EP3115112A1 - Legierung und trennverfahren - Google Patents

Legierung und trennverfahren Download PDF

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Publication number
EP3115112A1
EP3115112A1 EP15176162.4A EP15176162A EP3115112A1 EP 3115112 A1 EP3115112 A1 EP 3115112A1 EP 15176162 A EP15176162 A EP 15176162A EP 3115112 A1 EP3115112 A1 EP 3115112A1
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EP
European Patent Office
Prior art keywords
alloy
composition
feed material
liquid carrier
particles
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP15176162.4A
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English (en)
French (fr)
Other versions
EP3115112B1 (de
Inventor
Nicholas John TRILLWOOD
John Taylor
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Delta Products Uk Ltd
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Delta Products Uk Ltd
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Publication date
Application filed by Delta Products Uk Ltd filed Critical Delta Products Uk Ltd
Priority to ES15176162.4T priority Critical patent/ES2667809T3/es
Priority to EP15176162.4A priority patent/EP3115112B1/de
Publication of EP3115112A1 publication Critical patent/EP3115112A1/de
Application granted granted Critical
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C33/00—Making ferrous alloys
    • C22C33/02—Making ferrous alloys by powder metallurgy
    • C22C33/0257—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/06—Metallic powder characterised by the shape of the particles
    • B22F1/065—Spherical particles
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C33/00—Making ferrous alloys
    • C22C33/02—Making ferrous alloys by powder metallurgy
    • C22C33/0257—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements
    • C22C33/0278—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements with at least one alloying element having a minimum content above 5%
    • C22C33/0285—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements with at least one alloying element having a minimum content above 5% with Cr, Co, or Ni having a minimum content higher than 5%

Definitions

  • the invention relates to an alloy, and more specifically an iron based alloy that is preferably in particulate form.
  • the invention further relates to dense media separation, particularly the use of a new alloy in dense media separation processes, for instance in the metal recycling industries and mining industries.
  • Dense media separation is a process in which components of a material are separated into fractions on the basis of their differing densities. Typically, the separation is performed in a liquid that has a density that is equal to or greater than that of water (999.97 kg/m 3 ).
  • the liquid referred to in the art as a "heavy liquid" can be selected from tetrabromoethane, methylene iodide, lead sulfamate, thallium malonate or thallium formate.
  • a solid material referred to in the art as the "media”
  • a liquid carrier to form a suspension
  • a dense medium can increase the density of the liquid carrier to allow separation of components that have densities that are greater than that of water or a so-called heavy liquid.
  • a typical liquid carrier is water and typical media include ferrosilicon and magnetite.
  • the solid material is generally in particulate form.
  • the material that is to be separated into its component parts is introduced into the so-called heavy liquid/dense medium, which is typically in a conventional separating device, e.g. a static separation tank or a dynamic separator.
  • a conventional separating device e.g. a static separation tank or a dynamic separator.
  • the components of the material which are less dense than the heavy liquid/dense medium will rise and float.
  • the components of the material which have a greater density than the heavy liquid/dense medium will sink.
  • the addition of solid material to a liquid carrier to form a dense medium can be problematic due to the stability of the dense medium and the proclivity of the solid material particles to settle.
  • the particle size of the solid material should be small enough that the particles will not settle as rapidly as the components of the material that is to be separated.
  • the stability of the dense medium is therefore an important parameter, because it determines the consistency of the density gradient of the suspension, which directly influences the sharpness of separation of the material that is to be separated into its component parts.
  • ferrous metals as the solid material in a liquid carrier can present additional problems due to corrosion of the solid material and the formation of rust, which can alter the separation gradient and the sharpness of separation.
  • the apparent density and stability of the dense medium are influenced by factors such as specific gravity, particle shape, particle size and/or particle size distribution of the solid material added to the liquid carrier.
  • An ideal dense medium contains media that has a high specific gravity, which increases the efficiency of separation because lower amounts of the media need to be added to the liquid carrier to achieve higher apparent densities, which means the mobility of the component parts of a material that is to be separated through the dense medium is not significantly impeded.
  • a dense medium that contains media with a low specific gravity is less desirable because a greater amount of the media needs to be added to the liquid carrier to achieve higher apparent densities, which has a detrimental effect on separation efficiency because it negatively impacts on the velocity at which component parts of a material that is to be separated move through the dense medium.
  • an alloy comprising:
  • the amount of a given component in a composition is the percentage weight (wt%) of that component relative to the total weight of the composition, unless otherwise stated.
  • the iron content in the alloy is at least about 81%, preferably at least about 82%, preferably at least about 83%, preferably at least about 84%, preferably at least about 85%, preferably at least about 86%, preferably at least about 87%, preferably at least about 88%, preferably at least about 89%, and preferably at least about 90%.
  • the silicon content in the alloy is no more than about 8.4%, preferably no more than about 8.3%, preferably no more than about 8.2%, preferably no more than about 8.1%, and preferably no more than about 8.0%.
  • silicon is present in the alloy in an amount of at least about 7.0%, preferably at least about 7.1%, preferably at least about 7.2%, preferably at least about 7.3%, preferably at least about 7.4%, and preferably at least about 7.5%.
  • the silicon content in the alloy is preferably from about 7.0% to about 8.5%, preferably from about 7.1%% to 8.4%, preferably from about 7.2% to about 8.3%, preferably from 7.3% to about 8.2%, and preferably about 7.4% to about 8.1%, preferably about 7.5% to about 8.0%.
  • the chromium content is less than 7%.
  • the chromium content in the alloy is from about 3% to about 7%, preferably from about 4% to less than 7%, and preferably from about 5% to about 6%.
  • the alloy may further comprise one or more additional components, such as carbon, phosphorus and/or sulfur, and combinations thereof.
  • the carbon is present in an amount of no more than about 1.5%, preferably no more than about 1.4%, preferably no more than about 1.3%, preferably no more than about 1.2%, preferably no more than about 1.1 %, and preferably no more than about 1%. Carbon may be present in the alloy in an amount of at least about 0.3%, or at least about 0.4%, or at least about 0.5%, or at least about 0.6%, or at least about 0.7%, or at least about 0.8%.
  • the carbon content in the alloy may be from about 0.3% to about 1.5%, or from about 0.4% to about 1.4%, or from about 0.5% to about 1.3%, or from about 0.6% to about 1.2%, or from about 0.7% to about 1.1 %, or from about 0.8% to about 1.1 %, or from about 0.8% to about 1%.
  • the sulfur content in the alloy is no more than about 0.07%, preferably no more than about 0.06%, and preferably no more than about 0.05%.
  • Sulfur may be present in the alloy in an amount of at least about 0.01%.
  • the sulfur content in the alloy is typically from about 0.01% to about 0.07%, preferably from about 0.01% to about 0.06%, and preferably from about 0.01% to about 0.05%.
  • alloys which comprise at least about 80% iron, no more than about 8.5% silicon, and from about 3% to about 6% chromium.
  • alloys which comprise at least about 80% iron, no more than about 8.3% silicon, from about 3% to about 7% chromium, and from about 0.3% to about 1.5% carbon.
  • the shape of the alloy particles depends upon the way in which the particles are made.
  • the particles may be substantially round if the alloy is made by an atomization technique, or sharp-edged if the alloy is made by a milling technique.
  • the particles are made by an atomization technique.
  • the alloy particles are preferably substantially round.
  • the alloy of the invention can be supplied in various forms depending on the intended use and the form of the material that is to be separated into its constituent parts.
  • the different forms of the alloy can have different particle size distributions. Within the generic ranges set out above, suitable particle size distributions can be selected from:
  • the specific gravity (as defined herein) of the alloy of the invention is preferably in the range of from about 6.5 g/cm 3 to about 7.3 g/cm 3 , preferably from about 6.6 g/cm 3 to about 7.2 g/cm 3 , and preferably from about 6.7 g/cm 3 to about 7.1 g/cm 3 .
  • the alloy disclosed herein is produced in a furnace at a temperature of preferably at least about 1,500°C, and preferably at least about 1,600°C. Maintaining the temperature above 1,500°C ensures good melting, it assists in fluxing and it helps achieve a homogeneous alloy prior to atomization or milling.
  • the particles of the alloy are preferably obtained by atomization, but there are other methods that could be used that are familiar to the skilled person, e.g. such as milling. Atomization is preferred, because particles obtained typically have a high degree of roundness.
  • the alloy can be obtained by a milling method in which the molten alloy is subsequently water-cooled or air-cooled, dried, milled and classified into various grades. Unlike an atomization process, the milled particles are sharp-edged and they are not uniform in shape.
  • the alloy described herein is particularly advantageous because it provides compositions having a specific gravity similar to that of corresponding iron-containing compositions. Moreover, it retains its magnetic properties and the chromium content should make it more resistant to corrosion (e.g. rust) when compared with an existing alloy comprising 15% silicon and 85% iron. When compared to existing alloys, lower amounts of the alloy of the present invention can be used to achieve a greater range of operating densities, which improves separation efficiency because the viscosity of the resultant suspension is reduced.
  • the composition of the second aspect of the invention comprises preferably from about 8 wt% to about 58 wt% of the particulate alloy relative to the total weight of the composition, preferably 11 wt% to about 58 wt%, preferably from about 15 wt% to about 58 wt%, preferably from about 29 wt% to about 58 wt%, preferably from about 31 wt% to about 56 wt%, preferably from about 32 wt% to about 55 wt%, preferably from about 34 wt% to about 53 wt%, preferably from about 35 wt% to about 52 wt%, and preferably from about 37 wt% to about 50 wt%.
  • suitable amounts of the particulate alloy relative to the total weight of the composition of the second aspect of the invention include:
  • the apparent density of the composition of the second aspect of the invention is preferably in the range of from about 1.5 g/cm 3 to about 4.6 g/cm 3 , preferably from about 1.7 g/cm 3 to about 4.6 g/cm 3 , preferably from about 1.9 g/cm 3 to about 4.6 g/cm 3 , preferably from about 2.8 g/cm 3 to about 4.6 g/cm 3 , preferably from about 2.9 g/cm 3 to about 4.5 g/cm 3 , preferably from about 3.0 g/cm 3 to about 4.4 g/cm 3 , preferably from about 3.1 g/cm 3 to about 4.3 g/cm 3 , preferably from about 3.2 g/cm 3 to about 4.2 g/cm 3 , preferably from about 3.3 to about 4.1 g/cm 3 .
  • suitable apparent densities of the composition of the second aspect of the invention (and corresponding to the composition
  • a separation process comprising the steps of contacting a separating means with a feed material, and separating at least one component of said feed material from at least one other component of said feed material, wherein said separating means is a composition comprising the particulate alloy described herein and a liquid carrier.
  • the separation process is a dense media separation process.
  • the separation process comprises the steps of:
  • the dense media separation vessel comprises two chambers, each comprising a dense medium having two different apparent densities.
  • the apparent density of the first chamber is lower than the apparent density of the second chamber.
  • the apparent density of the dense medium in the first chamber is preferably from about 1.5 g/cm 3 to about 2.3 g/cm 3 , preferably from about 1.6 g/cm 3 to about 2.2 g/cm 3 , preferably from about 1.7 g/cm 3 to about 2.1 g/cm 3 , preferably from about 1.8 g/cm 3 to about 2.0 g/cm 3 .
  • a dense media separation vessel having two chambers which comprises a first chamber in which is contained a dense medium having an apparent density of from about 1.5 g/cm 3 to about 2.3 g/cm 3 and a second chamber in which is contained a dense medium having an apparent density of from about 2.7 g/cm 3 to about 3.5 g/cm 3 .
  • the dense media separation vessel is a tank, a drum, or it is substantially conical in shape.
  • the dense media separation vessel may be static.
  • the dense media separation vessel is dynamic to aid separation of the feed material into its component parts.
  • Said composition (i.e. the dense medium) and said feed material may be added to the dense media separation vessel sequentially or simultaneously.
  • said composition is added to the dense media separation vessel before the feed material.
  • said composition (i.e. the dense medium) and said feed material are agitated to aid separation of the material into its component parts and minimize or prevent sedimentation.
  • Agitation may be achieved by any suitable or conventional means, for instance by stirring or by rotation of the dense media separation vessel.
  • agitation may be achieved by centrifugal force using a cyclone.
  • the liquid carrier is preferably water, and a further advantage of the alloy of the present invention is that the chromium content should make it more resistant to corrosion (e.g. rust) when compared with an existing alloy comprising 15% silicon and 85% iron.
  • the particulate alloy disclosed herein forms a stable suspension in the liquid carrier (particularly water), which results in a consistent density gradient and a sharp degree of separation. Moreover, the alloy can be recovered easily, which reduces the overall consumption of the alloy when used in a dense media separation process.
  • the flask, water and material to be tested must be allowed to equalise at room temperature ( Supra ) and atmospheric pressure ( Supra ) for at least 24 hours prior to the test.
  • the flask is filled with water to the 0 cm 3 mark on the neck of the flask.
  • the inside of the flask will be dried above the level of the liquid (water).
  • the difference between the first and final readings on the stem of the flask represents the volume of liquid displaced by the mass of the material used in the test.
  • Apparent density in the context of the present invention refers to the weight of a sample of the composition (i.e. the dense medium) per unit volume.
  • the apparent density can be determined by the following protocol.
  • media refers to a solid material that is added to a liquid carrier to alter the density of the liquid carrier and form a suspension.
  • the resulting suspension is referred to as a "dense medium”.
  • the invention is illustrated by the following non-limiting example.
  • a bulk alloy comprising no more than about 8.5% silicon and from about 2 to about 7% chromium and a balance of iron was melted in a furnace at a temperature of at least about 1,500°C.
  • the molten alloy was poured through the nozzle of an atomizer.
  • the stream of molten alloy interacts with a spray of high pressure water to produce substantially round particles.
  • the particles were quenched and filtered and found to have a particles size such that at least about 90% of the particles of the alloy pass through a sieve having a mesh aperture of about 1 mm.
  • the particles of the alloy were found to be excellent when used in a suspension with water to form a heavy liquid for dense media separation.
  • An alloy of the present invention comprising 8% silicon, 85% iron and 7% chromium has a specific gravity as set out below.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Nanotechnology (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Powder Metallurgy (AREA)
  • Solid-Sorbent Or Filter-Aiding Compositions (AREA)
  • Processing Of Solid Wastes (AREA)
EP15176162.4A 2015-07-09 2015-07-09 Legierung und trennverfahren Not-in-force EP3115112B1 (de)

Priority Applications (2)

Application Number Priority Date Filing Date Title
ES15176162.4T ES2667809T3 (es) 2015-07-09 2015-07-09 Aleacion y proceso de separación
EP15176162.4A EP3115112B1 (de) 2015-07-09 2015-07-09 Legierung und trennverfahren

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP15176162.4A EP3115112B1 (de) 2015-07-09 2015-07-09 Legierung und trennverfahren

Publications (2)

Publication Number Publication Date
EP3115112A1 true EP3115112A1 (de) 2017-01-11
EP3115112B1 EP3115112B1 (de) 2018-04-18

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EP (1) EP3115112B1 (de)
ES (1) ES2667809T3 (de)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN108188040A (zh) * 2018-03-08 2018-06-22 杨宝祥 一种矿物液态法分选系统及其分选方法

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3312543A (en) * 1962-08-01 1967-04-04 Daniel J N Hoffman Heavy separation media
US4093538A (en) * 1974-08-28 1978-06-06 Hoechst Aktiengesellschaft Process for inhibiting the corrosion of heavy pulps for heavy media separation of minerals
US4266974A (en) * 1978-10-30 1981-05-12 Kawasaki Steel Corporation Alloy steel powder having excellent compressibility, moldability and heat-treatment property
US20120001710A1 (en) * 2009-03-09 2012-01-05 Yuya Wakabayashi Powder magnetic core and magnetic element using the same
US20130076477A1 (en) * 2010-06-09 2013-03-28 Yasushi Kino Fe-GROUP-BASED SOFT MAGNETIC POWDER
US20150083960A1 (en) * 2013-09-20 2015-03-26 Taiyo Yuden Co., Ltd. Magnetic body and electronic component using the same

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102362317B (zh) * 2009-04-02 2013-11-20 胜美达集团株式会社 复合性磁性材料和磁性元件

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3312543A (en) * 1962-08-01 1967-04-04 Daniel J N Hoffman Heavy separation media
US4093538A (en) * 1974-08-28 1978-06-06 Hoechst Aktiengesellschaft Process for inhibiting the corrosion of heavy pulps for heavy media separation of minerals
US4266974A (en) * 1978-10-30 1981-05-12 Kawasaki Steel Corporation Alloy steel powder having excellent compressibility, moldability and heat-treatment property
US20120001710A1 (en) * 2009-03-09 2012-01-05 Yuya Wakabayashi Powder magnetic core and magnetic element using the same
US20130076477A1 (en) * 2010-06-09 2013-03-28 Yasushi Kino Fe-GROUP-BASED SOFT MAGNETIC POWDER
US20150083960A1 (en) * 2013-09-20 2015-03-26 Taiyo Yuden Co., Ltd. Magnetic body and electronic component using the same

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN108188040A (zh) * 2018-03-08 2018-06-22 杨宝祥 一种矿物液态法分选系统及其分选方法
CN108188040B (zh) * 2018-03-08 2024-04-19 杨宝祥 一种矿物液态法分选系统及其分选方法

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EP3115112B1 (de) 2018-04-18
ES2667809T3 (es) 2018-05-14

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