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By Marcos Velho Ludolf

O projeto de Substituição dos Controladores Lógicos Programáveis da Sinterização tem como objetivo a substituição dos PLCs da Família S5 (Siemens) já obsoletos por novos PLCs de tecnologia atual. O projeto de substituição foi dividido em etapas, sendo que a primeira etapa ocorreu em 2012. Consequentemente, teremos novos e antigos PLCs na mesma plataforma de controle até o fim do projeto. Os maiores desafios foram fazer toda a migração e adaptação de hardware e software dos novos PLCs ao restante da planta adequando-se aos sistemas existentes tais como PIMS, comunicação com o Nível 2, comunicação com balanças já obsoletas, SCADA, outros PLCs e concluir toda a migração da primeira etapa do projeto em apenas 60 dias compreendendo desde a desmontagem do sistema anterior, montagem dos painéis novos, recomissionar todo o I/O substituído, conciliar todos os testes à frio e parciais com demais serviços de manutenção programados e realizar o comissionamento a quente de toda a sequência da planta nos últimos 04 dias de implantação, quando todas as linhas de operação foram liberadas para testes. Em 2014 foi iniciada uma segunda etapa, e um PLC de 600 pontos de I/O já foi substituído em apenas 80 h usando uma nova estratégia.

Jul 30, 2018

By Alessandro Marques

Based on a short overview regarding steel defects in the final product, several refractory approaches to maintain or increase steel cleanliness are reviewed in this publication. By applying a ladle to mold approach, one potential to maintain cleanliness is to reduce the probability of air ingress by selection of a suitable slide gate system. Following this path, also the influence of a special configured impact pot is presented to maintain steel quality. Finally, higher productivity as well as cleanliness can be provided by selection of PROIL as a revolutionary product at the casting machine.

Oct 30, 2017

By S. A. Sass

The design and construction of Solvay Minerals (formerly Tenneco Minerals) Soda Ash Expansion Project, which is the world's most modern natural soda ash facility, is detailed. Along with a discussion of design considerations, the international joint venture ownership and teaming arrangement for design and construction companies is examined.

Jan 1, 1994

By B. M. Munyungano

Rössing Uranium Mine operates a recovery circuit with continuous ion exchange followed by solvent extraction. Serious organic degradation problems were encountered during 1985/6, 2000 and 2005 in the solvent extraction plant. The preferential loss of the tertiary amine extractant was observed during the above-mentioned period. Previous investigations revealed that the tertiary amine was breaking down to nitrosamine, which cannot take part in the exchange reaction with U3O8. A reduction in the redox potential of the solvent extraction plant feed to below 500 mV halted this preferential loss. A lot of effort has been made to try and understand the actual mechanism for nitrosamine formation. Current understanding for the degradation is that formation is due to high nitrates on the strip side of the circuit emanating from nitrates from the precipitation process using ammonia. It is the current belief that pH lower than 3.7 on the strip side results in loading of nitrates onto the solvent. If oxidizing conditions prevail on the extraction side of the solvent extraction circuit, the tertiary alamine will then degrade into nitrosamine. This phenomenon is yet to be established and verified. It has, however, been established that the above process is brought about the following conditions ?High redox potential greater than 550 mV predominately caused by a high Fe3+/Fe2+ratio (4:1) ?Perception that if Fe2+<0.5 g/lit will contribute to high redox ?High concentrations of NO-3 in the conc eluate (feed to SX)/ammonium sulphate (NO-3> 4 g/l based on historic values) ?Presence of Mo as a catalyst ?Tests also have proved that the presence of nitrous acid in a concentration of 1 g/lat 550 mV leads to formation of nitrosamines from alamine.

Jan 1, 2007

US 4,141,854-Method of resolving water-in-oil emulsions from the organic solvent extraction of uranium from an aqueous ore leach solution The emulsion is treated at optimum temperature with a water-soluble acrylamide copolymer which contains 5-50% by weight of a lower alkyl substituted tertiary aminoethyl methacrylate or quaternary ammonium salts thereof The emulsion is broken, enabling recovery and reuse of the organic portion of the emulsion A M Pavilcius and M A Latko, assigned to Nalco Chemical Co Feb. 27, 1979 3 pp (252-301 1W) Filed: 12-14-77 (860,542). US 4,142,952-In the recovery of copper from an ore leach solution, the solution is contacted with a water-immiscible organic solvent containing 5 to 20 g/L of o-hydroxyaryloxime and 2 to 20 times the weight of the o-hydroxyaryloxime of nonylphenol The loaded solvent phase is separated from the aqueous phase and stripped with sulfuric acid Copper is recovered rapidly and in high yield from aqueous solutions containing high copper concentrations R F Dalton, as¬signed to Imperial Chemical Industries Ltd Mar 6, 1979 6 pp (204-106) Filed 1-3-77 (756,067). Priority: United King¬dom, 1-30-76 (3788/76), 6-15-76 (24722/76), and 10-21-76 (43711/76). Same- British 1,549,615, dated Aug. 1, 1979 US 4,148,631-In the recovery of nickel and cobalt from a mixed sulfate ore leach solution, both metals are extracted by means of a cationic extractant, the loaded extractant treated with an aqueous chloride or thiocyanate solution to back extract the cobalt, and the cobalt then recovered by solvent extraction or ion exchange with an anionic extractant Recovery is effected in a relatively few extraction steps. F Babjak, V A Ettel, and K. R Dymock, assigned to Interna¬tional Nickel Co , Inc, Apr. 10, 1979 6 pp (75-101 BE) Filed¬7-27-78 (928,401). Priority- Canada, 12-28-77 (293,967) US 4,148,813-An improved extractant for use in the recov¬ery of nickel and cobalt from an ore leach solution comprises a water immiscible organic solvent system containing solubilized mercaptide ions, e g , dodecanethiol. Cobalt and nickel mercaptides solvated in the organic phase are easily stripped in the presence of carbon monoxide and an aqueous alkaline solution A. S. Rappas and J. P. Pemsler, assigned to Ken¬necott Copp

Jan 1, 1980

By Pertti Pekkala

Outokumpu has 25 years of experience in the SX area. The development of the solvent extraction plants responds to an ever increasing demand for lower operational costs wd for adaptability to process disturbances with minimized risks. In this paper the features of the VSF ("Vertical Smooth Flow") SX technology are described, such as the separated pumping and mixing, the homogenous gentle mixing, the droplet coalescence and the ultra pure settling. A major advantage of the mixing technology is the high stage efficiency of above 99 per cent. The connection between this and some features of the settler front section is clarified. The present design of VSF plants is based on experience of existing operations at, for example, Zaldivar, Radomiro, Morenci, Kokkola and Harjavalta. These production plants cover a unit capacity range of 60 to 3,600 m3/h expressed as a total flow. It is evident that there are no restrictive factors to increase the total flow up to 5,000-6,000 m3/h by introducing the VSF technology. The copper SX technology has a long history reflecting many individual features of the separate copper SX plants. Still it is necessary to verify all actual running parameters by pilot tests taking into account impurities, chemicals used etc. The design of SX plants is not only about the delivery of equipment but also a process concept, and it is best tailor-made and adapted to specific local requirements.

Jan 1, 1999

By Fathi Habashi

SOLVENT EXTRACI ION involves two operations: 1) Extraction The metal values in the aqueous phase are extracted by agitation with an organic solvent immiscible in that phase. The two phases are then allowed to separate; the aqueous phase is discarded or recycled and the loaded organic phase saved.

Jan 1, 1970

This paper gives the background to the development of solvent extraction processes for the recovery of metals from aqueous solutions. Its growing importance in Australia for the recovery of both uranium and copper is dis- cussed, as well as the developments in mixer-settler design as applied to recent plants. The economic significance of solvent extraction as an alterna- tive to cementation is discussed and important features of each process are highlighted by comparison of costs for each process in a hypothetical situa- Tion.

Jan 1, 1971

By F. P. de Kock, P. West-Sells, B. Wassink, D .. B. Dreisingerl

During the cyanide leaching of gold ores containing copper minerals, aurocyanide (Au(CN)f) is produced and typically recovered using activated carbon. However, free cyanide, as well as cyanide associated with cuprous cyanide complexes, are generally not recovered from the barren liquor. This results in a significant economic penalty in high cyanide consumption due to the dissolution of copper. 1\vo different configurations of a novel method for the treatment of barren liquor streams for cop­per recovery and cyanide recycle are described. Recovery of copper and cyanide is affected using solvent extraction (XI 7950). Loaded organic is stripped with a high copper, high caus­tic solution which is electrowon to produce copper metal. Depleted electrolyte is treated with sulfuric acid to recover cyanide which is returned to the leaching circuit. Results of benchscale and mini-pilot plant experiments are presented.

Jan 1, 1996

By M. S. Safarzadeh, V. Agarwal

"The solvent extraction of cerium(III) and samarium(III) from mixed solutions of all rare earth elements (REEs) except promethium using PC88A (2-ethyl hexyl phosphonic acid mono-2-ethyl hexyl ester), an acidic extractant, was investigated. The effects of aqueous equilibrium pH, various acids (sulfuric acid (H2 SO4 ), hydrochloric acid (HCl) and nitric acid (HNO3 )), initial metal ion concentration and extractant concentration on the solvent extraction of Ce(III) and Sm(III) were systematically studied. From the experimental results, HNO3 and HCl were found to be the preferred aqueous media for the solvent extraction of both Sm(III) and Ce(III). The most promising experimental conditions of pH, PC88A concentration and metal ion concentration were identified for the extraction of Ce(III) and Sm(III). Separation results showed that H2 SO4 at pH 2 provided the best separation between Sm(III) and Ce(III). IntroductionIn recent years, demand for rare earth elements (REEs) has increased significantly because of their many commercial applications. REEs have especially important high-tech applications owing to their unique physical and chemical properties, and they are used in a wide range of areas such as catalysts, ceramics, magnets, lasers, glass, neutron absorption and alloys. As REEs have very similar physicochemical properties, their separation and purification from each other is challenging and gaining significant interest. Samarium (Sm) and cerium (Ce) are found in different REE minerals, including bastnäsite ((Ce,La,Nd(CO3)F), xenotime (YPO4) and monazite ((Ce,La,Nd,Th)PO4) at major production sites in the United States and China, as listed in Table 1 (Bleiwas and Gambogi, 2013). The most common acidic organophosphorous extractants used for REEs extraction and separation are DEHPA (di-(2-ethylhexyl)phosphoric acid), PC88A (2-ethyl hexyl phosphonic acid mono-2-ethyl hexyl ester), Cyanex 272 (bis-2,4,4-trimethylpentyl phosphinic acid) and Cyanex 301 (bis(2,4,4-trimethylpentyl)dithiophosphinic acid) (Sarangi, Reddy and Das, 1999; Surampally et al., 2012; Tian, Jia and Liao, 2013). Out of these extractants, PC88A is known for providing higher separation factors (Acharya, Mishra and Misra, 2015). El-Hefny et al. (2010) investigated the kinetics of the solvent extraction of Sm from chloride media using sodium salt of Cyanex 272 and reported the extracted species to be Sm(OH)A2•2HA. Lee et al. (2005) investigated the solvent extraction of Sm(III) with PC88A and saponified PC88A from chloride solutions and found the stoichiometry of the extraction reactions to be 1.5 with PC88A and 3 with saponified PC88A."

Jan 1, 2017

By D. Mohapatra

The possibility of using 2,2,4-trimethyl-1,3-pentanediol dissolved in tetrachloromethane as extractant for boron recovery is discussed. The parameters optimized for this purpose are contact time, boron concentration in the aqueous phase, extractant concentration, equilibrium pH and phase ratio. NaOH is used as stripping agent for boron recovery from the loaded organic phase. Boron extraction is found to be a slow process (equilibrium time 20 minutes) compared to boron stripping, which is reasonably fast (equilibrium time 5 min). Maximum boron extraction is possible at a broad pH range from 1.0 to 6.0. Using 1.0M extractant concentration, a 1:1 phase ratio (organic: aqueous) and two stages, ~99% boron extraction is achieved. More than 97% boron stripping is possible using 0.5M NaOH at a 1:1 (organic: aqueous) phase ratio in two stages. Overall, a 95.6% boron recovery was achieved. Loss of solvent into the aqueous phase and co-extraction of Ca, Na and K into the organic phase at higher equilibrium pH are two major concerns in his process.

Jan 1, 2008

By G. Bacon

The past decade has witnessed unprecedented growth in the development and implementation of solvent extraction technology in the extractive metallurgy of nickel and cobalt. Solvent extraction is proving to be a powerful tool, opening new opportunities for simpler, more cost efficient and environmentally sound metal refining processes. These advances, however, could not have been possible without the cooperative efforts between the nickel industry and the people and organizations involved with reagents, materials and equipment development and supply as well as solvent extraction research, aided by the accumulated knowledge and practical experience from the copper and uranium solvent extraction operations. This paper provides an overview of these developments and some of the challenges ahead.

Jan 1, 2002

Consideration was given to the.applicab on of a solvent extraction circuit to be&apos;included in the process&apos;for the-recovery of a high grade product from.:-the Rum Jungle Creek.South uranium ore body.The economics of two alternative processes, firstly the Eluex process which uses an ion exchange process followed by solvent extraction.-of a.high grade sulphuric acid eluate, and secondly a process using direct solvent&apos; extractioh of pregnant leach liquor, were studied. There was a small cost advantage favouring the Eluex process but when other factors were considered, the installation of a direct solvent extraction process appeared the better long term investment. A solvent extraction plant was installed at Rum Jungle in 1962.

Jan 1, 1963

By N. Dave

"IntroductionIn the mineral processing industry, certain minerals such as uranium, thorium and vanadium, etc., are selectively extracted with high degree of purity from solutions containing variety of other impurities by solvent extraction process. This separation process consists of bringing two immiscible or partially soluble liquid phases in contact, where mass transfer of one or more components takes place by ion exchange under certain controlling parameters such as pH, salt concentration and temperature. The processes taking place are primarily physical because the solutes being transferred are ordinarily recovered without chemical change. For efficient extraction more than one stage is required and the solutions are recycled counter currently through other stages. A multi-stage counter current solvent extraction plants essentially consist of four circuits namely: extraction, water wash, stripping, and solvent scrubbing. In extraction circuit the desired mineral is extracted at a certain pH from an aqueous solution onto an organic solvent by bringing them in contact with mixing in large mixer-settler units. The mixed solutions are allowed to settle and separate into component organic and aqueous phases in horizontal settlers by providing sufficient residence time. The solutions are then moved counter currently to other units- the aqueous from the underflow and the solvent organics from the overflow of the settler. The solution streams coming out of extraction circuit are loaded organics and barren aqueous or raffinate solution. The loaded organics are washed with water in a water wash circuit to remove transported impurities from extraction circuit. In the stripping circuit, the desired mineral is stripped selectively from the solvent phase back into an aqueous phase with a stripping agent at a selected pH. The solution stream leaving, stripping circuit are stripped organics and pregnant strip (aqueous) solution. The stripped organics are scrubbed off other loaded impurities with a conditioning solution in, scrubbing circuit and the cleaned solvent is re-used in the extraction circuit.A typical solvent extraction plant for uranium extraction and purification at Agnew Lake Mine is described in this chapter."

Jan 1, 1989

By E. Robles

The Tati Activox® Project (TA®P) is the first step towards the implementation of the Norilsk Nickel Activox® process. The ultrafine grinding (UFG) and autoclave pressure leach process conditions are the heart of the Activox® patent. Low grade base metal sulphide concentrates are leached in the process to recover the base metals and to produce LME grade nickel and copper cathodes and cobalt carbonates. The downstream processing of the metal-containing liquor produced by this process includes solvent extraction circuits to extract and concentrate metal-rich solutions, before the various final products are obtained. This paper gives an overview of many of the relevant design aspects taken into consideration in the design of the Tati Activox® solvent extraction circuits. It addresses key design elements related to leach process conditions such as scaling, materials selection for corrosive solutions, pH control, crud formation and treatment, multiple SX trains designed to prevent organic cross-contamination, and design aspects related to the mitigation of fire risks.

Jan 1, 2009

By Henry Freiser

For the last several years, a systematic investigation of the equilibrium extraction behavior of selective tervalent lanthanides with representative chelating extractions of a variety of chelating agent families has been undertaken for the purpose of learning how to obtain chelating extractants of improved selectivity for separating individual lanthanide ions. The equilibrium extraction data (expressed as log Kex) for each reagent system are linearly related to the reciprocal ionic radius of the tervalent lanthanide ions. The role of adduct formation, steric hindrance, as well as the nature of the bonding atom in the chelate ring, represent some of the factors affecting selectivity arising out of our database of over 200 individual extraction systems, which will be discussed.

Jan 1, 1989

By Fathi Habashi

The recovery of uranium from wet process phosphoric acid was applied on industrial scale in the 1940&apos;s by using octylpyrophosphoric acid as an extractant. Later, more efficient reagents were used, e.g., di(2-ethylhexyl) phosphoric acid and actylphenyl phosphoric acid. In the 1970&apos;s the rare earths in Kola phosphate were recovered in Finland and recently (1997) in Norway using HNO, as a leaching agent and di(2-ethylhexyl) phosphoric acid as solvent. It was demonstrated later on laboratory scale that both uranium and rare earths could be extracted from the rock by tributyl phosphate but at different pH values provided that the rock is leached with nitric or hydrochloric acids instead of the commonly used sulfuric. This new concept opens the way to the possibility of treating phosphate rock by in-situ, dump, or vat leaching for the recovery of phosphate values as well as uranium and the rare earths. Another solvent extraction process is used industrially for the purification of phosphoric acid using butyl and amyl alcohols.

Jan 1, 1998

By P. M. Cole

An unprecedented expansion of the global zinc industry is currently under way. While most new projects and plant upgrades remain committed to traditional processing technologies, recent advances in zinc solvent extraction (SX) have created opportunities for new process routes for both primary and secondary materials. The first commercial plant to use zinc SX for the mainstream processing of a low-grade ore is under construction and promises to become one of the lowest cost zinc producers. Several other oxide and sulphide projects in various stages of feasibility are considering the inclusion of SX in their process flowsheet. Zinc SX has also proved advantageous in the reprocessing of secondary materials, particularly for the treatment of zinc residues and furnace dusts. This review focuses on recent installations and projects underdevelopment that feature zinc SZ as the key separation step.

Jan 1, 2002

The mixer that is commonly encountered in hydro metallurgical operations consists of a single turbine and tank combination. However, it would be advantageous to examine some common solvent extraction mixing systems in the light of the fundamentals of chemical reactor design. The basic concepts of reactor design are commonly used in the chemical industry, and it should not be too difficult to apply them to solvent extraction. The factors that affect the engineering design of a reactor are: the reacting system; the type of reaction; and the configuration of the reactor. The reaction system in solvent extraction consists of a heterogeneous liquid phase, involving two immiscible liquids. It is essential f or the process that the reactor product can be separated efficiently in the subsequent settler. The type of reaction in solvent extraction system may be quite complex, and the picture is complicated by the presence of competing and side reactions. The reactors themselves have been generally continuous stirred tanks, and the nature of the mixer-settler makes it unlikely that the pumping mixer can be dispensed with. However, it appears that there should be some definite advantages to a system of stirred reactors in series. The kinetic experiments which are carried out should have the definition of optimum reaction conditions as one of their goals. The data obtained from these experiments must also be applicable to the design of reaction equipment. Reactor selection and design is often a unique problem for each chemical process, and does not lend itself to a systematic general approach. However, the application of chemical and physical principles to mixer design in solvent extraction should result in practical, more efficient plants.

Jan 1, 1979

By A. M. Ross

DEURING the past year the uranium milling industry has seen the installation and initial operation of solvent extraction circuits in the Climax Uranium Co. mill at Grand Junction, Colo.; the Kerr-McGee Oil Industries mill at Shiprock, N. M.; and the AEC pilot plant at Grand Junction, operated by National Lead Co. Inc. The Vitro Uranium Co. mill in Salt Lake City is converting to solvent extraction, and the new Union Carbide Nuclear Co. mill to be constructed at Rifle, Colo., will also employ this method. Solvent extraction circuits will be incorporated in two mills now under construction -the Texas Zinc Minerals Co. mill at Mexican Hat, Utah, and the Gunnison Mining Co. mill at Gunnison, Colo. In Canada the expansion of the Eldorado mill at Port Radium includes installation of a solvent extraction circuit. Solvent Extraction Process: In simplest terms, the organic solvent is mixed with leach liquor and then the organic and aqueous phases are allowed to separate. By this contact the solvent selectively extracts uranium from the liquor, leaving a raffinate, or barren leach liquor, which may be discarded. The pregnant solvent is stripped of its uranium by con- tact with a stripping solution, such as aqueous sodium carbonate, which has a greater affinity for uranium than the solvent does. The barren solvent from the stripping step is available for further leach liquor extraction, and the pregnant stripping solution, which usually contains 30 to 60 g U3O8 per liter, is ready for precipitation of a final product, or uranium concentrate.

Jan 9, 1957