Metal Smelting and Refining Sources of Cdd/Cdf
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Principles of Extractive Metallurgy Lectures Note
PRINCIPLES OF EXTRACTIVE METALLURGY B.TECH, 3RD SEMESTER LECTURES NOTE BY SAGAR NAYAK DR. KALI CHARAN SABAT DEPARTMENT OF METALLURGICAL AND MATERIALS ENGINEERING PARALA MAHARAJA ENGINEERING COLLEGE, BERHAMPUR DISCLAIMER This document does not claim any originality and cannot be used as a substitute for prescribed textbooks. The information presented here is merely a collection by the author for their respective teaching assignments as an additional tool for the teaching-learning process. Various sources as mentioned at the reference of the document as well as freely available material from internet were consulted for preparing this document. The ownership of the information lies with the respective author or institutions. Further, this document is not intended to be used for commercial purpose and the faculty is not accountable for any issues, legal or otherwise, arising out of use of this document. The committee faculty members make no representations or warranties with respect to the accuracy or completeness of the contents of this document and specifically disclaim any implied warranties of merchantability or fitness for a particular purpose. BPUT SYLLABUS PRINCIPLES OF EXTRACTIVE METALLURGY (3-1-0) MODULE I (14 HOURS) Unit processes in Pyro metallurgy: Calcination and roasting, sintering, smelting, converting, reduction, smelting-reduction, Metallothermic and hydrogen reduction; distillation and other physical and chemical refining methods: Fire refining, Zone refining, Liquation and Cupellation. Small problems related to pyro metallurgy. MODULE II (14 HOURS) Unit processes in Hydrometallurgy: Leaching practice: In situ leaching, Dump and heap leaching, Percolation leaching, Agitation leaching, Purification of leach liquor, Kinetics of Leaching; Bio- leaching: Recovery of metals from Leach liquor by Solvent Extraction, Ion exchange , Precipitation and Cementation process. -
Chapter 11: Beneficiation
CHAPTER 11 Beneficiation – Comminution Sponsored by: SPONSOR PROFILE Through pioneering the introduction of modern process • project controls and reporting plants and associated technologies to remote and logistically • contract management challenging locations, Lycopodium Minerals Pty Ltd has • procurement and logistics management developed a successful track record in developing and • inspection and expediting commissioning major resource projects worldwide. • quality assurance/quality control Since its establishment in 1992, Lycopodium has become a • financial evaluations leading international engineering and project management • client representation. consultancy, with an enviable reputation for providing Engineering technically innovative and cost-effective engineering solutions. They are focused on the evaluation and development of projects • Conceptual through to detailed design in the fields of minerals processing, materials handling and • across all disciplines: earthworks, civil infrastructure. • structural, mechanical, piping • electrical, instrumentation, control Lycopodium Minerals has undertaken studies and projects across a broad range of commodities including gold (free, • systems, automation and infrastructure. gravity, refractory, preg robbing), base metals (concentrators, Process hydrometallurgy), iron ore, uranium, rare earths and industrial minerals. Their resume of projects reflects diversity in not • Metallurgical test work design only commodity, but client background, technology, scale of • management and interpretation -
Sand, Gravel, and Crushed Stone On-The-Job Training Modules
SAND, GRAVEL, AND CRUSHED STONE ON-THE-JOB TRAINING MODULES Module 17 - “Primary Crushing Operation” UNITED STATES DEPARTMENT OF LABOR ELAINE L. CHAO SECRETARY MINE SAFETY AND HEALTH ADMINISTRATION DAVE D. LAURISKI ASSISTANT SECRETARY Originally Published AUGUST 2000 INSTRUCTION GUIDE SERIES MSHA IG 40 MODULE NUMBER 17 OF INSTRUCTION GUIDE NUMBER 40 ON-THE-JOB TRAINING FOR THE SAND, GRAVEL, AND CRUSHED STONE INDUSTRY PRIMARY CRUSHING OPERATION This module describes basic job steps, potential hazards and accidents, and recommended safe job procedures for primary crushing operations. This job is normally done by the crusher operator, but may be done by other occupations. Crusher operators must protect themselves, and other people in the area, from accidents and injuries resulting from operation of the crusher and associated equipment. There are several different types of primary crushers, however, there are many similarities in the job clxii procedures followed by crusher operators. Crushing is the first step in converting shot rock into usable products. Essentially, crushing is no more than taking large rocks and reducing them to small pieces. Crushing is sometimes continued until only fines remain. At some operations, all the crushing is accomplished in one step, by a primary crusher. At other operations, crushing is done in two or three steps, with a primary crusher that is followed by a secondary crusher, and sometimes a tertiary crusher. Raw material, of various sizes, is brought to the primary crusher by rear-dump haul units, or carried by a wheel front-end loader. Primary crushing reduces this run-of-mine rock to a more manageable size. -
Effect of Comminution Method on Particle Damage and Breakage Energy
EFFECT OF COMMINUTION METHOD ON PARTICLE DAMAGE AND BREAKAGE ENERGY Michael Moats, Jan Miller, Chen-Lun Lin and Raj Rajamani Department of Metallurgical Engineering University of Utah Outline • Our Department • High Pressure Grinding • Particle Damage Characterization • Breakage Energy • Application to Simulant Development Department of Metallurgical Engineering • University of Utah is located in Salt Lake City along the Wasatch Mtns. • Only stand alone Metallurgical Engineering department remaining in the U.S. • Traditional curriculum with critical mass of professors – Mineral Processing – Chemical Metallurgy – Physical Metallurgy High Pressure Grinding Rolls (HPGR) HPGR consists of a pair of counter rotating rolls, one fixed and the other floating. The feed is introduced to the gap in between the rolls and they compress the bed of particles. The grinding force applied to the crushing zone is controlled by a hydro-pneumatic spring on the floating roll. Speeds of the rolls are also adjustable to obtain optimum grinding conditions. Comparison of HPGR and AG/SAG Mills Aspect HPGR AG/SAG Mill Grinding Mechanism Inter-particle compression Impact, attrition and compression Residence Time Low-single pass High (feed migrates through length of mill) Wet/Dry Grinding Dry-Low moisture Predominantly wet milling Availability >90% -2-4 change outs pa >90% -1-2 change outs pa Size regulated feed Required Yes-strongly affects stud breakage AG-No, SAG-Sometimes Critical material size Not required Required Product particle Yes (beneficial for downstream Negligible micro-cracking processes Maximum Throughput 2000tph 4000tph Footprint Small Large Specific power 1-5kWh/t 5-12kWh/t Operating cost Overall plant 20% lower Overall plant 20% higher Capital Cost 25% lower 25% higher Delivery time Substantially faster Substantially longer Variation in feed hardness Single parameter variable High losses •Reference: Koenig, R.L. -
The Efficient Improvement of Original Magnetite in Iron Ore Reduction
minerals Article The Efficient Improvement of Original Magnetite in Iron Ore Reduction Reaction in Magnetization Roasting Process and Mechanism Analysis by In Situ and Continuous Image Capture Bing Zhao 1,2, Peng Gao 1,2,*, Zhidong Tang 1,2 and Wuzhi Zhang 1,2 1 School of Resources and Civil Engineering, Northeastern University, Shenyang 110819, China; [email protected] (B.Z.); [email protected] (Z.T.); [email protected] (W.Z.) 2 National-Local Joint Engineering Research Center of High-Efficient Exploitation Technology for Refractory Iron Ore Resources, Shenyang 110819, China * Correspondence: [email protected]; Tel.: +86-024-8368-8920 Abstract: Magnetization roasting followed by magnetic separation is considered an effective method for recovering iron minerals. As hematite and magnetite are the main concomitant constituents in iron ores, the separation index after the magnetization roasting will be more optimized than with only hematite. In this research, the mechanism of the original magnetite improving iron ore reduction during the magnetization roasting process was explored using ore fines and lump ore samples. Under optimum roasting conditions, the iron grade increased from 62.17% to 65.22%, and iron recovery increased from 84.02% to 92.02% after separation, when Fe in the original magnetite content increased from 0.31% to 8.09%, although the Fe masses in each sample were equal. For lump ores with magnetite and hematite intergrowth, the method of in situ and continuous image capture Citation: Zhao, B.; Gao, P.; Tang, Z.; for microcrack generation and the evolution of the magnetization roasting process was innovatively Zhang, W. -
Redesign and Fabrication of Hammer Milling Machine for Making Pasta
International Journal of ChemTech Research CODEN (USA): IJCRGG, ISSN: 0974-4290, ISSN(Online):2455-9555 Vol.12 No.03, pp 202-218, 2019 Redesign and Fabrication of Hammer Milling Machine for Making Pasta Workalemahu Manaye1, Beruk Hailu1,T Ashokkumar1*, 1Department of Mechanical Engineering, Institute of Technology, Haramya University, P.O Box 138, Dire Dawa, Ethiopia. Abstract : This study Aimed to redesign a Hammer mill machine for grinding,owing to the inability of existing mill to meet the demand of waste pastaflourin Dire Dawa food Complex. Rational design by drawing and calculations and Simulation in solid works. CAD software were used to bring this milltoreality. The modified pasta grinding milling machine efficiency will be 90%..Waste of Pasta, Macaroni, Biscuits, or Breads and there by impact cost of production through minimizing waste as well as inquests safe, hygienic & efficient way of grinding these by products at Dire Dawa food complex. Key words : Pasta Grinding, Solidwork, Belt Drive, Design. 1.Introduction Hammermills are more widely used in feed mills because they are easier to operate and maintain and produce particles spherical in shape (Kim et al., 2002; Amerah et al., 2007). To increase production capacity of hammer mills, they are equipped with an air-assist system that draws air into the hammer mill with the product to be ground, thus allowing particles to exit through screen holes (Kim et al., 2002).Hammer mills have been reported to produce a wide range of particle sizes compared to roller mills (Seerley et al., 1988; Douglas et al., 1990; Audet, 1995). During roller milling each grain passes through the mill independently of surrounding grains (Campbell et al., 2001). -
Recovery of Magnetite-Hematite Concentrate from Iron Ore Tailings
E3S Web of Conferences 247, 01042 (2021) https://doi.org/10.1051/e3sconf/202124701042 ICEPP-2021 Recovery of magnetite-hematite concentrate from iron ore tailings Mikhail Khokhulya1,*, Alexander Fomin1, and Svetlana Alekseeva1 1Mining Institute of Kola Science Center of Russian Academy of Sciences, Apatity, 184209, Russia Abstract. The research is aimed at study of the probable recovery of iron from the tailings of the Olcon mining company located in the north-western Arctic zone of Russia. Material composition of a sample from a tailings dump was analysed. The authors have developed a separation production technology to recover magnetite-hematite concentrate from the tailings. A processing flowsheet includes magnetic separation, milling and gravity concentration methods. The separation technology provides for production of iron ore concentrate with total iron content of 65.9% and recovers 91.0% of magnetite and 80.5% of hematite from the tailings containing 20.4% of total iron. The proposed technology will increase production of the concentrate at a dressing plant and reduce environmental impact. 1 Introduction The mineral processing plant of the Olcon JSC, located at the Murmansk region, produces magnetite- At present, there is an important problem worldwide in hematite concentrate. The processing technology the disposal of waste generated during the mineral includes several magnetic separation stages to produce production and processing. Tailings dumps occupy huge magnetite concentrate and two jigging stages to produce areas and pollute the environment. However, waste hematite concentrate from a non-magnetic fraction of material contains some valuable components that can be magnetic separation [13]. used in various industries. In the initial period of plant operation (since 1955) In Russia, mining-induced waste occupies more than iron ore tailings were stored in the Southern Bay of 300 thousand hectares of lands. -
Crushing Resource Book
Metalliferous Mining - Processing Crushing Resource Book C R U S H I N G Table of Contents TABLE OF CONTENTS............................................................................................................................2 INTRODUCTION TO CRUSHING .....................................................................................................................3 What is this module about?.....................................................................................................................3 What will you learn in this module? .......................................................................................................3 What do you have to do to complete this unit? .......................................................................................3 What resources can you use to help?......................................................................................................3 INTRODUCTION TO COMMINUTION ................................................................................................4 CRUSHING THEORY ...............................................................................................................................5 CRUSHING EQUIPMENT AND CRUSHING CIRCUITS.................................................................... 9 CRUSHING EQUIPMENT ...............................................................................................................................9 CRUSHING CIRCUITS AND STAGING .......................................................................................................... -
Banded Iron Formations
Banded Iron Formations Cover Slide 1 What are Banded Iron Formations (BIFs)? • Large sedimentary structures Kalmina gorge banded iron (Gypsy Denise 2013, Creative Commons) BIFs were deposited in shallow marine troughs or basins. Deposits are tens of km long, several km wide and 150 – 600 m thick. Photo is of Kalmina gorge in the Pilbara (Karijini National Park, Hamersley Ranges) 2 What are Banded Iron Formations (BIFs)? • Large sedimentary structures • Bands of iron rich and iron poor rock Iron rich bands: hematite (Fe2O3), magnetite (Fe3O4), siderite (FeCO3) or pyrite (FeS2). Iron poor bands: chert (fine‐grained quartz) and low iron oxide levels Rock sample from a BIF (Woudloper 2009, Creative Commons 1.0) Iron rich bands are composed of hematitie (Fe2O3), magnetite (Fe3O4), siderite (FeCO3) or pyrite (FeS2). The iron poor bands contain chert (fine‐grained quartz) with lesser amounts of iron oxide. 3 What are Banded Iron Formations (BIFs)? • Large sedimentary structures • Bands of iron rich and iron poor rock • Archaean and Proterozoic in age BIF formation through time (KG Budge 2020, public domain) BIFs were deposited for 2 billion years during the Archaean and Proterozoic. There was another short time of deposition during a Snowball Earth event. 4 Why are BIFs important? • Iron ore exports are Australia’s top earner, worth $61 billion in 2017‐2018 • Iron ore comes from enriched BIF deposits Rio Tinto iron ore shiploader in the Pilbara (C Hargrave, CSIRO Science Image) Australia is consistently the leading iron ore exporter in the world. We have large deposits where the iron‐poor chert bands have been leached away, leaving 40%‐60% iron. -
Smelting Iron from Laterite: Technical Possibility Or Ethnographic Aberration?
Smelting Iron from Laterite: Technical Possibility or Ethnographic Aberration? T. O. PRYCE AND S. NATAPINTU introduction Laterites deposits (orlateriticsoilsastheyarealsocalled)arefrequently reported in Southeast Asia, and are ethnographically attested to have been used for the smelting of iron in the region (Abendanon 1917 in Bronson 1992:73; Bronson and Charoenwongsa 1986), as well as in Africa (Gordon and Killick 1993; Miller and Van Der Merwe 1994). The present authors do not dispute this evidence; we merely wish to counsel cautioninitsextrapolation.Modifyingour understanding of a population’s potential to locally produce their own iron has immediate ramifications for how we reconstruct ancient metal distribution net- works, and the social exchanges that have facilitated them since iron’s generally agreed appearance in Southeast Asian archaeological contexts during the mid-first millennium b.c. (e.g., Bellwood 2007:268; Higham 1989:190). We present this paper as a wholly constructive critique of what appears to be a prevailingperspectiveonpre-modernSoutheastAsianironmetallurgy.Wehave tried to avoid technical language and jargon wherever possible, as our aim is to motivate scholars working within the regiontogivefurtherconsiderationtoiron as a metal, as a technology, and as a socially significant medium (e.g., Appadurai 1998; Binsbergen 2005; Gosden and Marshall 1999). When writing a critique it is of course necessary to cite researchers with whom one disagrees, and we have done this with full acknowledgment that in modern archaeology no one person can encompass the entire knowledge spectrum of the discipline.1 The archaeome- tallurgy of iron is probably on the periphery of most of our colleagues’ interests, but sometimes, within the technical, lies the pivotal, and in sharing some of our insights we hope to illuminate issues of benefit to all researchers in Metal Age Southeast Asia. -
ITP Mining: Energy and Environmental Profile of the U.S. Mining Industry: Chapter 4: Iron
Energy and Environmental Profile of the U.S. Mining Industry 4 Iron The chemical element iron is the fourth most common element in the Earth's crust and the second most abundant metal. About five percent of the Earth's crust is composed of iron. The metal is chemically active and is found in nature combined with other elements in rocks and soils. In its natural state, iron is chemically bonded with oxygen, water, carbon dioxide, or sulfur in a variety of minerals. Forms of Iron Minerals, Ores, and Rocks Iron occurs mainly in iron-oxide ores. Some ores are a mixture of minerals rich in iron. Other iron ores are less rich and have a large number of impurities. The most important iron ore- forming minerals are: • Magnetite - Magnetite (Fe3O4) forms magnetic black iron ore. There are large deposits of magnetite in Russia and Sweden. • Hematite - Hematite (Fe2O3) is a red iron ore. Hematite occurs in almost all forms, from solid rock to loose earth. It is the most plentiful iron ore and occurs in large quantities throughout the world. • Goethite - Goethite (Fe2O3.H2O), a brown ore, contains iron. • Limonite - Limonite (Fe2O3.H2O) is a yellow-brown iron ore. Limonite is a collective term for impure goethite and a mixture of hydrated iron oxides. Iron 4-1 Energy and Environmental Profile of the U.S. Mining Industry Taconite contains low-grade iron in fine specks and bands. It is an extremely hard and flinty - containing about 25 - 30 percent iron. The iron in taconite occurs principally as magnetite and hematite and finely dispersed with silica in sedimentary deposits. -
ENVIRONMENTAL CODE of PRACTICE Base Metals Smelters and Refineries
ENVIRONMENTAL CODE OF PRACTICE C ANADIAN E NVIRONMENTAL P ROTECTION A CT , 1999 First Edition Base Metals Smelters and Refineries March 2006 EPS 1/MM/11 E Metals Section Natural Resource Sectors Pollution Prevention Directorate Environmental Stewardship Branch Environment Canada Library and Archives Canada Cataloguing in Publication Main entry under title: Environmental Code of Practice for Base Metals Smelters and Refineries: Code of Practice, Canadian Environmental Protection Act, 1999. Issued also in French under title: Code de pratiques écologiques pour les fonderies et affineries de métaux communs : Code de pratique de la Loi canadienne sur la protection de l’environnement (1999). “First Edition”. Available also on the Internet. Includes bibliographical references. ISBN 0-662-42221-X Cat. no.: En84-34/2005E EPS 1/MM/11 E 1. Non-ferrous metal industries – Waste disposal – Canada. 2. Non-ferrous metals – Metallurgy – Environmental aspects – Canada. 3. Non-ferrous metals – Refining – Environmental aspects – Canada. 4. Smelting – Environmental aspects – Canada. 5. Best management practices (Pollution prevention) – Canada. i. Canada. Pollution Prevention Directorate. Metals Section. ii. Canada. Environment Canada. TD195.F6E58 2005 669'.028'6 C2005-980316-9 READERS’ COMMENTS Inquiries and comments on this Code of Practice, as well as requests for additional copies of the Code, should be directed to: Metals Section Natural Resources Sectors Division Pollution Prevention Directorate Environmental Stewardship Branch Environment Canada Place Vincent Massey 351 St. Joseph Blvd. Gatineau, Quebec K1A 0H3 Fax (819) 953-5053 Note: Website addresses mentioned in this document may have changed or references cited may have been removed from websites since the publication of the document.