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By R. Reed von Gal

The majority of zinc strip produced in the world today is cast on the Hazelett twiri-belt continuous casting machine. Ten of these machines are currently operating worldwide, and one machine is under construction for the People's Republic of China. The caster, which was first patented in 1947, was originally developed for aluminum and copper alloy casting. In the early 1960s, the design was expanded into zinc casting and within ten years the industry had essentially converted from casting and rolling ingots to twin-belt continuous casting with in-line rolling. The casting process employs two parallel, moving. water-cooled belts as the major mold surfaces. Together with two strings of side dam blocks, the design offers a four-sided moving mold which produces a continuous strip or bar. This paper will cover a bit of, the history, as well as the current technology surrounding this high production process for zinc strip production.

Jan 1, 1990

By A. C. Mollison

In November of 1983 a fire inside the autoclave caused the curtailment of operation of the Kidd Creek pressure leaching facility. Subsequent repairs and recommissioning of the autoclave in 1984 allowed Kidd Creek to increase its production of zinc as originally planned. This paper describes the operation of this process from 1984 to 1988 and details major mechanical work carried out on the vessel in 1.988:

Jan 1, 1990

By George C. Stone

WHEN George C. Stone, a Director of the Institute, and so well known to our Members in connection with the Institute's many activities was abroad in 1.919, he secured an interesting collection of these coins, which appeared in Zinc, a publication by the New Jersey Zinc Co. Regarding this collection of coin, Mr. Stone says: "During the war, all gold and most of the silver disappeared, making small change very scarce. As the French Government was fully occupied by the war, it allowed various Chambers of Commerce and other bodies to issue money, both paper and coins. Many of the latter were made of zinc, and I secured several while in Paris. We had all heard of the Belgian and German zinc coins, but I imagine few knew how many different kinds there were. The accompanying plates show both sides of those I got. I took all that the dealer had; but he said that there were a number of others in existence. The coins in the bottom line were issued by the Germans in Belgium during the war and all are still in common use. The first two in the next to the bottom line are German. All of the others were issued by Chambers of Commerce or corporations. A few have been nickel plated; these look and wear much better than the others. "Coins" made of pasteboard were also issued by similar bodies, also notes.

Jan 1, 1920

By M. Maeda, H. Sasaki

"Precious metals such as platinum, palladium, and rhodium are commonly used for automotive catalyst converters. To recover these metals with lower environmental load and cost, exposure to zinc vapor was proposed as a pretreatment prior to acid leaching. Alloying with zinc is expected to enhance dissolution of precious metals and reduce the amount of toxic chemical agents required for the leaching. This study examined the effect of the alloying pretreatment using model catalysts. Catalysts were immersed in leaching solutions for a predefined time with or without zinc vapor pretreatment, and the amount of dissolved metals was then evaluated. INTRODUCTIONAutomotive catalysts account for large portions of the world consumption of platinum (Pt), palladium (Pd), and rhodium (Rh) (Butler, J., 2011). Because of their limited production and high prices, recovery of the precious metals from spent catalysts is obviously an important issue. A representative structure of an automotive catalytic converter can be described as a monolithic ceramic support with a honeycomb structure which is coated with porous oxides such as those of aluminum (Al2O3), cerium (CeO2), and zirconium (ZrO2) (Heck & Farrauto, 2001; Matsumoto & Shinjoh, 2007). Small particles of precious metals, originally several nanometers or less, adhere to the oxides.Typical recovery processes for precious metals from scraps are shown in Figure 1 (a)-(c) (Habashi, 1997; Yoo, 1998; Shibata & Okuda, 2002). Precious metals can be recovered by using non-ferrous smelters as Figure 1 (a) shows. Smelted along with metals such as copper (Cu), precious metals and ceramics in the scraps are absorbed into the metal phase and slag phase, respectively. Because the metals separate from Cu as anode slime in successive electro-refining, such a process can recover precious metals as co-products of Cu. However, in order to prevent negative effects on the principal process, a specialized procedure is needed. Figure 1 (b) is a specialized approach in which scraps are melted at elevated temperature with Cu called the Rose process. Here Cu works as a collector metal, and the absorbed precious metals are then concentrated by oxidation of Cu. Such a process can separate precious metals from ceramics constituting catalyst converters. Smelting at high temperature, however, requires extensive equipment as well as a high amount of energy. On the other hand, hydrometallurgical processes may be effective to separate precious metals from ceramics into an aqueous solution, because chemical agents can act on these metals selectively (Figure 1 (c)). Leaching of precious metals, however, requires strong acid and oxidizing agents because of their corrosion resistance; this makes liquid waste disposal and the large environmental load controversial. To solve the problem, a metal vapor pretreatment was proposed (Okabe, Yamamoto, Kayanuma, & Maeda, 2003a, 2003b; Kayanuma, Okabe, Mitsuda, & Maeda., 2004; Kayanuma, Okabe, & Maeda, 2004; Itoh, Kayanuma, Miyake, Kimura, & Maeda, 2005). A flow diagram of the process using zinc (Zn) vapor is shown by Fig. 1(d). Exposed to Zn vapor, precious metals are expected to form alloys which dissolve more easily than pure precious metals, thus reducing the use of chemical agents and environmental load involved with successive leaching. In previous research (Sasaki, Miyaki, & Maeda, 2010; Sasaki & Maeda, 2010, 2012), dissolutions of precious metal alloys formed by Zn vapor treatment were examined in hydrochloric acid (HCl) using an electrochemical method, and it was confirmed that these metals dissolved at higher rates from the alloys than from their pure states (Figure 2). In this study, the availability of the alloying pretreatment was demonstrated by testing on model catalysts in leaching solutions."

Jan 1, 2012

By Y. Hayashi, A. Fuwa

To analyze zinc vaporization kinetics of zinc smelting slag in the ISP furnace, reduction reaction rate of zinc oxide from ZnO-FeOx-CaO-SiO2 slag system with CO-CO2-Ar gas mixtures has been measured by a therm o-gravim etric apparatus at various ZnO content, Pco, and temperature. The reduction rate was measured under a chemical reaction control in the initial three minutes where surface zinc content can be assumed constant. Through the reaction rate dependency analysis on ZnO contents, Pco and temperature, discussion has been made on its reaction mechanistic information in terms of rate coefficient, adsorption/desorption mechanism and activation energy.

Jan 1, 2008

By Adolf Mikula

Lead-tin solders are commonly used in electronic packaging due to their unique combination of electrical, chemical, physical, thermal and mechanical properties. Since it is known that lead and lead containing alloys cause great environmental concern and health hazards it is necessary to replace lead in solder materials. Besides the environmental concerns new technologies in electronic packaging require new and improved solders. In most cases the new solders will consist of ternary or quarternary alloy systems, the main component will be tin or indium and the second element could be bismuth, silver, copper and gold and to improve certain properties a third element will be added. For a third element zinc, nickel, antimony and aluminum can be considered. This report will concentrate on solders containing zinc as an environmental safe element.

Jan 1, 2003

By Mikula Adolf

Lead-tin solders are commonly used in electronic packaging due to their unique combination of electrical, chemical, physical, thermal and mechanical properties. Since it is known that lead and lead containing alloys cause great environmental concern and health hazards it is necessary to replace lead in solder materials. Besides the environmental concerns new technologies in electronic packaging require new and improved solders. In most cases the new solders will consist of temary or quarternary alloy systems, the main component will be tin or indium and the second element could be bismuth. silver, copper and gold and to improve certain properties a third element will be added. For a third element zinc, nickel, antimony and aluminum can be considered. This report will concentrate on solders containing zinc as an environmental safe. element.

Jan 1, 2003

By Howard I. Young

WHEN so many statements are being made relative to the requirements of zinc metal, it is difficult for some of us who are acquainted with the industry to visualize how it is possible to step up production so as to supply some of the fantastic requirement figures that are published from time to time. I shall attempt to approach this subject from the standpoint of existing conditions which affect production, also keeping in mind the price ceiling under which the industry operates. Total production of primary and secondary zinc in the United States for 1941 will be about 878,000 tons, to which should be added about 36,000 tons of Mexican slab zinc available for consumption or export from the United States, giving a total available of 914,000 tons. Production of slab zinc of all grades in 1942 should be 953,000 tons. Adding the available Mexican supply should bring the total to 989,000 tons.

Jan 1, 1942

By D Martín, G. Díaz, F. Cubeddu, A. B. Mejias

The Modified ZINCEXTM Process (MZP), developed by Técnicas Reunidas, is an industrially proven flexible process. It can handle a wide range of primary and secondary raw materials, producing SHG zinc. The core of the Modified ZINCEXTM Process is the zinc solvent extraction unit. This unit is an effective barrier for any leachable impurities present in the raw material. As a result of this an ultra-pure zinc solution is always obtained. The high versatility of the process makes the application of the technology in different scenarios possible. MZP can be effectively applied when developing a whole new plant (Skorpion) or adapting its scheme to an existing refinery (Akita), in both cases giving the same results. Flexibility in terms of capacity of the plant is a great advantage of the MZP, there is the possibility to adapt the global process to a wide range of production capacities. Zinc production capacities of over 150 000 t/a may be achieved with a single solvent extraction plant train. The robustness of the Modified ZINCEXTM Process has been recently proven on two new plants currently in operation: Portovesme (Italy) and Horsehead (USA) after start up during 2013. The status of both plants is described in this paper.

Jan 1, 2014

Almost all of the world?s zirconium is mined in the form of zircon (ZrSiO4), the majority as a coproduct of titanium mining from heavy mineral sands deposits. These are placer type deposits, in which the dominant mineral is silica but which also contain a suite of ?valuable minerals,? often consisting of a mixture of titanium minerals, various alumino-silicates and zircon plus a range of other mineral species. The composition of the valuable minerals in such deposits is known as the mineral assemblage. There is no reasonable consistent geological relationship between zircon and titanium minerals. They can derive from separate igneous rock deposits that rarely occur together. The connection emanates once these separate rocks have been eroded by weather and water, often across a very long geological period. Once this has happened, zircon and titanium minerals often find their way to the same locations because they share two major characteristics:

Jan 1, 2011

By J. Keith Seidler, David R. Lentz, Douglas C. Hall, Nicholas Susak

Abstract - The Ta-Nb-Zr-REE-rich McKeel Lake alkali granite pegmatite-aplite dike swarm is hosted within the late Silurian multiphase alkali granite intrusion (Welsford) near Browns Flats in southwestern New Brunswick. A steep easterly dipping series of pegmatite-aplite dikes trending 170º can be traced 150 m along strike; they are up to 40 cm wide, closely spaced (10-20 cm apart), and interconnected by narrow branching dikelets that generally trend perpendicular to the overall strike direction. The Welsford intrusion has mantle A-type affinities characterized by enrichment of Zr, Ta, Nb, Th, and rare earth elements (REE). Two separate sets of dikes have been identified: (1) an unmineralized fine-grained porphyry, which occurs at depth and seems to be the youngest intrusive phase; and (2) a mineralized pegmatite-aplite dike swarm (419 ± 20 Ma) that crops out at surface. The mineralized pegmatite-aplite dikes likely represent a late magmatic, highly fractionated phase of the Welsford intrusion. XRF and INAA data indicate that the Welsford intrusions and related pegmatite-aplite dikes show elevated levels of Ta (74-220 ppm), Nb (750-3,040 ppm), Zr (1,450-36,000 ppm), Y (540-3,070 ppm), Th (170-870 ppm), U (60-250 ppm), Ce (430-1,950 ppm) and Yb (110-290 ppm). Electron microprobe analysis of two samples identified Ta-Nb- and REE-rich phases: euxenite, fergusonite, aeschynite, (Y)-aeschynite, and a REE carbonate.

Jan 1, 2005

By F. L. Pirkle

The mineral zircon is mined for use as specialty foundry sands, abrasives, ores of ZrO2 and zirconium metal, refractories, and zirconium chemicals. It is produced as one of several products from heavy-mineral sand deposits associated with fossil shorelines. Because of its low coefficient of thermal expansion, its high melting point, its high refractive index, and its chemical inertness, it is an attractive refractory material. Zircon varies from deposit to deposit in terms of grain size, grain shape, and chemical impurity. Thus, there is a wide range of commercial products differing in impurity levels, particle shapes, and grain sizes.

Jan 1, 1992

By C. P. Manning

This paper reports recent progress in the development of a unique metal extraction technology utilizing zirconia-based inert anodes for the electrolytic reduction of metals from their oxides. In this process, the target metal oxide is dissolved in an ionically conducting liquid solvent phase. An extended anode consisting of an oxygen-ion-conducting stabilized zirconia membrane in intimate contact with a catalytically active electronic phase and an inert electronically conducting cathode are inserted into the molten flux containing the oxide. When the appropriate electric potential is applied between the electrodes the target metal is reduced at the cathode and oxygen ions are selectively transported across the stabilized zirconia membrane and oxidized at the anode. When the process is conducted at temperatures between 1200-1400°C, the ohmic resistance drop across the stabilized zirconia membrane is low, and high current densities on the order of I A/cm2 or greater can be obtained. In addition, the process efficiency can be increased further by directly reforming hydrocarbon fuel over the anode. Laboratory experiments at Boston University have demonstrated the technical viability of employing zirconia-based inert anodes for environmentally sound production of metals such as magnesium, tantalum, aluminum, etc., directly from their oxides. Significant progress has been made in the application of this concept to the electrolytic reduction of magnesium at 1300°C. The research topics covered include stability of the zirconia membrane in the selected molten solvent (flux), volatility of the flux, electrochemical characterization of the electrolytic cell, and analysis of the metals produced.

Jan 1, 2003

LARGE-SCALE production of zirconium by the Northwest Electrodevelopment Laboratory of the Bureau of Mines at Albany, Oreg., is an anomaly that justifies some explanation. The reduction of titanium tetrachloride with magnesium in an inert atmosphere, as perfected by Dr. W. J. Kroll before 1940, aroused renewed interest in zirconium, and in 1945 development work on this metal was initiated at Albany under Dr. Kroll's technical direction. Preliminary results were promising, and in February 1947 a pilot plant with a weekly capacity of 60 pounds of zirconium-metal sponge was put in operation. Shortly thereafter the Oak Ridge National Laboratory of the Atomic Energy Commission requested production of 1 ton of zirconium-metal sheet, with the provision that it have a low hafnium content. The Bureau of Mines was furnished with a. supply of Brazilian baddeleyite ore, containing less than 1 percent hafnium with respect to zirconium, from which was made about. 2,700 pounds of relatively low hafnium zirconium sheet of 0.080-inch thickness for test purposes. This was accomplished by melting zirconium sponge in a graphite crucible, hot-rolling the ingot in an iron sheath, and finishing by cold rolling. Concomitantly the Oak Ridge Laboratory developed a method for separating hafnium from zirconium; and, in cooperation with the Atomic Energy Commission and the Bureau of Ships of the Department of the Navy, a, larger pilot plant was erected to produce zirconium from very low hafnium zirconium tetrachloride furnished by the Commission. Pilot-plant work on producing zirconium tetrachloride from zircon sand and baddeleyite was discontinued. Production of zirconium sponge in the larger pilot plant of 500 pounds per week capacity was begun in June 1949.

Jan 1, 1956

By H. Conrad Meyer

The wizardry of nucleonics has added new and greater dimensions to the almost inseparable "twins"-zirconium and hafnium. So close is their relationship that neither element is found free of the other in any presently known mineral. Although zirconium in the form of its oxide was discovered in 1789 by Klaproth, the metal in an impure, nonductile form was not isolated until 1824 by Berzelius. About 100 years later -1925-van Arkel and deBoer developed and patented a technique for the deposition in vacuo of crystalline, coherent, highly ductile metal of extreme purity on an electrically heated filament through the dissociation of gaseous zirconium tetraiodide. Within the past five years both zirconium and hafnium have been dramatized by the press and in popular science magazines. This has led to the false assumption that practically all of the world consumption of zirconium ores is used in the production of the metals. Recent statistics on the subject show that not over 15 pct of the zirconium ore consumed in 1958 went to ferrosilicon zirconium and zirconium metal. The rest was consumed in refractories, foundry sand and facings and ceramics. The importance of zirconium as a component in compact, relatively lightweight nuclear energy units, such as those now used in the submarine Nautilus,6 is well established. A rival of zirconium metal as a casing for atomic fuels is a newly developed ceramic body. It is claimed to be cheaper than zirconium-to withstand higher temperatures-and to be more resistant to corrosion. Whether such ceramic casings have the required low thermal neutron absorption cross section, high strength and easy formability of zirconium is yet to be demonstrated. Hafnium, because of its low order of abundance and its close chemical relationship to zirconium, was not definitely recognized as a new element until around 1923, despite prior claims. A study of the X-ray spectra of zirconium led to its identification. The circumstances leading to the discovery of hafnium were much less fortuitous than those surrounding zirconium. The more precise tools of arc and X-ray spectrometry lent themselves admirably to the search for elements to fill certain gaps in the periodic table. [ ] Pure, ductile hafnium-a metal similar in appearance to stainless steel-has a specific gravity of 13.3 (zirconium 6.52) and a melting point of 2,200°C. In other respects it closely resembles zirconium except in one important respect which gives it a preeminent position in nuclear energy development, namely, a high thermal-neutron absorption cross section. This explains the necessity of hafnium-free zirconium in atomic piles. The ability of hafnium to capture thermal neutrons makes it an excellent "moderator" of "governor" when used as control rods in nuclear reactors (Table 1).

Jan 1, 1960

By Thomas E. Garnar

Zirconium and hafnium are the twin elements of the periodic table because they are always found together. They resemble each other so closely that hafnium was not discovered until 135 years after the discovery of zirconium. Zirconium was discovered by Klaproth in 1789 and isolated 35 years later by Berzelius. Because hafnium's chemical properties are so close to those of zirconium, it was not discovered until 1923 when Coster and von Hevesy detected it using X-ray spectrographic analysis. These elements occur most commonly in nature as the mineral zircon (ZrSiO,) and less commonly as baddeleyite (ZrO,). They also are found as a variety of other silicates. Zircon was identified as a component in alluvial and beach sands in 1895, but it was not produced in any quantity until 20 years later. During World War I, it was produced as a coproduct of beach sand mining for titanium minerals just south of Jacksonville Beach, FL, and was patented as a refractory. It was not until the 1930s, when Zircon Rutile, Ltd., began mining at Byron Bay on the east coast of Australia, that zircon was first used as foundry sand. Later in the 1940s, NL Industries and Humphreys Gold Corp. began production of zircon sands from fossil beaches in northeast Florida. Baddeleyite first became available as a commercial product in 1916, but never in the quantity of zircon. Zircon holds a unique position as an industrial mineral because it is used for both its physical and chemical properties and as an ore of zirconium and hafnium metals. Australia is the major zircon producer followed by the Republic of South Africa and the United States. Zircon is also produced in India, Sierra Leone, Sri Lanka, Malaysia, the former USSR, China, Thailand, and Brazil. The location of world zircon mines, baddeleyite mines, and undeveloped zircon ores are shown in [Fig. 1]. World production of zirconium mineral concentrates is shown in [Table 1].

Jan 1, 1994

By Thomas E. Garnar

Zirconium and hafnium are curious elements because they are almost always found together in nature. Zirconium was discovered by Klaproth in 1789 and isolated 35 years later by Berzelius. Because hafnium's chemical properties are so close to those of zirconium, it was not discovered until 1923 when Coster and Von-Heresey detected it using x-ray spectrographic analysis. These elements occur most commonly in nature as the mineral zircon (ZrSiO4) and less commonly as the oxide baddeleyite (ZrO2). They also are found as a variety of other silicates. Zircon was identified as a component in alluvial and beach sands in 1895, but it was not produced in any quantity until 20 years later. Zircon is always a coproduct from TiO2 mining and processing. During World War I it was produced as a coproduct of beach sand mining for titanium minerals just south of Jacksonville Beach, FL, and was patented as a refractory. It was not until the 1930s when Zircon Rutile, Ltd. began mining at Byron Bay on the east coast of Australia that zircon was first used as a foundry sand. Later in the 1940s, NL Industries, Humphreys Gold Corp., and E. I. du Pont de Nemours & Co., Inc. began production of zircon sands from fossil beaches in northeast and northcentral Florida. Baddeleyite first became available as a commercial product in 1916, but never in the quantity of zircon. Zircon holds a unique position as an industrial mineral because it is used for both its physical and chemical properties as well as an ore of zirconium and hafnium metals. Australia is the major zircon producer followed by South Africa and the US. Zircon is also produced in India, Sierra Leone, Sri Lanka, Malaysia, China, Thailand, and Brazil. Undeveloped heavy mineral beach sand reserves containing zircon are known to occur in Egypt, Malawi, Senegal, and Tanzania. Locations are shown in Fig. 1. Mineralogy Zirconium and hafnium are always present together in naturally occurring compounds. Most commonly they form as the silicate sometimes containing iron, calcium, sodium, manganese, and other elements. Less commonly they are found as oxides in combination with titanium, thorium, calcium, and iron. Zircon is the most common form. It is extremely resistant to weathering, therefore, often it is present in ancient beach sands and placer deposits. Although resistant to alteration from external sources, it is vulnerable to internal alteration as the result of thorium and uranium substituting for zirconium either in the zircon lattice or in solid solution. Alteration to the metamict state takes place as radioactive emanations from these elements disorder the crystal lattice, accompanied by hydration, reduction in specific gravity, and changes in color. The mineralogy of zircon and baddeleyite and variation of physical and chemical properties are shown in Table 1. The effects of zircon's internal alteration and darkened color can be corrected by heating to 1000°C for 30 min or so. A certain time-temperature relationship makes it possible for decolorization and reordering of the crystal lattice to take place when heating at higher temperatures for shorter periods or at lower temperatures for longer periods. After heating, x-ray diffraction patterns are sharper, the grains may be harder, and except for particles of malacon, the grains will be white or colorless in the absence of grain surface coatings. The color change is only temporary and the particles slowly darken with time. Zircon fluoresces light yellow in shortwave ultraviolet light. If exposed to ultraviolet light for extended periods of time, white (calcined) zircon turns purple. With time the induced color begins to fade and eventually disappears (e.g., calcined Florida zircon exposed to ultraviolet light for 24 hr still retains faint, but discernible, purple color after six months).

Jan 1, 1983

By P. A. Distin, Jr. da Silva

The history of commercial processes for zirconium/hafnium production and separation is reviewed. A new technology is then proposed as a potential alternative for zirconium/ hafnium separation in a simpler, cleaner way than achieved with current processes. Primary sources of zirconium always contain small amounts of hafnium that must be removed during production of zirconium metal for nuclear applications. This separation is usually carried out by a solvent extraction process, developed in the 1950s, that selectively extracts hafnium, as a thiocyanate complex, using methyl isobutyl ketone (MIBK). Environmental problems inherent to this process are the high aqueous solubility and low flash point of MIBK, and possible gaseous contaminants formation generated by the decomposition of the thiocyanic complexes in hydrochloric acid medium (H2S, HCN, mercaptan’s formation). The present work shows how these problems could be avoided by using organophosphorous extractants that were unavailable when the MIBK process was developed.

Jan 1, 1998

By W. M. Raynor

LARGE quantities of "midnight oil" have been consumed by researchers in attempting to develop a process to produce cold ductile zirconium at low cost. The tantalizing facts that zirconium is a bright, silvery, tarnish-proof metal and is 2 1/2 times as abundant in the earth's crust as copper, and thirteen times as plentiful as lead have resulted in much speculation on uses, ranging from automobile radiator grills to kitchen sinks. but unfortunately no low-cost process of producing it has so far been found. In the case of zirconium, we cannot say that "virtue is its own reward" for the principal virtues of the metal, namely, corrosion resistance at ordinary temperatures and ability to absorb gases at high temperature, are the very characteristics that defeat all of the usual recovery methods such as sintering, plating, or direct chemical reduction. The only method giving a pure metal sufficiently low in oxides, nitrides, etc. to be truly cold-malleable is the one developed by Van Arkel and DeBoer in 1925. This process involves decomposition of zirconium tetraiodide in contact with a hot filament and pre

Jan 1, 1947

By Banqiu Wu

Zirconium carbide powder has been synthesized from zircon concentrate and methane using a high temperature plasma reactor, a non-transferred DC plasma torch was used as heat source. A high temperature filter consisting of graphite felt was designed, built and operated to separate the zirconium carbide from silicon carbide during the process. Characterization of the collected powders was done by wet chemical analysis using Atomic Absorption (AA), Scanning and Transmission Electron Microscopy (SEM and TEM) and by X-Ray Diffraction (XRD). It was found that the zirconium carbide purity was around 95% with silicon carbide being the primary impurity. The powders had particle sizes between 30 and 80 nm. The effect of several experimental variables are presented as well as temperature and velocity profiles calculated in the reactor.

Jan 1, 1997