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By R. D. Brittain

In order to analyze and control the transport of harmful trace-element impurities in various smelting processes, it is necessary to have fundamental information about the chemical thermodynamic properties of the pertinent condensed and vapor phases. This paper describes recent thermodynamic studies of the gaseous arsenic sulfides and of the activity of arsenic in a copper-iron sulfide matte phase. These studies were carried out by high temperature mass spectrometry and by effusion vaporization techniques, which permitted clear identification of the molecular species involved, a decided advantage in such complex systems. The nature of the results obtained and comparisons with previous interpretations will be described.

Jan 1, 1983

By Biao Zhou, Qian Li, Kuo-Chih Chou, Yi-Long Liang, Jie-Yu Zhang, Qun Luo

"In this work, the phase transformational behaviors and microstructural characteristics of 60Si2CrVAT spring steel were systematically investigated as a function of applied cooling rates in the range of 0.l-10°C/s. A quenching deformation dilatometer was used to austenize and quench. The dilatometric curves between length changes and temperature of samples suggest three characteristic stages could be identified as different ranges of cooling rates, which meets well with metallographic examination and the measured hardness results. As the cooling rate increases, the structure transformed from pearlite, granular bainite to finally martensite. The F + P and B zones are completely overlapping in continuous cooling transformation (CCI) curve, which indicates that this steel is difficult to become single bainite and shows good hardenability.IntroductionThe 60Si2CrVAT, a high-carbon low ally super-high strength steel developed from the ?OCT 60C2XFA and 60Si2MnA, is often used for coil spring of heavy vehicles and high-speed railway by hot deformation or cold deformation [1-3]. The addition of Si improves relaxation resistance significantly, through the refinement of tempered carbides as the result of the retardation of E -carbide conversion to cementite during tempering. Due to its deleterious effects on decarburization and toughness, the maxinJum content of Si has limited to 1.5 or 2.0% [4-5]. Additionally, V and Cr can improve sag resistance due to the precipitation of fine carbonitrides during hot rolling [6-7]. To best of our knowledge, the strengthening by precipitation of alloy carbides of Cr and V often referred to secondary hardening [8]."

Jan 1, 2013

By J. L. Sanchez

Using a special double-zone transpiration reactor, the vapor transport chemistry of vanadium pentoxide in the presence of water vapor has been investigated. Three possible volatile hydroxides above V,O,(s) are reported in the literature: VO,(OH),, V,O,(OH),, and VO(OH),. In the present study, it was established that VO(OH), is the principal gaseous hydroxide species formed. The predominant reaction was found to be: { } The vapor pressure of VO(OH), was measured as a function of temperature, water pressure, oxygen pressure and flowrate. The results have been used to determine the Gibbs free energy of the above reaction as a function of temperature: { } The results of the present work were combined with thermodynamic data reported in the literature to obtain expressions for the AGO for the reaction above V,0,(1) and the AGO of formation (units in cal/g-mole).

Jan 1, 1993

By Y. A. Chang

The objective of the present study is to evaluate and compile the relevant phase equilibria and thermodynamic data reported in the literature for the ternary system Cu-Fe-S. It is hoped that the results presented here will be useful to practising engineers and scientists in industry who are attempting to improve continually the existing processes of copper extraction and refining. At the same time, the present work will undoubtedly reveal the lack of some basic data which are important for the improvement of our existing extractive processes. Lastly, this work will also show that the development of theoretical models for the alloy phases in the Cu-Fe-S system is essential before complete consistency between the phase equilibria and the thermodynamic data can be achieved.

Jan 1, 1976

By Elli Nurminen

In this work the thermodynamics of the metallic sulphate decomposition reactions were studied through thermodynamical calculations and thermogravimetric methods. The decomposition temperatures and mechanisms were determined for cupric sulphate, ferric sulphate and also for industrial flue dust from a copper flash smelting process. The aim was to determine the thermodynamic conditions for sulphate decomposition and to estimate whether the reactions are kinetically likely to take place in the flash smelting process heat recovery equipment. The information is essential in CFD-modelling of the reactions taking place in the boiler and for optimising the process.

Jan 1, 2006

By G. St-Amant, V. Cloutier, E. Ghali, S. Jin, G. Houlachi

During the casting of lead-silver anodes, variations in cooling rates result in the formation of an uneven microstructure. The slowly cooled areas (SCA) have a coarser microstructure than that of the remaining part (called "the general zone"). The effect of anode microstructure on the electrochemical behavior was investigated using galvanostatic, potentiodynamic and electrochemical impedance techniques. The results show that the resistances for the two steps of the oxygen evolution reaction on the slowly cooled areas of Pb- Ag anodes are higher than that on the general zone. The double layer capacitance for the first step of the oxygen evolution reaction (OER) and the pseudocapacitance of the second step of OER on SCA are smaller than those on the general zone. The potentiodynamic results show that the amount of lead dioxide formed on the SCA is greater than that of the general zone of the anode. The potential decay curves after 30 minutes of galvanostatic polarization at 45 mA/cm2 show that the corrosion potential of the SCA is 200 mV lower than that of the general zone. This can lead to perforation because of the formation of a galvanic cell with a small anode and a large cathode.

Jan 1, 2000

By A. L. D. Skury

In the synthesis of diamond, the precursor graphite must present a degree of crystallinity to assure optimum yield and quality for the transformed crystals. X-ray diffraction, SEM and TEM analyses were carried out to investigate the structural and morphologic transformations produced in natural graphite by high pressure-high temperature treatment. The present study had as its objective to characterize the morphological and structural changes suffered by a natural graphite that was subjected to high pressure and high temperature treatments in the region of diamond thermodynamic stability. The results indicate that the material that constitutes the gasket, for the deformable capsule, could act as catalyst in the graphite recrystallization process.

Jan 1, 2006

By Jeremy Gregory

The disposal of end-of-life electronics is an issue receiving increasing scrutiny. This paper evaluates several alternatives for recycling cathode ray tubes (CRTs) within monitors and televisions. The primary recycling options for the glass, reuse in new CRTs or as a smelter flux, are examined from economic and environmental standpoints. The economics are modeled using a cost model that includes dependencies on processing costs, transportation logistics, and incoming material composition. The environmental consequences are modeled using life cycle assessment methodologies to determine the energy embodied in each processing alternative. Results map out preferred processing alternatives across a range of technological and operational conditions. The results indicate that economic costs and environmental consequences are heavily impacted by transportation. The preferred destination of CRT glass for a recycler is highly dependent on the proximity of the consumer to the recycler, although it is generally economically advantageous for the recycler to extensively dismantle the CRTs.

Jan 1, 2006

By Andreas Stieben, Pierre Lutomski, Wolfgang Bleck, Martin Fischer

"For steel investigation and development, exact knowledge about the microstructural state is required. The information gained from 2D images often can't properly reflect the real 3D microstructural properties. In order to gain reliable information for meaningful models, simulations and correlations, it is necessary to accompany standard metallography with 3D information, which, unfortunately, is very difficult to access. This article presents a procedure for serial sectioning in combination with light optical microscopy. Only standard metallographic tools are employed in combination with image manipulation freeware. 3D microstructural data were extracted from three multiphase steel grades and in two cases virtual 3D-models of microstructural phases were generated.Three Dimensions Of MicrostructuresSince the invention of steel, craftsmen, inventers and engineers tried to improve its properties and tailor them to the requirements of new developments. For systematic development and enhancement of steels, the capability to investigate its inner structure is highly important, because it represents the linchpin between material production and properties. By having an in-depth understanding how production conditions form the microstructure and also how the microstructural state determines the material properties, steel design can be drastically improved. With this knowledge, microstructures can be designed to provide target material properties and process conditions can be identified that form these structures. Due to the key role of microstructure, the capability to gain accurate information about it is indispensable. It is the task of metallography to access and extract descriptive quantitative microstructural data like fractions, sizes, shapes and distributions of the different constituents. The most commonly used investigation tool in metallography is the light optical microscope (LOM). Besides this tool, additional high resolution techniques like Scanning Electron Microscopy (SEM) or Transmission Electron Microscopy (TEM) have become increasingly important. With these and other available methods, extensive information on the microstructural state of a material can be gained. Unfortunately, most metallographic methods have a major loss of information systematically built in. Analyses of microstructures are usually performed on surfaces, i.e. on 2D areas that emerge by cutting through the 3D material structure. This means, a complete dimension of information is not taken into account. How serious this reduction of information is and how it can affect interpretation of structures is exemplarily demonstrated in figure 1, which displays the planar structure emerging from a random cut through a simple 3D structure. It is very difficult to deduce or even imagine the original spatial structure from which this projection emerged and it is impossible to reconstruct it with absolute certainty without further information. The image has emerged from a random cut through a 3D structure of stacked cubes that is displayed in figure 2. The area shown in figure I is outlined. Although artificially constructed, this example demonstrates how distorted and misleading the view on structures can become by ignoring a spatial dimension."

Jan 1, 2012

By L. J. Lutz

The U.S. Bureau of Mines has developed an electrorefining process to recover Ni, Co, Cr, and other metals from mixed and contaminated superalloy scrap. The superalloy scrap is cleaned then directly electrodeposited as a Ni -Co deposit. The process recovers approximately 90 pct of the Ni-Co available from the scrap as a 99t pct pure Ni-Co alloy. During electrorefining the electrolyte undergoes a purification process which results in Cr and other refractory metals reporting to the purification residue. Operating data is given for a 3-L compartmented electrolytic cell. Techniques for the removal of Fe, Cr, and trace impurities from the recycled electrolyte are outlined. The economics of a facility producing 15 mt/d of a Ni-Co alloy are also discussed.

Jan 1, 1993

By S. P. Mathew

The ISASMELT Lead Process is a continuous two stage process for the production of crude lead from concentrate. It is based on the use of a top entry submerged Sirosmelt lance to produce turbulent baths in which high intensity smelting or reduction reactions can occur. The process involves oxidizing the concentrates in the first stage to produce a high lead slag. This slag is tapped continuously and transferred down a launder to a second furnace where it is reduced with coal. Crude lead and discard slag are tapped continuously from this furnace through a single taphole and separated in a conventional forehearth. Process and engineering design work for a commercial scale Lead ISASKELT plant designed to produce 60000 tpa crude lead has been completed. This plant is planned to be operational in 1991.

Jan 1, 1990

By T. T. Chen

Copper anodes generated from copper scrap are relatively rich in Sn, Zn and Fe. Because of the presence of oxygen, only trace amounts of Sn occur in solid solution in the copper crystals. Thus, Sn occurs mainly as SnO2, Cu-Sn-Ni oxide and Sn-Ni-Zn oxide in the copper anodes, and Zn and Fe occur mainly as minor constituents in the Sn-Ni-Zn oxide and Cu-Sn-Ni oxide. During electrorefining, these oxide species are liberated from the copper anodes and report directly to the anode slimes. The trace amounts of Sn present in solid solution in the copper crystals dissolve but reprecipitate as Sn arsenate or a Sb-As-Sn-O phase. Accordingly, high Sn contents in copper anodes do not lead to elevated Sn concentrations in the electrolyte.

Jan 1, 2010

By M. E. Ramos Rada

Mexicana de Cobre, which is part of Grupo Mexico, carried out studies for the construction of a copper refinery in the La Caridad Metallurgical Complex located in Nacozari, in the state of Sonora, Mexico. After the studies were concluded, the decision was made to construct a 180,000 t/y refinery using the state of the art permanent cathode Kidd Process. The basic engineering was developed by Fluor Daniel and the detail engineering and the construction were carried out in record time by the Mexican company Bufete Industrial. During the construction phase, Grupo Mexico decided to expand the refinery, and actions were taken to increase its capacity by an additional 120,000 t/y; the final result was a refinery capable of producing 300,000 tonnes of grade A cathode per year. Construction began in January 1996, and the operation of the first stage began on July 1, 1997. The operation of the second stage commenced on January 7, 1998. The capacity of the first stage was reached in November, 1997 and the total capacity of the refinery was achieved in May, 1998. This presentation describes the process and equipment installed in the refinery, the steps leading to the start-up, the operation and the results obtained during the first two years, the handling of anodes with high impurity contents, and the problems confronted and the way they have been solved. It also includes personnel productivity, the control parameters and the most relevant data on the operation of the process.

Jan 1, 1999

By Norbert L. Piret

During smelting of copper, arsenic in the feed reports to a large extent to the gas phase and some enters the anode copper. From the gas phase it is transferred during wet gas cleaning directly, or indirectly after dust processing, to aqueous solution. During the electrorefining and anode slimes processing, the anode arsenic content is also transferred to aqueous solution. Technology for the efficient removal of arsenic from process streams and cleaning of aqueous effluents is well established. However, the arsenic-bearing products, which thereby are generated, can vary widely in consistency, quality and quantity, from large amounts of gypsum contaminated with water-soluble arsenic compounds to residues with high arsenic content ' or arsenic products. Arsenic management in a copper smelter not only is involved with the duty of compliance to the gaseous and aqueous emissions standards but also should have as objective the minimization of the generation of arsenic-bearing and, in general, heavy metal-bearing solid waste. The present paper outlines options and the associated economic aspects for minimization of arsenic-bearing solid waste generation, for improvement of the environmental compatibility of the residues to be deposited and for the .production of commerciable arsenic compounds under appropriate market conditions.

Jan 1, 1999

By Denise Nascimento, Alice Barreto Bevitori, Felipe Perissé Duarte Lopes, Renan Carreiro, Sergio Neves Monteiro, Isabela Leão Amaral da Silva

"Natural fibers obtained from plants have increasingly been used as reinforcement of polymeric composites in engineering applications. This is the case of the fiber extracted from the piassava palm tree, a native of the southeast region of South America, which for a long time has been used in simple items like brooms and brushes. Recently it was reported that the tensile strength of the piassava fiber varied inversely with the equivalent diameter. Following that previous work, the elastic modulus and the density dependence on the diameter of stiffer piassava fibers of the Attalea fiinifera species was investigated. Precise measurements with a profile projector and Weibull analysis of the experimental results indicated that both the elastic modulus and the density of piassava fibers also follow an inverse correlation with the diameter. Scanning electron microscopy observations of the microstructure and fracture surface showed that defects and participation of microfibrils are responsible for this correlation.IntroductionIn the past decades, both the increase in the price of the petroleum and climate changes due to greenhouse gas emissions are motivating the use of renewable and low cost natural materials as a substitute for energy intensive and CO2 contributor synthetic materials [1]. A typical case is that of natural cellulose-based fibers extracted from cultivated plants in comparison to glass fibers, which are extensively used for composite reinforcement. In fact, these natural lignocellulosic fibers are increasingly being investigated [2-6] as possible reinforcements of polymeric composites, and in some cases, successfully replacing glass fiber composites in engineering applications [7]. The automobile industry has remarkable examples of lignocellulosic fiber composite substitutions [8-10]. Not only do some of these fibers display specific mechanical properties comparable to glass fibers but their composites also contribute to lower equipment wear and better finishing of molded components [6]."

Jan 1, 2012

By Jinwu Kang

The hydraulic turbine blade of the matensitic stainless steel (Cr13%,Ni5%,Mo1%) is a kind of large and curved shape, which is susceptible to deformation in both casting and heat treatment processes. The coupling analysis of heat transfer, phase transformation and stress in heat treatment process of the turbine blade for Three Gorges Project is carried out by using Deform-3D software. Its temperature fields, phase fields and stress fields in heat treatment process are obtained. And its deformation is predicted. In the cooling process of normalizing, the blade exhibits relatively large deformation. Based on the stress analysis and deformation prediction in heat treatment process, an algorithm for the determination of reverse deformation of the blade casting in heat treatment process is presented. And the reverse deformation distribution of blade is obtained.

Jan 1, 2010

By Ruiqing Li

It is possible to purify some liquid metals by exploiting the difference between the vapour pressure of the bulk metal and the minor constituents or impurities. The rates of purification can be improved by carrying out the process under reduced pressure, that is, so called, vacuum. Some commercial examples of vacuum refining are the purification of molten tin to eliminate trace amounts of lead and the refining of cobalt, also to remove lead. The objective of this paper is to review the basic theory behind vacuum refining technology in order to show how the feasibility of vacuum refining can be determined simply for a particular system by evaluating Olette's Volatility Refining Criteriont.

Jan 1, 1991

By Chikabumi Yamauchi

The comprehensive scientific development of conventional industrial technologies stimulates the creation of new ones in the next generation. Prof. Akira Yazawa has just accomplished such an important work in the non-ferrous pyrometallurgical field. The results of his successful research are immortal. The research group of the author has conducted since 1985 fundamental studies on the application of sodium carbonate slag to copper fire refining. In the present paper, a calculation method for the distribution ratios of impurity elements between sodium carbonate slag and molten copper will be shown. The specific treatment by sodium carbonate slag will also be presented as an effective way for reducing each impurity content in the molten copper to 0.1 mass ppm, which is the level required for the production of high purity copper. The thinking-out of this evaluation method gets a hint from the Equation (2) in the text which was proposed by Prof. Akira Yazawa.

Jan 1, 2003

By Holger Cordes

X-ray diffraction has long been used for qualitative and quantitative mineral analysis but Rietveld data analysis is still an under utilized method for mineral exploration and processing applications. In this full-profile approach the structural parameters of each mineral phase, together with experimental parameters, are refined by least-squares methods to minimize the difference between observed and calculated diffraction patterns. The result is a standard-less, quantitative analysis of the mineral abundance in the sample that is more accurate and considerably faster compared to traditional methods. The TOPAS software package combines a user-friendly interface with a unique approach to resolve overlapping peaks. Automated analysis options are also available and significantly reduce analysis time for routine samples. Several examples on a wide range of naturally occurring rock types are shown that illustrate the capabilities and limitations of the method. The examples include several options for the quantification of amorphous constituents like volcanic glasses.

Jan 1, 2006

By Yavuz Ali Topkaya

Rare earth ferrosilicide is a versatile alloy mainly used to control the detrimental effects of sulfur in steel and to modify graphite structures in cast iron. The aim of this study was to determine the optimum conditions to make rare earth ferrosilicon alloy using a preconcentrate produced from a bastnasite type of ore present in the Beylikahir-Eskisehir region of Turkey. This concentrate contained 23.5%REO, 41.37% CaF2, 10.69% BaSO4, 8.50% CaCO3, 4.18%Fe2O3, 2.83% Al2O3, 2.74% SiO2, 1.20% P2O5 and small amount of other oxides. The initial metallothermic reduction of this concentrate using ferrosilicon and aluminum in a graphite crucible placed in a muffle furnace gave very low recoveries due to the difficulties encountered in adjusting the slag composition, temperature and amount of additives. Therefore, two batches of rare earth oxide concentrate containing 61.1% and 81.7% cerium oxide, respectively, that were procured from a Turkish glass producer, were used to optimize with respect to temperature, duration, slag-making additives and amount of reducers. In these experiments, smelting and reduction was done in an induction furnace with graphite crucible, and, ferrosilicon and aluminum were added after melting the charge. As a result, there was no difficulty in obtaining a rare earth ferrosilicon alloy containing 35-55% RE, 5-25% Fe and 20-40% Si, with about 80% metal recovery. When the optimum conditions were applied to the preconcentrate, alloys of similar compositions were obtained with 70-80% recovery. Experiments were also done with mixtures of preconcentrate and rich concentrate, and, recoveries as high as 95% were obtained. Only in this case, to increase the recovery, mixtures had to be charged to the empty graphite crucible after heating the crucible to the required temperature.

Jan 1, 2006