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By M. I. Kalashnikova

In hydrometallurgical technological flowsheets several methods of target components removal from solution are used. One of these methods is non-ferrous metals removal in the form of rich selective or collective concentrates. In the present work pyrometallugical mattes, thiosulphate containing solutions and pulps, iron powder with elemental sulphur and calcium sulphate were used as the precipitator. It was shown that depending on precipitator compound and process parameters non-ferrous metals precipitate from solution in the different forms with varying content of components including Ni3S2, NiS, Ni3S4, NiS2, (Ni,Co)S2, CuS; Cu1,765S; Cu1,97S.

Jan 1, 2006

By D. H. H. Quon

Results of a study conducted to determine the properties of iron ore pellets made from Mount Wright and Carol Lake ore concentrate fines with partial and full substitution of bentonite by several organic binders are presented. Carboxy methyl celluloses 7H and 6TL, hydroxy ethyl cellulose (natrosol) and modified guar gum all produce pellets of acceptable wet, green and dry strength. However, when fully substituted, an inorganic binder such as calcium carbonate is required for satisfactory strength development after induration. Mixing the Carol Lake ore with Mount Wright ore in a 50-50 ratio also achieves the same result. The failure of the Carol Lake ore in the pelletization process is attributed to the low hematite content of the ore. The results are very similar to those from the extrusion studies reported earlier (8).

Jan 1, 1989

By A. V. Kuznetsov, R. I. Kamkin, V. M. Paretskiy, A. Y. Mamaev, V. P. Bystrov, A. S. Vernigora

"Vanukov furnace technology is an efficient, proven pyrometallurgical injection technology, used extensively in Russia and Kazakhstan for a number of different applications. The technology was most widely adopted for processing copper sulfide concentrates for matte in smelters in Norilsk, Revda (Russia) and Balkhash (Kazakhstan). The following applications also were developed and tested at industrial scale: treatment of sulfide lead and lead-zinc concentrates, laterite nickel ore, production of cast iron, treatment of antimony gold-containing ores, and municipal solid waste. In this paper, current experience of Vanukov furnace application to these technologies is described with a number of general development trends and new areas of application.IntroductionAt the present time, the Vanukov process, developed at the Moscow State Institute of Steel and Alloys at the Department of metallurgy of non-ferrous, rare and noble metals with collaboration with other research organizations, is a highly efficient technological solution for processing different kinds of raw materials. The process was invented by Professor Andrey Vladimirovich Vanukov, whose research work began in 1949. From 1956 to 1975 test runs of the technology were carried out at the smelters in Norilsk and Balkhash. In 1976 a pilot Vanukov furnace was built in Ryazan. Furnace designs was modified to suit the various test programs. A major objective of each experiment was the determination of optimal working conditions for processing different types of raw materials such as copper, copper-nickel, copper-zinc, lead or pyrite concentrates, and materials containing secondary lead and zinc. After the death of Andrey Vladimirovich Vanukov in 1986, this technology and furnaces based on the technology were named after him: “Vanukov process” and “Vanukov furnace”. Today, the following furnaces based on Vanukov technology are either working or were tested at semi-industrial scale: three in Norilsk, two in Revda (Russia) and two in Balkhash (Kazakhstan) for treatment of copper sulfide concentrates for matte, one in Orsk (Russia) for processing laterite nickel ore, one in the Buruktal plant (Russia) for antimony gold-containing ores for antimony oxide sublimates and gold-containing metallic antimony, and one in China for processing sulfide lead and lead-zinc concentrates for production of black lead and zinc-containing sublimates."

Jan 1, 2011

By J. Rajesh Kumar

The extraction equilibrium study of tetravalent platinum was carried out using tri-octyl/decyl amine (Alamine 336) and bis(2,4,4-trimethylpentyl) monothiophosphinic acid (Cyanex 302) in kerosene from hydrochloric acid media to investigate their extraction capacity, since they have different donor atoms, ?N? and ?S?. Their distribution equlibria were studied as a function of acid, extractant, diluents and temperature. The title metal shows the inverse behavior at higher acid concentrations. Extraction of tetravalent platinum increases with increase of extractant concentration. The plot of log D vs. log [Extractant], mol.L-1 is linear with slopes 1±0.3, indicating the association of one mole of extractant with the extracted metal species. Stripping of metal from the loaded organic (LO) with mineral acids and bases such as hydrochloric, sulphuric, nitric acids and ammonia, hydrogen peroxide, sodium hydroxide, thio- urea were studied. Regeneration and recycling capacity of Alamine 336/Cyanex 302 and extraction behavior of associated elements was also studied.

Jan 1, 2009

By Tianjiao Luo

Some literatures discussed on how to recycle the various reagent, but the discussion on how to reuse the waste liquid directly is very little. How to reuse the waste liquid directly was researched in this paper. Firstly, the waste liquid should be filtrated to remove the impurity; then some quantity of H2O2 solution was dripped into the waste liquid to pretreat it; finally, CuSO4solution was added into the treated waste liquid and the pH was adjusted to about 12, then some HCHO solution was added into the waste liquid, in which the treated carbon fiber can be plated. The morphology and composition of coatings were investigated by means of Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray Spectroscopy (EDS), the deposition rate was mensurated by the way of dissolution. The results indicated that, the plating effect was basically identical with new plating solution, and the solution is stable, and the plating rate is still about 0.8µm/h, and the copper coating is even and combines closely with carbon fiber. According to this way, the waste liquid can be reuse 5~7 times.

Jan 1, 2006

By Hannu Johto

Boliden Harjavalta has operated a flash smelter for nickel sulphide concentrates in Finland since late 1959. The original nickel flash smelting process was modified in 1995 to a novel nickel matte smelting (DON) with semi-low iron where the batchwise operated converting became obsolete. Since that, the process has been applied to multiple chemically variable nickel sulphide concentrates with high environmental performance. In this paper, the status of the current smelter operations is described together with the recent modernizations of the nickel flash smelting furnace and the slag cleaning furnaces.

By Ehsan Vahidi, Fereshteh Rashchi, Amirhossein Shahnazi

"The pig iron from steel manufacturing plants contains a high concentration of vanadium-bearing materials smelted with iron ore. During the oxidation process of the molten pig iron with oxygen lances, vanadium transfers to the slag. In this research, recovery of vanadium from LD (Linz-Donawitz) converter slag of steelmaking plant was investigated. The leaching residue was characterized by XRD and XRF techniques. The maximum vanadium recovery was achieved at optimum leaching conditions of 70 °C, S/L: 1/15, sodium hydroxide concentration: 3 M and leaching time: 150 minutes. The dissolution rate increased with rising sodium hydroxide concentration and temperature and decreasing particle size. The experimental data are treated graphically to explain the kinetics of the vanadium recovery process using shrinking core model (SCM). As a result, the controlling regimes in the SCM were analyzed separately using liquid film diffusion control, solid product diffusion control, and reaction control mechanisms.IntroductionVanadium is commercially important as a constituent of several alloys and catalysts. Nowadays, vanadium is mostly recovered as a by-product from secondary sources or from industrial waste streams such as titaniferrous magnetite, fly ash, spent catalysts, and petroleum coke. Steelmaking operations are specifically concerned by this problem due to the production of a huge quantity of by-products [1]. These by-products, including LD converter slag, sludge, fly ash, spent catalyst, ash, and alloyed scrap, contain a notable amount of heavy metals which may cause environmental problems. Solvent extraction is one of the techniques being increasingly used for the recovery of vanadium [2]. Apart from vanadium ore, secondary resources such as titanmagnetite, ilmenite and slag from the ferrous industry are a major source of supply. The pig iron from steel manufacturing contains a majority of vanadium-bearing materials smelted with iron ore. In a heat resistant shaking ladle the molten pig iron is oxidized with oxygen lances, causing the vanadium to be transferred to the slag. Normally, the vanadium in LD converter steel slag (coming from Linz-Donawitz steelmaking process) is ca. 5% as vanadium pentoxide (V2O5). This slag is the world's principal raw material for vanadium production [3, 4]. Moskalyk and Alfantazi [4] reported that a roast-leach process is used in South Africa for the production of vanadium oxides from magnetite ores while some of the slag was converted to ferrovanadium. A portion of the slag was exported to Europe for the production of vanadium oxide. The researchers mentioned that alkaline roasting was the main process at that time employed to extract vanadium pentoxide from vanadium slags."

Jan 1, 2012

By Keith Axler

The high reactivity of plutonium metal presents safety concerns related to material containment during fire scenarios. Plutonium metal is liquid at temperatures achieved under selected fire scenarios. The appearance of liquid plutonium challenges the corrosion resistance of the containment materials. However, by the in situ formation of intermetallic compounds, the plutonium metal can be stabilized as solid and the integrity of the containment vessels preserved. Studies have been conducted to demonstrate candidate materials, including lead, which can be introduced to the liquid-plutonium system and bind the corrosive liquid metal through the formation of intermetallic phases. The results of these investigations will be presented along with a discussion of the experimentally determined phase behavior for the plutonium-lead system.

Jan 1, 1995

By S. Viswanathan, Q. Han, A. S. Sabau

"In spite of recent advances in the mathematical modeling of fluid dynamics for materials processing applications, no significant advances have been made in the numerical discretization of these equations. In this work, the application of two-step projection methods for the numerical simulation of interdendritic flows is discussed. Unlike previous methods, the methods presented here are constructed for the exact equations which are characterized by variable density and volumetric fraction of the liquid. The drag terms, which describe the momentum loss due to the flow around and through the dendrite structures, are treated implicitly. Numerical examples for shrinkage-induced flow during solidification of an Al-4.5% Cu alloy bar is used to illustrate the effectiveness of the proposed algorithm.IntroductionLiquid contraction during solidification plays an important role in the formation of casting defects such as shrinkage voids, microporosity, and macrosegregation. Owing to their importance, the study of transport processes during solidification have received considerable attention during the past years [1, 2]. By the use of volume-averaging techniques, the mass and momentum equations for flow through a stationary dendritic structure were derived [3]. By using the volume-averaging techniques for multi-phase systems, two-phase transport equations for solidification problems were derived [4]."

Jan 1, 1999

By QinGuo, Shenghui Guo, Lei Li, Jinhui Peng, Linqing Dai, Libo Zhang

The ferrous removal process after carbothermic reduction of chromite fines with microwave heating combined with leaching was investigated. Under the following conditions: Reaction temperature: 1150 , Reaction time : 40min, Semi coke ratio: 12% , the iron content of the reduction product : 13.05% . Metallization achieved was 52.7%. Reduced chromite was leached with 8% of H2SO4 and FeCl3 aqueous solution. The results show that: the recovery rate of chromium can reach 88.06%, the mass ratio of chromium to iron is 3.5:1 for leaching 30 minutes with 8% of H2SO4; the recovery rate of chromium can reach 88.91%, the mass ratio of chromium and iron is 2.56:1 for leaching 4h at room temperature with FeCl3 aqueous solution (100g/L). The leaching time of latter is longer but can realize the circulation effectively and reduce the waste liquid processing problem.1

Jan 1, 2016

By Ulises Crossa Archiopoli

We describe a technique that allows rapid imaging of the thermal diffusivity of the sample by a modified photo-thermal technique. The thermal diffusivity in hardened steels strongly correlates to the hardness. Hence in a noncontact manner and with optical microscope resolution, a 2D map exhibiting the crystallographic phases and hardness of the sample can be retrieved. Two almost collinear laser beams scan the surface, one as a modulated pump and a second as a CW probe. The deflection of the probe carries information on the thermal expansion of the sample and with it, on the thermal diffusivity. It is shown that a single determination of the time delay of the modulation of the probe beam can be used to retrieve the thermal diffusivity.

Jan 1, 2010

By Hans Korfmacher

Product take-back regulations implemented in Europe have presented significant challenges to the consumer electronic product and battery industries. Initially companies established single compliance organizations within individual Member States. These programs met business needs but were inefficient and costly. They were protected from pressures of marketplace competition and could not leverage economies of scale. In order to address these problems P&G, Hewlett Packard, Sony and Electrolux conceived a pan-European compliance organization to collect waste electronic equipment Europe-wide. This organization, called the European Recycling Platform (ERP), operates in competition with existing national compliance systems. Since 2005 ERP has collected 800,000+ tons of waste electronic products and delivered millions of dollars in cost savings. This presentation reviews the steps needed to establish successful competitive collection organizations that provide sustainable recycling at the lowest cost.

Jan 1, 2010

By JiaPeng Xu, Brian Lo, Uday B. Pal, Yihong Jiang, Soumendra N. Basu

"The Solid-Oxide Oxygen-Ion-Conducting Membrane (SOM) electrolysis process has been successfully tested on a laboratory scale, producing silicon directly from silica in a cost-effective and environmentally friendly way. A yttria-stabilized zirconia (YSZ) tube, closed at one end was employed to separate the molten salt containing dissolved silica from a liquid metal anode placed inside the YSZ tube. When the applied electric potential between the liquid tin cathode in the molten salt and the anode exceeds the dissociation potential of silica, oxygen ions are pumped out of the molten salt through the YSZ membrane and oxidized at the anode while the silicon cations in the flux are reduced to silicon at the liquid tin cathode. The presence of high-purity silicon crystals on the surface of liquid tin cathode was confirmed by scanning electron microscopy (SEM) and energy dispersive x-ray spectroscopy (EDS). Silicon crystals were extracted from tin cathode by chemical etching.IntroductionPhotovoltaics (PV) generate electrical power by using solar cells, and dramatically reduce the emissions of greenhouse gases (GHG). Through 2006 to 2011, it grew the fastest of all renewable technologies with operating capacity increasing an average of 58% annually [l]. However, the cost of manufacturing solar-grade silicon (SoG-Si) for high-efficiency solar energy production represents a major barrier to achieving the industrial goal for solar power of $1/Wp (watt at peak exposure) which would enable widespread grid parity. The current contract price of silicon to PV manufacturers is $50-$60/kg, with the spot market in 2007-2008 showing prices as high as $300/kg [2]. This makes the development of low cost and environmentally friendly manufacturing of high purity silicon very important."

Jan 1, 2013

By Carla Lupi, Alessandro Pescetelli

"Spent lead battery recycling still shows few weak points in the achievement of a 100% recycling of different waste matters and by- products arising from the recycling process. Some of said problems are dealing with aqueous streams outgoing the recycling plant, and more particularly, a) the waste waters discarded from the breaking and separation unit, b) purification of the spent electrolyte drained from waste batteries and upgrade to a quality compatible with full re-use by the batteries’ manufacturers, c) purification of the mother liquors discarded in the sodium sulfate crystallization process so to produce a salt of commercial grade. All of the above listed problems have been satisfactorily overcome applying an electrochemical process that, through different process conditions and parameters, is able to remove the harmful impurities that hinder the successful commercialization of such by products, or, at least, that can avoid heavy and expensive treatment plant and operation.IntroductionAlmost 100% of commercial lead and lead alloys produced by secondary lead plants is recycled to the new lead accumulators manufacture. The other by-products and residues produced through the lead recycling process may be classified into two groups:a) matters reusable in the new accumulators production processb) matters produced as a result of various reagents and additives used in the recycling process, to be sold to different market sectorsQuality and saleability of by-products are significant points for the economics of the secondary lead plant operation, because, if said by-products are not saleable, they are just wastes, so offsetting potential revenues, and, at the same time, adding a heavy burden to operating cost, like disposal cost [1]. When looking at a typical, modern lead scrap batteries recovery cycle, it is quite evident that we are still rather far from dealing with a waste-less technology (fig.1).The group a) includes 3 by-products produced through the breaking process: among those matters the polypropylene only usually reaches a standard quality suitable for sale to lead manufacturing sector or to other sectors as well. The other two by-products, electrolyte and separators, do not still reach, through a viable and effective regeneration process, a quality standard sufficient for their re-use in the lead batteries sector ."

Jan 1, 2008

By M. Hochenhofer

Due to economic aspects and environmental regulations recycling of slag and waste from ferroalloy production became a very important issue for the companies during the last years. The treatment of slag depends prior on the composition, especially on their content of valuable metals and impurities. The final aim should be a total re-use of these materials in the industry e.g. cement industry, pig-iron production etc.. Therefore, to reach the required physical and chemical properties for a further use, possibilities of a metallurgical treatment have been investigated. The conditioning of slag with a high V-, Mo- and P-content via reducing metal bath showed to be one alternative. To determine the optimal process parameters, practical investigations with different slag compositions and thermodynamic calculations were carried out.

Jan 1, 2006

By Lawrence D. May, Harry Mudgett

"In the course of developing a new industrial process, information produced at the Research and Development (R&D) stage is critical to determining the technical and economic feasibility of the project. Understanding the fundamental operating parameters for each unit operation in a flowsheet typically comes from historical knowledge of similar systems or by technical development through a robust research program. This approach holds true for processes incorporating fluidized-bed technology. In this paper, the authors will present a practical approach for performing a research study that will allow a process owner to determine if the concept of using a fluidized-bed system can become a reality. Included are discussions of key steps required at each level of the R&D program, and the critical information required for advancing the project to the next stage.IntroductionThe conduct of a research and development program typically starts with a process owner identifying a new industrial need or modification to an existing operation. The owner can pursue this need through multiple routes, including initial in-house development, coordination through an engineering firm, contacting suppliers of key equipment envisioned for the process, or through direct contact with research and development organizations. Where and when the project is conducted is as variable as the number and types of owners who pursue them. Factors that can influence the decision of where to conduct a research program can include the type of process desired, the scale and scope of the project, the location of the project site relative to the R&D options, the experience, capability, and availability of the potential research sources, and the costs to conduct the program. Often, the owner may choose a combination of the available resources to achieve their objectives. In the end, the owner's choice should be based on a thorough understanding of their goals and objectives for the program, and a good understanding of how to measure success while achieving those objectives. Herein, the authors will describe the methods we have typically used to develop the information an owner needs to make an educated decision for investing in a new or modified process."

Jan 1, 2014

By Soobhankar Pati

Solid oxide membrane (SOM) technology has been successfully employed for the production of high energy metals such magnesium, titanium and tantalum by directly reducing their oxides. This paper reports on the recent investigation done for calcium production by SOM process from calcium oxide, dissolved in fluoride and chloride based fluxes. This process employs an inert oxygen-ion-conducting stabilized zirconia membrane to separate the inert cathode in the flux from the anode. When the applied electrical potential between the electrodes exceeds the dissociation potential of calcium oxide, oxygen ions are driven out of the melt and through the zirconia membrane to the anode where they are oxidized. Reduced calcium metal deposits or evolves at the cathode depending on the operating temperature. The SOM cell has been electrochemically characterized, and key concepts related to CaO dissociation, leakage current, solubility of Ca in the flux, and hygroscopic nature of the flux relevant to the SOM process are explained.

Jan 1, 2008

By C. Cheung, U. Erb

"Over the past few years, nano-processing of magnetic materials has received considerable attention, because many magnetic and other application-specific properties have been shown to be enhanced in materials with ultrafine grain size. This paper reviews recent advances in the production of nano-processed soft magnetic materials such as pure nickel and cobalt as well as binary nickel-iron and ternary nickel-iron-chromium alloys by electrodeposition. Magnetic, electrical and mechanical properties of these materials are presented and discussed in terms of their microstructural defects.IntroductionIn recent years, nano-processing of materials to enhance their magnetic properties has received considerable attention [1-23]. Thin films, compositionally modulated thin films, granular films and bulk materials have been produced by many different techniques. These include gascondensation [1-6], ball-milling [7,8], chemical processing [9,10], metal-organo complex routes, solution reduction and co-precipitation [11], sol-gel methods [12], sputtering [12-14], rapid solidification [15], devitrification of amorphous alloys [16-19] and electrodeposition [12,20,21]. The potential application of nano-engineered materials with enhanced magnetic properties has been specifically discussed for soft magnets [18,19,22,23], hard permanent magnets [15] as well as for layered materials showing giant magnetoresistance effects [13,14] and nano-composites for magnetic refrigeration [11,12].The purpose of the present paper is to review recent advances in the development of nanocrystalline soft magnetic materials by electrodeposition methods. These materials could find applications in areas such as magnetic recording heads, high efficiency electric motors, transformer cores, etc."

Jan 1, 1994

By Noritaka Horii, Katsuyoshi Kakinuma, Hiroshi Yamamura

"ZrO2 and Y2O 3-doped ZrO2 gel film were obtained by spin coating of sol from Zr-n-propoxide, n-propanol, acetylacetone, nitric acid, and water on a silica glass as a substrate. ·Dried gel films crystallized to monoclinic, tetragonal, cubic and their mixed phases, depending on the chemical composition of sol, .firing temperature, and coating cycles. ZrO2 films with highly preferential orientation were successfully obtained from a solution containing a large amount of n-propanol. The highly oriented ZrO2 film was found to have high transparency compared with non-oriented 'films. Electrical conductivity of 8 mol% Y2O 3 doped ZrO2 film was also measured.Introduction3 mol% Y2O 3 doped ZrO2, which has a tetragonal symmetry is ·well known to have a strong mechanical property and a high toughness. (1) On the other hand, 8 mol % Y 2O 3-doped ZrO2 is high oxide-ion conducting material and is applied to oxygen sensor, oxygen pump, and solid oxide fuel cell (SOFC). (2) Sol-gel methods using metallic alkoxide are widely applied for synthesizing ceramics such as high-purity fine particles, thin film, and fiber. (3) For ceramics films, many reports have been made on SiO2, (4) TiO2, (5) and PZT. (6) Several case studies have been done on zirconia film based on the sol-gel method, (7) - (11) but very few on preferentially oriented film and on systematic Y zO3 doping. Almost zirconia ceramic· films reported were prepared by means of dip-coating. Kamiya et al. (12) and Ganguli et al (13) converted zirconia into fiber. Sol from Zr alkoxide is usually very unstable, and a stabilizing agent such as glycol or ß-keton is used beforehand (7) (14)."

Jan 1, 2000

By Gustavo Díaz, Miguel A. García, Carlos Frías

"Under the auspices of the Commission of the European Union, a consortium composed of six European organi~ations has conducted a project to scale up the PLACID electrowinning cell to industrial size within the Placid process development. This paper is concerning the results and achievement of the industrial cell prototype after more than 1,000 hours operating time and about 10,000 Kg electrolytic lead production. In general, results have been very satisfactory, demonstrating the ability ofthe PLACID electrowinning cell to produce top quality electrolytic lead (> 99.99 %) with high current efficiency and low energy consumption.IntroductionThis paper is concerning the development of an industrial size PLACID electrowinning cell within the PLACID process development. This project began on January 1993 and was finished on April 1996.Lead metal production and manufacturing industries produce large amounts of dusts and also lead bearing slags. Spent lead-acid battery recycling also produces lead oxides from the battery pastes rather similar to those mentioned above. Those lead secondary materials are hazardous and difficult to handle by usual procedures.Existing processes to treat-lead oxides may inflict considerable damage on the environment, incur high operating costs and have limitations to produce top quality lead.The main aim of this project has been to develop a novel hydrometallurgical process able to deal with different lead bearing materials, mainly lead oxide secondaries: lead-acid battery pastes, lead fumes, furnace slags, oxide residues, etc., producing ""four nines"" pure lead in an efficient manner with a benign influence on the environment; it is called the PLACID process."

Jan 1, 1997