New Directions in Mineral Processing, Extractive Metallurgy, Recycling and Waste Minimization: An EPD Symposium in Honor of Patrick R. Taylor: Pyrometallurgy
Sponsored by: Society for Mining Metallurgy and Exploration, TMS Extraction and Processing Division, TMS: Pyrometallurgy Committee, TMS: Hydrometallurgy and Electrometallurgy Committee, TMS: Materials Characterization Committee, TMS: Energy Committee, TMS: Recycling and Environmental Technologies Committee
Program Organizers: Ramana Reddy, University of Alabama; Corby Anderson, Colorado School of Mines; Erik Spiller, Colorado School of Mines; Edgar Vidal, NobelClad; Camille Fleuriault, Eramet Norway; Alexandra Anderson, Gopher Resource; Mingming Zhang, Baowu Ouyeel Co. Ltd; Christina Meskers, SINTEF
Monday 2:00 PM
March 20, 2023
Room: 33C
Location: SDCC
Session Chair: M. Akbar Rhamdhani, Swinburne University of Technology
2:00 PM Invited
A Multi-scale View of Scalability Challenges in Hydrogen-Based Ironmaking: Leora Dresselhaus-Marais1; 1Stanford University
Modern metals manufacturing relies on centuries-old techniques that must be revisited for environmental and resource sustainability. While steel is ubiquitous, its refinement currently contributes 8% of the global CO2 footprint, 64% of which originates from ironmaking. Updating ironmaking processes requires careful studies of the fundamental science that complicates scalability and direct integration of those approaches with scale models. I will present my group’s work using in-situ X-ray and electron probes (diffraction and imaging) to directly resolve the kinetics and multiscale structural dynamics for H2-based direct iron reduction. By mapping these dynamics from the atomic through μm-scales, we demonstrate we demonstrate the intricate and complex links between mechanics, chemistry, and mass transport give rise to complex chemistry. Our finding shed light on the complex reaction dynamics of this system, paving the way for important insights into the energy-landscape of carbon-free steelmaking that offer an important starting point for process models.
2:30 PM Cancelled
Carbon Formation in MIDREX Hot Briquetted Iron: Emmanuel De Moor1; Michelle Herrera1; Christopher Harris1; 1Advanced Steel Processing and Products Research Center, Colorado School of Mines
The use of direct reduced iron (DRI) and hot briquetted iron (HBI) in electric arc furnaces (EAFs) is increasing to dilute residuals from scrap, notably copper. The carbon amounts in DRI may affect the thermal efficiency of the EAF and understanding carbon formation in DRI and HBI is therefore important. An assessment of the carbon contents of industrially produced DRI and HBI was conducted for a range of processing conditions. DRI and HBI characterization involved Leco carbon/sulfur analysis, x-ray diffraction, and Mössbauer spectroscopy.
2:50 PM
Application of Fiber Optics in Metallurgical Processes
Temperature Monitoring of Metallurgical Furnace with Distributed Temperature Sensing (DTS): Luis Gonzalez1; Luis Chambi1; Stefany Huanca Choque1; Carlos Javier Acho Quispe1; 1Universidad Mayor de San Andres
In Pyrometallurgy one of the main parameters for control and optimization of the process is the temperature. Conventional techniques for monitoring temperature in metallurgical furnaces are pyrometers, thermocouples and RTD. New technologies that are more dynamic processes like Ausmelt, Kivcet, etc demand continuous and accurate measurement but also high spatial resolution (more points of measurement). A continuous profile measurement of temperature will help to define the taping of the furnace, control of temperature of slag, metal, gases etc.Experimental measurements using fiber optics and a laboratory furnace was performed to obtain profile temperatures of the furnace at different operations conditions, simulating operations conditions that can happen on the industry. The furnace is wrapped with fiber optics and temperature measurements were obtain, every meter and minute. Results shows that application of this technology will help to optimize operations of the furnaces and reduce the downtime of this equipment.
3:10 PM
Lead Bleed-off from Dust of Copper Smelter: Kifu Matsuura1; Satoshi Shibata1; Kifu Matsuura1; Fumito Tanaka1; 1Mitsubishi Materials Corporation
There has been decreasing the grade of copper concentrate, leading to an increase in impurities load of copper smelter globally. Among such impurities, lead has a detrimental impact on electrorefining operation causing the passivation of anode. Although reductive smelting of dust to produce lead bullion has been known to be an option of lead bleeding off the copper production circuit, impurities other than lead included in “dirty concentrate” in recent years may suffer the operations of lead smelting and successive refining of the bullion, as well. The present paper will suggest a process from pretreatment of feed to the lead smelter to pyro-refining of bullion to ensure satisfactory quality of bullion while managing impurities other than lead and discuss process factors which are crucial for the process design of the present process.
3:30 PM Break
3:50 PM
Ga, In and Ge Extraction from Zinc Plant Residues by Chlorine Metallurgy: Santiago Iriarte Aguirre1; Patrick Taylor1; Stephen James1; 1Colorado School of Mines
Chlorine metallurgy has been studied to recover metals from complex ores, treat waste, or recover critical elements in waste streams. It has been evaluated for the recovery of valuable material from sulfides, oxides, and silicate ores. Chlorine metallurgy offers several advantages, such as opening ores, selectivity, regeneration of the chlorinating agents, and process versatility. During the production of primary zinc, gallium, germanium, and indium are enriched during the hydrometallurgical process. However, during the purification of the leachate, these elements report with the precipitate. The research objectives were: (1) explore selective chlorination to fume Ga, and Ge from zinc plant leach residues and (2) investigate, modify, and optimize the flowsheet for a primary zinc residue to include the capture of Ga, In, and Ge. Experimental results are presented, and a preliminary flow sheet is identified.
4:10 PM
Alternatives to Pyrometallurgical Recovery of Copper and Gold from Waste Printed Wiring Boards: Process Flow and Environmental Impacts Assessment: Eric Schwartz1; Haoyang He1; Oladele Ogunseitan1; Julie Schoenung1; 1University of California, Irvine
Copper and gold are important metals to recover from waste printed wiring boards (PWBs) due to the high copper content and high value of gold present in this waste stream. These metals are conventionally recovered from PWBs by pyrometallurgical techniques which are typically associated with high emissions of greenhouse gases and toxic compounds. Alternative techniques, mainly hydrometallurgical and biohydrometallurgical techniques, may offer reduced environmental impacts in comparison to pyrometallurgical processes; however, these three processes have not been quantitatively compared to verify potential benefits of the alternatives. In this study, we present industrially feasible processes to recover copper and gold from waste PWBs using pyrometallurgical, hydrometallurgical, and biohydrometallurgical routes, and we compare the environmental impacts of these processes with life cycle assessment and chemical hazard assessment. Our goal is to quantitatively determine which process is preferred in terms of environmental factors such as greenhouse gas emissions and toxic chemical use.