New Directions in Mineral Processing, Extractive Metallurgy, Recycling and Waste Minimization: An EPD Symposium in Honor of Patrick R. Taylor: Poster Session
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 5:30 PM
March 20, 2023
Room: Exhibit Hall G
Location: SDCC
Alternative Fluxes for Lead Bullion Refining: Samuel Asante1; Patrick Taylor1; 1Colorado School of Mines
Harris process for lead softening uses sodium hydroxide and sodium nitrate to remove arsenic, tin, and antimony from molten lead by oxidation. It is known to be better than oxygen softening however the process has a higher cost in terms of reagents used. Sodium hydroxide is corrosive and expensive. In the research, calcium carbonate, calcium hydroxide, and magnesium hydroxide were used as alternative for sodium hydroxide in the softening process. Based on initial results, the research focused on using calcium carbonate for subsequent softening process. In this research, activity coefficients of the impurities: arsenic, tin and antimony were calculated and compared with that obtained with sodium hydroxide in the melt. Softening experiments were conducted on lead bullion by design of experiment method by varying temperature, time, and reagent quantity. Dross obtained was quenched and analyzed chemically and with XRD to identify the phases formed. Experimental and theoretical results are presented.
D-26: Critical Review of Chemical Metallurgy of Tungsten: Raj Singh Gaur1; 1SH Nano Energy Powders
Tungsten is one of the most important refractory metals. Tungsten from its concentrates and secondary sources is processed as high purity Ammonium Para Tungstate (APT) through a multiple steps process. This paper will review the literature, especially, related to new conceptual APT-process which could lead to increased efficiency, energy reduction and waste minimization. Currently, there are two main APT processes: one uses solid ion exchange and the other uses liquid ion exchange. Both processes generate large amount of process wastewater. This paper will review some of the process-related issues such as processing of low grade ores, equipment scaling and the separation of critical impurities and reduction in process steps. Some new chemistry, which may be helpful in generating energy from process by-products and wastewater and will make the APT process less energy dependent and more sustainable in the coming future, will also be discussed
D-28: Estimated End-of-life Lithium-ion Battery Resources for Potential Recycling in Bangladesh: Md Rakibul Qadir1; Miao Chen1; Nawshad Haque1; Warren Bruckard1; 1CSIRO
This study analyses open access data on the input and generation of end-of-life lithium-ion battery waste for a potential commercial battery recycling industry in Bangladesh. Four main sources were identified in the battery waste pool: mobile phones, laptop and tablet PCs, small handheld devices, and hybrid electric vehicles. Their predicted generation rate and volume by type were forecasted to the year 2041 based on the available historic data and assumptions. Such batteries contain commercially recoverable quantity of base metals like Co, Ni and Mn as well as other common metals like Li, Cu, Al and Fe. These metals are in high demand for a densely populated country like Bangladesh where urban mining and “informal recycling” currently presents issues in respect of public health, ecological safety and resource efficiency. Realistic secondary resource inventory, cumulative growth and economic forecasting of battery waste can pave the way for “formal recycling” attracting likely national and international investments.
D-29: Gravity Driven Multiple-effect Thermal System (G-MET) Distillation for Continuous Efficient Lead Refining: Armaghan Ehsani Telgerafchi1; Daniel McArthur1; Chinenye Chinwego1; Adam Powell1; 1Worcester Polytechnic Institute
Gravity-driven multiple-effect thermal system (G-METS) distiller is an effective separation method with the potential to reduce the cost and energy consumption of high purity lead refining. As a result, lead devices, such as lead-acid batteries, may become more widely available for crucial energy storage applications. This paper presents analytical modeling of Pb alloy evaporation kinetics particularly lead alloy containing Sb, Sn, Ag, Cu, Se, Te, and Bi elements. In addition, the techno-economic model of cost, energy consumption, and emissions associated with lead recycling using the G-METS method is investigated.
D-30: In-situ Microscopy Observations of Oxide Phases Formation during High-temperature Oxidation of End-of-life Ni/Cu/Ni-coated-NdFeB Permanent Magnets: Deddy Nababan1; Reiza Mukhlis1; Yvonne Durandet1; Mark Pownceby2; Leon Prentice3; M. Akbar Rhamdhani1; 1Swinburne University of Technology; 2CSIRO Mineral Resources; 3CSIRO Manufacturing
An understanding of the reaction phases formed during the high-temperature oxidation of rare earth permanent magnets (REPM) is vital for developing appropriate strategies for their pyrometallurgy-based recycling processes aimed at the concentration and potential recovery of the rare earth elements (REEs). The current study uses in-situ high-temperature optical microscopy combined with ex-situ scanning electron microscopy to analyze oxide growth on the surface of an end-of-life Ni/Cu/Ni-coated NdFeB permanent magnet oxidized at 1173 K and 1473 K for up to 4 hours under ambient air conditions. Distinct oxide morphologies were observed at the two oxidation temperatures over time, ranging from porous, spherulitic, and spike-like structures. At the longest oxidation times, visible cracking of the surface of the magnet and protrusion of Fe2O3 and Nd2O3 phases were observed. The presence of a Ni/Cu/Ni coating on the magnets was found to significantly affect the oxidation growth.
D-31: Introducing Membrane Percrystallisation Technology for Hydrometallurgical Applications: Siti Nurehan Abd Jalil1; Julius Motuzas1; James Vaughan1; 1The University of Queensland
Crystallisation is an important unit operation in industrial settings for raw product formation, purification and waste removal. This process typically requires multiple processing steps (crystallisation, solid liquid separation and product drying) to attain the final product. Here, we introduce a novel process: membrane percrystallisation which achieves complete separation of solvent from solute in a single step. Liquid is vaporised at the inorganic membrane permeate surface, whilst dry solid product is continuously ejected from the permeate surface, under vacuum. This novel technology has been demonstrated in metal recovery and waste brine treatment applications. In summary, membrane percrystallisation is a new form of crystallisation process intensification which offers a simple, compact and closed system. Within this study, key percrystallisation operating parameters in salt crystallisation that employ supported continuous saccharides carbon membranes will be discussed with examples of potential applications in hydrometallurgical processes.
D-32: Investigating the Influence of Temperature and Atmosphere on the Formation and Decomposition of PAHs from Carbonaceous Materials Used in Industrial Processes: Method Development: Katarina Jakovljevic1; Thor Aarhaug2; Gabriella Tranell1; 1Norwegian University of Science and Technology; 2SINTEF
Polycyclic aromatic hydrocarbons (PAHs) represent a large group of compounds containing two or more fused six-membered rings. As air pollutants, they can spread over very long distances and are therefore internationally regulated. Metal producers use carbon materials as reducing agents, electrodes, lining materials, etc. As a consequence, they emit PAHs to varying degrees. Our goal is to develop a method for assessing and predicting PAH emissions from different carbon-based materials and increasing the fundamental knowledge about PAH formation and decomposition during various process conditions. Method development involves designing a setup for laboratory-scale experiments involving the use of two different furnace set-ups with instrumentation for off-gas analysis in order to examine the influence of process parameters such as temperature and gas atmosphere on the PAHs emission from carbon materials used in industrial processes. Analysis results for PAH 16 vs PAH 42 in two different laboratories were also compared.
Leaching of Arsenopyrite Contained in Tailings Using the TU-OX System: Erick Muñoz Hernandez1; Julio Cesar Juarez Tapia1; Martin Reyes Pérez1; Aislinn Michelle Teja Ruiz1; Gabriel Cisneros Flores1; Miguel Perez Labra1; Francisco Raúl Barrientos Hernández1; 1Universidad Autonoma del Estado de Hidalgo
Iron (Fe), being such an abundant element, is used in various industries such as the steel industry. Similarly, arsenic (As) can be treated to obtain an industrially useful by-product. For this reason, the leaching of arsenopyrite (FeAsS) from mining tailings is silvered, using the Thiourea (CH4 N2S)-Oxalate (C2O42-) system.The presence of FeAsS was confirmed by XRD and SEM-EDS, while the ICP analysis indicated a content of 5.47% Fe and 0.93% As. Likewise, the parameters analyzed were [CH4 N2S] and [C2O42-]. As a result, the highest recovery of Fe was 21.29% and As of 24.04%, in concentrations of thiourea of 0.03 mol and oxalate of 0.1 mol, at 60 minutes.
D-33: Rare Earth Reduction – A Technological Overview of State-of-the-art Technology and Novel Developments: Robert Rush1; Patrick Taylor1; 1Colorado School of Mines
Rare Earths are critical to the future of green technology, especially for wind turbines and electric vehicle motors. However, reducing these rare earths into the metals is challenging metallurgically and economically. An overview will be given on the state-of-the-art processes for reducing rare earths from the rare earth oxides to the rare earth metal. The benefits and the challenges of the state-of-the art processes will be presented. An overview of novel processes being developed in the field will also be given. These novel processes range from innovations in metallothermic reduction and molten fluoride electrolysis to ionic liquid electrolysis of rare earth oxides and attempts of reducing rare earth oxides using solid oxide membrane electrolysis. This lays the foundation for direction of future trends on commercial rare earth reduction technology.
D-34: Recovery of Bismuth in Blast Furnace Dust by Carbothermal Volatilization Reduction: Huaixuan Feng1; Yan Li1; Jingsong Wang1; Xuefeng She1; Qingguo Xue1; Guang Wang1; 1University of Science and Technology Beijing
Blast furnace gas sludge (BFGS) is a kind of solid waste generated from ironmaking process. It contains a small amount of indium. To plenty recycle valuable resource, the carbothermic reduction and volatilization method to recover indium of BFGS was used in this study. Thermodynamic calculations and thermogravimetric analysis were first used to determine the initial reaction temperature between In2O3 and C. To study the carbothermic reduction and volatilization process of indium, high-purity In2O3 and graphite were evenly mixed and heated at 900-1200℃ for 2h. Experimental results showed that the reduction volatilization of In2O3 was sufficient at 1200℃. Based on this result, we next attempted to recover indium from BFGS. The experimental results also yielded indium enrichment in the volatile dust. Therefore, this study illustrates that indium can be enriched and recycled in BFGS, as well as a certain practical approach to comprehensively utilizing such metallurgical solid waste.
D-35: Recovery of Valuable Metals from Li-ion Battery Waste through Carbon and Hydrogen Reduction: Thermodynamic Assessment and Experimental Verification: Bintang Nuraeni1; Katri Avarmaa1; Leon Prentice2; W. John Rankin1; M. Akbar Rhamdhani1; 1Fluid and Process Dynamics (FPD) Group, Swinburne University of Technology; 2CSIRO Manufacturing
The digitalisation of the world and electrification of transportation have been driving the increased usage of rechargeable batteries in the past decade. Recycling and recovering valuable metals from Li-ion batteries (LIB) waste is critical for securing the resources to meet the future demand and production of batteries. In this study, recycling of a battery waste, a black mass containing multiple metals from the cathode and carbon anode, was evaluated using a pyrometallurgical route. Reduction of battery cathode material using carbon from the anode combined with hydrogen as reductant was systematically investigated. The study included thermodynamic assessment using the FactSage™ thermochemical package combined with selected experimental results. The overall reduction mechanism was found to be uniquely characterized by the reduction temperature. The data and information obtained can be employed to develop and optimize the recycling process of Li-ion batteries.
Recycling End-of-Life Acrylonitrile Butadiene (ABS) as Reductant for Metallic Iron Production from the Opon Mansi Iron Ore: James Dankwah1; David Asubonteng1; Georgina Thompson1; 1University of Mines and Technology
The reduction of Ghana’s Opon Mansi iron ore (OPM) using chars generated from end-of-life acrylonitrile butadiene (ABS) has been investigated in a horizontal tube furnace. Composite pellets of the pulverised ore (-250 μm) containing pulverised chars of ABS (-250 μm) were rapidly heated at 1200 and 1500 °C under high purity argon gas and the off gas was continuously analysed for CO and CO2 using an online infrared gas analyser (IR). The extent of reduction after 40 min was calculated at each temperature and the metal produced was characterised by XRD and SEM/EDS analyses. The results show that OPM consists of medium grade hematite (assaying 74.56 wt % Fe2O3), which is easily reduced within 40 min by ABS. It was concluded that metals production from iron ores is a promising route for disposing of No. 7 plastics, which are usually not recycled in Ghana.
D-45: Removal of Iron from an Electrolytic Solution Rich in Copper by Selective Hydrometallurgical Routes: Ana Belen Cueva Sola1; Jungshin Kang2; Jin-Young Lee2; Rajesh Kumar Jyothi2; 1University of Science and Technology; 2Korea Institute of Geoscience and Mineral Resources
Current technological development towards a cleaner energy sources and an increased consumption of electronic devices are driving the increase in the demand of copper and iron. Even though, in the foreseeable future there is no predicted shortage of copper, it is imperative to improve the recovery from secondary sources in pro of the environment and the achievement of circular economy. Currently, cooper obtained from secondary sources are meeting the demand of around 30% worldwide. However, cooper usually comes associated with iron. By using hydrometallurgy, these metals are recovered and separated as a part of a continuous effort to reduce the environmental burden of wastewater and recover valuable metals. During this research, an electrolytic solution rich in Cu2+ (~ 50 g/L) with a small concentration of Fe2+ (~ 2 g/L) was processed using solvent extraction. The optimum conditions for extraction and stripping were derived and removal of iron was efficiently proposed.
D-41: Solar Thermal Application in Zn/ZnO Recovery from Spent Alkaline Batteries: Reiza Mukhlis1; Deddy Nababan1; Andrew Mackenzie2; M. Akbar Rhamdhani1; 1Swinburne University of Technology; 2Envirostream Australia Pty. Ltd.
Landfilling of spent alkaline batteries is considered as more attractive than recycling if economic perspective is the main factor taken into account. The current study explores the potential use of solar thermal energy in recovering valuable Zn/ZnO from the batteries in attempt to improve the economic competitiveness of the recycling process. The blackmass obtained from the batteries’ anode and cathode, mixed with carbon from End-of-Life lithium batteries at various concentration, were subjected to carbothermal reduction at 1100°C in a solar thermal simulator reactor under argon. It was found that high purity Zn/ZnO powder can be recovered from the blackmass, leaving valuable MnO in the reactor. The increase in argon flow was found to decrease the particle size of the Zn/ZnO powder, where the maximum size of 650nm obtained at 2L/min argon. The use of solar thermal energy reduces the production cost, while the decrease in particle size improves product value.
D-36: SPYRO: Share Skills and Good Practices in PYROmetallurgy: Gaurav Tripathi1; 1Eramet Ideas
In pyrometallurgical process management prompt responsiveness is key. This must be done while maintaining a safe work environment and compliance with environmental regulations. Currently, there is no training focused on these aspects of a pyrometallurgical facility. Thus, it is difficult for new hires with limited understanding to work safely and efficiently in industrial conditions. For this reason, the EIT RawMaterials-funded education project SPYRO (Share skills and good practices in PYROmetallugy) aims to bridge the gap between theory and the actual operation of industrial facilities in collaboration with industrial experts from Eramet, Elkem and MPI. SPYRO is an interactive training programme designed especially for new employees in the field of pyrometallurgical process management utilizing nine e-learning modules and one virtual reality module. Trainees (researchers, engineers, technicians and PhDs) will benefit from an up-to-date digital front door to the “pyrometallurgical environment”.