International Journal of Minerals, Metallurgy and Materials

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Inhibition of acid mine drainage and immobilization of heavy metals from copper flotation tailings using a marble cutting waste

Gulsen Tozsin

2016, 23(1): 1-6. doi: 10.1007/s12613-016-1204-5

中文摘要(189) PDF(11) SpringerLink

摘要:
Acid mine drainage (AMD) with high concentrations of sulfates and metals is generated by the oxidation of sulfide bearing wastes. CaCO₃-rich marble cutting waste is a residual material produced by the cutting and polishing of marble stone. In this study, the feasibility of using the marble cutting waste as an acid-neutralizing agent to inhibit AMD and immobilize heavy metals from copper flotation tailings (sulfide- bearing wastes) was investigated. Continuous-stirring shake-flask tests were conducted for 40 d, and the pH value, sulfate content, and dissolved metal content of the leachate were analyzed every 10 d to determine the effectiveness of the marble cutting waste as an acid neutralizer. For comparison, CaCO₃ was also used as a neutralizing agent. The average pH value of the leachate was 2.1 at the beginning of the experiment (t = 0). In the experiment employing the marble cutting waste, the pH value of the leachate changed from 6.5 to 7.8, and the sulfate and iron concentrations decreased from 4558 to 838 mg/L and from 536 to 0.01 mg/L, respectively, after 40 d. The marble cutting waste also removed more than 80wt% of heavy metals (Cd, Cr, Cu, Ni, Pb, and Zn) from AMD generated by copper flotation tailings.

Semi-industrial experimental study on bauxite separation using a cell–column integration process

Ning-ning Zhang, Chang-chun Zhou, Long-fei Cong, Wen-long Cao, You Zhou

2016, 23(1): 7-15. doi: 10.1007/s12613-016-1205-4

中文摘要(219) PDF(9) SpringerLink

摘要:
The cyclonic-static micro-bubble flotation column (FCSMC) is a highly efficient mineral processing equipment. In this study, a cell-column (FCSMC) integration process was investigated for the separation of bauxite and its feasibility was analyzed on a theoretical basis. The properties of low-grade bauxite ore from Henan Province, China were analyzed. Parameters such as reagent dosage, scraping bubble time, and pressure of the circulating pump during the sorting process were investigated and optimized to improve the flotation efficiency. On the basis of these parameters, continuous separation experiments were conducted. Bauxite concentrate with an aluminum-to-silicon (A/S) mass ratio of 6.37 and a 77.63wt% recovery rate were achieved via a flow sheet consisting of “fast flotation using a flotation cell, one roughing flotation and one cleaning flotation using flotation columns”. Compared with the full-flotation-cells process, the cell–column integration process resulted in an increase of the A/S ratio by 0.41 and the recovery rate by 17.58wt%. Cell–column integration separation technology represents a new approach for the separation of middle-to-low-grade bauxite ore.

Formation mechanism of the graphite-rich protective layer in blast furnace hearths

Ke-xin Jiao, Jian-liang Zhang, Zheng-jian Liu, Feng Liu, Li-sheng Liang

2016, 23(1): 16-24. doi: 10.1007/s12613-016-1206-3

中文摘要(305) PDF(12) SpringerLink

摘要:
A long campaign life of blast furnaces is heavily linked to the existence of a protective layer in their hearths. In this work, we conducted dissection studies and investigated damage in blast furnace hearths to estimate the formation mechanism of the protective layer. The results illustrate that a significant amount of graphite phase was trapped within the hearth protective layer. Furthermore, on the basis of the thermodynamic and kinetic calculations of the graphite precipitation process, a precipitation potential index related to the formation of the graphite-rich protective layer was proposed to characterize the formation ability of this layer. We determined that, under normal operating conditions, the precipitation of graphite phase from hot metal was thermodynamically possible. Among elements that exist in hot metal, C, Si, and P favor graphite precipitation, whereas Mn and Cr inhibit this process. Moreover, at the same hot-face temperature, an increase of carbon concentration in hot metal can shorten the precipitation time. Finally, the results suggest that measures such as reducing the hot-face temperature and increasing the degree of carbon saturation in hot metal are critically important to improve the precipitation potential index.

Effect of MgO content in sinter on the softening–melting behavior of mixed burden made from chromium-bearing vanadium–titanium magnetite

Zheng-gen Liu, Man-sheng Chu, Hong-tao Wang, Wei Zhao, Xiang-xin Xue

2016, 23(1): 25-32. doi: 10.1007/s12613-016-1207-2

中文摘要(308) PDF(20) SpringerLink

摘要:
The effect of sinter with different MgO contents on the softening–melting behavior of mixed burden made from chromium- bearing vanadium–titanium magnetite was investigated. The results show that with increasing MgO content in the sinter, the softening interval and melting interval increased and the location of the cohesive zone shifted downward slightly and became moderately thicker. The softening–melting characteristic value was less pronounced when the MgO content in the sinter was 2.98wt%–3.40wt%. Increasing MgO content in the sinter reduced the content and recovery of V and Cr in the dripped iron. In addition, greater MgO contents in the sinter resulted in the generation of greater amounts of high-melting-point components, which adversely affected the permeability of the mixed burden. When the softening–melting behavior of the mixed burden and the recovery of valuable elements were taken into account, proper MgO contents in the sinter and slag ranged from 2.98wt% to 3.40wt% and from 11.46wt% to 12.72wt%, respectively, for the smelting of burden made from chromium-bearing vanadium–titanium magnetite in a blast furnace.

Experimental study on sulfur removal from ladle furnace refining slag in hot state by blowing air

Li-hua Zhao, Lu Lin, Qi-fan Wu

2016, 23(1): 33-39. doi: 10.1007/s12613-016-1208-1

中文摘要(264) PDF(13) SpringerLink

摘要:
In view of the present problem of sulfur enrichment in the metallurgical recycling process of ladle furnace (LF) refining slag, a simple and efficient method of removing sulfur from this slag was proposed. The proposed method is compatible with current steelmaking processes. Sulfur removal from LF refining slag for SPHC steel (manufactured at a certain steel plant in China) by blowing air in the hot state was studied by using hot-state experiments in a laboratory. The FactSage software, a carbon/sulfur analyzer, and scanning electron microscopy in conjunction with energy-dispersive X-ray spectroscopy were used to test and analyze the sulfur removal effect and to investigate factors influencing sulfur removal rate. The results show that sulfur ions in LF refining slag can be oxidized into SO₂ by O₂ at high temperature by blowing air into molten slag; SO₂ production was observed to reach a maximum with a small amount of blown O₂ when the temperature exceeded 1350℃. At 1370℃ and 1400℃, experimental LF refining slag is in the liquid state and exhibits good fluidity; under these conditions, the sulfur removal effect by blowing air is greater than 90wt% after 60 min. High temperature and large air flow rate are beneficial for removing sulfur from LF refining slag; compared with air flow rate, temperature has a greater strongly influences on the sulfur removal.

Property enhancement of cast iron used for nuclear casks

R. K. Behera, B. P. Mahto, J. S. Dubey, S. C. Mishra, S. Sen

2016, 23(1): 40-48. doi: 10.1007/s12613-016-1209-0

中文摘要(284) PDF(12) SpringerLink

摘要:
Ductile iron (DI) is a preferred material for use in various structural, automotive, and engineering fields because of its excellent combination of strength, toughness, and ductility. In the current investigation, we elucidate the relationship between the morphological and mechanical properties of DI intended for use in safety applications in the nuclear industry. DI specimens with various alloying elements were subjected to annealing and austempering heat treatment processes. A faster cooling rate appeared to increase the nodule count in austempered specimens, compensating for their nodularity value and subsequently decreasing their ductility and impact strength. The ductility and impact energy values of annealed specimens increased with increasing ferrite area fraction and nodularity, whereas an increase in the amounts of Ni and Cr resulted in an increase of hardness via solid solution strengthening. Austempered specimens were observed to be stronger than annealed specimens and failed in a somewhat brittle manner characterized by a river pattern, whereas the ductile failure mode was characterized by the presence of dimples.

Effects of simulated on-fire processing conditions on the microstructure and mechanical performance of Q345R steel

Yi-chao Peng, Hao-hao Xu, Mai-cang Zhang

2016, 23(1): 49-56. doi: 10.1007/s12613-016-1210-7

中文摘要(138) PDF(10) SpringerLink

摘要:
A series of simulated on-fire processing experiments on Q345R steel plates was conducted, and the plates’ Brinell hardness, tensile strength, and impact energy were tested. Microstructure morphologies were systematically analyzed using a scanning electron microscope with the aim of investigating the effect of the steel’s microstructure on its performance. All examined performance parameters exhibited a substantial decrease in the cases of samples heat-treated at temperatures near 700℃. However, although the banded structure decreased with increasing treatment temperature and holding time, it had little effect on the performance decline in fact. Further analysis revealed that pearlite degeneration near 700℃, which was induced by the interaction of both subcritical annealing and conventional spherical annealing, was the primary reason for the degradation behavior. Consequently, some nonlinear mathematical models of different mechanical performances were established to facilitate processing adjustments.

Effects of normal stress, surface roughness, and initial grain size on the microstructure of copper subjected to platen friction sliding deformation

Shan-quan Deng, Andrew-William Godfrey, Wei Liu, Cheng-lu Zhang, Ben Xu

2016, 23(1): 57-69. doi: 10.1007/s12613-016-1211-6

中文摘要(199) PDF(14) SpringerLink

摘要:
The effects of applied normal stress, surface roughness, and initial grain size on the microstructure of pure Cu developed during platen friction sliding deformation (PFSD) processing were investigated. In each case, the deformation microstructure was characterized and the hardness of the treated surface layer was measured to evaluate its strength. The results indicated that the thickness of the deformed layer and the hardness at any depth increased with increasing normal stress. A smaller steel platen surface roughness resulted in less microstructural refinement, whereas the microstructural refinement was enhanced by decreasing the surface roughness of the Cu sample. In the case of a very large initial grain size (d > 10 mm), a sharper transition from fine-grain microstructure to undeformed material was obtained in the treated surface layer after PFSD processing.

Effects of HNO₃ concentration on the pit morphologies of aluminum foil etched in HNO₃–HCl and HNO₃–H₂SO₄–HCl solutions

Quan-xiu Yi, Ye-dong He, Ning Peng, Hong-zhou Song, Xiao-fei Yang, Xiao-yu Cai

2016, 23(1): 70-76. doi: 10.1007/s12613-016-1212-5

中文摘要(185) PDF(8) SpringerLink

摘要:
In this work, the effects of HNO₃ concentration on the pit morphologies of high-cubic-texture aluminum foil etched in HNO₃–HCl and HNO₃–H₂SO₄–HCl solutions were investigated. When the aluminum foil was etched in HNO₃–HCl solutions, the morphologies of pits transformed from irregular tunnels to typical tunnels (as inverted pyramids) and shallow cuboids as the HNO₃ concentration in the etchant solution was increased. However, as the HCl concentration in the etchant solution was increased, the morphologies of pits transformed from shallow cuboids to typical tunnels (as inverted pyramids) and irregular tunnels. When the aluminum foil was etched in n N HNO₃–(7.2−n) N H₂SO₄–0.8 N HCl solutions, the morphologies of the pits transformed from typical tunnels (i.e., the number of sub-tunnels formed on the main tunnels increased) to irregular tunnels (corrugated tunnels and polyline tunnels) as the HNO₃ concentration in the etchant solution was increased. These effects are attributed primarily to corrosion on the (100) and (010) faces of pits being accelerated and to the (001) faces being prone to passivation to different degrees when various concentrations of HNO₃ are added to the etchant solutions.

Microstructure, thermal properties, and corrosion behaviors of FeSiBAlNi alloy fabricated by mechanical alloying and spark plasma sintering

Hong-lei Wang, Tai-xiu Gao, Jia-zheng Niu, Pei-jian Shi, Jing Xu, Yan Wang

2016, 23(1): 77-82. doi: 10.1007/s12613-016-1213-4

中文摘要(213) PDF(11) SpringerLink

摘要:
An equiatomic FeSiBAlNi amorphous high-entropy alloy (HEA) was fabricated by mechanical alloying (MA). A fully amorphous phase was obtained in the FeSiBAlNi HEA after 240 h of MA. The bulk FeSiBAlNi samples were sintered by spark plasma sintering (SPS) at 520 and 1080℃ under a pressure of 80 MPa. The sample sintered at 520℃ exhibited an amorphous composite structure comprising solid-solution phases (body-centered cubic (bcc) and face-centered cubic (fcc) phases). When the as-milled amorphous HEA was consolidated at 1080℃, another fcc phase appeared and the amorphous phase disappeared. The sample sintered by SPS at 1080℃ exhibited a slightly higher melting temperature compared with those of the as-milled alloy and the bulk sample sintered at 520℃. The corrosion behaviors of the as-sintered samples were investigated by potentiodynamic polarization measurements and immersion tests in seawater solution. The results showed that the HEA obtained by SPS at 1080℃ exhibited better corrosion resistance than that obtained by SPS at 520℃.

Hot deformation behavior of uniform fine-grained GH4720Li alloy based on its processing map

Qiu-ying Yu, Zhi-hao Yao, Jian-xin Dong

2016, 23(1): 83-91. doi: 10.1007/s12613-016-1214-3

中文摘要(208) PDF(11) SpringerLink

摘要:
The hot deformation behavior of uniform fine-grained GH4720Li alloy was studied in the temperature range from 1040 to 1130℃ and the strain-rate range from 0.005 to 0.5 s⁻¹ using hot compression testing. Processing maps were constructed on the basis of compression data and a dynamic materials model. Considerable flow softening associated with superplasticity was observed at strain rates of 0.01 s⁻¹ or lower. According to the processing map and observations of the microstructure, the uniform fine-grained microstructure remains intact at 1100℃ or lower because of easily activated dynamic recrystallization (DRX), whereas obvious grain growth is observed at 1130℃. Metallurgical instabilities in the form of non-uniform microstructures under higher and lower Zener–Hollomon parameters are induced by local plastic flow and primary γ′ local faster dissolution, respectively. The optimum processing conditions at all of the investigated strains are proposed as 1090–1130℃ with 0.08–0.5 s⁻¹ and 0.005–0.008 s⁻¹ and 1040–1085℃ with 0.005–0.06 s⁻¹.

Porous α-Al₂O₃ thermal barrier coatings with dispersed Pt particles prepared by cathode plasma electrolytic deposition

Peng Wang, Ye-dong He, Shun-jie Deng, Jin Zhang

2016, 23(1): 92-101. doi: 10.1007/s12613-016-1215-2

中文摘要(203) PDF(10) SpringerLink

摘要:
Porous α-Al₂O₃ thermal barrier coatings (TBCs) containing dispersed Pt particles were prepared by cathode plasma electrolytic deposition (CPED). The influence of the Pt particles on the microstructure of the coatings and the CPED process were studied. The prepared coatings were mainly composed of α-Al₂O₃. The average thickness of the coatings was approximately 100 μm. Such single-layer TBCs exhibited not only excellent high-temperature cyclic oxidation and spallation resistance, but also good thermal insulation properties. Porous α-Al₂O₃ TBCs inhibit further oxidation of alloy substrates because of their extremely low oxygen diffusion rate, provide good thermal insulation because of their porous structure, and exhibit excellent mechanical properties because of the toughening effect of the Pt particles and because of stress relaxation induced by deformation of the porous structure.

Structural, morphological, Raman, optical, magnetic, and antibacterial characteristics of CeO₂ nanostructures

Fazal Abbas, Javed Iqbal, Tariq Jan, Noor Badshah, Qaisar Mansoor, Muhammad Ismail

2016, 23(1): 102-108. doi: 10.1007/s12613-016-1216-1

中文摘要(236) PDF(11) SpringerLink

摘要:
In this study, CeO₂ nanostructures were synthesized by a soft chemical method. A hydrothermal treatment was observed to lead to an interesting morphological transformation of the nanoparticles into homogeneous microspheres composed of nanosheets with an average thickness of 40 nm. Structural analysis revealed the formation of a single-phase cubic fluorite structure of CeO₂ for both samples. A Raman spectroscopic study confirmed the XRD results and furthermore indicated the presence of a large number of oxygen vacancies in the nanosheets. These oxygen vacancies led to room-temperature ferromagnetism (RTFM) of the CeO₂ nanosheets with enhanced magnetic characteristics. Amazingly, the nanosheets exhibited substantially greater antibacterial activity than the nanoparticles. This greater antibacterial activity was attributed to greater exposure of high-surface-energy polar surfaces and to the presence of oxygen vacancies.

Synthesis of crystalline perovskite-structured SrTiO₃ nanoparticles using an alkali hydrothermal process

U. K. N. Din, T. H. T. Aziz, M. M. Salleh, A. A. Umar

2016, 23(1): 109-115. doi: 10.1007/s12613-016-1217-0

中文摘要(302) PDF(15) SpringerLink

摘要:
We report an experimental route for synthesizing perovskite-structured strontium titanate (SrTiO₃) nanocubes using an alkali hydrothermal process at low temperatures without further heating. Furthermore, we studied the influence of heating time (at 180℃) on the crystallinity, morphology, and perovskite phase formation of SrTiO₃. The SrTiO₃ powder, which is formed via nanocube agglomeration, transforms into cubic particles with a particle size of 120–150 nm after 6 h of hydrothermal sintering. The crystallinity and percentage of the perovskite phase in the product increased with heating time. The cubic particles contained 31.24at% anatase TiO₂ that originated from the precursor. By varying the weight ratio of anatase TiO₂ used to react with the strontium salt precursor, we reduced the anatase-TiO₂ content to 18.8at%. However, the average particle size increased when the anatase-TiO₂ content decreased.

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2016年第23卷第1期

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2016年第23卷第1期