The process varies when extracting copper from copper ore to obtain a preferred purity level of the final product. However the most common type of process in the United States is called Smelting. This is only achieved once the copper ore has been processed to a specified concentration level. This is done by grinding the ore into a concentration of slurry with chemical agents and water. The copper will float to the top of the slurry mixture when air is blown through the mixture and a frothed layer or a foaming layer allows the copper to attach and overflow the tank, this is called ore benefaction. This is when the concentrated copper gets refined. The concentrate is dried and sent into a reverberatory furnace. The minerals are partly oxidized and melted, resulting in isolated layers. The matte layer refers to the iron-copper sulfide mixture which sinks to the bottom. The slag, which refers to the remaining impurities, floats on top of the matte and the discarded. Sulfur dioxide gases are also collected and made into sulfuric acid for use in hydrometallurgical leaching. The matte is recovered and moved to the converter, a cylindrical vessel into which the copper is poured. Air, lime and silica are added to react with the metal oxide. The slag is removed and the Sulfur dioxide and converted into sulfuric acid, this forms blister copper which is 97-99% pure. Blister copper then goes through the fire refining and then cast into copper anodes and placed in an electrolytic cell. Each copper anode is placed in a tank made of concrete. A sheet of copper is placed on the opposite end of the concrete tank to become the cathode or the negative terminal. An acidic copper sulfate solution is then poured into the concrete tanks; this forms the e... ... middle of paper ... ...is produced. (1999, May 16). Retrieved from Rocks and Minerals: http://www.rocksandminerals.com/aluminum/process.htm Iqbal, M. K. (2013, March 27). NED University of Engineering and Technology. Retrieved from Department of Metallurgy Engineering: http://www.neduet.edu.pk/myd/TE/MY%20302.pdf MatWeb. (n.d.). Overview of materials for Low Carbon Steel. Retrieved February 7, 2014, from MatWeb: http://www.matweb.com/search/DataSheet.aspx?MatGUID=034970339dd14349a8297d2c83134649 U.S. Environmental Protection Agency. (1995). Profile of the Iron and Steel Industry. Office of Enforcement and Compliance Assurance. Washingto, DC: Office of Compliance. Retrieved February 07, 2014, from http://nepis.epa.gov/Exe/ZyNET.exe US Army Correspondence. (2000). METAL PROPERTIES, CHARACTERISTICS,. US ARMY REPAIR SHOP TECHNICIAN WARRANT. Retrieved from www.hnsa.org/doc/pdf/metal-properties
...at the joint venture with U.S. Steel would hinder the quick decision making typical at Nucor. Iverson had gambled by committing to the first phase of the new process on his own, without first testing the process in a pilot plant on a small scale. The next stage was to complete the new process with a plant in the United States, relying on the high level of research and development skills at U.S. Steel and the ability of Nucor to pioneer new methods. Analysts wondered whether Nucor could coexist with U.S. Steel, with its large, hierarchical structure and strong union. This challenge was especially important since the new venture was felt to be the focal point for the continued growth of Nucor.
In other words, the alloying element affects the temperature of which the oxide scale forms and its behaviour is at higher elevation temperature as well as gas composition and moisture level [3].
has become a benchmark for both the U.S. steel industry and U.S. industry in general. Nucor is one of the fastest growing and most efficient steel producers in the world. Despite declining demand for steel, Nucor’s growth has been phenomenal, from pouring its first batch of steel in the 1960s to support in-house operations, the company has become one of the top five producers of steel in the U.S.. Without an R&D department, Nucor has repeatedly achieved technological feats other steel producers thought impossible. Their hourly pay is among the lowest in the industry, yet they have the highest productivity per worker of any steel producer in the U.S. and near zero employee turnover" (Boyd & Gove,
The liquid metal is allowed to cool down, and after solidification the metal is taken out of the mold or by breaking the mold. Casting process is used in the production of small or mediate components like pistons, wheels, liners, mill rolls, liners, cylinder blocks, machine tool beds etc.
As our technology advances further, there will be a demand and need for new performance from engineering materials.
Remus, R., Roudier, S., Aguado-Monsonet, M. A. and Delgado Sancho, L. 2013. Best available techniques (BAT) reference document for iron and steel production. Luxembourg: Publications Office.
There are ranges of different methods of extracting copper from different ores. The process below will examine a sequence of procedures to effectively extract as much copper from sulfide ores also known as Chalcopyrite (pyrites).
Wire rod is used in the construction sector and for a host of other product applications such as fencing materials, nails, pins and many other engineering applications. The company has also introduced a number of additional grades of wire-rod with diverse chemical compositions and distinctive physical properties, offering flexibly to cater for different applications. Our coil mill has the shortest rolling program cycle of any major steelmaker in the GCC region, enabling the company to cater for short lead times for its local industrial
Aluminum is the most abundant metal and the third most abundant element in the earth's crust, after oxygen and silicon. It makes up about 8% by weight of the earth’s solid surface. Aluminum also chemically reactive to occur naturally as the free metal (Kobayashi et al, 2002). There are many applications of Aluminum in our daily life, such as construction machinery, aircraft construction, ship construction, home furnishing and electronics component. For the vehicle industry, Aluminum has established a worldwide position because of its advantages over the other competitive materials, like light weight, providing exceptional unit strengths (strength/density ratio), high corrosion resistance, low maintenance costs, good temperature resistance (even in arctic environments), ductile, easily joined by all commercial processes such as welding, brazing, or soldering, at the last, aluminum can be easily formed by all common processes, including extrusion (a major advantage) and can be recycled.
We used a small specimen cut from the metal to be examined. To be able to see the structure clearly, we first cleaned and polished the specimen. First we start polishing with emery paper no: 1 and some finer grades. One should be careful about the coarse abrasive particles and striations from them. Cleaning and rotating the specimen 90° during the transfer can prevent these. The next step is polishing, yet washing the sample before polishing gives a more successful result. Finally, we polished the specimen on a rotating cloth covered with an effective abrasive like Al2O3-Water suspension. We kept polishing until we obtained a mirror like face.
Usually Melting processes are done into the Furnace. In Furnace Raw material is converted into molten Metal.
Tullmin, M. (2003). Corrosion Monitoring and Control - History. Retrieved 04 04, 2010, from Corrosion Club: http://www.corrosion-club.com/historyhome.htm
these steel are useful for application requirering maximum wear and abrasion resistance. They are deep hardening alloys suitable for sever characterized by fatigue , abrasion, impact , high temperature stresses or combination of such condition in small and large section. This steel is available hot and cold rolled sheet and strip , hot rolled and cold finished bar , cold heading quality , aircraft quality and premium aircraft quality bar and seamless tube . they are used for small gears , pinion , ball studs , high strength belt , cap screws , socket , recessed head screw which can be heat treated after machining and forming
Nickel: Nickel increases strength to a modest extent but reduces ductility. The addition of nickel imparts resistance to softening at higher temperature but gives poor casting and machining characteristics. The addition of nickel to Al-Cu and Al-Si type alloy system improves hardness and strength at elevated temperature. It improves resistance to corrosion in powder metallurgy products.
The Continuous Casting is a highly efficient manufacturing process, whereby molten metal is solidified into long, semi-finished shapes with constant cross section for subsequent processing in the finishing mills. Every year around 1 billion tons of steel, 20 million tons of aluminium and over 1 million tons of nickel, copper and other metals are produced all over the world in this manner. Continuous casting is distinguished from other solidification processes by its “steady state” appearance. That is, the molten metal freezes against the mould walls and is withdrawn from the bottom of the mould at a rate which keeps the solid / liquid interface at a constant position with time, relative to an outside observer. The