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By Walter E. Dean

Twenty six samples of carbonaceous gold ores and associated rocks from outcrop and mine localities in northcentral Nevada were analyzed for concentrations of major. minor, and trace elements, total sulfur, and organic carbon. Q-mode factor analysis was used to define six distinctive carbonate, organic, and detrital associations of elements, and to group samples based on these associations. The trace metals that have clearly enriched the organic-carbon-rich samples are V, Zn, Ni, Cu, Cr, and Mo, although few of the samples could be considered "metal-rich" when compared to other organic-carbon-rich black shales. Rock-Eval pyrolysis was used to evaluate thermal maturity and hydrocarbon yield of the samples. Unfortunately, most samples were too thermally altered to be suitable for routine organic geochemical characterization of organic matter. The 813C values of organic carbon in rocks from different deposits have a trimodal distribution, but there is no clear distinction between the three groups of deposits that can be related to age, thermal history, or depositional environment.

Jan 1, 1987

By M. Benavides

An experimental study is carried out With sulphide ore obtained from Bailadores-Venezuela as well as artificial concentrates. Concentrates of the minerals from froth flotation are fused to study equilibrium between the matte and slag phases. The first part of the work deals with obtaining a concentrate by flotation experiments with collective and selective reagents, with acceptable metallurgical recovery, studying the influence of different parameters in the process. The second part gives the results of the experimental investigation. on thermodynamic equilibrium in smelting which facilitates knowledge of the elemental processes, giving bases for the possibilities of reducing the loss of metal in slag.

Jan 1, 1983

By Atsuhiro Nabei, Ken-ichi Yamaguchi

"Wet chlorination process of de-copperized anode slime is followed by de-chlorination stage in which lead-sulfate and metallic silver form silver residue. The silver residue is subsequently reduced to Ag2Se matte and PbO-SiO2 slag to remove lead to the slag in a short rotary furnace. Although this smelting process is proven well in actual operations, few papers have investigated its metallurgical aspects. This paper will describe the effectiveness of controlling parameters adopted at the Naoshima Smelter & Refinery and discuss the decisive factors influencing silver loss to PbO-SiO2 slag.IntroductionThe precious metals plant at Naoshima smelter & refinery was established in 1989, and has produced electrolytic silver, refined gold and platinum-group metals (PGM) from de-copperized anode slime as by-products of electrolytic copper. The process for gold production has been innovated from conventional smelting process to hydrometallurgical process since 2004 [1], while the process for silver production has still remained the same.The process for silver production at the Naoshima smelter & refinery is illustrated schematically in Figure 1. De-copperized anode slime is, at first, concentrated in the froth flotation process, then leached in the wet-chlorination process, and converted to silver residue in the de-chlorination process. The silver residue, which is a mixture of lead-sulfate and metallic silver, is charged to a short rotary furnace for the oxidation roasting to volatilize selenium dioxide and subsequent reduction smelting. In the smelting stage, silver residue and reverts containing selenium are smelted with flux and carbonaceous materials to form PbO-SiO2 slag and Ag2Se matte. Furthermore, Ag2Se matte is transferred to a rotary cupell and oxidized by air with the addition of sodium carbonate and sodium nitrate to produce silver anodes while removing impurities into litharge. Silver anodes are electrolytically refined by the Moebius process. Electrolytic silver is washed, dried and, finally, cast into 30kg-bars."

Jan 1, 2011

By B. Mishra

The major waste product of the alkaline extraction of alumina from bauxite [Bayer Process] is known as red-mud. Approximately, a ton of red-mud is produced for every two tons of bauxite that is mined. The red-mud produced from Jamaican bauxite is rich in hematite, alumina and titanium oxide. It has been shown that over 90 wt. pct. alumina can be recovered from red-mud by soda-ash sintering and caustic leaching. Hematite can be carbothermically reduced with a degree of metallization of over 94 pct. At this stage, the product could be charged through the tuyeres in an iron blast furnace or smelted to produce pig iron. The mineralogical characteristics of the reduced product are not amenable to magnetic separation for iron recovery. The problems associated with the use of reduced red-mud as an alternative to direct-reduced iron [DRI] has also been discussed. Special attention has been paid to lower the alkali content of the reduced material. If smelted, the concentration of titanium oxide in the slag will be significantly high justifying its recovery by an acid-leach process. This paper describes the successful efforts of iron and alumina recovery.

Jan 1, 2000

By N. J. Themelis

It is a pleasure to introduce this session on frontier technology and present an overview of pyrometallurgical technology, as it is today and where it may be heading. While there have been many advances in hydro-metallurgical processing in our times, pyrometallurgy has not been still, and more novel processes have been introduced in the last four decades than in all previous ages of humanity put together. As a result, pyrometallurgy has managed to remain the predominant mode of producing metals from ores and concentrates: over 95% of the world primary metals production, including iron, manganese, copper, lead, chromium and nickel, is obtained via the high temperature route. Some of the characteristics of pyrometallurgy, along with the corollary industrial advantages are shown in [Table 1]: [ ] On the other hand, the necessity of operating at high temperatures also entails special problems and it is unfortunate that research on how to overcome these problems has not, in most cases, kept up with the development of these wonderful novel processes. We shall first speak of the important developments in pyrometallurgy which have brought us to the current state of the technology, and subsequently on the problems still encountered and the kind of research and development that will be necessary to bring pyrometallurgy on a par with other late twentieth-century technological developments.

Jan 1, 1985

By Anthony McDonald, Dominic Verhelst

"Hudson Bay Mining and Smelting Co. Ltd. (HBM&S) started up a zinc plant and smelter in late 1930, employing technology of that period. The zinc plant has since converted from a roast/leach operation to a two stage pressure leach operation to eliminate sulphur dioxide emissioms. The smelter, however, is still continuing with much of the original roaster/reverberatory furnace technology. This paper reviews the process flow of the copper smelter, with some comments on past and recent changes.Smelter FlowsheetPrior to July 1993, the HBM&S smelter operation consisted of seven areas, namely feed preparation, roasters, reverberatory furnace, converters, anode casting, fuming plant, and dust collection. A simplified smelter flowsheet is shown in Figure 1. The data for tonnage of materials moving through the circuit are presented in Tables I to 4, and are representative of the time period from July 1992 to June 1993. A change in the zinc plant technology in 1993 resulted in the elimination of a zinc-bearing sulphide leach residue from the smelter feed blend, thereby greatly reducing the zinc content of slag produced in the smelter. Consequently the fuming plant and ancillary equipment, such as the drying plant, were shut down. These areas will, however, be described. With the closure of the zinc fuming furnaces all the slag from the reverberatory furnace is now discarded to stockpile.The over-all smelter metal recoveries are 96% for Cu and rn.5010 for Au and Ag. Figures 2 and 4 indicate historical production numbers of copper, silver and gold, respectively. A review of the minor element distribution in the smelter can be found elsewhere."

Jan 1, 1994

By G. W. Toop

"The Cominco smeller in Trail, British Columbia, is a large integrated lead-zinc production facility. In the plant description, emphasis is given to the pyrometallurgical operations including zinc concentrate roasting, lead singer-blast furnace processing and silver refining. Production figures for the main metal products - zinc, lead, silver and gold - are provided.IntroductionIncorporated in 1906, Cominco Ltd. is an integrated natural resource company with principal activities in mining, smelting and refining, mineral exploration, fertilizer production and electrical power generation.Cominco is one of the world's largest producers of zinc and lead, accoW1ting for about 10070 of mine production in the western world. The company also produces and sells copper concentrate, copper sulphate, copper arsenate, sodium antirnonate, silver, gold, cadmium, bismuth, indium, and germanium dioxide and a range of fertilizers and sulphur products.Zinc OperationsRoastingThe roasters currently treat about 1400 t/d of zinc concentrates. Over half of the total concentrate treated originates from the Red Dog Mine in Alaska. During the summer, concentrate is shipped from Alaska to Vancouver where it is loaded into rail cars and hauled inland, transferred to trucks and delivered to Trail. The remainder of the roaster feed is made up of Sullivan concentrate and various custom concentrates. These arrive either by train or by truck.There are three roasters available for roasting the concentrate. The two major roasters are Lurgi fluid bed units. Each Lurgi roaster can process concentrate at about 1:7 tonnes per hour (tlb). A smaller Cominco suspension roaster with a capacity of 10 tlb is also used. The flowsheet for the high temperature section of the fluid bed circuit is shown in Figure 1.Concentrates fed to fluid bed roasting are conditioned with 7 1/min water to give 8% moisture in feed. Two slinger belts throw the mixture into the fluidized bed. The fluid bed roasters are 10.4 m in diameter with a bed depth of 1 m. Grate area is 84 m2• Normal operating conditions include bed temperatures of 930°C to 950°C, fluidizing air at 750 Nm3/min and a wind box pressure of 2000 mm H2O."

Jan 1, 1994

By J. J. Moore

Combustion synthesis, or self-propagating high-temperature synthesis (SHS), reaction systems are discussed with respect to thermodynamics and kinetics. In particular, the effect of the process parameters, e.g. particle size, [All] ignition and combustion temperatures, on these self-sustaining reactions is discussed. Combustion theory is used to investigate the effect of the overall actuation energy of the SHS reaction on the combustion front propagation rate and in obtaining a clearer understanding of the transition from stable to unstable propagation. Finally, examples of the application of combustion synthesis to advanced materials processes are made, in particular the synthesis of Ni-Ti-X intermetallic shape memory alloys, TiC-AI2O3 and ZrB2-AI203 ceramic composite materials.

Jan 1, 1992

By J. J. Moore

Combustion synthesis or self propagating high temperature synthesis (SHS) reaction systems are discussed with respect to thermodynamics and kinetics. In particular, tile effect of the process parameters, ego particle size, AHf, ignition and combustion temperatures on these self sustaining reactions is discussed. Combustion theory is used to investigate the effect of the overall activation energy of the SHS reaction on the combustion front propagation rate and in obtaining a clearer understanding of the transition from stable to unstable propagation. Finally, examples of the application of combustion synthesis to advanced materials processes are made, in particular the synthesis of Ni-Ti -X intermetallic shape memory alloys, TiC-Al2O3 and ZrB2 ?Al2O3 ceramic composite materials.

Jan 1, 1991

By M-A Van Ende, N Kumar, I-H Jung

In order to utilise the powerful thermodynamic databases for process simulations, a concept called Effective Equilibrium Reaction Zone (EERZ) was introduced to couple thermodynamic database calculations and reaction kinetics. Using the EERZ concept, many process simulation models for steelmaking processes have been developed within the FactSage steelmaking consortium. After validation of the simulation results by comparing with plant data, the simulation models have been applied to improve plant operations. Several success stories of the improvement of real steelmaking operations are shared. A new user-friendly FactProSim software developed for building process simulations is introduced.

Aug 21, 2024

By S Hughes

The smelting of concentrates and secondary materials has been subject to increasing challenges in recent years due to declining grades of feed materials, increasing impurity levels and ever more stringent environmental regulations. In addition there has been a growing focus on maximising the efficiency of energy usage and recovery of values. New opportunities have been created with rising metals prices and improved systems for the collection of secondary materials, giving rise to a need for more flexible process solutions.This paper focuses on a number of specific cases where a process solution has been developed using the Outotec« Ausmelt Process to meet particular feed material challenges and overcome limitations inherent when employing traditional pyrometallurgical processes.The first case involves the development and commercial implementation of a smelting process to recover values from zinc smelting residues typically deposited into dams as a waste product. The second case describes the application of the Ausmelt process for the smelting and converting of secondary copper feed materials, including e-waste. These materials contain a wide range of metals and plastics and need to be processed appropriately to maximise the recovery of values whilst avoiding environmental problems. The third case study covers the smelting of nickel concentrates containing elevated magnesia levels as well as nickel bearing catalysts with high alumina content, neither of which can be readily processed when employing traditional pyrometallurgical technologies. CITATION:Hughes, S, 2013. Pyrometallurgical process solutions for complex raw materials, in Proceedings MetPlant 2013 , pp 519-530 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 15, 2013

By Christoph Pichler

A special desulphurization slag accrues during the processing of iron ore to steel, which is needed to generate high quality steel. Sulphur removing is done by different technologies, but the most common one is the generation of a high sulphur containing slag by sulphur affine elements. Currently, this desulphurization slag is partly recycled, however, huge amounts are still dumped. To utilize this desulphurization slag for future purposes, a recycling process must be established. Therefore, first characterization of this material started some years ago at the Chair of Nonferrous Metallurgy, Montanuniversität Leoben. Subsequent trials in lab scale size were performed, also some investigations for different treatment steps were evaluated, starting with a parameter study in a hot stage microscope at various gas-atmospheres. Finally, the developed recycling process concept was verified in pilot scale trials to confirm the new recycling technology. Due to the successful treatment process, also a patent was applied.

By S. A. Shuey, E. E. Vidal, P. R. Taylor

The complex chemical make-up of electronic waste as well as the variability of feed material from post-consumer sources requires resilient processing systems that are able to handle a range of material without adversely effecting production. Several of the successful processes that are being operated by a number of large-scale metal producers are reviewed in this paper. This review outlines the processing path and final disposition of many of the important individual elemental components. Determining the chemical characteristics of processes is required to understand both metal recovery possibilities and controlling the fate of minor elements. The behavior of both the organic and metallic fractions of electronic waste during processing is evaluated thermodynamically and general conclusions are given. I

Jan 1, 2006

By A. V. Tarasov

The lack of technology for processing of sub-grade ore concentrates and intermediate products for extraction of Zn, Pb, Cu and precious metals at the metallurgical stage was a constraint for an increase in the production of these metals. The technology developed in the Gintsvetmet Institute is based on an improved electrothermal smelting process for treating calcined charge, ensuring thereby a reduction in power requirement and improving the environmental performance of the process. Electric smelting of sub-grade polymetallic concentrates produces lead bullion, to which the bulk of gold and silver reports, as well as well segregated matte and slag concentrating the bulk of zinc. Lead bullion and matte are commercial-grade products; zinc is recovered from high-grade (15% Zn) slag by slag fuming process. Reduced loss of precious metals in slag ensured by the given technology is attributed to the fact that the slag contacts with matte with low contents of gold, silver and lead, rather than with lead bullion. Limited amounts of off-gas typical of electrothermal processes ensure cost-effective operation of dust recovery devices and a reduction in emissions of harmful pollutants into the ambient air.

Jan 1, 2002

By Camille Fleuriault

Continuous development of lead recycling technologies has driven the increasing contribution of secondary lead in battery manufacturing over the years. This review presents and compares the different technologies available for pyrometallurgical processing of secondary lead materials. Smelting is most often achieved in reverberatory, blast, rotary or electric arc furnaces, using single or two stage routes. Thermal re fining is the most common technique used for the production of lead and its alloys. Some improvements in battery breaking technologies and emission control have also specifically contributed to improve the performance of the smelting and refining units. Recycling lead is facing the challenge of increasing production while meeting more and more stringent regulations. This review will also include an analysis of the current secondary lead market as well as an economic outlook for the years to come in regards to rapidly changing environmental standards.

Mar 1, 2018

By J. G. Whellock, R. J. Phillips, J. W. Matousek, P. J. Marcantonio

"Stillwater Mining Company (SMC), a partnership of Chevron Resources and Manville Corporation, produces a copper-nickel, platinum-palladium flotation concentrate at its Nye, Montana mine. The concentrate is then toll processed in Europe. Recognizing the economic advantage of treating the concentrates at the mine site and of retaining this strategic resource in the United States, the Company commissioned Tolltreck International Limited and International Process Research Corporation to conduct pilot scale smelting tests with a flowsheet that would maximize metal recoveries while satisfying the environmental requirements of operations at Stillwater.Primary smelting was conducted in a single phase, 50 k W, submerged-arc, electric furnace. Refining the product mattes to copper-nickel ""white-metal""; containing approximately 2% iron, was accomplished in a Tolltreck, IV-litre, top blown rotary converter. Over-all platinum and palladium recoveries were approximately 99%; copper and nickel recoveries averaged 94%. INTRODUCTION(l-4)Stillwater Mining Company (SMC) a partnership of Chevron Resources and Manville, operates a copper-nickel, platinum palladium mine and concentrator at Nye, Montana, located in the valley of the Stillwater River, approximately, 100 km southwest of Billings. It is North America's only primary producer of these precious metals. The Stillwater area was mined for chrome ore during World War U and the Korean War, but it was not until 1961 that attention was drawn to the similarities between the Stillwater Complex and the Bushveld Complex of South Africa with its deposits of platinum group metals.A concentrated search for platinum was begun by Manville Corporation in 1967. Its presence, together with palladium, in mineable quantities was confirmed in the period 1976-1978, and the first partnership to develop the deposits was formed by Manville and Chevron in 1979. Anaconda joined the group in 1983, and in 1985 its share was purchased by Lac Minerals. In 1988 the interests of Lac Minerals were purchased by Chevron and Manville.The decision to develop the mine and build a concentrator was made in 1986. Construction began in the fall of that year, and the first concentrate was produced six months later, in March 1987. Underground mining is done in a two-shift, five day- week operation. Since startup, the concentrator has operated on a 24 hour/day, 7 day/week schedule, treating an average of 635 tonnes of ore per day and producing approximately 10 tonnes of concentrate."

Jan 1, 1989

By Teuku A. R. Putra, Patrick R. Taylor

Various pyrometallurgical methods for treating copper concentrates that contain appreciable arsenic are reviewed. Various aspects of the engineering of these treatment methods are discussed. The methods discussed include: complete oxidation with arsenic fixation; selective volatilization of arsenic; acid baking, soda ash roasting, and others methods. Methods for the ultimate disposal, or marketing, of the arsenic are discussed.

Jan 1, 2014

Pyrometallmurgical reactors constitute a key processing component in the total primary and secondary resource cycle, being involved both in primary smelting, converting and extraction, as well as the reprocessing of scrap, from aluminum cans to end-of-life automobiles. To effectively control the overall resource cycle, one needs to take a systems modeling approach of the whole cycle, seeking to also understand the dynamic process behavior of the individual components of the cycle, and then especially the part that contributes most to the chemical conversion, namely the pyrometallurgical reactor. This paper highlights the role of pyrometallurgical thermodynamics, in the whole resource cycle and specifically places equilibrium thermochemistry in the context of process dynamics where large variable inventories are recycled or maintained within the system. This paper will therefore review the semi-empirical dynamic modeling tools, which are used to model complex systems with the specific goal of developing dynamic predictive models, which also include slag-alloy chemistry, towards controlling the recycling in a feed forward manner. To illustrate the primary processing side, high carbon ferrochrome will be presented as a brief case study. It also will show how the distributed nature of the chemistry of melts in the case of primary extraction, and secondary materials such as recycled end-of-life vehicles, have a significant impact on the process outcomes and model predictions. It is therefore argued that the fundamental thermodynamics and kinetics in metallurgical reactors playa final crucial role in modeling the closed material cycle, but only when it is used in conjunction with process systems theory based on reconciled data for parameter estimation and model calibration.

Jan 1, 2003

Pyrometallurgical reactors constitute a key processing component in the total primary and secondary resource cycle, being involved both in primary smelting, converting and extraction, as well as the reprocessing of scrap, from aluminum cans to end-of-life automobiles. To effectively control the overall resource cycle, one needs to take a systems modeling approach of the whole cycle, seeking to also understand the dynamic process behavior of the individual components of the cycle, and then especially the part that contributes most to the chemical conversion, namely the pyrometallurgical reactor. This paper highlights the role of pyrometallurgical thermodynamics, in the whole resource cycle and specifically places equilibrium thermochemistry in the context of process dynamics where large variable inventories are recycled or maintained within the system. This paper will therefore review the semi-empirical dynamic modeling tools, which are used to model complex systems with the specific goal of developing dynamic predictive models, which also include slag-alloy chemistry, towards controlling the recycling in a feed forward manner. To illustrate the primary processing side, high carbon ferrochrome will be presented as a brief case study. It also will show how the distributed nature of the chemistry of melts in the case of primary extraction, and secondary materials such as recycled end-of-Iife vehicles, have a significant impact on the process outcomes and model predictions. It is therefore argued that the fundamental thermodynamics and kinetics in metallurgical reactors playa final crucial role in modeling the closed material cycle, but only when it is used in conjunction with process systems theory based on reconciled data for parameter estimation and model calibration.

Jan 1, 2003

By G. F. Archer

Selenium and tellurium, trace metals found in copper smelting, report to blister copper during smelting. Winning these metals from anode slimes, the primary commercial source, is discussed. At Asarco's Amarillo Copper Refinery, slimes treatment segregates selenium and tellurium to a water-soluble soda slag. Aqueous precipitation of tellurium oxide and selenium by sulfur dioxide is valence dependent. Se+6 and Te+6, which constitute a portion of total selenium and tellurium, are not susceptible to this base case treatment. "Secondary Selenium" is formed from these hexavalent species. We describe a process whereby simultaneous oxidation of selenium and tellurium effects a separation. Process conditions for separating selenium dioxide, and efficiency of fume capture are examined.

Jan 1, 1995