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By Oscar Jaime Restrepo, Juan Camilo Restrepo, Jorge Ivan Tóbon

Portland cement is obtained by a conventional synthesis process from a mixture of limestone and clay at high temperature (1450 °C). This work reports the possibility to obtain cement silicates via alternative methods like Solution Combustion Synthesis (SCS), which optimize both time and temperature, and the consequences to energy efficiency and mitigation of CO2 emissions. The production of one ton of cement emits between 0.62 and 0.97 tons of CO2 into the atmosphere. In this process the CO2 emissions are between 21 and 59%. The combustion methods are chemical redox processes in which, at high temperature, a self-sustaining and fast wave is generated from using chemical precursors and organic fuels.

Jan 1, 2016

By Jean-Pierre Birat, Ana-Maria Iosif, Denis Ablitzer, Olivier Mirgaux

"Integrating environmental considerations into the product traditional process design is now the major challenge for steel industry. Life Cycle Assessment (LCA) is nowadays considered as an appropriate method for assessing environmental impact and selecting new technologies to reduce CO2 emissions for steel industry.In this paper we propose a new methodological concept which combines LCA thinking with process simulation software in order to carry out the life cycle inventory of classical steelmaking process.Using Aspen PlusTM software, a physicochemical model has been developed for the integrated steelmaking route. This model gives the possibility to carry out life cycle inventories for different operational practices in order to optimise the use of energy, to calculate CO2 and other emissions and to control the mass and the heat balances of processes.It is also shown that such approach can be used to design and assess new technologies for steelmaking without large industrial application.IntroductionDuring recent years, it was recognised that CO2 emissions are the major factor of the global warming effect. In order to meet Kyoto requirements, the steel industry is embracing the challenge of sustainable development by improving its competitiveness and economic success while reducing its environmental impacts. Integrating environmental considerations into the traditional product design process, for powerful eco-efficiency, is now one of the major priorities for steelmakers.The European Steel Industry has measured up to this challenge by creating ULCOS (Ultra Low CO2 Steelmaking) consortium that has taken up the mission to develop breakthrough steelmaking process with the potential to reduce CO2 emissions (Eurofer, 2005). In order to develop technologies to reduce emissions, it is necessary to assess the environmental impact of the classical steelmaking route (coke plant, sinter plant, blast furnace, basic oxygen furnace, continuous casting and hot rolling)."

Jan 1, 2009

By D. A. Milligan

Ammonia leaching of copper sulfide concentrates, matte, scrap or other sources of copper yields copper amnine sulfate solutions which are converted to metal in a two-stage process involving precipitation of inter- mediate sulfites and their thermal decomposition to copper powder of high purity. Processing details and results are given. Considerable simplification in circuitry and cost savings are indicated. Energy requirements are reduced by substitution of copper powder precipitation and ammonium sulfate crystallization for solvent extraction, electrowinning and lime boil.

Jan 1, 1976

By Jörn E. Fischer

Cracks were observed at the top of spray formed billets for some alloys. In this paper the effect of process parameters on crack probability is discussed. After the spray run the thermal conditions at the top of the billet change rapidly. A hot spot with melt residue] can occur inside the billet and shrinkage will be suppressed due to the solidified surface of the billet. In this situation hot cracks can be initialized. The temperature history of the billet during and after the spray run is calculated. The temperature difference between core and outside diameter of the billet is taken as indicator for hot crack probability. The effect of different process parameters on the hot crack probability is discussed. The results lead to a better understanding of the process. The calculations are taken as a tool to find process parameters in order to reduce or avoid hot cracks in spray formed billets.

Jan 1, 1999

By Binxu Zhaug, Mark Jolly, Xiaojun Dai

"In conventional investment casting process of aluminium alloys for the application of the aerospace industry, to assure the quality of the final casting, usually the foundry uses large runner system which results in low yield, high energy consumption and high GHGs emission. In one case of this investigation, the yield is between 5 ~ 10% which means that the current casting process wastes large amount of energy and generates lots of scraps. By applying a new casting method, the bulky runner system and the melting/holding time are significantly reduced, the quality of the casting is improved, and in the meantime the related energy consumption and GHGs emission are significantly decreased. In the investigation, the energy efficiencies and GHGs emission between the current and traditional processes are calculated and compared.1. IntroductionAs one of the conventional casting process, Investment Casting Process (ICP) and its applications can be traced to thousand years ago [l]. In current casting industry, ICP still plays an important role in the production of small and precious castings with high quality requirements in automobile and aerospace industries. Both casting quality and manufacturing costs which mainly consist of energy costs have crucial effects on the competitiveness of castings in the market. In the production of aluminium alloy castings using ICP, the energy cost and energy efficiency of a casting facility depend mainly on the efficiency of its melting and heat treating performance. In association with the two performances, more than 60 % of the total process energy costs are symbolised in a typical casting facility [2]. Additionally, in conventional ICP of aluminium alloys for the application of the aerospace, to assure the quality of the final casting, typically the foundry uses huge runner system including big risers/feeders which cause low yield, creates lots of scraps and generates high energy consumption. Consequently, there are huge opportunities for casting industry to choose the best practices for potential energy saving. Furthermore, the reasons such as the stringent limitation of environmental legislation in Europe and the pressure of the rising energy price force the casting industry to reduce the energy consumption and greenhouse gases (GHGs) em1ss10n."

Jan 1, 2012

By Yasushi Sawada

An experimental investigation was carried out to study the rates of reduction of iron oxides dissolved in liquid Ca0-SO2-A203 slags by Fe-C droplets at temperatures ranging from 1325 OC to 1550 OC. The %FeO in the slag was varied from 5.5 to 18. Flash X-ray images were employed to observe the behavior of Fe-C droplets in the slags during the reactions and for determining the slag-gas-metal interfacial area. Effect of P205 in the slag and sulfur in the droplet was also investigated. The reduction rates were determined by measuring the volume of CO evolved as a function of time and the estimated slag-gas- metal interfacial area. The reduction rates have increased with increasing %FeO in the slag and the slag temperature. The experimentally established relationship between the reduction rates and FeO (wt%) in slag is given by

Jan 1, 1992

By GILBERT E. SEIL

GREAT advances in the preparation of ores for reduction to ferro-alloys have been made, although standard methods of reduction have been continued at most plants. Efficiencies, yields per furnace, and energy requirements per ton are generally better than previously attained. The advantages of sizing and conditioning of ore, fluxing stone, and coke have been realized. Conditioning varies from drying the furnace burden to chemical rearrangements to facilitate reduction reactions and sometimes to furnish some of the energy required for the reaction before the burden reaches the furnace. During the war period it is impossible to discuss in detail many of the advances made. They are subjects for postwar papers. However, the new procedures mentioned in the following paragraphs are indicative of the work already done and in progress.

Jan 1, 1944

By G. G. Krishna Murthy

Interactions of wustite and hematite pellets with Fe-C melts were investigated experimentally by examining the effect of pellet size and bath temperature on the reduction rates of the pellets. Experiments were carried out in the temperature range 1473-1923 K. A flash X-ray equipment was used to obtain images of the melt surface during its reaction with an oxide pellet. The reduction rates were calculated using experimentally estimated time for complete reaction of a pellet, tR. The value of tR was determined employing gas mass flow rate, or pressure rise in the sealed furnace, versus time traces. The value of tR was the same for both wustite and hematite pellets of equal weight at or above 1723 K and it decreased with increasing melt temperature. But the reduction rate was substantially lower at temperatures below 1651 K, the melting point of wustite. The rates were defined as the rate of moles of oxygen removed from the pellet per unit area of bath free surface and it was found that the bath surface area affects the reduction rates. It was established that the overall reaction followed nth-order rate kinetics with the values of n falling between 0.3 and 0.4 for temperatures above the melting point of wustite. The apparent activation energy determined using the apparent rate constants obtained from the experimental data was 76.2 + 27.7 kJ/mol-O.

Jan 1, 1992

In the flotation of a copper ore, entrainment of fine silicate and iron sulfide gangue minerals resulted in poor copper concentrate grade. In the cleaning stage, rejection of these gangue minerals was particularly difficult due to severe mechanical entrainment when the rougher concentrate was ground to 10 µm. To reduce gangue entrainment, polymeric depressants were tested. The rationale being that with the use of such polymeric depressants that also possess flocculation power, not only minerals-to-be-depressed can be made hydrophilic, but their particle size can also be enlarged. In this manner both the "genuine" flotation and the mechanical entrainment can be reduced. An effective polymer to reduce entrainment of silicate gangue mineral in sulfide flotation was identified from bench flotation tests conducted on single minerals. It was then applied to the flotation of a copper-gold ore confirming the beneficial role of the polymeric depressant in the reduction of fine gangue entrainment.

Jan 1, 2007

By S. Y. Ezz, K. El•Guindi

A vertical tube, 8 m long and 2.5 cm in diameter, electrically heated to 650°C throughout the majority of its height, was used to study the-effect of ore feed rate and hydrogen flow rate on the reduction of fine iron ore particles. A correlation could be obtained between the combined effect of the amount of reducing gas and reduction time and the per-cent reduction. The results suggest that a method based on the reduction of fine iron ores while falling through up-streaming hydrogen cannot be recommended for industrial application.

Jan 1, 1969

By Martin Froehling, Curtis Mohns, Rahim Rajwani, Michael Fullam

"The Kemess mining and milling complex is operated by Northgate Minerals Corporation and is located in the mountains of north-central British Columbia, 430 kilometers northwest of Prince George. The complex consists of the Kemess South open pit mine and a 52,000 tonnes per day mill. Hypogene, supergene and leach cap ores are processed using conventional crushing, grinding, and flotation techniques to produce gold-copper concentrates with minor by-product silver value.The rougher flotation concentrate is re-ground in closed circuit before being cleaned to final concentrate grade. Historically, gold losses in the cleaner tailings were primarily associated with pyrite, with only minor amounts of free gold. More recently, with the processing of high pyrite ores, the major losses were found to be free gold less than 10 microns in size. The fine grind required for the high pyrite ores resulted in over-grinding of the free gold particles in the regrind circuit, contributing to poor flotation characteristics. It was thought that if this free gold could be recovered by gravity at coarser size in the regrind circulating load, the free gold losses in the cleaner tailings could be reduced.Preliminary test work carried out by Knelson Gravity Solutions indicated the potential for free gold recovery in the regrind circuit. A Knelson XD-30 Concentrator was installed with variable speed capability, and a series of optimization tests were carried out. In addition, cleaner tailings were characterized with gravity operating and with gravity not operating to determine the overall gold recovery benefit. The single Knelson XD-30 installation recovers ~10% of the total gold in the regrind circuit and increases overall recovery by 3% when high pyrite ores are processed."

Jan 1, 2007

By Arthur B. Foote

THE ball mill has superseded stamps for the reduction of gold ores in most of the recently designed plants, partly because stamps are not suited to die fine grinding required for flotation, and partly to save space and construction cost. Experience with these new mills seems to confirm the idea that it is more difficult to recover bold from a ball-mill product than it is when stamps are used for crushing. Microscopical examination of particles of gold that have passed through a ball mill show that the gold has been pounded into exceedingly thin flakes coated with a talcy surface, making it more difficult to save by amalgamation, flotation, or concentrating. Bearing in mind that gold is extremely malleable, it seems reasonable that this should be so. Contrast the action in a stamp battery, where the crushing is by impact in the presence of mercury, to the grinding and rolling under pressure in a ball mill. It is well known that a better recovery can be obtained by panning or amalgamation from a sample of ore that has been crushed by mortar and pestle than from one reduced on a bucking board.

Jan 1, 1937

By Caryn Wendt, Donna Post Guillen, Armando McDonald, Erik R. Coats, Chaston Ellis, Kevin Feris

Dairy operations constitute ~2.5% of annual U.S. greenhouse gas (GHG) emissions, making dairies one of the largest sources of industrial GHG emissions. We are developing a novel, integrated system to achieve a net reduction in dairy GHGs while producing value-added materials and products. This integrated manure-to-commodities system converts dairy manure to bioenergy, sequesters carbon by converting volatile fatty acid-rich fermenter supernatant to bioplastics, and utilizes anaerobic digester (AD) and polyhydroxyalkanoate (PHA) reactor effluents to produce algae that can be harvested and internally recycled to enhance PHA production and sequester carbon. A decision-making tool is being developed for the integrated system that quantifies net GHG reduction, carbon sequestration, nutrient management and economics.

Jan 1, 2016

By Guy Deschênes

Thiourea solutions can be used as leach liquors to treat gold ores or slimes. It is also efficient to elute resins or strip solvents that were loaded in cyanides solutions. The hydrogen pressure reduction is a practical step to recover gold and silver from leach solutions, and strips and eluates without any destruction of thiourea. It is a critical point because these processes have to consider the recycling of the liquors to be irore economical. The effect of temperature, pressure, acidity, compotation of the solution and the nature of catalysts on pressure reduction by hydrogen were investigated. An electranetallurgical study was? carried out to investigate the mechanism. The composition of the products was studied by different analytical methods. The process shows a good selectivity to precipitate gold and silver in a thiourea solution containing iron and copper. Gold and silver concentrations can be decreased to 0.2 ppm and 0.1 ppm at respectively 70 KPa H2 and 28°C. No decomposition of thiourea was evident during the tests. Metals such as nickel powder or platinum activate the reaction and improve the reduction.

Jan 1, 1989

By K. Prajapati, P. Hes

Transmission of vibration to the operator from percussive vibrating tools is increasingly of concern in industrial and mining applications. Prolonged exposure to high levels of vibration transmitted via the hand causes disorders known as hand-arm vibration syndrome (HAVS). The vascular component of HAVS is called vibration white finger (VWF) and has a debilitating effect on the hand. Vibration at frequencies below 1250 Hz, a tight hand-grip force and cold environments are reported to increase the likelihood of developing VWF. A vibration damping handle design with patents pending that addresses some of the causes of VWF has been developed and retrofits onto jackleg pneumatic rock drills. The handle is decoupled from the drill while maintaining jackleg twist-grip controls on the hand-grip using a combination of sealed self adjusting hydraulic pistons and compliant materials in series, and a new air control valve. The ergonomics of the hand-grip was also modified by the addition of a polyurethane sleeve with a diameter of 50 mm. The new hand-grip reduces direct cold metal contact and minimizes grip force. Measurement of vibration as the quantity acceleration was made in accordance with international standard ISO 5349. Overall vibration damping in all axes of 50% to 63% was attained at frequencies below 1250 Hz. The dimensions of the damping handle are comparable and its weight is only 100 g heavier than a standard handle.

Jan 1, 2001

By D. J. Zhao

The reduction of ilmenite pellets was investigated at 950°C and 1000°C under a CO-N2 gas mixture with 10 L/min gas flow rate. All the reducing reactions were conducted in a furnace with a thermogravimetric analysis system. The reduction rate is higher at 1000°C than that at 950°C. At the early stage of the reactions, with the CO concentration increasing in the gas mixture, the reduction rate increased at 1000°C. In addition, at the early stage of the reactions, a rapid temperature increment and a rapid conversion of oxygen were observed on the curves of temperature versus time and conversion of oxygen versus time under different experimental conditions. The solid reaction products obtained in these experiments were analyzed by Scanning Electron Microscopy (SEM) and Energy Dispersive Spectrometers (EDS). Metallic Fe with small amount of Ti dissolved in it and oxides of Ti were found in the solid reaction products, but the formation of any nitride phases was not found under the prevailing conditions.

Jan 1, 2014

By Marcelo B. Mourão

The reduction of iron ores by solid carbon, when both are agglomerated together in the form of pellets, has important kinetic advantages. Although several studies have been performed on the subject, some points on the controlling mechanisms need clarification. There is a big scatter in the values of the apparent activation energy reported in the literature, and this may be due to factors like heat transfer, flow of gases in the reduction system, pellet size and composition. This work is concerned with the effect of several parameters on the reaction rate. The parameters studied were temperature (in the range 1173 K to 1423 K), carbon type (coke or charcoal), pellet size, gas flow rate, catalyst action of the produced metallic iron and added sodium carbonate. It has been shown that the values of the apparent activation energy can change according to the reduction conditions employed, and hence any modeling effort will have to take account of these parameters. EPD Congress 1994

Jan 1, 1994

By Heihachi Kamura

In this research, the proper temperature for the reduction of iron ores by carbon monoxide was determined. Also, the difference of the rate of reduction on the sizes of ore under four mesh per linear inch was estimated, but no evidence could be found. Rates of reduction on the seven kinds of ore were compared with the results of the experiment, showing a close relation between reducibility and density of ore. Finally, the maximum size of ore that can be reduced in applicable length of time was determined. The author thinks that the process of production of steel may be replaced by low-temperature reduction of iron ores some time in the future. THE reduction of iron oxide, such as Fe203, to iron in the blast furnace is performed principally by carbon monoxide, but partly by solid carbon by the two following reactions: Fe203 + 3CO = 2Fe + 3CO2 2Fe203 + 3C = 4Fe + 3CO2 It is known that reduction by carbon monoxide takes place at a much lower temperature than reduction by carbon and that the reducing action of carbon monoxide progresses to the inside of the ore in lump form by gaseous diffusion. In the reduction by carbon, however, the reducing action takes place only at the contact surface of the ore and carbon, so that the more complete the reduction by carbon monoxide, the more efficient is the operation. However, the reduction does not progress as shown in the foregoing formula, because carbon dioxide acts oxidizingly on the metallic iron to such a degree that when the gaseous composition reaches a certain proportion of carbon dioxide to carbon monoxide, the reduction practically stops, even though the gases are moving slowly through the heated ore. The proportions of carbon monoxide and carbon dioxide in the gas depend on the kind of iron oxide and the temperature of reduction, also the duration of time in the reaction. The longer the time of the reaction, the higher the proportion of carbon dioxide obtained in the gas, but finally it will attain to a condition of equilibrium.

Jan 1, 1925

By George Kazonich

The high costs and environmental problems associated with making iron and steel in the United States is driving the development of new technologies to replace the blast furnace. A prototype reactor incorporating rocket technology was designed and built. This rapid rate reactor was operated successfully and consistently made iron metal. Minus 325-mesh magnetite particles could be reduced to iron metal in less than 50 ms in a high temperature flow through reactor. Iron product was recovered inside the reactor and in a downstream cyclonic separator. The results of typical operation and how parametric changes affected the reduction of iron ore concentrates are discussed.

Jan 1, 1993

By A. Warczok, T. A. Utigard

"Slags from smelting of copper concentrates contains from 1 to 15% of copper. Copper is present in the form of copper or copper matte inclusions of size from 2 to 1000 micro, and as dissolved cuprous oxide. Removal of the copper requires the slag reduction, primarily reduction of magnetite and co-reduction of cuprous oxide. Thus, the kinetics of the slag reduction play an important role in copper recovery. Instantaneously, at the contact of carbon and a slag the gaseous film is formed. The magnetite and cuprous oxide reduction is going through a gaseous film, separating the slag and carbon of a coke or electrodes. The thickness of a gaseous film grows to a critical value and gas bubbles, containing CO and CO2, are created and rise up in the slag. Results of measurements of kinetic of the slag reduction with graphite showed high value of activation energy, close to the value of activation energy of Boudouard reaction. Strong temperature dependence of the reaction rate points out the thermal instability of the reacting system. It was found that the slowest process in the reduction stages determines the loop of CO and CO2 transfer and magnetite diffusion to the slag/gas film boundary. Strongly endothermic Boudouard reaction seems to cause thermal instability on the reaction surface. So, heat transfer to the reaction surface is very important. Due to low thermal conductivity of a slag the convection dominates in the heat transfer. So, any slag stirring accelerates the rate of reduction and coalescence of metallic copper or copper matte inclusions."

Jan 1, 2015