Abstract: A process for producing solid carbon and gaseous oxygen from CO2 via electrolysis using an electrolysis apparatus is disclosed. The apparatus includes a chamber with an electrolyte inlet, an electrolyte outlet, a liquid electrolyte containing CO2 in the chamber, at least one cathode-anode pair, with the cathode including a liquid metal capable of catalysing reduction of CO2 to solid carbon at a selected operating temperature of the process. The process includes causing the electrolyte to flow from the inlet to the outlet in fluid communication with the cathode-anode pair, applying a voltage between the cathode-anode pair and causing solid carbon to form on the cathode from CO2 in the electrolyte and gaseous oxygen to be evolved at the anode from CO2 in the electrolyte.

Abstract: A process for producing solid carbon and gaseous oxygen from CO2 via electrolysis using an electrolysis apparatus is disclosed. The apparatus includes a chamber with an electrolyte inlet, an electrolyte outlet, a liquid electrolyte containing CO2 in the chamber, at least one cathode-anode pair, with the cathode including a liquid metal capable of catalysing reduction of CO2 to solid carbon at a selected operating temperature of the process. The process includes causing the electrolyte to flow from the inlet to the outlet in fluid communication with the cathode-anode pair, applying a voltage between the cathode-anode pair and causing solid carbon to form on the cathode from CO2 in the electrolyte and gaseous oxygen to be evolved at the anode from CO2 in the electrolyte.

Abstract: There is disclosed a material processing method wherein a material is fed between a pair of opposed moving surfaces which converge such that a nip is defined therebetween, whereby the material is drawn into the nip to be compressed or compacted between the surfaces, and thence output from between the surfaces, the method comprising subjecting the material to an asymmetric and/or non uniform flow condition between the surfaces to effect shearing in the material in a direction generally parallel to the direction of flow of the material between the surfaces.

Abstract: A method of leaching a metal value from a heap of a metal-containing ore and a heap leaching operation are disclosed. The method includes establishing a downward flow of a leach liquor through a section of the heap by supplying the leach liquor onto a top surface of the section and allowing the leach liquor (containing metal values in solution) to drain from a lower part of the section. The method is characterized by supplying the leach liquor onto the top surface of the section at a flow rate that is sufficient so that the downwardly flowing leach liquor saturates the section of the heap.

Abstract: A method of leaching a metal value from a heap of a metal-containing ore and a heap leaching operation are disclosed. The method includes establishing a downward flow of a leach liquor through a section of the heap by supplying the leach liquor onto a top surface of the section and allowing the leach liquor (containing metal values in solution) to drain from a lower part of the section. The method is characterized by supplying the leach liquor onto the top surface of the section at a flow rate that is sufficient so that the downwardly flowing leach liquor saturates the section of the heap.

Abstract: A steelmaking process is disclosed. The process includes producing molten steel and molten steelmaking slag in a steelmaking process, the steelmaking slag including iron units and flux units, and thereafter producing molten iron in a molten bath based direct smelting process using a substantial portion of the steelmaking slag as part of the feed material requirements for the direct smelting process. A direct smelting process is also disclosed. The process includes pre-treating ferrous material including steelmaking slag and thereafter direct smelting molten iron using the pretreated ferrous material as part of the feed material for the process.

Abstract: A method and an apparatus for crushing material, particularly mined material, are disclosed. In one embodiment two or more pairs of crushing rolls successively crush mined material. The pairs of crushing rolls are arranged and operated so that an upstream pair of rolls produces a feed, preferably a pressurized feed, for a downstream pair of rolls. In another embodiment, at least an upstream pair of rolls is driven intermittently, for example, by means of a stepping motor to provide stepped rotational movement of the rolls.

Abstract: A steelmaking process is disclosed. The process includes producing molten steel and molten steelmaking slag in a steelmaking process, the steelmaking slag including iron units and flux units, and thereafter producing molten iron in a molten bath based direct smelting process using a substantial portion of the steelmaking slag as part of the feed material requirements for the direct smelting process. A direct smelting process is also disclosed. The process includes pre-treating ferrous material including steelmaking slag and thereafter direct smelting molten iron using the pretreated ferrous material as part of the feed material for the process.

Abstract: A steelmaking process is disclosed. The process includes producing molten steel and molten steelmaking slag in a steelmaking process, the steelmaking slag including iron units and flux units, and thereafter producing molten iron in a molten bath based direct smelting process using a substantial portion of the steelmaking slag as part of the feed material requirements for the direct smelting process. A direct smelting process is also disclosed. The process includes pre-treating ferrous material including steelmaking slag and thereafter direct smelting molten iron using the pretreated ferrous material as part of the feed material for the process.

Abstract: A method of separating potassium chloride and sodium chloride from a heated solution of these salts, such as a solution obtained from potash ore, to recover potassium chloride from the ore is disclosed. The method includes a combination of steps of (a) extracting water from a heated solution containing potassium chloride and sodium chloride using a membrane system and (b) subsequently cooling the solution discharged from the membrane system, whereby steps (a) and (b) make it possible to selectively recover potassium chloride and sodium chloride from the solution.

Abstract: A method of treating ore particles to facilitate subsequent processing of the ore particles to recover valuable components from the ore is disclosed. The method includes exposing the ore particles to microwave energy and causing structural alteration of the ore particles. In one embodiment structural alteration is achieve without significantly altering the mineralogy, i.e., composition, of the ore. In another embodiment structural alteration is achieved with minimal change to the sizes of the ore particles. In another embodiment the method includes exposing the ore particles to short duration, high energy pulses of microwave energy.

Abstract: A method and an apparatus for crushing material, particularly mined material, are disclosed. In one embodiment two or more pairs of crushing rolls successively crush mined material. The pairs of crushing rolls are arranged and operated so that an upstream pair of rolls produces a feed, preferably a pressurised feed, for a downstream pair of rolls. In another embodiment, at least an upstream pair of rolls is driven intermittently, for example, by means of a stepping motor to provide stepped rotational movement of the rolls.

Abstract: A direct smelting process and a fixed, ie non-rotatable, metallurgical vessel for producing metal from a metalliferous feed material is disclosed. The process is a molten bath-based process which includes injecting solid feed materials with a carrier gas into the molten bath via one or more downwardly extending lance/tuyere (11) and causing gas flow from the molten bath at a flow rate of at least 0.30 Nm3/s/m2 at the interface between the metal layer (15) and the slag layer (16) of the molten bath (under quiescent conditions).

Abstract: A reactor for aerating a fluid with a gas comprises a mixing tank (12) for the fluid and a centrally located vertical draft tube (13) submerged in the fluid to divide the mixing tank (12) into an inner chamber (21) and an outer chamber (23). The reactor further comprises a motor driven axial flow impeller (14) located in the draft tube (13) for circulating fluid downwardly through the inner chamber (21) and upwardly through the outer chamber (23). The reactor further comprises an external circuit for withdrawing a portion of the fluid from the mixing tank (12), aerating the fluid, and returning the aerated fluid to the mixing tank (12). The aerator is in the form of a venturi device (17).

Abstract: A direct smelting process and a fixed, i.e. non-rotatable, metallurgical vessel for producing metal from a metalliferous feed material is disclosed. The process is a molten bath-based process which includes injecting solid feed materials with a carrier gas into the molten bath via one or more downwardly extending lance/tuyere (11) and causing gas flow from the molten bath at:a flow rate of at least 0.30 Nm3/s/m2 at the interface between the metal layer (15) and the slag layer (16) of the molten bath (under quiescent conditions).

Abstract: A direct smelting process for producing metals from a metalliferous feed material is disclosed. The process includes forming a molten bath having a metal layer (15) and a slag layer (16) on the metal layer in a metallurgical vessel, injecting metalliferous feed material and solid carbonaceous material into the metal layer via a plurality of lances/tuyeres (11), and smelting metalliferous material to metal in the metal layer. The process also includes causing molten material to be projected as splashes, droplets, and streams into a top space above a nominal quiescent surface of the molten bath to form a transition zone (23).

Abstract: A direct smelting process and a fixed, ie non-rotatable, metallurgical vessel for producing metal from a metalliferous feed material is disclosed. The process is a molten bath-based process which includes injecting solid feed materials with a carrier gas into the molten bath via one or more downwardly extending lance/tuyere (11) and causing gas flow from the molten bath at a flow rate of at least 0.30 Nm3/s/m2 at the interface between the metal layer (15) and the slag layer (16) of the molten bath (under quiescent conditions).

Abstract: A reactor for aerating a fluid with a gas comprises a mixing tank (12) for the fluid and a centrally located vertical draft tube (13) submerged in the fluid to divide the mixing tank (12) into an inner chamber (21) and an outer chamber (23). The reactor further comprises a motor driven axial flow impeller (14) located in the draft tube (13) for circulating fluid downwardly through the inner chamber (21) and upwardly through the outer chamber (23). The reactor further comprises an external circuit for withdrawing a portion of the fluid from the mixing tank (12), aerating the fluid, and returning the aerated fluid to the mixing tank (12). The aerator is in the form of a venturi device (17).

Abstract: A reactor for aerating a fluid with a gas comprises a mixing tank (12) for the fluid and a centrally located vertical draft tube (13) submerged in the fluid to divide the mixing tank (12) into an inner chamber (21) and an outer chamber (23). The reactor further comprises a motor driven axial flow impeller (14) located in the draft tube (13) for circulating fluid downwardly through the inner chamber (21) and upwardly through the outer chamber (23). The reactor further comprises an external circuit for withdrawing a portion of the fluid from the mixing tank (12), aerating the fluid, and returning the aerated fluid to the mixing tank (12). The aerator is in the form of a venturi device (17).

Abstract: A method and an apparatus for producing metals and metal alloys from metal oxides in a metallurgical vessel containing a molten bath having a metal layer and a slag layer is disclosed. The method is characterized by injecting a carrier gas and a solid carbonaceous material and/or metal oxides into the molten bath from a side of the vessel that is in contact with the molten bath or from above the molten bath so that the solids penetrate the molten bath and cause molten metal to be projected into the gas space above the molten bath to form a transition zone. The method is also characterized by injecting an oxygen-containing gas into the gas space to post-combust reaction gases released from the molten bath into the transition zone.