No description available.

No description available.

No description available.

No description available.

Thesis (MEng) -- Stellenbosch University, 2014. / ENGLISH ABSTRACT: The copper sulphate leach solutions produced during the final pressure leach stages in base metal refinery processes contain low concentrations of other precious metals (OPMs, namely Rh, Ru and Ir ) and impurities in addition to the base metals (BMs) of interest. Se and Te impurities, in particular, must be removed from the leach solution before it is fed to copper electrowinning because these species have adverse effects on electrowinning efficiency. Currently, these elements are being precipitated from the leach solution with sulphurous acid. Se precipitation is satisfactory but Te removal still proves challenging. Previous studies have shown that tellurium can either be precipitated as cuprous telluride from copper sulphate solutions by reduction with sulphurous acid alone, or by the addition of SO2 as a precipitating agent and metallic copper as an additional precipitating agent. The objective of this study was to evaluate the effects of different process variables on Te and Se recovery in order to propose operating conditions at which increased tellurium precipitation can be achieved with minimal co-precipitation of base metals of interest (notably Cu and Ni). This would also aid in the development of a better understanding of tellurium and selenium precipitation mechanisms in CuSO4-H2SO4 medium. / AFRIKKANSE OPSOMMING: Die kopersulfaat logingsoplossing wat gedurende die finale druklogingstadia in basis metaal raffinaderye produseer word bevat, behalwe vir die basis metale van belang, ook lae konsentrasies ander edelmetale (AEM, naamlik Rh, Ru, en Ir) sowel as onsuiwerhede. Se en Te onsuiwerhede, in die besonder, moet vanuit die logingsoplossing verwyder word voordat die oplossing na die koper elektrowinning gevoer word omdat hierdie spesies negatiewe effekte op die elektrowinning effektiwiteit het. Hierdie elemente word tans met swaweligsuur vanuit die logingsoplossing gepresipiteer. Se presipitasie is voldoende, maar die Te verwydering bly steeds problematies. Vorige studies het getoon dat tellurium as kuprotelluried vanuit kopersulfaat oplossings presipiteer kan word deur middel van reduksie met swaweligsuur alleen, of met die byvoeging van SO2 as presipiteermiddel en metallieke koper as addisionele presipiteermiddel. Die doelwit van hierdie studie was om die effekte van verskillende prosesveranderlikes op Te en Se presipitasie te ondersoek ten einde bedryfstoestande voor te stel wat verbeterde tellurium presipitasie toelaat met minimale kopresipitasie van basis metale van belang (hoofsaaklik Cu en Ni). Dit sal ook bydra tot die ontwikkeling van ʼn beter begrip van die tellurium en selenium presipitasie meganisme in ʼn CuSO4-H2SO4 medium.

M.Sc. (50/50) Research project submitted to School of Chemical and Metallurgical Engineering, Faculty of Engineering and the Built Environment, University of the Witwatersrand, Johannesburg, South Africa July 2017 / This study and the work done involves investigating the effects of different parameters on the decarburization process of high carbon ferrochromium melts to produce medium carbon ferrochrome, and takes into account the manipulation of the different parameters and thermodynamic models based on actual plant data. Process plant data was collected from a typical plant producing medium carbon ferrochrome alloys using AODs. The molten alloy was tapped from the EAF and charged into the AOD for decarburization using oxygen and nitrogen gas mixtures. The gases were blown into the converter through the bottom tuyeres. Metal and slag samples and temperature measurements were taken throughout the duration of each heat. The decarburization process was split into two main intervals namely first stage blow (where carbon content in the metal bath is between 2-8 wt. % C) and second stage blow (carbon mass% below 2 wt. %). The first and second blow stages were differentiated by the gas flow rates whereby the first stage was signified by gas flow ratio of 2:1 (O2:N2), whilst the stage blow had 1:1 ratio of oxygen and nitrogen respectively. The effect of Cr mass% on carbon activity and how it relates to rate of decarburization was investigated, and the results indicated that an increase in Cr 66.54 – 70.5 wt. % reduced carbon activity in the metal bath from 0.336 – 0.511 for the first blowing stage. For the second blowing stage, the increase in Cr mass % of 67.22 – 71.65 wt. % resulted in an increase in C activity from 0.336 – 0.57. The trend showed that an increase in chromium composition resulted in a decrease in carbon activity and the same increase in Cr mass% resulted in reduced carbon solubility. Based on the plant data, it was observed that the rate of decarburization was time dependent, that is, the longer the decarburization time interval, the better the carbon removal from the metal bath. An interesting observation was that the change in carbon mass percent from the initial composition to the final (Δ%C) decreased from 10.18 – 8.37 wt. % with the increase in Cr/C ratio from 8.37 – 10.18. This effect was attributed to the chromium affinity for carbon and the fact that an increase in chromium content in the bath was seen to reduce activity of carbon. It was also observed that the effect of the Cr/C ratio was more significant in the first stage of the blowing process compared to the second blowing stage. A mass and energy balance model was constructed for the process under study to predict composition of the metal bath at any time interval under specified plant conditions and parameters. The model was used to predict the outcome of the process by manipulating certain parameters to achieve a set target. By keeping the gas flow rates, blowing times, gas ratios and initial metal bath temperature unchanged, the effect of initial temperature on decarburization in the converter was investigated. The results showed that the carbon end point with these parameters fixed decreased with increasing initial temperature, and this was supported by literature. The partial pressure of oxygen was observed to increase with decrease in C mass % between the first and second blow stages. For the second stage blow the partial pressure changed from 5.52*10-12 – 2.1*10-10 and carbon mass % increased from 0.754 – 2.99 wt. %. A carbon mass % of 7.87 had an oxygen partial pressure of 4.51*10-13 whilst a lower carbon content of 1.53 wt. % had an oxygen partial pressure of 8.06*10-11. The CO partial pressure however increased with increase in carbon composition in the metal bath. When the oxygen flow rate increased, a corresponding increase in the carbon removed (Δ%C) was observed. For the first stage of the blowing process, an increase in oxygen flow rate from 388.67 – 666.5Nm3 resulted in an increase in carbon removed from 5.06 – 7.28 wt. %. The second blowing stage had lower oxygen flow rates because of the carbon levels remaining in the metal bath were around +/- 2 wt. %. In this stage oxygen flow rates increased from 125 – 286.67 Nm3 and carbon removed (Δ%C) from 0.16 – 2.093 wt. %. The slag showed that an increase in basicity resulted in an increase in Cr2O3 in the slag. As the basicity increased from 0.478 – 1.281, this resulted in an increase in Cr2O3 increase from 0.26 – 0.68. Nitrogen solubility in the metal bath was investigated and it was observed that it increased with increasing Cr mass %. The increase in nitrogen solubility with increasing Cr mass % was independent of the nitrogen partial pressures. / MT2018

The addressed topic is to investigate the power distribution at a base metal refinery and to identify the potential improvement in power consumption efficiency. The work included in this study revealed that the power consumption efficiency at the evaluated base metal refinery can be improved. The significance of this study relates to Eskom’s tariff increases and directive to mining and large industrial companies to reduce their power consumption as well as the recent incremental increase in power tariffs. Base metal refineries are substantial power consumers and will be required to evaluate the efficiency of their base metal production. A load study was conducted at a base metal refinery in order to determine the current power consumption at the various process areas. The measurements obtained from the load study formed the basis for calculations to determine the potential efficiency improvement. The load study revealed that the electro-winning area contributes to the majority of the power consumed (52% of total apparent power) at the refinery. The potential improvement in efficiency at the electro-winning process area was identified by means of evaluating the rectifier and rectifier transformer power consumption. Methods and technologies for the reduction in power consumption was consequently evaluated and quantified. The potential reduction in conductor losses by converting from global power factor correction to localised power factor correction for the major plant areas was furthermore identified as an area of potential efficiency improvement and consequently evaluated. The improvement in motor efficiency across the base metal refinery was identified by means of comparing the efficiency and power factor of high efficiency motors to that of the standard efficiency motors installed at the refinery. The work included in this study reveals that an improvement in power consumption efficiency is achievable at the evaluated base metal refinery. An efficiency improvement of 1.785% (real power reduction of 2.07%) can be achieved by implementing localised power factor correction and high efficiency motors. An average efficiency improvement of 1.282% (total real power reduction of 2.78%) can be achieved with the additional implementation of specialised, high efficiency rectifier transformer designs. The implementation of localised power factor correction as well as high efficiency motors was identified as short term efficiency improvement projects. A financial study was conducted in order to determine the cost and payback period associated with the reduction in real power consumption for implementation of the recommended efficiency improvement projects. The payback period, required to achieve an average efficiency improvement of 1.785%, was calculated to be approximately 4 years. The initial capital investment required to implement the efficiency improvement projects is about R22.5 million. The monthly electricity utility bill savings associated with the efficiency improvement projects is approximately R455,000. / Thesis (M.Sc.Eng.)-University of KwaZulu-Natal, Durban, 2012.

The process of precious metal refining can be up to 99.99% efficient at best, and although it may seem small, the amount of valuable metal lost to waste streams is appreciable enough to warrant recovery. The method currently used to remove entrained metal ions from refinery wastewaters, chemical precipitation, is not an effective means for selective recovery of precious metals from a wastewater. Biosorption, the ability of certain types of biomass to bind and concentrate metals from even very dilute aqueous solutions, may be an effective point-source metal recovery strategy. The yeast, Saccharomyces cerevisiae, has been found capable of sorbing numerous precious and base metals, and is a cheap and abundant source of biomass. As such, it represents a possible precious metal sorbent for application to refining wastewaters. In this investigation, S. cerevisiae biomass was immobilized, using polyethyleneimine and glutaraldehyde, to produce a suitable sorbent, which was found to be capable of high platinum uptake (150 to 170 mg/g) at low pH (< 2). The sorption mechanism was elucidated and found to be a chemical reaction, which made effective desorption impossible. The sorption process was investigated in a packed bed column conformation, the results of which showed that the diameter and height of the column require further optimization in order to attain the metal uptake values achieved in the batch studies. When applied to a refinery wastewater, two key wastewater characteristics limited the success of the sorption process; the high inorganic ion content and the complex speciation of the platinum ions. The results proved the concept principle of platinum recovery by immobilized yeast biosorption and indicated that a more detailed understanding of the platinum speciation within the wastewater is required before the biosorption process can be applied. Overall, the sorption of platinum by the S. cerevisiae sorbent was demonstrated to be highly effective in principle, but the complexity of the wastewater requires that pretreatment steps be taken before the successful application of this process to an industrial wastewater.

Note:

Removal of nitrogenous compounds from precious metal refinery (PMR) wastewater is important in terms of avoiding eutrophication (environmental protection), metal recovery (increased overall process efficiency and value recovery) and reuse of treated water (maximum use of natural resources). Extreme pH conditions (4 to 13 depending on the wastewater stream), high chemical oxygen demand (> 10,000 mg/I), numerous metals and high concentrations of those metals (> 20 mg/l of platinum group metals) in the wastewater are the main challenges for biological removal of nitrogenous compounds from PMR wastewater. Nitrogenous compounds such as NH₄⁺-N and N0₃-N are strong metal ligands, which make it difficult to recover metals from the wastewater. Therefore, a bioprocess was developed for removal of nitrogenous compounds from carefully simulated PMR wastewater. A preliminary investigation of metal wastewater was carried out to determine its composition and physico-chemical properties, the ability to nitrify and denitrify under different pH conditions and denitrification with different carbon Source compounds and amounts. Even at pH 4, nitrification could be carried out. A suitable hydraulic retention time was found to be 72 hours. There was no significant difference between sodium acetate and sodium lactate as carbon sources for denitrification. Based on these results, a reactor comparison study was carried out using simulated PMR wastewater in three types of reactors: continuously stirred tank reactor (CSTR), packed-bed reactor (PBR) and airlift suspension reactor (ALSR). These reactors were fed with 30 mg/l of Rh bound in an NH₄⁺ based compound (Claus salt: pentaaminechlororhodium (III) dichloride). Total nitrogen removal efficiencies of > 68 % , > 79 % and > 45 % were obtained in the CSTR, PBR and ALSR, respectively. Serially connected CSTR-PBR and PBR-CSTR reactor configurations were then studied to determine the best configuration for maximum removal of nitrogenous compounds from the wastewater. The PBR-CSTR configuration gave consistent biomass retention and automatic pH control in the CSTR. Ammonium removal efficiencies > 95 % were achieved in both reactors. As poor nitrate removal was observed a toxicity study was carried out using respirometry and the half saturation inhibition coefficients for Pt, Pd, Rh and Ru were found to be 15.81, 25.00, 33.34 and 39.25 mg/l, respectively. A mathematical model was developed to describe the nitrogen removal in PMR wastewater using activated sludge model number 1 (ASMl), two step nitrification and metal toxicity. An operational protocol was developed based on the literature review, experimental work and simulation results. The optimum reactor configuration under the set conditions (20 mg/I of Rh and < 100 mg/I of NH₄⁺-N) was found to be PBR-CSTR-PBR process, which achieved overall NH₄⁺-N and N0₃⁻-N removal efficiencies of > 90 % and 95 %, respectively. Finally, a rudimentary microbial characterisation was carried out on subsamples from the CSTR and PBRsecondary. It was found that the CSTR biomass consisted of both rods and cocci while PBRsecondary consisted of rods only. Based on these experimental works, further research needs and recommendations were made for optimisation of the developed bioprocess for removal of nitrogenous compounds from PMR wastewater.