Abstract: A method and apparatus are provided for making high purity and preferably oxygen free substantially void free and inclusion free copper castings such as billets from high purity copper. The castings are particularly useful to make sputtering targets used in sputtering deposition processes in the fabrication of electronic components. The method comprises melting high purity copper in a covered crucible using a non-contaminating heating source such as a coil induction furnace. The melted copper in the crucible is solidified using a specially controlled cooling procedure wherein the bottom of the crucible is cooled so that molten copper is maintained on top of solidified and solidifying copper until the copper is solidified.

Abstract: Wrought copper cathode starting sheets for use in the electrolytic production of copper made preferably by a continuous casting and rolling process are provided. Refined copper is melted in a shaft furnace and continuously cast preferably using a twin belt horizontal caster and straight line rolled to reduce the thickness of the casting by about 25% to 98% to produce a sheet having a thickness up to about 0.123 inch. The continuous sheet is cut after the rolling process from uncoiled sheet into discrete rectangular shapes suitable for use as a starting sheet, as a starting sheet blank or other metal sheet uses such as cladding and roofing.

Abstract: A method is disclosed for improving the making of metals such as steel and copper by using a molten metal gas measurement system to measure the gas content of the molten metal particularly H.sub.2 content, and to controlling the metal making process based on the gas content value. The preferred gas analyzer comprises an improved long lasting immersion probe body and an analyzer wherein the probe body is immersed in the molten metal and a carrier gas is cycled through the probe and analyzer. The carrier gas entrains gases diffusing into or formed in the probe body and this gas mixture is electronically compared with a reference value to provide a measurement of the gases in the molten metal and the process is controlled based on the analyzer results. Another important use of the gas analyzer is in molten metal degassing operations such as used in the steel industry.

Abstract: Wrought copper cathode starting sheets for use in the electrolytic production of copper made preferably by a continuous casting and rolling process are provided. Refined copper is melted in a shaft furnace and continuously cast preferably using a twin belt horizontal caster and straight line rolled to reduce the thickness of the casting by about 25% to 98% to produce a sheet having a thickness up to about 0.123 inch. The continuous sheet is cut after the rolling process from uncoiled sheet into discrete rectangular shapes suitable for use as a starting sheet, as a starting sheet blank or other metal sheet uses such as cladding and roofing.

Abstract: A method is provided for the hydrometallurgical recovery of metal values from metal sources containing more than one metal such as antimony, lead, copper, zinc, bismuth, tin, cadmium and other metals by leaching the metal containing source with a ferric fluoborate/fluoboric acid solution to provide a metal containing leach solution. The leach solution is extracted with organic extractants, ion exchange resins and the like to provide a loaded extract and a raffinate which contains fluoboric acid produced in the extraction step. The fluoboric acid concentration is controlled (reduced) in the raffinate by adding to the raffinate a metal oxide of a metal in the raffinate to form an acid adjusted raffinate. The acid adjusted raffinate is then electrowon or otherwise treated to form the desired metal and to provide a ferric fluoborate solution which is recycled for leaching additional metal containing material.

Abstract: A method for improving the making of metals such as steel and copper by specially using a gas measurement system to analyze molten metals for gas, particularly H2 content, and to controlling the metal making process based on these values. The preferred gas analyzer comprises a hollow probe and an analyzer wherein the probe is immersed in the molten metal and a carrier gas containing a reducing gas such as CO is cycled through the probe and analyzer. The carrier gas entrains gases in the probe and this gas mixture is electronically compared with a reference value to provide a measurement of the gases in the molten metal and the process is controlled based on the analyzer results.

Abstract: An improved method and apparatus is provided for the production of copper using a solvent extraction electrowinning process. Process streams formed during the process containing entrained liquids are fed to a cyclone to remove either organic extractant or water (aqueous solutions) from the stream. A raffinate stream fed to a cyclone removes entrained organic phase which organic phase may be recycled to the process. The separated raffinate stream would then typically be recycled to the copper ore leach step to form a pregnant leach solution without the loss of organic solvent and/or the environmental concerns associated with entrained solvent. In a preferred new process, mixers, preferably inline, are used in conjunction with cyclones to provide a solvent extraction electrowinning process which is continuous and efficient and the use of conventional mixers, and particularly settlers, are eliminated.

Abstract: A method is provided for banding copper cathodes which is efficient and cost effective using a system comprising stacking the cathodes, moving the stacked cathodes on a conveyor belt, weighing the stack, identifying the stack by a bar code or other identification means, pressing the stack to align the cathodes, banding the stack and then removing the banded stack from the system. A control system is also provided whereby predetermined stack and method parameters are compared with stack data obtained by weighing the cathode stack and/or reading a bar code or other identifying indicia associated with the stack to control the system and operate the method.

Abstract: A method is provided for the hydrometallurgical recovery of metal values from sources containing more than one metal of antimony, lead, copper, zinc, bismuth, tin, cadmium and other metals by leaching the metal containing source with a ferric fluoborate/fluroboric acid solution to provide a leachant metal containing solution. The leachant solution is contacted with specific organic extractants such as an organophosphoric acid ester, an alkyl salicylaldoxime and an amidobis(thiophosphoryl) compound in a series of extraction steps to separate metals based on the extractant used. The organic extractant solution is stripped of the extracted metal(s) and the metal(s) recovered. The remaining leach solution after extraction being either further treated to extract other metals or processed to provide metal values contained therein.

Abstract: Machinable lead free brasses for potable water applications are provided wherein a combination of bismuth and selenium are substituted in the alloy for lead and the bismuth and selenium are added to the alloy in the form of an additive product comprising bismuth selenide. A method of making the brasses which meets environmental and safety regulations is also provided. The bismuth selenide is preferably made by sintering particles of bismuth and selenium in a Bi/Se weight ratio of about 1.8 or greater and fusing the sinter.

Abstract: A method is provided for producing bismuth and bismuth alloy shot particles by a procedure whereby molten bismuth at a temperature less than about 100.degree. C. above the melting point of the bismuth is used to form drops of molten bismuth which fall through a vessel containing a material more viscous than water with the method having a Reynolds Number less than about 100. Preferred materials are polyethylene glycols having a molecular weight of about 4500 and 8000.

Abstract: A method is disclosed for improving the continuous casting process for making copper by using a probe and analyzer which measures the gases present in the molten copper and controls the process based on the analyzer results.

Abstract: A new environmentally safe fire refining precious metal assay method is provided wherein bismuth oxide is used with a special flux composition as the precious metal collector and the cupelling procedure is performed in a controlled temperature range.

Abstract: A method and apparatus are disclosed for producing copper wire by electrolytically engrossing a copper starting wire. Basically the invention utilizes an electrolytic tank employing a pair or pairs of shafts positioned externally of the tank upon which a minimum of one but generally at least two starting wires are transported on each pair for transfer of the wires through the tank. Multiple tanks, e.g., 10 to 1000 or more, may be used in a single facility for refining or electrowinning processes depending on the quantity of copper wire desired to be produced.

Abstract: A method is disclosed for melting copper without incorporating unwanted oxygen and/or hydrogen into the copper by effectively controlling the burners used to melt the copper within desired fuel/air ratio operating limits by employing a special fuel/air mixture sampling and control system.

Abstract: An improved process for deleading debismuthized dross is provided wherein the upgraded dross is treated by cupellation to form a slag until the level of bismuth in the upgraded dross reaches about 45% by weight. After cupellation, the partially deleaded upgraded dross may be treated by conventional means such as halogenation to provide a substantially pure bismuth product.

Abstract: Bismuth impurity is removed from copper electrolyte by contacting the electrolyte with an effective amount of finely divided lead oxide.

Abstract: Fume generated by roasting speiss is contacted with an oxygen-containing gas at an elevated temperature for a sufficient time to product arsenic and antimony products which may be separated from each other by means such as condensation. Further, in the roasting of antimony-containing phases (such as speiss) the presence of arsenic can enhance the volatility of the antimony.

Abstract: Continuous casting of discrete solid shapes from a molten material using modified continuous casting machines and processes are disclosed. In a conventional twin belt continuous caster, for example, forming means such as dividers are employed on the upper belt to define a mold cavity in the casting region of the machine. Different size and shape forming means may be used to provide a variety of cast products.

Abstract: The invention relates to a method and apparatus for electrolytic refining of copper and the production of copper wires for electrical purposes on a continual basis which produces round copper wires directly from impure copper anodes and to treat such wires in order to impart the desired characteristics as electrical conductors. The apparatus handles copper anodes of customary size refining them at normal current densities of less than 55 amps/foot.sup.2 onto starting wires of adequate tensile strength which is done continuously, the wire being provided to an electrolytic bath and, after withdrawal from the bath, the wires are finished by drawing and annealing.