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By Zhao Guangwen, Wu Tan, Qiuzhan Tian, Duan Shuzhen

"A thorough study of lost currents in bipolar cells has been made for the development of the great potential of bipolar cells in energy saving. A proper equivalent circuit for bipolar cells has been found, and mathematic methods for computing lost currents at all kinds of polarization have been developed.At linear polarization, the lost currents can be computed by solving either a tridiagonal matrix or an ordinary differential equation of second order. This kind of values can be used to evaluate the minimal lost currents at given conditions. At other kinds of polarization, the lost currents can be computed by the same methods as above if the necessary experiments of measuring the cell voltages of every electrolytic compartment have been made. This kind of values can be used to design bipolar cells at practical conditions.Extensive experiments have been made to evaluate the effects of electrode polarization, emf of galvanic cell for the formation of electrolyzed substance, gaseous products, geometric dimensions of electrolytic cells, special resistance of electrolyte used, and the total and ordinal number of electrolytic compartments on lost currents. It is the first time to make such a systematic research by experiments in the world. Experiments showed that theoretic models were in good agreement with measured data. Experiments also showed that D.C. energy consumption of 0.45 kwh/kg of Pb for lead electrolysis from molten chlorides could be achieved in a cell with 7 bipolar electrodes.IntroductionIt is very promising to apply bipolar electrolytic cells to electrolysis of aluminum, magnesium, lead, zinc and perchlorinates for their great potential of energy saving for example, bipolar cells had been used in the production of magnesium and saved more than 30% of energy, being one of the three main techniques of energy saving in the production of titanium sponge (1)."

Jan 1, 1988

By Huaming Yang

Infrared materials are a special kind of material widely used in military, biological engineering and chemical industry. However, the problems associated with them such as unstable properties, high cost and a high thermal expansion coefficient seriously restrict the development and the wide application of the traditional infrared materials with the SiC or ZrSiO4 matrix. The ultrafine quartz powder is normally used to prepare the infrared materials by hot-pressing technology. The aim of the paper is to investigate the thermal expansivity, the effect of the SiO2 size and the addition of AI2O) or Fe2O3 on the infrared emissivity of the quartz matrix of the infrared material (QMIM) in a 8-25um wavelength range. The results indicate that 89% of infrared emissivity and 0.4x 10.5°C of thermal expansion coefficient of QMIM can be obtained. The affeeting mechanism of Al2O) and Fe2O3 on the infrared emissivity of QMIM were also discussed.

Jan 1, 2003

By N. Kanarin

A thermodynamic study is reported on the chlorination of Fe(1-x.)O, Fe2O3, Cr2O3, MgO, Mg2SiO4 with chlorine in the presence or the absence of reducing atmospheres. The reactivities of these compounds as well as that of Mg3Si2O5(OH)4 using Cl2+N2, Cl2+air, and Cl2+CO gas mixtures were studied by non isothermal thermogravimetric analysis between 20 and 1000 °C. The same solids were chlorinated in a horizontal experimental set, during two hours between 350 and 1000 °C, in reducing and oxidizing atmospheres: The chlorination products were examined by XRD and SEM, and possible reaction paths were examined. Results indicate that the carbochlorination of these solids was better than their chlorination; Furthermore, the carbochlorination was performed at lower temperatures than those of the chlorination. Finally, the reaction extent was higher in the case of carbo-chlorination of these compounds. Based on these results, a process was suggested for the selective recovery of chromium compounds from the chromite concentrate.

Jan 1, 1995

By Qian Xu, Xionggang Lu, Xingli Zou, Zhongfu Zhou, Shuhua Geng, Hongwei Cheng

Herein we report an electrochemical route from oxides (SiO2, TiO2)/sulfide (MoS2)/carbon mixture precursors to Mo-Si-Ti-C composites in molten salt. The electrochemical process was carried out in molten CaCl2 at 800 °C with a potential of 3.1 V, and a graphite-based anode was used in the electroreduction process. The reaction mechanism and the influences of the stoichiometry of the initial mixture precursor on the morphology and phase composition of the final products were investigated. It has been found that Mo5Si3/MoSi2/Mo3Si/Mo, Mo5Si3/MoSi2/Mo2C/SiC, and Mo5Si3/Mo2C/Ti3SiC2/TiC/Mo composites can be electrosynthesized directly from their oxides/sulfide/carbon mixture. The preliminary experimental results suggest that the electroreduction process can be used for the controllable electrolytic production of alloys/carbide-containing composites from oxides/sulfides/carbon precursors.

Jan 1, 2016

By Avijit Moitra

The behavior of the solidifying shell in the early stages of solidification has an important influence on the final quality of continuously-cast steel slabs. In order to understand the thermal and mechanical behavior of the shell, a two-dimensional transient piecewise-coupled finite-element model has been developed. The model simulates a transverse section of the slab as it moves down through the mold and incorporates the effects of heat conduction, solidification, shrinkage, turbulent fluid flow, thermal distortion of the mold and the visco-plastic behavior of the steel. Coupling between the thermal and the mechanical model is based on the mutual dependence of heat transfer across the interface between the shell and the mold and the size of the gap. The effects of mold distortion and taper on the gap size are also included. The effect of fluid flow has been incorporated via a heat flux imposed at the solid-liquid interface, which is obtained from a separate fluid flow model. The high temperature creep and plasticity of the steel is incorporated through a unified constitutive law defining the inelastic strain rates as a function of temperature, time and stress state. The model can be applied to various problems in continuous casting, such as the formation of surface defects and the design of mold taper.

Jan 1, 1992

By Edgar E. Vidal

The deposition of ceramic materials onto substrates is of special interest in the development of surface related technologies. Research interest has been placed on using thermal plasma as the deposition method, specifically inductively coupled plasmas. Many different modifications to the same basic principle of deposition have been performed through out the materials research community. Such a technique may have many advantages over more conventional techniques, such as high deposition rates, high surface area coverage, clean energy source, no contamination from electrodes and operation near atmospheric pressures. Materials deposited vary from simple oxide systems like TiO2 to more complex structures like ternary oxides and nitrides. This paper reviews recent developments relative to the inductively coupled plasma deposition of thin films.

Jan 1, 2003

By F. -Z. Ji

Carbon injection into metallurgical slag is important in electric arc furnace (EAF) steelmaking for foamy slag practices and in nonferrous slag cleaning operations. The current publication presents kinetic data for coal injection into EAF slag to understand the interaction between injected carbon and metallurgical slag. Coal particles were injected into EAF slag and the kinetics were followed by gas and slag analysis. The results were analyzed, in terms of fundamental rate equations for each possible reaction step, as a function of temperature and slag composition.

Jan 1, 2003

By I. Gaballah

The chalcopyrite ore's anodic and cathodic electrodissolution are studied using a Porous Pulsed Percolated Electrode (3PE) reactor. Stationary solid electrode experiments are also performed to explore the mechanism of electrochemical dissolution of chalcopyrite. Experiments with a low - grade natural ore have been carried out at 25 "C in solutions containing 1 M NaCl and 1 M HCl. Galvanostatic and potentiostatic conditions are employed. The influences of current and potential on selectivity of the chalcopyrite ore dissolution are assessed. Anodic oxidation of this ore leads to a preferential dissolution of iron bearing minerals, whereas cathodic reduction is more selective with respect to chalcopyrite. However, in both cases the electrochemical dissolution is incomplete and the current efficiency is low. Design of the actual reactor has to be modified to increase the bed conductivity and to allow continuous experimentations.

Jan 1, 1994

By M. E. Coleman, G. Money

"Clyde Materials Handling is an established customer-driven solutions provider, which utilizes its knowledge, expertise and technologies to transform the production processes of its customers, who operate in the ferrous and non-ferrous metals industries.With over 30 years experience in the process improvement industry, Clyde Materials Handling has helped their global customer base transform the way in which they operate their processes, which has enabled them to generate sustainable economic benefit and maintain their positions as leaders in their respective markets.Clyde Materials Handling has supported operators within the metals market by developing and deploying pneumatic conveying and pneumatic injection technologies. These environmentally supportive and sustainable solutions have been used to transport raw materials within operating facilities, from storage to silo, as well as injecting these materials directly into the heart of production processes.Clyde Materials Handling has worked closely with their customers, such as Codelco in Chile, where their pneumatic solutions have been used to inject a consistent, pulseless and accurate flow of copper concentrate into a bath smelter, which has helped to fuel the operational capacity, availability and productivity.This paper will discuss and highlight the ways in which pneumatic injection technologies, created by Clyde Materials Handling, and applied in partnership with their customers, have helped to improve the operational performance of the production processes of operators across the non-ferrous metals markets with specific reference to applications in the Peirce Smith Converter.Clyde Materials Handling has applications injecting Electronic Scraps, Dusts, Reverts, and other additives to the Peirce Smith Converter. They also have experience of modified PS Units used for Slag Cleaning. There experience with the Codelco Teniente Converter is also directly related to this area of operation."

Jan 1, 2009

By Nobuaki Sato

For decontamination of SO2 containing waste gases from industries such as ferrous and non-ferrous metal companies, desulfurization with hydrogen production by the reaction of Br2 and SO2 was proposed as bromine-sulfur (BS) process. In this process, SO2 is fixed as H2SO4 in the presence of Br2 and H2O forming H2SO4 and HBr. Then hydrogen is produced by the decomposition of HBr and Br2 as byproduct is recycled. The reaction of Br2, SO2 and H2O was found not to occur in liquid phase but to occur in vapor one. The production ratios of H2SO4 and HBr showed a maximum at temperatures around 60 oC. The highest production ratio was obtained at 70 oC with a mixing ratio of Br2:SO2:H2O=1:1:10. The experimental results were discussed with thermodynamic consideration.

Jan 1, 2006

By Zdzistaw MiGzkowski

At KGHM Polska Miedi S.A. a direct flash smelting process is used for smelting of chalcocite concentrate for the production of blister copper. The paper presents a model of complex oxidation process of single concentrate grains smelted at KGHM. The description covers main chemical reactions, phenomena of heat and mass ex-change inside the grains and between a grain and the surrounding space. In the model, two zones describing the course of process inside the grain were distinguished: ? The first one, which moves faster towards the centre of a grain, both organic and carbonate carbon are freed. The process takes place without the presence of oxygen and results in an increase of the temperature in the core of the particle. ? The second zone moves slower into the grain and the rate of the movement is deter-mined by the presence of oxygen. In that zone the sulphur is eliminated and the oxidation of the organic compounds vapours moving from deeper layers of a grain takes place. Based on the results of laboratory tests, the coefficients that describe the oxygen transportation into the grain and decide the progress in the chemical reaction were determined. The paper contains the results of model calculations for single grains reacting in environment of various content of oxygen as well as the results of model calculations for the laboratory reactor system.

Jan 1, 2003

By E. Oshima

The only one reverberatory furnace smelting in Japan has been alive in Onahama Smelter, Onahama Smelting and Refining Company. The fuel for the reverberatory furnaces had been changed from bunker C-oil to mainly coal and partially waste tires to reduce the energy cost. The steam, recovered by the waste heat boilers of the reverberatory furnaces, has been utilized fully for the power generation to save the purchase power. Copper concentrate has been smelted also by injection through tuyeres in the P.S. converters since 1983. The amount of concentrate, treated in the converters, was increased by the construction of small oxygen plant in December, 1990. In the paper, the current practice and improvements in the reverberatory and converter operations are described.

Jan 1, 1993

By Randall M. Gennan

Generally sintering is focused on the bonding of particles at high temperatures; possibly with simultaneous densification. However, an important aspect of sintering occurs during heating at relatively low temperatures where polymer processing aids are removed via control of the atmosphere, heating rate, or hold time at intennediate temperatures. New insights into burnout processes show impact from the polymenype, particle size, amount of polymer, atmosphere, part geometry, and thermal profile. This presentation focuses on the key parameters to demonstrate improved mechanical property levels are available in traditional powder metallurgy alloys by proper selection of the processing polymer and proper care in its thermal extraction. The focus is on mechanical property, where gains up to 40% are demonstrated due 10 changes in the processing polymer. Further, atmosphere control during polymer burnout provides a benefit by allowing formation of desirable carbonitrides, giving strength levels over 3 GPa (over 400 kpsi). Insight is? gleaned from powder injection molding, where high polymer contents mandate proper processing control.

Jan 1, 1996

By William Petruk

The Kidd Creek base metal deposit near Timmins, Ontario contains around 0.15 wt% Sn, mainly as cassiterite. The cassiterite occurs largely as inclusions in sphalerite, with 85% being in grains smaller than 18.5 micrometres in diameter. Concentrates and tails from the company's Cu, Pb and Zn circuits were studied to determine the liberations and recoveries of cassiterite in the products. The ore had been ground to about 65.% minus 44 micranetres in diameter (-325 mesh); 55% of the cassiterite was liberated. About 92% of the liberated cassiterite and 70% of the unliberated cassiterite were in the concentrator tails, and 20% of the unliberated cassiterite in the zinc concentrate. The company had attempted to recover the cassiterite from the concentrator tails by gravitational methods but recoveries were low. The grain size of the cassiterite in the gravity Sn concentrate was similar to the grain size of the liberated cassiterite in the concentrator tails. Research on flotation of the fine grained cassiterite from Kidd Creek ore has been conducted,

Jan 1, 1990

By Gaballah I.

Elimination of arsenic, mercury and zinc from synthetic solutions containing H;\A.sD4. HgCI2 and ZnCI2 using modified barks was investigated. The pH range was varied from ?1 to 10. The initial concentrations of individual element were 10,100 and 1000 ppm. More than 99 % of mercury and 65 % of zinc cations were removed by the modified bark .. In this case, the modified bark reacts as a cation exchanger leading to the release of ' two protons for every HgII or ZnII fixed by this material. About 30 % of arsenic was eliminated from the solution. This 'low efficiency could be attributed to? the presence of arsenic ,as. anion. Decontamination of a treated industrial effluent containing 4 ppm of ion? metals was performed on a pilot plant scale by the modified bll(k. More than 70'% of these ion metals were eliminated.

Jan 1, 1995

By Fabio J. Esper, Guillermo R. Martín-Cortés, Francisco R. Valenzuela-Díaz, Cassio P. Carvalho, Giorgio Grotti, Reginaldo B. Santos

"Rejected sands from smelting metallurgical process because contain lead and others heavy metals are a problem to dispose as waste in all the countries. A procedure that is being proposed for it is to incorporate it on common clay bodies in the fabrication of structural ceramic products as bricks, blocks and roof tiles. The main goal of this paper is to present the results obtained with mixtures of sands from smelting metallurgical process with common clay from Jundiaí, São Paulo, Brazil. Preliminary incorporation tests (1,0% in weight) were made with hand formed spherical samples. With the higher compression strength of the spheres after drying and firing (950ºC) experiments on bricks production were made for quality technological test. Seven hundred hallow blocks containing 1,0% waste were produced and presented ceramic properties similar to those without sand incorporation. Introduction In last the fifteen years the LMPSol - Raw Materials & Non-metallic Solids Laboratory – Metallurgic Eng. & Materials Depto. – Polytechnic School - University of São Paulo comes studying the possibilities of incorporate industrials waste materials to the production of bricks and other products of construction aiming at to remove pollution products of the environments and to user the properties of the same ones in the structural ceramics products. Examples are the study of the influence of rejected steel furnace dusts in structural ceramic [1], another example is the main subject of the present paper: use of rejected sand from smelting metallurgical process in the production of bricks an other products of structural ceramics. Antecedents More or less one year ago, specialist and members from the direction board of METALÚRGICA GROFE LTD. Company contacted researchers and professors of the LMPSol – PMT – EPUSP seeking for a solution to their concern with the disposal of rejected sand from smelting metallurgical process."

Jan 1, 2008

By Neng-Wen Yu, Miao Wang, Ji-He Wei

The mass transfer characteristic between powder particles and liquid steel in the RH-PTB (Powder Top Blowing) refining has been investigated in a water model of 1/5 scale for a 90t RH degasser. The sodium chloride powder with analytical purity has been used as the flux for blowing. The mass transfer coefficient of the liquid side has been determined under the conditions of RH-PTB process. The influences of the main technological and structural parameters on the mass transfer rate have been examined. The results indicated that under the conditions of the present work, the mass transfer coefficient on the liquid side increases with raising the lifting gas blowing rate, inner diameter of the up-snorkel, circulation rate of the liquid and particle size of powder flux. And it decreases with an increase in the inner diameter of the down-snorkel. It is in the range of (l.36-7.30) x 10·4 mis, the appropriate dimensionless relationships have been obtained as follows:

Jan 1, 2000

By Qinmeng Wang

The oxygen bottom blown copper smelting process is a new technology which has been widely applied to the copper production in China. In this work, a computational thermodynamics model for this technology has been established, based on smelting mechanism and theory of Gibbs free energy minimization. The calculated results from the model agree well with the actual industrial data, indicating that the model can be used for the predictions under different operating conditions. The tendencies of the key parameters (such as Cu losses and Fe3O4 content in slag) and the distribution ratios of the minor elements (such as Pb, Zn, As, Sb and Bi) can be predicted by adjusting the oxygen/ore ratio charged into the bottom blown copper smelting furnace. The model can be used to monitor and optimize the industrial operations of the oxygen bottom blown copper smelting process.

By Shengli Wu, Fengjie Zhang, Feng Chang, Hua Lu, Kaiping Du

In order to make a complete understanding of steel plant metallurgical dusts and to realize the goal of zero-waste, a study of their properties was undertaken. For these purposes, samples of two sintering dusts (SD), two blast furnace dusts (BFD), and one electric arc furnace dust (EAFD) taken from the regular production process were subjected to a series of tests. The tests were carried out by using granulometry analysis, chemical analysis, X-ray diffraction (XRD), scanning electron microscopy (SEM), energy dispersive spectroscopy via SEM (EDS), and Fourier transform infrared spectroscopy (FTIR). The dominant elements having an advantage of reuse are Fe, K, Cl, Zn, C. The dominant mineralogical phases identified in sintering dust are KCl, Fe2O3, CaCO3, CaMg(CO3)2, NaCl, SiO2. Mineralogical phases exist in blast furnace dust are Fe2O3, Fe3O4, with small amount of KCl and kaolinite coexist. While in electric arc furnace dust, Fe3O4, ZnFe2O4, CaCO3, CaO, Ca(OH)2 are detected.

Jan 1, 2015

"Mixing phenomena in a bottom blown air-stirred one-seventh water model of CLU (Creusot-Loire Uddeholm) reactor was studie9-using three different configurations of straight circular nozzles fitted axially at the bottom of the vessel. The mixing time has been determined by pH measurements at various gas flow rates, bath heights and nozzle orientations in the presence and in the absence of a second phase.Experimental results reveal that the mixing time decreases with increasing gas flow rate. For a given gas flow rate the mixing time increases non-linearly with increasing bath height. Off-center configuration gives slightly lower mixing times as compared to center configuration. It is found that the contribution of buoyancy to the total stirring energy density is very small, but its contribution increases with increasing bath height. In the presence of an upper oil layer, the mixing time increases significantly for all configurations.IntroductionIn high temperature metallurgical melts mixing is carried out by injection of a gas either from top or bottom of the vessel in order to accelerate the rates of chemical reactions and to promote bath homogenization. When a gas is injected into a liquid through a submerged lance, porous plug or nozzle, the gas, rising as a two phase plume to the surface, imparts momentum to the surrounding liquid and causes gross circulation in the bath which promotes mixing."

Jan 1, 1997