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By Donald R. Fosnacht

An investigation was initiated to obtain the scope of the problems associated with recycling various waste oxide materials generated at Inland Steel and to identify and? test techniques that could possibly aid in increasing the amount of waste oxide materials recycled to primary. operations. Based on the results of this work, several new techniques were developed ?and tested on ?a plant or laboratory scale. These include the use of cold-bond agglomeration methods for producing waste oxide agglomerates for use as a cooling agent or scrap substitute in steelmaking operations, and the use of various techniques for beneficiating blast furnace flue dust and soaking pit rubble so that the upgraded materials can be utilized in sinter plant or ironmaking operations. The physical and chemical characteristics of the waste oxide materials and the results of the laboratory and plant testing are discussed in this paper.

Jan 1, 1985

By Rak-lun Choi

Plasma-induced damage of InGaN/GaN multiple quantum well (MQW) light-emitting diodes (LEDs) has been studied in terms of forward turn-on and reverse breakdown voltages, together with etch rate and surface morphology. The physical degradation of sidewall along with rough surface morphology of n-GaN caused by increased ion scattering induced the deterioration of the forward and reverse voltages. It was found that the turn-on voltage is sensitive to the surface roughness of the etched n-GaN and the breakdown voltage is strongly affected by the sidewall contamination. Annealing under nitrogen after the mesa etching improved the electrical properties of the InGaN/GaN MQW LEDs. Efficient blue light-emitting diodes (LEDs) were fabricated using InGaN/GaN triangular MQWs. The LEDs with triangular QWs showed a lower operation voltage and 2.4 times higher light output power than those with the rectangular MQW LEDs at 20 mA and 20 °C. The intensity of electroluminescence (EL) at 20 mA was almost independent of ambient temperature in the triangular QW LED, but decreased substantially in the rectangular one.

Jan 1, 2003

By Bora Derin

The partial pressure ratios of sulfur and oxygen for several copper flash smelting plants were derived using the Reddy-Blander (RB) model and predicted dissolved sulfur contents available in the literature. The sulfide capacities (Cs) of six different flash smelting plants (FeO-CuO0.5- CaO-MgO-FeOwAIOl.s?SiO2) slags were calculated. The log (Po2/PS2) versus matte grades of various industrial processes was determined. The PoiPS2 ratio increased with an increase of copper grade. The calculated partial pressure ratios for the copper flash smelting are in good agreement with those of the experimental data.

Jan 1, 2003

By Jianxin Zhang

A process, in which arsenic in the residue is transformed directly into scorodite and copper dissolves into the solution simultaneously, was studied. The process was carried out in acidic ferrous sulfate solution under oxygen pressure. The optimum conditions of the process were determined as follows: the initial H2SO4 concentration of 10 g/L; liquid/solid ratio of 10; Fe/As molar ratio in the feedstock of 1; the addition of calcium lignosulphonate was 1% of sludge; oxygen pressure, temperature and reaction time were 1.5 MPa, 150 °C and 6 h, respectively. Under these conditions, arsenic transformed to crystalline scorodite in size of 5–10 μm, and the transformation efficiency reached 97.60%; meanwhile, the copper was leached with a high efficiency of 93.34%. The stability of the leaching residue was evaluated by TCLP testing, and the results indicated the concentration of arsenic in the leaching solution was extremely low as 0.04 mg/L and met the standard of safe stockpile.

By R. M. Lamya

A considerable part of gold encapsulated in some refractory sulphides can be dissolved during sulphide matrix decomposition in non-complexing aqueous media. This has been concluded from laboratory results of gold extraction from pyritic and arsenopyritic concentrate containing 172.8ppm Au, into 10% hydrochloric, sulphuric and nitric acids. The degree of sulphides decomposition in the non-oxidative acids limits the gold extraction from this specific concentrate to about 10%. In the case of nitric acid, the gold dissolution follows the rapid decomposition of sulphides, reaching 32 to 42% of extraction at almost total decomposition of the sulphidic minerals. Accumulation of gold in this acidic and non-complexing solution to several ppm was not affected by the soluble products of the sulphides decomposition. An attempt to explain this gold behaviour is undertaken and some practical implications are discussed. In the investigated concentrate the "soluble gold" is mostly associated with arsenopyrite. This is consistent with the latest findings of other authors that gold disseminated in arsenopyrite can occur as cation Au3+. In a comparative test the gold extraction into highly concentrated chloride solution, in the same oxidative conditions, amounted to 92.34%.

Jan 1, 1995

By I. S. Blair

The introduction of the 36 MVA smelting furnace at Mufulira, and the experience gained during the first five years of operation have been described previously (6). Based on this experience the furnace was rebuilt in 1977., Details of the modifications made during this rebuild are described. Subsequent to the rebuild, refractory failures, particularly in the electrode ring bricks of the sprung arch roof, continued to cause concern, and repair and improved roof control methods are described. Electrode breakages continued, but developments in casing design and electrode preparation have resulted in significant improvements. Modifications in the electric furnace gas handling system are outlined, together with details of further changes to be implemented in the near future. The systems developed for metallurgical control of the furnace and the thermo-dynamics of the process are discussed. The electric furnace at Mufulira is now operating at above design production levels, and has decisively justified the choice of this technology in situations with inexpensive electric power. The potential for further increases in production capacity from the Mufulira unit, and improvements in design for new units are discussed.

Jan 1, 1983

By Takeshi Nagano

Copper pyrometallurgy in Japan has experienced quite fundamental changes in last fifteen years. The severe environmental restriction coupled with increase of energy costs accelerated the development work of the new continuous process in Mitsubishi Metal Corporation. After several years of pilot plant test work the commercial plant was put into operation at Naoshima Smelter in 1974, the design capacity of which was 4,000 tonnes of copper per month. Many modifications and improvements have been incorporated into the process and 7,200 tonnes per month of copper production was achieved in 1983, proving that continuous process was much more economical than conventional process. It is now possible to design and operate the continuous process in wide range of capacity. This paper will review the process and describe the progress of the process in these 10 years. 311

Jan 1, 1985

By D. Raghavan

In recent years, the environmental issues related to the landfill shortage received considerable importance. Many polymeric solid wastes have high resistivity to chemical and biological degradation, and options are sought by which these wastes can be recycled and reused, or reduced in volume. The present study investigated the biodegradation of polyethylene by Aspergillus niger, and biodesulfurization of rubber by pure and mixed cultures of Thiobacillus thiooxidans and Thiobacillus ferrooxidans. The fungus, A. niger, was found to metabolize portions of polyethylene. Quantitative calorimetric measurements revealed that the amorphocity of the sample decreased during biodegradation. Removal of sulfur from synthetic rubber samples containing 2 to 15% sulfur, was studied in shake flask experiments and the associated oxygen consumption was studied in Warburg respirometers. The mixed bacterial cultures were more effective in the desulfurization of rubber samples than the pure cultures of T. thiooxidans and T. ferrooxidans. The data obtained in these studies may have far reaching consequence for the development of new effective processes regarding the remediation and management of discarded polymeric packaging wastes and car tire rubber materials.

Jan 1, 1993

By F. F. Lins

There is a large use of mercury in Brazil by the gold miners in the so called "garimpos" (non registered mining operations), where it is usual to recover the gold contained in the gravity concentrates by amalgamation, which is highly deleterious to environment if not conducted properly. Unfortunately, this is a common practice there. After presenting in brief the modus operandi generally practiced in the garimpos and the environmental problems, this work reviews some of the research conducted in CETEM according to two approaches: (i) replace amalgamation by other processes and (ii) develop technology to treat mercury-contaminated soils and effluents. Conventional processes like froth flotation, to recover gold from gravity concentrates, and centrifuges were considered. Also as alternatives to amalgamation, innovative process like the recovery of gold by coal-oil agglomerates and a technology that is currently under development in our laboratory, called gold-paraffin process, are described in brief, some results presented and their potential use assessed. To reclaim sites already polluted a technology was developed to float mercury selectively from contaminated soils. The potential use of centrifuges to pre-concentrate the mercury is also discussed. The scope for applying the last techniques is to concentrate the pollutants in a small volume of mass which would be suitable for recycling or isolation from the environment. A prospective technology to treat contaminated soils, or mercury concentrates, is the immobilization of mercury by adding inorganics. Concerning the ionic mercury which may be present in effluents, precipitation of the ions and flotation of the precipitates are being studied.

Jan 1, 1994

By Suguru Kohno, Yoshihiro Momose, Masakazu Honma, Tokirou Kamosawa

Copper metal surfaces have been examined by an extremely sensitive surface analysis technique called temperature programmed photoelectron emission (TPPE). The surfaces were ultrasonically cleaned and subsequently abraded by a screw in organic solvents and water. The TPPE apparatus is composed of a Geiger counter with Q gas (He+ iso-C4H10). The curve of photoelectron emission (PE) intensity vs. wavelength from 300 to 170 nm, termed PE spectrum, was repeatedly measured at different temperatures in the temperature- increase process from 25 to 350°C. The number of emitted electrons in a PE spectrum (PE total count) increased, reached a maximum at-250°C, and decreased with increasing temperature. With the surfaces cleaned alone in the liquids the maximum PE total count decreased in the order C3H70H > (CH3) 2CHOH > C2HpH > CHPH > H2O. With the mechanically abraded surfaces in the liquids the maximum PE total count changed as a function of the abrasion period and the maximum tended to appear at higher temperature with increasing abrasion period; the maximum value at 10-min abrasion decreased in the order H2O > CHpH > C2HPH > (CH3) 2CHOH > n-C3HpH. It was suggested that the TPPE behavior can be related to the acid-base interaction between the alcohols and the abraded metal surfaces and the presence of a contaminant over layer on the surface. From the XPS analysis of the 01 s spectra it was suggested that the chemical change of the adsorbed oxygen to oxide oxygen with temperature plays a substantial role in the appearance of the maximum PE total count.

Jan 1, 2000

By Kafui Nyavor

Acid mine drainage (AMD) is presently the biggest single environmental problem facing the mining industry. New and expanding metal mines in most parts of the world have to demonstrate their ability to contain this problem to obtain operating permits. Conventional methods of controlling acid mine drainage have primarily been limited to collecting the drainage and neutralizing with alkaline materials which do not provide a permanent solution to the AMD problem. Since acid mine drainage results from the oxidation of sulfides in the presence of oxygen, water and iron-oxidizing bacteria, controlling any of these three factors contributing to pyrite oxidation provides a potential at-source remedy for reducing or preventing acid mine drainage formation. Physical properties such as hydrophobicity also play an important role in the attachment of bacteria, adsorption of oxygen, water, and other ions that subsequently lead to the oxidation of pyrite. In this communication, the suppression of pyrite oxidation by treatment with fatty acid amines (FAA) was investigated. The FAA treated pyrite samples were tested at various conditions of temperature and pressure. At an elevated oxygen pressure of 500 psi and a temperature of 600 C, less than 0.2% oxidation was obtained for the FAA treated pyrite samples, while over 1.2% oxidation was obtained for the untreated samples in 10 hours of oxidation time. Accelerated column oxidation tests at ambient condition showed that FAA mated samples reduced pyrite oxidation by at least 75% in 81 days.

Jan 1, 1994

By E. Ozberk

The copper and nickel smelting industries are important contributors to the technical and economic well-being of Canada while some of the smelters are among the largest sources of sulphur dioxide emissions in Canada. A review of the operations in six smelters - Falconbridge Limited, Falconbridge, Ontario; Hudson Bay Mining and Smelting Co. Limited, Flin Flon, Manitoba; Inco Limited, Copper Cliff, Ontario and Thompson, Manitoba; Noranda Mines Limited, Horne Division, Noranda, Quebec and Gaspe Mines Division, Murdochville, Quebec - have shown that about 80% of the total sulphur input to these smelters was emitted to the atmosphere in 1980. A simultaneous review of the existing and emerging technologies which can directly or indirectly reduce the sulphur dioxide emissions indicated that it is possible to reduce the emissions to below 20% of the sulphur input to these smelters. This can be achieved by varying degrees of modifications to the smelting operations and installing sulphur fixation facilities at significant costs which may increase the metal production costs. This would consequently make the competitiveness of the Canadian copper and nickel producers more difficult in the already tough world metals market.

Jan 1, 1983

By Magnus Ek

After the installation of three new converters as part of the recent expansion of the Rönnskär smelter completed in 2000 work continues to further improve the converter operation. The converter upgrade led to an increase in blister copper taps from 150 tons per batch to more than 300 tons. The total cathode copper production increased from 130,000 tons in 1999 to 230,000 tons in 2001, the first year in full production. In recent years focus has been to improve operating practise, maximize the blowing time, extend the converter campaigns hence to reduce the specific brick consumption and improve the converter slag composition.

Jan 1, 2005

By Sacha Neven

Submerged lance technologies combine high intensity processing characterized by rapid mixing and reaction rates using a simple reactor design. The Isasmelt technology uses a central submerged lance to inject oxygen-enriched air and fuel into a bath thus creating large gas bubbles and intensive turbulence and splash. The lance is equipped with swirlers to increase gas velocity and heat transfer. This enables the formation of a frozen slag layer on the lance which protects it from the aggressive environment. Water models as well as high temperature reactors were used to validate the Davidson-Schiiler model on bubbling. Frequencies and pressure amplitudes were measured in a wide range of gas flow rates: from m3/sec using a water model to more than 30 m3/sec in an industrial process. Agreement with the model was satisfactory. The experiments however also clearly showed that cross-flow and bubble wake induce slightly higher frequencies. No influence of the use of swirlers on the bubbling frequency was observed in the water models.

Jan 1, 2002

By Arsenio Enriquez, Adrian Deneys

"Rio Tinto through its subsidiary Kennecott Utah Copper Corporation (KUC) and Praxair have implemented the CoJet® gas injection system for copper anode refining. The system provides the capability to melt on average 60 to 70 tons of scrap copper per heat (with acceptable NOx emissions). The system has demonstrated the potential for tuyere-less sulfur and oxygen removal using coherent jet technology.This paper describes the process concept, system development, laboratory testing, implementation, current operation and ongoing developments."

Jan 1, 2009

By Jinrong (Patrick) Mang

Three of the most challenging problems in phosphate beneficiation are discussed: flotation efficiency, resource conservation and environmental impact. Some new flotation machines offer the opportunity of reducing power and reagent consumption significantly, while increasing specific capacity many fold. Efficiency might also be improved dramatically by replacing the "double float" process with a single-collector scheme. Model based software control is a powerful tool for improving overall plant efficiency. Recovery of phosphate values from the phosphatic clays could extend phosphorus reserve life significantly. phosphate recovery from the slimes might be achieved by sizing-flotation, selective flocculation and bioleaching. Reducing the volume of phosphatic clays produced is another key stop to minimizing phoephate logs. Such a reduction may be realized by floating at finer cut size. Although an ideal' dolomite separation process is yet to be developed, a cationic flotation process may prove to 'be economically feasible. Loss of phosphate in the desliming stage is the major problem with most of the flotation schemes for removing dolomite.

Jan 1, 1995

By Jana Dobrovska

Solidification and cooling of a continuously cast slab and simultaneous heating of a mould is a very complicated problem of transient heat and mass transfer. Nowadays, the solving of such a problem is impossible without numerical models of the temperature field not only of the slab itself, while it is being processed through the whole concasting machine (Caster), but of the mould as well. Two original numerical models have been developed and used in the investigation of a continuously cast steel slab. The first (one of two) 3D model of the temperature field of a concasting is capable of simulating the temperature field of a caster. Experimental research and data acquisition have to be conducted simultaneously with the numerical computation-not only to confront it with the actual numerical model, but also to make it more accurate throughout the process. After computation, it is possible to obtain the temperatures al each node of the network, and at each time of the process. The utilization of the numerical model of solidification and cooling of a concasting plays an indispensable role in practice. The potential change of technology-on the basis of computation-is constantly guided by the effort to optimize, i.e. to maximize the quality of the process. The user can therefore choose any appropriate longitudinal or cross-section of a slab and display or print the temperature field in a 3D or 20 graph whenever necessary. The second numerical model of dendritic segregation of elements assesses critical points of slabs from the viewpoint of their increased susceptibility to crack and fissure. In order to apply this model, it is necessary to analyze the heterogeneity of samples of the constituent elements (Mn, Si and others) and impurities (P, S and others) in characteristic places of the solidifying slab. The numerical model, based on measurement results obtained by an electron micro-probe, generates distribution curves showing the dendritic segregation of the analyzed element, together with the distribution coefficients of the elements between the liquid and solid states. The combination of both models enables the prediction of cracks and fissures in critical points of the continuously cast carbon-steel slab. Both models had been applied in the industrial investigation of a cast low-carbon-steel slab.

Jan 1, 2003

By Chao Lian, Hongxu Li, Hao Bai, Wei Wei

"Application of high-emissivity coating on inner walls in industrial furnaces increases the furnace thermal efficiency. The coating with high emissivity strengthens radiation heat transfer in the furnace, however, according to Wien's displacement law and Planck's radiation law, under heating temperature, the wavelengths of the radiation transfer are mostly between 1-5 µm, implying that increasing emissivity of the coating in near infrared band is more effective for higher thermal efficiency. In this paper, a new CuO-ZnO-based coating material sintered at 1600K was developed. The emissivity of the samples were measured and the result shows that, in near-infrared band, the emissivity of the sample reaches 0.98 at 773K with 13at.% of CuO doped in ZnO. In addition, the effects of CuO doping and use temperature on emissivity were also discussed. Furthermore, crystallization behaviors of ZnO-CuO sintering were investigated by DTA,XRD and SEM-EDS etc., which offered information for possible optimal design of the material.1. IntroductionIndustrial furnaces are widely used in various industrial heating. For example, the metal smelting furnace, ore sintering furnace in metallurgical industry; the distillation furnace, cracking furnace in petroleum industry etc,. The research on efficient energy saving technology has important significance. High emissivity coatings are widely used in many high temperature applications to effectively transfer the heat by radiation [ 1]. The theoretical calculation and experimental studies have shown that, coated high emissivity coating in the heating surface is an effective method to enlarge the infrared radiation power [2].At present, the infrared high emissivity coating has been widely used in China, and have been achieved remarkable energy saving effect. According to Wien' s displacement law and Planck' slaw, most energy of the black body at high temperature is radiated in the wavelength range of l-5µm; however it happens that many materials have the low emissivity within this range. Thus, it is important to improve the near-infrared band emissivity of materials [3]."

Jan 1, 2013

By P. D. Lee

The effect of strontium on porosity formation in aluminum-silicon alloys is not well understood and there is no consensus upon the cause of the effects observed. This paper describes a series of experiments where the effect of adding strontium on pore formation was observed directly with combination of a traditional temperature gradient stage and real time micro-focus radiography. These in situ observations provide a new insight into the effect of strontium on the nucleation and growth kinetics of porosity. The addition of strontium was found to have a minor effect on the growth of the pores in the mushy zone. However, strontium appeared to alter the nucleation and stability of hydrogen bubbles within the melt. The interaction of strontium with titanium-boride grain refiners produced an even stronger change in the nucleation and stability of the bubbles formed.

Jan 1, 2002

By Dmitri Nassyrov, In-ho Jung

"All relevant thermodynamic and phase diagram data in the CaO-Fe10-CaF2 system were critically reviewed. One set of model parameters describing the Gibbs energy of all phases has been obtained as a result of critical evaluation of the available data and optimization of the model parameters. The Modified Quasichemical Model was used to describe the interactions in the liquid phase. All calculations were performed using the FactSage thermochemical software.IntroductionSlags contaimng CaF2 are of significant interest to the steelmaking community. Notable examples of slags containing significant amounts of CaF2 include Electro-slag Remelting (ESR) slags [1] and mould flux for continuous casting [2]. The role of these slags is, among other things, to refine steel by absorbing inclusions and dissolved impurities. During slag-steel interaction, some iron from the steel will inevitably get oxidized and form iron oxides which will dissolve into the slag. With this in mind, it is important to understand the interaction between CaF2 and Fe,0 for accurate prediction of slag composition and process optimization. A thermodynamic optimization of the CaO-FetO-CaF2 was thus undertaken."

Jan 1, 2013