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By K. Sadrnezhaad

Industrial and experimental induction furnaces are used for melting various types of iron ingots, returned scraps and DRI sponge pellets to produce high purity cast-iron and steel heats. The lowest consumption of the electrical energy is determined for continuous feeding operation to be 0.3 KWH/Kg for production of cast-iron in 1.5-ton industrial furnace and 0.45 KWH/Kg for production of steel in 25-Kg experimental furnace. The optimum feeding rate for lowest energy consumption is obtained to be 12.5 grams per second for continuous feeding of DRI in 25-Kg induction furnace. Similar measurements show that the optimum size of the DRI pellets is around 8 millimeter.

Jan 1, 1988

By James Vaughan

Ionic liquids are solvents of interest for applications such as electro- plating, winning and refining of metals. Of particular interest is the possibility of processing reactive metals such as aluminium, magnesium and titanium that cannot be deposited from aqueous solutions. Aluminium has been electro deposited from AlCl3 : ionic liquid mixtures at low temperatures relative to conventional Hall-Héroult smelting. Imidazolium ionic liquids are have been used in the past due to their relatively high ionic conductivity and cation stability. The less studied and less expensive phosphonium ionic liquids systems may provide a viable alternative to imidazolium ionic liquids for certain applications. New information regarding the physical properties and electrochemical behaviour of phosphonium ionic liquid systems is presented.

Jan 1, 2006

By James D. Navratil

Ferrites have been used to separate a wide range of substances such as dissolved metal species, particulate matter, and organic and biological materials; they have been used almost exclusively for metal waste treatment applications. The versatility of the ferrite waste treatment technique is evident in the wide variety of application methods. Furthermore, ferrites can be used to remove selected impurities in feed solutions containing metal products requiring purification. A brief overview of ferrite properties and recent applications for metal recovery and waste processing will be presented.

Jan 1, 1990

By I. Iwasaki

Flotation characteristics of pyrrhotite by itself and in complex sulfide ores are reviewed with respect to the effects of oxidation, grinding media and other electroactive minerals.

Jan 1, 1988

By P. K. Jha, M. M. Mahapatra, H. K. Mohanty, Pradeep Kumar

"During friction stir welding, the tool geometries affect the weld together with the process parameters like welding speed, vertical pressure and tool rotational speed. The present investigation deals with the three dimensional computational fluid dynamics modeling of friction stir welding process considering material flow around the tool, welding speed with respect to tool geometries. Friction stir welding tools with different tool geometries were used for the experiments to achieve acceptable aluminum welds. The temperatures near the welds for each tool were experimentally observed. A 3-D computational fluid dynamics (CFD) model was developed. Temperature-dependent material properties of the aluminum alloy were used in the CFD model. Thermal analysis was carried out considering rotational speed, vertical pressure and traverse speed for the tool geometries. The numerically predicted stirring patterns and temperature profiles closely matched with the experimental ones. IntroductionThe friction stir welding (FSW) is a solid state welding process where generally the metallic materials are joined by the combined action of frictional heating and weld zone stirring by a rotating tool [1]. The heat generated in the process is much below the requirement of melting the plates; hence the FSW process is devoid of harmful effects those are observed during arc welding. The FSW process utilizes a tool which has a shoulder and a protruding pin known as the probe. The shoulder is responsible for frictional heating while the pin probe facilitates stirring of the joint material. A schematic of FSW process is shown in Fig. 1."

Jan 1, 2012

By Juliana G. Gutierrez-Paredes, Gabriel Plascencia-Barrera, Fidel Reyes-Carmona

In Mexico, many tonnes of nickel from waste petrochemical catalysts are dumped every year. In order to recover all that nickel, a hydrometallurgical reactor was designed. This design was performed in a systematical fashion, which included the chemistry of the system under study, both a kinetic and mass transfer study, and finally the use of the RID function, to optimize the reactor size. It was found that the NiO leaching with sulfuric acid is well represented by a first order reaction. The mass transfer results are in good agreement with the experimental results, obtaining over 95% nickel extraction in both cases. A marketing study was also completed that determined that it is possible to make a good profit by processing this residue provided the capital cost was low.

Jan 1, 2000

By T. S. Montgomery

The performance of carbon-magnesia brick in electric arc furnaces (EAF) is interpreted in light of their observed optical microstructures. Features at the bricks' hot faces were protruding periclase grains, metal globules, graphite-metal contacts and linear void patterns. These features were com-pared to similar features previously seen from microstructures of basic oxygen furnace (BOF) refractories. Modes of formation were sought; an attempt was made to interpret their influence related to wear mechanisms.

Jan 1, 1982

By Tomas Astorga

APEC, the Asia Pacific Economic Cooperation is the forum of 18 economies, having a combined GDP of approximately 56% of the total world income, and over 45% of global trade. Its mining sector produces a large portion of the main minerals and metals in the world. In 1997, APEC economies produced 67% of world copper output, 55% of gold, and over 45% of other base metals. Mining in APEC captures more than 60% of the total mining investment in the world. Against this background, the Expert Group on Minerals and Energy Exploration and Development, in short GEMEED, was created in 1996, under the auspices of the APEC Energy Working Group. The sustainable development of mining activities is a main concern in APEC and GEMEED. Several programs related to the subject are actively being pursued by the Expert Group. Among them, it should be noticed the creation of an Environmental Cooperation Sub Group coordinated by Japan, whose main aim is to encourage proposals related to the environmental soundness of mining projects in the region. Also, it should be noted the existence of a Database Steering Committee whose focus is the development of an information network related to mining opportunities in the region GEMEED is a gathering of experts from all the APEC economies. As such, it represents a privileged forum to discuss policy issues related to mining. On this regard, the paper focuses on concrete actions taken by GEMEED to enhance the sustainability of the copper activity in the region.

Jan 1, 1999

By Ruhi Bux, Akshay Verma, Mohini Saxena, P. Asokan

"Due to the colossal increment in the industrialization, the generation of wastes gathered as a result of different extraction, benefaction and generation processes is having an alarming problem for waste disposal. The best and most acceptable way is to use the waste in accordance to its potential for the generation of high value lucrative composite goods. The study in this paper elucidates the potential of several industrial wastes like fly ash, red mud and marble slurry dust for the production of different wood substitute products like doors, windows, roofing sheets and instant houses for the rehabilitation on the sites of catastrophes. Wastes were initially characterized for the physical, chemical and mineralogical properties and then used in different formulations with binder like Polymer along with natural fiber like Jute to intensify the physical as well as mechanical properties of the resultant composite. The study also reveals that these composites have better mechanical properties than the available ones like teak, medium density board, Rice husk board etc. Also, the fly ash and red mud composites have better mechanical properties than marble slurry based composites. The results fosters the implementation of natural fiber with the industrial waste in the generation of eco-friendly and non-hazardous composites.IntroductionOver the last few decades, there has been a tremendous increase in the generation of industrial wastes gathered as a result of various extractions, benefaction and generation processes. The condition worsens even, when it comes to high quantum generated wastes like Fly ash, Red mud and Marble slurry dust. The primordial motif behind the incorporation of industrial wastes as filler in the development of composites is primarily composed of two main objectives; Firstly waste management, the colossal waste dissemination in the environment has disturbed the ecological balance by polluting land, surface water, ground water, air, natural resources and even disturbing the public health [1]. Secondly, to act as a perfect substitute for the conventionally existing building materials, this will aid in dwelling places to many with the least incorporation of exhaustive natural resources as woods quid pro quo."

Jan 1, 2008

By Nexhmedin Lohja

The production of high-carbon ferrochromium in a submerged electric furnace based on double-level technology has some advantages compared to close-type furnaces with one tap hole. These advantages include the reduction of the specific energy consumption for the overall process, good separation of ferrochromium from slag, an effective treatment of raw materials including lean chrome ores (low percentage of Cr2O3) etc. An outline of the operation of this furnace along with the production line of briquettes from fines of chrome ore by using organic and inorganic binders, will be followed by a description of the recent work carried out to improve the energy consumption in this furnace through a pre reduction process of Cr2O3 ores by the off-gas energy recuperated from the furnace and the use of SiC in the feed. A short theoretical analysis of the new work will also be given.

Jan 1, 2006

By Randy Martin

"Greenstone Resources Ltd. constructed and operates the Santa Rosa open pit, heap-leach gold mine in Veraguas, Panama. The project was commissioned in 1995 at a designed capacity of 1.8 million tons per year. The ore exhibits a long leach up to three years, and requires three stage crushing to minus 3/8 inch to achieve on average a 74% gold recovery. The crushing plant is required to handle high volumes of clay and the circuit includes a Barmac Crusher. Panama receives over 3 meters of rain annually and Greenstone is using innovative means to control the project's water balance. Greenstone has developed a successful approach to operating a low grade (1.5 gm Au/T) deposit under difficult operation conditions.ABSTRACT ONLY"

Jan 1, 1997

By Joachim Lemke

The stainless steel sheets of permanent cathodes at Norddeutsche Affinerie (NA) were damaged by corrosion after nearly 11 years in operation. The necessary raising of the strength for stripping the copper had increased the deformation of the stainless steel blades. Current efficiency declined. After investigating the possibilities, like buying new cathodes or treating the steel surface, i.e. by sliding, a repair process was developed whereby the stainless steel sheet was exchanged. Special laser technology for cutting used blades und welding new stainless steel sheets underneath the used hanger bar was applied because the energy input into steel is the lowest of all welding methods. The new stainless steel sheet was welded with the rolling line in a horizontal direction. The achieved flatness of the repaired cathode blades amounted to less than 4mm per meter. During 11 months NA repaired nearly 36,000 permanent cathodes and put them back into operation. Repair costs were much lower than the costs of buying new ones and current efficiency increased again to more than 96% with a current density of 340 A/m².

Jan 1, 2006

By W. Y. Kim, K. H. Song, K. Nakata

"The present study was carried out to evaluate the mechanical properties of friction stir welded Inconel 600/SS 400 lap joints. In this process, friction stir welding (FSW) was performed at a tool rotation speed of 200 rpm and welding speed of 100 mm1min, and argon gas was utilized to prevent surface oxidation during the welding. Application of FSW notably decreases the grain size of Inconel 600 alloy from 20 µm in the base material to 8 ~ in the stir zone. However, the grain size of SS 400 in the weld zone was slightly coarsened, when compared to the base material. Also, the hooking in the advancing side and the intermetal1ic compounds (M7C3) in the weld interface between Incone1 600 and SS 400 were well formed. These intermetallic compounds and hooking were effective to increase in mechanical properties such as tensile and peel strengths.IntroductionFriction stir welding (FSW), applicable welding process at solid state, has several advantages in defect suppression such as blow hole, segregation and cracking which mainly occurs in fusion welding [1, 2]. Notable grain refinement in the stir zone due to FSW can expect the outstanding increase in mechanical properties of the welds. In constructing the chemical and power plants, Ni base superal10ys have been used in many parts, moreover, fusion welding as construct method, such as gas tungsten arc welding, electron beam welding and laser welding, has been mainly used [3-5]. However, fusion welding has a limit in an increase in chemical and mechanical properties in the welds. Lately, Ni base superalloys to which FSW applied have been reported with notable enhancement in mechanical properties, which resulted from refined grains in the welds [6-10]. These researches showed the possibility in applying the FSW, directly."

Jan 1, 2012

By Yushiro Hirai

Saganoseki smelter & refinery had operated two flash smelting furnaces from 1973, attaining 330,000 mtpy of copper production in 1989. In 1996, however, it carried out a "integration of two flash furnaces". That is, it doubled the feeding capacity to one flash furnace to shut down another furnace while maintaining the same production. Single flash furnace operation has successfully started in March 1996 accomplishing a great reduction of the total production cost. The production had reached to 350,000 mtpy in 1997, and further increased to 450,000 mtpy by executing the expansion program with single flash furnace in 1998. This paper introduces results of the single flash furnace operation and describes about an outline of the expansion.

Jan 1, 1999

By J. Sjöblom

New copper and nickel processes, flash converting and DON, direct high-grade nickel matte smelting, have been developed in order to replace the conventional and not so environmentally friendly PS-converting process. With a laboratory scale laminar-flow furnace the combustion reactions of sulfidic feed particles can be investigated under simulated flash smelting conditions. In the present study, finely ground and screened feed fractions of a copper matte and a nickel matte were flash oxidized in a laminar-flow furnace. The experiments were carried out using 20, 21 vol% and 75 vol% O2 in nitrogen, at temperatures 1100 and 1300 °C and reaction zone length of 7.5-16 cm. The samples were quenched in a water film after a specified reaction time. The matte particle reactions were stopped after short residence time intervals in order to obtain a better understanding of the reaction mechanisms. Chemical analysis was used to determine oxidation degree, and optical and scanning electron microscope combined with energy dispersive analysis was used for characterization of the reacted particles. On the basis of the experimental results the reactivity of the mattes is discussed and possible reaction and dust formation mechanisms are considered.

Jan 1, 1999

By Jr. Pomykala, B. J. Jody, E. J. Daniels

Each year, about five (5) million ton of shredder residues are landfilled in the United States. ·Similar quantities are landfilled in Europe and the Pacific Rim. Landfilling of these residues results in a cost to the existing recycling industry and also represents a loss of material resources that are otherwise recyclable. In this paper, we outline the resources recoverable from typical shredder residues and describe technology that we have developed to recover these resources.

Jan 1, 2000

By Ryosuke O. Suzuki

A combined process of electrolysis of CaO in the molten CaCl2 and of calciothermic reduction, so-called OS process, was applied to prepare metallic vanadium directly from V2O3. The fine metallic powder containing 1860 mass ppm oxygen was obtained using 0.5mol%CaO-CaCl2 melt for 10.8 ks at 1173 K. The oxygen level did not decrease further even when twice electricity was applied. Because the metallic vanadium could be electrochemically deoxidized to the level of 10 ppm oxygen from 1.48 %, the large amount of by-product, CaO, due to reduction and the large surface area of the fine particles are the reasons of high oxygen content in the reduced powder.

Jan 1, 2006

By Shigehito Isobe

The Li-N-H system composed of LiH and LiNH2 catalyzed by titanium compound desorbs ~6 mass% hydrogen and a quite small amount of ammonia in temperature range from 150 to 250 °C under He flow atmosphere. In this work, hydrogen desorption (H-desorption) mechanism in the reaction from LiH+LiNH2 to Li2NH+H2 in a non-equilibrium condition was clarified by TDMS, TG and FT-IR analyses for the products replaced by LiD or LiND2 for LiH or LiNH2,respectively. The results suggested that H-desorption reaction progresses through two-step elementary reactions mediated by ammonia. As a next step, we carefully determined the amount of the ammonia containing in desorbed hydrogen for the Li-N-H system in a closed system from the practical point of view. The results indicated that a quite small of ammonia thermodynamically coexisted in the desorbed hydrogen in closed system, although ammonia could not be almost detected in emitted hydrogen gas by TDMS under some non-equilibrium conditions. Moreover, for understanding the role of titanium, the chemical bonding state of the titanium compounds doped as catalyst in the mixture was examined by XAFS measurement. The results indicate that the Ti atoms, which can induce catalytic effect, are in a particular chemical bonding state.

Jan 1, 2006

By Dachun Liu, Yifu Li, Baoqiang Xu, Yongnian Dai, Bin Yang

"The removal of impurity arsenic from crude tin is one of the major problems in the process of tin refining. Through a thermodynamic analysis on vacuum refining process of crude tin, the vapor pressure of impurity arsenic under different temperatures can be obtained, which demonstrates that it is possible to separate tin and arsenic by the vacuum refining process. This paper attempts to verify the behaviors of impurity arsenic. The experiment result shows that through vacuum distillation, crude tin with 0.16% arsenic can be refined from crude tin with 0.96% arsenic, and about 50% impurity arsenic can be collected in the form of metallic arsenic.PrefaceThe crude tin obtained by the reduction process is insufficiently pure for most applications, even smelting from tin concentrate. Arsenic is a common impurity in crude tin and also one of the predominant elements to affect tin performance. Arsenic is a poisonous metal that has long been linked to an increased risk of cancers, diabetes, thickening of the skin, diseases of the liver and digestive complications, so there is a mandatory limit on the amount of arsenic (<0.015%) in tinfoil wrapper and tin layers for food packaging. Arsenic causes a poor appearance and plasticity, and increases viscosity. The impurities content of crude tin fluctuate over a wide range; a lot depends on composition of tin ore concentrate, treatment method and technological process before reduction smelting. And the content range of arsenic is usually 0.5~4%, but it is higher in some factories."

Jan 1, 2012

By Ray D. Peterson, Annette Revet

The optimization of secondary aluminum furnaces is critical to the efficient operation of a recycling facility. Since all metal loss occurs in the drosses, physical and chemical analyses of these by-products are valuable diagnostic tools. Dross analyses can provide information concerning total furnace metal recovery efficiency as well as identifying areas for potential improvements. A complete dross analysis is a labor-intensive process that requires significant care both in sampling and performing the analytical techniques. Experiments can be done at a bench- or plant-scale depending on the facilities available. This paper outlines the benefits and information that can be generated through dross studies. Furthermore, several analytical methods are discussed as well as the special requirements needed to gain accurate results. Experimental data from industrial studies is provided to demonstrate the use of dross evaluations for ~ace optimization.

Jan 1, 2000