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By Anil Saigal, Mark H. Shooter, Michael A. Zimmerman

Liquid Crystalline Polymers (LCPs) provide favorable dielectric properties for extremely high frequency (30–100 GHz) radio frequency device packaging and printed circuit board substrates. The material studied in this work is a proprietary, thermotropic LCP composite developed and manufactured by iQLP (Woburn, MA, USA). Dielectric constants measured in the flow direction of the post-processed materials differ between the two processes, 3.51 in injection molded plaques, and 4.23 in cast films. This investigation sought to determine the cause of process-induced variation in the dielectric constant between injection molded and cast film extruded LCP. The complex thermomechanical environment present during processing of LCPs creates a through-thickness hierarchical structure, simplified in this study as a skin and core layer. The volume fraction of skin layer of the post-processed LCP was determined to be the differentiating factor, and responsible for the difference in dielectric constant between the injection molding and cast film extrusion processes. The resulting dielectric constant is a function of this volume fraction with a near linear relationship.

Mar 1, 2017

By Xun Zhang, ZhiLong ZHAO, Lifeng Zhang, Huiqing Tang

A two-dimensional gas-solid model has been developed for examination of the blast furnace (BF) performance under hot charge operation. Simulation conditions were obtained from the actual operation conditions of the BF with inner volume of 2500 m3 and molten iron output of 6250 ton hot metal (THM) per day. The simulation results indicate that hot charge operation could change the thermal state of the BF in the region above cohesive zone (CZ) and has little influence on the thermal state of CZ zone and the region below CZ; it could intensify both the indirect reduction of the ore and the gasification of the coke in the region above the CZ. The optimum temperature for hot charge operation is 750 K, under which, a coke rate reduction of 25 kg/THM could be obtained.

Mar 1, 2017

By Fuming Wang, Xi Chen, Shuai Liu, Changrong Li, Dan Wu, Yaxu Zheng

The effects of B content and austenitizing temperature on hardenability and toughness of Cr–Mo alloy steel have been studied. The results show that the hardenability is deteriorated with increasing B content and austenitizing temperature. With increasing temperature, more and more B containing particles were dissolved in austenite and increase the amount of B atoms segregating at grain boundaries. Moreover, the coarsening grains reduce area of grain boundaries and also increase the amount of B atoms at unit grain boundary, excessive B atoms segregating at grain boundaries promotes precipitation of M2B, which accelerates ferrite nucleation and reduces hardenability. The main elements in M2B phase are Fe, Cr, Mo and B. The B atoms segregating at grain boundaries during austenitizing promote precipitation of M2B during tempering which deteriorate toughness significantly.

Mar 1, 2018

By Shilai Yuan, Huimin Lu, Panpan Wang

A big andalusite ore bed was found in Dingxi District, Gansu, China. In this paper, the feasibility of producing solar grade silicon from aluminum-silicon alloys by carbothermal reduction of andalusite ore was studied. First, the carbothermal reduction experiments were conducted in a 100 kVA DC submerged arc furnace with reducing temperature 2000–2200 °C and reducing time 4 h, the hypereutectic aluminum-silicon alloys containing 50–55 mass% aluminum and 35–45 mass% silicon were obtained; then the investigation on solidification of the hypereutectic Al-Si melts under the temperature gradient as an intensified separation silicon way was carried out. According to previous investigation, the optimized technical process for solar grade silicon and eutectic Al-Si alloy from andalusite ore was proposed.

Mar 1, 2017

By Jorge A. S. Tenorio, Pedro F. A. Prado, Denise C. R. Espinosa

There is an increasing challenge of waste management regarding the growth of photovoltaic (PV) technology. Often overlooked by its environmental benefits of greenhouse gas emission reduction, PV technology contain metals that are highly hazardous for the environment. Amorphous silicon (a-Si) PV modules employ indium-tin-oxide as transparent conductive oxide and given the high price of indium its recovery could be advantageous from an economic perspective as well. Leaching of indium was predicted by comparing the Pourbaix diagram with the values of oxidoreduction potential and pH measured on a phosphoric acid solution. The a-Si panel was subjected to thermal treatment to remove the proprietary, protective coating and allow leaching to occur. Then, indium could be leached by phosphoric acid in a jacketed reactor, reaching a concentration of 55 ppm (67% leaching rate) with a 0.2 g/mL of a-Si panel to aqueous solution ratio. The leaching of indium with phosphoric acid is novel and could open doors for many other recycling routes for solar panels.

Mar 1, 2018

By Chengyi Ding, Xuewei Lv, Senwei Xuan, Jie Qiu, Yun Chen, Kai Tang

The influence of SiO2 on the reducibility of the CaO–Fe2O3–SiO2 system was fully examined in this study. The isothermal reduction kinetics of CF and CF8S (CaO/Fe2O3 = 1:1, wt% (SiO2) = 8) were investigated through thermogravimetric analysis at 1123, 1173, and 1223 K with 30% CO and 70% N2 gas mixtures. The reduction of the samples with 8% SiO2 was not only highly accelerated but also proceeded easily. Rate analysis revealed that CF and CF8S reduction occurs in two stages, the Fe3O4-to-FeO stage overlaps with the previous Fe2O3-to-Fe3O4 stage and tends to approach the following FeO-to-Fe stage with the addition of SiO2. The apparent activation energy values of CF and CF8S reduction are 46.89 and 8.71 kJ mol−1. Sharp analysis indicated that CF and CF8S reduction was expressed by the Avrami–Erofeev equation presenting a 2D shrinking layer reaction.

Mar 1, 2017

By Mansoor Barati, Yindong Yang, Yonggang Wei, Bo Li, Alexander McLean

Reduction roasting followed by magnetic separation is an important method for treating laterite nickel ores. In this work, garnierite type laterite ore from Yunnan province in China was reduced by methane under different conditions followed by magnetic separation to obtain the ferronickel concentrate. The phase and microstructure transformations of garnierite in the reduction process were investigated using XRD and SEM-EDS. The experimental results showed that reduction temperature from 873 to 1173 K had only a small effect on content and recovery of nickel and iron. The content and recovery of nickel and iron in the concentrates increased slightly with prolonging reduction time. In addition, the nickel and iron content decreased with increasing methane concentration, but the recovery of nickel and iron increases. A decrease in the iron content and recovery were observed when the dosage of sodium sulfate varied from 5 to 20% at a temperature of 1073 K and reducing time of 90 min, while the nickel content and recovery gradually increased.

Mar 1, 2018

By S. L. I. Chan, M. Z. Quadir, D. C. Austin, P. J. Hazell, A. Chen, A. A. H. Ameri, D. East, J. P. Escobedo, M. A. Bevan, A. D. Brown

The microstructure and mechanical response of additive manufactured Ti64 under compression and tension has been investigated. Quasi-static and dynamic experiments were conducted on electron beam powder bed Arcam A1 (EBM) and blown powder laser Optomec LENS MR-7 (LMD) additive manufactured specimens. Hot isostatic pressing (HIP) was conducted on both of the additive manufactured specimens and results were compared with as-received specimens. Digital image correlation (DIC) was utilized to observe the in situ development of deformation fields during tensile loading. Optical microscopy was conducted on pristine and deformed specimens to examine the microstructure of the specimens. HIP treatment reduced the porosity by *90% with a concomitant increase in hardness by 40%. The results from tensile experiments show that additive manufactured Ti64 display a higher values for the yield stress, hardness, and ultimate tensile strength than conventionally manufactured Ti64. Under quasi-static compression, it was observed that EBM specimens exhibit a higher yield strength and ultimate tensile strength than LMD specimens.

Mar 1, 2017

By C. G. Bastos Andrade, F. R. Valenzuela Diaz, S. M. Toffoli

The modification of structural clays by chemical processes is a common method. It usually uses strong inorganic acid attacks, aiming at improving the clay’s properties and applications. Among the applications are its use in clay-polymer nanocomposites, cosmetics, medicines, and bleaching clays. Tests using acid attack to modified Brazilian bentonites were successfully performed and, resulted in significant improvement in the clay properties. This paper discusses the use of a Brazilian bentonite modified by acid attack as bleaching clay. The treated bentonite samples were characterized by XRF, specific surface area (BET) and SEM/EDS. The treated clay exhibited improved bleaching capacity for Brazilian nut oil and other Amazonian oils.

Mar 1, 2018

By Duclerc Fernandes Parra, Vijaya Kumar Rangari, Washington Luiz Oliani, Danilo Marin Fermino, Ademar Benevolo Lugao, Nilton Lincopan, Luiz Gustavo Hiroki Komatsu

Polyethylene is widely used for packing applications. Different grades of polyethylene, LLDPE and LDPE play a major role in the film blowing industry. The use of nanoclay in polymer matrices (non-polar) requires the use of a compatibilizer agent, ethylene graft maleic anhydride copolymer (PE-g-MA), which acts as a bridge for nanoclay-matrix-interaction. In our study, blown films of LLDPE, LDPE, and their blends were produced using a twin screw extruder. The combination of PEs as matrix, montmorillonite (MMT) and silver nanoparticles (AgNPs) intended to improve mechanical and thermal properties. Nanocomposites films with 1 wt% of montmorillonite and 0.5–1.0 wt% silver nanoparticles were prepared by blow extrusion and evaluated. Nanoclay intercalation/exfoliation degree was investigated by X-ray diffraction spectroscopy (XRD) and scanning electron microscopy (SEM). Mechanical and thermal properties were evaluated. The results showed optimum dispersion at intercalation/exfoliation levels for polyethylene nanocomposite (PENC), slight increasing in mechanical and especially improvement in thermal properties.

Mar 1, 2017

By Chengyi Ding, Xuewei Lv, Senwei Xuan, Chenguang Bai, Kai Tang, Gang Li

Sinter is an important iron-bearing material charged into blast furnace. Calcium ferrite (CF) is one of the most significant liquid phases in fluxed sinter. The isothermal reduction kinetics of CF and CF8M (n(CaO):n(Fe2O3) = 1, wt%(MgO) = 8) with 30% CO and 70% N2 gas mixtures at 1123, 1173, and 1223 K were investigated through thermogravimetric analysis in this study. Rate analysis illuminates that the reduction processes of CF and CF8M are mainly expressed as a typical two-stage reaction. Sharp analysis indicates that CF and CF8M reduction is expressed by the Avrami–Erofeev equation presenting a 2D shrinking layer reaction. The apparent activation energy values of CF and CF8M reduction are 46.9 and 31.8 kJ mol−1 individually based on model-free method.

Mar 1, 2018

By Yunqing Tian, Wenbin Huang, Weidong Zhang, Xiaopeng Wang, Gele Qing, Xiangjuan Duan

Pellet production requires iron ore concentrates have fine particle size, high specific surface area and good balling performance, so iron ore concentrates appropriate for pelletizing is limited compared to sintering. In order to extend the iron ore resources for pelletizing, the iron ore fines for sinter are studied in this paper.The effect of grinded iron ores o npelletizing, roasting and pellet quality were studied in this paper. The bond grinding index of iron ore fine is between 12.5 and 16.98 kwh/t. The grinded iron ore fine has good balling performance, the drop number and compressive strength of green pellet were improved with increase of grinded iron ore fine ratio. The compressive strength of roasted pellets were decreased with increase of grinded iron ore fine ratio, however it can be reached 2500 N.P −1 while proportioned with more than 80% of magnetite iron ore concentrate.

Mar 1, 2018

By Ramana G. Reddy, Yuxiang Peng

The long-term corrosion behavior of Haynes 230 (H230) alloy in MgCl2–KCl eutectic salt was evaluated at 1273 K for 500 h in Ni crucible in argon gas. The results showed H230 alloy has good corrosion resistance. In addition, corrosion was noted to occur by depletion of Cr, which was deposited on the Ni crucible. Based on the calculation of Gibbs energy of Ni-Cr alloy and exchange current density of Cr in MgCl2–KCl, the Tafel model was constructed to investigate the corrosion potential and rate. The galvanic corrosion can be explained as the predicted results were in agreement with the experimental data.

Mar 1, 2017

By R. H. Eric, P. Taskinen, A. Bhalla, P. Halli

Sustainable development requires less energy consumption with lower carbon footprint. In this review the solid state reduction behaviour of three oxide ores using methane gas are briefly summarized based on experimental work conducted in our laboratories. The discussion concentrates mainly on mechanisms of the reduction studied through SEM-EDAX and X-ray diffraction techniques. Limited preliminary kinetic input is also mentioned. Iron ore containing titanium and vanadium could be reduced significantly in the solid state with methane-hydrogen mixture up to 400 °C lower than is needed in ordinary solid state carbothermic process. The reduction of chromite and manganese ores were possible similarly at lower temperatures with potential energy savings lower carbon footprint.

Mar 1, 2017

By A. Rikos, G. Pantazopoulos, A. Vazdirvanidis, A. Toulfatzis

In this study, the mechanical properties of an annealed CuZn36 rolled brass alloy with 0.2 mm thickness with respect to anisotropy expressed in terms of plastic strain ratio measurements (r-values, normal and planar anisotropy) are related with the development of specific rolling and recrystallization texture components obtained by EBSD. Anisotropic behaviour is primarily controlled by the crystallographic texture and constitutes an indicator of multi-axial mechanical behaviour, affecting directly the drawability and sheet metal formability. Microstructure examination employing optical and Scanning Electron Microscopy of tensile specimens are performed in order to investigate the emergent damage mechanisms in relation to the texture and structure evolution of the final product.

Mar 1, 2017

By Raj K. Rajamani, James R. Nagel, York R. Smith

In this work, we examine the efficacy of Electrodynamic Eddy Current Separation (EECS) to recover valuable materials from end-of-life solar panels. Traditional rotary-based eddy current separators are capable of excitation frequencies of 1 kHz or less and struggle to economically separate particles smaller than 1 cm. A new design of eddy current separators has been developed at the University of Utah which has no mechanically moving parts. The design is capable of excitation frequencies up to 50 kHz, allowing sorting of particles as small as 1.0 mm. Recently, we have been successful in separating mixtures of Si/Al and CdTe/Al particles (1–3 mm) with recovery and grades greater than 85%, an energy demand of 68 kWh/short ton of sorted material, and throughput of roughly 10 kg/h. Current and future challenges utilizing this method for valuable material recovery from end-of-life solar panels are discussed.

Mar 1, 2017

By G. E. S. Lima, I. K. R. Andrade, N. G. Viana, R. O. G. Martins, L. M. Sathler, L. G. Pedroti, C. M. M. E. Torres, W. E. H. Fernandes, C. M. Silva, M. A. Caetano

In Brazil, kraft pulp mills are rapidly expanding and industrial waste generation is increasing. Technical feasibility of using solid wastes from kraft pulp mills as raw material in other industries may be an interesting approach to manage environmental and economic aspects of the industry. This paper proposes the incorporation, in different proportions (0, 2.5, 5 and 7.5%), of alkaline solid wastes from pulp mills, namely dregs and grits, to clinker in the Portland cement industry. The research was carried out in two steps: (i) characterization of dregs, grits and clinker; (ii) laboratory testing (determination of soundness by the Le Chatelier method, determination of setting times, determination of water content of the paste with normal consistency, determination of compressive strength and static modulus of elasticity). The results showed that the addition of dregs and grits to the clinker up to 2.5% were feasible according to the Portland cement Brazilian standards.

Mar 1, 2017

By Bowen Li, Canhua Li, Mingsheng He

Steelmaking slag is a by-product in considerable volume and a valuable material for various applications. In general, steelmaking slag is an alkaline compound of CaO, Fe2O3, and SiO2. However, its characteristics varies depending on the feedstocks, steelmaking process and cooling method of the slag. To utilize this by-product effectively, this study investigated the characteristics of steelmaking slags taken from Wuhan Iron & Steel Co. Ltd. The results showed that the slags mainly consist of the oxides of calcium, iron, and silicon, with low contents of magnesia, alumina, and manganese oxide with a feature of high alkalinity and lime saturation factor. The major mineral phases include belite, calcium ferrite, calcium hydroxide, wustite, quartz, and small amount of elite. Thermogravimetric analysis indicated the weight loss from ambient temperature to 800 °C is 8% in total. Melting test showed the glass transition temperature is between 1300 and 1350 °C, flow temperature is about 1400 °C. The slag samples investigated in this study can be considered as a typical glass-ceramic composite.

Mar 1, 2018

By T. F. Oliveira, E. B. Zanelato, J. Alexandre, L. J. T. Petrucci, A. R. G. Azevedo

The paper and cellulose industry is responsible for generating large amounts of solid waste, which are produced during various stages of the production process. Currently this material goes to places like landfills and other generating costs for the company. Furthermore, cement, mortar and concrete represent a significant economic and environmental cost. This study aims to determine the pozzolanic activity index in the residue studied to verify its viability in the incorporation of the same in cement. It will be used Luxan method for this determination. The data found show that the material has the possibility of being incorporated in the mortar due to its pozzolanic activity index.

Mar 1, 2017

By Zhenzhou Yang, Zuotai Zhang

In the present study, we proposed a method that using sewage sludge (SS) as alternative fuel and raw material to produce cement clinker. It was found that the increasing amount of SS can favor for the formation of tricalcium silicate (C3S) but the excessive amount can cause the impediment effect. Furthermore, SS contains high contents of trace elements, especially for zinc and manganese. The thermodynamic equilibrium calculation of Zn and Mn are also conducted to further understand their transformation behaviors and the results show that zine is predicted as a volatile element while manganese shows great condensed potential during the cement clinker calcination process.

Mar 1, 2017