Kinetic study on pressure leaching of high iron sphalerite concentrate

The kinetics of pressure leaching high iron sphalerite concentrate was studied.The effects of agitation rate,temperature, oxygen partial pressure,initial acid concentration,particle size,iron content in the concentrate and concentration of Fe2 +added into the solution on the leaching rate of zinc were examined.The experiment results indicate that if the agitation rate is greater than 600 r/min,its influence on Zn leaching rate is not substantial.A suitable rise in temperature can facilitate the leaching reaction,and the temperature should be controlled at 140-150℃.The increase trend of Zn leaching rate becomes slow when pressure is greater than 1.2 MPa,so the pressure is controlled at 1.2-1.4 MPa.Under the conditions of this study,Zn leaching rate decreases with a rise in the initial sulfuric acid concentration;and Zn leaching rate increases with a rise of iron content in the concentrate and Fe 2+ concentration in the solution.Moreover,the experiment demonstrates that the leaching process follows the surface chemical reaction control kinetic law of“shrinking of unreacted core”.The activation energy for pressure leaching high iron sphalerite concentrate is calculated,and a mathematical model for this pressure leaching is obtained.The model is promising to guide the practical operation of pressure leaching high iron sphalerite concentrate.

Sulfuric acid leaching of high iron-bearing zinc calcine

Sulfuric acid leaching of high iron-bearing zinc calcine was investigated to assess the effects of sulfuric acid concentration, liquid-to-solid ratio, leaching time, leaching temperature, and the stirring speed on the leaching rates of zinc and iron. The results showed that the sulfuric acid concentration, liquid-to-solid ratio, leaching time, and leaching temperature strongly influenced the leaching of zinc and iron, whereas stirring speed had little influence. Zinc was mainly leached and the leaching rate of iron was low when the sulfuric acid concentration was less than 100 g/L. At sulfuric acid concentrations higher than 100 g/L, the leaching rate of iron increased quickly with increasing sulfuric acid concentration. This behavior is attributed to iron-bearing minerals such as zinc ferrite in zinc calcine dissolving at high temperatures and high sulfuric acid concentrations but not at low temperatures and low sulfuric acid concentrations.

Comprehensive recovery of Fe,Zn,Ag and In from high iron-bearing zinc calcine

A beneficiation-metallurgy combination process is developed to recover Zn, Fe and to enrich In, Ag from high iron-bearing zinc calcine based on our former researches. In gaseous reductive roasting process, the roasting conditions were tested by magnetic separation of roasted product. It is found that the V_(CO)(P_(CO)/(P_(CO+CO_2)) in roasting atmosphere should be maintained below 30% to avoid the generation of zinc iron solid solution(Fe_(0.85-x)Zn_xO), which can bring a decrease of iron recovery in magnetic separation. After roasting, acid leaching and multistage magnetic separation are carried out for the recovery of Zn, Fe and enrichment of Ag and In. About 90% of zinc is extracted and 83% of iron is recovered in the whole process. The Ag mainly enters the tailings with a recovery of 76%, the Ag grade increases from 0.12 g/t in raw materials to 1.18 g/t in the tailings. However, the In mainly enters the iron concentrations and the recovery reaches 86%. This process was proved to be technically feasible and may be a favorable option in the treatment of high iron-bearing zinc material with high Ag or In content.

Effect of fluxes on high iron and low silica sintering

Burnt lime and serpentine were incorporated into the sinter mix to improve high iron and low silica sinte-ring. Optimization of how to use burnt lime including dosage of burnt lime, moisture of sinter mix, hydrating andgranulation time was performed. Evaluations of sinter characteristics including sinter mineralogy, reducibility, lowtemperature reduction degradation, softening and melting down properties were carried out. Compared with the re-sults of traditional process in base case, the tumbling index (TI) is increased by 1.53%-2.33% through proportio-ning high ratio of burnt lime or adding serpentine in the sinter mix. It is shown that effective granulation, better per-meability and improved high temperature reactivity in the sinter bed are achieved, resulting in an increase in 3.13 %- 5.10% calcium ferrite occurring in acicular and columnar shape and decrease in glass phase, and with the reduc-ibility index(RI) being increased by 1.65%- 3.25%.

Interface characteristics and wear resistance of Ni-B_(4)C plated ZTA reinforced high chromium cast iron composite

A chemical composite plating of Ni-B_(4)C was used to prepare the surface-modified zirconia toughened alumina(ZTA)ceramic particles.The ceramic preforms were prepared by the plated ZTA and sodium silicate solution binder,followed by casting infiltration to prepare the ZTA particles reinforced high chromium cast iron(HCCI)composites.The result reveals that a distinct interface layer forms at the ZTA/HCCI interface,which consists of phases of ZrB_(2),FeB,Fe_(2)B,and NaSiO_(4).The interfacial wettability between ZTA and HCCI is improved by the diffusion and reaction of Ni and B_(4)C.The wear test reveals that the Ni-B_(4)C plated ZTA particles can effectively improve the wear resistance of the ZTA/HCCI composite,and the wear rate of the composite is decreased to 11.6%of HCCI.

FeCe nanocomposite with high iron content as efficient catalyst for generation of COx-free hydrogen via ammonia decomposition

FeCe nanocomposite catalysts with different iron contents were synthesized by a facile co-precipitation method.The as-prepared materials were characterized by various techniques including powder X-ray diffraction(XRD),N2 adsorption/desorption and high-resolution transmission electron microscopy(HRTEM).Catalyst with the highest iron content(90 FeCe) shows the best activity for the hydrogen generation via ammonia decomposition.83% NH3 conversion is achieved at 550℃ and nearly full conversion of NH3 is realized at 600℃ with a GHSV of 24000 cm3/(gcat·h).The large content and small size crystal particles of iron species are responsible for the good catalytic performance.Temperatureprogrammed reduction by hydrogen(H2-TPR) was performed to investigate the interaction between cerium and iron species.It is found that slight cerium can exert strong interaction with iron compound thus effectively prevent the self-aggregation of active iron species,so as to improve the catalytic activity for ammonia decomposition.

Effect of Cryogenic Treatment on Property of 14Cr2Mn2V High Chromium Cast Iron Subjected to Subcritical Treatment

Effect of cryogenic treatment on the microstructure, hardening behavior and abrasion resistance of 14Cr2Mn2V high chromium cast iron （HCCI） subjected to subcritical treatment was investigated. The results show that cryogenic treatment after subcritical treatment can obviously improve the hardness and abrasion resistance of HCCI because abundant retained austenite is transformed into martensite and fine secondary carbides E（Fe, Cr）23 C6 ] precipitate. The amount of martensite and precipitated secondary carbide in HCCI experiencing subcritical treatment followed by cryogenic treatment was more than that experiencing the subcritical treatment followed by air cooling. When the abrasion resistance of HCCI reaches the maximum, its microstructure contains about 15 % retained austenite. Cryogenic treatment can further reduce the austenite content but the retained austenite cannot be transformed in to martensite completely.

Effect of Ti-V-Nb-Mo addition on microstructure of high chromium cast iron

The effects of trace additions of multi-alloying elements(Ti,Nb,V,Mo)on carbides precipitation and as- cast microstructure of eutectic high chromium cast iron containing 2.85wt.%C and 31.0wt.%Cr were investigated from thermodynamic and kinetic considerations.The thermodynamic calculations show that Ti and Nb exist in the multi-alloying system in the forms of TiC and NbC.The formation of VC during the solidification is not feasible from the thermodynamic consideration.XRD analysis shows that the V exists in alloy compounds(VCr2C2,VCrFe8).The first precipitated high melting point particles(TiC,NbC)can act as the heterogeneous substrate of M7C3 carbides, which results in significant refinement of the M7C3 carbides.After the addition of alloying elements,C atom diffusion is hindered due to the strong affinities of the strong carbide forming elements for carbon,which decreases the growth rate of carbides.The combined roles of the increase of nucleation rate and the decrease of carbides growth rate lead to the finer microstructure.

Effects of Rare Earths and Al on Structure and Performance of High Chromium Cast Iron Containing Wolfram

Effects of RE and Al on the structure, impact toughness, hardness, and wear resistance of high chromium cast iron containing wolfram were investigated. The results show that without modification the volume fraction of austenite is high and the carbide appears to be thick lath and the grain size is relatively large; proper modification using RE combined with Al can reduce volume fraction of residual austenite in the as-cast structure obviously, refine grain size of primary austenite notably, and make the morphology of carbide changing from thick lath to thin lath, rosette, and feather-like modification can also increase hardness, wear resistance and impact toughness of cast iron.

High Cr white cast iron/carbon steel bimetal liner by lost foam casting with liquid-liquid composite process

Liners in wet ball mill for mineral processing industry must bear abrasive wear and corrosive wear, and consequently,the service life of the liner made from traditional materials,such as Hadfield steel and alloyed steels,is typically less than ten months.Bimetal liner,made from high Cr white cast iron and carbon steel,has been successfully developed by using liquid-liquid composite lost foam casting process.The microstructure and interface of the composite were analyzed using optical microscope,SEM,EDX and XRD.Micrographs indicate that the boundary of bimetal combination regions is staggered like dogtooth,two liquid metals are not mixed,and the interface presents excellent metallurgical bonding state.After heat treatment,the composite liner specimens have shown excellent properties,including hardness>61 HRC,fracture toughnessα k >16.5 J·cm-2 and bending strength >1,600 MPa.Wear comparison was made between the bimetal composite liner and alloyed steel liner in an industrial hematite ball mill of WISCO,and the results of eight-month test in wet grinding environment have proved that the service life of the bimetal composite liner is three times as long as that of the alloyed steel liner.

SPHERICAL MICROSTRUCTURE FORMATION OF THE SEMI-SOLID HIGH CHROMIUM CAST IRON Cr20Mo2

The nondendritic semi-solid slurry preparation of high chromium cast iron Cr20Mo2 has been studied in this paper. The experiments show that the proeutectic austenitic particles are more spherical under a larger stirring power condition, even if the stirring time is shorter, while the proeutectic austenitic particles are not very much spherical under a smaller stirring power condition and some proeutectic austenitic dendrites also exist, even if the stirring time is very long. The experiments also show that when stirred for 5-6 minutes under the test condition, the semi-solid slurry with 40vol.%-50vol.% solid fraction and spherical proeutectic austenite in the size of 50-80μm can be obtained.

Microstructure and Property of Hypereutectic High Chromium Cast Iron Prepared by Slope Cooling Body-Centrifugal Casting Method

In this paper, the ring-type ingot of hypereutectic high Cr cast iron was obtained by slope cooling bodycentrifugal casting method （SC-CCM）, and its microstructure and impact toughness were investigated, respectively. The results indicated that, first, the primary carbides in the microstructure are prominently finer than those in the hypereutectic high Cr cast iron prepared by conventional casting method. Second, in the ring-type ingot, the primary carbides near radial outer field are finer than those near radial inner field; furthermore, there is dividing field in the microstructure. Finally, the impact toughness values of the specimens impacted on the radial outer face and on the radial inner face are improved respectively about 36% and 138% more than that of the hypereutectic high Cr one prepared by conventional casting method.

Effect of Rare Earth Elements on Carbide Morphology and Phase Transformation Dynamics of High Ni-Cr Alloy Cast Iron

The effect of rare earth(RE) elements on carbide of high NiCr alloy cast iron was investigated. Meanwhile, the continuous cooling transformation(CCT) curves of cast iron with and without RE addition were determined. The results show that the carbides in high NiCr cast iron can be refined and changed from network and long strip structures into island and block ones. The phase transformation temperature was raised and incubation period of bainite transformation was shortened by adding RE element in high NiCr alloy cast iron.

Effect of partial remelting time on the initial carbide in semisolid structure of hypereutectic high Cr cast iron

In order to review the effect of partial remelting time on the morphology of initial carbides, semisolid ingots of hypereutectic high Cr17 cast iron were remelted at 1270℃ for four different times, and the changing characteristics of shape factor and the equivalent diameter of initial carbides were analyzed quantitatively using a Leica image analyzer. The results indicate that firstly, the evolution process of the initial carbides' morphology undergoes melting, spheroidization and refining during the partial remelting; secondly, the solute diffusion and interface tension take dominant roles at the primary and the middle-final stages respectively in the process of initial carbide evolution; finally, a perfect structure can be obtained by remelting semisolid ingots at 1270℃ for 15 min.

OXIDATION BEHAVIOUR OF HIGH Cr CAST IRON

The oxidation behaviour of high Cr Cast iron was investigated at 950 and 800℃ in terms of Cr content in matrix and the amount of carbide.The morphology and types of oxide films and the microstructure of subsurface were also examined.The main conclusions are:1)The original chromium content in the matrix determines the type of oxide film and it is an important factor for the oxidation resistance of high chromium cast iron;2) The oxidation resistance improves with increasing carbide content at 950℃ because of the decomposition of the carbide,while the decompsition of the carbide do not take place at 800℃ so the oxidation resisteance do not improve with increasing carbide volume.

Effect of surface Cr/C infiltration on microstructure,mechanical properties and wear resistance of high chromium cast iron

A new type of high chromium cast iron(HCCI)was prepared,and its microstructure,mechanical properties,and abrasion resistance were investigated systematically.Results showed that after surface carburizing and chromizing,the microstructure of HCCI mainly consists of martensite,boride(M_(2)B),and carbide(M_(7)C_(3)),accompanied with a large amount of secondary precipitations M_(23)C_(6).Moreover,the morphology and hardness of the carbide and boride in HCCI change little,while the volume fraction of carbide and boride increases from 16.23%to 23.16%.This effectively increases the surface hardness of HCCI from 64.53±0.50 HRC to 66.58±0.50 HRC,with the result that the surface of HCCI possesses a better abrasion resistance compared to the center position.Furthermore,the wear mechanism of HCCI changes from micro-plowing to micro-cutting with the increase of surface hardness.

Effects of CaO and Na2CO3 on the Reduction of High Silicon Iron Ores

The effects of CaO and Na2CO3 on the reduction of high silicon iron ores at 1 250 ℃ were studied. The experimental results showed that the metallization rate was significantly hindered by the addition of CaO and Na2CO3, particularly at the early stage of roasting, compared to the rate without additives. In the absence of additives, iron oxides were quickly reduced to metallic iron, and fayalite was difficult to form. When CaO and Na2CO3 were added, the low reducible iron-containing silicate compounds formed and melted, subsequently retarding the metallization process. The inhibition of Na2CO3 was more noticeable than that of CaO, and higher Na2CO3 doses resulted in stronger inhibition of the increased metallization rate. However, when Na2CO3 was added prior to CaO, the liquid phase formed, which facilitated the growth of the metallic phase. To reinforce the separation of the metallic phase and slag, an appropriate amount of liquid phase generated during the reduction is necessary. It was shown that when 10% CaO and 10% Na2CO3 were added, a high metallization rate and larger metallic iron particles were obtained, thus further decreasing the required Na2CO3 dosage.

Mixture of ilmenite and high phosphorus iron ore smelted by oxygen-enriched top-blown smelting reduction

In order to reasonably utilize the abundant resources of high-phosphorus iron ore and ilmenite in China,the technology of top-blown smelting reduction with oxygen enrichment was used to smelt the mixed ore of high-phosphorus iron and ilmenite.The effect,which is related to basicity,reduction temperature,carbon-oxygen ratio and time of ventilated oxygen to iron recovery,dephosphorization rate,content of iron,phosphorus,sulfur and titanium in pig iron,was investigated in the experiment.The results show that an ideal outcome can be gained in condition of 6:4 ration on Mengqiao concentrate and Huimin iron ore,temperature of 1 500 °C,basicity of 1.3,1.0 on molar ration of carbon to oxygen,time of 10 min on blowing-oxygen.The outcome is that there is no foamy slag in generation,a good separation of slag and iron,iron recovery with 91.41%,content of phosphorus with 0.27% and tilanium content less than 0.001%.The atmosphere of strong oxidizing in the upper of reduction container and high potential of oxygen in the composition of slag in this technique bring phosphorus,titanium and silicon into slag,which ensures less content of impurity in pig iron.

Use of electron microscopy on microstructure characterization of high chromium cast irons

The physical metallurgy underlying the development of cast microstructures in abrasion resistant high chromium cast irons, and their structural modification by thermal treatments is relatively complex. Structural characterisation via electron microscopy therefore has a key role to play in furthering our understanding of the phase transformations that control the microstructures and hence the service performances of these irons as wear parts. This paper shows how both scanning and especially transmission electron microscopy can provide valuable information on the nature of eutectic and secondary carbides and on the matrix structures in these irons. Particular attention is given to current characterisation research on conventionally cast 30%Cr irons that are used for applications involving corrosive wear e.g. slurry pumps and on a semi-solid cast 27%Cr iron that has a potential for applications in industry.

Niobium alloying effect in high carbon equivalent grey cast iron

The effect of niobium on the formation of NbC phase and solidification structure in high carbon equivalent grey cast iron was investigated.The experimental results indicated that an increase in the niobium content is favorable to refining the graphite and eutectic cell;and the pearlite lamellar spacing is reduced.Based on the thermodynamic calculation the formation of NbC is prior to the eutectic reaction.The reduction in the pearlite lamellar spacing is mainly attributed to the decrease of eutectic temperature with the addition of niobium.Additionally,properties including hardness and wear resistance were improved after the addition of niobium.