There are presents the internal recycling in anode furnace, in addition to mainly blister copper and converter copper. During the process
there arise the two types of semi-finished products intended for further pyro metallurgical processing: anode copper and anode slag. The
stream of liquid blister copper enters into the anode furnace treatment, in which the losses are recovered, e.g. copper, resulting from
oxidation and reduction of sulfides, oxides and the oxidation of metallic compounds of lead, zinc and iron. In the liquid phase there are
still gaseous states, which gives the inverse relationship relating to the solid phase, wherein the gases found an outlet in waste gas or
steam. The results of chemical analysis apparently differ from each other, because crystallite placement, the matrix structure and the
presence of other phases and earth elements are not compared, which can be regained in the process of electrorefining. One should not
interpret negatively smaller proportion of copper in the alloy, since during the later part of the production more elements can be obtained,
for example from sludge, such as platinum group metals and lanthanides. According to the research the quality of blister copper, to a large
extent, present in the alloy phase to many other elements, which can be recovered.
The investigation results of the mechanical reclamation of spent moulding sands from the Cordis technology are presented in the paper.
The quality assessment of the obtained reclaim and the influence of the reclaim fraction in a matrix on the core sand strength is given. The
reclaim quality assessment was performed on the basis of the determination of losses on ignition, Na2O content on reclaim grains and pH
values. The reclaim constituted 100%, 75% and 50% of the core sand matrix, for which the bending strength was determined. The matrix
reclamation treatment was performed in the experimental rotor reclaimer RD-6. Spent sands were applied in as-delivered condition and
after the heating to a temperature of 140 o
C. Shaped samples for strength tests were made by shooting and hardening of sands in the warmbox
technology.
This article discusses issues related to continuous casting of brass. The tested material was CuZn39Pb2 brass with the use of continuous casting and different parameters of the process. The position consists of a melting furnace with a graphite refining pot of about 4000 cm3 chuting capacity, a graphite crystallizer of 9,5 mm nominal diameter, a primary and secondary cooling system and an extracting system as well. The analysis was carried out in terms of technological parameters of the process and type of charge. Highlighted: feedrate ingot, number of stops, and technological temperatures. The surface quality of the obtained ingots and the structure were analyzed. The most favorable conditions were indicated and technological recommendations indicated. They have been distinguished for ingots for plasticity and other technologies. Favorable casting conditions are low feed and low temperature. Due to the presence of impurities coming from the charge it is disadvantageous to have Ni greater than 0.053% by mass, and Fe more than 0.075% by mass. It is recommended to maintain a high zinc content in the melt which is associated with non-overheating of the metal during casting and earlier melting.
The article presents the role of the ceramic layered moulds used in the investment casting method with new (certified) and recycled material from ceramic moulds (CM) after casting process. The materials that were obtained are mainly aluminosilicates and SiO2. The investigation of changes in the quality of ceramic moulds (including the recycled ceramic material) includes the chemical composition of the ceramics as recovered ceramic material, changes in the particle size of the layered covering material, the gas permeability during the pouring of liquid metal, and the creation of the porosity are presented. Than the thermophysical parameters and dimensional accuracy of the casting manufactured in the new ceramic layered shell moulds were analysed. Additionally the global cost savings and improved ecological conditions in the foundry and its surroundings was estimated.
FeCl3 bearing etching solution is mainly used for etching of metals used in shadow masks, PCBs and so on. Due course of Invar alloy etching process the FeCl3 bearing etching solution get contaminated with Ni2+ which affect adversely the etching efficiency. Hence, FeCl3 bearing etching solution discarded after several cycle of operation causes an environmental and economic problem. To address both the issues the etching solution was purified through solvent extraction and remained Ni2+ recovered by wet chemical reduction using hydrazine. For optimum Fe3+ extraction efficiency, various extraction parameter were optimized and size and morphology of the recovered pure Ni powder was analyzed. The reported process is a simple process to purify and recover Ni from industry etching solution.
Industrial steelmaking (EAF) flue dust was characterized in terms of chemical and phase compositions, leaching behaviour in 20% sulphuric acid solution as well as leaching thermal effect. Waste product contained about 43% Zn, 27% Fe, 19% O, about 3% Pb and Mn and lesser amounts of other elements (Ca, Si, Mo, etc.). It consisted mainly of oxide-type compounds of iron and zinc. Dissolution of metals (Zn, Fe, Mn) from the dust was determined in a dependence of solid to liquid ratio (50-200 g/L), temperature (20-80oC) and leaching time (up to 120 min). The best result of 60% zinc recovery was obtained for 50 g dust/L and a temperature of 80oC. Leaching of the material was an exothermic process with a reaction heat of about –318 kJ/kg. Precipitation purification of the solution was realized using various ratios of H2O2 to NH3aq. A product of this stage was hydrated iron(III) oxide. Final solution was used for zinc electrowinning. Despite that pure zinc was obtained the highest cathodic current efficiency was only 40%.
This investigation is concerned with the extraction of nugget copper particles from copper recovery plant slag which recycled of copper scrap. For this purpose, the Falcon concentrator was used because of its enhanced gravity properties. The Falcon concentrator has a fast spinning bowl which creates a centrifugal force to separate fine size minerals on the basis of their density differences. In the tests, the tailings of the copper recovery plant were used and the test sample was divided into two groups and one of them was classified in narrow particle sizes. The operational parameters were determined as particle size, centrifugal force and washing water pressures. The water pressure and centrifugal force have an inversely proportional relationship. Because of this phenomenon, the G/P parameter was created. The test conditions were applied to the whole distribution sample and narrow size distribution samples in the same way.
The test results indicate that the average grade was elevated from 1.04% to 6.50% with the recovery of 15.07% and 619% enrichment ratio for narrow sizes, whereas grade was elevated to 4.36% with 13.24% recovery and 415.94% enrichment ratio for the whole distribution. As a result, the recovery and grade values of concentrates are not good enough for gravity concentration process for both samples. However, this process was applied to the double recycled material and the lower recovery, grade values can be tolerated because of concentrate is nugget copper metal. The concentrate can also be washed in cleaning table for increasing the grade value for adding to initial feed of plant. This process can, therefore, supply important earnings not only economically but also environmentally.
Dust generated at an electric arc furnace during steel production industry is still not a solved problem. Electric arc furnace dust (EAF) is a hazardous solid waste. Sintering of well-prepared briquetted mixtures in a shaft furnace is one of possible methods of EAFD utilisation. Simultaneously some metal oxides from exhaust gases can be separated. In this way, various metals are obtained, particularly zinc is recovered. As a result, zinc-free briquettes are received with high iron content which can be used in the steelmaking process. The purpose of the research was selecting the appropriate chemical composition of briquettes of the required strength and coke content necessary for the reduction of zinc oxide in a shaft furnace. Based on the results of the research the composition of the briquettes was selected. The best binder hydrated lime and sugar molasses and the range of proper moisture of mixture to receive briquettes of high mechanical strength were also chosen and tested. Additionally, in order to determine the thermal stability for the selected mixtures for briquetting thermal analysis was performed. A technological line of briquetting was developed to apply in a steelworks.
The paper presents the idea of the integrated recycling system of used moulding sands with organic resins. A combination of the method of
forecasting averaged ignition loss values of moulding sands after casting and defining the range of necessary matrix reclamation
treatments in order to obtain its full recycling constitutes the basics of this process.
The results of own investigations, allowing to combine ignition loss values of spent moulding sands after casting knocking out with
amounts of dusts generated during the mechanical reclamation treatment of such sands, were utilized in the system.
Magnesium alloys are one of the lightest of all the structural materials. Because of their excellent physical and mechanical properties the
alloys have been used more and more often in various branches of industry. They are cast mainly (over 90%) on cold and hot chamber die
casting machines. One of the byproducts of casting processes is process scrap which amounts to about 40 to 60% of the total weight of a
casting. The process scrap incorporates all the elements of gating systems and fault castings. Proper management of the process scrap is
one of the necessities in term of economic and environmental aspects.
Most foundries use the process scrap, which involves adding it to a melting furnace, in a haphazard way, without any control of its content
in the melt. It can lead to many disadvantageous effects, e.g. the formation of a hard buildup at the bottom of the crucible, which in time
makes casting impossible due to the loss of the alloy rheological properties. The research was undertaken to determine the effect of an
addition of the process scrap on the mechanical properties of AZ91 and AM50 alloys. It has been ascertained that the addition of a specific
amount of process scrap to the melt increases the mechanical properties of the elements cast from AZ91 and AM50 alloys.
The increase in the mechanical properties is caused mainly by compounds which can work as nuclei of crystallization and are introduced
into the scrap from lubricants and anti-adhesive agents. Furthermore carbon, which was detected in the process scrap by means of SEM
examination, is a potent grain modifier in Mg alloys [1-3].
The optimal addition of the process scrap to the melt was determined based on the statistical analysis of the results of studies of the effect
of different process scrap additions on the mean grain size and mechanical properties of the cast parts.
A liquid crystal display (LCD) recycling process is needed to increase its efficiency by recovering the resources in addition to metals and plastics. This study investigates the pre-treatment process for recycling LCD glass. Recycling pre-treatment includes dismantling the LCD from the waste product, crushing the glass, and separating the glass particles from the impurities. Scanning electron microscopy confirmed that the oscillation milling process is more effective in maintaining uniform powder shape and size as compared to the cut milling process. The glass particles crushed by the oscillating mill, optimized at 1500 rpm, had a uniformly distributed particle size of less than 10 µm. These small particles were separated from the organic impurities, achieving a 98% pure powder that can be used as recycled raw materials. The proposed pre-treatment process for recycling LCD glass will enhance the ability to use waste glass as a valuable resource in the manufacturing of future displays.
This paper is focused on the manufacturing and properties of light weight aggregates made from local waste materials. The waste materials were car windshield glass contaminated by PVB foil, fly ash, mine slates as well as wastes after toothpaste production. The main aim of the research was to combine car windshield glass and the aluminosilicate coal mine slates as a basis for light weight aggregates manufacturing. Fly ash were added in order to modify rheological properties of the plastic mass. Toothpaste wastes were introduced as a source of carbonates and CO2 evolution during thermal treatment. After milling and mixing all materials they were pressed and sintered at temperature range of 950°C-1100°C in air. The results show that it is possible to receive light weight aggregates only from the Silesian local waste materials. The significant influence of sintering temperature on properties of aggregates was observed.
The technology of recycling with foamed bitumen is a new technology of road rehabilitation. Due to the climatic conditions in the Central European countries, road pavement structure should be moisture and frost resistant. Because of its specific production conditions, this is especially important for pavements rehabilitation with the cold recycling technology. Determining the physical and mechanical properties, as well as moisture and frost resistance, depends on binder and filler contents. They are the key elements before its use for road building. The tests presented here have been performed on mineral recycled base mixes with foamed bitumen. The material from the existing layers was used. The content of bitumen binder amounted to 2.0%, 2.5%, 3.0% and 3.5%, while that of cement to 1.0%, 1.5%, 2.0%, 2.5%. The results were subject to the optimization process. This allowed to state that with the use of 2.5% foamed bitumen and 2.0% of cement, the base had the required properties, as well as the moisture and frost resistance.
Electron beam melting(EBM) is a useful technique to obtain high-purity metal ingots. It is also used for melting refractory metals such as tantalum, which require melting techniques employing a high-energy heat source. Drawing is a method which is used to convert the ingot into a wire shape. The required thickness of the wire is achieved by drawing the ingot from a drawing die with a hole of similar size. This process is used to achieve high purity tantalum springs, which are an essential component of lithography lamp in semiconductor manufacturing process. Moreover, high-purity tantalum is used in other applications such as sputtering targets for semiconductors. Studies related to recycling of tantalum from these components have not been carried out until now. The recycling of tantalum is vital for environmental and economic reasons. In order to obtain high-purity tantalum ingot, in this study impurities contained in the scrap were removed by electron beam melting after pre-treatment using aqua regia. The purity of the ingot was then analyzed to be more than 4N5 (99.995%). Subsequently, drawing was performed using the rod melted by electron beam melting. Owing to continuous drawing, the diameter of the tantalum wire decreased to 0.5 mm from 9 mm. The hardness and oxygen concentration of the tantalum ingot were 149 Hv and less than 300 ppm, respectively, whereas the hardness of the tantalum wire was 232.12 Hv. In conclusion, 4N5 grade tantalum wire was successfully fabricated from tantalum scrap by EBM and drawing techniques. Furthermore, procedure to successfully recycle Tantalum from scraps was established.
The presented article describes the method for determining one of the trace elements occurring in coalbismuth. The subjects of the analysis were coal type 34, 35 and their fly ashes derived from Jastrzębska Spółka Węglowa. The main reason for the research was the extensive use of bismuth in many industry sectors. Additionally, bismuth is on the list of deficit elements, therefore the possibility of obtaining an alternative for its recycling source of it is needed, is required. The research was carried out using atomic absorption spectrometry with electrothermal atomization in a graphite cuvette. The samples were incinerated at 800°C and microwave mineralization in a high-pressure closed system was performed until the spectrometric analysis was achieved. In order to achieve mineralization, a mixture of HF and HNO3 acids was used to turn the samples into acidic solutions. The preparation of the samples was based on available literature data and own observations. In the experiment, the effects of the additive modifier was modified by changing the temperature in further steps: drying, incineration, cooling, atomization and burning were described. In addition, the palladium modifier was used in order to limit secondary reactions and enable the evaporation of matrix components. The measurement conditions which are presented in this article allow for a linear calibration curve to be established. However, this is not clear and the definitive method for determining the bismuth in coal is carried out through the use of ET-AAS.