Search Documents

By Zhang Chuanfu

Keywords: solid solution, Ni-Co alloy powders, thermal decomposition, fibres. Synthesis of fibrous Ni-Co alloy powders was achieved by thermal decomposition of precursor of complex Ni-Co oxalates solid solutions obtained via modified coprecipitation method among intimate mixing solution of NiCl2?6H2O , CoCl2?6H2O and H2C2O4?2H2O in the presence of surfactant polyvinylpyrrolidone (PVP) and organic solvent ethanol. Scan electron microscopy (SEM), X-ray diffraction (XRD), X-Ray photoelectron spectroscopy (XPS), disperse energy X-ray analyses (EDX) were used to characterize the structure features and chemical compositions of the as-prepared fibres. The influences of decomposition conditions, including temperature, time, the flow rate of N2+H2, and the heating rate, on the morphology, average size and specific surface area of the Ni-Co alloy powders were investigated. It is found that a trend of the mutual alloying of nickel and cobalt: the formation of perfect solid solution for any compositions NixCo100-x was indicated and corresponding NixCo100-x alloys with fcc phase can be obtained under the optimal conditions.

Jan 1, 2005

By J. C. Agarwal

Slags produced by modern smelting furnaces contain copper values which are unacceptably high for discard. The electric arc furnace is employed commercially to clean copper from flash furnace slags but the addition of highly oxidized converter slags to an electric furnace has created operational problems. Highly oxidized Noranda Reactor slags have not been processed successfully in a pyrometallurgical process. These slags, which contain large concentrations of copper (5 to 10 per cent), are treated in slag concentrators (controlled cooling, crushing and milling, and flotation) which produce a copper concentrate that must be resmelted. Though commercially operable, it will be shown that the slag concentrator has important process and cost disadvantages as compared to a pyrometallurgical process. In this paper an economic comparison is made between a pyrometallurgical process and the slag concentrator. For the analysis, five hypothetical smelting plants are considered. Each plant treats 1200 tons of copper concentrate per day and produces 109,000 tons of copper annually. The plant configurations used in this study are:

Jan 1, 1976

By N. L. Piret

Reprocessing of low zinc-bearing residuals with a zinc content of less than 10%, originating from the iron and steel industry, has been given more and more attention in the last few years, due to the potential landfill liability and the increasing cost of disposal by dumping. Whereas, recycling of hazardous electric arc furnace dust is already being performed commercially on a large scale in the U.S., Japan and Western Europe, almost no reprocessing takes place in the case of these low grade zinc-bearing materials. In blast furnaces and basic oxygen furnaces dusts and / or sludges are generated at a rate of 1 to 2 % of the respective production. The technologies for the retreatment of these types of materials, either commercially available or still being developed are briefly described hereafter. They involve internal recycling, upgrading by physical separation methods, separate hydrometallurgical processing and pyrometallurgical treatment. Their scope and limitations are critically assessed in terms of technological applicability, economic feasibility and environmental compatibility. Since, the possibtlity of achieving economic profitability is unlikely with this type of material, the main criteria for acceptability of the treatment process are: generation of a iron-rich material, suitable for treatment by the iron/steel industry, acceptance of the non--ferrous metal-bearing sub-product by zinc smelters, generation of non-hazardous waste materials.

Jan 1, 1992

By E. I. Gedgagov, A. V. Tarasov, V. M. Paretsky, A. D. Besser

"Hydrometallurgical technology and equipment have been developed in the Gintsvetmet Institute (Moscow, Russia) for processing of rhenium-containing alloys waste to produce commercial- grade metal products with recovery of all valuable components. The technology is based on waste treatment with hydrofluoric acid with subsequent decomposition with nitric acid at pH = 1 to 1.5 to ensure maximum degree of rhenium conversion to the liquid phase of pulp. Some experimental lots of ammonium rhenate and ammonium molybdate were produced at a pilot plant. The following main techno-economic performance values have been achieved when processing grinding residues (balance-based tests were conducted with a lot of SP-2 alloy waste) to produce ammonium rhenate of high purity, as well as tantalum-niobium, nickel-cobalt and tungsten-molybdenum concentrates: rhenium recovery of 92.3% into a commercial product from grinding waste; production cost of 170-210 US Dollars per 1 kg of rhenium in commercial-grade ammonium perrhenate taking into account its recovery; tantalum and niobium recovery of 75- 77% into bulk concentrate; nickel and cobalt recovery of 88-89% into a mixed concentrate; tungsten and molybdenum recovery of 88% to 91% into concentrate. Introduction During the recent years the use of rhenium has been increasing at a fast pace worldwide [1]. The growing prices for this refractory metal are an essential factor encouraging collection and processing of rhenium-containing wastes. Double-component waste, such as molybdenum- rhenium or tungsten-rhenium alloys can be readily decomposed and the process of rhenium recovery does not cause, therefore, any difficulties. The main separation of metals takes place at the stage of waste digestion with acid, because molybdenum and especially tungsten remain in precipitate in the form of hydrated oxides and rhenium reports in the liquid phase, from which it can be easily extracted by solid ion-exchange or solvent extraction techniques. However, most of rhenium is contained in super-alloy waste [2]. Such waste has different contents of valuable components, such as tantalum, niobium, molybdenum, tungsten, cobalt, nickel, chromium and other metals. The basis of all such super-alloy waste is nickel. Refractory metals in the super- alloy composition are in the form of metallized target-oriented eutectics, and due to this reason hydrometallurgical decomposition of such alloys is a difficult technological task."

Jan 1, 2008

By C. S. Simons

This paper presents a review of the extractive processes used in the production of nickel, with emphasis on developments since the beginning of the Second World War. Attention is given to the factors, many outside the nickel industry itself, which determined the direction of process research and strongly influenced the ultimate commitments to industrialize the resulting developments. An example of such a factor is the sudden surge in demand, far exceeding the then available nickel production capacity, that was caused by the advent of World War II; the result was the first serious consideration ever given to low- grade laterites as a viable source of primary nickel. Other factors discussed include such items as process development in the extraction of other metals - particularly copper; the availability of increasingly sophisticated materials of const- ruction; the advent of the "environmentalist" and related political developments; the massive escalation in the price of energy - particularly oil. The paper concludes with an attempt to forecast the nature of the most effective nickel process of the future, based on extrapolation from the economic and political situation that exists today.

Jan 1, 1988

By John R. FitzPatrick

The separation and purification of uranium from either nitric acid or hydrochloric acid media tan be accomplished by using either solvent extraction or ion-exchange. Over the past two years at Los Alamos, emerging programs are focused on recapturing the expertise required to do limited, small-quantity processing of enriched uranium. During this period of time, we have been investigating ion-exchange as a method for extraction/purification of uranium from acidic media. In addition, waste stream polishing is associated with this effort in order to achieve more complete removal of the uranium prior to recycle of the acid. Extraction chromatography has been demonstrated' to further polish the uranium from both nitric and hydrochloric acid media thus allowing for a more complete recovery of the actinide material and creation of less waste during the processing steps. We will discuss contact experiments for evaluation of eleven different resins for uranium removal from nitric acid, the evaluation (again by contact experiments) of uranium elution from the ion-exchange media by various chemicals, and small-scale experiments for the removal of 235U from nitric acid. Larger-scale (100-gram) flow experiments using depleted uranium, were done after the small-scale evaluation Of the selected resin. A discussion is also included concerning the shortcomings of the contact experiments and how the flow experiments were modified in order to overcome these problems. We will also discuss the application of ion-exchange for some specific process needs at Los Alamos Contact experiments were used to evaluate some commercially available solvent-impregnated resins in addition to evaluation of several resins of this type synthesized in our laboratory. These experiments' involved both nitric and hydrochloric acid media. The data from these experiments will be used to determine the column size and' amount of resin required to polish the waste stream produced by the ion-exchange process described above. Small-scale flow experiments will be described and data given on the mass balances achieved using this two step process. Future work for evaluation of new ion-exchange and solvent-impregnated resins as well as the search for new eluants will be discussed. Other future experiments for both processes, including large-scale experiments, will be discussed in detail.

Jan 1, 1996

By Kunihiko Takahashi, Gjergj Dodbiba, Hisayoshi Umeda, Toyohisa Fujita

"An increasing number of mobile phones is increasing the number of the discarded mobile phones. Many efforts are thus being made to collect and recycle these devices. This paper is a short introduction of the recycling system of precious metals from the discarded mobile phone, currently available in Japan. Moreover, an attempt has been made to compare the energy recovery and the mechanical recycling of plastic wastes from the discarded mobile phone. The assessment has been carried out in the context of the life cycle assessment methodology (LCA). The environmental impact of each option was assessed by calculating the following impact indicators: depletion of abiotic resources (ADP), and global warming potential (GWP). 1. Introduction In 2003, the demand for mobile phones was increased since the camera was included in a mobile phone and the 3rd generation of mobile phones was introduced. In turn, the number of discarded mobile phone is rising sharply. Generally speaking, all the metallic parts of mobile phones can be recovered and recycled by using smelting and purification techniques. The recycled materials are then used to fabricate other new products."

Jan 1, 2008

By W. William Culver

James Douglas became known in the nineteenth century for two reasons fundamental to his mining career: (1) his experimental work with copper hydrometallurgy, and (2) his grasp of the idea that the quantity of copper ore matters more than the quality. On the first reason, there is a moment for any technology that’s critically important—when it moves from an area of scientific interest to one that companies are founded on. This paper examines the original 1869 Hunt and Douglas Copper Process in the context of science and engineering as they were in the 1860 and 1870s. It was a “humid” process, developed at Quebec’s Harvey Hill Mine. Chemically, the Hunt and Douglas vat leaching process succeeded, but not the original companies using it. On Douglas’ understanding of ore quality versus quantity, luck had it that the first company to field test the Hunt and Douglas Copper Process was in Chile. The Hunt and Douglas patent made that transition from experimental model to operational plant in 1870 when the Compañia de Minas de la Invernada was organized in Valparaíso. As a joint-stock company, Invernada spread the risk of investing in the revolutionary, but untested, Hunt and Douglas Process. The company brought Douglas to Chile as a consultant in 1871. His experience with hydrometallurgy, combined with what he learned about the copper business while in Chile, set him off on a career in metal mining that both surprised Douglas and made him wealthy.

By Patrick R. Taylor

A non-transferred arc thermal plasma assisted cyclone reactor has been designed, built and operated to evaluate its use in vitrification of wastes. Simulated waste (liquid, slurry or fine particulate) is injected near the plasma flame, where nearly instantaneous dehydration and calcination reactions happen. A non-transferred arc plasma torch was attached tangentially to the cyclone and is utilized as both an enthalpy source and to provide the gas velocities required to generate the cyclonic gas flow patterns. The closed top cyclone flow sends the solid particulates to the wall, where they are captured by a thin film of molten glass that is injected as a powder at a position lower in the reactor. The molten glass is then collected in a crucible. The feasibility of simulant injection directly into the flame zone and its effect on electrode lifetimes has been studied. Several candidate refractory systems have been evaluated for their suitability for extended use under the demanding conditions present in the cyclone reactor.

Jan 1, 2002

By Won C. Park

Experiments showed changes in the mineral content of dolomitic oil shale at temperatures and exposure times which bracket conditions encountered during in situ retorting. Laboratory results correlate with cores from a spent in situ retort at Occidental's Logan Wash test site at Garfield County, Colorado. Dolomite, CaMg(CO3)2, decomposes rapidly to form periclase, MgO, calcite, CaCO3, and CO . Both calcite and periclase are intermediate products that can be stabilized by CO atmosphere at lower temperatures, while steam accelerates the formation 2 of silicates. The decarbonation of calcite appears to involve a direct reaction with both quartz and periclase in forming these silicates. Decarbonation preceeds the formation of akermanite, Ca2 MgSi 207, and diopside, CaMgSi 206, within several hours of heating and is followed by the nucleation of forsterite Mg2SiO4, and monticellite, CaMgSiO4. Under in situ retorting conditions, akermanite and diposide are the major minerals above 800°C. Equilibrium is not attained within 200-300 hours. In situ retorting temperatures above 800°C for extended periods of time should reduce potential ground water leaching by the formation of silicate minerals. These silicates are less soluble than free lime, magnesium or alkali oxides. There is a corresponding decrease in the natural pH of these silicates from approximately 12 down to 7.5 to 9:

Jan 1, 1981

By W. Kunda

Silver nitrate solution is a very common product in hydrometallurgical processes involving the treatment of various silver bearing materials. Silver is recovered by electrolysis. The alternative method for the recovery of silver from aqueous solutions is the precipitation by hydrogen at elevated temperature and pressure. A previous study by the authors revealed the feasibility of this technique for the silver ammine sulfate system. Further study showed different behavior for silver in the silver ammine nitrate system and a systematic study was initiated to establish the optimum conditions for the process. The study showed that the process can be controlled by (1) composition of the feed solution, (2) temperature and (3) hydrogen pressure. The recovered silver product was in the form of very fine powder.

Jan 1, 1989

By D. C. Lynch

While a sizable amount of data exist as to the activity and distribution of minor elements between matte and metal, there has been no unifying theory presented delineating the form of dissolution of these elements in molten sulfides. In order to alleviate that deficiency the literature concerning the behavior of As, Sb, Bi and Pb in mattes is reviewed. Models present in the literature, regarding the thermochemical behavior of minor elements, are tested, and new models are presented and evaluated using thermodynamic theory. The results of those analyses are used to predict optimum conditions for the volatilization of minor elements. The dearth of data on the behavior of minor elements in nickel mattes requires that this review focus on copper- iron mattes. An effort is made, however, to utilize basic knowledge regarding nickel sulfides and the interaction of nickel with the minor elements to predict the behavior of those elements in nickel-copper and nickel-iron mattes.

Jan 1, 1993

By J. G. Eacott

This paper reviews the role of oxygen potential and the advances that have been made in the application of tonnage oxygen in copper smelting. Brief reference is made to reaction kinetics before attention is turned to the thermodynamic considerations in copper melting to illustrate the importance of oxygen and. oxygen potential in the component parts of the overall smelting process. The chemical potential diagram for the Cu-Fe-S-O-Si02 system is used to elucidate the difference b etween the conventional matte smelting process and the modern continuous processes. A progressive oxidation scale' is constructed to show the common elements which exist, and the matte grades produced, during the smelting of concentrates to blister copper in commercially available copper smelting processes and those under development. The common route in producing blister copper from molten mattes, regardless of process, is illustrated on the Cu-Fe-S equilibrium phase diagram. The essential features of oxygen enrichment, in terms of its effect on combustion conditions (i.e. oxidation of fuel and sulphide minerals) and the heat balance are outlined. The benefits of oxygen enrichment are listed. The influence of tonnage oxygen and its effect on productivity, fuel savings, gas volume and strength in various copper melting processes are examined as a state-of-the-art review. Reference is made to the economics of tonnage oxygen utilization.

Jan 1, 1983

By Wang Zhi

High-Mg-content concentrates are usually treated in Jinchuan flash smelting Furnace. Because the viscosities of high-Mg-content slag is very high, the operation of flash smelting becomes very difficult. To solve this problem, the viscosities of the semi-synthesized FeO-MgO-SiO2 slag of different compositions were measured. The results showed that when in the slag the weight percentage of MgO [w(MgO)] is 6-10%, the ratio of the weight percentage of iron to that of Si02, w(Fe)/w(Si02) is 1.1-1.4 and the temperatures are within 1473-1773K, the slag viscosities increased with the increase of W(MgO) and w(Fe)/w(SiO,). When w(Mgo)<6%, the smelting temperature should be controlled at I 300°C in order to to keep the smooth operation. When w(MgO)>10%, the temperature should be kept above I 633K. When the content of MgO is higher, a lower viscosity slag can be produced by decreasing the ratio of w(Fe)/w(SiO,). The appropriate ratio of w(Fe)/w(SiO,) for Jinchuan flash smelting furnace is about 1.2.

Jan 1, 2003

By T. K. Bundtzen

Placer gold in the Iditarod and Innoko mining camps of western Alaska is derived from a suite of comagmatic, Late Cretaceous to Early Tertiary, alkali-calcic, meta-aluminous. volcanic-plutonic complexes and peralumi-nous rhyolite sills that intrude Mesozoic flysch. Heavy-mineral concentrates from 42 mining operations and streams draining known mineralized areas in the igneous complexes contain placer gold and a variety of ore minerals derived from epithermal to hypothermal conditions of formation. The minerals include cassiterite, ilmenorutile, samarskite, cinnabar, scheelite, chromite, stibnite, silver sulfosalts, monazite, and zircon. Results of the study show that 1) cinnabar. stibnite, and quartz formed with the bulk of the placer gold in an epithermal lode environment, 2) chromite appears to have originated in mafic phases of monzonite plutons and alkalic basalts, and 3) niobium-tin-tungsten-uranium-silver values may have been derived from stockwork accumulations in cupolas of monzonite plutons.

Jan 1, 1987

By W. K. Connor, O&apos

Thermal Treatment Technology Division Albany Research Center, U.S. Dept. of Energy Oregon. This evaluation included a characterization study and direct smelting tests conducted in a bench-scale electric arc furnace (EAF). In contrast to other thermal treatment technologies considered for these wastes (i.e., fluidized bed combustion), direct smelting in the EAF can process 100% of the wastes without prior beneficiation, and utilizes solid oxidant additions (in this case iron ore) rather than air to oxidize the carbon. This solid oxidant addition is advantageous because it results in the production of several value-added furnace products. These products include cast iron resulting from the reduction of the iron oxides, baghouse dust containing virtually all of the zinc from the residues, and a clean (nonhazardous) slag product suitable for recycle as concrete aggregate or construction fill. Offgas from the smelting furnace also holds potential as fuel gas for cogeneration. The direct smelting tests conducted thus far were successful at producing the desired furnace products, exhibiting the potential for complete recycle of the waste pile. A cast iron product of comparable quality to conventional cast irons was produced, at nearly 80% iron recovery to the metal. The slag product was determined to be nonhazardous, based on the EPA TCLP. Lead and zinc partitioning to the dust product was greater than 99%. The material balance over the furnace indicates that for every ton of feed processed, 540 lb. of cast iron, 600 lb. of slag, and 150 lb. of dust would be produced. Energy consumption was roughly 1.10 kWxh/lb of feed material. Prior experience suggests that these figures measured in the bench-scale furnace would translate to 0040 to 0.50 kWxh/lb at the industrial-scale.

Jan 1, 2000

By Mark Osborne, Ray D. Peterson, C. Edward Eckert

"The theoretical melting energy requirement for a typical hypoeutectic aluminum-silicon alloy is approximately 520 BTU/lb. It has been demonstrated, however, that even a state of the art secondary processing-automated lost foam casting operation can exceed this value by at least an order of magnitude when the actual thermal energy input from melting to solidification is monitored. Metal transfer and holding operations constitutes over 65% of this expenditure. The authors present relative benchmark energy expenditure information by unit operation for an offsite melting/lost foam casting line with a daily throughput in excess of 100,000 lbs. Efficiency improvements through optimization of the current process, and anticipated energy values at the culmination of a U.S. Department of Energy sponsored project to develop, integrate and demonstrate an advanced melting, transportation, and dispensation system will be cited.IntroductionThe size of the U.S. aluminum remelt pool was approximated to be 14.21 billion kg (31.27 billion pounds) by a recent study?, with the engineered castings (foundry) sector accounting for 3.25 billion kg (7.16 billion pounds) or 23% of that total. This study considered overall process yield and all major contributors to scrap. The values cited, therefore, are more meaningful than simply tabulating annual pounds shipped by sector.The foundry sector consists of Sand Castings, PM Castings and Die Castings categories appearing in Figure 1. All other categories comprise the wrought alloy sector. Wrought alloy production enjoys an energetic benefit from both scale and a relatively continuous operation. Many foundry operations, however, operate in batch mode at less than design metal throughput with characteristically longer melt holding periods. Since any detention of molten metal beyond melting represents an overhead use of energy, melt holding (secondary) energy expenditures can appreciably inflate melting energy requirements in the foundry."

Jan 1, 2009

By Joël P. T. Kapusta

Although Peirce-Smith converting remains the workhorse in matte converting, the copper and nickel industries are still confronted with production hindrances such as tuyere blockage, excessive refractory wear and limits in the oxygen enrichment levels of the blast air. The knowledge acquired on high-pressure gas injection technology as well as the invention of the concentric tuyere for steelmaking led to the development of the Air Liquide Shrouded Injector (ALSI) technology for copper and nickel converting. Following a technology demonstration in 1997-98 with four shrouded injectors installed in a Peirce-Smith converter, Falconbridge Limited implemented ALSI Technology on a commercial scale in May 1999 as an integral part of its new Slag Make Converter at Sudbury, Ontario, Canada. The paper presents the various aspects of commissioning ALSI Technology, as well as the operating changes and injector design modifications over the five years the shrouded injectors have been in operation.

Jan 1, 2005

By R. M. Sweetin

Detailed descriptions by operating area of the Kidd copper smelter are presented, together with accounts of complement staffing, training, and preparation activities for smelter start-up in June 1981. Concentrate tonnages smelted in the first twelve months of operation were constrained by the capacity of the furnace off-gas system. However, modifications designed and introduced over that period, plus sustained efforts by operations and maintenance personnel have resulted in stepwise improvements in smelter performance.. Consistent operation at design feed rates has been well demonstrated over the third and fourth smelter campaigns and efforts continue on further improving the continuous smelter on-line times and increasing campaign life. In November 1982., following a seventeen month preproduction period, the Kidd smelter attained full operating status.

Jan 1, 1983

By Thomas Weyand, Thomas Claridge, Dale Nickels

"This paper addresses the initial results of a project to evaluate the suitability of copper mining tailings as raw material for the production of structural products using PMET’s patented technology. Preliminary testing indicated that high performance structural products were possible using these materials. A demonstration scale project produced approximately 1,500 bricks in various colors. These products fall under under ASTM C- 73 and were found to present properties suitable for severe weather applications. Although the products in this project were of typical brick dimensions, other products are possible, for example concrete block substitutes or pavers. These products from the PMET process are commercially known as Brixx. This paper will provide operational details of the production process, mineralogy and mechanical properties of the products.INTRODUCTIONPMET has developed process technology that can convert various siliceous waste materials into competent structural products. This technology is the subject of US patent # 6,068,803. In general, the process consists of mixing lime, water and the major feed stock, pressing to form a “green” shape, and curing the product in an autoclave for 6 hours with saturated steam at ~200oC. The curing process forms Tobermorite, which acts as a crystalline binder. Freeport-McMoRan approached PMET to see whether mine tailings from the Sierrita mine, containing significant amounts of clay, might be a suitable feed material for the production of structural products. “Brixx” is the commercial term used to describe the resultant structural product formed in the test work. This paper is a preliminary evaluation of a technology that is being considered by Freeport-McMoRan. This report is not an endorsement by Freeport-McMoRan of the process or products, nor is it a commitment to use this technology."

Jan 1, 2008