NEW DIRECTIONS IN MINERAL PROCESSING, EXTRACTIVE METALLURGY, RECYCLING AND WASTE MINIMIZATION: An EPD Symposium in Honor of Patrick R. Taylor EDITED BY Ramana G. Reddy Alexandra Anderson | Corby G. Anderson Camille Fleuriault | Erik D. Spiller | Mark Strauss Edgar E. Vidal | Mingming Zhang The Minerals, Metals & Materials Series · · Ramana G. Reddy Alexandra Anderson · · Corby G. Anderson Camille Fleuriault · · · Erik D. Spiller Mark Strauss Edgar E. Vidal Mingming Zhang Editors New Directions in Mineral Processing, Extractive Metallurgy, Recycling and Waste Minimization An EPD Symposium in Honor of Patrick R. Taylor Editors RamanaG.Reddy AlexandraAnderson TheUniversityofAlabama GopherResource Tuscaloosa,AL,USA Tampa,FL,USA CorbyG.Anderson CamilleFleuriault ColoradoSchoolofMines ErametNorway Golden,CO,USA Sauda,Norway ErikD.Spiller MarkStrauss ColoradoSchoolofMines AquaMetals Golden,CO,USA Reno,NV,USA EdgarE.Vidal MingmingZhang NobelClad BaowuOuyeel Broomfield,CO,USA Shanghai,China ISSN 2367-1181 ISSN 2367-1696 (electronic) TheMinerals,Metals&MaterialsSeries ISBN 978-3-031-22764-6 ISBN 978-3-031-22765-3 (eBook) https://doi.org/10.1007/978-3-031-22765-3 ©TheMinerals,Metals&MaterialsSociety2023 Thisworkissubjecttocopyright.AllrightsaresolelyandexclusivelylicensedbythePublisher,whether thewholeorpartofthematerialisconcerned,specificallytherightsoftranslation,reprinting,reuse ofillustrations,recitation,broadcasting,reproductiononmicrofilmsorinanyotherphysicalway,and transmissionorinformationstorageandretrieval,electronicadaptation,computersoftware,orbysimilar ordissimilarmethodologynowknownorhereafterdeveloped. Theuseofgeneraldescriptivenames,registerednames,trademarks,servicemarks,etc.inthispublication doesnotimply,evenintheabsenceofaspecificstatement,thatsuchnamesareexemptfromtherelevant protectivelawsandregulationsandthereforefreeforgeneraluse. Thepublisher,theauthors,andtheeditorsaresafetoassumethattheadviceandinformationinthisbook arebelievedtobetrueandaccurateatthedateofpublication.Neitherthepublishernortheauthorsor theeditorsgiveawarranty,expressedorimplied,withrespecttothematerialcontainedhereinorforany errorsoromissionsthatmayhavebeenmade.Thepublisherremainsneutralwithregardtojurisdictional claimsinpublishedmapsandinstitutionalaffiliations. ThisSpringerimprintispublishedbytheregisteredcompanySpringerNatureSwitzerlandAG Theregisteredcompanyaddressis:Gewerbestrasse11,6330Cham,Switzerland Preface Professor Patrick R. Taylor is the George S. Ansell Endowed Chair Professor of Chemical Metallurgy and Director of the Kroll Institute for Extractive Metallurgy attheColoradoSchoolofMines.HeisanactivememberofTMSandhasover45 yearsofexperienceinmineralprocessing,extractivemetallurgy,recyclingandwaste minimization, engineering, research, teaching, and consulting. He has published numerous papers and given invited presentations in over 13 nations and holds 9 patents.Hehasadvisedandmentoredover100graduatestudentsandpostdoctoral researchassociatesandservedasaconsultantformorethan20companies.Professor Taylor is a Fellow of ASM International and a Distinguished Member (Fellow) of SME.Hehasreceivedseveraloutstandingawardsfromseveralsocietiesandorgani- zationsincludingtheMiltonE.WadsworthAwardfromSME,theEPDDistinguished LecturerAward,theTMSEPDDistinguishedServiceAward,andtheAIMEJames DouglasGoldMedal. To honor Professor Taylor and his vast contributions to extractive metallurgy, The Professor Patrick R. Taylor International symposium titled “New Directions inMineralProcessing,ExtractiveMetallurgy,Recycling,andWasteMinimization” washeldduringtheTMS2023AnnualMeetinginSanDiego,California,USA,from March19-23,2023. The new concepts and fundamentals, update on reactor design and processes, industrial practices and developments, and environmental issues which influence the selection of metallurgical processes are discussed in the scientific papers publishedinthisproceeding.Theseissuesarediscussedrelativetonewdirectionsin pyrometallurgy,hydrometallurgy,electrometallurgy,mineralprocessing,metalsand e-wasterecycling,wasteminimizationandinnovationsinmetallurgicalengineering educationandcurriculumdevelopment. The editors thank the symposium sponsors Society for Mining, Metallurgy & Exploration (SME), TMS Extraction and Processing Division, and its committees of Pyrometallurgy, Hydrometallurgy and Electrometallurgy, Materials Characteri- zation,Energy,andRecyclingandEnvironmentalTechnologies.Wealsothankthe authors forproviding the invaluable scientific and technical information contained v vi Preface in this book, and session chairs for their keen interest and support in making the symposiumasuccess. TheleadorganizerandeditorProfessorRamanaReddywouldliketoacknowledge theassistanceandencouragementofCorbyG.Anderson,ColoradoSchoolofMines, Erik D. Spiller, Colorado School of Mines, Edgar E. Vidal, NobelClad, Camille Fleuriault, Eramet Norway, Alexandra E. Anderson, Gopher Resource, Mingming Zhang,BaowuOuyeel,ChristinaMeskers,SINTEF,andMarkStrauss,AquaMetals, Inc., who were very helpful in numerous areas, particularly in soliciting invited papers,organizingsessions,andreviewingandeditingthemanuscripts. Finally,wethankTMSHeadquarters,particularlyPatriciaWarren,KellyMarkel, TrudiDunlap,andJamesRobinsonwhomadeitpossibletoorganizethesymposium andpublishthepapersinthebookNewDirectionsinMineralProcessing,Extractive Metallurgy, Recycling and Waste Minimization: An EPD Symposium in Honor of PatrickR.Taylor. Dr.RamanaG.Reddy LeadOrganizer Contents DevelopmentofIronmakingTechnologybytheDirectGaseous ReductionofIronConcentrate ...................................... 1 HongYongSohn Evaporation of Phosphorus from FeO-CaO-SiO -P O 2 2 5 SynthesizedSteelmakingSlagbyCarbothermicReduction ............ 15 HuafangYu,MikiTakahiro,YasushiSasaki,andTetsuyaNagasaka LeadBleed-OfffromDustofCopperSmelter ........................ 23 KifuMatsuura,SatoshiShibata,andFumitoTanaka Simulation and Post-mortem Studies: The Holistic Approach forOptimizedandEngineeredLiningConcepts ...................... 33 D.Gregurek,G.Unterreiter,C.Lind,andA.Spanring AKineticDescriptionofPhysico-ChemicalProcessesTakingPlace intheBurdenofHCFeMnSubmergedArcFurnaces ................. 43 AinurNigmetova,BertilFarjaudon,HaoxueHan,AstridHecquet, andGillesNussbaum Lanthanum-Light Metal Alloys Production Using Secondary Resources—ThermodynamicAnalysis ............................... 55 AhmadRizkyRhamdani,M.AkbarRhamdhani,GeoffreyBrooks, MarkI.Pownceby, YudiNugrahaThaha, TrevorB.Abbott, JohnGrandfield,andChrisHartley Selective Chlorination as an Innovative Extraction Method forValuableMetalsfromIronContainingMatrix .................... 65 S.Steinlechner,L.Höber,andK.Witt HighVacuumSolarThermalDissociationforMetalandOxide Extraction ........................................................ 77 M.G.Shaw, G.A.Brooks, M.A.Rhamdhani, A.R.Duffy, andM.I.Pownceby vii viii Contents DevelopmentofaDynamicModelofCollisionandCoalescence forMoltenMatteDropletsinCopperSmeltingReactionShaft ConsideringInterfacialDeformation ................................ 87 YukoGoto,ShungoNatsui,andHiroshiNogami OptionsforSustainingMetallurgicalEngineeringEducation .......... 95 E.JakandP.C.Hayes SeparationofCo(II)OverNi(II)fromChlorideLeachedSolution ofSpentLi-IonBatteriesUsingCyphosIL104 ........................ 107 SadiaIlyas,HyunjungKim,andRajivRanjanSrivastava ResearchandIndustrialApplicationofSeleniumandTellurium RecoveryProcesses ................................................ 117 ShijieWang NickelMatteasNovelReductantinGalvanicLeachingofSpent Lithium-IonBatteryBlackMass .................................... 125 ErikPrasetyoandSulalitBandyopadhyay Recyclability of Proton Exchange Membrane Electrolysers forGreenHydrogenProduction .................................... 137 NawshadHaque,SarbGiddey,SejutiSaha,andPaulSernia Rare Earth and CriticalBaseMetals Electrodeposition Using Urea-CholineChlorideIonicLiquids ................................ 151 RajyashreeLenkaandRamanaG.Reddy EstimatedEnd-of-LifeLithium-IonBatteryResourcesforPotential RecyclinginBangladesh ........................................... 161 Md.RakibulQadir,MiaoChen,NawshadHaque,andWarrenBruckard RecyclingofSpentLithium-IonBatteriesatSwerim .................. 175 XianfengHu,ElsayedMousa,LudvigÅnnhagen,andGuozhuYe ComparisonofHydrogenReductionofDifferentLead-Bearing MaterialsforLeadRecovery ....................................... 187 A.Rukini,M.A.Rhamdhani,G.A.Brooks,andA.VandenBulck SelectiveSeparationandRecoveryofTitaniumfromTitanium AlloyGrindingScrapViatheElectrostaticSeparation-Oxidative Roasting-AcidLeachingProcess .................................... 199 XianglinCheng,ShangfengXu,ZijianSu,andYuanboZhang Investigation of Heavy Metal Levels in Tin Mine Wastes and the Implication to Mine Closure Plan: A Case Study ofRutongoMine,Rwanda .......................................... 209 JeanClaudeIshimwe,AbubakarySalama,andKennethSichone Contents ix ProcessingofLuanshyaCopperSmeltingSlag ....................... 223 YakiChiyokomaNamiluko, YotamuRainfordStephenHara, AgabuShane, MakwendaThelmaNgomba, IreenMusukwa, AlexanderOld,RonaldHara,andRainfordHara SeparationofLiandCofromLiCoO CathodeMaterialThrough 2 AluminothermicReductionUsingDifferentAluminumSources: ChemicalGrade,Swarf,andDross .................................. 233 D.C.Nababan, R.Mukhlis, Y.Durandet, L.Prentice, andM.A.Rhamdhani TowardsFrameworkDevelopment forBenchmarking Energy EfficiencyinFoundationIndustries:ACaseStudyofGranulation Process ........................................................... 245 ShoaibSarfraz,ZiyadSherif,MarkJolly,andKonstantinosSalonitis AlternativeFluxesforLeadBullionRefining ......................... 257 SamuelAsanteandPatrickTaylor Comprehensive Utilization of Copper Slag in a Pyro-Hydrometallurgical Process for Iron Phase ReconstructionandValuableMetalsRecovery ....................... 275 ChangdaZhang,BinHu,MingeYang,GuiqingZhang,ShijieZhao, ZhiqinLiao,QiuxiangLiu,andMingyuWang CriticalReviewofChemicalMetallurgyofTungsten .................. 285 RajP.SinghGaur EfficientExtractionofBismuthinaTwo-StageLeachingProcess fortheRecoveryofZincandLeadfromZinc-RichDust ............... 297 YanLi,HuaixuanFeng,JingsongWang,XuefengShe,KepiaoRen, andQingguoXue EfficientUtilizationofAlloyPowderDuringLimoniticLaterite SinteringProcess .................................................. 311 YikangTu,YuanboZhang,ZijianSu,andTaoJiang ExperimentalStudyonSolubilityofMetalOxidesinNovelDeep EutecticSolventsofCholineChloride-OrganicAcid .................. 321 PengYang,XiaopingLiang,GuodongCui,andChenYang In-Situ Microscopy Observations of Oxide Phases Formation During High-Temperature Oxidation of End-of-Life Ni/Cu/Ni-Coated-NdFeBPermanentMagnets ........................ 331 D.C.Nababan,R.Mukhlis,Y.Durandet,M.I.Pownceby,L.Prentice, andM.A.Rhamdhani Introducing Membrane Percrystallisation Technology forHydrometallurgicalApplications ................................ 343 SitiNurehanAbdJalil,JuliusMotuzas,andJamesVaughan x Contents LeachingofArsenopyriteContainedinTailingsUsingtheTU-OX System ........................................................... 355 ErickJesúsMuñozHernández, AislinnMichelleTejaRuiz, MartinReyesPérez,GabrielCisnerosFlores,MiguelPérezLabra, FranciscoRaúlBarrientosHernández,andJulioCesarJuárezTapia Optimization of Citric Acid Leaching Conditions forZinc-ContainingElectricFurnaceDustBasedonOrthogonal Experiment ....................................................... 365 ZhihuiGuo,ChengboWu,andXuefengBai OptimizationoftheRatioofAirandFuelinIgnitionChamber ofSinteringMachine .............................................. 375 YapengZhang, WenPan, ShaoguoChen, HuaiyingMa, XiaochenZhang,JieLiang,andSidaRen PreparationofSlagWoolFibersUsingCastingResidueSlagBased onGasQuenchingTechnology ...................................... 385 Wen-fengGu,JiangDiao,Jin-AnWang,Wen-FengTan,Hong-YiLi, andBingXie Rare Earth Reduction: A Technological Overview of State-of-the-Art Technology and Novel Developments ..................................................... 393 RobertG.RushandPatrickR.Taylor RecoveryofBismuthinBlastFurnaceDustbyCarbothermal VolatilizationReduction ............................................ 419 HuaixuanFeng,YanLi,JingsongWang,andXuefengShe RecoveryofValuableMetalsfromLi-IonBatteryWasteThrough Carbon and Hydrogen Reduction: Thermodynamic Analysis andExperimentalVerification ...................................... 437 BintangA.Nuraeni, KatriAvarmaa, LeonH.Prentice, W.JohnRankin,andM.AkbarRhamdhani SelectiveExtractionofVanadiumfromSodiumTungstateSolution UsingP507 ........................................................ 449 HanyuWang, GuihongHan, YanfangHuang, ShengpengSu, BingbingLiu,andKunpengShi Solar Thermal Application in Zn/ZnO Recovery from Spent AlkalineBatteries ................................................. 457 ReizaMukhlis, DeddyNababan, AndrewMackenzie, andMuhammadAkbarRhamdhani