Nickel Smelter Research Articles

Ore Composition’s Impact on Smelting Profitability: An Optimum Pricing Index Model for Long-Term Nickel Ore Feedstock Purchasing Agreements

Global Nickel (Ni) smelters’ have been experiencing profit losses for nearly a decade due to the 2008 recession still impacting the industry, oversupply, and fluctuating ore quality. This paper proposes to aid the Ni smelters with the lattermost issue, presenting an optimum pricing index model for purchasing raw Ni ore materials. The model is developed using data from a major Ni smelter in operation in Korea, including parameters such as revenues, investment expenses, and ore purchasing costs and the impact Ni and Iron (Fe) content variation has on them. In contrast, existing published Ni price forecasting models are based on external variables (e.g., GDP) and are intended for profit forecasting versus contractual agreements. In executing a Monte-Carlo simulation of 1000 possible life-cycle costs analysis with and without the use of the proposed model, the model increased the likelihood of the smelter earning a profit by approximately 5% with an average approximate increase of $50 million. As such, the proposed index model provides new Ni and nonferrous metals smelters material quality fluctuation risk mitigation. Although this model is presented for the Ni smelting process, the findings could theoretically be applied to any long-term procurement activity with variable quality and market conditions.

An optimization framework for scheduling of converter aisle operation in a nickel smelting plant

The scheduling of converter aisle operation in a nickel smelting plant is a complex task with significant ramifications to plant profitability and production. An optimization-based scheduling formulation is developed using a continuous-time paradigm to accurately represent event timings. The formulation accounts for environmental restrictions on sulfur dioxide emissions, using event timing constraints. Flash furnaces are characterized by a continuous inlet flow and intermittent, discrete material removal, which is captured via novel semi-continuous modeling. An innovative sequencing and symmetry-breaking scheme is introduced to exploit identical units operating in parallel. A rolling horizon feature is included to accommodate real-time optimization. Tightening constraints are developed to improve the computational performance. A unique, multi-tiered procedure enhances the practicality of the solution and supports additional operability objectives, without compromising the optimality of the primary objective. The success of the approach is demonstrated via case studies arising from industrial production scenarios.

Biogeochemistry of Cadmium: Anthropogenic Dispersion, Bioaccumulation, and Ecotoxicity

The article considers biogeochemical features of cadmium as one of the most dangerous elements. Data on its concentrations in waters of small lakes in the European Russia (from the tundra to deserts) and large river systems (Volga, Severnaya Dvina, Pechora) are given. It is shown that, despite the relatively low concentrations of the element in waters, its enrichment factor is hundreds and thousands of units, especially in the northern regions and regions subjected to the influence of non-ferrous metallurgy. Data are presented on the bioaccumulation of cadmium within fish body systems, which is determined by the concentration of the element in waters, as well as by the water pH and the calcium content. It is proved that the highest Cd concentrations are accumulated in kidneys and liver of whitefish and salmon, causing pathological disturbances. Data are reported on the accumulation of cadmium in kidneys and liver of human population of the industrially developed Northern region under impacts of copper–nickel smelters. The similarity in tendencies of the Cd accumulation and pathological disturbances in fish and the population consuming water from contaminated sources makes it possible to recommend fish as a bioindicator of the environmental pollution by cadmium.

Manufacture of Nickel Collimator for BNCT: Smelting of Nickel Using Electrical Arc Furnace and Centrifugal Casting Preparation

Collimator is a tube that functions to direct neutrons generated by a nuclear reactor for BNCT (Boron Neutron Capture Therapy Cancer). Appropriate design of the collimator for BNCT application is a tube with an inner diameter of 16 cm, an outer diameter of 19 cm and a length of 13 cm total with 12 pieces with nickel purity above 95%. Manufacturing of the BNCT collimator will be planned using centrifugal casting method and smelting of nickel with electrical arc (EA) furnace. This article reports on the smelting process of nickel, setting the parameters of the electrical arc furnace, and the chemical composition of the nickel. Results of the study show that nickel with purity 98% can be melted perfectly using the EA Furnace with a current of 600-800 A and a pouring temperature of 1600°C. The fluidity of nickel can hold up to 1 minute at a 35°C environment that allows for the centrifugal casting process. The chemical composition of the nickel before being melted is Ni (98.89%), Si (0.79%), S (0.17%), and Fe (0.15%) and after being melted is Ni (97.89%), Si (0.92%), S (0.26%), and Fe (0.90%). The chemical composition of the nickel after smelting in an EA Furnace meets the requirements of BNCT collimator.

Experimental investigation and thermodynamic re-assessment of the ternary copper-nickel-lead system

Due to their high corrosion resistance and thermal stability, Cu-Ni-alloys have essential role in many materials engineering applications. Lead is an alloying element in these alloys although it may also be considered as an impurity in certain cases. In copper rich alloys, lead tends to diffuse into the grain boundaries and weaken the hot-working properties. In addition to alloys design, accurate knowledge of phase relations and solubilities in the ternary Cu-Ni-Pb system has important role in improving the copper and nickel smelting and refining processes.In the present work, an isothermal equilibration technique was used to measure the mutual solubilities of liquid lead and solid CuNi foil in the temperature range 1280–1530 K. The samples were equilibrated and an Inductively Coupled Plasma Atomic Emission Spectrometer (ICP-AES) and an Electron Probe Micro Analyzer (EPMA) were used to quantify the chemical composition of the phases. Selected solubility data obtained in this work were combined with the literature data to obtain a thermodynamic description of the Cu-Ni-Pb ternary liquid and fcc solid solution phases by applying the CALPHAD method. The ternary assessment agrees well with the experimental observations in this work.

Multivariate Mapping of Heavy Metals Spatial Contamination in a Cu–Ni Exploration Field (Botswana) Using Turning Bands Co-simulation Algorithm

With a mining-driven economy, Botswana has experienced increased geochemical exploration of minerals around existing mining towns. The mining and smelting of copper and nickel around Selibe-Phikwe in the Central Province are capable of releasing heavy metals including Pb, Fe, Mn, Co, Ni and Cu into the soil environments, thereby exposing humans, plants and animals to health risks. In this study, turning bands co-simulation, a multivariate geostatistical algorithm, was presented as a tool for spatial uncertainty quantification and probability mapping of cross-correlated heavy metals (Co, Mn, Fe and Pb) risk assessment in a semiarid Cu–Ni exploration field of Botswana. A total of 1050 soil samples were collected across the field at a depth of ~ 10 cm in a grid sampling design. Rapid elemental concentration analysis was done using an Olympus Delta Sigma portable X-ray fluorescence device. Enrichment factor, geoaccumulation index and pollution load index were used to assess the potential risk of heavy metals contamination in soils. The partially heterotopic nature of the dataset and strong correlations among the heavy metals favors the use of co-simulation instead of independent simulation in the probability mapping of heavy metal risks in the study area. The strong correlation of Co and Mn to iron infers they are of lithogenic origin, unlike Pb which had weak correlation pointing to its source in the area being of anthropogenic source. Manganese, Co and Fe show low enrichment, whereas Pb had high enrichment suggesting possible lead pollution. We, however, recommend that speciation of Pb in the soils rather than total concentration should be ascertained to infer chances of possible bioaccumulation, and subsequent health risk to human by chronic exposure.

The Price of the Arctic

This review explores the relevance of environmental and historical environmental research in Russia, focusing on Andy Bruno’s The Nature of Soviet Power. An Arctic Environmental History as a complex study of environmental changes in the Kola Peninsula, and, more particularly, of such projects as the construction of a railway, the mining and enrichment of apatite, the smelting of nickel and copper, the construction and operation of thermal, hydroelectric, and nuclear power plants, etc. While stating that the book contains a great many facts, the reviewer emphasises that what is more important about this research is its analytical approach, generalisations, and a hypothesis that regards nature as an active participant in the Soviet project. The book consists of several essays about Arctic nature management which provide a detailed description of the development and practical application of the idea of the conquest of nature, crucial for the Soviet era and still topical today.

Impact of an iron mine and a nickel smelter at the Norwegian/Russian border close to the Barents Sea on surface soil magnetic susceptibility and content of potentially toxic elements

An important problem in soil magnetometry is unraveling the soil contamination signal in areas with multiple emitters. Here, geophysical and geochemical measurements were performed at four sites on a north - south transect along the Pasvik River in the Barents Region (northern Norway). These sites are influenced by depositions from the Bjørnevatn iron mine and a Ni-Cu smelter in Nikel, Russia. To relate the degree and type of pollution from these sources to the corresponding magnetic signal, the topsoil concentrations of 12 Potentially Toxic Elements (PTEs) (As, Cd, Co, Cr, Cu, Fe, Mo, Ni, Pb, Se, Ti, Zn), were determined, magnetic hysteresis parameters and thermomagnetic properties were measured. In situ magnetic low-field susceptibility decreases from north to south with increasing distance from the iron mine. Relatively large magnetic multidomain grains of magnetite and/or titanomagnetite are responsible for the strong magnetic signal from the topsoil close to Bjørnevatn. These particles are related to increased enrichment factors of As, Mo and Cu, yielding high positive correlation coefficients with susceptibility values. At a site furthest away from the iron mine and located 7 km from the Ni-Cu smelter magnetic susceptibility values are much lower but significant positive correlations on the level of p < .1 with 8 PTEs (Ni, Cu, Co, Se, As, Zn, Cd, Cr) have been observed. The magnetic signal in this area is due to fine-grained primary sulphides and secondary fine-grained magnetite and/or maghemite.

Optimization and microstructure study of the reduction of nickel smelting slag mixed with calcium carbide slag and coke dust for recovering iron

How to treat more industrial solid waste friendly and environmental have become the global issues. In this study, direct reduction-magnetic separation (DRMS) process was employed to recovery iron from the nickel smelting slag (NSS) with calcium carbide slag (CCS) as the additive and coke dust (CD) as the reductant. Response surface methodology (RSM) approach using central composite design (CCD) was adopted for optimizing the effects of reduction temperature, reduction time and CCS dosage on the iron content of iron concentrate powder (ICP) and iron recovery. The results were modeled and the impact factors were evaluated. All the plots show that there were positive correlations between investigated impact factors and responses in a certain range but if exceeded, the positive correlations would be broken down. The overall optimization reaction conditions were converged as around 1287 oC, 2.8 h and CCS dosage of 57.19 %. Under these proven optimization reaction conditions, the iron content of ICP and iron recovery were reached up to 91.30 % and 95.44 % respectively. The micro phase of reduced samples were investigated by X-ray diffraction analysis (XRD), in reduction process, and the microstructure of reduced samples under the optimal condition were investigated by SEM for further discussion and analyzation. The experimental results and microstructure analysis suggests that utilizing CCS and CD in DRMS process were viable.

New Slag for Nickel Matte Smelting Process and Subsequent Fe Extraction

Large quantities of residual slag with high Fe content are left behind in pyrometallurgical nickel processing. How to separate and recover iron from the high fayalite residue is still a problem because iron mainly exists as iron-magnesium silicate in slag. This article suggests that the slag for nickel smelting is adjusted by increasing the amount of lime, partly instead of quartz, to form liable reduction compounds for subsequent Fe extraction. Based on the thermodynamic analysis and phase diagram of the FeO-SiO2-CaO-MgO slag system, the new slag composition was chosen, the suitable melting point of relevant slags was measured, and the phase change was observed. The new slag with a composition of 7 to 9 pct MgO, 10 to 15 pct CaO and 1.5 to 1.8 Fe/SiO2 was found to work well for nickel matte smelting. With the increase of CaO and decrease of SiO2 content in slag, Ca(Fe, Mg)Si2O6 and Mg(Ca)Fe2O4 are the main existing phases instead of (Fe, Mg)2SiO4 in the residual smelting slag. More than 50 pct of Fe-containing phases are in the form of MgFe2O4 when 15 pct CaO is added, which is what we want because the MgFe2O4 is much better for magnetic separation and reduction than the original (Fe, Mg)2SiO4. In this way, Fe can be much more easily extracted from residual slag and have multipurpose benefits.

The Integration of Plant Sample Analysis, Laboratory Studies, and Thermodynamic Modeling to Predict Slag-Matte Equilibria in Nickel Sulfide Converting

The Kalgoorlie Nickel Smelter (KNS) produces low Fe, low Cu nickel matte in its Peirce–Smith converter operations. To inform process development in the plant, new fundamental data are required on the effect of CaO in slag on the distribution of arsenic between slag and matte. A combination of plant sample analysis, high-temperature laboratory experiments, and thermodynamic modeling was carried out to identify process conditions in the converter and to investigate the effect of slag composition on the chemical behavior of the system. The high-temperature experiments involved re-equilibration of industrial matte-slag-lime samples at 1498 K (1225 °C) and P(SO2) = 0.12 atm on a magnetite/quartz substrate, rapid quenching in water, and direct measurement of phase compositions using electron probe X-ray microanalysis (EPMA) and laser ablation–inductively coupled plasma–mass spectrometry (LA-ICP-MS). A private thermodynamic database for the Ca-Cu-Fe-Mg-Ni-O-S-Si-(As) system was used together with the FactSage software package to assist in the analysis. Thermodynamic predictions combined with plant sample characterization and the present experimental data provide a quantitative basis for the analysis of the effect of CaO fluxing on the slag-matte thermochemistry during nickel sulfide converting, in particular on the spinel liquidus and the distribution of elements between slag and matte as a function of CaO addition.

Behavioral interventions to reduce nickel exposure in a nickel processing plant

ABSTRACTNickel is a widely-used material in many industries. Although there is enough evidence that occupational exposure to nickel may cause respiratory illnesses, allergies, and even cancer, it is not possible to stop the use of nickel in occupational settings. Nickel exposure, however, can be controlled and reduced significantly in workplaces.The main objective of this study was to assess if educational intervention of hygiene behavior could reduce nickel exposure among Indonesian nickel smelter workers. Participants were randomly assigned to three intervention groups (n = 99). Group one (n = 35) received only an educational booklet about nickel, related potential health effects and preventive measures, group two (n = 35) attended a presentation in addition to the booklet, and group three (n = 29) received personal feedback on their biomarker results in addition to the booklet and presentations. Pre- and post-intervention air sampling was conducted to measure concentrations of dust and nickel in air along with worker's blood and urine nickel concentrations. The study did not measure significant differences in particles and nickel concentrations in the air between pre- and post-interventions. However, we achieved significant reductions in the post intervention urine and blood nickel concentrations which can be attributed to changes in personal hygiene behavior. The median urinary nickel concentration in the pre-intervention period for group one was 52.3 µg/L, for group two 57.4 µg/L, and group three 43.2 µg/L which were significantly higher (p< = 0.010) than those measured in the post-intervention period for each of the groups with 8.5 µg/L, 9.6 µg/L, and 8.2 µg/L, respectively. A similar pattern was recorded for serum nickel with significantly (p < 0.05) higher median concentrations measured in the pre-intervention period for group one 1.7 µg/L, and 2.0 µg/L for group 2 and group 3 compared with the post intervention median serum nickel levels of 0.1 µg/L for all groups.The study showed that educational interventions can significantly reduce personal exposure levels to nickel among Indonesian nickel smelter workers.

Influence of emission from copper–nickel smelters on the chemical composition of lake water: Acidification forecast

The influence of the emission of sulfur dioxide and solid substances from Pechenganickel and Severonickel copper–nickel combines (Murmansk oblast) on the chemical compositions of lake water and the development of acidification is analyzed. The temporal dynamics of ∼100 lakes, studied in 1990, 1995, 2000, 2005, 2009, and the response of the chemical composition of the lake water to the impact of acid-forming substances depending on the load level (the distance of combines), geologically controlled sensitivity of catchment areas of the lakes studied to acid deposition, and the lake areas is discussed. The likely further changes in sulfate concentration and pH value in the lake water under the scenarios of increase/decrease of sulfur dioxide emissions from smelter are estimated.

Polluted environment does not speed up age-related change in reproductive performance of the Pied Flycatcher

Environmental pollution can exacerbate deterioration in fecundity with advancing age, directly via the toxic effects of pollutants or indirectly via pollution-related resource (e.g. dietary antioxidants) constraints. Since there are very few studies on age-related changes in reproduction with regard to pollution, we analyzed a long-term (25 years) set of reproduction data from a small insectivorous and migratory passerine bird, the Pied Flycatcher Ficedula hypoleuca, to determine whether female birds showed a faster age-related decrease in average breeding parameters in a metal-polluted area around a copper–nickel smelter than in the control area. In our population-level analysis, all the breeding parameters (clutch size, hatching success, fledging probability, and fledgling number) were lower in the polluted area. Nevertheless, none of them indicated a faster decrease with age in the polluted area. Clutch size and fledgling number increased after the first breeding, but showed no significant change later on. Hatching probability decreased slightly after the second breeding, while fledging probability showed no significant age-dependent variation. Our results suggest that moderate long-term pollution does not reduce the viability of our study population via a faster age-related decrease in fecundity.

Zinc bioaccumulation by microbial consortium isolated from nickel smelter sludge disposal site

AbstractHeavy metal pollution is one of the most important environmental issues of today. Bioremediation by microorganisms is one of technologies extensively used for pollution treatment. In this study, we investigated the heavy metal resistance and zinc bioaccumulation by microbial consortium isolated from nickel sludge disposal site near Sereď (Slovakia). The composition of consortium was analyzed based on MALDI-TOF MS of cultivable bacteria and we have shown that the consortium was dominated by bacteria of genus Arthrobacter. While consortium showed very good growth in the zinc presence, it was able to remove only 15 % of zinc from liquid media. Selected members of consortia have shown lower growth rates in the zinc presence but selected isolates have shown much higher bioaccumulation abilities compared to whole consortium (up to 90 % of zinc removal for NH1 strain). Bioremediation is frequently accelerated through injection of native microbiota into a contaminated area. Based on data obtained in this study, we can conclude that careful selection of native microbiota could lead to the identification of bacteria with increased bioaccumulation abilities.

Urban geochemistry in Kristiansand, Norway

Kristiansand is one of the participating cities in the European URGE project (URban GEochemistry) that aims to map potentially toxic elements (PTEs) in the soil of European cities, identify sources of contamination, use health-based criteria for classification and cooperate with the local health authorities. For more than a century a metallurgical industry, including a large nickel smelter, was in operation in Kristiansand City. Despite the long industrial history of the Ni smelter, elevated Ni values (contaminated 200–<1200mg/kg) in the surface soil (0–10cm) are only found in a radius of <1.5km from the smelter and no samples within this zone are classified as extremely contaminated (120–<2500mg/kg). Moderately elevated Ni-values (60–<135mg/kg) are interpreted as natural elevated concentrations, and are ascribed to the local sulphide-bearing bands occurring within the banded gneiss that dominates the bedrock of Kristiansand. The general scarcity of easily accessible moraine and gravel in the Agder province and Kristiansand municipality has traditionally resulted in extensive reuse of urban soil, which might be reflected in some of the hot spots of PTEs in the suburban areas. None of the 300 samples collected in the area are above the Norwegian uncontaminated to moderately contaminated classification regarding Hg (1–<2mg/kg) and Cd (1.5–<10mg/kg). In general, the urban soil quality in Kristiansand is good and represents no hazard to human health. An exception is the residential areas close to the Ni smelter that are characterised by elevated values of As, Cu, Ni and Pb. Precaution has to be taken when old wooden houses are renovated to avoid the generation of new contamination of local soil and discharge to the Kristiansand fjord of PTEs that are in house paint.

Dynamic Modeling System for Analysis Smelter Development Plan in National Baluran Park, Situbondo

This Studies in several countries, the waste from the nickel smelter cause adverse effects on the environment, which indirectly affect the economy condition. Plan development of Nickel smelter which is directly adjacent to the national park Baluran in Situbondo quite disturbing some people. National park has a beach about 48 km long with a stretch of coral reef 5-10 meters out to sea into creating high productivity in these waters, especially various types of reef fish such as grouper. The highest numbers of catches are in district Banyuputih where the glaze was located 1734.65 tons in 2011, followed by the District Besuki with catches of 964.20 tons. In general activities in the nickel smelting are result some waste such as heavy metals such as Cu, Fe, Zn, Mn, waste heat from cooling water and wastewater canal SO2. Heavy metals and waste heatare potential adverse impact on the coral reefs, fish capture fisheries and the other marine commodities. While waste SO2 causes acid rain damage potential plant of agriculture, fisheries not only in the park but it could be damaging crops in the National Park that have an effect on the scenery, the number of visitors, and reduce operating revenues derived from the national park. We use the concept of gaming between actors to estimate the associated policy goal of this smelter. As for observing the behavior of the system over the next 10-30 years used the dynamics modeling system with 3 scenarios. Optimist scenario(there is Green smelter), excisting scenario(Condition without smelter) and pessimist scenario(there is non green smelter).

Landfill Waste from the Production of Nickel and Cobalt in the Slovak Republic

The complex of the former Nickel smelter is located in the Podunajská rovina (Danubian plane) on the border Sereď town and village Dolná Streda. The landfill presents a highly negative hazardous element for environment and quality of life. It is a very anthropogenic damaged area which is located in the agrarian landscape. Some parts of the areas of the agricultural soils were from the fund of the agricultural soils excluded. Degradation of the region is the result of the non-conceptual socialist industrialization of Slovakia. After 30 years was stopped the production of nickel and cobalt (1963-1993) for economic and ecological reasons. Waste from production of nickel and cobalt remained here and degrades the environment in nowadays. Today is the landfill of waste a private property and owner exports the waste to foreign countries.

Cancer incidence among copper smelting and nickel refining workers in Finland.

Among workers employed at a nickel refinery in Harjavalta, Finland an increased risk of lung and sinus cancer has been demonstrated in two previous studies. The current study adds 16 more years of follow-up to these studies. A total of 1,115 persons exposed to nickel and 194 non-exposed workers in the Harjavalta nickel smelter and refinery were followed up for cancer from 1967 to 2011 through the Finnish Cancer Registry. The total number of cancer cases in men was 251 (Standardized incidence ratio (SIR) 1.05) and in women 12 (SIR 1.22). In the most nickel-exposed work site (refinery), there were 14 lung cancers (SIR 2.01) and 3 sinonasal cancers (SIR 26.7, 95%). It is likely that exposure to nickel compounds is the main reason for elevated nasal cancer risk among the nickel refinery employees and may also contribute to the excess risk of lung cancer. Am. J. Ind. Med. 60:87-95, 2017. © 2016 Wiley Periodicals, Inc.

MTDATA and the Prediction of Phase Equilibria in Oxide Systems: 30 Years of Industrial Collaboration

This paper gives an introduction to MTDATA, Phase Equilibrium Software from the National Physical Laboratory (NPL), and describes the latest advances in the development of a comprehensive database of thermodynamic parameters to underpin calculations of phase equilibria in large oxide, sulfide, and fluoride systems of industrial interest. The database, MTOX, has been developed over a period of thirty years based upon modeling work at NPL and funded by industrial partners in a project co-ordinated by Mineral Industry Research Organisation. Applications drawn from the fields of modern copper scrap smelting, high-temperature behavior of basic oxygen steelmaking slags, flash smelting of nickel, electric furnace smelting of ilmenite, and production of pure TiO2via a low-temperature molten salt route are discussed along with calculations to assess the impact of impurities on the uncertainty of fixed points used to realize the SI unit of temperature, the kelvin.