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As a basic mechanical component, the sealing ring is widely used in industrial, aerospatial, and other fields. In this study, an elastic metal C-shaped sealing ring with a wave structure was taken as an example, and its performance was analyzed theoretically and measured experimentally. First, an experimental study was performed on the C-ring seal. The proposed method for experimental measurement of the contact stress of the C-ring seal involved innovative use of a universal electronic testing machine and pressure sensitive paper, in conjunction with the hue&ndash, saturation&ndash, brightness (HSB) method. Based on the discoloration of the pressure sensitive paper after contact stress, computer software was used for analysis, the discoloration was digitized, and the contact stress was established. Second, a theoretical calculation model of the C-ring seal was established using ANSYS software, and a finite element theoretical calculation of the mechanical properties of the sealing ring was established. Finally, the contact stress results were compared with the model calculation results of the C-ring seal. The error between the two was small (4.8%), which proved the validity of the calculation model and the scientificity of the experimental method.

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The failure of a proximal humerus internal locking system (PHILOS) used in a pantalar arthrodesis was investigated in this paper. PHILOS constructs are hybrids using locking and non-locking screws. Both the plate and the screws used in the fusion were obtained for analysis. However, only the plate failure analysis is reported in this paper. The implant had failed in several pieces. Optical and scanning electron microscopic analyses were performed to characterize the failure mode(s) and fracture surface. The chemical composition and mechanical properties of the plate were determined and compared to controlling specifications to manufacture the devices. We found that equivalent tensile strength exceeded at the locations of high stress, axial, and angular displacement and matched the specification at the regions of lower stress/displacement. Such a region-wise change in mechanical properties with in vivo utilization has not been reported in the literature. Evidence of inclusions was qualitatively determined for the stainless steel 316L plate failing the specifications. Pitting corrosion, scratches, discoloration and debris were present on the plate. Fracture surface showed (1) multi-site corrosion damage within the screw holes forming a 45° maximum shear force line for crack-linking, and (2) crack propagation perpendicular to the crack forming origin that may have formed due to the presence of inclusions. Fracture features such as beach marks and striations indicating that corrosion may have initiated the crack(s), which grew by fatigue over a period of time. In conclusion, the most likely mechanism of failure for the device was due to corrosion fatigue and lack of bony in-growth on the screws that may have caused loosening of the device causing deformity and pre-mature failure.

This paper proposes selective leaching of molybdenum from Mo/Cu complex bulk concentrates in a 5 M NaCl solution using the electro-oxidation method. Here, the effects of several factors such as pH, pulp density, current density, and temperatures were investigated. A higher leaching yield of Mo increased with increasing pH from 5 to 9 and decreased with increasing pulp density from 1 to 10%. A rise in current density did not help enhance Mo, and the elevating temperature did not always result in a higher leaching yield. Application of ultrasonic led to higher leaching yield of Mo. Ninety-two percent of leaching yield was obtained upon leaching of Mo in 5 M NaCl at 25 °C, pulp density of 5%, and the current density of 0.292 A/g under ultrasonic irradiation with a power of 27 kW. The resultant residue mainly consisted of chalcopyrite.

The recycling of electronic scrap is an important subject not only from an environmental aspect but also for recovering metal resources such as copper. In this work, the microbial extraction of copper and other metals (Cu, Ni, Co, Fe and Al) present in the depopulated and shredded printed circuit board (PCB) is elaborated. Bacterial strains of A. ferrooxidans, A. thiooxidans and a fungal strain, A. niger are used for copper extraction along with other metals from shredded PCBs. An optimum metal recovery of 93% Cu was obtained at 308 K, pH 2 using 8% pulp density in 10 days by a mixed culture of A. ferrooxidans and A. thiooxidans. Whereas using A. niger, a metal recovery of 66% Cu was reported using similar experimental conditions. The results show the higher potential ability of bacteria as compared to fungus to bioleach copper. Additionally, the kinetics and mechanism of copper bioleaching from this e-waste by the chemolithotrophs and heterotrophs were evaluated. The leach liquor obtained from the optimized leaching process was subjected to separation and purification of copper as &gt, 99% pure copper sulfate using Acorga M5640 by solvent extraction.

Torrefaction of almond shells and olive stones, which are typically considered agricultural waste in the southern regions of the European Union, was investigated in this work for application as reducing agents in the metallurgical industry. Four different temperatures were tested: 250, 280, 300 and 350 °C. The evolution of the solid yields with the temperature was determined with TGA measurements. This showed that the duration of torrefaction should not exceed 45 min. The kinetic profiles were successfully fitted using the pseudo-first-order rate equation (PFORE). Then, torrefaction for 45 min was systematically carried out at every temperature and for each resource in a laboratory-scale batch device. The raw and torrefied biomasses were characterized using proximate, ultimate and calorific analyses. The carbon/oxygen ratio and the heating values were increased as a result of the torrefaction severity (from 20 MJ/kg for both raw biomasses to 30 MJ/kg at 350 °C). The highest mass losses were obtained at the highest temperature (67.35 and 65.04 %w for almond shells and olive stones, respectively, at 350 °C). The fixed carbon value also increased, being higher than 67 %w for torrefaction at 350 °C. The large-scale torrefaction at 350 °C (45 min) of these biomasses was carried out in a continuous pilot plant. The solids were characterized as well, and their properties were close to those of the biomasses torrefied in the laboratory-scale batch reactor under the same conditions. This thermal treatment provided biochars with all the required properties to be used as reducing materials in metallurgy.

This article presents the results of studies of a low-waste technology for processing enrichment tailings using a combined enrichment–hydrometallurgical method. After washing the enrichment tailings from harmful products and reducing their size, multi-stage flotation of the crushed material of the enrichment tailings was carried out. The use of a new reagent in the flotation process was studied in order to ensure the maximum recovery of the main valuable components from the enrichment tailings. A new collector of Aero 7249 (Shenyang Florrea Chemicals Co., Ltd., Shenyang, China) type was used for the flotation. The recovery of valuable components was as follows: Cu, 6.78%, Zn, 91.69%, Pb, 80.81%, Au, 95.90%, Ag, 82.50%, Fe, 78.78%. Tailings of the flotation were re-enriched using a fatty acid collector (sodium oleate). Additional (reverse) flotation resulted in obtaining a product corresponding to the composition of building sand in terms of the content of valuable components of the waste rock. The studies of the conditions for processing the enrichment tailings of lead–zinc ore indicate the possibility of its optimization in order to maximize the involvement of waste in the production.

Lithium has become an element of great relevance in recent times, because among its various applications is the manufacture of batteries, and it is a vital part of the growing development of new products such as electric vehicles. On the other hand, the geographical distribution of lithium reserves is very heterogeneous. Of the existing minerals, only some of them are important sources of exploitation, such as the salt in South America, while in other countries mineral deposits such as spodumene stand out. The process for obtaining lithium from spodumene consists of concentrating up to 3% lithium by flotation. Because other minerals associated with this mineral are mainly silicates (feldspar, clays, quartz and micas), great problems are generated in the thickening stage. This article seeks to study the effect of the addition of flocculants and KCl on the sedimentation rate, in addition to studying its effects on the turbidity of the supernatant in different types of water. This is done by Batch sedimentation tests with tailings pulps, to later characterize both the pulp and the supernatant by means of the turbidity of the clarified water. Magnafloc-338 flocculant is the most convenient to use with industrial water, since it reaches a high sedimentation rate of 34.2, 37.44, and 45.36 m/h, with doses of 5, 10, and 15 g/t respectively, and a low turbidity rate (31 Formazin Nephelometric Units (FNU)) at low flocculant dosages.

In the present paper, the leaching of copper from printed circuit boards (PCBs) using sulfuric acid with Cu2+ and O2 is proposed. The effects of various process parameters such as agitation speed, temperature, the type and the flow rate of gas, initial Cu2+ concentration, and pulp density were investigated to examine the dissolution behavior of Cu from PCBs in 1 mol/L sulfuric acid. The kinetic studies were performed using the obtained leaching data. The leaching rate of Cu from PCBs was found to be higher on addition of Cu2+ and O2 to the leachant in comparison with the addition of O2 or both Cu2+ and N2 in the leachant. The leaching efficiency of Cu was found to be increased with increasing agitation speed, temperature, O2 flow rate, and initial Cu2+ concentration and decreasing pulp density. The 96% of Cu leaching efficiency was obtained under the following conditions: sulfuric acid concentration, 1 mol/L, temperature, 90 °C, agitation speed, 600 rpm, pulp density, 1%, initial Cu2+ concentration, 10,000 mg/L, and O2 flow rate, 1000 cc/min. The leaching data and analyses indicate that the Cu leaching from PCBs followed the reaction-controlled model satisfactorily and determined that the activation energy was found to be 23.8 kJ/mol. Therefore, these results indicate that the sulfuric acid solution with Cu2+ and O2 as a mild leach medium without strong oxidants such as HNO3, H2O2, and Fe3+ is valid for Cu leaching from PCBs.

An innovative, efficient, and economically viable process for the recycling of spent alkaline batteries is presented herein. The developed process allows for the selective recovery of Zn and Mn metals present in alkaline batteries. The hydrometallurgical process consists of a physical pre-treatment step for separating out the metal powder containing Zn and Mn, followed by a chemical treatment step for the recovery of these metals. Sulfuric acid was used for the first leaching process to dissolve Zn(II) and Mn(II) into the leachate. After purification, Mn was recovered in the form of MnO2, and Zn in its metal form. Furthermore, during the second sulfuric acid leaching, Na2S2O5 was added for the conversion of Mn(IV) to Mn(II) (soluble in the leachate), allowing Mn to be recovered as MnCO3. Masses of 162 kg of Zn metal and 215 kg of Mn (both in the form of MnO2 and MnCO3) were recovered from one ton of spent alkaline batteries. The direct operating costs (chemicals, labor operation, utilities, energy) and indirect costs (amortization, interest payment) required for a plant treating 8 tons of spent batteries per day was calculated to be $CAD 726 and $CAD 534 per ton, respectively, while the total revenue from the sale of the metals was calculated at $CAD 1359.6 per ton of spent batteries. The development of this type of cost-effective industrial process is necessary for a circular economy, as it contributes to addressing environment- and energy-related issues, and creates opportunities for the economic utilization of metals.

The use of lignin can be one of the methods of coke powder substitution in the agglomeration process. This article specifies the material research of lignin and the technological and ecological parameters of the agglomeration process in laboratory conditions using biomass lignin. The methodology of the Raman and infrared spectroscopy, representing a new approach in the analysis and assessment for the purposes of material characteristics for the agglomeration process, was applied to study the structure of carbonaceous matter. The material research of lignin has determined that its calorific value corresponds to ca. 80% of the calorific value of coke powder, while its reactivity is higher than that of the coke. Although the substitution of coke powder using different types of waste biomass (e.g., wood sawdust) in the production of the agglomerate is limited to the maximum of 8&ndash, 15%, in case of lignin, more than 20% can be substituted, while the standard properties of the produced agglomerate are maintained. The lower emissions of sulfur and nitrogen oxides as well as the reduction of carbon footprint in the agglomeration process as a result of the so-called zero CO2 balance in the formation and processing of the biomass represent its positive aspects. Based on the laboratory research of lignin, up to a 50% substitution of coke powder with this type of biomass can be predicted for the technology of agglomerate production in real operation.

Electronic waste is a growing waste stream globally. With 54.6 million tons generated in 2019 worldwide and with an estimated value of USD 57 billion, it is often referred to as an urban mine. Printed circuit boards (PCBs) are a major component of electronic waste and are increasingly considered as a secondary resource for value recovery due to their high precious and base metals content. PCBs are highly heterogeneous and can vary significantly in composition depending on the original function. Currently, there are no standard methods for the characterisation of PCBs that could provide information relevant to value recovery operations. In this study, two pre-treatments, smelting and ashing of PCB samples, were investigated to determine the effect on PCB characterisation. In addition, to determine the effect of particle size and element-specific effects on the characterisation of PCBs, samples were processed using four different analytical methods. These included multi-acid digestion followed by inductively coupled plasma optical emission spectrometry (ICP-OES) analysis, nitric acid digestion followed by X-ray fluorescence (XRF) analysis, multi-acid digestion followed by fusion digestion and analysis using ICP-OES, and microwave-assisted multi-acid digestion followed by ICP-OES analysis. In addition, a mixed-metal standard was created to serve as a reference material to determine the accuracy of the various analytical methods. Smelting and ashing were examined as potential pre-treatments before analytical characterisation. Smelting was found to reduce the accuracy of further analysis due to the volatilisation of some metal species at high temperatures. Ashing was found to be a viable pre-treatment. Of the four analytical methods, microwave-assisted multi-acid digestion offered the most precision and accuracy. It was found that the selection of analytical methods can significantly affect the accuracy of the observed metal content of PCBs, highlighting the need for a standardised method and the use of certified reference material.

In the present investigation, results obtained from the process of the biosorption of Zn(II) in synthetic wastewaters are presented, using three agricultural wastes (coffee pulp, banana pseudo-stem, and corncob). Firstly, the percentage of lignin and cellulose for each material was determined. Then, using the free software XLSTAT, the waste with the highest removal for this metal was selected and, after this, the optimum pH, kinetics, adsorption isotherm, and point of zero charge (pHpzc) were found. Finally, a comparison with other lignocellulosic materials derived from banana, corn, and coffee crops was carried out. According to the results obtained, coffee pulp was the material that showed a high removal compared to the other two (63.58%), for which the optimum pH was 5.0 units. The kinetic model, which was adjusted to the process of biosorption, was the pseudo second order of Ho and McKay, which in turn presented an isotherm of Langmuir&rsquo, s linearized model where the maximum adsorption capacity with that waste was 13.53 mg &times, g&minus, 1, obtained with a particle size of 180 &micro, m, contact time of 90 min at 100 RPM, temperature of 25 &deg, C, and pHpzc 3.95 units. Lastly, the authors state that this type of agricultural waste can be used as a green technology in the treatment of wastewater, particularly in the removal of the aforementioned pollutant, in order to fulfill goals 3.9 and 6.9 of the Sustainable Development Goals of the 2030 Agenda, to the level of challenge of the research, the authors propose for the future to carry out the implementation of this type of waste, without chemical modification, in the treatment of wastewater for the removal of the mentioned pollutant in a pilot study with different wastewaters and industries.

Utilization of local-based waste materials can be a challenge due to the resource’s limitations. This study investigated the utilization of rubber tree bark (RTB) as a reductant for mill scale. RTB was blended with coal into five ratios, namely RTB#1–RTB#5. The blends were heated at 1000 °C under argon for 1 h. The char was mixed with scale to produce a carbon-mill scale composite pellet (CCP) with a 1.5 C/O molar ratio. The reduction of CCP was carried out in a tube furnace at 1550 °C for 30 min under argon flowing at 1 L/min. The reduced Fe droplets separate clearly from the residues. The CCP produced from blends RTB#1–RTB#5 shows better reduction with metal of 35.28–39.82 wt.%. The degree of metallization (DOM) ranges between 75.25–84.51%, which is two times higher than that of coal. RTB#3 shows the optimum condition with the highest DOM. CaO in RTB plays a role in forming an ash layer on the metal surface and reacting with Fe2O3 to form a new phase. Utilization of our local-based biomass, such as RTB as a reductant for mill scale, is possible. The consumption of fossil fuel in the process could be decreased by 30%, thus also the production cost.

Hydrometallurgical processes for metal extraction are becoming more and more popular as average ore grades are declining and huge tonnages of tailings and recycle materials containing valuable metals are being accumulated all around the world [...]

This study proposes a cleaner lead-acid battery (LAB) paste and pyrite cinder (PyC) recycling method without excessive generation of SO2. PyCs were employed as sulfur-fixing reagents to conserve sulfur as condensed sulfides, which prevented SO2 emissions. In this work, the phase transformation mechanisms in a PbSO4-Na2CO3-Fe3O4-C reaction system were studied in detail. Furthermore, the co-treatment of spent LAB and PyCs was conducted to determine the optimal recycling conditions and to detect the influences of different processing parameters on lead recovery and sulfur fixation. In addition, a bench-scale experiment was carried out to confirm the feasibility and reliability of this novel process. The results reveal that the products were separated into three distinct layers: slag, ferrous matte, and crude lead. 98.3% of lead and 99% of silver in the feed materials were directly enriched in crude lead. Crude lead with purity of more than 98 wt.% (weight percent) was obtained by a one-step extraction. Lead contents in the produced matte and slag were below 2.7 wt.% and 0.6 wt.%, respectively. At the same time, 99.2% total sulfur was fixed and recovered.

Surface paste tailings’ disposal has emerged recently as an optimal and efficient method to favor tailings’ self-containment after being deposited into dams. This disposal method can improve the reuse of water and reduce the generation of acid mine drainage (AMD) and the release of leachates (e.g., acid and heavy metals). However, the implications of chemical factors or mixed-water chemistry in the stability of paste tailings over time are not clear. In this work, we evaluated the release of sulfate from tailing samples and the role of sulfate as a critical factor in the tailings’ strength, consistency, and stability. Our results showed that the release of acid runoff with high sulfate load from the tailings is negligible. Leaching tests were performed for 180 days and did not show a significant release of sulfate, heavy metals, or acid waters. However, the presence of sulfate salts derived from the binders used in the pretreatment of the paste tailings shows an impact on the tailings’ consistency. Undrained triaxial monotonic compression tests revealed low effective cohesion forces in the tailings samples. In addition, it was observed that, in tailings slurries prepared with varying concentrations of sulfate (0, 500, and 1000 mg/L), the slump test value dropped Δ−55% when the sulfate concentration increased from 0 to 1000 mg/L. These results support the idea that the presence of sulfate within the tailings could be relevant for the paste consistency after storage. This knowledge will contribute to a better understanding of the critical chemical factors that affect the stability of paste tailings over time.

Porphyry-type deposits are the major sources of copper and molybdenum, and flotation has been adopted to recover them separately. The conventional reagents used for depressing copper minerals, such as NaHS, Na2S, and Nokes reagent, have the potential to emit toxic H2S gas when pulp pH was not properly controlled. Thus, in this study the applicability of microencapsulation (ME) using ferrous and phosphate ions as an alternative process to depress the floatability of chalcopyrite was investigated. During ME treatment, the use of high concentrations of ferrous and phosphate ions together with air introduction increased the amount of FePO4 coating formed on the chalcopyrite surface, which was proportional to the degree of depression of its floatability. Although ME treatment also reduced the floatability of molybdenite, ~92% Mo could be recovered by utilizing emulsified kerosene. Flotation of chalcopyrite/molybdenite mixture confirmed that the separation efficiency was greatly improved from 10.9% to 66.8% by employing ME treatment as a conditioning process for Cu-Mo flotation separation.

Novel and environmentally benign adsorbents were prepared via a simple sulfuric acid treatment process using the wastes of astringent persimmon, a type of biomass waste, along with persimmon tannin extract which is currently employed for the tanning of leather and as natural dyes and paints. The effectiveness of these new biosorbents was exemplified with regards to hydrometallurgical and environmental engineering applications for the adsorptive removal of uranium and thorium from rare earths, cesium from other alkaline metals such as sodium, hexa-valent chromium from zinc as well as adsorptive recovery of gold from chloride media. Furthermore, reductive coagulation of gold from chloride media for the direct recovery of metallic gold and adsorptive recovery of palladium and platinum using chemically modified persimmon tannin extract were studied. OPEN

This study provides an up to date review of tannins, specifically quebracho, in mineral processing and metallurgical processes. Quebracho is a highly useful reagent in many flotation applications, acting as both a depressant and a dispersant. Three different types of quebracho are mentioned in this study; quebracho “S” or Tupasol ATO, quebracho “O” or Tupafin ATO, and quebracho “A” or Silvafloc. It should be noted that literature often refers simply to “quebracho” without distinguishing a specific type. Quebracho is most commonly used in industry as a method to separate fluorite from calcite, which is traditionally quite challenging as both minerals share a common ion—calcium. Other applications for quebracho in flotation with calcite minerals as the main gangue source include barite and scheelite. In sulfide systems, quebracho is a key reagent in differential flotation of copper, lead, zinc circuits. The use of quebracho in the precipitation of germanium from zinc ores and for the recovery of ultrafine gold is also detailed in this work. This analysis explores the wide range of uses and methodology of quebracho in the extractive metallurgy field and expands on previous research by Iskra and Kitchener at Imperial College entitled, “Quebracho in Mineral Processing”.

Hydrometallurgical and pyrometallurgical processes to recover gold (Au) from cell-phone printed circuit boards (PCBs) have the disadvantage of generating corrosive residues and consuming a large amount of energy. Therefore, it is necessary to look for biological processes that have low energy consumption and are friendly to the environment. Among the biological alternatives for the recovery of Au from PCB is the use of cyanogenic bacteria and filamentous fungi in cultures with agitation. Considering that it is important to explore the response of microorganisms in cultures without agitation to reduce energy expenditure in the recovery of metals from PCB, the present investigation evaluated the capacity of Aspergillus niger MXPE6 and a fungal consortium to induce Au bioleaching from PCB in a culture medium with glucose as a carbon source and without agitation (pH 4.5). The results indicate that the treatments with PCB inoculated with the fungal consortium showed a considerable decrease in pH (2.8) in comparison with the treatments inoculated with A. niger MXPE6 (4.0). The fungal consortium showed a significantly higher Au bioleaching (56%) than A. niger MXPE6 (17%). Finally, the use of fungal consortia grown without agitation could be an alternative to recover metals from PCB, saving energy and material resources.

Bauxite residue (BR) is a well promising resource for critical metals, especially scandium (Sc), a rare and expensive metal with increasing applications in advanced technology. Greek BR seems to significantly favor a commercially viable recovery of Sc combining optimized leaching and advanced separation techniques. Leaching with mineral acids emerges as the dominant selection compared to other techniques. This study investigates an optimized leaching condition set for Sc recovery, using the most advantageous option of sulfuric acid. The main target is to develop a leaching scale-up process to be established in the premises of Mytilineos S.A. (formerly Aluminium of Greece, the largest Greek alumina and aluminum producer), taking into account the feed requirements of a subsequent advanced ion exchanged procedure. Several parameters were studied individually or combined in order to achieve high Sc concentration in the leachate and to ensure selectivity, especially concerning iron. The most significant parameters prove to be the solid-to-liquid ratio (S/L), the final pH value, and the leachate&rsquo, s recycling. The proposed process, with low molarities of sulfuric acid and ambient conditions, integrates rapidly, leading to high and selective Sc recovery. Finally, a leaching process flow diagram under continuous operation on an industrial scale is developed.

The pretreatment processes consisting of grinding followed by roasting were investigated to improve the selective leaching of Nd and Dy from neodymium- iron- boron ( NdFeB) magnet scraps. The peaks of Nd( OH) 3 and Fe were observed in XRD results after grinding with NaOH as the amount of water addition increased to 5 cm(3). These results indicate that the components of Nd and Fe in NdFeB magnet could be changed successfully into Nd( OH) 3 and Fe, respectively. In the roasting tests using the ground product, with increasing roasting temperature to 500 degrees C, the peaks of Nd( OH) 3 and Fe disappeared while those of Nd2O(3) and Fe2O(3) were shown. The peaks of NdFeO3 in the sample roasted at 600 degrees C were observed in the XRD pattern. Consequently, 94.2%, 93.1%, 1.0% of Nd, Dy, Fe were leached at 400 rpm and 90 degrees C in 1 kmol . m- 3 acetic acid solution with 1% pulp density using a sample prepared under the following conditions: 15 in stoichiometric molar ratio of NaOH: Nd, 550 rpm in rotational grinding speed, 5 cm3 in water addition, 30 min in grinding time, 400 degrees C and 2 h in roasting temperature and time. The results indicate that the selective leaching of Nd and Dy from NdFeB magnet could be achieved successfully by grinding and then roasting treatments.