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By Hector M. Henao

In order to provide the thermochemical data regarding the slag system, which are of importance for sulfide smelting and metallurgical processes but still lacking, an experimental study was carried out on the phase relations and activity of iron oxide in the FeOX-CaO-SiO2 system at temperatures between 1300 and 1400 °C and partial pressures of oxygen between 10-9 and 10-4atm. First, the solubility of CaO and SiO2 in the solid FeO were obtained and the tie lines connecting between the solid wustite (FeO) or magnetite (Fe3O4) phase and the liquid phase were determined. Secondly, iso-activity lines for FeO in the homogeneous liquid region were determined, based on the activity of iron in the Pt-crucible used in the equilibrium experiments. The activity coefficient of FeO in this region was also derived from the composition of FeO and FeO1.5 in the liquid region. Finally, the effect of (CaO/SiO2) ratio in the system and partial pressure of oxygen on these thermochemical quantities is discussed.

Jan 1, 2006

By Laurentiu Nastac

"The importance of investigating solute redistribution during the unidirectional solidification of multi-component alloys is broadly discussed in the literature. A previously developed analytical model that was experimentally validated for Al-Cu, Sn- Bi and Fe-Si dilute binary alloy systems is used in this article to study in detail the solute redistribution, the liquid/solid interface stability based on an extended transient constitutional undercooling criterion and the size of the initial transient region during the unidirectional solidification of Ti-6-4 and Ti-17 alloys. A comparison between Ti-6-4 and Ti-17 alloy systems with respect to interface stability and the size of the initial transient region is also provided. The effective partition coefficients of the alloying elements in these alloys were determined based on specially designed experimental measurements.IntroductionThe importance of investigating solute redistribution during alloy solidification is broadly discussed in the literature [1-5]. One of the relevant applications of this study would be the mathematical modeling of equiaxed and columnar solidification of multicomponent alloys. This includes the instability of the solid/liquid interface. There are several mass and heat transfer processes that involve the calculation of solute redistribution during directional solidification such as industrial directional solidification processes, continuous casting, remelting processes, Czochralski crystal growth technique, floating zone techniques, etc."

Jan 1, 2012

By Paykan Safe

The primary source of fugitive gas emissions in most copper smelters are the Peirce Smith converter operations. The modem trend is towards installation of secondary gas collection systems which are intended to collect fugitive gases from charging, standby, and skimming operations. These have been installed with varying degrees of success. Often, the major source of emissions from the converter area is leakage of process gas from the primary hoods when the converter is blowing. This gas is typically collected by the secondary system and discharged to atmosphere or scrubbed with an alkaline agent. Those smelters considering installation of secondary hoods or scrubbing of gases from secondary systems should first address the issue of gas leakage from the primary hoods. Improving the primary hood gas collection efficiency will often be more cost effective than installing secondary hooding. In the case of secondary gas scrubbing, it will significantly reduce the reagent consumption and operating cost of the scrubbing system. This paper examines the parameters that determine whether or not a primary hood will effectively collect process gases without leakage and demonstrates, using Computational Fluid Dynamics (CFD), the effects of variations in these parameters on the overall performance of the hood. It also looks at the application of CFD techniques in the design of secondary hoods and presents a summary of measured emissions from converter buildings.

Jan 1, 2002

By Ricardo Morales

Reactions between solids and a gas phase have many interesting theoretical aspects as well as technological applications. The present group had carried out experimental investigations as well as theoretical studies of a number of gas-solid reactions over the past decade and was able to derive interesting results. Studies of the decomposition of alkaline earth carbonates were carried out by thermogravimetric analyses. The experiments were carried out using thin powder beds as well as iso-statically pressed compacts with thermocouples embedded in the same. The investigations revealed the complexity of the reactions and the impact of the heat- and mass transfer aspects on the reaction kinetics. In the case of BaCO3, the kinetics of decomposition was complicated by the formation of a liquid phase. In the case of SrCO3, the reaction kinetics could be simulated by theoretical modeling. Gas-solid reactions were also employed as a versatile process tool towards the production of alloys and intermetallics involving transition elements by hydrogen reduction of complex oxides involving transition metals. Thin powder beds were employed to examine the micro-kinetics, while fluidized bed technique was utilized to produce bulk alloys. Preliminary correlations could be drawn between the thermodynamic stabilities of the oxides and the activation energies of chemical reduction steps. Adjusting the process parameters, products at nano-scale could be produced. The structural, mechanical and thermal properties were investigated in the case of these products. The potentialities of this method as a green route to produce industrially important alloys and intermetallics with unique properties are demonstrated.

Jan 1, 2006

By Ken-ichi Miyazawa

A Center of Excellence (COE) titled the Creation of Nature-Guided Materials Processing, called Nature COE, has been established at Nagoya University. In the Nature COE, a new field of material research is being developed through learning the laws of nature, namely, methods of attaining ?appearance of the maximum function under the minimum substance and energy consumption?, which the nature and living organisms have acquired through their evolution in long period. As one of the specific features, an ?Open Cluster Program? was originated for promoting the researches conducted by young researchers and Ph.D. students with those in and out of the university and also for fostering them, together with such educational programs for Ph.D. students as the research incentive, the oversea training and the international lodging seminar programs. The Open Cluster Program has been found to be effective for fostering of young researchers and students, for promoting their researches, for gathering researchers and knowledge from the world and for propagating the research fruits. Through conducting these programs, world-highest intelligent fruits and a gathering of young minds to lead the new field are expected. In this COE, the researches are conducted on (1) materials used for living bodies, (2) mimicking structures which nature or living bodies are forming and (3) materials processing by mimicking processes to form the structures observed in the nature or the living bodies. These researches are conducted by four groups to extend the processes observed in the natural world to a new type of processing that is thoroughly rationalized by plunging a scalpel of engineering, and to establish a new academic field of materials science and engineering.

Jan 1, 2006

By Esperidiana A. B. Moura, Mariana N. Sartori, Vijaya K. Rangari, Angel Visentim Ortiz, Francisco R. V. Diaz, Rene R. Oliveira

"This work presents the preparation and characterization of a nanocomposite based on Poly(butylene terephthalate) PBT and Brazilian smectitic clay (bentonite chocolate clay). Before being incorporated as clay nanoparticles in PBT resin, the clay was organically modified by the addition of a quaternary salt and sodium carbonate. PBT/Clay nanocomposite (96.3:3.70 wt %) was obtained by using a twin-screw extruder machine. After extrusion process, the nanocomposite was characterized by tensile, flexural and impact tests, SEM, Vicat, HDT, DSC, TGA and XRD tests. The results showed that the properties of the nanocomposite obtained were superior to those of neat PBT. Concerning the temperature of thermal distortion (HDT) an expressive gain of around 45 % was presented to PBT/Clay nanocomposite compared to PBT evidencing the interaction of nanofiller with the polymeric matrix.IntroductionPolymer-clay nanocomposites, also called as polymer layered silicates nanocomposites have attracted much attention from both industry and academia over the past decade because they frequently exhibit unexpected properties. In contrast to the traditional fillers, nanofillers, in particular, nanoclay, is found to be effective. The addition of a small amount (< 5 wt.%) can show significant improvement in mechanical, thermal and barrier properties, flammability resistance, and electrical/electronic properties of the final polymer nanocomposite without requiring special processing techniques. Also, as with other nano-size particles, the overall crystallization rate and the glass transition temperature are also affected. It is generally believed that the improvement of properties of nanoclay composites is directly related to the complete exfoliation of silicate layers in the polymer matrix. However, a processing technique that produces complete exfoliation is still a technical challenge [1,2]."

Jan 1, 2012

By R. T. Jr. Faria, H. Vargas, R. Toledo, S. Cosin, V. P. Souza

"With the purpose of decrease environmental impact, caused by industrial residues (just discarded in the environment) and clay extraction in the ceramic industry, sanitary ware wastes were incorporated into clay. In contrast, it is important to evaluate not only the technological essays but also gases emissions in the ceramic firing process. The pollutant gases emitted in ceramic with residues can be in much larger concentrations than that in a pure clay ceramic firing or, on the other hand, can decrease the pollutant gas concentrations. With the aid of thermal analyses and photo acoustical techniques it was observed that sanitary ware waste can reduce the C02 emission. The gas emissions were shown as in function of firing temperature from 300 DC to 1100 DC. In order to analyze phase transformations during the firing process, clay samples and wastes were both analyzed by x-rays fluorescent chemical analysis and x-rays diffraction.IntroductionResearch works on the structural and physical changes that wastes, mainly industrially produced, cause to the final ceramic product has been rapidly expanding in these last two decades. See, for instance references in [1]. In spite of these examples of a continuous effort to incorporate wastes into clay ceramic motivated by technical and economical advantages, environmental issues are still a matter of concern. However, the gas emission due to the clay firing process and its related atmospheric pollution may be enhanced as a consequence of an incorporated waste [2]. It is known that the firing of clay ceramics in conventional furnaces using fuels such as wood, charcoal, heavy oil and natural gas generates appreciable amounts of gaseous components, mainly carbon dioxide (CO2), carbon monoxide (CO) and methane (CH4). Additionally to the atmospheric pollution, these gas sets could be harmful to the human health and can corrode equipments [3,4]."

Jan 1, 2012

By Hideyuki Itou

Municipal wastes are mainly incinerated in Japan. Both bottom ash and fly ash from the incineration treatment are smelted recently to decrease the volume. Direct smelting of municipal wastes is also becoming popular. The smelting treatment generates fly ash which contains concentrated heavy metals such as Zn, Pb and Cu, and the harmfulness is causing concern. The smelter fly ash is mainly landfilled after stabilization. An effective treatment process of the smelter fly ash is required to recover the metals. For the treatment process, an application of chloridizing volatilization technique is considered. Chloridizing volatilization experiments were carried out to determine the effects of various factors on the volatilization behaviors in this study. A pretreated ash was mixed with a main raw material which mainly consists of hematite. Calcium chloride water solution was added into the mixture. The mixture was pelletized, dried and used as samples for the volatilization experiments. The sample was placed in the reaction tube heated in an electric resistance furnace. 5%02-95%N2 gas with controlled humidity was introduced into the reaction tube. Effects of humidity in the carrier gas, addition of calcium chloride and mixed ratio of the ash to the main raw material were investigated on the volatilization of Zn, Cu and Pb. To determine the volatilization behavior, samples were taken from the furnace at specified temperatures on the heating stage. In addition, experiments at specified holding temperatures for 15 minutes with shortened heating time were conducted. The two series of experiments revealed the effect of heating temperature on the volatilization behavior of Zn, Cu, Pb and Cl.

Jan 1, 2006

By Michael Stelter

Lead alloys are a typical material for anodes in technical electrowinning processes. The life time of those anodes differs from 2 years to more than 5 years in tankhouse practice depending on the type of alloy, the mechanical damaging and last but not least the chemical corrosion in the electrolyte. Different types of alloys, such as PbSb, PbCa, PbAg, PbSnCa or PbAgCa have been developed and used in the past, their rate of corrosion being more or less a philosophic discussion. Comparable investigations on the corrosion behavior in dependence of the concentrations of alloying metals, the grain structure and the mechanical and thermal treatment during production have not been conducted before. In the last years the Institute for Nonferrous Metallurgy and Purest Materials of the TU Bergakademie Freiberg investigated the corrosion behavior of the typical lead alloys for metal electrowinning under comparable conditions. Correlations between different alloys, mechanical treatments like rolling or thermal treatment like annealing to the rate of corrosion were made, leading to the conclusion that grain structure and grain size are of eminent importance for the rate of corrosion in technical electrolytes. From these results new and optimized lead alloy anodes can be produced with an increase in life time of the factor 3 ? 5. The optimized lifetime in terms of corrosion stability can not protect from mechanical damaging in tankhouse practice, but with a careful practice the increase in lifetime can save a lot of money and problems.

Jan 1, 2006

By Vahid Rastegar

"Characterization of the microstructure and revealing dendrites in the microstructure and also measuring the dendrites arm spacing and the distribution of silicon were studied in various pieces of compacted graphite cast irons with 0.17, 0.185, 0.2, 0.22 and 0.24 percent of mischmetal. Black-white and color metallography (quantitative and qualitative) were carried out on the various steps of the cast samples. Distribution of silicon was studied quantitatively using spot analysis with scanning electron microscopy. Furthermore, effects of two variables (cooling rate and mischmetal percentage) on dendrites arm spacing were investigated.In order to color metallography, the samples were plunged into a boiling solution of 18% KOH, 9% NaOH and 9% picric acid in distilled water. It was inferred that the microstructure coloration varies according to the sequence: green-->red-->yellow-->blue-->dark brown->light brown as the silicon content decreases. After observing dendrites, dendrites arm spacing was measured. In this method, it seems to be possible to predict the mechanical properties of compacted graphite cast irons by knowing dendrites arm spacing and without any destructive testing. After studying the two variables, it was concluded that dendrites arm spacing decreases as the amount of mischmetal increases and it increases as the cooling rate increases.IntroductionIn general, detecting of primary austenite dendrites is not possible in cast irons due to their solidification system. Observing the dendrites in the room temperature is possible only in those gray cast irons that contain type D graphite. With collecting data of dendrites arm spacing (DAS) measurements, it could be possible to achieve the mechanical properties of cast irons without any destructive testing. In this research by applying a particular method, primary austenite dendrites and also distribution of silicon in the microstructure has been observed."

Jan 1, 2012

By Ju Shao-hua

Although nowadays gold extraction methods are very abundant, none of them is satisfying, especially, in the field of heap leaching of low grade gold ore. The traditional heap leaching method of cyanide method plays an inglorious role of badly environmental pollution. In this paper, a bran-new and innoxious method of gold extraction system, metal-ammonium-chloride-ammonia (MACA), was proposed, and also analyzed both thermodynamically and practically. Thermodynamically, according to the principles of simultaneous chemical equilibrium and electronic charge neutrality, the thermodynamics of Au-NH4Cl-NH3-H2O system was studied by using the exponential computation method and through MATLAB programming, and the solid figure of its potential - c(NH4Cl) - c(NH4OH) was drawn. The results showed when the concentrate of ammonia is higher than 0.6 mol?L-1, fAu+/Au is only about -0.2 v. Practically, the leaching results of a cuprous gold ore showed that the extraction of gold can reach to 80% in this system. The preliminary results of reduction of the rich solution with copper and zinc powders showed that with deoxygenizing, the reduction effects were relatively good. These new findings and results have established a theoretical and practical base for developing a new process for heap leaching of low grade gold ores in this system. And the new process owns a series of merits such as, non-cyanogens, nontoxic, broader applicability.

Jan 1, 2006

By Xian-Dong Zhou, Guo-Sheng Sun, Jianzhong Luo, Hong-An Guan

"Oxygen utilization rate of the pretreatment process which adopts biological contact oxidation method for slightly polluted supply water is relatively low, less than 10%, usually lower than 3%. So the aeration amount is not determined by calculated value of oxygen demand when doing process design, but by the ratio of gas and water. The aeration way of the biological pretreatment process for slightly polluted supply water was introduced in this paper. In the foundation of the principles of mass transfer kinetic theory and experimental data, the change law of DO (dissolved oxygen) and ammonia in the aeration tank was analyzed to explore aeration method which will help to improve the overall effectiveness of handling capacity.IntroductionThere are many kinds of filler used in the biological contact oxidation process, such as flexible solid filler, composite filamentous filler, powdery clay filler, particle ceramic filler and so on. Regardless of the different forms of filler, there are a couple of common points in the function of the aeration[1,2]: (1) The aeration process in biochemical tank not only provides adequate oxygen for the biological reaction, but also plays as a role of stirring water; (2) Biochemical reactions mainly happen in the upper reaches of tank, but seldom at down-streams.This paper, from the perspective of changing aeration way, discussed the feasibility of improving the effectiveness of biochemical reactions without increasing aeration amount, which would have some leading significances for the operation and management of similar projects."

Jan 1, 2008

By John O. Marsden

The past fifteen years have seen a number of important developments in copper hydrometallurgy, including the commercial application of biological heap leaching of secondary (chalcocite-dominant) copper ores, the commercial demonstration of chalcopyrite concentrate leaching technology using pressure leaching and biological processes, and the application of novel configurations of solution extraction circuits. Significant emphasis is now being placed on the development of effective stockpile leaching practices for primary ores (chalcopyrite and bornite-dominant mineralization). Some of these developments have been highly successful, and will pave the way for further development and commercialization. Others have been less successful. These developments are reviewed in the context of the metal price cycle and trends for the future are identified.

Jan 1, 2006

By John O. Marsden

The past fifteen years have seen a number of important developments in copper hydrometallurgy, including the commercial application of biological heap leaching of secondary (chalcocite-dominant) copper ores, the commercial demonstration of chalcopyrite concentrate leaching technology using pressure leaching and biological processes, and the application of novel configurations of solution extraction circuits. Significant emphasis is now being placed on the development of effective stockpile leaching practices for primary ores (chalcopyrite and bornite-dominant mineralization). Some of these developments have been highly successful, and will pave the way for further development and commercialization. Others have been less successful. These developments are reviewed in the context of the metal price cycle and trends for the future are identified.

Jan 1, 2006

By John O. Marsden

The past fifteen years have seen a number of important developments in copper hydrometallurgy, including the commercial application of biological heap leaching of secondary (chalcocite-dominant) copper ores, the commercial demonstration of chalcopyrite concentrate leaching technology using pressure leaching and biological processes, and the application of novel configurations of solution extraction circuits. Significant emphasis is now being placed on the development of effective stockpile leaching practices for primary ores (chalcopyrite and bornite-dominant mineralization). Some of these developments have been highly successful, and will pave the way for further development and commercialization. Others have been less successful. These developments are reviewed in the context of the metal price cycle and trends for the future are identified

Jan 1, 2006

By John O. Marsden

The past fifteen years have seen a number of important developments in copper hydrometallurgy, including the commercial application of biological heap leaching of secondary (chalcocite-dominant) copper ores, the commercial demonstration of chalcopyrite concentrate leaching technology using pressure leaching and biological processes, and the application of novel configurations of solution extraction circuits. Significant emphasis is now being placed on the development of effective stockpile leaching practices for primary ores (chalcopyrite and bornite-dominant mineralization). Some of these developments have been highly successful, and will pave the way for further development and commercialization. Others have been less successful. These developments are reviewed in the context of the metal price cycle and trends for the future are identified.

Jan 1, 2006

By John O. Marsden

The past fifteen years have seen a number of important developments in copper hydrometallurgy, including the commercial application of biological heap leaching of secondary (chalcocite-dominant) copper ores, the commercial demonstration of chalcopyrite concentrate leaching technology using pressure leaching and biological processes, and the application of novel configurations of solution extraction circuits. Significant emphasis is now being placed on the development of effective stockpile leaching practices for primary ores (chalcopyrite and bornite-dominant mineralization). Some of these developments have been highly successful, and will pave the way for further development and commercialization. Others have been less successful. These developments are reviewed in the context of the metal price cycle and trends for the future are identified.

Jan 1, 2006

By John O. Marsden

The past fifteen years have seen a number of important developments in copper hydrometallurgy, including the commercial application of biological heap leaching of secondary (chalcocite-dominant) copper ores, the commercial demonstration of chalcopyrite concentrate leaching technology using pressure leaching and biological processes, and the application of novel configurations of solution extraction circuits. Significant emphasis is now being placed on the development of effective stockpile leaching practices for primary ores (chalcopyrite and bornite-dominant mineralization). Some of these developments have been highly successful, and will pave the way for further development and commercialization. Others have been less successful. These developments are reviewed in the context of the metal price cycle and trends for the future are identified.

Jan 1, 2006

By John O. Marsden

The past fifteen years have seen a number of important developments in copper hydrometallurgy, including the commercial application of biological heap leaching of secondary (chalcocite-dominant) copper ores, the commercial demonstration of chalcopyrite concentrate leaching technology using pressure leaching and biological processes, and the application of novel configurations of solution extraction circuits. Significant emphasis is now being placed on the development of effective stockpile leaching practices for primary ores (chalcopyrite and bornite-dominant mineralization). Some of these developments have been highly successful, and will pave the way for further development and commercialization. Others have been less successful. These developments are reviewed in the context of the metal price cycle and trends for the future are identified.

Jan 1, 2006

By John O. Marsden

The past fifteen years have seen a number of important developments in copper hydrometallurgy, including the commercial application of biological heap leaching of secondary (chalcocite-dominant) copper ores, the commercial demonstration of chalcopyrite concentrate leaching technology using pressure leaching and biological processes, and the application of novel configurations of solution extraction circuits. Significant emphasis is now being placed on the development of effective stockpile leaching practices for primary ores (chalcopyrite and bornite-dominant mineralization). Some of these developments have been highly successful, and will pave the way for further development and commercialization. Others have been less successful. These developments are reviewed in the context of the metal price cycle and trends for the future are identified.

Jan 1, 2006