Search Documents

By D. G. Eskin

"It is well known that it takes some time for the solid phase to completely dissolve upon melting, especially inside the defects of insoluble particles, e.g. oxides. Until then the oxides remain active solidification substrates in the case of subsequent solidification. It is also known that ultrasonic melt treatment causes grain refinement through activation and dispersion of solidification substrates (one of the mechanisms) and also accelerates the dissolution of solid metal in the melt. In this study we combine these effects and demonstrate that the introduction of an alloy rod into the matrix melt of the same composition results in significant grain refinement, this effect being increased by the ultrasonic vibration of the rod. The achieved grain size is comparable to that obtained by a standard Al–Ti–B grain refiner. All samples were cast using a standard TP-1 mould to enable correct comparison. The effect of the temperature range of the rod introduction, as well as the effect of ultrasonic vibrations are discussed.INTRODUCTION The fact that by introducing solid metal into the melt one can achieve structure refinement is rather well known. As early as in the 1930s–1950s a series of papers and patents have been published, showing the benefits for grain refinement when dissolving solid metal in the melt before solidification (Danilov and Neimark, 1938; Scheil, 1956). Later on this way of structure refinement was developed further and dubbed “suspension casting” or introduction of “internal chills” (Madyanov, 1969; Zatulovsky, 1981). The solid metal was added in a form of cut wire, cut sheet, or powder, with the resulting grain refining, elimination of columnar grain structure in ingots and castings of steel, copper and aluminium alloys. The underlying mechanisms have been suggested as (1) rapid cooling of the melt due to the latent heat consumption upon melting of the solid metal with the resultant melt undercooling and (2) introduction of many solidification substrates in the form of crystal fragments and active non-metallic inclusions (Danilov & Neimark, 1938; Balandin, 1973). A number of patents have been filed where either the same solid alloy or a master alloy with additions (e.g. Ti for Al alloy) is introduced in the amounts up to 50% (typically less than 10%) into the melt close to the liquidus temperature (Schmidt, 1966; Talbot & Soller, 1973, Krupp, 1974; Bondarev, 1979). The main reason that this technique is not widely used in industry is the possible incomplete dissolution of the solid parts introduced into the melt with ensuing inhomogeneous as-cast structure and potential defects. Also the selection of the temperature range where the technology works the best is not clear."

Jan 1, 2018

By T. Billotte, G. Tirand, J. Zollinger, V. Robin, B. Rouat, D. Daloz

The grain structure prediction of metallic alloys during a welding process is often an issue. In addition to the welding parameters and the alloy nominal composition and properties, the base metal grain structure and chemical homogeneity also play an important role in the formation of the final microstructure. In this paper intensive characterisation of solidification structure in gas tungsten arc welding of Ni base alloy 600 are described. It is shown that in transverse section of the weld, while the grain structure shows some texture following constrained solidification growth, grain density in the weld is similar or greater than grain density in the heat affected zone. This suggests that simulation of the welding structure needs, in order to be predictive, to take into account : epitaxial growth, secondary nucleation events and 3D growth inside the weld pool.

Jan 1, 2015

By R. A. Masumura, C. S. Pande, D. Agassi

"Grain size has a different effects on the critical current density (Jc) of high and low transition temperature (Tc) superconductors. In high Tc superconductors, the critical current density Jc across grain boundaries depends sensitively on the misorientation 8. It was pointed out by Pande that this dependence is directly related to dislocation structure of the grain boundaries i.e., it is due to dislocation cores and stresses. These ideas are developed further in this paper leading to a relation between Jc and 8. The analytical result is compared with the experimental results on bicrystals and used to explain the difference in behavior between high and low Tc superconductors.IntroductionThe grain size distribution and its evolution with time and temperature is important in determining the properties of high and low transition temperature (T c) superconductors. The distribution is a convenient function to characterize the processing of a high Tc material during sintering. For example, it is known that the maximum density of ceramic materials is obtained when the grain growth is reduced but grain boundaries are still mobile. For practical superconductors, the processing parameters are selected to achieve optimum properties: highest possible T c and maximum critical current (Jc). In terms of an average grain size, the requirements for optimum T c and Jc are sometime in conflict. In A15 type superconductors and even in NbTi, larger Jc have been measured in smaller rather than larger grain sized material. Conversely, in a high Tc materials like YBa2Cu307, higher Jc have been found in larger grain sized or single crystal specimens.Extended defects such as grain boundaries in low T c superconductors can be effective pinning agents for magnetic flux lines, thereby increasing the transport critical current density of these materials [1]. On the other hand, the transport critical currents in polycrystals of high Tc superconductors such as YBa2Cu307 is found to be relatively small (much smaller than those in single crystals of the same material) [2]. It is now known that grain boundaries in high Tc polycrystals can in many cases form ""weak links"" reducing the critical current density across them. This phenomenon can be studied more precisely by experiments on bicrystals, where there is only one grain boundary. It is found that the critical current density is quite sensitive to the misorientation angle of the bicrystal [3,4]. Although the original experiments were conducted on YBa2Cu307, other Tc superconductors have been shown to give the same result [5]."

Jan 1, 1994

By W. Stumpf

Mill log analyses and complementary hot deformation studies were carried out on the as-cast structure and on a hot rolled structure of the same low carbon steel (SAE 1006) that had been processed according to the direct or hot charge route in a compact strip plant. The main softening mechanisms during hot rolling were found to be complete dynamic recrystallization during each pass above about 1000°C for the as-cast structure with an austenite grain size of 277µm and, secondly, incomplete static recrystallization after each pass with a finer austenite grain size of about 26 µm and tested below 1000°C. A two-stage hot working mechanism has also been found by others on a similar steel also processed by the hot charge route and this may appear to be a characteristic of this type of material. Constitutive constants determined from hot working studies were combined with other constants from the literature and incorporated into a grain size development model that correctly predicts the final ferrite grain size in the hot rolled strip steel. The predicted incomplete static recrystallization during the last three finishing passes in the plant appears to result in some retained strain in the hot rolled austenite as it transforms to ferrite on the run-out table. Analyses with the model predict relatively little sensitivity of the final ferrite grain size to process and product variables such as temperature and strain per pass for the last three passes and also the starting austenite grain size in the slab. Keywords: Low carbon steel, hot rolling of strip steel, rolling mill log analyses, austenite grain size, ferrite grain size, grain size modelling.

Jan 1, 2003

By Božidar Šarler, Umut Hanoglu

A rolling simulation system has been developed to calculate the macroscopic rate of deformation, stress, strain, and temperature fields by using a novel meshless method. The model is based on two-dimensional traveling slice assumption. The slices are aligned towards the rolling direction. The initial size of the billet, bloom or slab and the geometry of the grooves at each rolling stand, the distances between the rolling stands, and continuous or reverse rolling can be arbitrarily considered. The purpose of this paper is to complement these development by predicting and visualizing also the grain size of steel over the strand cross-section for each position in the rolling mill. The grain size models have been in one-way coupled to the macroscopic calculations. First the critical strain for dynamic recrystallization is being checked. If the calculated strain is higher than that, considering also the time for meta-dynamic recrystallization, dynamic or meta-dynamic grain size calculations are carried out. If the strain is too low then only the static recrystallization is considered together with its required time. Finally, austenite grain size and ferrite grain size are calculated respectively as the steel cools down. The listed physical models are based on collection of empirical relations found in literature. The user of the system is free to choose or create the model he wants with his own parameters. The simulation system has been coded as a user friendly computer application for an industrial use based on C# and .NET framework and runs on regular PCs. The computational time for a rolling simulation is usually less than one hour and can thus be straightforwardly used for optimization of the rolling mill design in a reasonable time.

Oct 1, 2019

By Chidchai Loyprasert, R. A. Stoehr

"A computer model has been developed to predict grain structures in alloys solidified under unidirectional flow using a combination of three techniques -- solution of the equations for flow of an incompressible fluid bounded by curved surfaces by the SOLA-SURF algorithm, calculation of heat flow by a finite difference method, and simulation of grain formation by a two-dimensional cellular automaton (CA) model. The changing rigid surface has been taken into account. Heterogeneous and homogeneous nucleation are considered, and the growth kinetics of a dendrite tip are evaluated by the Kurz-Giovanola-Trivedi (KGT) model. These calculations were applied to solidification of an Al-4.5% Cu alloy flowing over a chill on the bottom of a channel, a system for which experimental results were available. Using a variety of flow rates and superheats, agreement between the computed and experimental results were very good including transitions between columnar and equiaxed grains, the aspect ratio of the grains, and the inclination of the grains to the flow.IntroductionModeling of casting and solidification processes has developed over the years along two distinct tracks: (1.) modeling of macroscopic heat transfer and fluid flow for design purposes, and (2.) modeling of microscopic processes such as nucleation and growth in order to improve the scientific understanding of the phenomena involved. The present work is an attempt to combine the macroscopic and microscopic approaches for the solidification of an alloy flowing over a chill. The specific case chosen is that of an aluminum-4.5 % copper alloy flowing linearly over a water-cooled copper chill for which experimental results were available over a range of flow rates and superheats. For the macroscopic calculations, the SOLA-SURF algorithm for solution of the twodimensional fluid flow equations was combined with the finite difference method (FDM) for calculating heat transfer. For the microscopic calculations, heterogeneous and homogeneous nucleation were considered, and the growth kinetics at the dendrite tips were evaluated. The cellular automaton (CA) technique was used to apply the microscopic kinetics to the temperature and .flow conditions."

Jan 1, 1999

By Zay Jeffries

THIS paper will include a brief discussion of Prof. Howe's paper on The Supposed Reversal of Inheritance of Ferrite Grain Size from that of Austenite.1 The general subject of grain refining in steel and iron will also be treated. The conclusions reached are stated in the following hypotheses which are discussed more in detail below. 1. The ferrite grain size in pure iron, the ferrite and pearlite grain size in hypoeutectoid steel, the pearlite grain size in eutectoid steel and the cementite and pearlite grain size of hypereutectoid steel are not inherited from the grain size of the mother austenite. 2. The only structural feature that is generally inherited from the austenite of hypo- and hypereutectoid steels on cooling through their transformation ranges is the position of the excess ferrite or cementite at the austenite grain boundaries, sometimes causing complete and sometimes incomplete networks which outline the old austenite grain boundaries. Rapid cooling through the transformation range will cause the non-inheritance of this structural (network) feature. 3. The austenite grain boundaries themselves are nearly always effaced in all steels and also in pure iron during the Ar transformations. 4. The grain-size refining of steel and iron is brought about by the combined. effect of non-inheritance of the transformation products on either heating or cooling, i.e., the austenite transformation .products do not inherit their grain size from the austenite on cooling through the transformation range for does austenite inherit its grain size from the products which form austenite on heating. 5. In general, in both iron and carbon steel the larger the austenite ,grain size, the larger will be the grain size of the transformation products on cooling. This, of course, assumes all other conditions constant except the austenite grain size. An exception is found to this general rule in very pure iron such as electrolytic iron. 1n this instance small austenite grains may form very large ferrite grains on cooling through Ar3.

Jan 11, 1917

By Cyril Stanley Smith

THE art of metallography is mature and the forms in which various micro-constituents appear are well known. Investigations almost without end have disclosed the importance of the exact manner of distribution of phases on the physical properties and usefulness of an alloy. Surprisingly, however, relatively little attention has been paid to the forces that are responsible for the particular and varied spatial arrangements of grains and phases that are observed. Like the anatomist, the metallurgist has been more concerned with form and function than with origins. In this paper it is proposed to develop the simple concept that many microstructures result from an attempted approach to equilibrium between phase and grain interfaces whose surface tensions geometrically balance each other at the points and along the lines where they meet. From this follows a number of principles which may prove to be of interest to the metallographer and of practical use in explaining failures and in designing alloys for particular service. In general, the discussion will be limited to structures obtained after full annealing. The simple principles do not apply to structures resulting from Widmanstatten mechanisms in precipitation, or to other structures not in local equilibrium and in which lattice coherency is a determining factor. INTERFACIAL TENSION Much has been written by physical chemists about the free energy of surfaces, which manifests itself as a measurable surface tension. Two- and three-phase interfaces in fluids seek a condition of minimum energy and approach a geometrical configuration in which the various forces are in vectorial balance.* Measurement of the angles established between the interfaces when in equilibrium provides a quantitative value for the relative value of the surface forces involved. The case of two fluids meeting at the surface of a solid (of great importance in connection with the flotation of minerals) has often been studied, but there have been few investigations of the equally definite interface between two or more crystals of a single solid phase, or the more complex cases where crystal grains of more than one phase are involved. The principles are best illustrated by considering first the case of two and three immiscible liquids. If, as in Fig I, a liquid, 2, is dropped into a less dense liquid, I, it will form a sphere-if gravity and viscosity can be ignored-for in this shape the interface has the smallest possible area. If these two phases should together encounter a third phase in which they are both immiscible, the geometry will change to become that which gives the lowest total energy for all three interfaces. Thus, if the spherical drop of liquid, falling through r, eventually reaches the interface between liquids 3 and I (we are assuming that the density of 3 is greater than 2, and 2 than I), it will assume the shape of a lens, the angle

Jan 1, 1948

Granduc lies near the Alaskan border in British Columbia, about 600 miles (960 km) north of Vancouver. Prospecting in the area must take place in the short summer months of fog and rain because the winter is bitter cold, with snowfall up to 960 inches (24.4 m) accompanied by avalanches. Despite these difficulties, the mineral ized area was discovered in the 1920's. By 1956, Newmont Mining Corporation had developed mineable ore reserves estimated at 32,500,000 tons of 1.93% copper. Newmont and ASARCO, in a joint venture, then began development of the ore body, which was partially covered by glaciers. It was apparent a concentrator could not be built at the mine site where overland access was impossible due to the weather conditions and the terrain. Years of engineering studies of all possible access routes finally dictated the driving of an 11 mi long (17.6 km) tunnel passing under three glaciers and three mountain ranges to the nearest feasible concentrator site at Tide Lake. Even then, a mountain road subject to an average snowfall of 800 in. (20. 3 m) had to be built 32 mi (51 krn) from the concentrator through Alaska to Stewart, British Columbia, the nearest port. At Stewart, which is located at the head of a fjord 120 mi (192 krn) from the Pacific Odean, a fully equipped marine terminal was built. The tunnel, the lifeline between mine and mill, was to be driven from both ends; however, in 1965, an avalanche occurred at the Leduc portal, killing 26 crew members and wrecking much of the camp. The tunnel was then driven from one heading adjacent to the concentrator site at Tide Lake, a distance of 53,744 ft (16,381 m) to a point under the ore body. The remote location, type of terrain, and bad weather made supply of crews, equipment, and construction materials difficult; but in spite of these extremely adverse conditions, the tunnel crews set many world records. Mineralization throughout the ore zone is generally uniform in grade and composition and is primarily chalcopyrite and pyrrhotite associated with pyrite. Mining is mainly by sublevel caving. After blasting, rubber-tired load-and-haul equipment moves from level to level by means of an internal connecting ramp system on a 15% slope. At the gathering haulage level, 15-ton bottom-dump cars deliver the ore to a 600-ton pocket equipped with a Hudson "Rock-Flo" dump. The bottom of the ore pocket forms the feed chute to the primary

Jan 1, 1978

By H. Qi, J. L. Feng, D. J. Li

"In the present paper, the characteristics of the granite burst under loading/unloading conditions was studied by means of both laboratory experiment and finite-discrete element method (FDEM). After gaining the mechanical properties of the granite samples under uniaxial compression conditions, the parameters taken as input arguments in the FDEM modelling were then carefully calibrated so as to provide some basic data including Young’s modulus, Poisson’s ratio, uniaxial strength, Lame constants, cohesive strength, and frictional angle for further being used in simulating granite bursts. All the simulating results by the FDEM were basically in agreement with that obtained from the uniaxial compression test and triaxial granite bursts in laboratory, respectively. This study shows that that such computational mechanics of discontinua can be employed to gain powerful insight into the failure mechanism of granite burst, which could also be a useful tool to clarify the collapse mechanism of rock structures in rock engineering design and rock test scheme optimisation. INTRODUCTIONBased on discontinuum state a priori, discontinuous modeling techniques that are commonly referred to as discrete element methods (DEM) treat the material directly as an assembly of separate blocks or particles, which was originally proposed by Cundall (1971) and Cundall and Strack (1979) from the viewpoint of analogous molecular dynamics simulation to better account for and understand the interaction between the blocks. The distinct feature of these formulations is that a constantly changing problem of geometry and contact conditions can be addressed by solving the equations of motion using an explicit time marching scheme (most often in a ‘leap-frog’ format), while updating contact force histories as a consequence of contacts between different discrete elements and/or resulting from contacts with model boundaries (Bicanic 1998). The most notable implementations of DEMs are arguably represented by the universal distinct element code (UDEC) (Itasca Consulting Group Inc., 2013) and the particle flow code (PFC) (Itasca Consulting Group Inc., 2012). Another formulation is the discrete crack framework that is based upon some criteria for an advancement of crack front, which is coupled with extensive local and global re-meshing while simulating by numerical methods such as finite element technique, commonly using fracture theories. Certainly, it is relatively easy to trace the propagation of single crack front governed by some principles of energy release rates (Ingraffea 1997) but tracing of multiple cracks leads to topological and algorithmic complexities. Otherwise, there is no consideration of interacting cracks in these formulations of finite element or enhanced finite element techniques (e.g., in XFEM and ABAQUS)."

Jan 1, 2015

By G A. Partington

Recent research has highlighted the potential of a relatively new style of gold mineralisation related to granite intrusion. New discoveries in Alaska, Central Europe and Asia and Eastern Australia with total resources of 1600 t Au offer attractive targets for regional exploration in areas which may have been overlooked in the past. A spatial information system was developed to target granite-gold systems in eastern Australia and the West coast of New Zealand, using well constrained geological and exploration models derived from current research. Target areas were recognised in Queensland, New South Wales, Victoria, Tasmania and on the West Coast of the South Island of New Zealand that have similar spatial data relationships to known granite gold mineralisation elsewhere in the world. The second phase of the modelling better constrained the regional scale target areas by including more detailed geological, geochemical and geophysical data in the GIS to develop prospect-scale targets and to allow the acquisition of tenements over these areas. A geological review of each target area was carried out in the field to put the GIS models into context. The fieldwork has highlighted the potential for this style of mineralisation in New Zealand and will increase investment in mineral exploration and development in New Zealand in the near future.

Jan 1, 2005

By Park Wright

THE fact that granite has been encountered by the drill by those in search of oil and gas in Kansas is becoming more and more a matter of interest, not only to the oil producer but to everyone directly and- indirectly connected with the oil business. It is, therefore, time that someone should offer an explanation for its presence and form a definite opinion based on all the data available in regard to the effect it will have on the future prospects of the area affected as probable oil- and gas-producing territory. At present there seems to be no consensus of opinion. To the writer's knowledge, only one attempt has been made to explain; by Erasmus Haworth, State Geologist of Kansas, in a paper entitled Bulletin, Number Two on Crystalline Rocks in Kansas. The purpose of the present paper is to offer a theory for the presence of the granite and to draw conclusions which will aid in determining the prospective oil and gas value of the area in question. In taking up this question it will be well to consider first the tests in which granite has been reported, with a general history of each. The accompanying map (Fig. 1) shows the location of all wells described. The first well in which granite was reported was that drilled just south of Zeandale in section 27, township 10 south, range 9 east, by a local company which had taken up a block of leases in that vicinity. At a depth of 958 ft. (291.99 m.) granite was encountered. Drilling was continued to a depth of 1,093 ft. (333 m.) in the same formation, at which depth the hole was abandoned. Another well was started 1 mile east of the first well and the same rock was found at a depth of 945 ft. (288 m.). Drilling was continued to a depth of 1,200 ft. (365.76 m.) with the bit in the sane formation. Samples of the drill cuttings have been examined and they are undoubtedly crushed granite. The next well in which granite was found was that drilled by DeLaat and Shepard, independent wildcat operators, in section 34, township 19 south,. range 7 east, near the town of Elmdale. Granite was struck at 1,707 ft. (520 m.) and the hole was abandoned in the same formation at 2,525 ft. (769 m.). Mr. DeLaat watched the drilling of this well very closely and he has described to me in some detail the formation immedi-

Jan 8, 1917

By R Peden

Recent, detailed mapping, (Allibone, 1986; Peden, in prep.) of north west Stewart Island, has shown that the Rakeahua Granite (Watters et al, 1968), is comprised of a wide range of granitoid bodies ranging from diorite to leucogranite. As a result of the wide variation in granitoids Allibone (1986), suggests renaming of the Rakeahua Granite to the Rakeahua Granitoid Complex. Names were also proposed for the individual granitoid bodies mapped.

Jan 1, 1987

By P Shen, K Hattori, H Pan, E Seitmuratova

"An EXTENDED ABSTRACT is available for download. A full-length paper was not prepared for this presentation. Ore-bearing intrusions in the Central Asian Orogenic Belt (CAOB) were examined from nine mines: Boshekul, Nurkazgan, Kounrad, Borly, Aktogai, Koksai, Baogutu, Tuwu and Erdenet. The intrusions are diorite, granodiorite and tonalite with SiO2 contents ranging from 58 to 75 wt per cent, and show mildly fractionated rare earth elements (REE) ([LREE]N/[HREE]N = 2.7–4.7) – light REE and heavy REE – and varying Eu anomalies ([Eu]/[Eu]* = 0.58–1.4). The ratios of Sr/Y vary from 7.9 to 115 and the contents of Y from 4.6 to 23.9 ppm. The parental magmas of the intrusions are intrinsically oxidised. Zircon grains in the ore-bearing rocks from large- and intermediate-sized porphyry Cu deposits show high Ce4+/Ce3+ ratios characterised by 65–422 at Boshekul (>4.1 Mt Cu), 76–480 at Kounrad (>4.8 Mt Cu), 90–280 at Aktogai (>12 Mt Cu), 80–250 at Erdenet (>11 Mt Cu) 74–370 at Nurkazgan (>3.9 Mt Cu), 100–210 at Koksai (>1.6 Mt Cu), and 71–340 at Tuwu (~2.0 Mt Cu). In two small deposits, the ore-bearing rocks display low values of Ce4+/Ce3+; Borly (0.6 Mt Cu) ranging from 28 to 158, and Baogutu (0.6 Mt Cu) from 29 to 113. The Ce4+/Ce3+ ratio of 120 distinguishes large intermediate-size deposits from small-size deposits. This information is potentially useful in exploration for porphyry Cu deposits in the belt.CITATION:Shen, P, Hattori, K, Pan, H, Jackson, S and Seitmuratova, E, 2015. Granitoids associated with porphyry Cu deposits in the Central Asian Orogenic Belt – characteristics and oxygen fugacity, in Proceedings PACRIM 2015 Congress, pp 377–382 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Mar 18, 2015

By Indresan Govender

A continuum based granular flow model of charge motion that combines the inherent frictional nature of particles with its distinctly fluid-like structure is presented. Starting with Newton?s 2nd Law on a volume element of charge, we derive the velocity field in the bed free-surface and the rising en-masse region. Invoking flux conservation within the two regimes of interest then yields a (simple) differential equation for the free-surface of the charge body. Combining the velocity field gradients with a suitable constitutive choice for the shear stress completes the picture with a description of the in-situ rate of shear power dissipation in a tumbling mill ? a mechanistically correct account of power draw in a tumbling mill. Positron Emission Particle Tracking (PEPT) was used to measure the in-situ flow fields of the charge within opaque systems like tumbling mills. The accurate velocity and mass distribution derived from PEPT form the basis for direct verification of the resulting granular flow models. In this regard a wide range of milling conditions is investigated and presented in this paper.

Sep 1, 2012

By J Pan, B-J Shi, X-B Li

The granulation behavior of specularite fines which possess poor ballability was studied with limonite fines as a function of nuclei particles and adhering fines. The results show that the permeability of granules deteriorated as the ratio of specularite fines increased in the mixture, and the optimal granulation moisture content also decreased. The granulation kinetics results demonstrate that the adhering load of specularite fines increases rapidly within three minutes and then levels off. With increasing specularite fines ratio, the adhering speed is accelerated but the granulation duration needs to be longer to reach adhering balance. The microstructure of granule quasi-particles indicates that the fine limonite particles act as binders to bond together the specularite particles which are dispersed in the adhering layers. This can improve the adhering strength of the granules. Hence, the granulation behaviour of specularite fines can be improved by blending them with fine limonite ores which have high adhering capabilities.CITATION:Zhu, D-Q, Li, X-B, Pan, J and Shi, B-J, 2015. Granulation behaviour of specularite fines in ferrous sinter mixtures, in Proceedings Iron Ore 2015, pp 91–96 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By Fernando Hernández Polanco

Transportation and handling metals and alloys from mills to consumption factories as well as dosing in conventional processes with ingots and scrap has always been considered a complicated activity with high operating costs. Several manufacturers of ferroalloys willing to solve these problems have chosen an alternative for their products that can be used to secure, during transport and dosage in the processes to making special steels, with more efficient consumption of ferroalloys. The trend for the production and sale of ferroalloys is to provide the product in the form of granules packed in bags or in bulk. In this paper we will show you how the granulation process was developed and rapidly adopted the ferroalloys industry as an effective solution to reduce operating costs, create cleaner and safer working environments.

Oct 30, 2017

By David Norval

Water solidification of mattes, metals, alloys and certain slags with high metal entrainment has customarily not been practiced due to the belief that such processes are too dangerous and unproven in the Pyrometallurgical Industry. Slag granulation on the other hand is extensively applied, although in some cases crudely, with disastrous effects, as a result of not recognising the high heat capacities prevalent in slags. This paper will examine the most common air solidification processes and compare such processes with water solidification, mainly slag and matte granulation processes and design criteria for safe and reliable operation. Finally, purpose designed granulation and solidification processes will be discussed taking into account specific applications and the individual signatures of alloys and slags, emphasising that no slag, matte or alloy responds in similar fashion to a granulation practice.

Jan 1, 2006

A molten metal granulator was designed and fabricated at the U.S. Dept. of Energy, Albany Research Center, for granulation of precious metal-bearing alloys and slags. The system was designed to safely granulate a metal alloy at a temperature of up to 1,600°C at a rate of roughly 50 kg of alloy per minute. The primary water jet was supplied by a 18.6-kW, 600 liter per minute pump which provided approximately 600 kg of water per minute through the primary jet. Two 3.7-kW, 150 liter per minute auxiliary pumps provided additional wash water to wet the granulation trough through 4 secondary jets, which were placed at either side of the primary jet. The water supply was closed-loop, including a 37,850-liter supply tank and 22,710-liter recovery tank. Magnetic separators and particulate filters were included for collection of the finest fraction of the granulation product, which cleaned the water sufficiently for continuous recycle.

Jan 1, 2006

By P. Beukes, D. Bessinger, R. Glenewinkel

High titania slag is produced by the smelting of ilmenite and a suitable carbonaceous reductant in electric furnaces. Currently liquid slag is cast into large blocks, which take about 10 days to cool down before they can be crushed, milled and classified into two final products. The two products, chloride and sulphate grade slag, are differentiated according to their size. Granulation of titania slag has been identified as a possible alternative to the conventional block route. This paper discusses some of the work carried out at Exxaro Research and Development to investigate both wet and dry granulation of titania slag.

Jan 1, 2007