARY fertilizer minerals include borax, gypsum and sulphur and such compounds as the sulphates of copper, magnesium, manganese and zinc; also the carbonate and oxide of magnesium. Potash, phosphates and nitrogen are generally considered to be primary fertilizer materials. The growing plant, under the average conditions of growth, is able to get from the soil the mineral elements required for the completion of its life cycle. The elements taken up are numerous and the vital functions of some of them yet remain to be determined. However, in the commercial growing of the plant (farming) something much more than the mere completion of a life cycle is required. There the maxi- mum possible growth of plant or yield of seed or fruit are the objective and for that objective the average soil is deficient in some elements, and additions from artificial sources are desirable. Commercial fertilizers (15,000,000 tons in 1946) are designed to supply those deficiencies. Long experience has taught that nitrogen, phosphorus, and potassium are the elements most apt to be required and in a greater degree, and to supply them is the-basic function of the fertilizer industry. Thus nitrogen, phosphate, and potash are designated as the major plant-food materials. But other mineral crop nutrients may likewise be deficient in varying degrees as determined by diagnostic techniques, soil tests, plant analysis and foliar symptoms,3 calling for their addition from artificial sources if maximum crop yields are to be obtained. Because used in lesser amounts and frequently in relatively minute amounts as compared with the major three, they are designated either as "minor elements," or, if used in larger amounts, as "secondary elements." Thus, included under the two designations, in alphabetical order, are: borax; copper sulphate; magnesium carbonate, oxide and sulphate; manganese sulphate, and zinc sulphate. Obviously, the sulphates of the metals copper, manganese, and zinc cannot be considered as "industrial rocks," but they are given brief mention for whatever interest may pertain there to.

Jan 1, 1949

By M Magee, D Way

The Mount Isa Copper Concentrator was commissioned in 1973. In 1991, two autogenous grinding mills were installed replacing two stages of crushing, one stage of rod milling and one stage of primary ball milling. The cyclone overflow P80 of the secondary ball milling circuit was reduced to 120 microns due to the increased operating power in the AG/SAG mill circuits. A study of the mineralogy of the milled products and the plant flotation recovery indicated that the installed secondary grinding energy was more than what was required for adequate liberation of the chalcopyrite and half of it had potential for more effective use elsewhere. Halving the secondary grinding energy meant only one of the two secondary ball mills would be needed. The predicted saving in operating cost of one less ball mill was more than two million dollars per annum. This paper summarises various plant trials that were conducted in the Copper Concentrator to decommission one of the two secondary ball mills.

Jan 1, 2004

By Judy B. Jones, Bradley A. Crenshaw, Theodore DePooter

This paper reviews groundwater issues leading to a secondary grouting program at the Chattahoochee Tunnel that was implemented subsequent to the contact grouting program. The secondary grouting program was developed based on infiltration data, geology, and testing programs. This paper includes a brief description of the geological features encountered, as well as describing the grouting program. The success of this grouting operation has been quantified by several methods, and is presented to help others project the costs and benefits of this type of program. Review of initial results and refinements of techniques are also discussed.

Jan 1, 2005

By John L. Lamont, Walter Crafts

SECONDARY hardening in tempering has long been recognized as a typical characteristic of steels containing large amounts of carbide-forming alloys. These steels, when quenched and tempered, tend to soften somewhat after tempering at low temperatures, and to reharden at intermediate tempering temperatures before finally softening to low hardness. This behavior in tempering has been studied by many investigators, chiefly with respect to the secondary hardening of high-speed steels. The initial softening has usually been ascribed to decomposition of martensite and growth of iron carbide particles. The secondary hardening has been explained by formation of fresh martensite from residual austenite, formation of very fine alloy carbide particles and by precipitation hardening of metallic compounds in the ferritic matrix. However, factors derived for the calculation of tempered hardness in low-alloy steels1 indicated only a tendency toward retarded softening rather than a discontinuous rehardening. A study was, therefore, made to determine whether fresh martensite from residual austenite and precipitation hardening are essential to rehardening and the degree to which tempered martensite could be rehardened by precipitation of alloy carbides. The mechanism of carbide rehardening was also investigated to determine the nature of the process. The causes of secondary hardening in high-speed steel have received serious consideration for about thirty years. Among the earlier workers Bain and Jeffries2 in 1923 recognized residual austenite as a significant factor, but in addition, emphasized the effect of the formation of alloy carbide particles of "critical" size. They conceived that freshly quenched martensite forms low-alloy iron carbide at low tempering temperatures; with further tempering the iron carbide is then modified by alloying elements that can diffuse most readily at intermediate temperatures (850°F); and that the iron carbides grow in size by coalescence so that the steel tends to lose hardness. At higher tempering temperatures carbide stability rather than alloy availability becomes the controlling influence and in high-speed steel "iron-tungsten carbide is the most stable one and forms to the elimination of the earlier formed carbides. . . . The iron-tungsten carbide particles reach approximately the size for critical dispersion after a short reheat at 1100°F." This concept, the formation of alloy carbide nuclei, redissolving of the iron carbide, and diffusion of carbon to the alloy carbide, was restated for vanadium steel in 1932 by Houdremont, Bennek, and Schrader.3 Subsequent studies have confirmed that iron carbide changes to alloy carbide at 1000 to 1100°F, but the mechanism of the process has received little consideration .

Jan 1, 1948

By W. G. Matteson

THE origin of the salt domes of the Gulf coastal plain has been investigated by many of the most able geologists, but the problem cannot be said to have been satisfactorily solved. Since 1860, numerous theories have been presented, only to be discarded, at least in part, as more complete information revealed their fundamental weakness. Real progress toward solution dates from 1902, when Hill' advanced the theory of secondary deposition of the domal materials from saturated solutions of hot saline waters ascending from great depths under hydrostatic head along structural lines of weakness. Shortly thereafter, Harris,2 using Hill's hypothesis as a basis, explained the doming and pronounced uplift associated with these salt cores as the result of forces exerted by growing salt crystals. This was a marked advance over the ideas of Coste3 and Hager,4 since no. evidence of igneous intrusives, as they assumed to explain the uplifts, had been found associated with the domes. Harris5 developed his theory until it offered such apparently plausible explanations of so many details of dome phenomena that his hypothesis and conclusions received widespread acceptance, despite some serious objections, and today his theory, somewhat modified, is considered by many able investigators to be the best explanation of, the origin of these domes. The immense production of oil per acre, the recognition of the high lubricating quality of the oil, the development and recognition of the efficiency and advantages of oil-burning vessels, with the, subsequent

Jan 2, 1921

By Kenneth N. Pike

The need to comply with environmental regulations and increase production has resulted in modifications to the East Penn blast furnace operation. Changes made include furnace design modifications, closed loop water cooling with heat recovery, automated weighing and charging, automated tuyere punching, ammonia scrubbing of tail gases and improved metal and slag handling to minimize environmental impact. These changes have resulted in a marked increase in yearly production and compliance with many of the air, water and solid waste regulations.

Jan 1, 1990

By Karl D. Libsch, Modesto E. Erneta

Both battery design and environmental pressures are forcing the secondary lead industry to consider new and different processes. Trends in battery design are making normal decasing increasingly difficult. Lead in air, sulfur dioxides, and solid/liquid waste heavy metal restrictions are tightening. There is no clearly defined industry trend toward a given process, but it is clear that plants will be larger, less labor-intensive, and automated.

Jan 1, 1977

By J. E. Hoffman, T. J. Keefe, Michael E. Stout, O&apos

M.A. Industries, Inc. has developed and is now offering on a commercially available basis, complete systems to recover and recycle lead from spent SLI batteries. The system begins with the breaking and separation of the component parts of the batteries and subsequent treatment of the effluent water produced by this operation. The recyclable materials recovered from this process are metallic lead, lead paste and polypropylene. The lead paste is introduced into a process to convert it from a lead sulfate to a lead carbonate. The process also regenerates the salt solutions into reusable carbonate. The lead carbonate is then leached into an acid bath where it is later recovered by a proprietary electrolytic process. The metallic lead is recovered in a short rotary furnace producing metal for further refining and alloying. The polypropylene is further washed and then introduced to a reclaim extruder along with the proper modifiers and additives. The resulting resin can then be sold on the open market to injection molding processors. This complete system greatly reduces the amount of waste to be disposed of and completely complies with all applicable EPA guidelines.

Jan 1, 1993