Materials Science and Engineering Commons^™

Separation Of Ferric Ions From Waste Aqueous Solution Using Solvent Extraction/Precipitation Process With Deep Eutectic Solvents And Resonant Accoustic Mixing, Frank Agyemang

Honors Theses

The problem of ferric ions (Fe³⁺) in industrial wastewater is a critical issue for several sectors, such as mining, electronic plating, and metal finishing, due to both its environmental and economic impact. Traditional treatment methods using energy-intensive procedures and unsafe organic solvents are not in compliance with sustainability, but can succeed in achieving a valid metal recycling. By utilizing deep eutectic solvents (DES) and resonant vibratory mixing technology, an environmental friendly method is developed to selectively extract/precipitate ferric ions from waste aqueous solutions. Deep eutectic solvents (DES) have been developed to replace common organic solvents, representing environmental friendly alternatives with …

Improving Direct Reduced Iron Briquette Properties, Abigail Clark

Honors Theses

Fines are generated during the reduction, handling, and transportation of iron oxide pellets and lump ore. These fines present significant safety concerns due to their tendency to oxidize rapidly and combust spontaneously. In addition, they contribute to material losses and reduced revenue. However, DRI fines can be recycled through briquetting and reused in downstream steelmaking processes. Briquettes are produced by agglomerating and compacting direct reduced iron (DRI) fines with binders such as molasses and lime, calcium stearate, and bentonite. Although many different binders have been developed and studied for iron oxide agglomeration and induration, far fewer studies have been conducted …

Selective Oxidation And Reduction For Recycling Samarium-Cobalt Permanent Magnets, Mitchell Harvey

Honors Theses

Samarium cobalt (SmCo) based magnets are among the strongest permanent magnets second only to neodymium iron boron (NdFeB) based magnets. While SmCo-based magnets have lower remanence and coercivity than NdFeB-based magnets at room temperature, SmCo-based magnets retain these properties better at higher temperatures. As a result, SmCo-based magnets find use in a variety of devices operating at elevated temperatures including traveling wave tubes for satellite communications, electrical generators, and control surface actuators for aviation system. With increasing geopolitical tension over the sourcing of Sm and Co, there is a renewed interest in recycling end-of-life SmCo-based magnets. This work explores a …

Energy Materials Health Monitoring With Interpretable Machine Learning, Osumanu Musah Mohammed

Honors Theses

Reliability and the lifecycle of energy materials have become key concerns for sustainable, decarbonized power systems [1]. More recent reports on photovoltaic (PV) device technologies, fuel cells, hydrogen storage, and novel composite materials have indicated that material deterioration is a constraint on large-scale exploitation and cost-effectiveness, rather than on energy conversion efficiency [2], [3]. The energy infrastructure of tomorrow needs to be smart and efficient; however, more to the point, it needs to be self-aware, self-diagnostic, and able to overcome any form of degradation before breaking down [4]. The US dilemma is also directly related to federal concerns. That is …

Recovering Sn From Ultrafine Tails At Mina San Rafael, Peru, Angelica Plenge

Honors Theses

San Rafael is currently the only mine producing tin (Sn) in Peru, operating two concentrators. In the first, called the San Rafael plant, tin concentrate is produced through gravity separation circuits consisting of jigs, spirals, and Mozley tables, followed by reverse flotation, where sulfides are floated while cassiterite (78.77% theoretical tin content) is depressed. Material containing tin values is then directed to a desliming circuit, where the pulp density is adjusted prior to sulfide reverse flotation. The tailings from this stage are subsequently processed through another flotation circuit but, in this case, the Sn is floated. Cycloning is applied throughout …

Collector Blends For The Flotation Of Rare Earth Silicates, Padmore Fosu Amankwah

Honors Theses

Rare earth elements (REEs) are critical for modern technologies, but their extraction from minerals remains challenging due to various factors, and their impact on mineral bonding and resulting crystal structure. Fundamental studies have shown that the concentration of rare earth minerals (REMs), such as rare earth silicates (RES), depends on factors such as Lanthanide contraction (LC), Coordination Number (NC), and silicate polymerization (SP). These influence flotation responses pending silicate type (e.g., sorosilicates, phylosilicates, nesosilicates, inosilicates, orthosilicates, etc.). To better understand this behavior and optimize REE recovery, samples from Halleck Creek, an American Rare Earth property in Wyoming, were obtained. Characterization …

Recovery Of High Energy-Value Materials From Mine Wastewater, Zainab Nasrullah

Graduate Theses & Non-Theses

The increasing global demand for high-energy-value materials (HEVM), such as rare earth elements (REEs), copper (Cu), nickel (Ni), cobalt (Co), and lithium (Li), coupled with their limited availability and environmental concerns associated with traditional mining methods, necessitates the development of alternative and sustainable recovery strategies. Wastewater streams from industrial processes, mining operations, and electronic waste treatment represent untapped reservoirs of these valuable materials. Research is proposed to develop sustainable, cost-effective, and scalable methods for selectively recovering HEVM from mine wastewater (Berkeley Pit, Montana). Two innovative approaches, the adsorption process using functionalized adsorbent and solvent extraction (SX) using organic or hydrophobic …

Recycling Ndfeb Magnets I: Production Of Ree Fluorides By A Novel Lpc Process, Isaac Joseph Cobbinah

Graduate Theses & Non-Theses

Neodymium-iron-boron (NdFeB) magnets account for over 60% of global magnet sales and are widely used in high-tech, military, and clean-energy applications (Ormerod, 2022). However, they contain critical rare earth elements such as Nd, Pr, and Dy which poses supply chain and geopolitical risks for country like the United States, which rely extensively on foreign sources. Recycling end-of-life NdFeB magnets provides a sustainable solution that diminishes environmental impact, strengthens supply security, and supports stable domestic production of important rare earth elements. A three-stage process has been developed for recycling the REE-content of NdFeB magnets. While the focus is on neodymium (Nd), …

Production Of Rare Earth Elements By Molten-Salt Electrolysis, Mohammed Moro

Graduate Theses & Non-Theses

Rare earth elements (REEs) are indispensable, high-value resources that play a crucial role in renewable energy, defense systems and advanced technological systems. REEs are commonly extracted from natural ores or recycled materials such as permanent magnets using hydrometallurgical or pyrometallurgical techniques. In hydrometallurgy, the REE source is leached with acid, followed by solvent extraction and precipitation steps to obtain rare earth compounds like oxides and fluorides. Pyrometallurgy involves dissolving rare earth compounds in a molten halide bath, followed by high-temperature electrolysis to convert them into metals, which are then recovered at the cathode. This process typically includes melting, refining, and …

Process Intensification For Rare Earth Elements Adsorption By Resonant Vibratory Mixing (Rvm), Mehran Saddat

Graduate Theses & Non-Theses

Rare earth elements (REE) are crucial to the advancement of modern technologies. REE applications include electronics, defense systems, wind turbines, catalysts, magnets, and aircraft. Bastnasite, monazite, and xenotime are the primary resources, while the secondary resources, including coal ash, E-waste, and acid mine drainage, are for REE extraction. The primary processing techniques are chemical leaching, ion exchange, chemical precipitation, pyrometallurgy, solvent exchange, biosorption, and adsorption. Adsorption technique is simple, cost-effective, and environmentally friendly, with higher efficiency but at the cost of a longer mixing time. Therefore, there is a pressing need for an optimized mixing technique to improve the adsorption …

L.G. Twidwell: A Summary Of Fifty-Six Years Of Research, Larry G. Twidwell

Metallurgy

No abstract provided.

L.G. Twidwell: A Summary Of Fifty-Six Years Of Research, Larry G. Twidwell

Metallurgical & Materials Engineering

No abstract provided.

Rare Earth Mineral Flotation – A Comparison Of Silicates To Oxides, Carbonates And Phosphates, Abdul Mamudu

Graduate Theses & Non-Theses

Flotation is a processing method used to separate valuable minerals from gangue minerals based on differences in hydrophobicity. When applied to ores bearing rare earth minerals (REMs) variations in rare earth element (REE) concentrations within the REMs can lead to inconsistent flotation results. Prior work at Montana Technological University examined the adsorption of collectors on the surfaces of synthetic REMs to assess recovery via flotation. Previous studies showed that the results obtained for Salicyl Hydroxamic Acid (SHA) on rare earth oxides REO), rare earth carbonates (REC), and rare earth phosphates (REP) vary depending on the coordination number (CN) and the …

L.G. Twidwell Fifty-Six Years Of Research A Summary, Larry G. Twidwell

Metallurgical & Materials Engineering

Larry G. Twidwell, D.Sc. is Emeritus Professor in the Department of Metallurgical and Materials Engineering at Montana Technological University. He has fifty-six years of experience in teaching and directing research in Metallurgical and Materials Engineering at Montana Tech. Twidwell and his graduate students and coworkers have conducted research emphasizing extractive metallurgy and the application of extractive metallurgical engineering to the treatment of metallurgical wastes, process waters and byproducts. Four books, seventy-seven M.Sc. theses, one-hundred-thirty refereed publications and one hundred-eight national and international presentations have resulted from their research efforts. Twidwell has received several outstanding teacher/researcher awards during his tenure at …

Selective Leaching Of Rare Earth Elements From Complex Rare Earth Ore Using Deep Eutectic Solvents, Frank Agyemang, Mehran Saddat, Zainab Nasrullah, Richard Ladouceur

Metallurgical & Materials Engineering

Rare earth elements (REEs) are valuable for various modern technological applications, including metallurgy, machine building, radio electronics, instrument engineering, nuclear engineering, and manufacturing. The extraction and separation of rare earth elements (REEs) from their complex ores is challenging due to their distinct physical and chemical properties, contributing to their market scarcity. At present, REE recovery utilizes traditional pyro- or hydrometallurgical processes. The overall process in the recovery and separation of individual elements from complex REE systems suffers from high energy demands and the use of many hazardous chemicals that negatively impact the environment. With the growing trend toward a circular …

Process Intensification By Resonant Vibratory Mixing For The Recyclable Samarium - Cobalt Magnets After Chemical Leaching With Deep Eutectic Solvents, Zainab Nasrullah, Frank Agyemang, Mehran Saddat, Richard Ladouceur

Metallurgical & Materials Engineering

To sustain the circular economy, defense applications, and other renewable technologies, recycling rare earth elements (REEs) and other critical elements from their secondary resources is important. This cause has resulted in rigorous research and development for viable extraction and separation of REEs. Previously, Sm-Co recycling has been done with technologies, which fall under the categories of pyrometallurgy, physical separation, and hydrometallurgy. All these methods have limitations associated with energy, cost, and environment. Reportedly, the chemical leaching technology has successfully recovered and separated Sm-Co. Still, it has limitations associated with slow mass transfer and leaching kinetics, and there is a need …

Surface Chemistry And Adsorption Mechanism Of Orfom® D8 For Cu Depression In Cu-Mo Flotation, Patrick Jeff Mensah

Graduate Theses & Non-Theses

In traditional chalcopyrite-molybdenite (Cu-Mo) flotation separation systems, inorganic depressants such as NaSH and NaCN are used to selectively depress chalcopyrite making it more hydrophilic so molybdenite can be floated and recovered. NaSH and NaCN are highly toxic, have high explosion potential, strong odor, and readily oxidize in air resulting in a high consumption rates. To control oxidation, nitrogen gas, and Nokes reagent are both necessary, making the process even more expensive. In addressing these challenges, attention is fast shifting to disodium carboxymethyl trithiocarbonate (Orfom® D8), a novel organic depressant designed to replace conventional inorganic depressants because it does not easily …

Optimizing The Physical Properties Of Biochar For Co2 Adsorption Using Resonant Vibrations, Amirhosein Riahi, Richard Ladouceur

Mining Engineering

Among various Carbon Capture and Sequestration (CCS) technologies, significant emphasis has been placed on biochar as an effective post-combustion CO2 capture method. Biochar demonstrates potential as a technically effective method for stabilizing carbon. However, the efficacy of CCS based on adsorption phenomenon depends on factors such as the CO2 uptake of the adsorbent, kinetic rates, and cyclic adsorption. The study shows that Low-Frequency High Amplitude (LFHA) resonant vibratory mixing improves the physical characteristics and adsorption properties of hemp biochar. According to the results of an analysis of variance (ANOVA), increasing both the mass of biochar and the intensity of resonant …

Stability, Mechanical Properties, And High-Pressure Structural Modifications Of Some Industrially Relevant Metallic Glasses, Alexander George

Graduate Theses & Non-Theses

Metallic glasses are metal-based alloys that have an amorphous structure and glass transition behavior as a result of being cooled rapidly enough to suppress crystal nucleation and growth[1]. Metallic glasses have been formed with two to eight constituents[2][3][4]; however, the most stable glass-forming systems typically contain four or more elements. With few exceptions, metallic glass-forming alloys are extremely unstable, requiring cooling rates on the order of 10⁸-10^-2 K/s to form a glassy sample. This instability translates to reheating, where onset crystallization temperatures infrequently exceed the glass transition by more than 100K. Strong glass-forming ability typically occurs over …

Solar Process Heat Pyrolysis, Maxwell Triepke

Graduate Theses & Non-Theses

Solar process heat pyrolysis mobilizes the production of biochar via selective solar absorbance. Mobilization allows for the production of pyrolysis products at the location of the biomass source while eliminating the need for infrastructural power to operate the reactor. Traditionally, the implementation of economies of scale has led to large, permanent biochar production facilities; however, biochar feedstock is often in remote locations or stockpiled temporarily in mill/forestry operation locations. Modular reactors are important to eliminate feedstock location, transportation, and variability limitations. Previous work at Montana Technological University’s CHAR Laboratory has developed two lab scale modular, both tethered to infrastructural power. …

Computational Fluid Dynamics Modeling Of 12.25” Horizontal Wellbores To Identify The Effects Of Pipe Rotation On Cuttings Transport Efficiency, David Rathgeber

Graduate Theses & Non-Theses

As global demand for oil and gas continues to rise alongside pressures to curb climate change, Exploration and Production (E&P) companies look to reduce their surface footprint and increase drilling efficiency through longer horizontal well drilling. In addition, the depletion of conventional reservoirs is causing E&P companies to target more difficult reservoirs, often miles offshore (Gupta et al., 2014; Meader et al., 2000a). The increased horizontal reach of these wells often leads to increased challenges in adequate hole cleaning during drilling operations. Efficient hole cleaning becomes a greater challenge in high-angle wells, with gravitational forces causing pipe eccentricity, flow channeling, …

Effects Of Magnetite Particle Morphology On Adsorption Of Copper Ions From Aqueous Solutions, Alisa Hashley

Graduate Theses & Non-Theses

Adsorptive processes can be used for metal contaminant removal. This work addresses magnetite, a magnetic iron oxide, as the adsorbent for use in an adsorptive removal system, known as the continuous flow material recovery system (CFMR), developed by Leitzke et al. [1]. Though the system is effective in removing contaminants from aqueous solution, efforts to further improve efficiency are being made. One way to improve the efficiency of the CFMR is to analyze the magnetite particles being used and investigate how the particle properties effect adsorption. The author’s research is presented and discussed here to describe the effects magnetite particle …

Selective Separation Of Metal Ions From Aqueous Process Streams Using Magnetite Adsorbent, Daniel Geottlich

Graduate Theses & Non-Theses

The effect of coexisting ions on the selectivity of adsorption onto magnetite nanoparticles (MNPs) for various elements in aqueous solutions was investigated. Surrogate solutions of varying concentrations of rare earth elements (REEs), heavy metals, and gangue elements (low commercial value elements or metals) were mixed with MNPs. Selectivity experiments were performed on surrogate samples based on the composition of a REE ore concentrate and a leach liquor from the chlorinated products of the roasted REE ore concentrate. Adsorption efficiency of magnetite was determined by measuring ion concentration in a sample using inductively coupled plasma-optical emission spectroscopy (ICP-OES). Magnetite is selective …

Electrical Resistance Tomography Measurements In Column Flotation Of Pure Hydrophobic And Hydrophilic Systems, Vimeipha Vilayphone

Graduate Theses & Non-Theses

Column flotation was phenomenologically investigated with Electrical Resistance Tomography (ERT) as an uninterrupted instrument to measure gas holdup. Two-phase tests were performed to use the measurements for examining gas dispersion. Results were found to duplicate the findings in a previous thesis. With confidence attained in experimental procedures, three-phase tests were then performed to compare gas holdup with hydrophobic and hydrophilic solids. Hydrophobic solids included talc as well as dolomite with dodecyl amine (DDA) collector. Hydrophilic solids included dolomite as well as talc with carboxymethyl cellulose (CMC) depressant. Variables throughout the research included frother concentration and sparger size. Results showed gas …

Process Intensification For Rare Earth Elements Adsorption By Resonant Vibratory Mixing, Oluwatosin Adebayo, Richard Ladouceur, Zainab Nasrullah

Graduate Theses & Non-Theses

The adsorption capacity for six rare earth elements (Lanthanum, Terbium, Neodymium, Dysprosium, Praseodymium, and Holmium) by biochar produced from hemp feedstock was investigated. An innovative approach to enhancing the adsorption of rare earth elements using biochar was studied and investigates the potential of resonant vibratory mixing (RVM) as a process intensification method compared to conventional mechanical mixing for the adsorption process. Hemp hurds as source of biomass was pyrolyzed to produce biochar at a temperature of 4500C for 60 minutes. The biochar was characterized by FTIR (Fourier Transform Infra-red), SEM (Scanning Electron Microscopy), Surpass 3 Electrokinetic solid surface analyzer, and …

Enhancement Of The Mechanical Behavior Of Nitinol Wire For Vascular Stent Applications By The Addition Of A Polymer Matrix Composite Coating, Baylie Phillips

Graduate Theses & Non-Theses

Several clinical studies since 2008 have reported stent failure through mechanical means from inadequate strength, fatigue failure, coating failure via delamination and cracking, and pathological failures. Enhancement of the mechanical performance and stability of the polymer coating has the potential to minimize coating failure, aiding in the prevention of the other failure modes. The present study fabricated a polymer matrix composite coating from poly(D,L-lactide-co-glycolic) acid (PLGA) and hydroxyapatite (HA) nanoparticles on nitinol wires. Five weight fractions of HA (1.0, 2.5, 5.0, 7.5, and 10.0 wt.% HA) were studied for their influence on the mechanical performance of nitinol. The coatings were …

A Guide To Fifty Years Of Research At Montana Tech: Part 3-Decontamination Of Ratioactively Contaminated Steel By Melt Refining/Slagging Processing, Larry G. Twidwell, Samuel A. Worcester

Metallurgy

This presentation includes a discussion of the research conducted at Montana Tech in the Department of Metallurgical and Materials Engineering. The discussion is focused on Decontamination of Radioactively Contaminated Steel by Melt Refining/Slagging. This presentation is based on the research of Master of Science graduate students, industrial and academic colleagues, at the Montana College of Mineral Science and Technology (which morphed to Montana Tech [1977], then to Montana Tech of The University of Montana [2000], then to Montana Technological University [2019]). The referenced work of each of the graduate students in this presentation is gratefully acknowledged. The following summary presentation …

Investigations Of Dual-Electrolyte Layer Protonic Ceramic Fuel Cells For Enhanced Electrochemical Performance And Longevity, Abdul-Sommed Hadi

Graduate Theses & Non-Theses

A cermet anode comprising of yttria-doped barium zirconate, BZY and nickel, Ni is now the preferred choice of materials for use in proton conducting fuel cell (PCFC) anodes because of their influence on anode oxidation kinetics. The Ni grains, being in a solid solution with the BZY support, helps improve on the catalytic activity and conductivity, in addition to the relative stability of BZY in steam and hydrocarbon reforming environments, as well as BZY’s excellent protonic conductivity.

Ni-BZY based anodes, sintered onto a ~600-micron electrolyte-supported substrates of BZY, BCZY (yttria- and ceria-doped barium zirconate), and a BZY/BCZY dual electrolyte-layer substrate, …

A Study Of Biochar Production Via Continuous Vacuum-Assisted Pyrolysis, Max Wohlgenant

Graduate Theses & Non-Theses

The present study focuses upon the design, fabrication, and feasibility of the bulk production of scientific biochar for mobile delivery. In the 2022 annual report, the National Academies of Science, Engineering, and Medicine recommended the integration of mobile, decentralized reactors that employ flexible manufacturing and circular economic principles. Biochar production, involving the thermal degradation of biomass under an inert atmosphere to yield remediation media is an ideal material to satisfy this recommendation. Many potential application sites, such as abandoned mines, are remote and limit the construction of large infrastructure. The continuous vacuum-assisted pyrolysis (CVAP) reactor was designed to: increase biochar …

Optimization Of Porosity In Cold Spray Produced Copper And Zinc Coatings, Cameron Hughes

Graduate Theses & Non-Theses

Since its invention in 1981, the cold spray (CS) additive manufacturing (AM) process has been studied and optimized to produce well-adhered, dense material coatings. CS can operate at a wide range of temperatures if the feed material remains in a solid state. Copper and zinc were studied to characterize and understand the effects of heating element voltage, travel speed, and standoff distance on deposit porosity, grain size, microhardness, and coating thickness. Samples were sprayed on 3.2 mm x 25 mm x 150 mm 6061 aluminum substrates. Sections were taken from the middle of the samples to represent steady-state conditions. Sample …