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By Ray Y. Lin, Sunil G. Warrier

"Low cost processing of metal matrix composites is an essential requirement for this class of materials to be acceptable in commercial application. In an effort to reduce the cost of processing of metal matrix composites, an infrared pressureless liquid infiltration technique has been developed. The salient features of infrared infiltration are that it is rapid, simple and a low cost process. The rapid processing capability causes very little oxide formation on the alloy resulting in both improved wetting and flow characteristics and reduced oxygen contamination in the composite. Thus, vacuum is normally not required. Using infrared inflltration, aluminum and titanium matrix composites have been prepared under an ambient argon atmosphere. Reinforcements in these composites include carbon fibers, silicon carbide Nicalon fibers and Textron's SCS fibers. Microstructural and mechanical test results indicate that completely consolidated composites with good fiber distribution, limited interfacial reaction and high mechanical properties can be manufactured by this process. IntroductionAluminum and titanium matrix composites reinforced with ceramic reinforcements are strong candidates for numerous applications in the aerospace and automotive industries. Aluminum matrix composites are commonly fabricated by either solid state vacuum hot pressing, liquid state pressure infiltration or squeeze casting [1]. Although liquid state pressure infiltration and squeeze casting has significant advantages over solid state processes, the requirement for pressure makes these composites uneconomical for large scale industrial application. Titanium matrix composites are primarily fabricated by solid state diffusion bonding [2]. Pressureless liquid infiltration can significantly reduce the cost of fabrication in both the composite systems. However, during pressureless infiltration processes, several complications concerning the wetting characteristics and chemical compatibility arise."

Jan 1, 1994

By Shijie Wang

In pressure oxidation leaching of copper anode slimes, than 65% of the tellurium is m' cxtraoted during decopperizing. About l0- 15% of the selenium is also dissolved simultane¬ously by severe leach conditions. Current operation for the treatment of the leachate is to constantly recirculate the leach solution through a bed of copper turnings. The tellurium and sele¬nium are precipitated from the leach liquor as copper telluride and copper selenide and sepa¬rated from the solution by filtration. In order to improve the reaction efficiency and reduce the process cost, viz, minimize the copper addition, cut retention time, and reduce the energy consumption; a chemical reducing agent is studied and the cementation process tested in the laboratory. In this paper, the test results are presented and the process chemistry is discussed.

Jan 1, 2003

By Jogre A. S Tenório

he aim of the present investigation was to investigate technological features of the Fe-NbC dissolution in liquid Fe-C alloys. Fe-NbC is a Ferro-niobium alloy with 7%C, has a particle size smaller than 150 pm and its micro constituents are polygonal niobium carbides and an iron matrix. The obtained dissolution time was less than one-minute and the yields were in the range of 80-90% at 1873 K. In the Fe-NbC dissolution process, the dissolution occurs at first, and as a consequence the niobium carbides become free to dissolve. These carbides will dissolve until the melt reaches a saturation point. The non-dissolved carbides remain trapped in the liquid or will form a dross. The addition yields decreases when the niobium concentration reaches this limit value, that depends on the carbon concentration. These define a saturation curve.

Jan 1, 1994

By Hongbo Yang, Tongbo Zhang, Ting Huang, Jingshe Li, Fangfang Song

"Liquid core length is a very important parameter of the process of continuous casting, which directly reflects the cooling status in secondary cooling zone and solidification rate of the slab. In this paper, the billet caster in some steel plant in China was chosen as the prototype of simulating. A numerical simulating model for calculating the liquid core length of continuous casting billet was built by ProCAST software, which was verified reasonable and accurate by pin-shooting technique. Based on the model, the relationships between casting speed, casting temperature and liquid core length of casting billet were found, which was very practically useful for the workers on sit to improve casting billet quality. IntroductionContinuous casting process developed very rapidly because of the high metal yield, energy saving, and low-cost 111• And the quality requirements of continuous casting billet for customers became higher and higher with the fast development of economic121• Internal defect usually is the major quality problem for continuous casting billet[3•61 , which is influenced by the solidification process of casting billet, especially the solidification process of liquid core17•81 • So it is very important to study on the relationship between casting parameters and the liquid core length which means the distance between the crystallizer meniscus and the casting billet solidification end-point. In practical production process, the workers usually control the quality of casting billet according to the liquid core length."

Jan 1, 2013

By Yuzhe Zhang, Xiaodi Huang, Xinli Wang, Bowen Li, Matthew Andriese, Jiann-Yang Hwang, Zhiwei Peng, Likun Li

With the development of the world, the waste tires have been a serious environmental problem. There are about 2 billion waste tires produced all over the world every year and about 500 million waste tires are produced in the United States. Most of the waste tires are land filled, which waste a lot of space. It takes hundreds of years to resolve the macromolecules of waste tire into the standard which does not pollute the environment. Microwave irradiation is a thermal processing way for waste tires decomposition. In this study, the relative dielectric loss factor of the tire at various temperatures was determined to understand the behavior of tires under microwave heating.

Jan 1, 2016

By Yang Guangqing, Shao Jiugang, Zhang Jianliang, Wan Dan, Fu Yuandi, Guo Hongwei

"Resource of metallurgical coke is becoming scarce, and although coke can be partially replaced by pulverized coal injection, there are many restrictions for further increase in coal ratio. Mixed charge of ore and lump coal from top to replace more coke was studied in this paper. Softening-melting property of the burden was affected by charge of lump coal. Softening-melting properties of mixed charge of ore and coke, mixed charge of ore and lump coal were tested respectively. Results show: the property of the burden mixed with coke is superior to the burden mixed with lump coal; lump coal would not deteriorate softening-melting property of the burden and some of them can even improve softening-melting property of the burden. Top charge of lump coal would not deteriorate softening-melting process, and this should be a new way to increase coal consumption to decrease coke rate.IntroductionThe blast furnace is still the predominant process for the reduction of iron ore and will probably remain so for the next decades. Metallurgical coke is becoming scarce and expensive, so the cost of hot metal can be decreased by reducing the consumption of metallurgical coke[l]. Coke can be partially replaced by pulverized coal injection, currently the highest rate of pulverized coal reached 266kg/tHM, most of blast furnace PCR is about 150kg/tHM, and it is very difficult to further increase of PCR. Nut coke is charged into blast furnace mixed with iron ore, not only for improving utilization of metallurgical coke, but also for lowering the coke rate. Presently the majority of blast furnaces in the world use nut coke although its amount is very different: from 10-20 to 70--100 kg/tHM and more[2-4].The effect ofnut coke in blast furnace is extensively researched, and the main conclusions recommend: to improve gas permeability of cohesive layer in blast furnace, to promote reduction of iron burden, protect metallurgical coke from the solution in the shaft due to higher reactivity of nut coke. There is no special requirement for the strength of nut coke[5-8]. Nut coke is also used for sintering fuel, which may lead to the shortage of the nut coke charging into blast furnace. So lump coal mixed with iron ore is considered to be charged into the blast furnace, not only to reduce the cost of grinding coal, but also to increase the use amount of coal."

Jan 1, 2013

By K. R. Barrett

The cupellation of dore/lead bullion to recover precious metals is one of the oldest metallurgical processes known to man. In recent times this has been carried out in small reverberatory furnaces but the process suffers from a number of disadvantages. A new process has been developed at the Northfleet refinery of Britannia Refined Metals Ltd, which gives much improved performance. The process depends upon the injection of oxygen through a nitrogen shrouded lance at the bottom of the furnace. The lance is consumable and of unique design. Reaction rates are high giving short process time; fuel consumption is low; oxygen efficiency is high and dore recirculation is low. The new process has resulted in substantially lower operation costs.

Jan 1, 1989

By Zhang Jianliang, Zuo Haibin, Gao Bing, Wang Zhe

"As a result of the shortage of coking coal and the quality decrease of coke, it is important to know how to make better use of highly reactive cokes. The co-gasification behavior of highly and lowly reactive coke for blast furnace is investigated. The results show that: In the middle stage of reaction, the weight loss ratio of highly reactive coke reacted together with lowly reactive coke is higher than that of it reacted individually. However, the weight loss ratio of lowly reactive coke is lower. The weight loss ratio of highly and lowly reactive coke is almost the same as that of the weighted average. The scanning electron microscope analysis indicated that the reaction degree of surface and interior of lowly reactive coke is relatively uniform with the reaction time increased. And the reaction degree of surface of highly reactive coke is obviously higher than that of interior.IntroductionIn blast furnace iron making process, coke functions as heat supplier, reducing agent, carburizer and skeleton. With development of blast furnace iron making technology, the skeleton function of coke is becoming more and more important in requirements of large scale furnace and high pulverized coal injection. High reactivity coke is usually produced by cheap coal with bad quality, and is not good for blast furnace process. The reactivity of coke is mainly determined by the coals used, and the resource of good quality coking coal is limited and is non-renewable. In order to fulfill the need of blast furnace, a lot of research have been done to improve coal matching using new kinds of coal to enlarge resource, in which coking coal and fat coal are reduced, whereas low price coal with bad caking property are used to lower the cost, and this would inevitably increase the reactivity of coke [1-4] Blast furnace iron making would still be the main stream for a predicted future, and high reactivity coke would correspondingly be used more and more, so it has great importance to study how to use high reactivity coke in blast furnace."

Jan 1, 2013

By Tianyou Huang, Yuan Lu, Haimin Long, Jinwu Kang, Gang Nie

"The distortion of metal parts during heat treatment process is one of the main obstacles in industry to ensure high-quality work and less or no machining allowance, especially for large but thin steel castings such as heavy turbine blades. In the paper, a method is proposed to control the distortion by adjusting heat transfer coefficient of metal parts during heat treatment process. Required heat transfer coefficients can be realized by getting the metal parts into contact with various media such as water spray, insulation felt or materials with different heat conductivity. The control method based on this idea is set up and achieved. By using insulation felt and water spray to change the heat transfer coefficient during the stages of heat treatment process, the results indicate that the proper control time and vary with materials.IntroductionThe distortion of metal parts during heat treatment process is one of the main obstacles in industry to ensure high-quality work and to realize less or no machining allowance [1]. For example, the Three Gorges turbine blade’s distortion is as large as 50mm during heat treatment process. The uneven heating and cooling during heat treatment process is the main reason for distortion [2]. By adjusting heat transfer coefficient of different areas of metal parts, the heat treatment process could be controlled. The temperature variation, direct cause for distortion, could be under control. Loeser Klaus used high pressure gas to achieve uniform heat transfer during gas quenching and proposed the possibility to use ""Dynamic Quenching"" processes where the quenching severity is varied during quenching by stepwise control of either gas velocity or gas pressure [3]. Li Zhichao also suggested minimizing distortion by marking a component into several areas and imposing different heat transfer coefficients on each area [4]. Heat transfer coefficient can be controlled by getting the metal parts into contact with different media such as water spray, insulation felt, air or different heat conduction materials. In addition, the exact time to adjust the heat transfer coefficient is another factor for distortion. A method is presented in this paper by actively adjusting heat transfer coefficient for different areas of metal parts and different stages of heat treatment process to control their distortion. The corresponding experiments have been made by using different metal materials."

Jan 1, 2012

By Rina Kim

There are many factors which affect the gold cyanidation mechanism— mineral composition, free cyanide and dissolved oxygen (DO) concentrations, heavy metal additions, etc. This study combines electrochemistry and surface analysis methods to examine the effectiveness of the above factors on gold cyanidation process. Three gold ore samples were used in this study. Sample 1 was a pyrite concentrate, contained mercury and silver. Sample 2 also contained sulfide minerals, including galena. Sample 3 contained pyrite with sphalerite and galena. In the case of samples 1 and 2, the presence of heavy metals enhanced gold cyanidation kinetics, though the addition of higher DO was not effective on improving the kinetics. Sample 3 showed an opposite behavior: the kinetics was not enhanced by galena, because of its relatively small amount, however, the use of higher DO made improvement in the gold leaching kinetics, likely caused by iron species generated by pyrite oxidation.

By J. Pérez

A lead smelter slag with high copper, lead, arsenic and silver contents was treated at laboratory scale for arsenic removal. The slag was first leached at atmospberic pressure with sulfuric acid and oxygen. According to arsenic contents leaching of most of the arsenic was achieved in either one or two stages, producing a lead-silver rich residue and a solution high in copper and arsenic concentrations. Alternative routes were considered to treat the resulting solution. Firstly, solvent extraction of arsenic with a mixture of TBP and 2-etbyl-bexanol was tested and extractions of over 95 percent of arsenic were achieved. Secondly, a copper arsenate precipitation treatment was done to eliminate arsenic and copper from solution.

Jan 1, 1996

By Nils Eivind Kamfjord, Roar Jensen, Ingeborg Solheim

"SINTEF has carried out several pilot scale silicon process experiments in the past, but always with an open off gas system. In order to test the possibilities in running a semi closed furnace operation, a new off gas hood has been designed and tested. The off gas hood is designed to collect all off gases to gain insight into the phase compositions in the off gas and at the same time have the opportunity to monitor and maintain the charging/stoking of the furnace. The furnace hood has regulation and control of the air inlet into the combustion zone in two different heights. The off gas temperature and composition was continuously monitored and analyzed during the experiment. In order to expand the knowledge on NOx- formation in silicon metal production, such information is vital.IntroductionBecause of the negative environmental impact, the attention towards all kinds of NOX emissions increases in Norway. The authorities’ demand towards better surveillance and control of emissions increases as well.Earlier and new industrial measurements in FeSi- and Si-metal furnaces reveal quite high NOX-emission. The measurements also show that the NOX formation (mainly as thermal NOX) is distinct connected to the formation of dust (SiO?SiO2) in the combustion chamber above the furnace surface, when the temperature is high and the access to N2/O2 is good. This means that stoking, charging and temperature straight above the furnace surface is important factors for the NOX formation."

Jan 1, 2012

By Xiao Songwen

Based on the anion coordination polyhedron growth unit theory, the polymorph transformation mechanism of antimony white (Sb2O3) in hydro-process was investigated. The new findings had been verified in the commercial-scale test and it was shown that adding a small amount of tartrate ions was economical and effective for polymorph transformation of antimony white in hydro-process.

Jan 1, 2003

By Shigem Kuramoto

Pure copper is known to exhibit intermediate temperature embrittlement when it is deformed at a slow strain rate, and a small addition of zinc suppresses this embrittlement. In the present study, the relation between zinc addition and hydrogen behavior was taken into account since the impurity hydrogen is believed to deteriorate the ductility at intermediate temperatures. Pure copper and Cu-l mass % Zn alloy specimens are prepared by melting in argon and in vacuum, so that a comparison can be made between the specimens with normal hydrogen content and those with' less hydrogen content. Tensile tests are performed at temperatures ranging from room temperature to 600 "C, and hydrogen behavior is analyzed using a newly developed testing machine that can detect gas evolution from the specimens during deformation and fracture in ultra high vacuum. The small addition of zinc to pure copper decreases hydrogen content, leading to the improved ductility at intermediate temperatures. In addition, the samples of both pure copper and Cu-1%Zn melted in vacuum exhibited higher ductility at intermediate temperatures than those melted in argon atmosphere, which is attributed to reduced hydrogen content.

Jan 1, 1998

By Cheng Yan, Yugang Li, Qian Wang, Lizhi Zhang

In continuous casting process, mold powder has lots of metallurgical effects, such as covering the molten steel to prevent liquid steel from oxidation by air, preserving heat for top layer liquid steel, lubricating initial shell and so on. However, mold powder also can deteriorate the quality of final products obviously after the entrapment of mold powder in steel. In the present work, based on the similarity theory the effect of technological parameters on mold powder entrainment was investigated by water model. Experiment was carried out in the water mold using oil and water to simulate slag and steel, respectively. The results showed that increasing casting speed increased the water-oil interfacial fluctuation and entrainment frequency; viscosity of oil also had a great impact on the interface fluctuation and entrainment; water-oil interfacial tension effect the entrainment while not changing the interfacial fluctuation; submergence depth had little impact on entrainment and interfacial fluctuation.

Jan 1, 2015

By Junji Shibata

It is important to recover and reuse the metal values contained in various industrial wastes in a viewpoint of environmental preservation. Most of industrial products are made through the processes to separate impurities in raw materials, solid and liquid wastes being necessarily discharged as industrial wastes. Chemical methods such as solvent extraction, ion exchange and membrane, and physical methods such as heavy media separation, magnetic separation and electrostatic separation are considered as the methods for separation and recovery of the metal values from the wastes. In this paper, some examples of the application of solvent extraction to the treatment of wastes are introduced. The treatment of solid wastes such as Ni-Co alloy scrap, Sm-Co alloy scrap, fly ash and flue dust, and liquid wastes such as plating solution, the rinse water, etching solution and pickling solution are accomplished using solvent extraction technique.

Jan 1, 1996

By Tatiana Pereira Moreno, Priscilla Aki Mori de Hanashiro, Viviane Tavares de Moraes, Denise Crocce Romano Espinosa, Hugo Hashimoto

"Nowadays, End-of-Life (EoL) Liquid Crystal Displays (LCDs) are traditionally disposed in landfills. The increasing access to LCD technology over the last years by Brazilian consumers has intensified LCD' s disposal as an environmental and economic issue. This study aims to characterize used LCDs to identify the main components for recycling. Characterization was performed through scrap disassembly and its components were identified, separated, and weighted. LCDs were disassembled and the following divisions were applied: screen, metal frame, polymeric frame, polymeric sheets and electronic part. Some techniques were used to determine the concentration of Indium in the LCD, the glass/plastic ratio and the different kinds of polymers that compose the screen. The techniques used for characterization included inductively coupled plasma optical emission spectrometry (ICP-OES), Fourier transform infrared spectroscopy (FTIR) and thermogravimetric analysis (TGA). This method, when applied to a wide range of LCDs, can allow the development or improvement of an EoL management of LCD.IntroductionWaste Electrical Electronic Equipments (WEEEs) are waste from discarded equipment, such as computers, monitors and cellphones [1]. Over the past years, treatment of WEEE has been emphasized. It occurs due to the technology's advancement that leads to an even larger increase of WEEES [2].Among WEEEs, there are the liquid crystal displays (LCD). LCD technology is applied in cell phones, tablets, computers and monitors. Nowadays, it's the most well known technology when it refers to monitors, due to its advantages over the Cathode Ray Tube (CRT) technology. Some of them are energy saving, smaller size and no radiation emission [3].This feature in the LCD's global market along with the speed at which electronic equipment becomes obsolete affects society economically and ambiently.This issue becomes even more serious when considering the final destination of the liquid crystal displays. LCDs are lead to landfills as other WEEEs. Besides the different materials long degradation time, the environment is damaged by the disposal of the potentially reusable and hazardous materials [ 4]."

Jan 1, 2014

By Fumitaka Tsukihashi

Phase diagrams of the CaO-SiO2-FeOx-MgO, Al2O3 systems are necessary for the analysis of copper smelting reactions and sintering process of iron ore. The effect of MgO and Al2O3 addition on the liquidus of the phase diagram of the CaO-SiO2-FeOx system at low oxygen partial pressure was observed. The liquid phase area changed by the addition of MgO and Al2O3 with a changing oxygen partial pressure from 10-8 to 10-3 atm (10-1 to 102 Pa) at 1573K. The effect of Fe3+/Fe2+ ratio on the melting mechanism is discussed.

Jan 1, 2003

By Steve Naruk

Microscopic point-count analyses, although time-consuming, provide detailed mineralogical information which is not obtainable by any other means. Such information can be invaluable for evaluating mill circuit behavior. In comparing two months of operation of a Cu-Pb-Zn sulfide flotation circuit, chemical analyses show that higher copper recoveries and concentrate grades were obtained from lower grade ore, but they provide no explanation of how the improvements were obtained. Quantitative micro-scopic analyses, on the other hand, show the following: 1. There was no change in the identity of the Cu-bearing minerals. 2. Increased copper recovery was achieved primarily by increased recovery of chalcopyrite middling particles. 3. The increased recovery of chalcopyrite middling particles also increased the amount of gangue entrained as locked particles. 4. Increased rejection of free gangue particles, particularly those finer than 25 microns in size, resulted in a net decrease in gangue content.

Jan 1, 1981

By Jorge A. S. Tenorio, Girley F. Rodrigues, Joner O. Alves, Denise C. R. Espinosa

"Rock wools are mineral fibers composed of amorphous silicates, due to their thermo-acoustic characteristics this material has a broad consumer market in the construction, automotive, and electric-electronics industries. This work studied the recovery of wastes from ornamental rocks (granite and marble) as partial raw materials in the production of rock wools. Residues from granite and marble cuttings are industrial wastes with considerable production and limited applications. These wastes should be appropriately managed because when discharged in rivers or lakes can cause siltation, and also they can cause serious human health problems, such as silicosis. Samples of produced materials with thickness smaller than 500µm were characterized by chemical analyses, XRD, and DTA. Results showed that the rock wools produced using granite or marble wastes have important properties, especially the melting point. This process decreases the extraction of mineral resources and provides a profitable destination for the ornamental rock wastes.IntroductionThe ornamental rocks industry is a sector with large production of wastes. During the granite and marble extraction processes and specifically during the rocks cutting (see Figure 1), approximately 35 tons of powdered rock per month can be produced. These residues should be appropriately managed, because when discharged in rivers, lakes or watersheds, they can cause siltation. Also, these wastes can cause serious human health problems, such as silicosis [1].Currently, the granite and marble wastes are mainly used in civil construction to produce materials in the form of mortar, bricks and tiles. However, due the current produced volumes and the average growth of world production estimated at 6% per year, new applications for these wastes are necessary [2]."

Jan 1, 2011