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By Pinakin C. Chaubal

An industry ? university consortium was set up to develop advanced tools necessary to understanding of the various phenomena occurring in the hearth of the modern iron making blast furnace. The major driver for this work was to provide the technological support required to extend campaign life of blast furnaces, which, by current agreement is tied to the life of the furnace hearth. The hearth wear is significantly affected by the hot metal velocity, temperature distribution and refractory temperatures. Due to the difficulty in making measurements inside the hearth, novel approaches to gain a fundamental understanding of the detailed physical and chemical processes in the hearth must be developed. The approach used in this project was to develop a 3-D CFD (Computational Fluid Dynamics) model coupled with extensive validation efforts. The CFD model is being utilized (1) to understand the phenomena in the hearth, (2) to understand the impact of changes in the internal conditions of the hearth on wear patterns; and (3) to design a monitoring/controlling system for prolonging campaign. In this paper, the results will be reviewed.

Jan 1, 2006

By Susumu Okabe

Mitsubishi Continuous Copper Converter employs the top blowing lance system for the continuous supply of reaction gases into the molten bath. In order to avoid the excessive refractory wear caused by the melt splash without loss of the reaction efficiency, the furnace design and the blowing condition should be optimized. Empirical equations which correlate the splashing rate on the' side wall with the dimensions of the furnace, lance position, lance size, gas velocity and bath properties were obtained by by the physical model study, and compiled into a computer program. The computer program is effectively utilized for the analysis of the actual operation and for the optimum design of new furnaces.

Jan 1, 1998

By Ting Liu, Qian Li, Peng Deng

The wastewater containing Hg2+ and Pb2+ does great harm to the environment and human bodies. Traditional wastewater treatment cannot fundamentally put a stop to heavy metals pollution for producing secondary pollution. In this paper, Hg2+ and Pb2+ in wastewater were removed and recovered by sulfide precipitation- flotation. Sodium sulfide was used as precipitant and butyl ammonium aerofloat was used as collector. Results indicated that Hg2+ and Pb2+ could be reduce to less than 0.03mg/L and 0.16mg/L respectively by both coprecipitation- floatation and fractional precipitation- floatation. In these two methods, fractional precipitation flotation could not only remove Hg2+ and Pb2+ from wastewater, but also could recover mercury and lead effectively. The infrared spectrograms showed that the adsorption between butyl ammonium aerofloat and mercury precipitate or lead precipitate is chemisorption.

Jan 1, 2015

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 Manuel Pérez-Tello

An experimental study on the oxidation of chalcopyrite (CuFeS2), pyrite (FeS2), covellite (CuS) and chalcocite (Cu2S) particles was conducted by means of differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA) techniques. Oxygen concentration in the process gas was set to 40 and 70% by vol. and a heating rate of 40 °C/min was used. Response variables included: the temperature of incipient reaction, the total exothermic heat of reaction, particle mass, morphology, and mineralogy of the reacted particles. Based on the experimental data and phase stability calculations, reaction mechanisms were proposed to represent the behavior of the particles during oxidation. The reaction mechanisms were verified by X-ray diffraction (XRD) analyses of the oxidized particles, and by thermochemical and mass balance calculations to reproduce the DSC and TGA thermograms. Overall kinetic models were developed to represent the evolution of the exothermic heat of reaction for each mineral as a function of time. Experiments conducted with copper concentrate particles containing the minerals studied suggest that the reaction mechanisms for the individual minerals can be used to represent the oxidation behavior of the copper concentrate particles.

Jan 1, 2006

By Brandon R. Ball

An investigation of the effects of ozone and ozone-induced hydroxyl radical on reducing whole effluent toxicity is described and discussed relative to the application of ozone for industrial water treatment. Results from operation of an ozone system treating industrial effluent from a lead and zinc mine in Colorado are presented. The mine discharges 1,000 gpm of wastewater into a tributary of the Arkansas River and has historically exceeded Whole Effluent Toxicity (WET) limits and on occasion has exceeded numeric limits for copper, ammonia, and cyanide. Based on results of a Toxicity Identification Evaluation (TIE) conducted on the effluent and individual process waste streams, the source of effluent toxicity is believed to be primarily associated with organic reagents used in the milling process. Based on test results, an applied ozone to COD ratio of 3: 1 by weight and a contact time of 30 minutes was found to be effective for reducing whole effluent toxicity at pH 11 but not at pH 7, indicating oxidation by hydroxyl radical to be the dominant mechanism responsible for toxic-ity reduction. At an applied ozone to COD ratio of 3:1 and a pH of 11, toxicity was improved from 0 percent survival to 100 percent survival for Ceriodaphnia dubia and fathead minnow (Pimephales promelas) based

Jan 1, 1996

By Ludovic Charpentier

Production of metallic wires directly from liquid jets would avoid drawbacks of extrusion (space needed, damaging, cost?) and enable recycling. But liquid jets tend to break, due to capillary instabilities, unless a solid layer (coating or start of solidification) surrounds it. We recently developed a process to produce tin wires, cooled by water flow parallel to the jet. Superficial oxidization of tin produces a glass coating around the jet. Studies showed the length of wires increased when increasing speed of tin jets, and that water average speed should be the closest possible to the jet one to have smooth fibers. Producing 1 mm diameter wires is possible. The length of wires is limited by the experimental setup, which does not provide possibilities to coil the wire. Most of other metals do not generate glass-like oxides. The lack of coatings makes it necessary to reduce the capillary instabilities to obtain fibers.

Jan 1, 2006

By Oscar J. Restrepo

Through reactions in solid form at high temperatures, using iron oxide (Fe3O4) and chromium oxide (Cr2O3) in fixed proportions as precursors, the compound was synthesized with spinel structure type FeCr2O4. For different temperatures synthesis was conducted the characterization of the material obtained through X-ray diffraction (XRD), spectroscopy UV-VIS-NIR, scanning electron microscopy (SEM), energy dispersion analysis of X-ray (EDX) thermal analysis (DTA / TGA) and magnetic susceptibility of alternating current. The changes in the spectra of reflectance changes are related to the phase identified, the degree of crystalline structure, the spatial order of cations and the magnetic behavior obtained.

Jan 1, 2009

By Ladislav Bebar, Tomas Parizek, Radek Dvorak, Petr Stehlik

"More and more sweeping environmental regulations initiate research, development and introducing into operation up to date technologies for cleaning off-gas and flue gas generated in various branches of industry and municipal waste treatment. The following systems based on novel types of equipment are shown: thermal and catalytic treatment of waste gases polluted by VOC (Volatile organic compounds) and carbon monoxide (alternatively NOx), catalytic filtration for efficient destruction of PCDD/F (dioxins) and potentially NOx, wet cleaning of flue gases polluted by SO2, HCl and HF with a original type of homogenizer “O-element”, integrated equipment for cleaning waste gases polluted by solid particulates, SO2, HCl, HF and heavy metals (alternatively NOx or PCDD/F). The outstanding features of all equipment mentioned above are low investment and operating costs together with high removing efficiency of pollutants. These units can be used mainly in incineration plants, refineries and other chemical plants. The paper represents a review based on papers published in reputable international journals and a monograph under preparation as well as on experience from industrial applications.IntroductionIn the recent years, more and more emphasis is put on preserving clean environment. One of the most closely monitored objects of general public attention are exhaust gases, containing a number of undesirable compounds like NOx, CO, SO2, HCl, HF, fly ash a PCDD/F. These harmful species are created in chemical processes mainly in the industry, transport and energy sectors. There is therefore a strong impetus for abatement of these harmful pollutants. Sectors of industry are thus subject to emission regulations specific to various types of units. In the framework of increasing demand for a clean environment, the concerned legislation is becoming increasingly strict and requires removal of pollutants by modern methods that would ensure efficient abatement of emissions at reasonable investment and operating costs.Attention is focused chiefly on methods for decreasing harmful emissions from thermal waste treatment facilities processing industrial and municipal waste that may be subsequently applied in other sectors of industry. Units for the thermal treatment of waste not only provide means of its disposal, but may become also important sources of energy, provided that strict emissions limits are satisfied. Figure 1 compares emission limits given by the legislation for municipal waste incinerators and limits for a selection of energy sources with heat capacity up to 50 MW (see EU regulation 200/76/EC). The Figure implies that the values of emission limits for waste incineration are mostly comparable with emissions from the combustion of natural gas. Thanks to the continuing improvements of the methods for removal of harmful pollutants, the emissions from waste incinerators are typically deep below the limits."

Jan 1, 2008

By C. E. Abbey, M. S. Moats

It is well known that the addition of cobalt to copper sulfate — sulfuric acid electrolytes decreases the overpotential for oxygen evolution and decreases the rate of corrosion of Pb–Ca–Sn anodes. This effect, however, has not been ade- quately quanti fied in the presence of iron and manganese in this type of electrolyte. This work provides quanti fiable data on the effect of cobalt concentration in the range of 0 –0.6 g/L in synthetic electrowinning electrolytes with and without the presence of iron. The effect of cobalt on anode potential was determined using 2 and 24 h chronopotentiometry experiments. As expected, Pb–Ca–Sn potentials increased with decreasing cobalt concentration over the range of 0–0.6 g/L Co with and without the presence of Fe. Two regression models were developed to allow plant operations the ability to predict anode potentials as a function of cobalt concentration with or without iron in the electrolyte.

Mar 1, 2017

By Jing Zhan, Tian-zu Yang, Wei-feng Li, Li-Hua Jiang, Shi-yan Xu, Jian-yang Huang, Chuan-fu Zhang, Yan-qing Fan

The amount and activity of coal, reduction temperature and other parameters of the process of bottom-blown reduction of liquid high lead slag were investigated in laboratory. Methods to strengthen the bottom-blown reduction process were studied by industrial production. The results were in the follows: the reduction temperature was 1150℃; reduction time was 1.5h; the reductant was anthracite; lead content in slag was controlled to 2%; the rate of coal was 7% and gasification loss of coal in high temperature was severe; liquid lead slag reduction rate was faster with coal; prolonging the reaction size had little effect on reducing lead in slag; the size of the reactor can be further reduced.

Jan 1, 2015

By Metehan Erdogan, Mustafa Serdal Aras, Sedef Cift Karagul, Ishak Karakaya, Esra Karakaya, Merve Kolay Ersoy

Pickling is the treatment of metal surfaces by removing oxide layer, rust, scale, inorganic contaminants or other impurities from ferrous metals, copper or precious metals. A strong inorganic acid such as hydrochloric acid is used for plain carbon or low alloy steel pickling. When the concentration of copper in the pickling solution exceeds about 100 mg/L, reversion may take place and randomly plating of copper onto the steel strips which causes visual incompatibility occur. Furthermore, efficiency of pickling decreases with the increase of copper content. The reversion may be delayed to higher Cu concentrations by adding fresh acid to the line. Increased acid consumption only delays the time to discard the solution but increases the cost and hazardous nature effect on the environment. An experimental electrochemical procedure has been conducted to remove copper from pickling solution to reduce the concentration below 100 mg/L. Within this scope, effects of applied current density, copper concentration and electrolysis duration on copper deposition were studied. Current density was determined as the most effective parameter to remove copper from the regenerated pickling solutions of steel plants.

Mar 1, 2018

By Hiroaki Kawamura, Takeshi Yoshikawa, Kazuki Morita, Yutaka Yanaba

"To develop an alternative metallurgical process for phosphorus removal in the production of solar-grade silicon (SOG-Si), slag treatment of metallurgical-grade silicon (MG-Si) was conducted, followed by acid leaching. Phosphorus-doped silicon alloy or MG-Si containing certain amounts of phosphorus and calcium was reacted at 1723 K and 1773 K with CaO--CaF2 of several compositions. Phosphorus removal from the molten silicon into the slag phase was confirmed by reduction to phosphide ions, P3-, and phosphate ions, P3-. These ions were separately determined using a wet chemical analysis method developed by ourselves. The highest phosphorus distribution ratio obtained was 2. 7 after reaction for 18 h with 17.5 mass% CaO--CaF2 slag. We then conducted acid leaching of the silicon and achieved removal of a large fraction (over 90 % ) of the phosphorus, which was much higher than that obtained by ordinary oxidizing slag treatment.IntroductionIn recent years, the production of solar cells has been increasing rapidly. Because of this, the demand for solar-grade silicon (SOG-Si) has also been growing rapidly. The development of lower-cost mass production processes is therefore needed to provide silicon feedstock. Phosphorus is one of the impurities in metallurgical-grade silicon (MG-Si). Because of its large segregation coefficient (kp = 0.35) [l ], it is difficult to remove phosphorus using a solidification refining process. Vacuum melting is considered to be a promising method for removing phosphorous from MG-Si [2], but the issues of high cost and large energy consumption have still to be resolved.Slag treatment is often used to remove impurity elements by oxidizing reactions during general oxidation refining processes. For example, phosphorus in molten steel is removed into a slag phase as phosphate ions, PO4 3-l-, by the following reaction:"

Jan 1, 2013

By Marilda Macagnan, Rosana de Cassia de Souza Schneider, Valeriano Corbellini, Tiago Bjerk, Mariela de Souza Vieira

The great potential of Brazil for the agricultural production makes our country a generator of agro industrial residues. In this context, the solid-state fermentation appears as a technology that shows alternative ways for those residues, adding values to these raw materials, through the production of substances of industrial interest, besides reducing the possible environmental problems. The main objective of this study was to apply the bovine fat residue associated to the garden grass for the fungal lipase production. Initially, 75 microbial cultures were isolated from garden grass samples after incubation of the mixture with bovine fat. From these cultures were selected the filamentous fungi, whose lipase production abilities were evaluated. The isolation and the selection were accomplished by using a differential culture medium containing Tween 80 as inducer substrate of lipase production. The colonies with lipolytic potential were detected by the presence of white precipitation haloes on the agar. With agro industrial residues the best lipase producer fungus was identified as Penicillium sp in 6 days of solid state fermentation. The crude enzyme obtained was tested in transesterification process for the biodiesel production.

Jan 1, 2008

By Gerhard Bayer

X-ray and thermoanalytical studies were carried out on the formation and stability of Ca-, Mg-and Mn-tungstate, and of the corresponding minerals scheelite and wolframite. The tungstates were synthesized by different methods: precipitation from solution, solid state reactions, displacement reactions with solutions and in the solid state. The reactivity of natural scheelite and wolframite with different salt solutions and in mixtures with other minerals was investigated.

Jan 1, 1989

By Jewel A. G. Gomes

Green rust (GR) are layered Fe(II)-Fe(III) double hydroxides, having a pyroaurite-type structure consisting of positively charged hydroxide layers and hydrated ions in interlayers. This special feature of GR is very efficient for wastewater treatment as the pollutants are easily taken in or exchanged with the anions in the interlayers. It can be simply and cost-effectively produced by electrocoagulation (EC). Chicken processing plant (CPP) produces large amount of wastewater containing variety of readily biodegradable organic compounds, fats, and proteins. The possible re-use of properly treated CPP wastewater would be economic and environment friendly. In this study, we present our work on treatment of CPP wastewater using EC, specifically for the removal of COD. Analysis of the EC-treated water for reuse in the same plant is discussed considering the U.S.EPA regulations. Two types of EC-reactors were used for this purpose. To better understand the treatment mechanism, EC-floc was also characterized using XRD and SEM-EDS.

Jan 1, 2010

By Masaru Imaizumi, Hiroyuki Nomura, Mitsuharu Takita

"Cast iron possesses many superior characteristics caused from precipitated graphite structure, for example, castability, wear resistance, solid lubrication, damping capacity. But the more graphite hyper-eutectic cast iron contains, the lower its mechanical strength becomes, because graphite gives a negative effect to strength of cast iron. In addition, primary graphite tends to segregate during solidification, so uniform materials are difficult to be produced.In this study, authors introduced semi-solid processing in developing new and high quality cast iron. A series of semi-solid processing experiments were carried out to clarify the effect of stirring condition; solidification temperature and etc. on microstructures and characteristics of cast iron. In particular much attention is paid to the appearance of ternary eutectic zone at the final stage of solidification. As the results advanced hyper-eutectic cast iron was obtained with high quality of both the mechanical strength and wear resistance. As for the mechanical strength, 300MPa and 0.60% are obtained as the tensile strength and the elongation values, respectively, under the controlled stirring condition. This indicates that semi-solid processed hyper-eutectic cast iron is used prospectively without spheroidization.IntroductionCast iron has various good properties such as wear resistance, solid lubrication, damping capacity and machinability. The characteristics of cast iron are mainly decided by graphite structure, namely graphite shape and its distribution in the matrix. Mechanical strength of cast iron is large in the case of small quantity of graphite particles which are precipitated uniformly, however, it becomes small in the case of large quantity of graphite precipitated flakily."

Jan 1, 2000

By William K. Tolley

The U.S. Bureau of Mines (USBM) is investigating hydrometallurgical processing techniques to recycle metals from semiconductors and other advanced materials. Cadmium and tellurium were recovered from mixed CdTe/CdS scrap produced in the manufacture of thin-film photovoltaic devices. Cadmium and tellurium dissolution was achieved using hydrogen peroxide in dilute sulfuric acid. Leaching the scrap in 2.2 N H2SO4 yielded 99% Cd extraction and 98% Te extraction. Sulfur remained in the leach residue primarily in the elemental form. Elemental tellurium was precipitated from the leach liquor by adding Na2S2O5. Cadmium sulfate was recovered by evaporation. A preliminary process evaluation suggests that the process may have economic potential. Alternative recovery schemes are discussed.

Jan 1, 1995

By K. Sadrnezhaad

Industrial and experimental induction furnaces are used for melting various types of iron ingots, returned scraps and DRI sponge pellets to produce high purity cast-iron and steel heats. The lowest consumption of the electrical energy is determined for continuous feeding operation to be 0.3 KWH/Kg for production of cast-iron in 1.5-ton industrial furnace and 0.45 KWH/Kg for production of steel in 25-Kg experimental furnace. The optimum feeding rate for lowest energy consumption is obtained to be 12.5 grams per second for continuous feeding of DRI in 25-Kg induction furnace. Similar measurements show that the optimum size of the DRI pellets is around 8 millimeter.

Jan 1, 1988

During electrowinning of nickel chloride, hydrochloric acid was regenerated instead of chlorine in a two membrane cell, by segregating the chloride catholyte with an anion exchange membrane, and the sulphate anolyte with a cation exchange membrane from the middle electrolyte (ampholyte) compartment. Successful operation of such a cell depends on controlling chloride leakage through the cation exchange membrane to the anolyte. Small amounts of chlorine gas could be detected in the oxygen evolved at the anode. In this paper, the chloride. leakage as a function of various types of cation exchange membrane and different composition of the anolyte is reported and discussed. Ag+ was added to the anolyte to eliminate chloride leakage to the anode. The cell voltage, electrode potential and voltage drop over the membrane as a function of current density has also been investigated.

Jan 1, 1996