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Steel Ladle in Bhilai Steel Plant, SAIL, India, passes through VAD & LF-RH route and this exposes refractory lining to a severe operating conditions. Ladles are lined with in-house manufactured MgO-C refractories. Lining life used to be 35 heats, out of which 18-20 heats were through VAD/LF-RH, hence, ladle availability had become a constraint. Laboratory studies were carried-out to optimize granulometry and composition. Granulometry was developed by adopting Andearssen packing model. A suitable plasiticiser was identified to eliminate inconsistency caused due to variation in resin quality and weather condition. It reduced variation in green bulk density from 6 to 1.3%. Abrasion and slag erosion studies were conducted, which shows that with increase of carbon, abrasion resistance decreases and corrosion resistance improves. Based on these studies, graphite in slag zone was increased from 10 to 12.5% and in metal zone it was reduced to 7.5%. Different process parameters of brick making were optimized to make MgO-C bricks of maximum bulk density with reduced coke porosity. Modified bricks have bulk density of 2.99-3.02 g/cc and coke porosity of 9.5-10.5%. Further, shape of the bricks were changed from side arch to mini keys and thickness was increased from 80 to 100 mm. Mini key bricks are pressed from sides, thus eliminating variation in thickness which is critical dimension for dry joints. These modifications improved average lining life of steel ladles to 64 heats, which includes 37-40 secondary heats. Maximum life obtained is 87 heats.

Jan 1, 2006

By Nozomu Uchida, Uematsu Keizo, Daisuke Shouji

"Grain orientated microstructure was developed for the improvement of ceramic characteristics. Novel polarized light microscopy was developed to examine the grain orientation quantitatively. The degree of grain orientation was estimated from the retardation determined with a Berek compensator. The method was essential to determine a minor grain orientation, which could not be analyzed by means of conventional X-ray measurements. The data were favorably related to ceramics characteristics. The comparis of the ceramics with various degree of orientation was very important to explain the change of ceramic characteristics with processing.IntroductionMicrostructure with grain orientation has a high potential for greatly improving characteristics of ceramic. However, there has been strong restriction on processing and material for developing this structure. It has been crucial to apply forming methods involving high shear such as injection molding1). Grains must have an elongated shape.In recent years, much attention has been paid on the effect of high magnetic field on diamagnetic materials2)3)4), Many ceramic materials are known to be diamagnetic. High magnetic field has a high potential to orient grains. The principal driving force for grain orientation is the magnetic anisotropy of material, which is generated by non-cubic crystal symmetr5). This method of grain orientation is not restricted by grain shape, and can be applied to all materials having non-cubic crystal structure.This study uses alumina as raw materials, and produces alumina ceramics with orientated grain in high magnetic field (10T). Alumina has a magnetic anisotropy due to hexagonal crystal structure. The degree of grain orientation in the green and sintered bodies will be examined and their relevance to magnetic field will be discussed."

Jan 1, 2000

By E. V. Redin, B. A. Dubrovsky, E. V. Knyazev, A. I. Starikov

"Ti-V magnetite is one of the most abundant composite ore resources in the world. This ore cannot be fully processed via blast furnace technology because of high content of Ti02. According to the investigations carried out in the USA and Japan ITmk3 RHF (Rotary Hearth Furnace) technology is a breakthrough in Ironmaking. Reduction, melting and slag removal can be achieved in just 10 min. The main objective of the investigation is to establish optimum operation conditions for the production of iron nuggets from Ti-V magnetite ore via the ITmk3 by means of the lab scale testing. Samples of ore from the Maly Kuybas deposit (Southern Ural), carbon reductant and fluxes were chemically analyzed. Green pellets were processed via a lab chamber furnace to simulate RHF conditions. The nuggets and slag were chemically analyzed. This preliminary test work provides valuable information which may be used for large-scale testing in a commercially sized RHF.IntroductionThe ITmk3 process upon which this paper focuses was developed by Kobe Steel in its research facilities [l]. After pilot testing at Kobe Steel's Kakogava Works in 1999-2004 the pilot demonstration plant was built and operations were successfully carried out by Mesabi Nugget joint venture in 2002-2004. Steel Dynamics put into operation the commercial plant at the Mesabi Nugget site in Hoyt Lakes (Minnesota) in 2010. Results were consistent with nugget characteristics confirming ITmk3' s flexibility with respect to raw material inputs. At the same time, no research in the field of nugget from the Ti-V magnetite bearing ore with high content of Ti02 and Alz03 has been done. It is well known, if a lot of Ti02 and Alz03 enter the blast furnace, slag becomes viscous. The viscous slag is obstacle for stable operation of the blast furnace. Besides, high content of Alz03 raises the melting temperature of gangue minerals disturbing the coalescence of reduced iron to the nuggets."

Jan 1, 2013

By Yuhua Pan

Generic mathematical models have been developed for simulating heat transfer in two types of slag resistance heating electric furnaces for sulphide smelting: i) six-electrode-in-line rectangular furnaces and ii) three-electrode circular furnaces. The models are based on three-dimensional steady-state heat transfer of conduction, convection and radiation. Solidification of liquid slag into solid slag by water-cooling units, for use as freeze lining of furnace walls, is also considered in the models. The developed models are capable of providing predictions with reasonable accuracy for electric furnaces on 1) temperatures in slag, matte, cooling water, freeze lining and other solid regions as well as temperatures at various fluid/solid interfaces, 2) freeze lining thickness, 3) furnace smelting rate and 4) furnace heat loss rate. These computer models are built into executable application programs that are very efficient, with execution time less than one second, and can be easily portable to most computing platforms. This paper describes, as an example, the modelling results on heat transfer in six-electrode furnaces. The major modelling results show that in six-electrode furnaces uniform electric power inputs to the electrodes likely lead to low temperature regions close to slag and matte tapping ends of the furnaces, and the power input and the formation of air gaps between freeze lining and cooling units have significant influences on the thickness of freeze lining maintained by the cooling units.

Jan 1, 2006

By Susumu Okabe

Top blowing lances are employed by the Mitsubishi Continuous Copper Converter for the continuous supply Of reaction gases into moken bath. In order to minimize the refractory wear caused by the interaction between the furnace lining and the melt splash. optimum furnace design and blowing condition are? required. An empirical equation obtained by the physical model study enables the estimation of the splashing rate on a vel1ical plane at a certain distance from the lance.

Jan 1, 1996

By Kazuaki Mita

There are various intermetallic compounds in the Zn-Fe system. We synthesized them at about 673K. A specimen was examined chemically and X-ray diffraction was applied to ensure the formation of intermetallic compounds. Material containing two phases was placed in a Knudsen type effusion cell and the mass spectrum studied to evaluate the vapor pressure of zinc. The thermodynamic properties of intermetallics was then evaluated through measured intensity.

Jan 1, 1999

By Ning Wang, Bing Xie, Hong-Yi Li

"Compared to traditional sodium roasting, calcified roast inhibits chlorine pollution. A vanadium extraction technique based on a calcified roast is especially suitable for vanadium slag with high calcium content. In this report, V205was extracted from vanadium slag by calcified roast followed by acid leaching and hydrolysis precipitation. In optimized conditions, the high silicon low vanadium slag was roasted at 850'C for 2 hours without CaO addition. The roasted materials were leached with 35 % H2SO4 in liquid/solid ratio of 5:1 (mL/g) at 95OC for 4 hours. The extraction of vanadium was as high as 97.66 %. These results are instructive to V2O5 production in industry.IntroductionVanadium slag is produced in converter, sodium salt roasting is the commonly used technique to extract vanadium. In sodium salt roasting, vanadium slag is roasted with sodium salts including sodium chloride and soda as additives, followed by leaching with acidic or basic solution [1]. However, in this process chloride reacts to produce corrosive gases including HC1 andCl2- SO2 and SO3 can also corrode equipment severely and are also an environmental contaminant. The low melting point of sodium salts leads to fusion agglomeration, which blocks vanadium oxidation and thus decreases the extraction rate of vanadium. A large amount of sodium salts consumed as roasting additives increases the production cost. Moreover, sodium salt roasting requires low CaO content in vanadium slag. When the CaO content increases to 1%, V2O5 extraction can amount to 4.7%-9% [2]. For vanadium slag with high CaO content, the sodium salt roasting technique leads to low vanadium extraction rate."

Jan 1, 2012

By Alexander I. Raitchenko

"An electroconductive viscous liquid may flow in laminar or turbulent regime under Lorentz-force generated by the intercrossed electric current and magnetic field. When there is a starting flat layer between hard and free boundaries with surface tension the spatial Lorentz-force can create a specific stationary regime of flow: the plane free surface will transform into the wavy one, and the movement in the depth will be not laminar and not turbulent, but this regime will be characterized by organized forms with indications of ""rolling of long cylindrical drops"". Wave-length is determined by the viscosity, the density, the surface tension, the average thickness of layer, and Lorentz-force. ·The limit of wavy regime is determined by most long of wave which is directly proportional to the critical value of specific flow and inversely proportional to the kinetic viscosity. The proper critical value of Reynolds number is determined by the dimensionless combination containing surface tension, density, viscosity, and Lorentz-force. The mentioned dimensio.nless combination in our case is some criterion substituting the known Kapitsa number for case of the thin viscous liquid layers under gravity. Spreading of admixture by mechanism of wavy regime is more rapid than by common diffusion or by laminar flow. The suggested conception can be a contribution into the theoretical basis for elaboration of some specific liquid metals technologies."

Jan 1, 1999

By Michael L. Free

Bacterial oxidation of an arsenopyritic gold-ore .concentrate was carried out with continuous-flow .operation in 14-liter, mechanically agitated reactors. Samples from the slurry reactors were separated into solid and liquid fractions and analyzed separately to determine the electrochemical rates of sulfide conversion by the bacteria and the rates of direct bacterial oxidation of sulfide. The rates of the individual mechanisms are compared to the overall rates of biooxidation in the continuous-flow slurry reactors. The results show that the commonly hypothesize4 direct and indirect mechanisms of biooxidation both play a significant role in the bacterial oxidation of sulfide ores.

Jan 1, 1991

By Amanda C. Lima, Luiz Augusto H. Terrones, Sergio N. Monteiro

"Fabric from weaved yarns made of jute fibers have been considered as reinforcement for polymeric composites. In particular, these fabrics obtained from discarded sackcloth are presently being investigated as environmentally friendly composites with recycled polyethylene matrix. The objective of the present work was to compare the practical properties and economical aspects of these composites with those of conventional materials such as wooden board and gypsum panels for building application. The comparison showed that, depending on the amount of post-used jute fabric, a cost/benefit analysis favors these composites over the conventional materials.IntroductionThe increasing amount of wastes generated by human activities is becoming a worldwide problem of pollution with growing consequences to the environment. The question on how to dispose these wastes is, therefore, a major global issue. Among the possibilities of it gating the problem, the use of materials with characteristics of being renewable, biodegradable and recyclable is considered an environmentally correct solution. Examples of this type of materials are left over lignocellulosic fiber from coconut husks and sugarcane bagasse [1] that, after the primary extraction of edible pulp and juices, can be recover for industrial application. Nowadays, the main use of these fibers is to reinforce polymeric composites applied as components for building construction and automobile parts [2,3]. In addition to these applications, composites reinforced with residual lignocellulosic fibers may replace conventional furniture and panels made of wood and thus help to reduce deforestation [4].Environmental protection is not the only motivation for recycling natural fiber wastes. In developing regions activities associate with collecting and processing residual fibers provide job opportunities for low-income people. Moreover, if the lignocellulosic fiber is collected as a recyclable waste, it hes the economic advantage of a comparatively cost, which constitutes in a relevant difference as a choice for commercial utilization."

Jan 1, 2008

By R. T. Hernández, I. Hilerio, A. Altamirano, M. A. Barrón

"The principal objective for finishing surfaces is to protect and/or to decorate them. This can be achieved by adding or removing material from the work surface. The addition of aggregated material is called coating or recovering. In this work, mecano-chemical techniques are investigated for surface finishing. For these techniques, barreling or polishing by the friction method will be used. These are the cleaning or finishing processes most used for great volumes of small pieces. These methods improve the surface finishing by eliminating burrs, sharp pointed, tool marks and crusts of casting. They are used to clean metallic pieces, ceramics and polymeric materials. The process is based on rubbing or friction by abrasives. The pieces are arranged in the barrel with an abrasive and an additive (water or chemical additive). The machine produces a rotating movement on the pieces. When the abrasive passes against the surfaces of the pieces, it produces an action of rubbing and impact that cleans the surfaces. The rubbing action is developed when the upper layer of the charge slides to the lower extreme when the barrel rotates. The barrel can be hexagonal or octagonal to facilitate the sliding of the charge. The barrels can be between 15 to 120 cm in length and they can have almost any diameter and velocity of rotation. There are several types of barrel: individual, multiples, and multiple compartments. The barrels are rotated using a wheel spindle or rolling pins, that the can ride horizontally or be tilted to produce an additional movement of the charge.IntroductionShot penning is a cold method in which compressive effects are induced on an exposed surface of a metallic piece, by the impact of a rain of shots directly on the surface of the metal, at great speed under controlled conditions. This differs from cleaning with the help of air, because even when shot penning cleans the surface of the metal, this function is incidental. The main purpose of shot penning is to increase the resistance of the piece to fatigue. The process has other applications: raises the tensile strength and decrease corrosion fracture."

Jan 1, 2012

By John J. Mahoney, George P. Demopoulos, Matthew T. Bohan

In recent times processing of arsenic-laden complex ores and heightened awareness of the detrimental health effects of arsenic has put an increasing burden on metallurgical operations to remove arsenic from processes for disposal in an environmentally stable form. At present, arsenic is removed and prepared for storage by precipitation of insoluble secondary arsenic-bearing minerals. It has been suggested that Ca(II)-Fe(III)-As(V) phases resembling the natural mineral yukonite, under certain conditions, may have a role in controlling arsenic pore water concentrations in arsenical waste storage facilities. In this study, a previous synthesis method of yukonite (Ca3Fe5(AsO4)4(OH)9⋅4H2O) is revisited and new solubility/stability data is presented based on a modified method.

Jan 1, 2014

By Edita Vircikova

The best demonstrated available technology (BOAT) for the removal of dissolved arsenic and some heavy metals as reported by USEPA (Contaminants and Remedial Options at Metal Sites, Draft Report, August 1993) (1) is still the chemical precipitation. Coprecipitation with the excess of iron is usually practised because of the availability of iron at low/no cost and also in order to meet the stringent regulatory discharge limits. The arsenic is usually removed with iron because of its common occurence in the mined orebodies and the excellent adsorptive property of the precipitated hydrous ferric oxide compounds. There has been controversy, however, over the long-term stability of the arsenic-bearing ferrihydrite which is produced.

Jan 1, 1995

By Kazutaka Kunii

It is invariably certain that after punching for IC Leadframes, scrap metal were generated. These seraps were re-dissolved and in order to use as raw material for leadframes, it is necessary to remove the Ni plating. In this study a simple method was developed for the removal of Ni plating by surface oxidation of Ni plating. For this purpose a fundamental study was carried out on the oxidation behavior of Ni plating. Results showed that by controlling the oxidation condition, a considerably high rate of Ni could be removed.

Jan 1, 1996

By Maria Margarida Lima, Maria Lucelinda Cunha, Dora Algarvio

"The main goal of the present work is the quality improvement of the recycled aggregates produced by a construction and demolition waste (C&DW) recycling facility located in Montemor-o-Novo, Portugal. The recycling process was developed on a pilot plant scale with 50 t/h of capacity. Process operations are the hammer mill comminution, magnetic separation and screening.In order to improve the knowledge on the C&DW, a characterization procedure was implemented by hand-sorting, magnetic and density separation on representative samples. On the other hand, to improve the quality of the produced aggregates, the bar screen size fractions were analysed, according to the Portuguese Standard (NP EN 933-1 2000).Wood was identified as the critical contaminant, representing 17% by weight of the total contaminants. Sieving results showed that about 97%, 76%, 56%, 98% and 57% were on the correct size range, which lower results are probably due to the type of screens and/or the material characteristics of the recycled aggregates.IntroductionThe construction and demolition waste problemConstruction and demolition waste (C&DW) is generated by the construction activity, resulting from both, buildings or other structures construction and old structures demolition. As a reference, it can be told that C&DW comprises about 40 to 50% of rubbish (concrete, asphalt, bricks, blocks and dirt), 20 to 30% of wood and related products and 20 to 30% of miscellaneous wastes [1]. In Portugal, C&DW is classified in the LER (Portuguese nick name for the European Waste List), Chapter 17, and includes a diversity of wastes, like concrete, bricks, ceramics, bricks, wood, glass, plaster, copper, zinc, lead, iron, steel, as well as insulation and roofing materials. C&DW stream has several characteristics which make it particularly difficult to deal with and are summarized in the following five items.(1) Lack of information on quantities generated: In Portugal, the C&DW sector has been neglected over the past years, which meant that there are not consistent information concerning the quantities and composition of these wastes yet. Several estimates, based in different assumptions, indicate different results, which may vary from 219 Mt to 10 931 Mt [2]."

Jan 1, 2008

By Bo Jiang, Lianyun Liu, Hongmin Zhu, Kai Huang

"Watermelon peel is selected as a novel adsorbent to remove Pb(II) from aqueous solution. A simple saponification process is proposed to modify the peel and the adsorbent is characterized by SEM and FTIR. The effects of pH, contact time, initial concentration of Pb(ll), biosorbent dosage and temperature on adsorption of Pb(II) are investigated. Different models are used to fit experimental data. These models indicate that the adsorption process follows the Langmuir model and pseudo-second-order model. The maximum adsorption capacity obtained from Langmuir model is 1.05mol kg-1 for the prepared sorbent. Equilibrium time is attained in 5-10 min for the studied concentrations. The watermelon peel can be used as an effective and low-cost biosorbent for removal of Pb(ll) from aqueous solution.IntroductionRecently, removal of heavy metal ions from industrial effluents by biosorption has become a very attractive topic, since the more serious pollution issues caused by heavy metals emerge frequently, and more strict requirements for its control are called upon by society [1,2]. In this case, most conventional purification technologies are not suitable due to poor cost-effectiveness [3]. For example, chemical precipitation by alkaline reagents usually can not decrease the metal ion concentration below the permissive levels, and also it will produce a large amount of sludge containing toxic metals. Membrane separation techniques can realize deep purification of wastewater easily, although its operating cost is usually high. Thus, considering the high effectiveness, low cost and free-sludge operation, bisorption has become a promising technique in water treatment [4]. The most important thing for this technology is the synthesis of a suitable biosorbent, whose adsorption properties will determine the removal efficiency and economic cost for the whole process. Watermelon is one of the most popular fruits for mankind for its delicious flavor. Usually, the watermelon is consumed mainly for its edible pulp, and its peel is discarded or only used as feed for livestock. Considering the pectin contained in the watermelon peel, just like that in orange wastes in the reported literatures [3], the idea of using it as the raw material to prepare the biosorbents for heavy metal ions removal from the aqueous solution was evaluated in this study."

Jan 1, 2012

By Djalma Souza, Rubén Sánchez, Regina Maria Pinheiro, Carlos Maurício Fontes Vieira, Sergio Neves Monteiro

"This work has for objectives to characterize a waste generated in the form of sludge during the treatment of the effluent of a paper making industry and to evaluate the effect of its incorporation up to 10 wt.% on the properties of a clayey body used for brick production. For the characterization of the waste the following techniques were used: X-ray diffraction, X-ray fluorescence, differential thermal analysis and termogravimetric analysis with mass spectrometry. Specimens were prepared by uniaxial pressing at 20 MPa before firing at 750 °C. The physical and mechanical properties evaluated were: linear shrinkage, water absorption and flexural rupture strength. The results showed that, in agreement with the characteristics of the waste, its recycling into red ceramic can contribute to decrease the consumption of fuel during the firing stage. However, the waste changes the physical and mechanical properties, generating a deleterious effect on the water absorption and flexural rupture strength of the ceramic.IntroductionAccording to the Brazilian Association of Pulp and Paper, in the last 10 years, the global production of paper grew 35%. Brazil produced 8,2 million tons of paper in 2004 and held the position of the seventh largest world manufacturer of pulp, with about 9,4 million tons per year [1]. The pulp and paper industry generates effluents that present problems related to their disposal, even after the treatment. Among the solid wastes generated by this industry, the main waste is the primary sludge from the effluent treatment plant (ETP).After the initial treatment the decanted solids go through a dewatering stage, generating the solid form denominated primary sludge. This sludge resembles a paper paste of dark gray color when humid, and clear gray color when dry. This primary waste is composed basically of kaolin, pulp, traces of chemical substances and water. This waste generated in the pulp and paper industry depends on the characteristics of the process and of the employed techniques. It can vary significantly from one industrial unit to another, even in the case that the final products are similar. Its composition is approximately 60% of kaolin and 40% of pulp, and these percentages can vary in some moments as a function of the process [2,3]."

Jan 1, 2008

By W. G. Davenport

Chapters 7,8and 9 calculated three combinations of: blast composition (mass% O2, mass% N2) oil quantity per tonne of concentrate blast temperature that will steadily produce molten 65% Cu matte from pure chalcopyrite-concentrate. The combinations are:

Jan 1, 2001

By Guozhu Ye, Mikael Larsson, Eric Burström, Sten Ångström

"Increased use of scrap in steelmaking including scrap use in BOF has a high economic and environmental potential in terms of increased productivity, energy saving and reduced emission of CO2. Preheating and surface cleaning of steel scrap is a concept developed by MEFOS in a four year research program funded by MISTRA, Swedish Foundation of Strategic Environmental Research. The process concept consists of four major steps: 1) Combustion of ASR or other waste fuel and composing of the gas composition. 2) Scrap heating and cleaning in a shaft where the coated zinc is removed as ZnCl2 and scrap is heated to about 600 ºC. 3) Dust separation for recovery of metal zinc. 4) Gas cleaning. This paper will describe the process concept and highlight the major results from preliminary trials around the scrap heating and cleaning shaft.IntroductionSteel is often coated to increase the corrosion resistance. Share of coated and galvanized steel in the world marked is steadily increasing. This results in increased amounts of scrap with different types of coatings. Use of galvanized scrap in EAF plant results in an EAF dust with high content of zinc ferrite and many other impurities like Pb, Hg, Cd and halide. EAF dust is classified as hazardous waste in most of the developed countries and the steel plant has to pay for external treatment for zinc recovery. For use in BOF plant this will result in a BOF dust containing typically 1-5%Zn making it impossible for recycling to the blast furnace.Different approaches for surface cleaning have been investigated in past. Dapper et al. [1] examined the possibility to evaporate Zn, Ni, Cr, Sn from coated materials using chlorine. Chlorinated rinsing of non iron oxides and metals using HCl from combustion of PVC was discussed by Fray [2]. Further studies by Tee and Fray [3-5] have been concentrated on the possibility to vaporize coatings with an air and chlorine gas mixture. The O2:Cl2 ratio in the gas mixture was found to have great importance for control of the process. To avoid the chlorination of iron, this ratio should be kept at a level of 10:1.Scrap pre-heating up to about 600 ºC is a well known method and this alone could save up to 100 kWh per ton steel. The technology has been established since many years and efficient processes were developed in the 90’s. However, no process has fully gained the expected energy savings as the large quantity of the exhaust gas has to be reheated to over 1000 ºC again to destroy the hazardous components like dioxins."

Jan 1, 2008

By Mokka N. Rao

In this experimental investigation, the principal operating parameters of the spirals HC 1870 and HG 8/7 are determined for the hydrogravimetric separation of the friable siliceous iron minerals of the Piar Distric, Venezuela. Mineralogical characterization including optical microscopy of feeding materials and the products after separation are presented. Comparative analysis is made of effectiveness of productivity between the two spirals.

Jan 1, 1999