Abstract: Processes and methods for refining ferronickel alloy, and producing nickel sulfate or other nickel product, are provided, where the ferronickel alloy is treated with an oxidizing leach. The oxidizing leach may be, for example, a pressure oxidation (POX) leach or a leach with peroxide or copper (II) ions. The treatment may be in the presence of added copper, such as by providing a copper sulfate solution. Producing nickel sulfate may comprise removing copper and iron after the leach, removing impurities, and either crystallizing the nickel sulfate or precipitating/winning another nickel product.

Abstract: A system measures parameters of the electricity drawn by an arc furnace and, based on an analysis of the parameters, provides indicators of whether arc coverage has been optimized. Factors related to optimization of arc coverage include electrode position, charge level, slag level and slag behaviour. More specifically, such indicators of whether arc coverage has been optimized may be used when determining a position for the electrode such that, to an extent possible, a stable arc cavity is maintained and an open arc condition is avoided. Conveniently, by avoiding open arc conditions, the internal linings of the furnace walls and roof may be protected from excessive wear and tear.

Abstract: A configuration of switches added to a line control circuit allows for switching back and forth between a configuration featuring a series-connected thyristor switch and reactor and a configuration featuring a parallel-connected thyristor switch and reactor. Connecting the reactor in series with the thyristor switch allows a controlled high-impedance circuit configuration that is particularly well adapted for cold furnace start-ups and furnace idling. In this manner, there is reduced need for such equipment as extra startup transformers, alternate low-voltage power supply configurations and temporary specialty electrical apparatus for cold furnace start-ups.

Abstract: It is proposed herein to employ thyristor firing angles as a fast prediction of flicker in power supply for an electric arc furnace. It is further proposed to actively modify operating variables for the electric arc furnace to maintain the flicker below a predefined threshold. Aspects of the present application use the thyristor firing angles in combination with control ranges of variable reactance devices to predict the flicker severity level generated by the electric arc furnace with thyristor-controlled variable reactance devices. Based on the predicted flicker level, at least one operating variable of the electric arc furnace may be changed, if required, to maintain flicker to acceptable limit.

Abstract: An electronic device, and a magnetic energy harvesting device and method of harvesting magnetic energy, for electric metallurgical furnaces and similar environments. The device comprises a conductor which is configured to become induced with electricity in response to a time-varying magnetic field. The field may be irregular, such as near a metallurgical furnace or a similar environment. The electronic device may be a transmitter in a metallurgical electric furnace. The transmitter may be connected to an environment sensor. The electronic device may be powered by the magnetic energy harvesting device. The magnetic energy harvesting device may a wire loop or a coil. The method comprises inductively harvesting energy from magnetic field fluctuations caused by a metallurgical furnace or a similar environment to wirelessly power the electronic device.

Abstract: A method of managing a liquid solvent inventory in a condensing solvent gravity drainage extraction chamber includes growing the extraction chamber by injecting a solvent vapour under conditions which cause at least a portion of the solvent vapour to condense on a hydrocarbon extraction interface at a condensation temperature, then accumulating within the extraction chamber condensed liquid solvent which is draining through the chamber under the influence of gravity, which liquid solvent includes a hydrocarbon rich fluid production layer which is proximal to said extraction interface, and then heating a portion of the extraction chamber from a location near, in and/or above the injector to create a heated zone having a temperature above the condensation temperature without heating the hydrocarbon rich production layer to permit the hydrocarbon rich production layer to continue to drain to a production well.

Abstract: A process for generating a metal sulfate that involves crystallizing a metal sulfate from an aqueous solution to form a crystallized metal sulfate in a mother liquor with uncrystallized metal sulfate remaining in the mother liquor; separating the crystallized metal sulfate from the mother liquor; basifying a portion of the mother liquor to convert the uncrystallized metal sulfate to a basic metal salt; and using the basic metal salt upstream of crystallizing the metal sulfate. So crystallized, the generated metal sulfate may be battery-grade or electroplating-grade.

Abstract: An aluminum reduction cell having a shell structure with a pair of longitudinally extending sidewalls, a pair of transversely extending endwalls, a bottom wall, and an open top having an upper edge. The aluminum reduction cell also has a transverse support structure with transverse bottom beams located under the shell structure and extending transversely between the sidewalls, each of the transverse bottom beams having a pair of opposed ends. The aluminium reduction cell also has compliant binding elements fixed to the transverse support structure, each extending vertically along an outer surface of one of the sidewalls for applying an inwardly directed force said sidewall. The compliant binding elements are in the form of cantilever springs. Each spring has a metal member with a lower end which is secured to the transverse support structure, and a compliant, upper free end which is movable inwardly and outwardly in response to expansion and contraction of the shell structure.

Abstract: A method of managing a liquid solvent inventory in a condensing solvent gravity drainage extraction chamber includes growing the extraction chamber by injecting a solvent vapour under conditions which cause at least a portion of the solvent vapour to condense on a hydrocarbon extraction interface at a condensation temperature, then accumulating within the extraction chamber condensed liquid solvent which is draining through the chamber under the influence of gravity, which liquid solvent includes a hydrocarbon rich fluid production layer which is proximal to said extraction interface, and then heating a portion of the extraction chamber from a location near, in and/or above the injector to create a heated zone having a temperature above the condensation temperature without heating the hydrocarbon rich production layer to permit the hydrocarbon rich production layer to continue to drain to a production well.

Abstract: A flexible electrical connector assembly is adapted to connect a bus bar of an electrolytic cell to a collector bar of the electrolytic cell. The assembly includes an electrical connector including a plurality of conductive metal sheets, the electrical connector having a collector bar end and a bus bar end. The electrical connector may be adapted for being joined, at the collector bar end, to the collector bar and, at the bus bar end, to the bus bar. The electrical connector may be adapted to implement a change in direction, at a bend along a current-carrying path between the bus bar end and the collector bar end, the bend assisting to define the change in direction as greater than 90 degrees.

Abstract: A method for determining a length parameter of an electrode during operation of an electric arc furnace. An internal duct extends through the length of the electrode and is open at its lower end. A waveguide having a solid core is received in the internal duct and comprises a material having a low dielectric constant and high temperature resistance. The solid core of the waveguide includes at least one target. An electromagnetic radiation signal is emitted from a source and transmitted through the waveguide and the signal is diffracted and/or reflected from at least one target to produce at least one return signal which is transmitted back through the waveguide. A time or frequency difference between the emitted signal and the return signal is measured and the length parameter is calculated based on this difference.

Abstract: An abrasion-resistant material for the working face of a metallurgical furnace cooling element such as a stave cooler or a tuyere cooler having a body comprised of a first metal. The abrasion-resistant material comprises a macro-composite material including abrasion-resistant particles which are arranged in a substantially repeating, engineered configuration infiltrated with a matrix of a second metal, the particles having a hardness greater than that of the second metal. A cooling element for a metallurgical furnace has a body comprised of the first metal, the body having a facing layer comprising the abrasion-resistant material. A method comprises: positioning the engineered configuration of abrasion-resistant particles in a mold cavity, the engineered configuration located in an area of the mold cavity to define the facing layer; and introducing molten metal into the cavity, the molten metal comprising the first metal of the cooling element body.

Abstract: A system and method for identifying imperfections in a reflective surface. The reflective surface may be a metal coating on a sheet such as in a galvanization process. The system comprises a laser detector. The laser detector may be part of a triangulation unit. The laser detector takes readings corresponding to the angles of travel of diffuse light of a laser off of different portions of the reflective surface. Imperfections in the surface are identified based on variance in the readings. The method comprises detecting diffuse light of a laser beam off of different portions of the reflective surface, and identifying imperfections based on variances in the angles of travel of the diffuse light detected.

Abstract: A reactor comprises an outer sidewall and a bottom wall enclosing a hollow chamber comprising a lower fluidized bed zone and an upper freeboard zone. A plurality of inlets is provided for injecting at least one fluidizing medium into the fluidized bed zone and creating a swirling flow. At least one feed inlet communicates with the fluidized bed zone; and at least one product outlet is provided for removing a product from the chamber, the outlet(s) communicating with either the fluidized bed zone or the freeboard zone. The reactor has at least one internal barrier located inside the hollow chamber, and at least partly located in the fluidized bed zone. The internal barrier(s) have at least one opening within the fluidized bed zone, such as an underflow opening, to permit internal recirculation of material from the product zone to the feed zone, thereby simplifying reactor structure.

Abstract: A measuring apparatus, for measuring the distance to a surface having fluctuating reflectivity, the measuring apparatus comprising, a measuring light source and sensor unit positioned at an angle to the perpendicular of the surface to allow the light to be reflected to a diffuse target surface in a known position; and a processor unit, wherein the processor unit is adapted to collect and analyze data from the a measuring light source and sensor unit and classify whether the reading of the measuring light source and sensor unit is a direct reading or a reflected reading.

Abstract: Supplementary cooling elements in addition to a primary cooling element of a furnace. The supplementary cooling elements, with two or more components, may be inserted from the outside of the furnace into holes that pass through and the primary cooling element such that the cooling elements protrude beyond the inner surface of the primary cooling element. An inner one of the components of the supplementary cooling element may be received by an outer one of the components in a manner that forces the outer component into a thermally conductive pressure connection with the primary cooling element.

Abstract: A process and reactor for arsenic fixation in which a first gas stream comprises oxygen and an iron-containing particulate material. The oxygen and particulate material may be fed to reactor through respective first and second inlets. A second gas stream containing one or more volatile arsenic compounds is fed through a third inlet and mixed with the first gas stream and the particulate material to produce a combined gas stream containing the volatile arsenic compounds and the particulate material. The arsenic compounds are reacted with iron in the particulate material as the combined gas stream flows through the reactor to produce solid iron arsenates which are then recovered. The portion of the reactor including the first, second and third inlets is vertically oriented, and the reactor may include a venturi arrangement having a throat at which the second inlet is located.

Abstract: A method for recovering metal values from a molten slag composition includes atomizing the slag with an oxygen-containing gas in a gas atomization apparatus, to produce solid slag granules. Oxygen in the atomizing gas converts metals to magnetic metal compounds, thereby magnetizing the metal-containing slag granules. These metal-containing slag granules are then magnetically separated. Larger amounts of metals may be removed by passing the molten slag through a pre-settling pan with an adjustable base, and/or discontinuing atomization where the metal content of the slag exceeds a predetermined amount. Solid slag granules produced by atomization may be charged to a recovery unit for recovery of one or more metal by-products. An apparatus for recovering metal values from molten slag includes a gas atomization apparatus, a flow control device for controlling the flow of atomizing gas, a control system, and one or more sensors to detect metal values in the slag.

Abstract: A process for preparing solid slag granules from a molten slag composition comprises: (a) providing the molten slag composition; (b) converting the molten slag composition into the solid slag granules in a dispersion apparatus; and (c) sorting the solid slag granules by shape in a separator to produce a plurality of fractions having different sphericities. Granular slag products comprise one or more fractions of solid slag granules produced by the process, and include proppants, roofing granules, catalyst supports, which may be porous or non-porous, and coated or uncoated.

Abstract: A highly flexible sealing arrangement designed to seal high-temperature furnace ports, particularly the electrode port of an electric furnace. The seal comprises an annular support member fixed to a flexible sealing member and employs the use of a garter spring to uniformly apply the desired amount of seal compression. The arrangement and flexibility of the sealing member allows the seal to adapt itself to the wide range of operating and upset conditions that typically exist for a furnace electrode seal. Frictional wear on the seal may be greatly reduced as the design inherently allows for a much lower amount of seal compression to be applied, furthermore, the seal is able to move axially which can significantly reduce wear caused by electrode regulation.