Our Thermal Reduction Units (TRU’s) are custom built to enable maximum efficiency in both volume processing and purpose. Mastermelt America is soon to have the largest burning capacity in the US with a total of twelve TRU’s all of which are designated for the sole purpose of the reclamation of precious bearing materials.
Mastermelt America currently operates using numerous Ball Mills;. The Ball Mill is used after the material has been treated by the TRU (thermal reduction unit) and after the material has been cooled to a manageable temperature. The Ball Mill operates using a series of small metal balls that are rotated and consequently pulverize the precious bearing material to a fine powder. The powder material is then fed through a screener, removing any oversize for further processing.
Mastermelt America use a Turbula jar blender in its sample lab as a means to ensure that a homogenous sample is obtained. This ensures that a statistically representative sample can be obtained for the accurate analysis of precious metal content.
Mastermelt America utilizes a Retsch DR100 splitter for sampling purposes to ensure homogenous, accurate and non-biased samples are obtained. The material that has already been blended via our Turbula is then sent through our splitter which ensures that equal parts and hence equal weights are sent to each capsule to ensure accurate sample sizes.
The gold room is a designated facility that enables Mastermelt America to process precious metal plated materials. Mastermelt America processes these materials through chemical leaching utilizing a cyanide rich solution. Each drum shown in the image above is capable of holding up to 50 gallons and has proven to be an efficient processing method for certain materials.
The Inductively Coupled Plasma (ICP) Spectrometer is a device Mastermelt America utilizes to distinguish the preliminary content and volumes of precious metals. The ICP provides the operator with results which are then used to determine an initial starting sample weight for fire assay, (the next stage of precious metal evaluation).
Mastermelt America uses a dimethyglyoxime (DMG) solution to a sample containing Palladium. The DMG causes the Pd to separate from the solution which enables Mastermelt to determine a gravimetric weight for the sample. The sample weight of the Pd after the DMG solution is then applied to calculate the content of the lot of material.
Mastermelt adds chlorine to a sample which contains Silver. By adding the chlorine to the solution the Silver precipitates from the solution and can be gravimetrically weighed and used to determine the value of a given material lot.
Fire assay is a technique in which lead and the components of glass are mixed together with the sample. The mixture is melted and the lead collected in a specialized mold. Lead alloys with precious metals. The lead is then heated in a special bone-ash cup (cupel) which absorbs the lead leaving a precious metal (bead) in the cup. The bead can then be dissolved and analyzed by ICP.
Melt shop – Stir
Mastermelt America has a purpose built melt shop. Our melting capabilities currently workshop consist of five Inductotherm electric induction melters. The melters vary in size ranging from 5t/oz. to 1 ton. Mastermelt America prides itself in its melting capabilities.
Stirring the melt ensures that the molten material is homogeneous and will pour smoothly.
Mastermelt America utilizes Inductotherm electric induction furnaces which can reach a temperature of 3300 degrees Fahrenheit. Molten metal is poured from silicon carbide crucibles to one of several different molds.
Wet Scrubber System
The wet scrubber system is the environmental control portion of the thermal reduction process. The afterburner, quench/venturi scrubber packed bed scrubber ensure that any residual particulate is removed from the off gas and exits through the stack.
This system and configuration are also specifically designed for this application to achieve the highest possible pollution prevention efficiencies. Our certified ISO 14001 program insures that the system and associated equipment is always monitored and maintained to maximize the desired efficiency of the entire system.