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By A. E. Isaacson

Bureau of Mines researchers developed and tested equipment to measure corrosion rates on a commercial-scale mill as an aid in predicting the effect of corrosion on minerals and how this effect relates to downstream processing. Bench-scale experiments were designed for duplicating ore grinding conditions closely enough that realistic rate determinations can be made in laboratory tests. Rates measured in a laboratory system compared favorably with those measured in the field. Cast steel was found to have corrosion rates in a copper mill and laboratory test cell of 22 and 21 mpy, respectively. Corrosion was found to account for less than 5% of the total grinding media wear in the operations studied.

Jan 1, 1987

By Dian Adisty, Leiv Kolbeinsen, Eli Ringdalen

In Si and FeSi production, the main Si source is SiO2, in the form of quartz. Reactions with SiO2 generate SiO-gas that further reacts with SiC to Si. During heating, quartz will transform to other SiO2 modifications with cristobalite as the stable high temperature phase. Transformation to cristobalite has been investigated and shown to be a slow process where the rate varies between the investigated quartz types. The effect of quartz versus cristobalite as SiO2 source has been studied for reaction (1) 2SiO2 + SiC = 3SiO + CO, by heating of pellets with SiO2 + SiC in Ar-gas. The reaction was faster with cristobalite than with quartz. Initial experiments indicates that this is the case only in Ar and not in CO-atmosphere The higher specific surface area of cristobalite is believed to contribute to the higher rate. The industrial consequences of the observed difference between quartz types are discussed.

Jan 1, 2014

By G. Upadhya

Considerable success has been achieved recently in modeling microstructural evolution during solidification of castings bthrough the coupling of macroscopic heat transfer with microscopic solidification kinetics models. However, a complete model for simulation of solidification in complex shaped castings involves: (i) the description of fluid flow, during and after mold filling, coupled with (ii) heat transfer to the mold and surroundings by use of a macro model, followed by (iii) a description of subsequent solidification of liquid metal by use of a micro model for solidification of the alloy under consideration. This paper describes the coupling of solidification kinetics model to a 3D, transient, fully coupled fluid flow and heat transfer model. Coupling between the macremicro models is achieved by using the latent heat method. Micro models for the eutectics of gray, white and ductile iron are discussed. This coupled code has been used for predicting the thermal history and microstructural data for shaped castings. Various applications of the model, including prediction of shrinkage defects, grain density contours, and graylwhite transition region in the casting, are presented for a relatively complex casting geometry.

Jan 1, 1992

By C. E. Hunt

Since the turn of the century, copper-nickel sulphide ores have been processed at the Sudbury, Ontario operations of INCO Limited, currently the largest integrated mining, milling, smelting and refining complex in the free world. Through the years operational, ecomomic, social and legislative changes have dictated the need for research and development directed at mitigating the impact of existing operations on the surrounding natural environment and also the reclamation of areas affected by earlier mining activities. Approximately one hundred years of mining history and the current annual processing of some 12 million tons of ore presents significant challenges with respect to waste disposal, liquid effluent treatment and land reclamation, particularly in light of rapidly evolving environmental regulations' and controls within the Province of Ontario.

Jan 1, 1992

By Animesh Jha, Chris Dometakis

"Without the use of a flux, only a poor dispersion of ceramic phase can be achieved. A molten-flux-assisted ceramic phase dispersion technique for producing aluminium alloy metalmatrix composites has been developed. In this paper, we report the physical chemistry for the dispersion of TiB2 in molten aluminium. In particular, aspects of the interfacial energy and the thermodynamics of the dispersion reactions are briefly discussed for enhancing the volume of dispersion phase in the molten metal and for controlling their morphology. This investigation also addresses the role of molten flux in the fabrication of AI-alloy mmc using a casting technique. The morphological aspects of the dispersion are explained on the basis of the classical theory· of nucleation.IntroductionMetal matrix composites (MMCs), have long been recognised as an important class of material due to their greater wear resistance, specific stiffness and temperature capability when compared to conventional monolithic alloys. Particulate reinforced composites produced by melt casting techniques have been amongst the first MMCs to achieve commercial market viability. The advent of melt mixing techniques such as the Duralcan™ process have enabled low cost, easily fabricated composites based on the AI-SiC and AIAlz0 3 systems to be produced. In this process, uncoated ceramic particles with diameters 10ltm and larger, are incorporated into conventional monolithic alloys with reinforcement levels up to 25 volume percent. The AI-7Si-SiC metal-matrix composites have good wear resistance, high strength, low density and high thermal conductivity. The combination of these physical and mechanical properties has become a major attraction for the fabrication of light-alloy composite disc rotor brakes for the automotive sector2. However, in silicon-free alloys, SiC is thermodynamically unstable above the composite melting point and is extensively attacked by the melt to form aluminium carbide3 :"

Jan 1, 1996

By K. Adham

"Fluidized beds are utilized in a wide range of high-temperature applications throughout the metals and materials industry. Their main advantage is the fast and uniform heat and mass transfer between the hot combustion gases and the particulate solid feed. A further benefit can be the lowering of the processing plant's energy consumption, through heat recovery from the fluid bed processes used for solids heating. Here, the enhanced energy efficiency of fluidized systems is investigated and the modeling results are discussed for three configurations: the flash tube, the single bubbling bed and the multi-stage fluid bed. Key thermal design aspects of each system are identified based on results from process simulations, in order to benchmark their main operating features and overall energy efficiency. Suitability and applicability of each configuration is also discussed based on a number of process and material property considerations.IntroductionCombustion based heating of particulate solids is commonly done using three different types of fluidized beds. The flash tube (FT) is similar to a hot pneumatic transport system. The single-stage fluidized bed (FB) typically uses in-bed combustion. The multi-stage fluidized bed (MSFB) can have two or more stages stacked into a tower.Flash tube (FT) suspends the incoming solid charge in a high-velocity stream of hot combustion gases. To maintain the solids suspension in the FT, two parameters are required: high velocity for elutriation of the particles and adequate solid-to-gas ratio for avoiding high pressure drops and solids drop-out [l].The fluid bed (FB) works at much lower velocities than the flash tube. Therefore, most of the solids are not conveyed in the gas stream, but are only suspended in a liquid-like manner. At minimum fluidization velocity (Umr), the gas flow exerts just enough force on the solids to keep them suspended in place [2].Multi-stage fluid bed (MSFB) heats up the solids as they are transferred from an upper bed level to a lower one, counter-current to the rising flow of hot gases generated at the lowest stage. As the temperature and volumetric flow of the gases decrease from bottom to the top stage, smaller bed diameters can be used in the energy recovery stages [3]."

Jan 1, 2014

By Albert F. S. Seboukens

A 5;6 MVA pyrometallurgical demonstration-scale pilot plant was commissioned at Mintek, South Africa, in 1994, using lead blast-furnace slag and coke as raw materials. The plant included a.d.c. power. supply, two plasma-arc furnaces' and an ISP lead-splash condenser. Slags containing typically 12 per cent zinc oxide and 3 per cent lead oxide are produced as a waste during the smelting of lead in a blast furnace. These slags are a potential: resource for the recovery of lead and zinc. During 1994, about 600 t of lead blast-furnace, slag was proceced through the pilot plant using the Enviroplas process. Zinc and lead oxides were reduced to their respective metals, volatilized, and collected in an. ISP lead splash condenser. Prime Western grade zinc and slags disposable in accordance with current US legislation, were produced. Zinc condensation efficiencies of about 80 per cent were achieved.

Jan 1, 1995

By Patricia A. Wells

In the remelting of scrap, the ultimate goal is to produce clean aluminum while minimizing metal losses. Recently, it has become more difficult to make significant recovery improvements in Reynolds' Reclamation Plants since metal recoveries were nearing the theoretical maximum. In an effort to gain a better understanding of the factors impacting Reynolds remelting process, a series of experiments using a Taguchi-type design was performed. Specifically, the critical variables and interactions affecting metal recovery of shredded, delacquered Used Beverage Containers (UBC) melted in a side-well reverbatory furnace were examined. This furnace was equipped with plunger-style puddlers and metal circulation. Both delacquecing and melting processes operated continuously with downtime only for necessary mechanical repairs. The experimental design consisted of an orthogonal array with eight trials, each using nominal 500;000 lb shred charge volumes. Final recovery results included molten output and metal easily recovered from dross generated during the test.

Jan 1, 1995

By P. Gray

Process and engineering development of the Warner Zinc Process over the past two decades has proceeded alongside the world-wide collection and analysis of operating and cost data of current processing practices from sulphide ores to refined metals. Study of these data shows that recoveries are dependent on mineralogical characteristics of the sulphide matrix and point to the inadequacy of differential flotation as a tool for preparing feed for smelters. The paid-for return at the mine on the combined metal values in zinc rich sulphide ores rarely exceeds 80% and increasingly runs as low as 50-60%. Surveying the possible alternative ways of improving these performances leads to the conclusion that the Warner Process is the only technology in sight that could meet a target of 90% paid-for recovery and that its development has now reached a point where it can be a fully practicable process for all mixed sulphide ores.

Jan 1, 2000

By S Ivanaj

Oxidation of chalcopyrite from a copper concentrate in an electrochemical cell having separate-anodic and cathodic compartments was studied by potentiodynamic, potentiostatic and galvanostatic experiments. Oxidation of chalcopyrite particles was mainly realized by in-situ electrogenerated FeIII and Cull ions. The use of an ion exchange membrane, in this experimental set, avoids the reduction of the ferric and cupric ions. The effects of particle size, current feeder potential, current intensity and pulp density were studied to optimize the oxidation parameters. Selective complete oxidation of chalcopyrite was achieved. Oxidation of pyrite was negligible. Mom than 85 % of sulfur was obtained in its elemental form. This may allow selective extraction- of copper from the chalcopyrite concentrate without sulfur dioxide emissions.

Jan 1, 1995

By Kenneth S. Coley, Michael Pomeroy, Elaine Chen

Recent work on modeling of BOF steelmaking is reviewed, highlighting the critical aspects of each approach. It is concluded that the most successful models should be based on a deep understanding of the mechanisms and kinetics of the critical reactions. The importance of the decarburization mechanism is discussed with particular reference to its role in droplet swelling or bloating which has a profound influence on the droplet residence time in the slag. Conditions which cause bloating are discussed and the rate determining step is proposed to be primarily nucleation of CO bubbles inside the metal droplet with some influence from growth by reaction at the bubble/metal interface. The discrepancy in the super-saturation ratio required for classical nucleation is discussed and an approach using a surface tension modifying parameter is illustrated. Finally, the role of CO nucleation in controlling the driving force for dephosphorization is discussed.

Jan 1, 2014

By Shilai Yuan, Huimin Lu, Zhijiang Gao, Panpan Wang

"Solvent refining of silicon through using Si-Al melts is a valid method to remove the impurities from metallurgical grade silicon (MG-Si) melt. The thermodynamic behavior of impurities Fe, Al, Ca, Ti, Cu, C, B and P in MG-Si during the solidification of MG-Si was studied based on the available thermodynamic parameters and experimental data. The morphology of inclusions was investigated by Scanning Electron Microscope (SEM). The chemical composition of inclusions in MG-Si and Al-Si melt was analyzed by EPMA. It is found that the amount of white inclusion reduces and most impurities are solved into the Al-Si melts. After solidification of Si–Al alloy using induction heating and acid leaching, impurities can be effectively removed. The solidification of silicon from the Si–Al melt is found to be more effective for purification than general silicon solidification.IntroductionPhotovoltaic energy is one of promising energy resources in a sustainable society because of its inexhaustibility and cleanliness. Although the production and installation of solar cells have increased significantly during the last decade, the cost of solar cell installation is still high. Multicrystalline silicon has now become the main material in the photovoltaic market because of its low production cost and because of the relative high conversion efficiency of solar cells made from this material, which has been studied for a long time [1-3].Electronic grade (EG) silicon (99.9999999% Si) is commonly used as the raw material to produce SOG-Si (99.9999% Si). Silicon produced from the chemical routes restricts the development of solar cells due to environment threaten, high energy consumption and low productivity. Purification of metallurgical grade silicon (MG-Si) is a low cost, environment friendly method. Although several metallurgical processes such as directional solidification, vacuum refining and electron beam melting [4], have been developed, the cost reduction and refining efficiencies for manufacturing silicon is still have to be further optimized.In the purification process, it is difficult to remove boron and phosphorus by the conventional metal refining method. The refining efficiency depends on the segregation behavior of different elements in solid silicon and the liquid phase. The segregation ratios of all investigated impurities were found to be much smaller than the segregation coefficients between solid and liquid Al-Si melts [5]. For instance, the segregation coefficient of B in Si is 0.8 at the silicon melting point (1687K), whereas it is around 0.2 when silicon is solidified from Si-Al melt at 1273K. For phosphorus the segregation coefficient is 0.06 when silicon is solidified from Si-Al melt at 973K°C, which is much less than 0.35 for recrystallization from liquid silicon. Since the segregation coefficient of boron in silicon is 0.8, it cannot be removed by directional solidification."

Jan 1, 2014

Thallium is a very minor element found in lead ores. It's behaviour during lead smelting has recently become of much greater interest due to the effects it had on the health of waste heat boiler maintenance contractors at a Canadian smelter. In this paper the behaviour of thallium in both traditional and direct lead smelting processes will be examined using computational thermodynamics techniques. Yazawa and his coworkers have made extensive use of computational thermodynamics to examine and illustrate pyrometallurgical processes. It has been shown that thallium behaviour during smelting is strongly influenced by the extent of oxidation of the lead concentrate and by the presence or absence of chlorine in the charge. The condensation behaviour of thallium species in the waste gas handling system was also modelled and it has been confirmed thallium-rich deposits can form at the high temperatures prevailing in waste heat boilers.

Jan 1, 2003

By Florian Kongoli

Converters have been playing an important role in the extraction and processing of metals ever since the first type of converter was invented about 100 years ago. Historically their operation has been mainly based on the experience of talented operators rather than on strict control and optimization technologies. However, in the new realities of unavoidable necessity to increase productivity and in the conditions of diversification of primary materials from various geographical areas, improving control and optimization techniques have become indispensable. In this paper a review of the authors? previous work in terms of improving control and optimization of converter operational practices related to magnetite content and precipitation, slag and metal blows, problematic and dangerous elements such as As, Sb etc. has been described by highlighting the advantages that the new control and optimization methods and tools bring to everyday converter practices. Several examples are given and future work is underlined

Jan 1, 2005

By Mitsutaka Hino

The contents of gangue minerals, such as A1203, P205, crystalline water and so forth in the iron ore imported to Japan tend to increase year by year, Though the increments of such gangue contents are approximately 0.1-0.2 mass%, some problems for the blast furnace operation in ironmaking process have already been reported, In order to clarify the mechanism of harmful effect caused by the small increment of gangue minerals, mainly A1203, on the blast furnace operation, the dripping behavior of FetO-CaO-SiO2-AI2O3-MgO slag from the iron funnel, which simulated the micro-porosity in sinter ore, has been observed with the wide range of basicity, Al2O3, FetO and Mgo contents. The effect of MgO on the dripping behavior of slag has been summarized in this paper, It was found that the addition of 2mass% MgO resulted in large increase of hold-up on the most of the conditions. When FetO content was less than 20mass% and the basicity was lower than 0.8, MgO lowered the hold-up even if the slag contained 10mass% Al2O3. Every slag hold-up showed the minimum at the basicity of less than unity on the conditions of constant FetO and A1203 contents. This trend became remarkable when the slag contained 2 mass% MgO.

Jan 1, 2003

By Marco Pasetto

The possibility to re-use marginal materials (by-products) deriving from industrial activities in the construction of road infrastructures, as total or partial substitution of natural aggregates, successfully combines demands for economy and environmental sustainability. The paper presents the results of a laboratory study, conducted at the Experimental Road Laboratory of the University of Padova, to verify the suitability of a particular type of electric arc furnace slag to be recycled in the lithic skeleton of high-performance asphalt mixes (porous asphalt, high modulus mixes, stone mastic asphalt, nonskid surfacings) for road and airport flexible pavements. the process of transformation of iron and steel slag into a product that can be used in road building is described, along with the characterisation of the mixtures, plus an analysis of the results of a wide battery of mechanical-performance tests. This study forms part of wider theoretical ? experimental research being done at the University of Padova in order to improve knowledge of the characteristics of succedaneum materials and check their possible applications in road and airport construction.

Jan 1, 2006

By Heikki K. Jalkanen

Thermodynamic properties of copper-iron mattes and slag-matte distribution of copper and some minor matte constituents (Ni, Co, Mo, As, Sb and Bi) are discussed on? the basis of equilibrium measurements: a change from. oxidic to sulfidic solubility as the predominant form of dissolution of copper takes place as matte grade decreases. Distribution coefficients of minor matte constituents are complex functions of sulfur and/or oxygen potentials?. The distribution behaviour of different? metals can be qualitatively derived from their affinities to copper and stabilities. of their sulfides and oxides. The equilibrium results are compared with commercially observed values. from Outokumpu.Oy flash smelting furnace.

Jan 1, 1983

By Xiangru Chen, Qijie Zhai, Wei Zhang, Haicheng Li, Chao Yang

In this paper, ductile iron material with different content of niobium was prepared by a scientific melting method. Image Analysis Software was used to studied the effect of niobium microalloying on both pearlite content and pearlite lamellar spacing in ductile iron quantitatively. The results showed that the addition of a small amount of niobium could increase the pearlite content and decrease pearlite lamellar spacing of ductile iron effectively.

Jan 1, 2015

By C. F. Feng, L. Froyen

"In-situ processes have emerged as new and promising techniques for metal matrix composite fabrication. They offer significant technical and economic advantages over conventional processing. One of the in-situ processing routes that have been used is reactive free sintering of a mixture of powder reactants. However, materials synthesised via this route are always porous because of density differences between reactants and products. An example are the porous Al/(TiB2+Ah03) MMCs obtained by heating powder mixtures of Al+ Ti02+B with Ti02 and B in stoichiometric ratios for forming TiB2• In this study, porous Al/(TiB2+Ah03) composites were further processed by hot-pressing at temperatures above 600°C. This processing cycle was designed so that the composites could be densified. Furthermore, the reaction kinetics of the in-situ processing are studied by means of DSC analysis measured at different heating rates. The activation energies of the three intermediate steps that are involved in the reactive processing for preparing AV(TiB2+Alz03) MMCs are determined to be 923 kJ/mole, 241 kJ/mole and 235 kJ/mole respectively.XRD proved that the hot-pressed products consist of Al, TiB2 and Al203- Properties of the products are assessed by microstructural characterisation (LOM, SEM and EDS), microhardness, Young's modulus and bending tests. The results show that good microstructures, elastic properties and strengths, as well as acceptable ductilities were achieved. For the composition 79.74wt% Al-15.95wt% Ti0z-4.31wt% B, after the reactive free-sintering and hot-pressing cycles, Young's modulus is 105 GPa, bending strength is 509 MPa and maximum strain is 5.0%; for composition 88.73wt% Al-8.87wt% Ti0z-2.40wt% B, they are 89 GPa, 311 MPa and 8.2% respectively. It can be seen that the properties of products can be tailored by adjusting the relative amounts of reactants in green samples. Furthermore, for comparison reasons, Al and a binary system Al-Ti02 were identically processed as the ternary systems. Their microstructures and properties were studied."

Jan 1, 1998

By Simon N. Lekakh, D. G. C. Robertson

A new integrated CFD-combined reactors approach is proposed for the description of processes in metallurgical vessels. CFD simulations were used to obtain the melt flow pattern in the vessels (ladle, tundish, and continuous caster mold). From these simulations, the characteristic curves were derived: (i) the residence time distribution curves (RTD) for flow-through systems (at tundish exit or at dendrite coherency surface in the mold) and (ii) the mixing curves for closed systems (ladle). In the next step, the melt flow was represented in a “combined reactors” system consisting of a combination of unit reactors (Plug Flow, Mixer, and Recirculated Volume). An inverse simulation was used to define the volumes of the reactor units and the melt flow rates between them by fitting to the characteristic curves from both methods (CFD and combined reactors). The suggested approach is demonstrated for multiple designs of Ar-stirred ladles, tundish, and SEN. This methodology can be used to enhance traditional post-processing CFD analysis and also as a tool for on-line process control.

Jan 1, 2014