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By E. F. Vegman, Ndabezinhle Dube

"In the practice of conventional sintering, production is always afflicted with the problem of being unable to get a uniform quality of produced sinter in the bed. Invariably the top layer of the sinter cake is composed of weak but highly sinter, while the bottom layer is over-fused, forming a sinter that is very strong but less reducible. These symptoms point to a variable distribution of the heat balance in the process of sintering which results in a deficit of heat in the top layers of the sinter bed and an excess of heat in the bottom layers, due to an increasing input of regenerated heat in the heat balance down the bed. This causes losses in the productivities of the sinter machine and the blast furnace.The current work was designed to improve on the solution to the above problem through the establishment of a more accurate combustion zone heat balance of the sintering process. This development is mostly on the method of determining the regenerated heat input in the overall heat balance. Previous methods were based on the assumption that the width and the velocity of the combustion zone remain constant through out its whole life, which is not the case since tests have shown that both its width and velocity increase as the combustion zone moves down the bed. In this work, these factors have been taken into account. Tests and calculations using the model were carried out for haematite and limonitic ores. The high sensitivity of the model to changes in the sinter mix composition and sintering conditions was demonstrated.The results present the following prospects:• The minimum theoretically possible coke breeze consumption during the sintering of any type of iron ore fines, under any sintering conditions, can be established.• The model can be used to control the metallurgical quality of the sinter in any point in the sinter bed since calculation data includes desired basicity, combustion zone temperature and FeO content in the sinter produced."

Jan 1, 2001

Sanes are utilized to make molds for metal castings in the foundry industry. Approximately a half ton of sand is disposed of for each ton of metal cast in this country. The purpose of this investigation was to study and develop a process to separate chromite sand and silica sand from reclaimed sands for a steel foundry. Physical separations were utilized to yield silica and chromite sands with desirable molding properties. Several different separation methods, including electrostatic, magnetic, and various gravitational approaches were examined. Experimental results are presented. A method was developed to separate chromite sand from silica sand after mechanical or thermal reclamation. The reclaimed sands are passed through a rare earth magnetic separator to separate chromite sand and magnetic impurities from non-magnetic silica sand. Chromite sand can be recovered from magnetic silica sand or magnetic impurities very effectively using a wet concentrating table. The applicabilities of the separation methods are discussed.

Jan 1, 1995

By Artur R. P. Junior Sergio, Pedro A. Netto, N. Monteiro, Foluke S. de Assis, Frederico M. Margem

Synthetic fibers are being replaced gradually by natural materials such as lignocellulosic fibers. Compared to synthetic fibers, natural fibers have shown advantages in technical aspects such as environmental and economic. So there is a growing international interest in the use of those fibers. The banana fiber presents significant properties to be studied, but until now few thermal properties on banana fiber as reinforcement of polyester matrix were performed. The present work had as its objective to investigate, by photoacoustic spectroscopy and photothermal techniques the thermal properties of diffusivity, specific heat capacity and conductivity for polyester composites reinforced with banana fibers. In the polyester matrix will be added up to 30% in volume of continuous and aligned banana fibers. These values show that the incorporation of banana fibers in the polyester matrix changes its thermal properties.

Jan 1, 2015

By Y. K. Rao

In the carbonyl process for the refining of crude nickel CO(g) reacts with nickel in the 310-370K range producing nickel tetracarbonyl, Ni(C0)4(g). Iron and cobalt impurities also form gaseous carbonyls but their partial pressures are low. The carbonyl is led to a decomposer plant wherein the gas disproportionates in the 500-600K range depositing pure metal on nickel pellets that move countercurrent to the gas-flow. This system serves to illustrate the fundamental principles involved in the vapor phase mass transport of elements, against temperature-gradient, under the influence of chemical potential gradient. Unlike in the crystal growth, the source is at a lower temperature (say 350K) whereas the seed is in the hot-zone (say 550K) of the closed ampoule-type reactor. By assuming virtual gas-solid equilibria in the end zones, with diffusion of gaseous species between them acting as a slight perturbation, the quasi-steady- state mass-transport rates are computed for a range of CO-pressures and temperatures.

Jan 1, 1993

By Z. W. Zhang, Songsong Xu, Jinhui Li, Yun Zou, Yu Zhao

High strength low alloy (HSLA) steels with high strength, high toughness, good corrosion resistance and weldability, can be widely used in shipbuilding, automobile, construction, bridging industry, etc. The microstructure evolution and mechanical properties can be influenced by thermomechanical processing. In this study, themomechanical processing is optimized to control the matrix microstructure and nano-scale precipitates in the matrix simultaneously. It is found that the low-temperature toughness and ductility of the steels are significantly the matrix microstructure during enhancing the strength by introducing the nano-scale precipitates. The effects of alloying elements on the microstructure evolution and nano-scale precipitation are also discussed.

Jan 1, 2016

By C. A. Young

The remediation of cyanide (CN-) and nitrate (NO)-) anions in mine and agricultural waters by various photolytic methods has been reviewed and investigated. Photolytic methods such as direct photolysis, homogenous photolysis, and heterogeneous photocatalysis are briefly described and compared. Results and discussions show that each method has certain advantages and disadvantages. For each method, Eh-pH diagrams prove useful for determining reaction mechanisms. Preliminary results obtained for cyanide oxidation and nitrate reduction show that homogeneous photolysis can be superior due to faster kinetics than the other methods. The photolytic methods were individually, not simultaneously, tested and compared. Differences in concentrations of products were obtained and attributed to differences in photoconversion efficiencies and other inherent characteristics of .the photolytic methods. Various reaction mechanisms are proposed in accordance with the literature as well as measurements obtained from solution analysis using ion selective electrodes and ion chromatography .

Jan 1, 1995

By S. N. Monteiro, C. M. F. Vieira, M. M. Ribeiro

"This work has as its objective to evaluate the effect of incorporation of the powder waste retained in the eletrostatic precipitator of the sintering stage from an integrated steel making plant on the physical and mechanical properties of a red ceramic. Formulations were prepared with incorporation of the waste in amounts up to 20 wt.% into a kaolinitic clay. Rectangular specimens were prepared by uniaxial mold-press at 20 MPa and then fired at 750, 900 and 1050°C. The evaluated physical and mechanical properties were: linear shrinkage, water absorption and flexural rupture strength. The results showed that the waste has a potential to be used into red ceramics. The incorporation of the waste enhanced the properties of the ceramic, decreasing the water absorption and increasing the mechanical strength at all investigated temperatures.IntroductionThe sintering stage of an integrated steel-making plant is dedicated to the agglomeration of a mixture of iron ore, coke or coal, fluxes and water [1]. It is a common practice in this stage to use of solid wastes with great amounts of iron in the form of sludge and powder. One of the atmospheric pollutants generated during the sintering process is the particulate material, which is normally retained in an equipment denote as electrostatic precipitator. This equipment retains very small particulates, present in the gaseous emissions by application of an electrical potential difference in between the plates that the fluid is forced to go through. [2]."

Jan 1, 2011

By cheng Peng-fei, TANG Hai-yan, guo Xiao-chen, LI Jing-she, Liang Yong-cang, Zhao Baojun

In the process of oxygen blast furnace, the lower coke ratio and the higher coke load make the skeleton coke more important. To understand the dissolution of coke in melting and dropping zone, the influence of FeO content, temperature and reaction time on the dissolution of coke with slag were studied by single-factor experiment. Meanwhile, the three factors and three levels orthogonal were conducted. The dissolution degrees were characterized by the weight loss ratio and diameter variation. The results showed that the weight loss ratio increased and the diameter decreased with the increase of FeO content, temperature and time. The three factors and three levels orthogonal test showed that time was the most significant factor on coke dissolution, FeO content of the second, and finally the temperature. The microstructure of coke after reaction indicated that the dissolution occurred on coke surface.

Jan 1, 2016

By Jose Bengoa

Low metal prices and environmental restrictions are always a challenge for copper smelters operation and its productivity. Thus, in order to reduce production costs and control gas emissions, improvements of the Teniente Converter (CT) operation were made at 110 Smelter Plant of Southern Peru Copper Co., 110, Peru, and the main objective was to increase its capacity for smelting copper concentrates without affecting normal operation. The present work corresponds to a recent study conducted during the normal industrial operation of the Teniente Converter in this plant and, it shows the effect of increasing air oxygen enrichment from 28 to 34% on its productivity. The results show an increasing of concentrate smelting rate from 800 to 1370 tpd and hence a notorious improving in copper production, and practically no effect on the refractory consumption. The increment of the concentrate throughput, increases also the SO2 concentration and the sulfuric acid production, showing the effort done by this operation in order to accomplish the environmental Peruvian regulation.

Jan 1, 2003

By Joseph Goodwill

1. PURPOSE The objective of this paper is to summarize a study undertaken by the EPRI Center for Metals Production (CMP). The overall purpose of the study was to identify electrolytic opportunities that might merit consideration for joint development by industry and EPRI. 2. SCOPE The electrolytic technologies of interest to this study include: Electrorefining, Electrowinning, and Fused-salt electrolysis. Recovery from primary, secondary, and waste materials were included in this effort; however, we excluded from consideration: Plating and coating operations, such as electrogalvanizing; Mining and milling operations in which electric energy is predominantly used for comminution; Electrothermal processes in which submerged-arc, open electric-arc, and plasma-based smelting processes use electric energy largely to provide a melting or refining ("heating") capability; and Aluminum electrotechnologies since these were the subject of a separate study (CMP 86-2). We recognize that there may be some "gray areas" between these excluded areas and the electrolytic sectors of interest. For this reason, a secondary criterium was used, namely, if the major use of electric energy was to extract or refine the

Jan 1, 1990

By Huimin Lu, Shi Zhou, Lisha Yang

"The Zeolitic imidazolate frameworks (ZIFs) were successfully synthesized by applying a combination of ionothermal synthesis and microwave energies for rapid synthesis. The synthesis was proceeded under various conditions including different raw materials, reaction temperature as well as microwave irradiation time. Zeolitic imidazolate frameworks (ZIFs), also known as coordination polymers, are new type of porous materials formed by inerratic polyhedral in three-dimensional. They are the ideal crystalline substances for gas separation and storage. The assynthesized samples were characterized by X-ray diffraction (XRD), scanning electron microscopy (SEM), thermal gravimetric analysis (TGA) and C02 adsorption test. Results illustrated that the synthesized samples had stable structure, high thermal stability (up to 530 °C) and C02 adsorption capacity (10.2 cm3/g at 0°C under ambient pressure). This novel method also showed great advantage with high energy efficiency, safe synthesis conditions, and rapid crystallization time (60 minutes).IntroductionNowadays, carbon dioxide capture has become imperative due to the global warming caused by the increase of C02 in the atmosphere, especially produced by the concentrated sources such as power plants [1]. Zeolitic imidazolate frameworks (ZIFs), also known as coordination polymers, are ideal crystalline substances for gas separation and storage due to their structure diversity, high thermal and chemical stability [2-5]. They are formed by inerratic polyhedra in threedimensional with large cages and small apertures. Traditionally, ZIFs are synthesized by solvothermal method in a sealed autoclave under autogenous pressure [6-9]. However, in order to generate the products, the solvothermal temperature should not be lower than 100°C according to the sovlothermal mechanism. Moreover, at such a temperature, molecules with a low boiling point (such as water) may generate high pressure in reactor which might cause danger [9]. Thus the synthesis requires the equipment to possess resistance to autogenous pressure and corrosion. Further, conventional solvothermal methods need a long time to prepare products, usually a few days, which is a large energy consumption and inefficiency. So it is interesting to synthesis ZIFs through other ways under mild reaction condition with high energy efficiency."

Jan 1, 2012

By Baozhong Ma, Qian Li, Yonggang Wei, Shiwei Zhou, Bo Li, Chengyan Wang, Hua Wang

The magnesium-rich nickel oxide ore (w (Ni) =1.09 %, w (MgO)=29.08 %) mixed with 6 % and 8 % anthracite were roasted at different temperatures. XRD and SEM/EDS techniques were utilized to characterize the phase and microstructure transformation of the ores. The results show that lizardite and chrysotile of raw ore were converted into forsterite and enstatite during reduction roasting process. Simultaneously, iron and nickel oxide were reduced and migrated from the initial magnesium silicate. Fe3Si were formed when the roasting temperature went up to 1300 ℃ and 1350 ℃, and a small amount of Ni was observed in it. Temperatures got too high were not benefit to the polymerization of ferronickel.

Jan 1, 2015

By A. McLean, Y. Uchida, M. Iwase, M. Myochin, K. Wiikimoto

"Phase diagrams of FeO-containing ternary systems could be derived from experimental data for the activities of FeO. The systems investigated are CaO-CaF2-FeO, SrO-SrF2-FeO; BaO-BaF2-FeO, CaO-CaCl2-FeO, SrO-SrC12-FeO, BaO-BaC12-FeO, CaO-A12O3-FeO and BaO-SiO2-FeO.IntroductionThe importance of phase diagram cannot be overemphasized. In a book, ""Alloy Phase Equilibria""[l], the author, Professor A Prince, states, ""A metallurgist has been defined as a person who thinks in terms of phase diagram"". Whether one accepts this statement or not, it is self-evident that an ability to interpret phase equilibria is essential to the professional metallurgists.The physical chemistry studies of iron and steelmaking process often require phase diagrams of FeO-containing slags. Iso-thermal section of the phase· diagrams of such systems can be derived from experimental data for chemical potentials of FeO. Due to the recent developments in the area of solid state electrochemistry, rapid determinations of the FeO activities have become possible. The present paper is aimed at documenting the derivation of the phase diagrams of FeO containing slags.Experimental AspectsAn electrochemical method incorporating stabilized zirconia can be used for the measurements of the activities of FeO in various slags and fluxes[2]. For the details of the experimental technique, reference should be made to reference 2"

Jan 1, 2000

By Baozhong Zhao

Laboratory experiments have been conducted on the removal of As, Sb and Bi from molten copper by SF 6 injection. The results showed that the impurities can be removed by SF6 injection in the? sequence of Sb >As >,Bi and the rate of Bi removal is affected significantly by the concentration levels of As and Sb in the copper melt. Analysis of the experimental data indicates that the impurity removal process is under chemical reaction control rather than by mass transfer of impurity through the molten copper phase. On the basis of experimental results, a kinetic model was developed and the order of chemical reaction and the volumetric chemical reaction rate coefficients of impurity removal were determined.

Jan 1, 1996

By Isabella Lancellotti, Fabrizio Passarini, Luisa Barbieri, Fernanda Andreola, Ivano Vassura, Luciano Morselli

"The techniques able to incorporate wastes by means of a heat treatment present the advantage to fix the residue with chemical bonds. Among these techniques there are vitrification and sintering which are characterised by different operating temperatures in the range of 950-1500°C and the involved raw materials develop silicatic crystalline phases and glassy matrices capable to immobilize heavy metal contents in the waste matrix. In this work incinerator bottom ash, polishing and glazing ceramic sludges have undergone to thermal treatments in order to valorise the waste as secondary raw material for the obtainment of re-products. The chemical efficiency of the process adopted has been evaluated by comparing the results of release tests applied to the as-received wastes and to the thermally treated materials in order to verify the effectiveness of the different matrices to fix the waste components.IntroductionVitrification is one of the most promising technological options for the treatment of some kinds of waste. The high temperature involved in the process (1200-1500°C) leads to the complete destruction of organic pollutants, such as dioxins, and glassy network formed can incorporate heavy metals. Some vitrification processes naturally occur: glasses produced by volcanic eruptions, such as obsidians (Na2O-K2O-Al2O3-SiO2) and basaltic (CaO-MgO-Al2O3-SiO2) rocks, are basically inert materials even when they contain toxic elements, because these are embedded in an extremely stable glassy matrix. The disadvantage of vitrification is that it is an energy-intensive process involving relatively high costs, therefore its use is better justified if a high-quality product with optimised properties can be fabricated. The most effective way to improve the properties of the vitrified material is the transformation into glass ceramic. This is a fine-grained polycrystalline material (typically from 50% to 98% of the volume may be crystalline) formed when a glass of suitable composition is heat treated and hence undergone to controlled crystallisation (phenomenon named devitrification). The three key variables in the design of a glass-ceramic are: glass composition which controls glass viscosity related to the effectiveness of nucleation and rapidity of crystallisation; glass-ceramic phase assemblage (that is, the types of crystals and the proportion of crystals to glass) which is responsible for many of the physical and chemical properties; nature of the crystalline microstructure (crystal size and morphology and the textural relationship among the crystals and glass) which is the key to many mechanical and optical properties. In particular, a partly crystalline material can be obtained by powder sintering."

Jan 1, 2008

By Edgar Blanco

A thermodynamic and experimental investigation to develop a new process for converting molybdenite concentrate to molybdenum dioxide by a water-vapor oxidation process was carried out. In addition, the behavior of rhenium and selenium in molybdenum concentrate during the process was investigated. The kinetics of the reaction were determined by measuring the weight change of a sample with time in water vapor at temperatures between 700-1000°C. The results were analyzed by a Shrinking Unreacted Core model under chemical reaction control, which showed an activation energy value of 102 kJ/mol. To determine the behavior of rhenium and selenium, their concentrations in the molybdenum sulfide and the product molybdenum dioxide were measured by the use of ICP. While most rhenium remained with the molybdenum dioxide after the water vapor oxidation, almost all selenium volatilized. These results agree with thermodynamic analysis.

Jan 1, 2006

By Robert Vidal

The performance of a laboratory-scale cell for the electrolysis of an aqueous chrome alum solution was studied. Electrode potentials, pH, and Eh were recorded. An optimum catholyte pH of about 2.5, consistent with information from the literature was observed. Values exceeding this range resulted in a precipitate formation and are detected by wavering cathode potentials. The role of anodically produced dichromate ions was investigated by chemical analysis. It was found that the steady state concentration of dichromate ions varies inversely with fluid flow from catholyte to anolyte. This concentration was also reduced with the use of precious metal coated titanium anodes.

Jan 1, 1994

By E. Allain

Extraction of basic metals from sulfides by conventional pyrometallurgical processing leads to the emission of SO2. To avoid this inconvenient, low temperature selective chlorination of sulfide concentrates could be an alternative. However, such process generates hazardous chlorides SxCly. A part of sulfur chlorides such as SCI2 can be recycled as a chlorinating agent of metal sulfides. Hydrolysis of sulfur chlorides, using a solution containing Na2S.9H2O, led to the recovery of more than 90 pct of elemental sulfur. Reduction of SxCly by hydrogen was investigated between 300 °C and 800 °C. About 70 and 90 pct of elemental sulfur were recovered from SC12 and S2C12, respectively. A flow sheet for the chlorination of metal sulfides and the treatment of sulfur chlorides was suggested.

Jan 1, 1998

By Jean P. Murray

The extractive metallurgical industry is a major consumer of high-temperature process heat. It is, consequently, a major contributor of C02 emissions and other greenhouse gases derived from the combustion of fossil fuels for heat and electricity generation, or from the process itself. These emissions can be substantially reduced by replacing fossil fuels with solar energy as the source of process heat. Concentrated solar radiation can supply a large amount of thermal energy to endothermic reactions at temperatures exceeding 2000 K. Another potential for C02 emission reduction exists as well. Thermodynamically, the total amount of energy required for metal production at any given temperature is the enthalpy change of the reaction, AH. Of this total, an amount equal to the Gibbs free energy AG must be supplied as high quality energy in the form of electrical work or by using a reducing agent. Many conventional metallurgical electrolytic processes and reducing furnaces are unable to add only the thermodynamically required electricaVchemical energy due to process inefficiencies. Electrical work in excess of AG for the reaction may be used to supply process heat, or excess chemical reducing agent burned to supply process heat. Besides the thermodynamic and economic drawback, this inefficiency results in excess C02 emissions derived from the combustion of fossil fuels. With these practices, energy becomes an important cost element of the metal produced. Highly-concentrated solar energy has the demonstrated potential to separate these two forms of process energies, allowing the addition of only the thermodynamically required high-quality energy while high-temperature solar process heat is provided to the reactor. Examples of metal oxide reduction processes that have been studied experimentally in solar furnaces include the production of Fe, Al, AI/Si alloy, Mg, Zn, Tic, Sic, CaC2, TIN, Si3N4, and AIN by carbothermic reduction of their oxides, and the high-temperature solar- electrothermal reduction of ZnO.

Jan 1, 1999

By Yuan-bo Zhang, Gui-hong Han, Yan-fang Huang, Tao Jiang, Guang-hui Li

"Under isothermal conditions, the reduction behavior of oxidized pellets balled with bentonite was investigated with CO-CO2gas mixers in the temperature range from 900°C to 1100°C. The whole reduction of oxidized pellets was followed up by means of weight-loss technique. And the swelling index of pellets was examined by visualizing physical changes of pellet in a horizontal tube furnace. The results present that the reduction rate of oxidized pellets is increased with the increase of reduction temperature. While the swelling index is firstly increased and then decreased with the increase of reduction time and reduction extent, which can be ascribed to the disruptive stresses induced during the transformation of hematite to magnetite. The maximum swelling index is gradually increased with the increase of reduction temperature and CO content.IntroductionWith the rapidly development of iron and steel industry, direct reduction iron has been considered as one kind of high quality burdens in electric furnace steelmaking [1]. At present, ""Two-step"" coal-based direct reduction process, which employs oxidized pellets as raw materials, has been used in industrial production [2]. The reduction behavior of iron ore oxidized pellets has been becoming one of the most frequently studied topics in extractive metallurgy[3]. The heat and mass transfer in direct reduction processes results in a series of stepwise reduction reaction (hematite--magnetite--wustite--iron), accompany with the volumetric swelling of pellets[4]. A lot of literatures have been reported on the reduction model of ferrous oxides and swelling behavior of pellets. A. A. El-Geassy K, et.al [5-7] revealed that the reduction process was controlled by chemical reaction at early stage by employing pure Fe203 as raw materials and CO as reduction gas. Chen Y [8] made research on the reduction kinetics of porous oxidized pellets and obtained the rate constant and activation energy of at different reduction stage. In addition, the swelling and disintegration of iron ore pellets was affected by chemical composition of pellet and reducing parameters, which have been studied by numerous investigators [3,9, 1O]."

Jan 1, 2013