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By Minge Zhao, Yuandong Pei, Zhixing Zhao, Zejun Ma, Lili Ban

"Confocal scanning laser microscope (CSLM) has been applied to carry out the in-situ observation of melting and solidifying characteristics during iron ore sintering process, accompanied with TG-DSC test. It can be found that apparent Liquid phase forming temperature(LFT) and ending solidifying temperature(EST) is about 1190? and 1160?, respectively. Forming liquid phase during sintering process goes through four courses, these are shrinking, expanding, shrinking and expanding coexisting and expanding totally. For Yandi fine, the corresponding temperature of these four courses is about 1120-1160?, 1190-1196?, 1218-1220? and 1233-1270?, respectively. Although CAJ fine has more difficulty in forming initial liquid phase, but when liquid phase expands, it may have better fluidity and easier for liquid phase formation. Adding enough CaO, CAJ fine takes on high fluidity like Yandi fine, because liquid phase during sintering process is formed mainly by reaction between CaO and Fe2O3.IntroductionConfocal scanning laser microscope (CSLM for short) has been applied to carry out the in-situ observation of metallurgical phenomena, especially in steelmaking process. Recently, many researches on ironmaking process were conducted with CLSM. While for high temperature properties during sintering process, there are limited reports on in situ observation1-2). In this paper, melting and solidifying characteristics of iron ore were observed with CLSM under simulated sintering temperature, and high temperature properties of iron ore during sintering process was clarified based on the in situ observation results and TG-DSC research."

Jan 1, 2012

By Zachery Zanetell

Flotation circuit performance has become increasingly more challenging due to the complexity of available ore sources. To optimize value mineral recovery, the mineralogical composition of the ore should be evaluated and understood. Utilizing a variety of mineralogical and analytical tools, flotation processing challenges can be overcome and potential limitations understood. In this paper, several case studies will be discussed in terms of the value that has been provided through the use of mineralogical analysis to optimize flotation performance.

By M. B. Mesina

Mechanical separation systems are widely used nowadays for scrap metal processing, but they have natural limitations in product quality. The quality of the final product is considerably improved when sensors are used in the separation process. This paper describes new methods using sensors for scrap metal sorting and quality control. An example is the electromagnetic sensor, which uses the electrical and magnetic properties of materials to distinguish between different non-ferrous metals. The measurement results of two prototypes are reported. The benefits and the possibility to integrate such systems into practical applications regarding the processing of secondary raw materials are also described.

Jan 1, 2003

By cheng Peng-fei, TANG Hai-yan, guo Xiao-chen, LI Jing-she, Liang Yong-cang, Zhao Baojun

The origin and evolution of non-metallic inclusions for Al-killed casing steel during EAF-LFVD- CC process were studied by industrial tracer experiments. The formations of Al2O3 and MgO·Al2O3 micro- and macro-inclusions from ladle slag were analyzed by theoretical calculations. The results show that micro-inclusions were formed during deoxidation and temperature decreasing in the process of casting, most of the macro-inclusions come from entrapped ladle and mold slags. In addition, most of the Al2O3 formed were modified into 12CaO·7Al2O3 and 3CaO·Al2O3 inclusions which are liquid at steelmaking temperature. MnS cannot be fully modified to CaS and it was only wrapped outside the alumina or calcium aluminate in the form of (Ca,Mn)S with the amount of Ca-Si wire fed during the test.

Jan 1, 2016

By Naiyang Ma

"High oil concentration is one of the major barriers for recycling of mill scale of steel hot rolling mills. It is of vital importance to find cost-effective technologies of reducing oil concentration in mill scale in order to recycle the mill scale without causing detrimental effects on production and environment. This paper discusses in-process separation of mill scale from oil at steel hot rolling mills. Formation of mill scale and status of oily wastewater at hot rolling mills are reviewed in the first place. A mathematical model is then formulated to relate oil concentration in mill scale to physical properties of mill scale, chemical and physical properties of wastewater and interacting parameters between mill scale particles and wastewater. From this model, three approaches of in-process separation of mill scale from oil are derived: (1) avoiding contacts between mill scale particles and oily wastewater, and (2) maintaining low oil concentration in wastewater, and (3) collecting mill scale in upper streams of wastewater flows. In-process separation of mill scale from oil might have advantages of lower capital cost, lower operating cost and less additional environmental concerns, compared to other strategies of separating mill scale from oil.IntroductionHot rolling is an inevitable step in producing finished steel products. Figure 1 schematically shows a steel hot rolling process. Semi-finished steel products, slabs here, are reheated first, and then the reheated slabs are discharged from the furnaces and transported on hot rolling trains to descaling units for removing scale with pressurized water. After being descaled, the slabs are rolled by roughing mills. After treated with cropping and the second descaling, the slabs are finally rolled into finished products, coils here, by finishing mills."

Jan 1, 2012

By Hongli Wen, Guangkun Shen, Qiong Deng, Shoujian Huang, Min Gan, Xiaohui Fan

"Due to the low iron grade and high sulfur content, pyrite cinder is difficult to be directly used for iron-making. In this paper, technology of magnetic roasting -grinding and magnetic separation -acid leaching was put forward for reclamation of pyrite cinder. For pyrite cinder of TFe53.51%, S2.20 %, studies showed that good magnetic effect can be achieved at roasting temperature 650~7000, reducing atmosphere CO/(CO + C02) 10~20% and roasting time 10~30 minutes. In separation conditions of grinding size -0.045mm accounting for 96.09% and magnetic field intensity of 1240 GS, iron concentrate of TFe64.81 %, S0.18% and iron recovery rate 91.44% was achieved. Acid leaching was studied to strengthen desulfurization. Results showed that high-quality iron ore concentrate of TFe66.3 l %, S0.10% was obtained under the conditions of hydrochloric acid mass fraction of 5%, pulp density of30%, leaching temperature of70? and leaching time of2 hours.IntroductionPyrite cinder is produced as a by-product of sulfuric acid industry [1] Domestic production is more than 12 million tons every year and occupied area is over 10 million square meters [2,3]. The pyrite cinder outdoor not only pollutes air but also damages surrounding surface [4] It after treatment used for iron-making is an ideal reclamation approach for its rich iron which is commonly 40-60% [5]. But pyrite cinder gets low utilization for its low iron grade and high sulfur content in China [6]. Therefore, comprehensive utilization of pyrite cinder has profound significance to environmental protection and the development of domestic iron and steel industry."

Jan 1, 2013

By Shu Xinqian, Zhou Weining, Shan Zhiqiang, Feng Jifu

"Modified calcination conditions on the extraction of rubidium resources from muscovite (KAlz[AlSi301o](OH)2) ore are systematically studied. The impact of various factors on the rubidium leaching rate is also analyzed, including the agent types, roasting time, the mass ratio, roasting temperature, etc. The results indicate that the best agent is a combination of sodium chloride and calcium chloride, its mass ratio ofmuscovite/NaCl/CaClz is 1:0.25:0.25. Calcined at 8500 for 30 minutes, the rubidium leaching rate is up to 90%. The reaction of muscovite ore with the chlorinating agent CaC12 has been studied by TG/DSC, the calcined intermediates are identified by XRD, and the surface morphology before and after leaching is characterized by SEM. Rubidium chloride products can be obtained with a purity of 92% by using t-BAMBP extraction, hydrochloric acid reextraction and purification.IntroductionRubidium is one ofrare alkali metals, which is found in 1981 by German R.W. Bunsen and G.R. Kirchhof. Rubidium includes the following features: atomic number is 37, each atom weight 85, the body-centred cubic lattice, each unit cell has two metal atoms, and the density is 1.532g/cm3. The properties of low melting point (312.46 K) and malleability make rubidium have a strong chemical activity and photoemission. Rubidium provides a main material for manufacturing phototube with a wide range oflight waves, which possess high sensitivity and stability. Efforts are being made to carry out research on rubidium ion gngine, magnetic flux generators and thermoelectric transudcer, etc. Rubidium exists in muscovite ore(KA12[AlSh01o](OH)2 (monoclinic system and hexagonal layered structure) as isomorphism and replace the large radius of the potassium atoms, as well as part of rubidium locate between structure layers. The complex components bring great difficulty in comprehensive recycling."

Jan 1, 2013

By Donna L. Bodine

The ability of oxidized Upper Freeport bituminous coal to adsorb Cu2+, Cd2+ and Mn(VII) from very dilute aqueous solutions has been studied. Low-rank coal is known to adsorb heavy metal ions from dilute, aqueous solutions, probably by ion exchange and/or chelation by acidic functional groups on the coal surface. However, it would be advantageous to use higher rank coals for water treatment. Coal samples were oxidized thermally or by 30% H202 to increase the surface concentration of phenolic and carboxylic groups, then portions were shaken with Cu2+ and Cd2+ solutions. Acidic KMnO4 was also used to oxidize coal, with concurrent sorption of the resulting Mn(IV) and Mn(ll). The effect of oxidation treatment, metal ion concentration, and solution pH on metal uptake kinetics was investigated. Potential applications for treating effluents, especially those containing oxidizing ions, are discussed, along with possible flowsheet options.

Jan 1, 1995

By Susumu Okabe

Mitsubishi Continuous Copper Converter employs the top blowing lance system for the continuous supply of reaction gases into the molten bath. In order to avoid the excessive refractory wear caused by the melt splash without loss of the reaction efficiency, the furnace design and the blowing condition should be optimized. Empirical equations which correlate the splashing rate on the' side wall with the dimensions of the furnace, lance position, lance size, gas velocity and bath properties were obtained by by the physical model study, and compiled into a computer program. The computer program is effectively utilized for the analysis of the actual operation and for the optimum design of new furnaces.

Jan 1, 1998

By V. I. Lakshmanan

"Historically flowsheets are developed for efficient separation of metals for economic recovery. With increasing emphasis on reduction, reuse and recycle (3Rs) efficient methods are sought to recover values from a variety of feeds where cost of collection, transportation, local consumer behaviour and regulatory guidelines dictate the development of economically viable flowsheets. Innovative understanding of potential market applications can provide means to develop value added end products. The paper with examples will discuss the use of innovative-separation technologies to obtain value added end use materials from secondary sources.IntroductionFlowsheets are developed for the efficient separation of materials of value for economic recovery. However with increasing societal pressures and regulatory initiatives for stricter environmental guidelines, there is strong need to provide focus to recover materials efficiently and economically in an environmentally accepted manner. North American industries are increasingly caught between demands for high technology value added products and responsibility for environment. An aspect that is receiving increasing attention is Design for Environment'. This incorporates a system wide approach for product design and incorporates environmentally preferable features such as recyclability, disassembly, maintainability, reusability and use of safe materials as part of a product's design objectives.The present paper with case histories will address innovative flowsheet development to convert wastes into recyclables value added products or for minimising generation of waste materials. Case HistoriesProcess for Separating Fibres from Composite Materials 1In the automotive industry, sheet molded compound (SMC) is used to produce panels, bumpers and the like. During the manufacture and at the end of life, considerable waste materials are generated which are potentially recyclable. Fibre reinforced plastics where fibre substrate impregnated with thermosetting resin, find applications in several manufacturing processes and are potentially recyclable at the end of life."

Jan 1, 1996

By Kai Tang, Casper van der Eijk

Natural gas has been used as reductant in the production of iron for several decades. Recently, the use of natural gas as reductant for other metals has been drawing attention because of the low price of natural gas, as well as the reduction of CO2 emissions compared to the use of coke and coal. In this work, the reduction of a mixture of Ti- and Ni-oxides by natural gas has been studied. Within the Ni-Ti system, the intermetallic compound Ni3Ti is thermodynamically the most stable one. Therefore, powders of Ni-oxide and Ti-oxides were mixed in an atomic ratio of three to one and subsequently pelletized. Reduction was performed in a TGA furnace at constant temperature with varying reducing gas atmospheres. In a natural gas containing atmosphere, the Ni-oxide was easily reduced to metallic nickel while the Ti was reduced to Ti-oxycarbides or Ti-oxynitride when nitrogen was present. Depending on the process parameters, several percent of Ti was dissolved in the nickel-based solid phase.

Jan 1, 2014

By Jin Qiu

Experiments were performed to determine the extent of minor element elimination that occurred when mixtures of copper smelter dust and copper concentrate, were calcined under vacuum. Almost complete removal of the As, Sb, Bi and Pb occurred due to the conversion of the minor element compounds of these elements into their highly volatile sulphides by reaction with sulphur from the concentrate. Heat and mass balance calculations of the slag-blow in a copper converter found that ~30 tonnes of the vacuum calcine could be used to produce 100 tonnes of copper as white metal. The use of dirty concentrate as the sulphidizing agent in the vacuum calcination means that the minor element treatment capacity of the smelter complex could be increased by 60 %. Also the productivity of the converters may be increased by up to 8 % due to the supply of copper values and oxygen in the calcined mixture.

Jan 1, 2005

By S. V. Ketov, V. P. Menushenkov, V. S. Shubakov

"The glass samples were obtained by melting of the oxides mixture SrO-Fe2O3-B2O3(Al2O3) at 1200-1250°C with subsequent quenching of the melt on quickly rotating steel roller. Submicronsized Sr(Fe,Al)12O19 particles were formed in glass-ceramic matrix during the crystallization aging of glass. The aging temperature Tag varied in the range 650-950°C. The submicron-sized hexaferrite powder was obtained by removing of the matrix phases using etching. The samples were characterized by X-ray diffraction, scamiing electron microscopy and magnetization measurements. The glass-ceramic material exhibits very high coercivity value up to 10 kOe. The samples of magnets were obtained by pressing of the hexaferrite powder at RT and subsequent aging in the range 900-1200°C. The aged samples exhibit coercivity value up to 8 kOe.IntroductionStrontium M-type hexaferrites have been widely used in technology and industry mainly for production of permanent magnets owing to their appropriate magnetic properties, chemical stability and low cost [1,2]. The SrFe12019-based compounds are characterized by high magnetocrystalline anisotropy and single easy magnetization axis. The highest coercivity is received for monodomain, defect-free single crystal particles with size D - 100 mn. Finely grained strontium hexaferrite prepared by chemical methods such as sol-gel pyrolysis and oxide glass crystallization exhibits high coercivity up to 6-8 kOe [3-5]. Owing to the partial substitution of Al for Fe in the strontium hexaferrite leading to the increase in the magnetic anisotropy field Ha=2Ki/M,, the increase in the coercivity may be received [6]. The notable results were achieved using the SrO-Fe2O3-AlzO3-B2O3 glass crystallization and formation of perfect submicron crystals of alumina-doped hexaferrite [ 6, 7]. The coercive force of glassceramics reached values of up to 10 kOe. Hexaferrite particles are well faceted and have the shape ofhexagonal bipyramids with truncated vertexes [7].In the present paper, we report results of our investigation into the SrO-Fe2O3-B2O3(Al2O3) glass crystallization, hexaferrite powders and permanent magnets, which were prepared by pressing submicron-sized hexaferrite powders at RT and subsequent sintering at 900-1200°C."

Jan 1, 2012

By Mei-le He, Min Chen, Xiang Shen, Lei Xu, Lei Liu, Nan Wang, Xue-liang Yin

In the current study, Al2O3-MgO-CaO refractories were prepared at 1400-1600 by the addition of MnO micro-powders, and the effect of MnO addition on densification behavior of the refractory was discussed. The results showed that the doped MnO dissolved to MgAl2O4 phase, and promoted the growth of MgAl2O4 grains by the formation of MgAl2O4 solid solution. As a result, the dense microstructure was obtained, with the apparent porosity decreased from 19.2% to 5.4% and the bulk density increased from 2.78g/cm3 to 3.15g/cm3 after firing at 1600 for 2h by the addition of 4% MnO. In addition, a texture microstructure was observed, which is considered to be favorable to improve mechanical properties and the service life of Al2O3-MgO-CaO system refractories.

Jan 1, 2016

By Nicola Baldo, Marco Pasetto

"Recycling of tyre rubber in the road pavement, may be one of the best way to reduce waste tires in large quantities and, at the same time, improve some engineering properties of asphalt mixtures. The paper discusses the results of an experimental study, developed in order to analyse the potentialities of crumb rubber from road tyres in bituminous mixtures, using the dry process. Two types of porous asphalt mixtures and reference mixes without rubber were formulated by the traditional Marshall methodology, and mechanically evaluated by means of the Indirect Tensile Stiffness Modulus test, the Creep test (with confinement), and the Indirect Tensile Fatigue Test. Results of this study indicate that the tyre rubber has a positive influence on the performance characteristics, depending also on the grading and volumetric properties of the mix being studied: an interesting increase of the fatigue life, a better stiffness behaviour at lower temperatures and a bigger permanent deformation resistance at high temperatures are guaranteed. Introduction Recycling the rubber from used tyres, in the construction of road pavement layers, is potentially one of the more interesting and advantageous solutions from both the technical and environmental points of view, in order to reduce the total amount of car and lorry tyres to dispose. In road-building techniques, a technology, termed “wet”, for modifying bituminous binders with crumb rubber has by now become well consolidated. There have been numerous scientific studies conducted on this technology and its applications, particularly in the United States, where it has been adopted and codified in specific technical regulations (ASTM D-6114). If the wet process can be considered amply tested, the same cannot be said for a second technology, termed “dry”, which deserves careful study to evaluate its suitability and advantages. In “dry” processes, the rubber is usually used as a partial substitute of aggregate of equivalent grading and mixed with bitumen after integrating the crumb rubber in the lithic skeleton."

Jan 1, 2008

By Batric Pesic

Gold dissolution with bromine was studied by using the rotating disc technique. Geobram TM 3400 was used as a source of bromine. The parameters studied were: rotating speed, Geobrom 3400 concentration, pH, temperature, sulfuric and hydrochloric acid concentration, and the concentration of various cations (copper, iron, zinc, aluminum, manganese, potassium and sodium) and anions (chloride, bromide, sulfate, nitrate, and iodide) According to the Levich plot and activation energy, gold dissolution was controlled by a chemical reaction rate. Copper, iron, and manganese in their highest oxidation states, aluminum, zinc, sodium and potassium did not have any effect on gold dissolution rate. The presence of manganous ion dramatically decreased the gold dissolution rate. Kinetic performance of bromine, in the form of Geobram TM 3400, was compared with performance of cyanide and thiourea.

Jan 1, 1990

By Mim Li, Huimin Lu, Lisha Yang

"CuInS2 thin films solar cells have drawn much attention for their low-cost, stability and high conversion efficiency. The electrodeposition of Cu-In precursor films, as the first step in making CuinS2 solar cells electrochemically in the air-and water-stable ionic liquid based on choline chloride/urea eutectic mixture has been investigated at constant potential. Compared with aqueous electrolytes, the large electrochemical window as well as the high thermal stability of this ionic liquid allow the direct electrodeposition of Cu-In precursor films. Then the precursor films were sulfuretted in a tube furnace at different sulfurization temperatures to optimize the films properties. The films obtained were characterized by X-ray diffraction (XRD), scanning electron microscope (SEM), energy dispersive spectroscopy (EDS).IntroductionCuInS2 is one of the most prospective absorber materials for low cost thin film solar cells, with a high conversion efficiency that exceeds 32% in terms of theory and nearly 13% in laboratory level [1-2]. In addition to its long-term stability, CuinS2 has a band gap energy Eg ranging from 1.3 to 1.55 eV and an optimal optical absorption coefficient reaching 105cm-1 [3-4]. CuinS2 thin films have been prepared by several methods such as spray pyrolysis [5-6], r.f.sputtering [7], vacuum evaporation [8-9] and electrodeposition. Comparing with vacuum methods, electrodeposition has lots of advantages such as less energy consumption, preparation big area thin film, stable system and enabling cheaper films.The electrodeposition of most technologically important metals has been shown to be possible from a wide range of ionic liquids. These ionic liquids are currently applied in a wide variety area. It is reported that the cell efficiency of chalcopyrite absorber layer (CIS, CISeS, and CIGS) via an electrodeposition route in laboratory condition has reached 11.3% [10]. Copper and indium alloy film is regarded as important precursor for the production of compound semiconductors with sulfur. The electrodeposition of the alloy film from room temperature ionic liquid (RTIL) has not been widely investigated. Only few alloy films, such as ZnTe, CdTe, GaAs and AlSb have been electrodeposited."

Jan 1, 2011

By A. J. Schindler, F-P Sawyer, T. Logan, M. L. Shutey-McCann, R. M. Perry

"Test work on biooxidation pretreatment of low-grade refractory gold ores has been ongoing at Newmont Gold Company since 1988, including laboratory testing and pilot biooxidation heaps (360 to 23,000 tonne). Metallurgical results of the biooxidation process utilizing Thiobacillus ferrooxidans (T. ferrooxiddans) have culminated in the design, construction, and operation of a biooxidation demonstration facility. The facility has processed 708,000 tonnes of refractory ore, using a batched process with separate pads for biooxidation and ammonium thiosulfate gold extraction. Siliceous sulfidic refractory (SSR) and carbonaceous sulfidic refractory (CSR) ores are treated separately during biooxidation pretreatment unit operation. Following biooxidation, the ores are neutralization with lime and placed on oxide leach pads or stacked on the ammonium thiosulfate leach pad. Gold is leached with either cyanide for SSR ores or ammonium thiosulfate for preg-robbing CSR ores.This paper will only address the biooxidation pretreatment process of the SSR and CSR ores.AcknowledgmentsThe authors appreciate the cooperation and approval of Newmont Gold Company Carlin Operations management for its support and permission to publish this paper. The paper draws on efforts and assistance of the following people and several others which are to many to list who participated over the past five years in bringing this project to its fruition: Dr. James A. Brierley, Chief Microbiologist, Newmont Metallurgical Services; Dr. Rong-Yu Wan, Metallurgical Manager, Newmont Metallurgical Services."

Jan 1, 1997

By V. Blet

Rare earth elements (REE) are regarded today as highly critical raw materials but currently lack suitable recycling processes. A combined hydro- and pyrometallurgical process aimed at REE recovery from used NdFeB permanent magnets was recently developed by the CEA. The process integrates the physico-chemical treatment of magnets, followed by a solvent extraction step for the recovery and intra-REE separation using a selective extractant. A subsequent pyrometallurgical treatment via molten chloride salt electrolysis allowed the isolation of pure Dy metal. Technical-economic assessment and life-cycle analysis were also conducted. Following this first successful demonstration, a new project aimed at the recovery of REE from end-of-life nickel-metal-hydride batteries is currently being developed in association with industrial and academic partners. The project aims at evaluating from an experimental and economic perspective different processes converging at the production of value-added products such as cermet materials for catalytic applications, purified REO concentrates, or metallic alloys.

By Atul Kurnar

In the present research a two-cell polymer electrolyte membrane fuel cell stack (PEMFCS) with SS-316 bipolar plates has been tested. Different flow field designs were studied and a modified multi-parallel channel design is proposed. The stack is stable within ±3 mV even after 1000 hours of continuous operation, indicating efficient water management and effective removal of any metal ions from the stack. Also no iron is detected in membrane electrode assembly (MEA) by EDAX analysis after 1000 hours of cell operation. Results indicate that high operating pressures beyond 138 kPa didn't significantly increase the performance of cell, however added much to the pressurization cost of the system. Tests at different temperatures showed that at temperatures below 80°C, external humidification could be completely removed. The prototype stack is also tested under variable load conditions simulating highway-driving schedule. The experimental efficiency of PEMFCS is 48%, which is in good agreement with the model predicted efficiency of 53.8 %. Results show that 59% of the total losses are due to ohmic polarization in the cell. Further analysis on applications of the stack in automotive transportation system is in progress.

Jan 1, 2002