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By J. R. Bhamidipati, Nagy EI-Kaddah

"Over the years, mathematical modeling has been established as a viable tool for design and analysis of melting and solidification processes. Modeling of electromagnetic casting and melting systems involves three coupled problems -- determination of the containment field, the shape of the meniscus, and the temperature field -- which have to be solved simultaneously. One of the difficulties in numerical simulation of these systems is in defining and gridding the solution domain as the meniscus shape of the liquid region is not known a priori. This paper describes a methodology for solving these coupled problems in a two-dimensional electromagnetic containment field. This method is based on the solution of the electromagnetic, free surface dynamic, and heat transfer equations in a fixed domain in computational space by mapping the physical space into an invariant computational space during the search for the equilibrium shape using a variable non-orthogonal coordinate transformation. This approach, also, eliminates the need for regridding the liquid and solid regions during phase change. This methodology is demonstrated for two electromagnetic confinement systems -- the Magnetic Suspension Melting process and the electromagnetic casting of aluminum. The model predictions are in good agreement with available data for these systems. It is suggested that the methodology presented here is likely to provide a useful tool in the design, analysis, and optimization of electromagnetic confinement systems. IntroductionDuring the past decade, mathematical modeling has emerged as a viable tool for the design, analysis, and optimization of casting and melting processes /1-2/. It is generally recognized that the usefulness of modeling to study the interplay between the various process parameters without resorting to extensive experimentation relies heavily on accurate representation of the physical phenomena in these systems. In modeling electromagnetic confinement casting and melting systems, it is important that the model address all aspects of electromagnetic field interaction with the metal, if accurate predictions are to be obtained /3/. The electromagnetic field affects the heat transfer phenomena primarily through joule heating. In addition, the electromagnetic forces play a key role in heat redistribution in the molten pool via melt stirring, and, in confinement systems, support the molten metal pool."

Jan 1, 1994

By Buket Tunçer, Mehmet Buğdaycı, Onuralp Yücel

ZrB2 and TiB2 are one of the most significant metal borides. They are being used in various industrial areas from space technology to nuclear industry owing to their physical properties such as high melting point, high thermal/electrical conductivity and low density. Present study was conducted in two main stages: Self-propagating high-temperature synthesis (SHS) reactions and leaching. ZrO2, TiO2, B2O3 were used as starting material and Mg used as a reductant to produce ZrB2-TiB2 powders via SHS. Therefore, it was aimed to determine production parameters, leaching conditions and comprehensive examination of final product features. The samples were characterized by using chemical analysis (AAS), XRD, XRF and SEM/EDS techniques

Jan 1, 2015

By Mototsugu Matsuno

A new process has been developed to treat fly ash generated from municipal incinerators, which contains not only toxic metals such as lead and cadmium, but also dioxins. The process includes the following steps; fly ash is formed into green pellets with some additives and the pellets are then roasted to eliminate or stabilize the toxic metals and to decompose dioxins. A pilot plant with a capacity of approximately 100 kg/hr was used to test the process, The tests verified that heavy metals were either volatilized or stabilized and dioxins were decomposed by high-temperature roasting. The pelletized ash was found to be non-toxic, so that it can be recycled as artificial lightweight aggregate. It was also found that volatilized metals collected as secondary ash can be recycled as smelting resources.

Jan 1, 2003

By Edward Peters

Scandium (Sc) has unique properties and is one of the more valuable elements in the periodic table. Scandium can be used in solid oxide fuel cells and to produce high strength aluminium alloys of value, for example, in the aerospace industry. Scandium is often grouped together with the rare earth elements (REE). Amongst others, scandium can be found in bauxite residues, so called red mud. It is possible to extract and enrich scandium from red mud by leaching and solvent extraction. Scandium can then be recovered from the pregnant strip liquor by crystallization. The strip liquor will however still contain certain impurity elements. In the present work, a method for obtaining a pure scandium solid phase by direct crystallization from the strip liquor is evaluated. It was found that Fe and Ti co-precipitate with Sc under the conditions employed.

By Lucas Lopes da Costa, Sergio Neves Monteiro, Rômulo Leite Loiola

"Composites with DGEBA/TETA epoxy matrix reinforced with thinner and continuous bamboo fibers stripped from culms were mechanically characterized by tensile tests. Specimens with up to 30% in volume fraction of aligned fibers were tensile ruptured at room temperature. The results showed a steady increase in both the ultimate strength and the elastic modulus of the composites with the amount of incorporated bamboo fibers. The fractographic analysis by scanning electron microscopy showed evidence of moderate adhesion between the bamboo fiber and the epoxy matrix. This fiber/matrix adhesion by interaction mechanism apparently justifies the improved tensile properties of the composites.IntroductionIn recent years polymer composites reinforced with natural fibers, mainly those lignocellulosic obtained from plants, have been subject to extensive research works [1-5]. Environmental, economical, societal and technical advantages of these composites are motivating their substitution for similar polymer composites reinforced with synthetic fibers. In particular, R & D efforts have been conducted aiming to replace glass fibers composites that are comparatively more abrasive to equipments, non-recyclable, more expensive, heavier and toxic [6]. Among the many lignocellulosic fiber composites being investigated, those fabricated with bamboo stripped fibers, i.e., fibers longitudinally cut from the culm, still need information to support possible industrial applications. Several works, however, have been dedicated to bamboo stripped fibers as possible reinforcement of polymer composites [7-17]. These works reported mechanical properties that could markedly vary with the type of polymer matrix, the fiber disposition (if continuous, aligned, short-cut, mat interlayered, etc) and the test condition."

Jan 1, 2011

By Chris Doyle

From 1997-2000. PT INCO undertook the Fourth Line Expansion Project (FLEX) to increase annual production rates from 90-100 to 150 Mlbs Ni/year (68,000 MT Ni/yr). In 2003, PT INCO nickel production underwent a major sustainable step jump that finally exceeded the targeted rate. This paper presents the changes that led to this achievement. The focus of mining changed. Improving Ni grade was important but only if electric furnace feed met target chemistry so that on-specification slag could be produced. The intensity of diamond core drilling for exploration was dramatically upgraded, mine planning strategy was totally re- vamped and an ore chemistry quality assurance team was formed. In the processing plant, measurement systems were upgraded for better control. Teamwork between sections vastly improved. The final step jump in production occurred when the fifth hydro-electric power generator was added to the furnace grid to allow the power-starved furnaces to cruise in operation at 70+ MW. Keywords: Free cash flow, Ore Chemistry, Measure, Control, Improve

Jan 1, 2004

By Jiang Diao, Yong Qiao, Xuan Liu, Tao Zhang, Bing Xie

Adding CaO into the vanadium extraction converter is an effective way to decrease the dephosphorization burden in subsequent steelmaking process. The crystallisation process of spinel is one of the most decisive factors in the subsequent extraction. The theoretical calculation results show that the temperature of the peak total crystallization rate will decrease 5K with basicity increasing 0.1. The relation between cooling conditions and grain size of spinels is also discussed. It is found that low cooling rate and high basicity benefit spinel crystal growth. And the non-isothermal crystallization kinetics results indicated that the restriction factors of spinel growth is that solid crystals accept new components from liquid-solid interfacial. While the sample was cooled down to 1250 (1523K) at cooling rate of 5K/min, the crystal growth is consistent with Ostwald coarsening grew up law, and controlled by diffusion of particle.

Jan 1, 2016

By Mostafa Maazouz, Jeff Blackwood, Mauricio Gordillo, Sang Hoon Lee, Micah Ledoux, Liang Zhang

To meet rising requirements for the low-damage ultra-fine process with the focused ion beam (FIB) in the materials science and semiconductor industry, the advanced ion column and corresponding advanced applications as a solution are developed and demonstrated. Novel high-speed high kV milling, low kV cleaning and imaging capabilities have enabled the creation of impeccable ultra-thin structures such as TEM samples and nanometer scale structures. Minimizing Ga+ induced sample damage is achieved through the optimized final cleaning at 500 eV ion landing energy with the new ion optics, which utilizes close control of the ion dose, beam incidence angle, spot size, pattern algorithm and imaging performance. Newly introduced process solutions achieve the improved process throughput. Initial demonstration is performed on the latest 14 and 10 nm scale FinFET device. Validation of the thinnest <0.8 nm thick ion damage layer on the <7 nm thick lamella structure was confirmed through TEM analysis.

Mar 1, 2017

By L. M. Luckevich

Gypsum is a product from the neutralization of sulfuric acid by lime or limestone. This paper will discuss specifications for gypsum used in wallboard, cement and agriculture and the factors affecting its utilization potential. Process conditions during the neutralization which enhance or inhibit utilization potential will be included. In addition, this paper provides a technical and economic perspective of the gypsum industry in North America with a view to the factors affecting the utilization of synthetic gypsum in traditional applications. Current production and consumption of natural and synthetic gypsum in Nonh America are described and the impact of their differences on utilization options are discussed.

Jan 1, 1996

By T. T. Chen

Raw anode slimes consisting primarily of PbSO4, AgCuSe, Cu3Se2, Cu2-x Se, Cu2O, CuSO4.5H2O, Sn arsenate and Sb-Bi-As oxide are batch-leached with electrolyte-O2 to dissolve Cu. During this process, Cu2O and CuSO4.5H2O are solubilized and the Cu in the selenides is leached with the formation of Ag2Se and Se. A small amount of Cu remains in the Ag2Se, Sn arsenate and Sb-Bi-As oxide. The decopperized slimes are repulped in Na2CO3 solution to convert most of the PbSO4 to NaPb2(CO3)2(OH). The Sn arsenate and Sb-Bi-As oxide partly react, but the Ag2Se is not significantly affected by the Na2CO3 solution. The NaPb2(CO3)2(OH) intermediate phase is dissolved in acetic acid to leave a final product consisting of Ag2Se, Se, Sn arsenate and Sb-Bi-As oxide, together with small amounts of PbSO4, NaPb2(CO3)2(OH) and various gangue constituents.

Jan 1, 1993

By Jinsheng Wang, Wei Lv, Xuewei Lv, Pingsheng Lai, Jie Dang

The isothermal reduction kinetics of vanadium titanium magnetite sintering ore was investigated by thermo-gravimetric analysis at a temperature range of 1123–1223 K under 30% CO + 70% N2 gas mixtures. The apparent activation energy of reduction was calculated by iso-conversional method and its value is 36.7 kJ/mol. The model function describing the reduction mechanism was discussed by Sharp analysis and the results revealed that the reduction process is controlled first by random nucleation and nucleus growth mechanism (RNNGM) as reduction degree is lower than 0.5, followed by the mixed influence of RNNGM and phase boundary reaction when reduction degree is higher than 0.5.

Mar 1, 2017

By Alaina Mallard, Jannette Chorney, David Hutchins, Grant C. Wallace, Jerome P. Downey

Current commercial processes for producing ceramic carbides require temperatures of 1400–2000 °C and often use extensive milling operations to produce a powder product. A process that could reduce the energy requirements of commercial carbide production could allow for these materials to be implemented in a greater number of applications. In this study, tungstate (WO4 2−) and silicate (SiO3 2−) anions were adsorbed onto activated carbon and converted into silicon carbide (SiC) whiskers and a mixture of tungsten and tungsten carbide (W/WC) crystals via carbothermal reduction using inert and reducing gas atmospheres at temperatures much lower than what is required by current commercial processes (950 °C for W/WC/W2C and 1200 °C for SiC). The adsorption process was statistically-optimized via a central composite response surface analysis using DesignExpert 9. Inductive coupled plasma optical emission spectroscopy (ICP-OES) was used to measure, and optimize, adsorption efficiency while the carburization products were characterized using X-ray diffraction and scanning electron microscopy.

Mar 1, 2017

By Daniel Chen, Jewel Andrew Gomes, Venkata Palla, Sadia Afrin Jame, David Cocke, Paul Bemazzani

"Textile industries use various kinds of chemicals including dyestuffs and pigments during dyeing and finishing processes. The effluent from these processes includes suspended particles, strong color, high pH and high chemical oxygen demand (COD) that are extremely toxic and make environmental hazard. Although physical, chemical, photochemical, and biological methods are available for treating such wastewater, the electrochemical technique, electrocoagulation (EC), has emerged as an efficient, simple, and cost-effective technology in the last few decades. In this study we present the applicability of EC technique for removing dye, such as direct red dye using iron electrodes, and the optimized conditions such as dye concentration, current density and pH. The degradation of dye molecules was investigated using UV-visible spectroscopy. The EC-floe was also characterized using SEM/EDS, XRD and FTIR.IntroductionWastewaters generated by textile industries contain large amounts of toxic aromatic compounds, especially azo dyes. Azo dyes and their degradation products, such as aromatic amines, are highly carcinogenic. These effluents are also responsible for causing high levels of color. The colored wastewater released into the environment is also a source for disruption of aquatic life and aesthetic pollution as well [1].In most textile industries, dyeing and finishing are the two important processes which are generally applied. These two common processes generate significant amount of wastewater, which may contain, suspended particles, high pH, strong color and high chemical oxygen demand (COD) concentration [2]. Low pH and high temperature are other polluting factors from the waste water. Textile industries make use of about 10,000 dyes and pigments [3]. Disposal of these colored wastewaters poses a major problem for the industries as well as a threat to the environment. In textile industries, because of the low efficiency (60-90%) of dye fixing on textile fibers, substantial amounts of unfixed dyes are released in waste waters. The conventional method for treatment of textile wastewater was a combination of biological, physical and chemical methods [2]."

Jan 1, 2011

By L. I. C. Fernandez, E. B. Ferreira Filho, L. G. Pedroti, L. G. Justino, W. E. H. Fernandes, R. C. S. S. Alvarenga

More and more industries have been concerned with the disposal of the wastes generated in their production processes, once this generates a positive impact, both visual and economic enterprise, no more needing to have resources for transport and final disposal of wastes. In this context, and seen the importance of the Portland cement a sa building material, which aims the creation of an ecological cement from the mix of two wastes, the grits, which is a waste generated in pulp production, and the granite beneficiation waste. It proceeded initially with the chemical and physical descriptions of the wastes. Five mixtures, varying the percentages of the wastes and the preparation method of the raw materials, were prepared. After,the blends were sintered in a muffle furnace at 1300 °C for 15 min, forming new compounds that were compared with national cements, according to the Brazilian technical standards. It was concluded that the sintering of the product obtained satisfactory results, presenting good binder characteristics, however, some parameters were outside the limits for common Portland cements such as rapid setting time, large expandability and low compressive strength.

Mar 1, 2017

By Youn-Bae Kang, Jong-Jin Pak, Min-Kyu Paek

The critical evaluation and thermodynamic optimization of Mn-Si-C and its sub-binary systems have been carried out over the whole composition range from room temperature to above the liquidus temperature. The solution properties of the liquid systems have not been clearly described because the liquid solution exhibits a high degree of short-range-ordering. In order to predict the thermodynamics of the liquid solution, the liquid phases were optimized by the modified quasichemical model. The model parameters of the solid phases were also optimized by the compound energy formalism to best reproduce the phase diagram and important thermodynamic properties in Mn-Si-C system. Using the model parameters, various thermodynamic calculations were carried out. The present database will be a part of larger thermodynamic database for the ferromanganese alloy database.

Jan 1, 2014

By Yijun Cao, Shengpeng Su, Guihong Han, Xiangyu Song, Yanfang Huang

Binder is indispensable in the production of iron ore pellets and the quality of pellets seems to be related to the interactions between binders and iron minerals. Humic acid is proved a suitable binder for iron ore pelletizing. In this paper, the interactions between humic acid and iron minerals were investigated by adsorption experiments and molecular dynamic simulations. Adsorption experi- mentalresultsshowthattheadsorptionofhumicacidonhematiteiseasierthanthat on magnetite, and the maximum adsorption capacities of humic acid on hematite and magnetite reach 17.1, 7.39 mg/g, respectively. The results of adsorption iso- therms indicate that the Langmuir model provides the best correlation of the experimental data, while the thermodynamics results demonstrate that the adsorp- tion process is a spontaneous exothermic process. Molecular dynamic simulations reveal that the interaction between hematite and humic acid is stronger than that between humic acid and magnetite. (cid:1) (cid:1) (cid:1)

Mar 1, 2018

By Ming-Feng Ye, Guang-liang Wu

The microstructure and mechanical strength variations of chromite pellets preheated and roasted in air were studied systematically. The results show that the chromite (Fe,Mg)(Cr,Fe,Al)2O4 is oxidized to magnesium-rich (Mg,Fe)(Cr,Fe, Al)2O4 and ferrochromium complex oxide (Cr,Fe,Al)2O3 in the preheating process over 500 °C. When the temperature is higher than 1000 °C, the new phase (Cr,Fe, Al)2O3 is formed, which is mainly distributed in the outer layer of a single chromite particle. Inner the particles there are acicular (Cr,Fe,Al)2O3 and unoxidized (Fe,Mg) (Cr,Fe,Al)2O4, which forming an interwoven structure together. The oxidation rates of pellets can reach to superior limits in 20 min. With the temperature increasing from 950 to 1300 °C, the mechanical strength and oxidized rates increase to varying degrees correspondingly.

Mar 1, 2018

By Jiang Feng, Zhang Libo, Peng Jinhui, Guo Zhanyong, Ju Shaohua, Lei Ting

The basics of microwave drying process of CuCl residue were studied by comparing the dielectric property of the residue with different moisture contents. The dielectric properties were measured by microwave cavity perturbation method. The dielectric constant and dielectric loss factor of the CuCl residue have a linear correlation with the moisture content. With this relationship, we can realize on-line measurement of moisture content of the CuCl residue by dielectric properties. The microwave drying experiments with different thicknesses (1-5cm) of CuCl residue were carried out, and the heating curve of the materials under different microwave powers (250-450W) was made. From these parameters, an optimized operation parameter of microwave roasting technology, the thickness of CuCl residue filter cake to be microwave roasted should be 2cm , was deduced.

Jan 1, 2015

By Peter R. Sanford

Cyanides are present as a dilute constituent of streams from a variety of metallurgical and mineral-processing operations. In addition, a cyanide concentration in excess of approximately 100ppb is toxic to aquatic life, and consequently these operations require a waste-treatment process to reduce the already dilute cyanide species by several orders of magnitude. Furthermore, the waste streams may have flowrates in excess of a million gallons per day. The paper reports on research conducted with a laboratory?scale electrochemical porous (graphite felt) electrode (anode) flow-reactor, which was conducted in conjunction with a computer-aided simulation of a mathematical model describing the intrinsic rate-phenomena associate with the electrode processes. The laboratory-scale cell, of rectilinear geometry, was found to be capable of reducing a feed-stream anolyte (KCN-KOH and supporting electrolyte of a single salt ? K2SO4) with a cyanide concentration of 10ppm, to less than 100ppb, at current efficiencies in the neighborhood of 50%. The computer simulation of the cell performance based on the mathematical model (and constraints imposed for tractability) was found to provide only for qualitative agreement.

Jan 1, 1998

By Kimiaki Utsunomiya, Yasumasa Hattori, Yoshiaki Mori, Toyokazu Okubo

"The effect of various operating conditions on splashing behavior in a Peirce-Smith converter has been investigated with a 1/5.7 scale cold model. Dynamic similarity between the model and a commercial converter was attained by setting the modified Froude number in the model experiments in· the range for normal converter operation. It is known that for a given modified Froude number the dimensionless penetration length of gas into the liquid phase increases as the liquid density decreases. Moreover, penetration· length has a large effect on splashing behavior. Therefore, a heavy liquid, a mixture of water and lead concentrate was used as the liquid phase. It was concluded that the amount of splash dramatically decreases with a reduction in the buoyancy energy per, unit liquid mass and an increase in the horizontal distance between the tuyere tip and the edge of the mouth.IntroductionSubmerged gas injection is widely used in practice in ferrous and nonferrous pyrometallurgical operations to achieve large gas-liquid contact areas and good agitation of liquid for rapid chemical reaction. The common application in ·nonferrous industry is the Peirce-Smith converter with multi-tuyere for copper and nickel matte converting. This process has been used for over 100 years because of its effectiveness in mixing of the molten bath, as well as its merits of the engineering simplicity. However, the mechanisms which · determine the blowing performance is poorly understood, and the design and operating conditions of the Peirce-Smith converter varies widely from plant to plant, such as by diameter, length, mouth angle, tuyere position and level of molten matte. Smelters have continuously made an effort to increase converter productivity, implying maximum tuyere blowing rate. Above a certain critical blowing rate, splash of molten matte from the converter mouth becomes unacceptable because of dangerous ejection and accretion buildup around the converter mouth, which results in interference with effective hood sealing. In fact, a 1993 converter survey[!] reported that splash was a major limiting factor for blowing rate and 54% of responding plants from around the world regard it as a limiting condition[2]. In order to increase tuyere blowing rate a study of the effect of various operating conditions on splashing behavior is expected."

Jan 1, 2000