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By Mariola Saternus

The quality of the liquid metal has the biggest influence on the quality of the final products. In the metallurgical industry, and especially in aluminium production the refining process is the important technological stage. Today the most popular are refining reactors with impellers like URO ? 200, which can generate small gas bubbles. A rotary impeller also makes the metal bath to be stirred well. There are two basic hydrodynamic parameters: the flow rate of refining gas and the mixing of refining gas (impeller rotation) that influence metal stirring and generating small gas bubbles. The paper presents the influence of the flow rate of refining gas on the hydrogen removal process from aluminium (final hydrogen concentration), taking into consideration the refining process of AlSi7Mg alloy and using URO - 200. The mathematical model of this process is also presented. The equation needed for calculation of the final hydrogen concentration as a function of the equivalent bubble diameter is shown. Basing on this equation the calculations of bubble diameter and optimal refining time are done. This paper presents the physical model (the water one) of aluminium refining process and the gas dispersion taking into account the fact that the gas flow rate is changing from 2,5 to 17,5 l/min and the impeller speed is changing from 0 to 400 rpm. Schemes of gas dispersion in liquid metal in comparison with the model data are shown and the optimal values of the gas flow rate and the impeller speed are chosen.

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 V. Bojarevics, K. Pericleous

"A number of different methods have been developed for noncontact electromagnetic treatment of liquid metal and to investigate the melting/solidification processes. Applying AC magnetic field in terrestrial conditions, along with the buoyancy and thermo-capillary forces, results in turbulent flow. The use of a homogenous DC magnetic field allows damping both of the turbulence and the large scale flow at different rates leading to surprising results at some stages. The dynamic interaction of the turbulent flow with the oscillating interface needs to be accounted if it is required to levitate liquid metal of up to few kilograms without the contact to container walls. At the high values of magnetic field some oscillation modes are damped quickly, while others are modified with a considerable shift of the oscillating droplet frequencies and the damping constants from the non-magnetic case. Numerical models are used to investigate behavior of liquid metal suspended in high DC magnetic fields providing microgravity-like conditions with laminar viscosity and heat transfer to the surroundings.IntroductionSince the early Electro Magnetic (EM) levitation experiments [1] in AC magnetic field it became apparent that the levitated liquid metal is prone to oscillation and instability. The EM and electrostatic levitation experiments with liquid metal droplets show difficulties related to confinement stability and a need for complex correction functions to establish a correlation between the measurements and the droplet material properties [2,3]. Intense internal fluid flow is visually observed, apparently being in the turbulent regime for earthbound conditions."

Jan 1, 2012

By Xingjian Gao

The mechanical properties of a low carbon low alloy steel in the austenite and _-ferrite regions have been examined by thermal-tensile tests using a Gleeble-1500D system at temperatures in the range 600oC to 1300oC and at a strain rate of 10-3/s; these being the conditions that apply to the unbending operation during the continuous casting of steel. The yield strength and tensile strength of steel decreased with increasing test temperature and the embrittlement zone occurred in the temperature range 800oC to 970oC. In the embrittlement zone, the fracture surfaces and microstructures of the tensile specimens were examined by scanning electron microscope. The results showed that the cause of the embrittlement at 950oC in which the minimum %R of A was around 36% is the second phase particles precipitated along the _ grain boundary during deformation leading to inter-granular brittle fracture.

Jan 1, 2010

By Robert G. Robins

Precipitation of ferric arsenate is an effective method for removing arsenic(v) from hydrometallurgical process solutions. The solubility and stability of this compound. FeAs04.2H20, has received some attention in recent years and the reported solubilities of amorphous and crystalline material have varied considerably. This paper reviews previous studies and reports some recent work with a consistent model to explain the variable results. Free energy data for ferric arsenate and its associated dissolved complexes are presented.

Jan 1, 1990

By L. A. Barta

A new process for the leaching of chalcopyrite concentrates has been developed and tested in miniplant campaigns and locked cycle testwork carried out between 1996 and 1999. The process involves pressure leaching in a sulphuric acid solution, e.g. raffinate from copper solvent extraction. Iron in the feeds is precipitated predominantly as hematite in the autoclave, simultaneously with copper extraction. Gold and silver in the pressure leach residue are recoverable by conventional cyanidation, following flotation to remove elemental sulphur by-product. The results of recent miniplant tests and batch locked cycle tests are provided.

Jan 1, 1999

By K. L. Money, R. R. Bleakney, R. H. Hanewald

The processing of EAF baghouse dusts, rolling mill scales, and belt grinding swarfs from the specialty steel industry will be reviewed. In addition, the INMETCO process has been modified so as to recover nickel, chromium and iron from many other waste materials such as pickling solutions, filter cakes, spent nickel and chromium plating baths, super alloy wastes, and nickel-cadmium batteries. INMETCO is the only North American company presently capable of recycling nickel-cadmium batteries by high temperature metals recovery.

Jan 1, 2000

By Luciano B. Oliveira, Angela O. Costa, Sergio N. Monteiro, Luis Guilherme C. Marques

"Biofuels are gaining a relevant role in today’s world not only as a solution for the decreasing petroleum reserves but mainly as a positive contribution to the efforts in global warming mitigation. In Brazil, since 1975, the replacement of gasoline by ethanol started a so-called PROALCHOOOL program, which is now being complemented with the replacement of petroleum diesel by biodiesel. This biodiesel program was officially created in 2005 with mandatory goals, supported by legislation, of 2% addition in 2008 and 5% addition in 2013 into all commercialized regular diesel. In this work, a critical analysis of the Brazilian biodiesel program is presented. The technical aspects related to the different raw materials, including wastes, available for biodiesel conversion as well as the economical conditions associated with production costs and market logistic are discussed. The environmental benefits associated with the retention of greenhouse gases are also discussed.IntroductionToday the commonly accepted fact that the petroleum world reserves are probably passing through a maximum and start declining in terms of the total amount that can be extracted by existing technologies is motivating significant changes in our society. The continuous increase in the price of gasoline and other liquid fuels is an immediate worrisome and visible consequence. However, more than an economical problem, our civilization is already facing the effects of global warming, due to CO2 emission from burning fossil fuels, mainly from coal and petroleum. It is now realized that a large scale solution for these problems demands the prompt substitution of non-renewable fossil fuels by others that, in addition of being renewable, have a relatively lower contribution to the greenhouse gases."

Jan 1, 2008

By Liyuan Chai

The corrosion mechanism of A3 steel induced by chloride ions in the purified water had been investigated with the A C Impedance technique. The results showed that there were another two factors which determined its electrochemical corrosive rate: the electrode potential and coverage ratio of chloride ions on the surface of A3 Steel. The corrosion mechanism of A3 steel in the solution with chloride ions emendation was two steps of electrode process with the rate-determining step of 0,32kFeClFeCle+--¾¾®++.

Jan 1, 2009

By J. C. Huyhua

The effect or various oxidants on gold and silver dissolution in thiourea solutions (0.05 M in H2SO4) was studied using the rotating disc technique, a.t 2s c and 600 rpm. These studies were carried out at constant (4:1) initial molar ratio or thiourea to oxidant concentrations, to produce 50 % thiourea. oxidation. The initial dissolution rate of gold was approximately four times higher in the presence. of ferric sulfate (5.37 x 10-3mg cm-2 s-1) than in the presence of hydrogen peroxide (H2O2), potassium persultate (K2S2O3), or monopersulfa.te (KHS06). The dissolution rates for silver were considerably lower than gold for the same oxidants. Oxidation of thiourea in the presence of peroxygen and persulta.te compounds is a. fast reaction and it is completed in less than ten minutes. On the other hand, the oxidation or thiourea with? ferric.sulfate is slow, yielding a second-order reaction rate constant k = 6.09 I mol-1 h-1. Sulfur formation in the ferric thiourea system begins when ferric ion reduction approaches to completion. With hydrogen peroxide, sulfur is observed at lower thiourea concentration than ferric. Suifate. The presence of a large excess or free thiourea i.e., s to 20 % thiourea oxidation) retards sulfur formation and maintains favorable dissolution rates. Finally, carbon-in-leach experiments indicate that thiourea solutions a.re stable for several days, with ferric sulfate or hydrogen peroxide. The dissolution rates of gold and silver doubles in the presence or activated carbon when hydrogen peroxide is used as oxidant.

Jan 1, 1989

By Rachel De Lucas

Current methods of hydrogen storage are an impediment to the transition of our energy infrastructure from a hydrocarbon to a hydrogen base. The transportation, handling, and storage costs of hydrogen gas account for a majority of its selling price. Magnesium hydride slurry is a safe, environmentally friendly alternative for hydrogen storage. If this form of storage is to be adopted on a large scale, a cost-effective method for recycling the enormous amounts of magnesium hydroxide byproduct must be identified. The solid oxide membrane (SOM) process can be used to recycle the magnesium hydroxide byproduct into magnesium metal, which can be reformed into magnesium hydride and reused for fuel storage. Conventional magnesium extraction/recycling technologies require a great deal of energy and create byproducts that are harmful to the environment and human health. The SOM process poses none of these detrimental effects and requires less energy and feed preparation. The economic viability of a facility that utilizes the solid oxide membrane process for the direct reduction of magnesium must be examined in more detail if industry is to consider it. Cost analysis data related to the commercial viability of a scale-up will be compared to two standard industrial processes: current magnesium production techniques including electrolytic and metallo-thermic processes. We have shown in our cost comparison that the SOM process is cheaper than these traditional techniques and that it is also comparable to aluminum's Hall-Héroult process in cost but with none of the environmentally harmful byproducts.

Jan 1, 2006

By Dongok Kim

Regardless of the advantages of the Friction Stir Process (FSP), for age-hardened aluminum alloys, the mechanical properties such as hardness in the stir zone decreased after FSP due to the growth or dissolution of strengthening precipitates. Here, as a new technique, FSP was introduced to alloy copper nanopowders in Al7075 T651. Mechanical properties of copper nanopowder- alloyed Al7075 T651 together with micro and nanostructures were compared with those of as-FSPed Al7075 T651 using SEM, TEM, and Vickers hardness testing to understand structure-property relationships. It was observed that Vickers hardness of the stir zone in copper nanopowder alloyed Al7075 T651 increased by 20% compared to that of the heat affected zone, while the as-FSPed samples did not show a noticeable increase in hardness in the same zone. Xray mapping showed traces of copper nanopowder after the process. TEM is being used to verify if there was CuAl2 formed in the copper alloyed sample.

Jan 1, 2006

By José Sancho, Julia Ayala, Purificación García, Begoña Fernández

"Electrofilter dust, a residue generated in the last stage of the Bayer process in the hydroxide aluminum calcination, was characterized to evaluate the alumina that was potentially extractable with sulfuric acid. The process studied aims to produce aluminum sulfate for water coagulant uses, taking advantage of the residues that accumulate in large quantities in the proximity of plants with difficult recycling for storage. Acid leaching is carried out at different concentrations of sulfuric acid, at different temperatures, pulp densities, and times, to dissolve gibbsite and transition aluminas. The result is an aluminum sulfate solution without iron and with commercial specifications.IntroductionElectrofilter dust is a residue generated in the last stage of the Bayer Process [1] in the hydroxide aluminium calcination. The residue is a mixture of alumina and hydrates which have not completed their calcination process.Electrofilter dust, composed by alpha alumina, gibbsite and transition aluminas [2] can be leached in an acid medium by putting most of the aluminium in solution; the remaining residue should be mainly andisolved alpha alumina. In many hydrometallurgical processes, sulphuric acid has been selected as the cheapest and the most effective leachant [3,4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15]The aim of this study is to determine the effect of temperature, acid concentration and pulp density on the sulphuric acid leaching of electrofilter fines for aluminium dissolution, in order to produce aluminium sulphate for water coagulant uses. This will provide a commercial product and at the same time eliminate the environmental problem created as a result of the storage of large quantities of electrofilter fines in the vicinity of the Bayer plant."

Jan 1, 2008

By Tamas Kekesi

Anion exchange in HCl media is considered an efficient alternative to the combination of the conventional purification methods. Anion-exchange distribution functions have been determined for cobalt and the main impurity elements by the technique of batch equilibration. Results were confirmed by spectrophotometric investigations and elution tests. Based on the new and the available distribution functions, combined with the assessment of thermodynamic stability, a procedure of anion exchange separation has been devised to eliminate virtually all the impurities from the cobalt-chloride solution. Separation of copper has been enhanced by the introduction of a preliminary step under reduced conditions. The rest of the impurities are eliminated in a second anion-exchange step applying rinsing and elution stages under oxidized conditions. The optimum parameters of the procedure have been determined according to performance characteristics (purification ratios, yields and volume efficiencies) derived from the analysis of elution curves obtained with laboratory scale ion-exchange columns. Special computer programs have been developed to facilitate thermodynamic simulation, analytical correction and data processing.

Jan 1, 2003

By M. Wu, A. Kharicha, J. Bohacek, A. Ludwig

"During the horizontal spin casting of rolls, vibrations and mould deformations seems to have a significant effect on the final quality of the product. Sources for vibrations can be found in the poor roundness and a static imbalance of the chill itself. The bending of the mould axis is also considered. Both, vibrations and axis bending, are used as an input for CFD simulations of the flow dynamics of the liquid metal inside the rotating cylinder. The aim is to study the feedback of the free surface behavior in terms of wave propagation and various wave shapes. Introduction The horizontal spin casting process (HSC) is a casting process that has several advantages over the traditional gravity casting processes. Centrifugally cast products have a high degree of metallurgical purity and homogeneous microstructure. A significant gain is observed for the rupture strength, the rupture strain, and the Young modulus. These properties naturally depend on the centrifugal force and thus, the best mechanical properties can be found at the largest distance from axis of rotation. However proper selection of the angular frequency has to be done in order to prevent the so-called ""metal rain"" i.e. metal droplets can fall down from the upper part of the cylinder due to a too weak centrifugal acceleration. In the same time excessive speeds can lead to the appearance of longitudinal cracks caused by the hoop stress in the initially solidified layer. From empirical knowledge other parameters have important influence on the casting products, it includes the pouring temperature, the pouring rate, the mould coating etc. Recently the presence of natural or forced vibrations have been identified as possible additional factors to be taken into account [1-2]."

Jan 1, 2012

By Jinqian Zhao, Jiarong Li, Shizhong Liu

"Creep cavitation of in single crystal (SX) superalloy was investigated. The constant load creep tests, in single crystal superalloys DD6, were conducted at the conditions of 800°C/700MPa, 850°C/550MPa and 900°C/450MPa, respectively. It was found that there were square facets on the stress fracture surface, and microscopic cavities in the ruptured specimens in the vicinity of the fracture surface. Both the square facets on the fracture surface and microscopic cavities in the section of the ruptured specimens show the morphology of the same thing at the different views, namely creep cavities, which are take the form of flatten cuboid. In fact, creep cavities are the longitudinally tensiled creep cracks slowly growing during the stress tensiling. The factors of creep cracks nucleation and growth conditions include: (a) enough high temperature to activate diffusion (b) casting pores as nucleation origination (c) high strains and strain rates. Eventually, the instantaneous fracture mechanism of creep specimen is cleavage fracture.IntroductionFor the materials used in elevated temperature service, creep behavior has to be accounted for. It is well recognized that creep rupture in polycrystalline materials at high temperature occurs principally by the nucleation and growth of microscopic cavities at grain boundaries, followed by microscopic cavities linkage to form micro- and eventually macro-intergranular cracks[l,2]. Without the usual grain boundaries, SX superalloys have superior capabilities at high temperatures to polycrystalline superalloys, and have become an established feature of gas turbine technology where they are commonly employed in the manufacture of high performance blades[3]. A considerable amount of work has been done over the past tens of years, and many models for nucleation and growth of creep cavities have been proposed, however, those are mainly for polycrystalline materials.In order to improve creep resistance that single crystal superalloys, in which grain boundaries are removed, have been developed. Because there don't exist grain boundaries in SX superalloy, the mechanism of nucleation and growth of creep cavities must be different from that in polycrystalline materials.Understanding the formation and characteristics of creep cavitation is crucial to model the lives of single crystal superalloys.M. Marchionni and L.G. Zhao et al. found that there were square facets on the stress fracture surface [4,5]. Roger C. Reed pointed out creep cavities lie in the necked region[6]. In this paper, the effects on the formation of creep cavities are discussed, as well as the morphology of creep cavities and fracture mechanism of SX superalloys."

Jan 1, 2013

By Florian Kongoli

While calcium ferrite slags have been successfully used in continuous copper converting for the last 30 years, ferrous calcium silicate slag was proposed about 8 years ago as an additional alternative for copper smelting. Although both slags are normal extensions of each other their phase relations have not been completely clarified. In this paper the liquidus relations of both slags have been quantified at various areas that cover both of them. The existing experimental data have been first reviewed and discussed in relation to the solidification procedure. An original physical model is then used to predict various diagrams of the liquidus surface of both slags. It is shown that the ternary liquidus diagrams normally used for FeOx-SiO2-CaO system are not suitable for industrial slags. The new model diagrams of Fe/CaO versus SiO2 and Fe/SiO2 versus CaO as well as Fe/CaO versus Temperature and Fe/SiO2 versus temperature are proven to be much more convenient for ferrite and ferrous calcium silicate slags. Based on these diagrams the effect of SiO2 and CaO on the melting temperature is quantified. The effect of Cu2O is also quantified through the model. Some Fe/CaO versus Cu2O and Fe/SiO2versus CaO at various copper contents are predicted and the results show good agreement with the experimental data. It is also shown that in the presence of liquid copper, Cu2O is dissolved in the slag depending on the oxidation degree of the system and might lower the liquidus temperature. Some discussions are also presented taking into account plant observations and important conclusions are drawn for copper smelting and converting

Jan 1, 2006

By Florian Kongoli

While calcium ferrite slags have been successfully used in continuous copper converting for the last 30 years, ferrous calcium silicate slag was proposed about 8 years ago as an additional alternative for copper smelting. Although both slags are normal extensions of each other their phase relations have not been completely clarified. In this paper the liquidus relations of both slags have been quantified at various areas that cover both of them. The existing experimental data have been first reviewed and discussed in relation to the solidification procedure. An original physical model is then used to predict various diagrams of the liquidus surface of both slags. It is shown that the ternary liquidus diagrams normally used for FeOx-SiO2-CaO system are not suitable for industrial slags. The new model diagrams of Fe/CaO versus SiO2 and Fe/SiO2 versus CaO as well as Fe/CaO versus Temperature and Fe/SiO2 versus temperature are proven to be much more convenient for ferrite and ferrous calcium silicate slags. Based on these diagrams the effect of SiO2 and CaO on the melting temperature is quantified. The effect of Cu2O is also quantified through the model. Some Fe/CaO versus Cu2O and Fe/SiO2versus CaO at various copper contents are predicted and the results show good agreement with the experimental data. It is also shown that in the presence of liquid copper, Cu2O is dissolved in the slag depending on the oxidation degree of the system and might lower the liquidus temperature. Some discussions are also presented taking into account plant observations and important conclusions are drawn for copper smelting and converting

Jan 1, 2006

By Florian Kongoli

While calcium ferrite slags have been successfully used in continuous copper converting for the last 30 years, ferrous calcium silicate slag was proposed about 8 years ago as an additional alternative for copper smelting. Although both slags are normal extensions of each other their phase relations have not been completely clarified. In this paper the liquidus relations of both slags have been quantified at various areas that cover both of them. The existing experimental data have been first reviewed and discussed in relation to the solidification procedure. An original physical model is then used to predict various diagrams of the liquidus surface of both slags. It is shown that the ternary liquidus diagrams normally used for FeOx-SiO2-CaO system are not suitable for industrial slags. The new model diagrams of Fe/CaO versus SiO2 and Fe/SiO2 versus CaO as well as Fe/CaO versus Temperature and Fe/SiO2 versus temperature are proven to be much more convenient for ferrite and ferrous calcium silicate slags. Based on these diagrams the effect of SiO2 and CaO on the melting temperature is quantified. The effect of Cu2O is also quantified through the model. Some Fe/CaO versus Cu2O and Fe/SiO2versus CaO at various copper contents are predicted and the results show good agreement with the experimental data. It is also shown that in the presence of liquid copper, Cu2O is dissolved in the slag depending on the oxidation degree of the system and might lower the liquidus temperature. Some discussions are also presented taking into account plant observations and important conclusions are drawn for copper smelting and converting

Jan 1, 2006

By Florian Kongoli

While calcium ferrite slags have been successfully used in continuous copper converting for the last 30 years, ferrous calcium silicate slag was proposed about 8 years ago as an additional alternative for copper smelting. Although both slags are normal extensions of each other their phase relations have not been completely clarified. In this paper the liquidus relations of both slags have been quantified at various areas that cover both of them. The existing experimental data have been first reviewed and discussed in relation to the solidification procedure. An original physical model is then used to predict various diagrams of the liquidus surface of both slags. It is shown that the ternary liquidus diagrams normally used for FeOx-SiO2-CaO system are not suitable for industrial slags. The new model diagrams of Fe/CaO versus SiO2 and Fe/SiO2 versus CaO as well as Fe/CaO versus Temperature and Fe/SiO2 versus temperature are proven to be much more convenient for ferrite and ferrous calcium silicate slags. Based on these diagrams the effect of SiO2 and CaO on the melting temperature is quantified. The effect of Cu2O is also quantified through the model. Some Fe/CaO versus Cu2O and Fe/SiO2versus CaO at various copper contents are predicted and the results show good agreement with the experimental data. It is also shown that in the presence of liquid copper, Cu2O is dissolved in the slag depending on the oxidation degree of the system and might lower the liquidus temperature. Some discussions are also presented taking into account plant observations and important conclusions are drawn for copper smelting and converting

Jan 1, 2006