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By A. J. Paul

Traditionally, 16"/50 caliber projectile shells have been fabricated from forged steel. The Naval Surface Warfare Center (NAVSWC) has determined that cost savings of approximately 60% (-$4.7M/year) as well as improved shell fragmentation can be achieved by casting these shells from austempered ductile iron. One of the technical concerns arising out of this material substitution is the role of the casting process in controlling the quality of the cast shells. Optimizing the process through proper orientation of the mold, placement of chills, superheat, etc., can minimize shrinkage porosity and, consequently, flaw size. For this purpose, the mold filling and subsequent solidification of the projectiles was simulated using a 3-D, fully transient, coupled fluid flow and heat transfer model based on finite differences. Several casting orientations were investigated and the casting parameters were varied to optimize the process and minimize casting defects. A comprehensive software tool, which was developed using state-of- the-art visualization techniques, has been used to analyze the process of casting. Emphasis is placed on the use of this visualization tool as an aid to the foundry engineer for process optimization.

Jan 1, 1992

By Jilai Xue, Jun Zhu, Baisong Li

"TiB2-C/C Function Gradient Materials (FGM) is used in cathode materials to improve aluminum wettability and melt penetration in aluminum electrolysis. In this investigation, FGM was tested for use as part of the cathode materials, where a 10 mm thick TiB2-rich layer was on the top as an Al-wettable surface, the TiB2-C layers in the middle as a gradient layer and the carbon on the bottom as a base. Electrical resistances ofFGM were determined in the temperature range of25- 9600C in argon atmosphere. The results show that the present of TiB2-C gradient layer can reduce the open porosity and the electrical resistance of the cathodes materials at elevated temperatures. The cathode samples after aluminum electrolysis usually demonstrates an increase in electrical resistance, but the application of FGM layer can compensate such an increase for certain extend due to less variation in porosity and lower the level of melts penetration.IntroductionCarbon is still used for aluminum reduction cathodes dominantly, but it has a poor wetting properties by liquid aluminum and the anode-cathode distance has to be kept about 4-5cm with an additional 1.3-2.0 V voltage drop [l]. TiB2 has better wettability by liquid aluminum with higher electrical conductivity and stronger chemical resistance to the electrolyte attack. And the wettability ofTiB2-C composites cathode on liquid aluminum can be also improved, while liquid aluminum can completely wet the cathode surface ifTiB2 content exceeds 27% [2-4]. However, during the process of TiB2-C composites cathodes preparation and aluminum electrolysis, the deformation by temperature variation or sodium penetration are great disparity between TiB2 and carbon due to their physical properties difference. This will accelerate the cathodes cracking and deterioration."

Jan 1, 2013

Segregation roasting tests were carried out on Zaire cobalt oxide ores assaying about 2% Co and 3.5 to 6.5% Cu. The major parameters tested during the laboratory investigations were temperature, dosage and type of reducing agent, dosage and type of chloridizing agent, and particle size. Results showed that standard conditions suited to the segregation of copper ores, i.e. low temperature and low dosages of reducing and chloridizing agents, resulted in the segregation of copper only, while conditions suited to the segregation of lateritic nickel, i.e. higher temperature and increased dosages of reducing and chloridizing agents, led to a successful segregation of both copper and cobalt. Under the best conditions, 88% of the cobalt and 98% of the copper could be recovered in a concentrate assaying 32.5% Cu and 8.5% Co. Alternatives to process such a concentrate are briefly reviewed.

Jan 1, 1993

By H. Dong, J. J. Valencia, L. Nastac

"A comprehensive computer model was developed to understand and optimize the centrifugal casting process for manufacturing TiC/Al-bronze friction drums. Performance of these components requires proper distribution of TiC particles, which is shown by dimensional analysis to be dominated by centrifugal buoyancy effects and solidification kinetics.The model addresses the following: (1) a rheology-viscosity model of the interference between moving particles, (2) engulfment (entrapment) or pushing of particles in the mushy region by the advancing solid/liquid interface, (3) nucleation and growth of equiaxed and eutectic phases, (4) effects of particle size, particle concentration, and cooling rate on the final grain size, and (5) the impingement effect of particles on the nucleation and growth kinetics of solidifying microstructure.Parametric studies were conducted using the computer model to investigate the effects of various process and material parameters on the distribution of TiC particles. The effects of the volume fraction, size, and morphology of the particles (including clusters and agglomerates) on the particle distribution were evaluated in detail. The complex interaction between the solidifying structure and insoluble ceramic particles in centrifugally-cast metal-matrix-composites was also investigated.The model predictions of particle distribution and microstructure were validated with experimental data for centrifugally-cast A356/SiC and TiC/Al-bronze alloys.This work was conducted by the National Center for Excellence in Metalworking Technology, operated by Concurrent Technologies Corporation under contract No. N00140-92- C-BC49 to the U.S. Navy as part of the U.S. Navy Manufacturing Technology Program."

Jan 1, 2000

By L. G. Wiseman

The raw materials processed, highlights of technology used, and products produced at INCO's Copper Cliff Nickel Refinery in Ontario, Canada, are described in this paper. INCO's Bessemer matte separation process yields various nickel and copper products and intermediates. The latter presents the main supply of raw materials for the Refinery. Key features in the Refinery are Top Blown Rotary Converters and the INCO Pressure Carbonyl (IPC) process. Process improvements made since the commissioning of the Refinery in 1973 are also discussed. The Refinery produces a variety of nickel products, including nickel powders. Residue after carbonylation presents an important intermediate enriched in precious metals and cobalt that serves as feed to downstream operations for recovery of the residue's metal values. Also discussed are detection, measurement and control procedures which ensure safe operation.

Jan 1, 1988

By Christiana Mystrioti

Greece is the only EU country with extensive nickel laterite deposits. Since the 1960s, the Greek laterites are treated for ferronickel production via a pyrometallurgical route, which involves pre-reduction of the ore in rotary kilns and reduction smelting in electric arc furnaces. Due to the rising cost of energy and the decreasing grade of mined laterites, the pyrometallurgical treatment is economically marginal. For this reason, alternative treatment processes are currently under investigation. Potential applicability of hydrometallurgical treatment, using either H2SO4 or HCl, under atmospheric pressure conditions, for Ni and Co extraction from two low grade laterite ores, was examined in the present work. The two samples were selected to represent the different mineralogical composition of the saprolitic and limonitic ore deposits of the Greek laterites. The investigated parameters were temperature (65–90 °C), acid concentration (1–4 N) and solid to liquid ratio (10–30% w/v). The results indicated that HCl was more efficient than H2SO4 for the treatment of the saprolitic ore; Ni and Co extractions were very high for both elements, up to 98% and 96% respectively, while H2SO4 could leach efficiently Ni, up to 100%, but extracted only 34% of Co. Hydrochloric acid was also more efficient for the treatment of the limonitic ore, with Ni and Co extractions up to 98.3% and 87.6% respectively. With H2SO4 the maximum extractions were 71.3% for Ni and 52.1% for Co.

By Dong-dong Liu, Jian-ping Niu, Qi Liu, Shu-sen Cheng

A numerical model was developed to simulate the three-dimensional heat transfer in the belly and lower shaft region of the blast furnace wall consisting of copper steel composite stave, packing and shell. The temperature distribution of copper steel composite stave without the slag layer or refractory lining was investigated and then compared with the copper stave. The results showed that copper steel composite stave can satisfy the requirement of overheatingfree and had an analogous heat transfer behavior as copper stave but more stable cooling intensity. This model had been validated by the good agreement between the computed and measured temperature in the thermal test.

Jan 1, 2015

By Larry M. Southwick, Phillip J. Mackey, A. E. (Bert) Wraith, Albert Pelletier

In 1881, the first commercial pneumatic Bessemer-type converter treating copper matte was successfully introduced by Pierre Manhes at the Eguilles copper plant near Vedène in France. This development followed over a year of testing on a smaller scale at a foundry in Vedène, during which the vertical tuyeres of the conventional Bessemer converter had been successfully replaced by horizontal tuyeres in an effort to avoid the freezing of copper which had occurred in the bottom of the vessel having vertical tuyeres. The Manhes Converter, as it became known, was the first successful large-scale adaptation of the Bessemer concept of using compressed air blown into a melt for metal refining and treatment. Within a few years, Manhes Converters utilizing horizontal tuyeres in either the original type of vertical converter, or a later and more enduring horizontal barrel converter, were in operation at over a dozen copper smelters around the world. It was this process that Messrs Peirce and Smith essentially improved with the introduction of the larger converter which bears their name and the development celebrated at this Symposium. The present paper briefly traces the original development by Pierre Manhes in the early 1880s and which set the stage for the later Peirce-Smith adaptation. The paper observes that the original development by Manhes was in part driven by the need to reduce coal (energy) consumption and hence the production cost in order for Eguilles to remain competitive with the larger plants in Swansea, Wales, where a ready supply of cheap coal helped keep smelter treatment terms of the day low. These themes are eerily resonant of today where booming copper production in China has impacted the industry, and also where energy consumption, closely linked to today’s more familiar theme of ‘climate change’ remains an important challenge currently confronting the entire industry. The paper concludes with comments on these seemingly parallel situations today and offers some thoughts for the future.

Jan 1, 2009

By Zhiqian Zhang, Chao Wu, Chao Li, Hongxu Li, Yu Chen, Xiangxin Hao

"In this paper, the life cycle assessment models for automobile lightweight materials including high-strength steel, aluminum alloy and magnesium alloy are developed by Gabi software. The evaluation models and evaluation indicators such as acidification effects, rich eutrophication effect, ozone layer depletion effects, global warming, resource consumption and formation of ozone potential were taken into account. It is shown that the effects of acidification and ozone formation are mainly derived from the run phase of high-strength steel and they have strong environmental impact load. While considering the entire life cycle with materials production phase and resource consumption, the aluminum and magnesium alloy appe art o have large r environmental load than high-strength steel. Base d on the evaluation, some optimization tips are proposed.IntroductionAs the increasing of car ownership, automobile has its two sides. One which is the convenient, efficient and fast traffic vehicle; the other is aggravating energy consumption, emissions and environmental pollution. The car industry faces heavy pressure with energy saving, safety and environmental protection. Nowadays, the main study ways for automotive energy-saving and environmental protection are power system improvement, alternative energy sources and technologies. For limitation of technique, development cycle and market share, the development of car is little progress at this stage and the application has been restricted. And another important way is the lightweight of vehicle. Usually there are three ways to get the lightweight automobile body structure, automobile body structure optimized design, using advanced body manufacturing technology, development and application of lightweight high strength body material.The life cycle assessment (LCA)[1lis commonly used to evaluate environmental factors and potential environmental impacts of products and services. As an environmental management tool of product-oriented, it becomes increasingly popular in industry. In this study, the concept of LCA and GaBi software was used to develop models for the three automotive lightweight materials, evaluate the environmental impact and make horizontal and vertical contrast by choosing variety of evaluation systems and indexes."

Jan 1, 2013

By Dean Ilievski

Mathematical modelling of the precipitation process requires that the kinetics of crystal growth, nucleation and agglomeration be known: This paper reviews the current state of knowledge on these precipitation sub-processes (ie. growth, nucleation and agglomeration) and describes a number of experimental techniques for estimating their kinetics. The experimental methods used to generate the precipitation data and the data analysis techniques used to extract the kinetics information from the data are discussed separately. There is no universal "best" technique for determining the kinetics. However, studies on multi-crystal systems are more reliable for modelling purposes than are single crystal studies. The selection of a technique will depend on which sub-processes are present. A problem with all kinetics studies is that there is generally a large uncertainty in the estimated kinetic parameters. This stems from the scatter in the experimental data being further propagated by the mathematical techniques used to extract the kinetic parameters.

Jan 1, 1996

By Andressa A. Silva, Esperidiana A. B. Moura, Francisco R. Valenzuela-Diaz, Jorge N. Sales

This work aims to study the influence of the nanoclay Cloisite 20A incorporation on mechanical properties of ABS (acrylonitrile butadiene styrene). The incorporation of Cloisite 20A was made in two steps; firstly,a masterbatch was preparated and then, it was incorporated in ABS. The Cloisite 20A masterbatch using 40 % of nanoclay and 60 % of SAN (Styrene Acrylonitrile) was prepared in an adiabatic mill. After that, Cloisite 20A masterbarch at 1 and 5 % (wt) was added in ABS. The resulting nanocomposites were characterized by tensile tests and the correlation between properties was discussed.

Jan 1, 2015

By Z. Zhang, R. G. Reddy

The viscosities of industrial lead slags with various compositions were measured as a function of temperature. It was found that viscosities of lead slags decreased with increasing temperature, and the plots of ln(11) vs. 104tr followed a linear relation over the reported ranges of temperature. Using the data of this study and available other related data from the literature, a viscosity expression was developed as a function of composition and temperature. The calculated results using this viscosity expression are in good agreement with the measured data. The composition dependency of viscosity of lead slags is discussed.

Jan 1, 2000

By N. E. Idenyi

The effects of compositions and firing temperatures on the physico-mechanical properties of blended Nsu fireclay and Nkalaha redbrick clay have been investigated. The clay samples were compounded according to the following ratios: 10:90, 20:80, 30:70, 40:60 50:50, 60:40, 70:30, 80:20 and 90:10 in the order Nsu: Nkalaha respectively, and test samples made and fired at 9000C, 10000C 11000C and 12000C. The properties tested for were the modulus of rupture, porosity, shrinkage, apparent density, water absorption and bulk density. From the results obtained, it is inferred that the blends have a maximum service temperature of 11000C, with the 30: 70 blend presenting the best characteristics. A conclusion is drawn to the effect that the blend could be adapted for the production of ceramic earthenware, electrical porcelain pin insulators, cement manufacture and for refractory linings where temperature requirements are less severe.

Jan 1, 2006

By Lanre Oshinowo

Computational Fluid Dynamics (CFD) is used in conjunction with process modelling at HATCH to achieve a superior level of confidence in the process design of hydrometallurgical process plants. The use of these tools to evaluate designs through virtual prototyping reduces the risks associated with making design decisions. This paper highlights the development of a co-simulation strategy at Hatch for the seamless integration of process modeling software addressing different scales (process time and space): flowsheet level models and .equipment level models. With co-simulation, the process design engineers can improve design accuracy, troubleshoot and optimize performance and influence decisions impacting equipment operation by representing specific unit operations in the flowsheet model software with detailed CFD models. Specifically, this paper will focus on the co-simulation of a Ni/Co high-pressure acid leach (HPAL) process including heaters/heat exchangers and flash system, autoclave and quench/scrubber system. The knowledge developed can be transferable to other processes.

Jan 1, 2004

By V. I. Lakshmanan

Wastes when produced can be reused or recycled prior to disposal. Industries that cause environmental concerns during manufacturing include primary materials and primary metals. Pollution prevention mechanisms to achieve waste reduction require new separation, reclamation, control and process simulation technologies. Substituting recyclables for virgin resources will reduce energy use, water pollution, air pollution, water use and mining wastes. Shrinking landfill space will spur new technologies for waste treatment and recycling. These situations hence offer opportunities for innovative flowsheets with appropriate separation technologies. Development of innovative flowsheets to treat recyclables offer unique opportunities for process/product development, obtain green products and hence market advantage. The paper will illustrate with selected innovative flowsheets to treat recyclables.

Jan 1, 1996

By Karin Soldenhoff

Recovery of uranium in conventional ion exchange circuits, using strong base or weak base resins containing quaternary or tertiary amine functional groups, is based on an anion exchange mechanism. In saline liquors, chloride competes with uranium for the active resin sites and reduces resin loading. This results in significant negative impacts on the IX process in terms of plant throughput and operating costs. In this paper we present the results of a study on the recovery of uranium from an acidic in situ leach liquor containing approximately 9 g/L chloride. A range of resins was tested, and a high capacity strong base resin was identified with significantly enhanced loading compared to conventional resins. Other process-relevant criteria such as loading kinetics and elution efficacy are also discussed. The process developed was successfully tested during a recent ion exchange pilot plant operated in conjunction with a field-leach trial.

By Akio Ohta

The Hyuga smelter has been producing ferronickel by a rotary kiln-electric furnace process in Miyazaki, Japan. Several approaches to improve our operation have decreased the electrical energy consumption. A new process was developed to decrease the cost of energy even further. Oil and technical oxygen are injected through lances to heat up the calcined ores (calcine) instead of the electric power. Main problems during the development of the process were the short life of the water-cooled lances, the check on security of the safety system and the eruption of combustion gases through the calcine bed. These problems have now been overcome successfully, and stable operation can be maintained. The addition of 1 Litre of heavy oil per tonne of ore can save the electrical energy requirement by 8.6 kwh per tonne of ore. The new process has resulted in a reduction of the electrical energy consumption by more than 10 percent

Jan 1, 1992

By S. Agatzini-Leonardou

The objective of this work was to prove repeated loading capacities and investigate the selectivity of physically stabilized algal biomass from Spirulina platensis and Chlorella sp. for the removal and recovery of cobalt, nickel and chromium from laterite heap leach liquors. The testwork was carried out on a bench scale in small glass columns and proved that it was possible to immobilize the biomass on the highly porous surface of pumice stone (kissiris). Nickel and cobalt could be removed from pure aqueous solutions of each metal by the immobilized cyanobacterial biomass. Nickel and also cobalt biosorption was sensitive to the initial solution pH. Cobalt recoveries up to 80% were achieved after 5 loading cycles, from low concentration solutions, at pH 6.0. Nickel removal was complete under the same conditions, whereas chromium sorption was ineffective. Desorption of the metal loaded columns was effected by dilute sulfuric acid. The algal species giving the best adsorption capacities for the metals under consideration was selected for further experimental work with real laterite heap leach solution produced by column leaching. A statistical analysis of all obtained results was conducted using the fraction of metal removed as response. The ratio "mass of metal removed to mass of protein contained in the immobilized cells" was determined as well. The described method might be applicable for recovery of cobalt and nickel from diluted laterite heap leach solutions, such as heap wash waters, or for their removal from waste streams of a hydrometallurgical extraction process.

Jan 1, 1997

By Orlando C. Rojas

The Potrerillos Smelter commissioned a new El Teniente converter in 1985. As a result of the use of this technology, the Peirce-Smith converters have been processing only high grade matte or white metal. These operational changes resulted in damages to the converter shells, excessive splashing and cold dope generation and very short refractory campaigns. The paper shows the modifications to the tuyere angle, mouth design changes and new techniques for mouth cleaning and gas handling. Operational results up to 1991 are also shown.

Jan 1, 1993

By A. Navarra

Within conventional copper and nickel-copper sulfide smelters, ladles of molten matte are fed into converters. These converters blast oxygen-enriched air into the matte, thereby eliminating iron and sulfur. The converting reactions are exothermic and, indeed, the converter heat balance is often a limiting consideration on the smelter throughput. If a portion of the matte were fed in solidified (granulated) form, this would support higher oxygen enrichment, and lower volumes of converter offgas, allowing higher throughput. This approach is not applied in conventional smelters, partly because of the copious amounts of water that must be evaporated in typical granulators, as in the Kennecott-Outotec process. The current paper recalls a waterless matte granulator that had been pioneered in the 1990’s, and is applicable to conventional smelters. A mathematical formulation is presented that can be used in the context of simulation-based optimization, to estimate the size and impact of waterless matte granulation.