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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 Takaaki Shibata

The Tamano Refinery has developed two new processes for removing the impurities, arsenic, antimony, and bismuth from an electrolyte. The first process involves bleeding the surface electrolyte in the electro-refining cells. The copper concentration level in the outermost layer is lower than that in any of the other layers, while the impurity levels are almost the same in all layers. Bleeding the surface electrolyte increases the amount of impurities removed in the liberator by approximately 20%. The second process involves adsorbing antimony and bismuth from the electrolyte by means of chelating resin. As the electrolyte passes through the packed column of chelating resin, antimony and bismuth are selectively adsorbed. They are then desorbed by means of hydrochloric acid, and then recovered in the form of a highly concentrated antimony chloride solution by means of evaporation. This process almost doubles the capacity for removing antimony from an electrolyte.

Jan 1, 1987

By Ruirui Wei, Yanhui Liu, Fangqing Yin, Meilong Hu

In China, Basic Oxygen Furnace (BOF) slag is traditionally used as an aggregate for civil engineering, for road engineering and fertilizer. In order to make full use of BOF slag, the experiments of BOF slag with high temperature roasting has been carried out and the phase transformation is studied. The BOF slag from Chongqing Iron & Steel is roasted in the electric muffle furnace at three different temperature. The influences of the high temperature roasting on change the phase composition of BOF slag was characterized by XRD. The results revealed that SFCA was produced at the high temperature in air atmosphere and melting temperature of slag was lowered. Therefore, if the BOF slag which treated by roasting was utilized in the sintering process, it is advantageous to improve the sintering strength and the formation of the liquid phase and reduce fuel consumption in the sintering production process.

Jan 1, 2015

By Jack A. Simon

My remarks are directed at relating some of the mineralogical approaches mentioned in the preceding presentations to emerging energy issues. The assembling of this symposium on process mineralogy attests to the growing concern for energy development from the non-petroleum mineral fuels and the unconventional petroleum fuels. A report in 1979, prepared under the auspices of the National Research Council/National Academy, of Sciences, was published in two parts and dealt with "Redistribution of Accessory Elements in Mining and Mineral Processing." This report rather comprehensively considers broad aspects of minerals associated with the solid fuels considered in this symposium and focuses attention on some problems of process mineralogy relative to these fuels. Papers have dealt with coal, oil shale, tar sands, and uranium minerals. Problems associated with mining, processing, and use of these materials have significant differences, but also have some factors in common relative to the subject of this symposium.

Jan 1, 1981

By Tang Mo-tang

A new process for extracting indium from indium-zinc concentrates was proposed in this paper. The process can directly extract indium from removed copper solution by P204, and cancel the stage of removing iron in the traditional process because of using iron and part of zinc in the In-Zn concentrates for direct preparing high quality Mn-Zn soft magnetic ferrites. The technologies in the processes, such as leaching the neutral leached residues with high concentrated acid at high temperature, reduction ferric and removing copper, and extracting indium, were investigated. The results showed that total recovery ratio of indium has been increased from less than 70% in the traditional process to more than 95%. This process has the advantages of largely simplifying the procedure of indium extraction, zero draining off of iron residue and zero emitting of SO2. So this is a clean production process.

Jan 1, 2006

By W. H. Jay

Sulphide-containing minerals, particularly iron, lead to acid formation. In turn, the acid generates effluents such as copper acid drainage (AMD). The Berkeley Pit in Butte, Montana, USA and Mt Lyell in Tasmania, Australia, represent just two of many sites throughout the world for which acceptable treatment methods are required. In the gold cyanidation process, the presence of copper creates both a significant cost impediment and a potential environmental hazard. The tailings dam failure at Baia Mare in Romania which led to the release of copper and zinc cyanides created a major environmental disaster. The application of non-toxic water soluble polymers and ion exchange resins to selectively recover copper from AMD solutions, and the in-plant treatment of copper cyanide solutions and slurries to recover copper and recycle cyanide to prevent cyanide entering the tailings impoundment will be discussed. The economics of the various processes will be highlighted.

Jan 1, 2003

By Corby G. Anderson

Over the past 15 years, numerous pressure oxidation plants for pretreatment of gold ores and concentrates have been installed throughout the world. While this technology is now established, it suffers in terms of the complex engineering and operational characteristics inherent in utilization of high temperatures (i.e. up to 225oC) and high pressures (i.e. > 3000 kPag). This paper outlines the application of an industrially proven pressure leaching methodology utilizing nitrogen species catalyzed pressure leaching and alkaline sulfide gold leaching. As such, it stands as an economic and engineering advancement in pressure leaching and non-cyanide treatment of gold ores and concentrates. In particular, the technology offers significant technical and economic advantages over traditional pressure oxidation and cyanide gold recovery in the treatment of gold bearing chalcopyrite ores and concentrates. An example of this will application will be delineated in this paper.

Jan 1, 2003

By W. John Rankin

Professionals, technical and non-technical, working in the mineral and metal commodity industries need to understand the concept of sustainability and its implications for the industry. Undergraduate courses have not done this well in the past. Much has been written in this field, and there have been great advances in understanding. However, much of what has been published is superficial and sometimes misleading, and there is as yet no coherent, single account that can serve as an introduction or overview for mineral industry graduates. This paper presents an outline which can guide readers in developing an understanding of the topic and its relevance to their work. Key references are provided, particularly those accessible on the internet, which will serve to introduce the reader to the important principles and understandings. The guide should also be useful to academics preparing students to work in the minerals and metal production sectors.

Jan 1, 2010

By Kwang-Ho Lee

The Onsan copper smelter of LS-Nikko Copper Inc. has operated the Mitsubishi continuous process along with Outokumpu process since 1997. Mitsubishi process is a bath smelting process which needs adequate melts for smelting reaction in the furnace. After a campaign shutdown it requires time to make a start melt. Onsan smelter has had much experience in flash smelting, including the improvement of the concentrate burner which is one of the most important parts in a flash smelting furnace. Based on this experience, the lances of the Mitsubishi smelting furnace were modified in order to making the starter melt with flash reaction. In 2004, the flash reaction in the Mitsubishi S-furnace was completed and was able to make the starter melt using these modified lances. Although at that time it was still under development it reduced the time required to make the initial bath-melt by about half.

Jan 1, 2006

By S. Ozbilen

"Al-Li binary alloys with nominal Li contents of0.15, 1.1and2.8 (in wt%) were aged naturally at room temperature for two months, aged at low temperatures ( 65 and 1 OOEC) for up to 2 months and aged artificially at 190EC for 4 days after water quenching to 25EC following solutionizing at 530EC for 20 minutes. Ageing behavior of these binary alloys were studied by Vicker's Hardness measurements and DSC thermal analysis. Thermal analysis results indicate the formation of GP zones of Al-Li system in Al-2.8wt%Li binary alloy. In the same alloy, rapid quenching from one phase region (a) gives rise to precipitation of small o' particles in a matrix (a) with still high supersaturation. During ageing of this alloy below lOOEC an additional transformation, i.e., GP zone formation occurs proceeding at a very high rate which is described on the basis of the theoretical analysis for the quenched Al-Li system proposed by Khachaturyan et al [6]. Ageing at temperatures below 11 OEC takes place slowly by the formation of small d' particles of lower thermal stability than the quenched-in d precipitates in addition to GP zones resulting in an increase in hardness compared to water quenched samples. During artificial ageing, GP zones transform by dissolution to d' precipitates while d' particles already in the microstructure coarsen during under aged condition at which hardness increases with time till peak aged condition.IntroductionIn binary Al-Li alloys the d' (Al3Li) fully coherent internally ordered inetastable phase of Li2 structure with a=0.4038d [1-5] forms homogeneously between 120 and 190EC before the formation of stable d' (A!Li) phase and cause the superior mechanical properties. This is due to an appreciable age hardening effect resulting because of the d' precipitation during ageing [1]. The response of d' to decomposition and its formation kinetics have been studied previously and it is believed that the decomposition of the a-supersaturated solid solution occurs in a two stage process; i.e., a 6 d' (Al3Li) 6 d(A!Li). Khachturyan et al [6] theoretically investigated precipitation of the d' phase and gave an interpretation of the transformation paths of the quenched Al-Li alloys. They predict that the disordered supersaturated solid solution congruently orders, and then the uniformly ordered solution decomposes into ordered regions that differ in Li-content. Finally, ordered d' phase forms in the disordered matrix."

Jan 1, 1998

By S. Neogy, M. Gupta, D. Srivastava, V. Kain, S. Roychowdhury, R. C. Prasad, G. K. Dey

"Austenitic stainless steels are an important material of construction for Boiling Water Reactors (BWR). These stainless steels are amenable to strengthening by strain hardening. Various deformation modes at different test temperatures and strain become active. In the present investigation type 304LN stainless steel was used in the annealed and strain hardened condition. Thin foils were prepared from gauge section for transmission electron microscope (TEM) investigation after tensile testing at room temperature and at 288°C. TEM investigation reveals that twinning is the major mode of deformation for the tests done at room temperature while dislocation cross-slip is the major mode of deformation at higher temperature. Stacking faults were also observed to a limited extent. The extent of twinning was much higher for the tests done using the rolled material. The formation of martensite in the stainless steel due to straining was investigated by the analysis of selected area diffraction patterns.IntroductionAustenitic stainless steels (type 300 series) are an important material of construction in Boiling Water Reactors (BWR). These stainless steels cannot be heat treated but can be strengthened by cold working [1]. Nitrogen alloying of these stainless steels result in high strain hardening rates and higher strength without any loss in toughness [1]. Stress Corrosion Cracking (SCC) in BWR of these types of stainless steels have been attributed to surface strain hardening and strain hardening ofregions adjacent to constrained weldment [2].The test temperature [3, 4], prestrain [5] and nitrogen level [5] has been reported to affect the deformation mechanism during tensile testing. Byun et al. [3] have reported the formation of martensite, dislocations, stacking faults and twinning during tensile deformation, the extent of each depending on the test temperature. Strain localisation has been reported to occur during tensile deformation in irradiated stainless steels [ 6]. The behaviour of rolled material during tensile testing is similar to that of irradiated material to a large extent [3]. Austenitic stainless steels are low stacking fault energy (SFE) materials in which various types of microstructures have been reported to form during tensile deformation and the strain is also highly heterogeneous in nature in these stainless steels which aides SCC in BWR environment to a large extent [7]. During cold working of austenitic stainless steels second order twinning has also been reported [8]. Knowledge about the deformation mechanisms operative in the strain hardened austenitic stainless steels during tensile testing at different temperatures is essential to understand the material deformation behavior and the present study aims at enhancing the existing understanding."

Jan 1, 2011

By S. N. Ojha, Gouthama, R. K. Mandal

"Spray deposition processing of liquid immiscible alloys, based on AI-Pb and Cu-Pb systems have been investigated. Process variables have been optimized to generate uniform dispersion of ultrafine second phase particles in· the matrix of the primary phase. Mechanisms governing the microstructural evolution in this synthesis methodology are discussed. Results of the present investigation are used to demonstrate that rapid solidification of atomized droplets initially provides a high nucleation rate of the second phase during the liquid phase separation. The solid matrix phase nucleates at a later stage and grows with a high velocity enabling trapping of the dispersed phase. Subsequent alteration in the size and size distribution of the second phase is suggested to arise further during deposition of high velocity droplets. Possible reasons for this effect are brought out. Microstructural features of atomized powders and spray-deposits of these alloys are presented to support the present approach of synthesizing composites. IntroductionIn recent years, synthesis of advanced materials with metastable microstructures and ultra fine dispersion of second phase particles has led to the development of novel techniques of materials processing. The other requirement of such a processing methodology is to achieve near-net shape geometries in less number of processing steps. The solidification processing method via spray deposition route qualifies these criteria. This process primarily involves atomization of a melt by high energy gas jets into spray of droplets which are subsequently propelled by the kinetic energy of the gas towards a deposition substrate to build-up a thick high density preform. Although the concept of spray deposition was pioneered by Singer [1] in the early seventies, the fundamentals of the deposition process has been understood only recently [2-4]. Several benefits of spray deposition processing are by now well established [5,6]. Rapid solidification effects are inherent in spray deposition processing due to high heat exchange rate at the droplet-gas interface and also on the deposition surface by force convection. Since considerable heat extraction occurs from the atomized spray prior to droplet consolidation, a relatively low processing temperature is ensured in this process. As a result deleterious coarsening phenomenon can be minimized. In addition, controlled maneuvering of the substrate provides the capability of the process in producing disc, sheet or tube shape preforms of difficult to work materials in a single operation. A significant improvement in properties, resulting from microstructural homogeneity and refinement in grain size induced by spray deposition has been reported for several alloy systems [7,8]."

Jan 1, 1994

By G. Kugler, M. Tercelj

"The use of the up-to date light alloys and their development are in the sharp ascent especially in transportation industry. In the last years the use of the magnesium alloys for the various purposes was strongly increased. The aim of present research was to study the influence of solidification rate on hot workability and on obtained mechanical properties of AM60 magnesium alloy. The study was also focused on possibility to omit prior homogenisation process which would result in cost reduction. The solidification of gravity cast alloy has been investigated with various methods of the thermal analysis: in situ simple thermal analysis and simultaneous thermal analysis. In order to reveal optimal hot working conditions the deformation behaviour was studied in the temperature range 200-450°C and strain rates between 0.001-lOs-1. Mechanical properties have been studied with tensile and impact toughness testing.IntroductionIn recent years, the increased demand for magnesium alloys has been mainly driven by the need of automotive and transportation industry to reduce the weight, as this is the most important parameter to reduce the energy consumption. Beside their very low weight in comparison to other metals, the magnesium alloys are characterized by good machinability, corrosion resistance and good mechanical properties, and can thus compete with aluminium alloys and for some applications even with steels. Due their decreased workabilty they are typically used as cast alloys, but in recent years also the research of their wrought state has become more extensive [1-7]. Decreased hot workability of magnesium alloys originates from their hexagonal close-packed structure. One of the most popular magnesium alloys with great potential for many applications is AM60 (MgA16Mn), which is predominately used for casting. But its application could be increased if the mechanical properties, could be improved. This can be done by hot working. Namely it is well known that wrought microstructure is characterized by better mechanical properties in comparison to as-cast state. On the other hand due to its low hot workability the homogenization process is required prior hot deformation, which results in increased production costs. Thus the aim of the present research was to study the influence of solidification rate on hot workability of AM60 alloy in order to improve its mechanical properties and to check the possibility of producing near-net-shape casting products omitting homogenisation process by employing small additional deformations after casting. Within the framework of this research the solidification of gravity cast AM60 alloy has been investigated with various methods of the thermal analysis."

Jan 1, 2011

By L. M. Bianchi

"Oxide, nitride and other compound coatings often do not have adequate properties for newer applications when produced using very high deposition rates and simple evaporation techniques. Solar control, abrasion resistance, low reflectance and barrier effective engineered coatings require exacting properties. Such properties can be obtained by adapting the activated reactive evaporation (ARE) technology to Web production processes. Adaptions of the HAD and MAD processes will be described along with data on the high deposition rates obtained. These fast production capabilities were developed in order to make the processes economically competitive.IntroductionThe Physical Vapor Deposition technique (PVD) has been used to coat steel strip for over 20 years. (1) However, its use as a production process has been very limited because of the high cost of the PVD coating process and because, in some instances, the properties of the coating were not good enough to meet the customers requirements. Nevertheless, the PVD process has found wide application in the airplane engine and electronic component markets. These production processes have stimulated further development and advances in the technology.In 1971, Profession R. F. Bunshah developed the Activated Reactive Evaporation (ARE) process which was then used to produce hard coatings such as carbides, nitrides, oxides and other refractory compounds. (2) The process from a fundamental viewpoint -produces a coating on the substrate via the evaporation of metal in the presence of a low pressure (typically around 1 millitorr) of reactive gas, with a plasma created in the space between the metal source and the substrate.The plasma may be created by many means but its function is two-fold. First, it activates the reaction between the metal vapors and the reactive gas atoms/molecules resulting in the formation of a compound that deposits on the substrate. Second, because the plasma is in contact with the substrate, it results in a negative bias on the substrate and produces bombardment of the growing film with ions and energetic neutrals from the plasma. This bombardment causes many significant changes in the microstructure, properties and appearance of the coating.Recently another new technology Pulsed Magnetron Systems (PMS) has been introduced into PVD. This new technology has been pioneered in production scale equipment by Dr. S. Schiller (3) and associates. The use of a pulsed power supply on the magnetron prevents the problem of the anode being coated with a insulating layer which will then lead to micro and macro arcing producing defects in the coating."

Jan 1, 1998

By Dong Liu, Zejian Yang, Yong Li, Tao Jiang, Xiangxin Xue, He Yang

"The structure, composition, morphology, and adsorption property of UV-vis light of as-prepared samples were characterized using XRD, SEM, FTIR-EDS, and UV-vis DRS. UV-visible light induced photocatalytic degradation of methylene blue ~) over Ti02-doped diopside was investigated. Experimental results show that doping Fe + induced the formation of Ti-0 or Ti-0-Si in diopside, and promoted the light adsorption property of diopside. Photocatalytic reactivity of Ti02-doped diopside obviously depended on content of doping Ti02. The diopside with 3% Ti02 exhibited the superior photocatalytic activity with 76% degradation of methylene blue under light irradiation for 3 h.IntroductionPhotocatalytic technology has been extensively studied in the process of dealing with inorganic and organic pollutants. Ti02, with its own non-toxic, stable, low-cost and other advantages, has become the most widely studied photocatalytic materials[l-SJ_ The low utilization quantum made it restricted in the practical application. SrTi03 as the representative of the perovskite[9·121, Bi2W06 for the composite oxide[13,141, also attracted wide interest in the photocatalytic studies. However, these photocatalytic material has been mostly prepared in relatively strict experimental conditions with chemical reagents, they had small production, high cost, which made them difficult for practical applications.In our country, there has 400 million tonnes of ti-bearing blast furnace slag (TBBFS) each year in the process of smelting pig iron, which has lead to waste of titanium resources and pollution of the surrounding environment. In recent years, studies have shown that TBBFS instead of pure Ti02 to be photocatalytic materials is feasible[ 151. TBBFS has not only been higher photocatalytic degradation activity for the o-nitrophenol, methyl orange, nitrobenzene and other organic matter[16-191,but also exhibited excellent in the process of dealing with inorganic heavy metals in waste water (containing Cr6+i201. If TBBFS can be successfully applied to photocatalytic technology, the will make large accumulation of titanium-bearing slag reasonable used, so as promote the re-use of energy. At present, our understanding of the photocatalytic activity of TBBFS is steadily deepening. Photocatalytic activity ofCaTi03 has been reported as one of the main minerals ofTBBFS [21'21J, However, there were few studies for Another major mineral of TBBFS - diopside which had the content of9-15%. diopside would doped with Ti02 In the process of smelting pig iron, therefore, Ti02-doped diopside's photocatalytic activity in the UV-Vis was mainly studied in this paper."

Jan 1, 2013

By C. Liliane Carvalho

In the current study, bio-oxidation tests were carried out in shaking flasks with a flotation concentrate containing the sulphides pyrite, arsenopyrite and gudmidite. The tests were performed with mesophilic microorganisms (At. ferrooxidans) at 30 °C and also with the moderate thermophile S. thermosulfidooxidans, at 50 °C. The effects of (i) previous adaptation of the microorganisms to the concentrate, (ii) ferrous iron concentration and (iii) pulp density (2%, 4% and 6% (w/v)) on the dissolution of the sulphide were studied through arsenic extractions. S. thermosulfidooxidans was more sensitive to the pulp density in comparison to At. ferrooxidans as a reduction in sulphide oxidation was observed with the increase in the solid content to 6%. Therefore, the mesophilic strain was selected for further work, which comprised a rolling bottle experiment at 10% solids. After 40 days of bio-oxidation, the solid material was subjected to cyanidation, which revealed 85% gold extraction as compared to 21% from the original concentrate. The antimony sulphide grains in the bio-oxidized product showed similarity to what was observed in the original sample, suggesting such particles were not susceptible to the bio-oxidation process.

By lonkion M. Font

Due to the known disadvantages of the use of iron silicate slag in the nickel converting stage, i.e., high metal losses, high magnetite content, and low fixation of impurities in the slag, the development of the new proposed "ferrous calcium silicate slag" for smelting and converting processes of nickel is very promising. Hence, considering the successful experimental results of using CaO base slag for the nickel smelting process, a study based on a detailed comparison for the phase equilibrium, and the minor elements distribution between the NilS2-FeS matte with either FeOx-CaO or FeOx-Si02 base slag was investigated. The main results are summarized as: no difference in the nickel losses between both slags was found at high nickel content in the matte, and the fractional distribution analysis for arsenic and antimony pointed out their preferential fixation in the calcium ferrite slag rather than in the iron silicate slag. Considering the energy and pollution issues, the technical feasibility of using calcium ferrite slag in a converting process of the Bessemer matte will have a prominent future for the nickel industry.

Jan 1, 2003

By S. Abe

Various copper anodes to be electrorefined were subjected to a heat treatment comprising annealing at a temperature in the range of 700 °c to 1,000 °c followed by a slow cooling preferably on the order of about 150 °c, and using these heat treated anodes , a series of dissolution experiments were conducted under conventional electrorefining conditions. The results obtained have indicated that the above annealing/slow cooling process dramatically improves the dissolution activity regardless of the type of anodes. As an example, passivation times of l to 3 minutes in a standard test have been increased to more than 80 minutes by this innovated heat treatment. Other advantages sterning from the improved anodic activity include reduced electrical short circuiting which results in substantial labor effort in the tankhouse, reduced energy requirement, and reduced cost of processing anode slimes because the amount of anode slimes is reduced. In addition, this process gives rise to a dramatic change in the nature of anode slime layer formed in such a way that a comparable final cathode copper product can be achieved even from high-impurity copper starting material.

Jan 1, 1987

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 Caisa Samuelsson

Experimental studies in laboratory-scale equipment have been carried out to study the vaporisation from dust generated during the copper converting process. In the present work the vaporisation of Zn, Pb, As, Sb, and Bi from a dust collected in the electrostatic precipitator after the copper converter were studied. The results show that Pb, Bi and As were vaporised to a high degree from the dust at a temperature above 900°C in a gas containing N2, SO2 and a small amount of H2. The vaporisation was high for these elements also in a gas containing N2, SO2 and 02 at temperatures above 1120°C. In an earlier study, thermodynamic calculations showed that it is possible to selectively condense metals at high temperature' in a gas atmosphere generated during a copper converting process. The present study was carried out to verify the thermodynamic model. The results indicate that it should be possible for a selective condensation of Zn at high temperature. The temperature required for a selective condensation of Zn is dependent upon the gas atmosphere, e.g., the oxygen potential.

Jan 1, 1998