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By M. Kim, M. Ha

"The effect of red mud on the melting behavior of ferronickel slag was investigated by a laboratory-scale horizontal tube furnace. Melting and softening of slag samples fluxed with different amount of red mud was examined by in-situ visualization technique at temperature range from 1400 to 1550°C. FactSageTM 7.0 was used for the thermodynamic calculation of multi component system of ferronickel slag and red mud. Liquid phase area was extended to lower temperature by adding red mud indicating its suitability as a flux material. X-ray diffraction analysis confirmed the dependency of the phase changes on the red mud content. Microscopic observation by scanning electron microscope (SEM / EDX) clarified the phase transformations from olivine to spinel along with red mud additions.INTRODUCTION Ferronickel smelting by submerged arc furnace (SAF) is an energy intensive process performed at high temperature range 1500–1600°C. During the smelting process of saprolitic nickel laterite ore with a nickel content of 2.2–2.3 pct, a large quantity of ferronickel slag is being produced that account for 97 pct of ore charged. To achieve ferronickel grade of 15–20 pct Ni, electrical energy of 80 to 85 MW is used for the melting and reduction of nickel oxide (NiO) and iron oxide (FeO) in the ore (Rodd et al., 2010). Unreduced components, mostly MgO, SiO2 and partly FeO are removed from the furnace in a liquid slag form by a tapping operation. Due to the high melting temperature, forsterite (Mg2SiO4) based slag containing approximately 10 pct FeO requires typical process temperature of 1600°C. Flux in metallurgical process is a medium that decreases melting and operating temperatures while it increases fluidity of the liquid slags. Calcite and fluorite are examples of flux materials used for the ironmaking, steel refining and continuous casting process. Oxide systems based on CaO - CaF2 - SiO2 - Al2O3 - MgO cover most of the slag composition in ferrous metallurgy accordingly. Crucial operating factors for ironmaking and steelmaking slags are basicity (typically CaO/SiO2 ratio), viscosity and impurity levels. These are extensively controlled by the fluxes. General metallurgical fluxes such as limestone, dolomite and calcium fluoride are abundant in nature and supplied to steel mills at low prices. Meanwhile, in copper flash smelting process, silica is supplied with copper concentrate to remove iron oxide (FeO) generated from sulfide oxidation. FeO - SiO2 binary system formulates eutectic area at 25–38 pct of silica that has low melting temperature below 1205°C. Fayalitic system (Fe2SiO4) that has low viscosity (0.1 Pa·s) (Park et al., 2011) facilitates easy separation of slags from molten sulfide mattes. Recently, copper plants actively utilize recycled raw materials as a flux. Various recycled glasses are ground and fed to copper smelting process as a partial replacement of silica ore. Applying industrial wastes to smelting processes is advantageous since the operators can reduce the production cost remarkably. Not to mention the consumption of recycled materials can ultimately minimize the environmental risks and the waste management costs. The authors, therefore, investigated the reasonable waste materials that can be effectively used for ferronickel smelting process. Prerequisites for potential fluxing materials are non-recyclable property, low transportation cost and excellent performance as a flux."

Jan 1, 2017

By D. F. Zhang, X. Q. Jiang, N. Tahreen, D. L. Chen, F. S. Pan, D. Y. Li

Alloying with rare-earth elements has been proven to be an important tool for magnesium to achieve superior properties via texture randomization. The role of yttrium in texture weakening and the link between texture and formability are fairly well known. Since annealing is a vital part of metal processing which could significantly contribute to ductility, it is important to ascertain the impact of annealing in terms of texture change. Also, an understanding about texture development during pre- and post-deformation annealing is essential to improve the industrial deformation processing as texture is closely related to formability. While there is independent information in the literature regarding the effect of rare-earth addition and heat treatment on the texture formation, no systematic studies have been reported on the collective impact of yttrium addition, annealing and deformation on texture evolution. The present study was, therefore, aimed to identify the inter-relationship among texture evolution, yttrium content, heat treatment and deformation behavior in an extruded Mg-Zn-Mn-Y alloy. Annealing at 450°C for 1 hour and uniaxial compression tests at a certain amount of deformation were performed. The deformed and annealed samples were then subjected to annealing and compression test, respectively, followed by texture measurements. It was observed that yttrium addition effectively weakened the crystallographic texture in all conditions, which was evident from the changes in the microstructures and textures.

Jan 1, 2015

By J. Mizera, J. Zdunek, K. J. Kurzydlowski, A. Dobkowska

This work concerns comparison of corrosion resistance of the aircraft aluminum alloy composed of Al - 2.3%Li - 0.1% Zr. The alloy was hot rolled (HR) from 13 mm to a thickness of 4 mm (e = 2.4) and 1 mm (e = 5.2). Corrosion resistance was investigated by Potentiodynamic Polarization Test. The investigation relied on exposure samples in two different corroding medium: 0.5 M NaCl solution and 0.01 M Na2SO4 solution with added 0.01% of Cl- at room temperature. Furthermore, the microstructure was analyzed using the optical microscope with polarized beam. The hardness was measured on lengthwise profile. It was stated that alloy after the largest deformation (equivalent total strain e = 5.2) is characterized by the best mechanical properties and the best corrosion resistance. The alloys in initial state and after deformation to 4 mm (e = 2.4) are characterized by worse corrosion resistance. It is associated with microstructure and density of dislocation in analyzing material.

Jan 1, 2015

By S. Khallouk, J. Zollinger, J. R. Kennedy, E. Bouzy, B. Rouat, D. Daloz

Titanium aluminides recently replaced Ni-based superalloys as turbine blades in the last LP stage of aircraft engines. To extend their range of use at higher temperature their properties need to be improved, either by alloying or processing. An efficient solution is to reduce the grain size during the solidification process. In the first part of the paper, an overview is given on the possibilities for grain refinement of such alloys, based on literature data and new results. The most efficient grain refinement is obtained with boron addition which leads to boride formations that are detrimental for in-use properties of turbine blades. In this work, the use of the high grain refinement potency of inoculation with non-brittle particles has been used by developing new refractory-based inoculants. The effect of one of these inoculants on grain refinement of an as-cast structure in a Ti-46Al is presented; resulting in a reduction of the grain size by a factor of 3.While less efficient compared to the potency of boron containing alloys, the grain refinement is effective and does not introduce any embrittling particles.

Jan 1, 2015

By L. Callele, C. DiGiovanni, L. Li, R. Driver

"Hot-dip galvanizing is a common procedure used to protect structural steels from corrosive environments. However, in a construction project involving welded structural steel platforms by a Canadian steel structures company, numerous connections were found with large cracks in the welded corner joints and T-joints after galvanizing. Historically, in other similar projects by the same industry partner, cracking did not occur making this an unforeseen and new phenomenon. The project explored the mechanical properties of the base material, the thermal stresses induced by the hot-dip galvanizing, and the fracture surface of the cracks. A key feature to note, the fracture surface showed intergranular cracking with no plastic deformation. Lab testing showed the base material exhibited intergranular brittle behavior when heated and fractured at the galvanizing temperature. The transition to a brittle fracture mode is due to temper embrittlement and the segregation of elements in the grain boundaries.INTRODUCTION Galvanization is a common practice for protecting steel structures from the corrosive environment. Hot-dip galvanizing is the most common approach to bonding the zinc layer to the steel, and it is highly cost effective. In the case of welded structures, it is common to do the hot-dip galvanizing process after welding. This is so the protective layer can be applied to the structure as a whole and over the welds. In a recent construction project carried out in industry, a steel frame platform structure measuring approximately 3 m x 7 m was galvanized after welding fabrication. The structure was built of CSA G40.21 350W and CSA G40.20/G40.21 300W plain carbon steels and welded using a metal core arc welding process for the flanges and a flux core arc welding process for the webs of the beams. Due to their size, the platforms underwent a double-dip galvanizing process meaning half of the structures were submerged in the molten zinc path while the other half was exposed to the ambient air. This was repeated for the remaining side. Shortly after the galvanizing process was completed, numerous large cracks were found in the welded joints. Given there was no history of weld cracks after galvanizing in previous similar frames that were double dipped, this failure posed a new and curious problem."

Jan 1, 2017

By T. Billotte, G. Tirand, J. Zollinger, V. Robin, B. Rouat, D. Daloz

The grain structure prediction of metallic alloys during a welding process is often an issue. In addition to the welding parameters and the alloy nominal composition and properties, the base metal grain structure and chemical homogeneity also play an important role in the formation of the final microstructure. In this paper intensive characterisation of solidification structure in gas tungsten arc welding of Ni base alloy 600 are described. It is shown that in transverse section of the weld, while the grain structure shows some texture following constrained solidification growth, grain density in the weld is similar or greater than grain density in the heat affected zone. This suggests that simulation of the welding structure needs, in order to be predictive, to take into account : epitaxial growth, secondary nucleation events and 3D growth inside the weld pool.

Jan 1, 2015

By C. Cristonffanini, S. Nazari

"In the past, simulation was considered to be an offline tool disconnected from plant operation. Advancements in the computation power combined with utilizing physics and chemistry sciences have allowed us to significantly improve the modeling and simulation technology for mining and mineral processing. This paper investigates the benefits of first principle models and simulation by connecting them to real time operation. Process data are connected to high fidelity models executed in parallel to the operation. In recent literature, this concept is known as Digital Twins. The Digital Twin is used for various purposes such as optimization, virtual instrumentation and condition monitoring. Using IDEAS™ simulation software we are able to construct a digital twin for different equipment inside a mineral processing plant. Two case studies for building a digital twin for the primary hydrocyclone feed pump and thickener underflow are presented. Using the pump’s model, a digital twin is developed and is installed in a gold extraction plant that is able to infer the slurry density in real time. Additionally, it is used for detecting sanding in the pipes and impeller condition monitoring.INTRODUCTION Since the eighties, thanks to advances in computation technologies, computer based simulation of processes using first principle models has become a well-known engineering tool for various industries. As our understanding of processes has increased, their representative models have become more realistic and more sophisticated. Due to this increase of accuracy, use of simulation is becoming more fundamental in process industries. The main goals to use accurate simulation is to decrease the engineering and construction cost, optimize the process design and improve the operation performance by decreasing operation cost and increasing efficiency. The term Digital Twin was first introduced in 2010 by NASA (Shafto et al., 2012) in aerospace industry. Subsequently, the concept quickly spread through other industries. As of today, no standard organization has provided an official and unique definition of Digital Twin for process industries. However, there are three important aspects that are common throughout various descriptions. When simulation is core functionality of the process (1) along the entire life cycle of the plant (2) with direct linkage to operation (3), it is called that process has a Digital Twin. According to Gartner, the concept of Digital Twin has elected as fourth most important disruptive technology for the year 2018 (https://www.gartner.com/, 2017)."

Jan 1, 2019

By P. C. M. Knops, K. Rijnsburger, R. M. Santos

To overcome the challenges of mineral CO2 sequestration, this work utilizes a unique proprietary Gravity Pressure Vessel (GPV) reactor technology, and focuses on reaction products of high economic value. The GPV provides intense process conditions through hydrostatic pressurization and heat exchange integration that harvests exothermic reaction energy. Here, laboratory-scale tests of the envisioned process was performed in tubular and continuously stirred tank reactor (CSTR) autoclave reactors. The mineral used was Olivine (~Mg1.6Fe2+0.4(SiO4) + ppm Ni/Cr), although asbestos, steel slags and oil shale residues are also under investigation. The effect of several process parameters on reaction extent and product properties was tested: CO2 pressure, temperature, residence time, additives (buffers, lixiviants, chelators, oxidizers), solids loading, and mixing rate. The products (carbonates, amorphous silica and Chromite) were physically separated (based on size, density and magnetic properties), characterized (for chemistry, mineralogy and morphology) and tested in intended applications (e.g. as pozzolanic carbon-negative building material). Economically, it is found that product value is the main driver for mineral carbonation, rather than, or in addition to, the sequestered CO2. The approach of using a GPV and focusing on valuable reaction products could thus make CO2 mineralization a feasible and sustainable hydrometallurgical process.

Jan 1, 2015

By A. Miura, G. Granata, C. Tokoro, A. Fuwa

"The high copper demand as well as the lack of new high-grade deposits, are pushing the copper industry to process low-grade and refractory ores containing chalcopyrite. However, for a quantitative dissolution of copper from the chalcopyrite, the leaching performances still need to be improved. In the present research, we studied and optimized the iodide-assisted leaching of chalcopyrite in H2SO4-Fe2(SO4)3 media. The evolution of surface species during leaching was determined by x-ray photoelectron spectroscopy (XPS) and mineral liberation analysis (MLA). Inductively-coupled plasma spectrometry (ICP-MS) was used to determine the dissolved copper. Significance of experimental results was assessed by statistical analysis while a kinetic analysis of the leaching process was performed by fitting the experimental data with the Shrinking-core model. Results showed the significant positive effect of iodide on copper extraction rate. In the presence of KI, the dissolution rate of copper was almost double than in the parallel experiments without KI. Whether using KI or not, elemental sulfur was generated on the surface of the leached chalcopyrite. Nevertheless, in the presence of KI, the passivation layer did not arrest the leaching. Analysis revealed that the leaching rate was limited by the chemical reaction control step.INTRODUCTION Due to the large demand of copper, processing low-grade ores containing copper sulfides such as chalcopyrite (CuFeS2) has become unavoidable (Watling, 2013). Since ores with CuFeS2 may also contain appreciable amounts of arsenic that cannot be smelted, and because low-grade ores are uneconomic to smelt, the hydrometallurgical technologies are crucial for recovering the copper (Dutrizac, 1978). Sulfate-based processes are attractive because of the lower operating costs and because the sulfate ion is more suitable in case copper would be recovered via electrowinning. In ferric sulfate solution, chalcopyrite undergoes oxidation due to the large amount of Fe(III) and dissolution due to the presence of the sulfate ion (Majima, et al., 1985). The leaching reaction in ferric sulfate medium can be represented as in (1):"

Jan 1, 2017

By L. Tafaghodi, A. Hosseinpour

"Silicon is considered as the most appropriate semiconductor material for manufacturing solar cells because of its natural abundance and being nontoxic. The transferable knowledge and technology from the electronics industry and the long history of silicon-based semiconductors are also assisting the domination of silicon as the most common semiconductor material. Developing an environmentally and economically viable process for producing solar grade silicon has been one of the main challenges in the silicon industry in the past few years. Metallurgical refining processes have received significant attention because of their high productivity and low cost. Slag refining is one of the purification methods which is based on oxidation of the impurity elements, followed by its dissolution into a slag phase. This article presents a review of various slag refining processes that have been employed for purification of silicon and silicon alloys. SiO2, CaO, CaF2, CaCl2, Al2O3, MgO and Na2O are the major components of the slags used for silicon refining. These slags can be classified into three main categories including binary, ternary and quaternary slags.INTRODUCTION Silicon can be categorized into three different grades based on its application or purity: metallurgical grade silicon (MG-Si) with purity of ~98 %, solar grade silicon (SoG-Si) with purity of ~99.99999 % and semiconductor grade silicon (SeG-Si) which has the purity of 99.9999999 % (Johnston & Barati, 2010; Krystad, Tang, & Tranell, 2012; Tang, Øvrelid, Tranell, & Tangstad, 2009). Producing SeG-Si is carried out through an energy-intensive and complicated process named Siemens. This purification process is relatively slow and involves using toxic and corrosive reagents (e.g. Trichlorosilane). At present the majority of SoG-Si is produced via Siemens or Siemens-like processes and there is very limited production via processes dedicated to SoG-Si. Because of the difference in silicon specifications required in microelectronics and photovoltaic industry, and the cost and energy associated with the Siemens process, an interest has emerged to develop technologies dedicated to producing low cost SoG-Si (Istratov et al., 2003; Johnston, Khajavi, Li, Sokhanvaran, & Barati, 2012; Mitrašinovic, D'Souza, & Utigard, 2012; Wu et al., 2012)."

Jan 1, 2017

By X. Zhou

"Hydrogen induced failure and degradation in structural metals, namely hydrogen embrittlement, has been a long-standing industrial problem for more than one century and remains unsolved. Despite the proposal of numerous models, no consensus has been reached, and considerable discrepancies in experimental observations and theoretical calculations exist. One aspect that is central to the understanding of hydrogen embrittlement is the interaction between hydrogen and grain boundaries. In this study, we investigated the influence of several solute elements (i.e., Cr, Mo and Nb) on hydrogen segregation at the representative 9 grain boundary using first-principles calculations. Our results showed that the presence of Mo and Nb can reduce the tendency of hydrogen segregation at grain boundaries, while meanwhile enhance the grain boundary strength. This indicates that Mo and Nb are salutary elements that can be used to increase the material’s resistance to hydrogen embrittlement, providing new insights in designing hydrogen embrittlement resistant Ni alloys. INTRODUCTION Hydrogen embrittlement (HE), a phenomenon of hydrogen triggering premature failures in structural metals, has been a headache for industries ever since its first discovery one century ago (Johnson, 1874; Zhou, Marchand, McDowell, Zhu, & Song, 2016; Zhou, Ouyang, Curtin, & Song, 2016). It is well accepted that the segregation of hydrogen at microstructures such as grain boundaries (GBs) plays a key role in determining the occurrence and severity of HE. GBs are two-dimensional defects where significant local lattice distortion exist, which leads to large free volume and thus locations for hydrogen trapping and segregation. Numerous works have clarified GBs as the energetically preferable places for hydrogen segregation. For instance, Geng et al. demonstrated the preferential segregation of hydrogen at the S5(120) GB in several metals, and suggested a decohesion-type of HE in light of Rice-Wang thermodynamic theory (Geng, Freeman, & Olson, 2001). Birnbaum et al. illustrated that complete intergranular crack of Ni GBs can be induced by hydrogen segregation when the hydrogen concentration is sufficiently high, evidencing the significant role of hydrogen accumulation on GB weakening (Lassila & Birnbaum, 1987). Yamaguchi et al. demonstrated strong segregation hydrogen also occurs at S3 GBs in alpha-iron, showing that local hydrogen clustering (i.e., multiple hydrogen atoms, up to six, per unit cell) can be trapped at the S3 GB (Yamaguchi, Kameda, Ebihara, Itakura, & Kaburaki, 2012)."

Jan 1, 2017

By C. Tissot, R. Palmer

"Due to the low concentrations of gold, direct measurement of gold concentration in ore on belt has not been seriously considered to now. Pre-concentration or sorting strategies have largely consisted of particle sorting based on secondary characteristics such as colour, which can be successful in select cases. CSIRO has produced sample measurement results using gamma activation analysis of ~300 gm samples with accuracies of around 30 ppb at best. With this encouragement, a feasibility study into gold ore measurement on belt for the purpose of sorting pods of gold ore has been undertaken. The study described here included, prototype design options with existing industrial Linacs, extensive Monte Carlo modelling of measurement sensitivity and shielding, further sample measurement, a study of the interaction of target measurement accuracy and sorting efficiency, and a rough estimation of potential economic benefit. The projected model sensitivity of around 0.1-0.15 ppm (1 standard deviation) in 10 seconds for 1 ppm average feed result in good bulk sorting performance and intriguing economic potential.INTRODUCTION Pre-concentration or sorting strategies for gold ores have largely consisted of particle sorting based on secondary characteristics such as colour or density, which can be successful in select cases (Klein, 2010). No method is available to measure gold content for sorting in particles or even in bulk on belt, principally due to the low concentrations of gold present. In fact, in many cases it is difficult to do rapid bulk grade measurements of base metal ores with concentrations many orders of magnitude higher. By a fortunate quirk of nature gold is particularly amenable to gamma activation analysis (GAA). CSIRO has performed extensive work in GAA of samples of crushed ore (Tickner, 2017). This has resulted in the Photon AssayTM technique that is currently being commercialised through the CSIRO spinoff company Chrysos. The technique relies on the recent availability of industrial high intensity X-ray sources such as Linacs which are currently being used in industry for security, medical and sterilisation applications. This development has led to CRC ORE funding a feasibility study to determine whether on-belt measurement of gold concentration is possible at a rate and accuracy sufficient to be useful for bulk sorting, where pods of ore are diverted rather than individual rocks. The study in the first instance is based on Monte Carlo modelling that has successfully predicted the performance of the sample based gold measurements. As well as the measurement feasibility consideration was also given to the likely heterogeneity of gold ores and hence the degree to which useful separation could be achieved. This is then tied to a back of the envelope evaluation of the order of magnitude economics of bulk sorting in an example deposit."

Jan 1, 2017

By J. H. Pee, Y. J. Kim, H. U. Lee, G. H. Kim

The general recycling process of tungsten scrap to produce tungsten raw materials (tungstic acid, ammonium paratungstate (APT) and WO3) have been carried out by the oxidation, milling, sodium-fusion, dissolution, and extraction processes. Many studies on the high temperature oxidation of tungsten scrap have investigated various aspects such as swelling kinetics, fracture resistance, and the effect of alloying composition. However, the accelerating factors on the scrap oxidation rate during oxidation were not considered here. In general, oxidized products were fused with sodium carbonate or sodium hydroxide to produce Na2WO4. Later in the process, solid Na2WO4 was dissolved in water. This process required considerable reaction time and was a costly process. Therefore, the aim of this study was to increase the solubility of solid oxidized products to produce Na2WO4 solution by hydrothermal reflux method. Na2WO4 solution was used to produce CaWO4 and H2WO4 by general chemical reactions with calcium chloride and hydrochloric acid. Ammonia solution was also added to the tungstic acid to produce APT. In this study, the effect of ammonia addition on the APT precipitation process was investigated in detail.

Jan 1, 2015

By Michael Moser, Brighty Dutta, David Dreisinger

"Molybdenum is widely used in the industries as an alloying element in the manufacture of steels and super alloys. The widespread use of the element encourages a growing need to develop extraction processes for recovery from both primary and secondary sources. The Solvay Group has developed a solvent extraction reagent named CYANEX®600 for the recovery of molybdenum from acidic solutions originating from both low grade (e.g. copper solvent extraction raffinates, smelter dusts and slags) and high grade (molybdenite) molybdenum sources. CYANEX®600 is a purified form of CYANEX®272 with the active component bis(2,4,4- trimethylpentyl)phosphinic acid. The extraction behavior of CYANEX®600 towards molybdenum in sulphuric acid medium was evaluated. The uptake of molybdenum increased with the increase in concentration of CYANEX®600. The approximate stoichiometry of the extracted complex was: Mo: CYANEX®600 = 1:2. Efficient back-extraction could be achieved with 0.1 M disodium EDTA and 0.1 M (NH4)2CO3, thus providing the option of recyclability of the extractant. The detailed back-extraction studies are currently under progress to find out the possible option for complete transfer of Mo(VI) to the aqueous phase so that high purity Mo salts could be precipitated from the molybdate solutions.INTRODUCTION Molybdenum (Mo) is one of the world’s valuable metals and is highly sought after by researchers due to its versatile mechanical, thermal, chemical properties. Swedish scientist Carl Wilhelm Scheele demonstrated molybdenite to be a mineral sulfide in 1778. Peter Hjelm successfully isolated dark metal powder from the mineral sulphide and named it as ‘Molybdenum’ in 1782 (Gupta, 1992). Molybdenum is a refractory metal of silver gray appearance and is an important alloying element used in the manufacture of steels and super alloys. Molybdenum compounds are widely used in formulation of catalysts (Gupta, 1992). Molybdenum occurs in nature only in chemical combination with other elements. Several molybdenum bearing minerals have been identified, but the only one of commercial significance is molybdenite (MoS2). As molybdenum is a strategic metal for the industrial sector, its widespread use acts as a factor for depletion of the natural resources. Hence, there is growing need to develop extraction procedures for its recovery from both primary and secondary sources. United States, China, Chile, Canada, Peru, and Mexico are listed as the main producers by the U.S. Geological Survey, 2016 (U.S. Geological Survey, Mineral Commodity Summaries, January 2016)."

Jan 1, 2017

By Haibin Ma, Jie Song, Qingyou Han, Xiaoming Wang, Wei Vian

In the grain refinement of aluminum, Al3Ti and TiB2 particles are introduced to reduce the casting grain size down to 200 micrometer level, which makes cold working possible. The particles are brought in by the addition of Al-Ti-B type master alloys. It is generally believed that TiB2 particles are stable and nucleate a-Al grains in solidification in the presence of extra titanium than the stoichiometry of TiB2 from the dissolution of Al3Ti particle in the master alloys. Titanium in solution either form Al3Ti layers on the surface of TiB2 particles or as solute to promote the nucleation and to restrict the growth of a-Al grains. However, a consensus on a grain refinement mechanism is still to be reached due to the lack of direct observation. This paper presents finding on the TiB2/Al3Ti interfaces in an aluminum matrix. It demonstrates a strong epitaxial growth of Al3Ti on the surface of TiB2 particles, a sign of the formation of an Al3Ti layer on the surface of TiB2 particles in grain refinement practice. The Al3Ti layer has a crystal coherency with a-Al and hence offers a substrate for heterogeneous nucleation of a-Al grains.

Jan 1, 2015

By Janice Zinck, Maziar E. Sauber

"To counter the recent uncertainty in the rare earths market, diversify the supply source, and help meet the future demand in this sector Canada initiated development of several new rare earth deposits. In the past few years, a number of various studies on rare earths plant design have taken place mainly covering process development, process selection, and flowsheet design. The purpose of this paper is to provide an overview of known domestic and potential resources and reserves of rare earths and their status quo with a focus on the metallurgical processes using the information available in the public domain. Plant designs currently under consideration in Canada are reviewed and evaluated. An outline of the areas of opportunity for selective innovation and technology development in the rare earths flowsheet development and the associated risks and rewards is provided.INTRODUCTIONThe rare earth elements (REE) have a very small annual market, but they are categorized as very strategic metals vital to global economic growth due to their indispensability to the development of modern defence system, green technologies and electronic applications. The International Union of Applied and Pure Chemistry (IUPAC) defines the REE as the 15 elements on the lanthanide series on periodic table of elements, plus yttrium and scandium. REE are classified as light rare earth elements (LREE; La to Gd), and heavy rare earth elements (HREE; Tb to Lu). Physical properties and chemical reactivity of yttrium is similar to those of HREE, thus it is categorized as such. Properties of scandium are not similar enough to classify it as either a LREE or HREE (Weng et al., 2015; Sappin & Beaudoin, 2015). However, the mining industry does not always abide to this definitive classification of the split between LREE and HREE. Therefore, in a comparative study of projects, there is a need to pay attention to how the elements are classified."

Jan 1, 2016

By J. Girard, V. Aubé, M. Barakate, S. Bellec, M. R. Eddahabi, Y. Chaik, M. Deshaies

"The activated carbon used in the carbon-in-leach (CIL) process to absorb gold is subject to breakage. This carbon breakage can be minimized, but it will always be necessary to deal with fine carbon particles, known as carbon fines. These fines contain a significant amount of gold and mining operations generally struggle with the treatment of this product. Since IAMGOLD’s Essakane mine is located in Burkina Faso, shipping carbon fines out of the country was not considered a viable solution due to the logistical burden and legal procedures in place. A benchmarking study demonstrated the complexity of treating carbon fines on site. IAMGOLD partnered with the host government to find an innovative approach to economically recover the gold locked in these fines. This paper describes the new circuits commissioned in July 2016 built to improve carbon fines collection, incinerate the carbon fines and leach the gold in the ashes produced by incineration. These new circuits successfully demonstrate that it is possible to extract more than 94% of the gold content in the carbon fines. This is profitable for the company as it improves the overall mill recovery rate by 1.0% to 1.5% and significantly decreases gold inventory build-up on site.INTRODUCTION The activated carbon used in the carbon-in-leach (CIL) to absorb gold is subject to breakage. This breakage can occur in the CIL tanks, the stripping circuit, the regeneration process or anywhere throughout the pumping and handling processes of carbon through the circuit. Fine carbon particles are invariably created and, because of their small size, present a large specific surface which favors gold absorption (Hilsher et al., 2014). At the very beginning of operations at Essakane, the carbon fines were recovered by means of a thickener and a filter press, but the circuit was undersized and inefficient. Subsequently, a decantation basin was used to settle the fines before the thickener. The settled fines were shovelled from the basin into bags. All these bags were stored in the backyard of the plant. The average tonnage of carbon fines recovered monthly was 23.5 tons with a gold grade at 1938 g/t."

Jan 1, 2017

By D. C. R. Espinosa, P. Aliprandini, F. P. C. Silvas, J. A. S. Tenório, M. M. Jiménez Correa

"Nickel ores are divided into two types: sulfide deposits and lateritic deposits. About 60% of nickel resources are found in laterite ore, while the remaining 40% is contained in sulfide ore. Laterite ore is usually processed via pyrometallurgical means or through hydrometallurgical techniques that include acid leaching and metal value recovery from solution. In this study, copper and nickel adsorption by Dowex M4195 ion exchange resin from an acidic sulfate liquor was investigated. The acidic sulfate liquor was collected from an atmospheric leaching process (AL) of laterite ore. Ion exchange experiments were conducted in a batch system by varying parameters such as pH, time, metal concentration and temperature. Initially, mono-elemental synthetic solutions of nickel and copper were used in the experiments and then a synthetic solution simulating AL liquor was tested. Test results showed that the resin exhibited high selectivity towards copper and nickel, however, a high concentration of iron in the synthetic AL solution interfered with the recovery of nickel and cobalt by the resin.INTRODUCTION Nickel is one of the most important industrial metals in the world. It is widely used in industrial applications, such as the production of stainless steel, magnets, electroplating and special alloys (Dizge et al., 2009). The main sources of industrial nickel production are sulphide deposits; only 40% of industrial production uses lateritic ores. However, it is estimated that 60% of global nickel resources are found in nickel laterite deposits (Kuck, 2016). Since industrial nickel demand continues to grow, the development of new technologies for the extraction of nickel from laterite ores has become an interesting research topic (Agatzini-Leonardou, 2009)."

Jan 1, 2017

By James H. C. Martens

Among the many interesting problems of the pre-Cambrian of the Canadian Shield is that of the origin of certain types of gneisses which are intimately associated with the granites on the one hand and with the metamorphic rocks of known sedimentary origin on the other. The observations recorded in this paper on the structure and composition of these ancient rocks found in a small part of northern Quebec may help to lead to a clearer understanding of the way in which they were formed and also constitute a contribution to the regional geology and petrography of a district for which little detailed information is available. The area considered is located near the Ashuapmuchuan, or Chamuchuan, river about 180 miles north-northwest of the city of Quebec, and therefore well within the Canadian Shield. Although most attention was devoted to the rocks along this river from the 57th to the 70th mile above its entrance into Lake St. John, a few observations on other localities to the north and northwest of that lake will be included. The field work was done in the summer of 1924 in cooperation with L. W. MacNaughton, E. S. Roberts, and B. M. Shaub, all of Cornell University. The party ascended the Ashuapmuchuan river by canoe and spent about a month near the mouth of Stacker, or Brochet, river, the outlet of the lake of the same name, returning by way of Mikoasas river. The writer wishes to express his obligation to his associates for their co-operation in the field and for their permission to publish the results. He is especially indebted to B. M. Shaub for the photographs of rock outcrops. Professor A. C. Gill g:ive many suggestions which were helpful in the laboratory study of specimens and in the preparation of this paper.

Jan 1, 1927

By E. Eccleston, E. Gardner, F. Letarte, R. Schonewille

"In 2005, after nearly a decade of process development and feasibility work, the commercialization of the Falconbridge Nickel Smelting Technology (NST) began in earnest with the design and construction of a grassroots ferronickel plant at Koniambo Nickel in New Caledonia. The NST process was developed as an alternative to the conventional Rotary Kiln-Electric Furnace (RKEF) process for production of ferronickel from saprolitic nickel laterite ores. The NST process promised environmental and energy efficiency advantages over the conventional route. A key step of the NST process involves fluidized bed pre-reduction of calcined laterite ore using direct injection of pulverized coal as the reductant. Two parallel fluidized bed reduction roasters (FBRs) were installed at Koniambo Nickel, each designed for a maximum capacity of 4,200 MTPD of calcined nickel laterite ore. This paper describes the process development and scale-up of the fluidized bed pre-reduction process, the design challenges associated with the prototype commercial units, and the current status of the FBR operation at Konaimbo.INTRODUCTION In the mid-1990s, Falconbridge began to develop a new flowsheet for production of ferronickel from nickel laterite ores. The process that developed came to be known as the Falconbridge Nickel Smelting Technology (NST). The flowsheet, which is particularly appropriate for saprolitic ores, involves several major unit operations, including: drying in a hammer mill-flash dryer, calcination and preheating in a flash calciner, pre-reduction in a fluidized bed reactor, and smelting in a DC arc furnace to produce the ferronickel product. This paper focuses on the fluidized bed pre-reduction step of the process and provides an overview of the process chemistry, laboratory and pilot plant development work, scale-up and commercialization of the pre-reduction step, and the results obtained in the prototype commercial units."

Jan 1, 2017