Search Documents

By F. J. Tavera

Recently Jameson cell technology has gained acceptance in both mineral and non-mineral applications, mainly because of the high degree of contact between the involved phases in the downcomer, fact that leads to an efficient collection performance. The key for an acceptable performance of the downcomer operation depends on the stability of the jet zone, the mixing zone, and the plug flow zone. in this work the behaviour of the downcomer of a laboratory Jameson cell is reported, as a function of gas hold-up, superficial gas velocity, superficial liquid (or slurry) velocity, and length of the operating zones. The presence of carbon is evaluated in terms of its effect on the gas hold-up and bubble surface area flux. The influence of the downcomer operating conditions on the gas-liquid disengaging cell is presented. Keywords: Jameson cell, downcomer, gas hold-up, mixing, plug flow, conductivity.

Jan 1, 2003

By P. Hanniala

In the day-to-day life the copper business of today is influenced directly by the ever-increasing general concern about the environment. In addition to that the inherent shortcomings of the copper smelting business, have since many years been the falling real price level of the metals and the relatively high initial capital investments required for the production units. These shortcomings have been compensated for by high productivity, low specific operating costs, low metal inventory and unbeatable technological superiority. Thus today more than 50 % of the world primary copper is today produced by utilizing Outokumpu Flash Smelting Technology. This figure is expected to grow at an increasing speed in the near future. Characteristic for the Outokumpu Flash Smelting technology is high flexibility for a wide grade of concentrates and the highest sulfur capture owing to at the same time competitive investment and operational costs. The Flash Converting technology offers new options for copper production and optimization of the mine- concentrator-smelter production chain. In the following years it is expected that the trend in copper making is that higher grade concentrates are produced at the mines. Thus increasing amount of high grade concentrate will be available for direct-to- blister Flash Smelting causing an overall cost reduction in copper smelting i.e. both in capital and operational costs. In the '90s new technologies based on Outokumpu Flash Smelting technology have been taken into operation, thus eliminating the non-continuous Peirce-Smith converting process step. New innovative solutions have been used in the latest projects, as in Kennecott Utah Copper, where the new Kennecott-Outokumpu Flash Converting process was started up in 1995. Also, in 1995 the new DON process was started at Outokumpu Harjavalta nickel smelter followed by the Fortaleza nickel smelter in Brazil in 1997. The aim of the continuous development work at Outokumpu has been the expansion of the direct-to-blister process towards lower grade concentrates. The most recent example of this is the start-up at the Olympic Dam smelter in Australia, where the existing direct-to-blister Flash Smelting furnace was replaced with a new one having a capacity of 200 000 t blister copper per annum in just one smelting step.

Jan 1, 1999

By Qingcai Liu

The effect of the TiC addition on corrosion resistance of the Al2O3-C refractories in smelting reduction melts has been studied by quasi-station immersion and rotary immersion. The corrosion rate of Al2O3-C refractories is decreased with the TiC addition. The corrosion mechanism of Al2O3-C refractories is oxidization of graphite carbon by the oxides of the melts and the formation of deteriorate layer.

Jan 1, 2006

By Roderick 1. L. Guthrie, Mei Li

"A mathematical model was developed to study the role of orifice shape in the detection of inclusions in LiMCA (Liquid Metal .cleanliness Analyzer) system. The fluid flow field within the ESZ was obtained by solving the Navier-Stokes equations. The trajectories of entrained particles were calculated using the equations for motion of particles. A numerical study of the effect of orifice shape on signal shape generated by inclusions passing through orifice showed that the signals in a parabolic orifice are gaussian in shape, while those in a cylindrical orifice are trapezoidal in shape. This signal shape difference needs to be taken into account when performing particle discrimination. Orifice shape influences also pass-through fraction of inclusions. Finally, a study of the orifice shape on critical conditioning currents suggested that as the polynominal coefficient of the parabolic orifice increases, the critical conditioning current, which is also the maximum operating current, decreases dramatically. These critical conditioning currents also increase as the fluid flow velocity within the ESZ increases. IntroductionThe presence of non-metallic inclusions in metals often leads to impaired mechanical properties such as a reduction in fatigue strength, and to processing problems such as tear-offs in deep drawing and increased breakage rates in wire drawing operations. Similarly, inclusions cause a variety of surface defects in rolled or extruded products.Prior to the development of the LiMCA system (1) at McGill University in the early 1980's, it was not possible to measure inclusions, in situ, in liquid metals. Compared with other techniques, such as sedimentation, filtration and metallography, which require considerable amounts of labor and time, the LiMCA method has the advantage of providing not only information on the volume concentration of inclusions, but also on the size distribution of inclusions immediately and quantitatively."

Jan 1, 2001

By C. Zografidis, K. Karalis, E. Devlin, S. Tabouris

"The main parameters affecting energy and electrode consumption in smelting reduction of Greek nickeliferous laterites in submerged arc electric furnaces (E/F) were investigated. Within this framework, the operational data of E/Fs, such as energy consumption indicators, electrode consumption indicators and chemical characteristics of Fe-Ni and slag, were correlated with the physicochemical characteristics of the calcine, produced by roasting reduction of laterite in rotary kilns (R/Ks), such as reduction degree, temperature, chemical composition and granulometry. The results obtained provide a significant input for further research on the modelling of the roasting reduction – smelting reduction process, which is a critical tool for energy optimization.IntroductionThe two main steps of pyrometallurgical treatment of greek nickeliferous laterites for ferronickel production include: i) drying, pre-heating and controlled pre–reduction of laterite ores with solid fuel reducing agents and fuel oil in rotary kilns (R/Ks) for the production of a calcine, and ii) smelting reduction of the calcine in open-bath submerged-arc electric furnaces (E/Fs) for the production of Fe-Ni alloy with 12-16% Ni [1].The energy absorbed from the endothermic reductive reactions of iron, nickel and cobalt oxides (Fe2O3, FeO, NiO and CoO) of the calcine with the remaining carbon in the E/Fs, corresponds to about 16% of the total energy output in the smelting reduction step [1]. This is indicative of the significance of the calcine’s reduction degree for the electric energy requirements in the E/Fs. Moreover, the chemical characteristics and the granulometry of the calcine constitute critical parameters for the energy requirements as well as the smooth operation of the E/Fs."

Jan 1, 2012

By Billy W. Osborne

The use or primary dross as a source for aluminum ion in the manufacture of aluminum sulfate offers opportunities for an inexpensive raw material. The aluminum sulfate industry in the US is a mature market with numerous small plants operating close to major users. The majority of manufacturers use either bauxite or aluminum oxide trihydrate as a source for the alum¬inum ion.. However, using process technology developed and patented by IWC, the oxides are removed from primary dross for use in manufacturing aluminum sulfate prior to metal recovery. This process offers the benefit of reducing costs for metal recovery. This paper discusses some of the methodology used in this process.

Jan 1, 1995

By Luis M. González, Guzmánm Guillermo D., Davis Juan C.

"The Teniente converter (CT) of the Ventanas Smelter and Refinery of Codelco-Chile has two tuyeres for dry concentrate injection directly into the melt.The diluted phase injection system can feed 15 to 20 kg of concentrate for 1 kg of air, which creates a very abrasive solid/gas phase. The tuyeres commonly used lasted for about 3.5 days due to the accelerated decay of the shell, and 1.5 hours were necessary for the replacement of new ones in the reactor.Tests were carried out with common shell tuyeres with a tungsten based welding cover, and a life span of 28 days was reached, increasing the Teniente converter operational continuity between 1.5 to 2 %."

Jan 1, 2009

By Wang Dawan

During the process of arsenic bearing gold concentration biooxidation, the content of chloride ion in water is a very important factor to the activity of bacteria and the oxidation of sulfide minerals. In this paper, the influence of underground mine water with different chloride ion content to the biooxidation of arsenic bearing gold concentration and the limit of chloride ion content to bacteria were summarized. These results indicated if the content of chloride ion was less than 1.2g/L, the bacteria?s ability to oxidize sulfide minerals was little affected, and if the content of chloride ion were increased to 2g/L or more, the activity of bacteria was seriously restrained, and if the content of chloride ion were increased to 4g/L, the activity of bacteria was absolutely restrained. So, as the content of chloride ion in water was cumulated to 2g/L or more in biooxidation plant, the water must be refreshed to maintain normal production.

Jan 1, 2008

By Sang-Su Lee

This paper shows the application of the porous plug system in the Mitsubishi continuous copper smelting and converting process. This system has already been adopted and utilized in the steel industry to enhance productivity. Recently, some copper smelters have adopted this system but the results have not been satisfactory. The porous plug system was installed at the anode furnace in December 2001 to reduce the oxidation time and decrease the oil consumption. A good effect was that the nitrogen stirring of the melt through porous plugs improved the melt heat transfer. As the result of the enhancing heat transfer the oil consumption and the build up inside the furnace were actually decreased. But until now the oxidation time has not been sufficiently reduced. In the future, further research and tests are needed in order to increase the productivity and save costs.

Jan 1, 2003

By Thomas Gliick, Jianming Lu, David Dreisinger

"The Boleo project of Baja Mining (Vancouver) will process a mixed oxide-sulfide ore using an acid oxidation and reduction process in seawater to extract copper, zinc, cobalt and manganese. Copper will be extracted via SX-EW as copper cathode, zinc will be recovered as a zinc sulphate monohydrate crystal and cobalt will be produced as a cobalt cathode product after phosphinic acid extraction. Manganese may be recovered from the final solvent extraction raffinate by precipitation as manganese carbonate.The development of the cobalt recovery process (solvent extraction and electrowinning) will be discussed. The pilot plant solvent extraction circuit and subsequent bench and small pilot testing of cobalt electrowinning will be discussed. The Boleo project will produce approximately 1708 tonnes per armum of cobalt metal when fully commissioned.INTRODUCTIONThe Boleo property is held by the Mexican company, Minera y Metalllrgica del Boleo S.A. de C.V. (MMB). MMB is owned 70% by Baja Mining Corp. and 30% by a consortium of Korean companies consisting of KORES - Korea Resources Corporation, LS Nikko Copper, Hyundai Hysco, SK Networks and Iljin Copper. The project is fully financed and is now under construction with an expected startup in early 2013 .Average annual production, for the first six years for each of the metals is forecast as: 56,697 tonnes of copper cathode, 1,708 tonnes of cobalt cathode and 25,364 tonnes of zinc sulphate monohydrate. The project has an average life-of-mine cash cost (based on the three year trailing average metal prices, as of December 31, 2009, in accordance with SEC guidelines) of -$0.29/lb Cu, net of by-product credits for cobalt and zinc and with no credit for manganese production. There is the potential to produce up to 220,000 tonnes per armum of manganese carbonate (- 100,000 tpa contained Mn) via the relatively simple addition of a small number of unit operations to the proposed plant. The recovery of manganese metals from the manganese carbonate intermediate material is discussed in a separate paper in this proceeding."

Jan 1, 2012

By P. P. Knight

The Parkes Process is an important step in the pyrometallurgical refining of lead bullion and it is estimated that more than 50% of the Free world's primary silver production is processed by this route. The metallurgical efficiency of the process can have a significant impact on the overall refining costs, particularly with regard to zinc consumption and the costs of working up the silver-rich crusts?. Several authors have used mathematical or graphical methods in order to calculate the minimum required zinc additions and to study the merits. of alternative. operating procedures, but these methods are of necessity very cumbersome and are only able to deal with relatively simple systems. The paper explains how a computer model was developed which simulates the Parkes Process accurately and can predict the effects of changes made in operating methods. Examples are given of some of the findings and their relevance to the practical conduct of the process is? discussed.

Jan 1, 1990

By Roberto Parra

The operational control in a Flash Smelting Furnace is based on the mass and energy balance of the chemical and mineralogical composition of the concentrates. It is well known that many troubles in the dust formation and slag quality occur without a clear correlation to a specific process parameter such as the matte grade or heat balance. This paper outlines two new considerations that could both help improve the entire quality of the process: blend characterization and versatile slag composition control. Related to the blend control, laboratory scale study has shown that the magnetite and dust formation don't have a linear behavior with the weight proportion of the blend and some optimal blends of2 or 3 types of concentrates can be identified. Related to the control of stag composition, the quantification of the slag liquidus temperatures and viscosity could be an effective operational tool for both for ferrite and fayalite slag that can also directly help deciding the blending parameters. From these viewpoints the benefits of the combination of these two approaches for high temperature operation is discussed. Keywords: Optimization, Copper concentrates, Flash combustion, Blends, Slag composition

Jan 1, 2003

By Reimers. Jan H.

Practically all the world's lead is produced by sintering and blast furnace smelting, or the Imperial Smelting Process which is a variant of the blast furnace process. Increased coke and labour costs and strict lead emission limits have, however, made blast furnace smelting undesirable in most countries. A change-over to other lead smelting processes providing better working conditions and lower emissions is, therefore,. expected to occur once economic conditions improve and the necessary capital expenditures can be justified. The need for new lead smelting processes has long been evident and a number of new processes have been proposed 'and advanced to various stages of development. One of the new processes is already proven on commercial scale, while several others are still being tested on pilot plant scale.

Jan 1, 1983

By Freddy Syvertsen

"During the past two years the Association of Norwegian Foundries in Norway has been running a project in evaluation of CAD/CAM systems for foundries.In this work we have had a closer look to the various steps from drawings to the finished castings. On this background we have made a specification of the special needs in the foundry process. The main content of this paper is a presentation of this specification.Some CAD/CAM sytems have been compared with the specification and a summary of the result is presented.In the project we have also had a closer look at some systems where we actually have tried the user interface and some of the possibilities in the systems. In this way we have gained a more detailed knowledge of the systems and we have also got some experience in NC-machining from the systems.IntroductionThe development of CAD/CAM systems has taken place with almost no interaction with the foundry business. This becomes clear when you are having a closer look at the systems. Most of them have not the possibility to describe the complex sculptured surfaces that is often found on castings. The people developing the software, have paid little or no attention to the problems arising when a geometry is going to be transformed for the casting process. Among the problems are the decision of where to place the parting line and to adjust the draft angle. These problems must be solved properly to be able to withdraw the model from the sandmould. In die casting the problems must be solved to be able to get the casting out of the die.In Norway some companies have been developing CAD/CAM systems for several years, with limited interest in foundry problems till 1983. To present the special foundry problems to them a specification of the needs was made that year. Another reason for making this specification, was to compare it with the CAD/CAM systems on the market (1).Design of castingsGeometry transferThe foundries in Norway are small units with almost no design of their own casting products. They are subcontractors receiving paper drawings and limited informations about the product from the mechanical industry both in Norway and in other European countries. This is going to change, and in the future the geometry will be transferred by magnetic tape or by a network of computers."

Jan 1, 1986

By W. G. Davenport

H20 is present in many flash furnace inputs. Examples are: (a) moisture in concentrate and flux (b) humidity in blast (c) moisture in hydrocarbon fuel, particularly coal, Appendix IV. H20 may also leak into the furnace from damaged water-cooling jackets. H2O, especially that it be included H2O, exerts a strong cooling effect on the flash furnace. It is important our calculations. As will be seen from the calculations, gaseous and liquid H2O both increase flash furnace industrial oxygen and oil requirements. This is because gaseous H2O (humidity in blast) must be heated from its input temperature to the flash furnace off gas temperature. Liquid H2O must be evaporated and heated.

Jan 1, 2001

By Barry T. Kilbourn

A dominant characteristic of many derivatives of the lanthanides is stability at high- temperatures. Combine this with novel solid-state behavior under those conditions and there is the potential for new materials that can not only improve existing applications but also help create new technologies. These property themes will be traced through new uses ranging from efficient energy generation and raw material conversion to control of environmental emissions and temperature measurement. Conducting ceramics, methane conversion catalysts, sulfur oxide capture agents and phosphor hosts will be described. Some categories will account in the future for significant lanthanide consumption whereas others will remain commercially negligible but technologically vital. All uses will illustrate the versatility of those elements inappropriately termed rare.

Jan 1, 1992

By J. Y. Aubut

The modernization of the CCR Refinery to permanent cathode technology is presently underway. The 360,000 mt/y refinery is being retrofitted to accept the Kidd process. Part of this modernization includes the installation of Kidd stripping machines, and the total replacement of the materials handling equipment. It also involves the reinforcement of building structures to accept the new equipment and the ability to operate in different modes. The future equipment will interface with some existing apparatus, which is being retained for future operations. The whole operation will be automated and will allow product traceability for quality purposes. This retrofit poses important challenges given the size and scope of the modernization project and because it is being undertaken concurrently with normal plant operations.

Jan 1, 1999

By Robert D. Pehlke

"The evolution of oxygen steelmaking is reviewed and new operating processes are described. The developments which could impact this technology are summarized. Staged and continuous steelmaking are considered in the light of new technologies. The future opportunities for oxygen steelmaking processes are overviewed. IntroductionThe use of oxygen in steelmaking was originally brought on the scene by the development of pneumatic steelmaking. Sir Henry Bessemer in England originally conceptualized the use of gaseous oxygen in steelmaking, and then he and William Kelly in Eddyville, Kentucky independently developed the original pneumatic process which involved blowing air through a bath of molten pig iron to oxidize the carbon and silicon and produce steel. This process and many following processes, including those which would use pure oxygen gas, have been proposed.Beginning with the first commercial oxygen steelmaking vessels at Linz, Austria in 1952, the world steelmaking industry has adopted this style of processing. In general, the process has involved the use of steel scrap in amounts from 20 to 35% of the metallic charge with molten pig iron produced in blast furnaces making up the remainder. The impurities in the charge are oxidized through the use of oxygen gas injected into the steelmaking vessel.However, currently being adopted into commerical practice and on the horizon are a number of advances in this process which include the use of iron ores as a source of iron and oxygen, the use of an all scrap charge, incorporation of pre-reduced iron, the use of auxillary fuels to change the balance of cold and liquid iron-base charge materials and numerous refining techniques."

Jan 1, 1988

By G. T. Lapidus

One of Society’s major concerns with hydrometallurgical processing is the large amount of water that is quintessential to its nature. This is especially troubling in arid areas, where the population struggles to procure potable water for their daily needs. For that reason, it has become our responsibility to conceive, design and implement processing schemes that not only use as little water as possible, but recycle streams within the plant itself and minimize waste that exits its perimeter. With this in mind, the conference will center on the importance of selecting the appropriate chemical systems and integrating material balances to avoid reagent overkill and to detect impurity accumulation. The three “R’s” (reuse, recycle and recovery) of aqueous solutions within the processes are emphasized. Examples of processes for the recovery of lead, copper, precious and PG metals from minerals and waste materials will be presented.

By Pedro Morales C.

From its beginning in the 1970s, the Teniente Converter has consistently achieved continuous improvement, and has contributed to the competitiveness and sustainability of Codelco's copper operations. The later introduction of the Slag Cleaning Furnace technology has helped to create a full technology package, referred to as the Teniente Technology. This paper outlines the features of a new research and innovation program designed to bring the Teniente Technology as a modem, competitive technology into the 21st century. The overall objectives and features of the program are described and discussed. It is fully anticipated that these activities will help position the Teniente Technology as a world-class modem technology, well-integrated and operating in a fully continuous mode in conjunction with the other units at the plant, a competitive technology which operates in harmony with respect to environmental regulations.

Jan 1, 1999