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By Ioannis Paspaliaris, Dimitrios I. Gerogiorgis, Dimitrios Panias

"Red mud fiberization is a process with remarkable potential, alleviating environmental pressure by transforming an aluminum by-product into mineral wool, thus to various marketable products. A promising mineral wool process is molten slag fiberization via an impinging air jet, which avoids mechanical wear and rotating parts. The molten slag which remains after pig iron casting flows out of a heated ladle orifice at a high temperature (1600 °C) and adjustable flowrate, and forms a free-falling vertical jet which visibly radiates its excessive heat: at a given distance, a high-velocity impinging air jet meets the vertical melt jet perpendicularly (or at an angle), inducing intensive droplet generation, subsequent fiber elongation, collection and processing.This paper focuses on high-fidelity CFD modeling of the molten jet flow under external cooling: the model encompasses all physicochemical phenomena (melt laminar flow, radiative cooling) and considers several temperature-dependent slag transport properties in order to understand which operational degrees of freedom (manipulated variables) are useful to process optimization."

Jan 1, 2012

By Bernd Kos

The management of waste materials in the aluminum industry is as important as in other basic industries. Due to the high value of the-by products of the melting process and their toxic properties we took the challenge to develop a process technology to reduce the environmental impact and to help industry to get a better yield of their by products/raw materials. In melting operations metal losses due to oxidation are nearly unavoidable, the amount of such losses, however, can be controlled. Aluminum dross actually is a by product and any shop would like to get rid of it in the most economic way. This by product still contains up to 70% valuable metal! In the present work we describe possibilities to separate metal and residues for further processing. Recycling of metal concentrates, selling of dross and dumping of the residues have been the typical solutions up to now. But there are technologies available which are designed to reduce the waste to a minimum or even avoid it altogether. Such alternatives are processing of the dross into materials which can be reused in other industrial processes in order to avoid any dumping. This can be done by separating the metal and the residues by centrifuging and further use of the residues in the chemical or refractory industry. ECOCENT means economical and ecological recovery of aluminum by centrifuging of hot dross. This process, developed by FOCON Austria, is based on the idea of treating the hot dross as quick as possible in a single operation to avoid exothermic losses, intermediate storage and unnecessary handling as well as to save energy. In the ECOCENT process the hot dross is fed without any fluxing salt additions into a converter where the relevant parameters for separation, like temperature and viscosity, will be adjusted. Further big lumps of dross are ground into smaller pieces in order to improve the later separation of the metal. After homogenizing and adjusting the temperature, the hot dross is poured as quickly as possible into a centrifuge. In the ladle or alternatively the mould of the centrifuge the centrifugal forces are used for the separation of aluminum from aluminum oxide, the major constituents of dross. The separated pure metal can either be discharged liquid or as solidified aluminum ring. The design of the device for the production of liquid or solid metal is almost identical. As soon as the centrifuging is finished the liquid aluminum can be poured back into the furnace or can be used for ingot pouring. After the pouring of the metal the "dry" residues are removed just by turning the ladle. Alternatively the aluminum solidifies in the mould and is discharged as a compact ring. The separation of the residues from the aluminum ring is automatic. Due to the batchwise operation the composition of the metal is the same as in the skimmed furnace of origin. The complete treatment cycle needs about 40 minutes. The recovery rate of aluminum is better than 90% of pure metal. This technology is highly flexible by its nature and can easily accomodate various operational requirements. The consumption of energy is more than 50% lower compared to conventional dross processing as the ECOCENT process is using the inherent energy of the hot dross. These extremely good results are not dependent on the aluminum content of the dross even from very dry dross most of the metal can be recovered. The main advantages compared to conventional dross processing are the high recovery rate, the known analysis of the metal and the immediate reuse of the recovered aluminum. The high recovery rate and the pure metal result in a short amortization period. The compact ECOCENT unit needs a minimum of space since extensive handling can be avoided. The electronically controlled process needs no cooling water and is simple, safe and environmentally sound. The residues are free of fluxing salts, their content of metallic aluminum is low and the environmental problems are thus greatly reduced.

Jan 1, 1995

By G. Cifuentes

It is known that the cathode purity and the electrolyte treatment are affected by the solids present in the electrolyte. Anodic slimes properties (e.g., chemical composition, crystalline composition, sedimentation) were studied in copper electrorefining. These properties were modified through anodic composition and current density. In this investigation, we have worked with anode material from the Ventana Smelting, Hernan Videla Lira Smelting (ex - Paipote) of ENAMI (National Mining Company) and El Teniente Smelting of CODELCO-Chile (National Corporation of Copper of Chile). The characterization of the anodic slimes was done as a function of current density and anodic composition.

Jan 1, 1999

By Theo Lehner

Nasty, according to the Collins Dictionary, comprises the adjectives: bad, critical, dangerous, dirty, odious, serious, severe, sickening, unpleasant etc. From this we may at first conclude that each individual smelter relying on its own specific business surrounding would have a special definition of its nasties. But common product standards and common metallurgy makes us experience common nasties. To get an idea of possible problem elements we start with the demands on the products: [ ]

Jan 1, 1994

By E. M. Alcântara

This paper describes some aspects about the relationship between copper electrorefining addition reagents and the hydrogen in the cathode. The conditions of electrorefining were studied by factorial design methods. The advantages of this technique are reduction in the number of tests, well organized experiments; improvement in productivity and reliability of results. The dosage of the two main addition agents, glue and thiourea, were varied simultaneously and compared with the hydrogen content in the cathode. The influence of these factors, as well their interactions were analyzed by statistical methods denominated ANOVA (Analysis of Variance). The increase of thiourea quantities, within of levels studied, influenced significantly at 95% confidence in the hydrogen content in copper cathode.

Jan 1, 1999

By Admire Chaendera

A gas jet was blown through submerged nozzles to stir the bath in the presence and absence of slag. Mixing and mass transfer rates were then studied. Water and kerosene (10% by volume) were used to simulate the metal and slag phases respectively in the cold model. The mixing time (Tmix), defined at 99.66% bath homogeneity level, increased with bath height and decreased with an increase in the gas injection rate. Its value in the model vessel was related to gas flow rate (Q), bath weight (W), and bath height (H) by, Tmix = 4.39Q-0.73W0.24H1.12. Inclusion of the slag phase increased Tmix by about 16% and the mass transfer parameter, [(Reloc,r)0.25(Ret)0.32], values by about 32%. Mass transfer rates were higher near the bath surface and in the gas-liquid plume region. They increased with gas flow rate but decreased with an increase in bath height. The relationship, K Q0.08, showing derived mass transfer coefficient (K) dependence on the gas injection rate (Q) was established. The proportionality constant in the equation varied with gas flow rate and sample location.

Jan 1, 2006

By Sharon K. Young

What might an ideal leach-to-cathode/product system look like in the next century? The paper looks at the synergies of the 60's and 70's that led to the highly effective copper leach SX-EW system of the 90's. Standing in the year 2020 focuses on what breakthrough technologies might make possible a next generation leach/extraction/metal recovery system. Many of the pieces of such a technology have been developed, even piloted: in situ leaching, enhanced bioleaching, heap leaching of fine particles, resin in pulp, ion exchange, alternate anode reaction electrowinning, novel anode coatings. With nearly non-existent research on the part of individual large companies, the greatest challenge may not be inventing the technologies but rather inventing an industry "will to create."

Jan 1, 1999

By Zbigniew Smieszek, Ryszard Chamer, Ryszard Prajsnar, Zygmunt Kurek

"Lead-containing wastes processed at the IMN’s Division in Legnica originate mainly from dry and wet dedusting installations of the technological lines for copper production. These are lead dusts and lead-zinc dusts characterised by the specific properties resulting from the chemical composition of the Polish copper concentrates. Besides lead, they contain many accompanying metals and impurities such as zinc, copper, sulfur, chlorine, potassium, sodium, and also bituminous substances. Processing of lead-containing dusts is conducted in the installations of rotary-rocking furnaces heated with gas-oxygen burners fitted with auxiliary systems for cleaning process gases and refining re-circulating dusts. The processing technology utilizes innovative process and technical solutions enabling disposal of lead-containing wastes from copper metallurgy and from non-ferrous metals industry according to the BAT recommendations and to the guidelines specified in integrated permission. In this paper, the main technological aspects of processing lead-containing dusts at the IMN’s Division in Legnica have been presented.IntroductionCrude lead is obtained in Polish lead metallurgy from various primary and secondary materials, such as Zn-Pb concentrates, lead-bearing dusts of copper metallurgy and battery scrap. In zinc smelter Miasteczko Slaskie S.A. crude lead is produced from sulfide and oxide Pb-Zn concentrates in ISP process. Orzel Bialy S.A. and Baterpol Ltd. produce crude lead in short rotary furnaces in the process of smelting products of mechanical battery scrap separation– desulfurised or not desulfurised paste and metallic fraction. KGHM Polska Miedz S.A. and IMN Divison in Legnica produce crude lead in rotary furnaces in the process of smelting of polymetallic dusts and slimes from copper production processes."

Jan 1, 2008

By Roald Ysteboe, Finn Olesen

"Elkem has developed a process that utilizes SPL as a raw material for pig iron production. This process will be demonstrated in industrial scale during 2008 and 2009. The process developed produce iron, and the reduction material used, is the carbon present in the SPL. The iron source could be either virgin iron ore or waste/recycled material from the steel industry. The SPLrefractory and bath material is dissolved in the slag produced. The slag is designed so that any leaching of environmentally dangerous elements is minimized. This process can in addition to SPL, consume other types of waste derived from the primary production of aluminium. Elkem intends to supply this demo project with SPL and other waste products from external sources, domestic as well as international ones.IntroductionSpent Pot Lining (SPL) is generated when an electrolytic cell for producing aluminium is taken out of service and the refractory and carbon lining is removed from the steel potshell.The yearly generation of SPL world wide is exceeding 500 000 tonnes. The major amount of this quantity is stockpiled or land filled, unprocessed.SPL contain large amount of water soluble fluorides and some amount of cyanides and is classified as hazardous waste in most countries."

Jan 1, 2008

By R. M. Moon

Neutron scattering has played a crucial role in advancing our understanding of rare-earth materials. It has provided a detailed description of the rich array of exotic magnetic structures; it has confirmed the accuracy of theoretical wave functions for the 4f electrons; and it has provided fundamental data on the collective magnetic excitations in these materials. The fundamental property of the neutron which has been exploited in this work is the magnetic interaction which exists between the magnetic moment of the neutron and atomic magnetic moments on individual rare-earth atoms. This interaction produces scattering of neutrons in a manner closely analogous to the scattering of X rays by atomic charge distributions. In a material exhibiting long-range magnetic order, Bragg diffraction peaks will appear at scattering angles determined by the periodicity of the magnetic structure. The Bragg intensities are determined by the magnitude and relative directions of the atomic moments. The rare-earth metals and alloys are characterized by sinusoidal modulation of magnetic moment components which can be combined in various ways to produce a variety of magnetic structures. The periodicity of these modulations is frequently not related simply to the underlying periodicity of the chemical structure. The major features of these structures are explained by the combined, and sometimes competing, exchange and crystal-field interactions. At a more fundamental level, neutron diffraction also gives information on the spatial distribution of a magnetic moment in a rare-earth atom. This moment comes from the 4f electron shell, and accurate measurements of the neutron scattering amplitudes have been used to check the accuracy of atomic wave function calculations for the 4f electrons. It was found that relativistic Dirac-Fock calculations are in excellent agreement with the experimental results. Collective excitations of ordered magnetic systems are described in terms of spin waves, which are sinusoidal modulations in space and time of the direction of the ordered moments. Inelastic neutron scattering is used to measure the energy and wave length of these collective excitations. Analysis of these data gives direct information on the interatomic interactions responsible for the magnetib properties of these materials.

Jan 1, 1992

By F. Nava-Alonso, O. Alonso-González, A. Uribe-Salas, R. Pérez-Garibay

"Cyanidation is the most used method to recover gold and silver from their ores. In this process, other metals besides gold and silver may sometimes dissolve and interfere with the efficiency of extraction. Copper is one of those metals, reaching concentrations as high as 1000 mg/L in some cyanidation plants, making difficult the extraction and purification processes, and increasing the operating costs.This preliminary work was intended to study the feasibility of using amines to form a precipitate and to eliminate copper from a synthetic solution containing high copper and cyanide concentrations, as is the case of some cyanidation effluents. The solid formed is removed from the solution using conventional filtration techniques. Seven amines were evaluated at different pH values and amine additions. Up to 90% of copper present may be removed at the natural pH of the effluent (alkaline). The remaining copper would permit to recycle the solution back to the cyanidation process. IntroductionCopper is generally considered the most problematic metal in gold leaching due to the rapid formation of copper cyanide complexes when some readily-soluble minerals are processed (e.g., azurite, malaquite, cuprite, chalcocite and bornite). The copper solubilization as cuprous cyanide complexes leads to a significant economic penalty in terms of excessive cyanide consumption and high cost for cyanide elimination. When activated carbon is used to recover gold and silver, the copper-cyanide complexes decrease the efficiency of the process because of the competition of the cuprocyanides with the aurocyanide for the adsorptive sites on the activated carbon (Rees and Deventer, 1999).Several techniques have been developed to attempt to overcome the problems caused by the copper presence in cyanidation solutions, notably: acidification-volatilization-regeneration (AVR), ion exchange-electrolysis or solvent extraction-electrowinning (Lu et al., 2002). In this work the use of some amines is proposed to remove the copper-cyanide complexes by precipitation of a copper-cyanide-amine solid. The process was evaluated for different amine additions and pH values, using copper-cyanide synthetic solutions of composition similar to that presented by some cyanidation plants with high copper."

Jan 1, 2008

By Guo Xueyi

The nonferrous metal industry is facing the resource depletion, energy crisis and environmental deterioration. The resource recycling is a correct way to promote the nonferrous metal industry development towards sustainable. To realize the resource recycling, the technical support is most important. In this paper, the techniques barrier for nonferrous metal resource recycling are summarized, the fundamental on resource recycling of nonferrous metals are proposed.

Jan 1, 2006

By A. V. Tarasov

The natural resources of lead and zinc are primarily constituted by polymetallic and lead-zinc ores. Beneficiation of these types of ores to produce standard nonmetallic concentrates inevitably results in an increase in the loss of base and precious metals with tailings. An improvement in the grades of lead and zinc concentrates can be achieved by re-cleaner flotation, but it results in production of intermediate products (middlings) to which substantial amounts of lead, zinc, copper and precious metals report. Without an appropriate technology for treating such intermediate products, the recoveries of valuable constituents from lead-zinc ores would remain unsatisfactory. A process has been developed in the Gintsvetmet Institute for processing of polymetallic intermediate products produced at the ore beneficiation plants. This process is based on electrothermic smelting to produce lead bullion containing precious metals, commercial-grade copper-lead matte and high-zinc slags (up to 15-20% Zn) from which zinc can be extracted by slag-fuming or Waelz process. Tests have indicated that the recovery of lead from intermediate products into lead bullion and matte is about 83-85% and 13-14% respectively (the total recovery is 97-98%), while copper recovery into the matte and zinc recovery into the slag is 90-92% and 95-96% respectively. Precious metals (about 96-97%) report into the lead bullion.

Jan 1, 2006

By C. M. Acuña

Copper losses in slags are of great concern, specially in smelting and slag cleaning processes. It is widely accepted that the suspension of metallic copper and matte droplets is strongly affected by the viscosity of the slag. The Chuquicamata Division of Codelco- Chile produces concentrates high in zinc, an element which reports mainly to the slag phase. The ZnO may affect the viscosity and therefore the copper losses. This work aimed to investigate the effect of lime to control the viscosity of slags, and in turn to control the copper losses. By using the experimental viscosity data and the Stoke's law, the settling rate of matte prills in various slags was estimated. The results indicate the possibility of increasing the recovery of copper and/or decrease the process time.

Jan 1, 1999

By Ross McClelland

This paper provides a technical overview on the installation and commissioning of the Ausmelt lead smelting, slag reduction and slag cleaning operations at the HZL Chanderiya site in India. It also discusses theoretical concepts behind the process practices currently in place at HZL.

Jan 1, 2006

By Henry Salomon-De-Friedberg

Quebrada Blanca has had to overcome numerous challenges in achieving design throughput. The paper reviews how actual practice has evolved from the original design. The major challenges that were encountered from heap leaching to solvent extraction, the tankfarm and through to electro winning are discussed. The eventual solutions to some of the key issues are presented.

Jan 1, 1999

By John L. Uhrie

Oxide stockpile leaching operations can realize increased copper recovery and decreased acid consumption from in-situ generated acid resulting from the oxidation of intentionally introduced pyrite recovered from mill tailings or other sources. While all oxide leach ores can benefit from pyrite addition, low acid consuming ores can show remarkably increased recovery and net acid generation; however, more highly acid consuming ores will show benefit more exclusively through increased copper recovery. Additional work shows that the value of highly acid consuming ores can be optimized by balancing copper recovery against acid consumption.

Jan 1, 1999

By Z. S. Wronski

In rapidly solidified Fe-Nd-B permanent magnet alloys, the content and distribution of Nd-rich intermetallic and Fe-phases determine coercivity Hc and remanence Br. Consequently, microstructure plays a crucial role in deter- mining the (BH) max-product of permanent magnets fabricated from these alloys. A study has been initiated to investigate changes in microstructure and the effects on magnetic properties as the material is processed from arc-melted ingot to melt-spun flakes and finally to a product consolidated by hot-forming. Anisotropic magnetization behaviour has been observed in rapidly solidified flakes after low-temperature annealing.

Jan 1, 1989

By C. Anderson

Most applications of copper metallurgy are geared towards primary production. However, as recycling of materials is a growing industry, one future facility will rely on copper metallurgy as a means of processing precious metals. This paper will discuss the derivation of the proposed copper pyrometallurgical and electrometallurgical unit operations to be utilized in industrial recycling of secondary precious metals.

Jan 1, 1999

By B. J. Beaudry

The effect of various levels of purity of the rare earth fluorides and the calcium reductant used to prepare rare earth metals were determined. Metals which have low melting points such as La, Ce, Pr and Nd are not purified by distillation or sublimation. Impurities in the reactants remain as contaminants in these metals. Gd, Tb, Y and Lu which have slightly higher vapor pressures at their melting points than the first four metals are usually distilled to remove the Ta or W impurity introduced by the crucible and are purified slightly with respect to 0 and N by distillation. Rare earth metals that have high vapor pressures such as Sc, Dy, Ho and Er can be purified with respect to 0, N, C, as well as Ta or W by sublimation. The most volatile rare earth metals Sm, Eu, Tm and Yb are readily purified by sublimation and are usually prepared by a reduction-distillation process directly from the oxide. The importance of each step of the processes in determining the final purity of the individual rare earth metals is discussed.

Jan 1, 1989