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By E. Bélisle, Christopher W. Bale, S. Petersen, C. Robelin, K. Hack, J. Melançon, G. Eriksson, A. D. Pelton, P. Chartrand, S. A. Decterov, I. H. Jung, A. Gheribi

The FactSage® package consists of a series of information, database and calculation modules that enable one to access pure substances and solution databases and perform thermochemical equilibrium calculations. FactSage was originally founded by process pyrometallurgists and has since expanded its applications to include hydrometallurgy, electrometallurgy, corrosion, glass technology, combustion, ceramics, geology, environmental studies, etc. With the various modules one can perform a wide variety of thermochemical calculations and generate tables and graphs of complex chemical equilibria and phase diagrams for multicomponent systems. This paper presents examples of recent and current developments in FactSage in areas of particular interest to Dr. David Robertson. These include both ferrous and non-ferrous processing, as well as solidification and refining simulation. The paper also includes reference to the Internet Fact-Web education package.

Jan 1, 2014

By Simon Lekakh, Von Richards, C. Hank Rawlins, Kent Peaslee

"Batch aqueous leaching and carbonation tests were conducted using industrial steelmaking slags to determine the effect of carbonic anhydrase enzyme as a catalyst. Calcium leaching is a strong function of particle surface area, and the extent can be expressed as a function of time and particle size. Carbonic anhydrase did not affect the calcium-leaching rate, however, it did catalyze calcium carbonate formation to achieve a neutralization time near the theoretical rate. Additionally, carbonic anhydrase modified the precipitate morphology due to accelerated particle nucleation. Time controlled tests in which the pH dropped to ~6 decreased the amount of carbonate produced, and this effect was exaggerated by carbonic anhydrase, while pH controlled tests (>8.5) exhibited the highest rate of carbonation. Because the leaching rate was ~50% faster than the carbonation rate, a further increase in the amount of carbonation may be realized by using carbonic anhydrase however pH must be >10.3.IntroductionSteelmaking slag contains high fractions of alkaline earth oxide based phases (i.e., CaO and MgO) that exothermically form carbonates. Thus, it is being considered as a means of permanent carbon dioxide sequestration. At current U.S. steel production rates, approximately 13-17 million tons/year of slag are generated from basic oxygen furnace (BOF), electric arc furnace (EAF), and ladle metallurgy furnace (LMF) processes [1]. BOF and EAF slag is used as high quality mineral aggregate or cement clinker, while LMF slag, produced at ~15% the rate of BOF and EAF slags, has limited use as blast furnace flux or acid mine neutralization with the majority going to landfill [2]. Based on slag’s chemical nature and immediate availability as a co-product from steel production, the steel industry initiated a project to investigate hydrous carbonate formation in steelmaking slag as a method of sequestering carbon dioxide emitted in steelmaking offgas [3]. The goal of this project is to determine the reactor parameters suitable for the design of an industrial system for treating steelmaking offgas with raw or minimally processed slag."

Jan 1, 2009

By F. Kavicka

An original application of ANSYS simulated the forming of the temperature field of a massive casting from ductile cast-iron during the application various methods of its cooling using chills. The numerical model managed to optimize more than one method of cooling but, in addition to that, provided serious results for the successive model of structural and chemical heterogeneity, and so it also contributes to influencing the pouring structure. The file containing the acquired results from both models brings new and, simultaneously, remarkable findings of causal relationships between the structural and chemical heterogeneity and the local solidification time in any point of the casting. The determined relations therefore enable the prediction of the face density of the spheroids of graphite in dependence on the local solidification time. The calculated temperature field of 500x500x1000 mm casting of ductile cast-iron with various methods of cooling has successfully been compared with temperatures obtained experimentally. Acknowledgments. This analysis was conducted using a program devised within the framework of the GA CR projects (No.106/04/1334, No. 106/04/1006 and No. 106/04/094), of the COSTAPOMAT-OC526.10, MPO/FI-IM/021, EUREKA No.2716 COOP and KONTAKT 14/ 2005/06.

Jan 1, 2006

By Patrick R. Taylor

A non-transferred arc thermal plasma assisted cyclone reactor has been designed, built and operated to evaluate its use in vitrification of wastes. Simulated waste (liquid, slurry or fine particulate) is injected near the plasma flame, where nearly instantaneous dehydration and calcination reactions happen. A non-transferred arc plasma torch was attached tangentially to the cyclone and is utilized as both an enthalpy source and to provide the gas velocities required to generate the cyclonic gas flow patterns. The closed top cyclone flow sends the solid particulates to the wall, where they are captured by a thin film of molten glass that is injected as a powder at a position lower in the reactor. The molten glass is then collected in a crucible. The feasibility of simulant injection directly into the flame zone and its effect on electrode lifetimes has been studied. Several candidate refractory systems have been evaluated for their suitability for extended use under the demanding conditions present in the cyclone reactor.

Jan 1, 2002

By H. Jiang, S. Yang

"The main processes for nickel metallurgy in China consist of electric arc furnace smelting to produce low grade nickel matte and converter to high grade nickel matte, grinding and flotation to separate nickel sulfide from copper sulfide and direct electrolysis of nickel matte. Systematic studies on the properties of electric furnace slag, smelting process for nickel matte, anodic process of nickel matte, cathodic process of nickel electrolysis have been done in our labs. In addition, an approach to a new hydrometallurgy process for nickel matte has been done. The feature of the new process is one stage acidic leaching of high grade nickel matte. The leaching solution could be purified by deposition way or by solvent extraction way. There are two leaching rate-determing steps, chemistry reaction-determing one at temperatures below 600C and diffusion-determing one at temperatures higher than 600 c. The acidic leaching fraction reacted dvaties with leaching time t according to the equation 1-(1- a ) 1/3=kt. The experimental data also show that the leaching reaction rate varies with concentrations of H+, Cl-, and it is also effected by copper sulfide and Cu++. The Cu++ ion can retard the leaching reaction due to forming a copper sulfide layer on the matte surface and the equation 1- 2/3 a. - (1- a: ) 2/3 akt can be used for the case. However the copper sulfide added into nickel matte can facilitate the leaching process. The research work for nickel metallurgy done by others in China has also been mentioned in this paper.Large scale production of nickel in China started in 1960s.The main processes consist of electric arc furnace smelting to produce low grade nickel matte and converter to high grade nickel matte grinding and floatation to separate copper sulfide from nickel sulfide and direct electrolysis of nickel matte.To reduce nickel loss in slag a reseaech group organized by Jinchuan Company and Central South Institute of Mining and Metallurgy (now the Central South University of Technology) measured the viscosity surface tention density conductance melting point and structure of the slag(I).lt has been found that the physico-chemical properties of the slag depend on the components SiO2 ,MgO and FeO but FeO in the slag is too high and the statistic analysis of data from industry gave an equation to correlate the content of Ni in slag with the content of Ni in matte and the composition of slag again it was pointed out that the content of FeO in slag effected the loss of Ni in slag very much (2). The ratio (FeO+MgO) to SiO2shouid be less than 1.13 and the content of Fe3O4should be as low as possible but the reaction"

Jan 1, 1988

By Akihide Hosokawa

The void growth and coalescence in model materials involving a pre-existing three dimensional void array (i.e. multiple layers of a void array) was studied by X-ray computed tomography (XCT) coupled with in situ tensile deformation. To reduce the recording time, a new technique called fast tomography was employed. The model materials used in this paper were fabricated by the combination of an ultra-short pulsed laser machining system and a diffusion bonding technique, and two different types of arrays were prepared namely, FCC 1 and FCC 2 type array. This methodology allowed the authors to capture the entire process of growth and coalescence events of a void array embedded in the metal matrix. The failures in the both materials involved internal necking and shear localization. One of the highlights of this paper is that the plastic strain at the onset of void coalescence was measured for each model material. These values are in fact the adequate values to be compared with the coalescence strain predicted by existing void coalescence models such as the Brown and Embury model, the Thomason model and the Pardoen and Hutchinson model. The comparison suggested that the Brown and Embury model underestimated the coalescence in neither of the current model materials, while the Thomason model and the Pardoen and Hutchinson model showed a quite good agreement with the result for FCC 1 material. On the other hand the result from FCC 2 material agreed with none of the models probably due to the geometry of the void array that is not compatible with the existing models.

Jan 1, 2010

By P. N. Anyalebechi

The effects of a cross-hatched grooved mold surface topography, casting speed, and superheat on the morphology of solidifying shells of aluminum alloy 3003 have been characterized by a series of immersion tests. The cross-hatched grooves were 0.232 mm deep with wavelength or spacing between 1 mm and 15 mm. The shells solidified at casting speed of less than 10 mm/s on the 1 mm spaced cross-hatched grooved mold surface were fairly uniform with little or no localized variations in thickness. However, the propensity for non-uniform shell growth morphology was exacerbated by an increase in casting speed, melt superheat, and the wavelength of the cross-hatched grooves. This is provisionally attributed to their effects on interfacial heat transfer and wetting of the mold surface by the molten metal.

Jan 1, 2008

By Edward Rosenberg

The synthesis and characterization of silica polyamine composites modified with a variety of sulfur containing ligands is described. The two most successful ligands in terms of sulfur in-corporation and mercury capture are ethylene sulfide and carbon disulfide. The ethylene sulfide forms either an amino mercaptane or a polysulfide upon reaction with amino groups on the composite. The carbon disulfide undoubtedly forms a dithiocarbamate functional group upon reaction of the amino group under basic conditions. Both materials posses excellent capture kinetics and capacities for mercury, Once captured, the mercury is extremely difficult to remove from the composite materials, even with concentrated acids, and they easily pass the TCLP test. The materials are compared with related thioether modified silica polyamine composites and appropriate potential applications are discussed.

Jan 1, 2003

By Valdeci Paula Alvarenga, Sergio Luiz Costa, Itavahn Alves da Silva, Filipe Bueno Carvalho, Varadarajan Seshadri, Carlos Antonio da Silva

Use of fluorspar in steel refining operations is one of the environmental concerns and as such reduced consumption of this material or substitution of the same is one of the objectives. Industrial runs were carried out at Aperam Steel making convertor unit (Timóteo, MG, Brazil) using recycled/briquetted slag for partial or complete substitution of fluorspar. Samples were collected from the metal bath and slag after oxygen blowing to assess dephosphorization with several combinations of recycled/briquetted slag and fluorspar. The results showed that partial substitution of fluorspar by BOF slag briquettes did not affect the efficiency of dephosphorization. In general average Phosphorus content was reduced to 0.010% in the case of partial substitution compared to 0.016% in the regular refining procedure with no substitution. This replacement also resulted in 40% reduction of the fluorspar consumption in the converter

Jan 1, 2015

By Qiang Zhong, Bin Xu, Qian Li, Wei Gao, Yongbin Yang, Yaxuan Wang

Lump coal with high volatility is used for providing heat and reductive gas, and ensuring permeability in COREX. However, it is apt to be pulverized in transport and storage process. Therefore, comprehensive utilization of the pulverized coal to produce coal briquettes with appropriate binders is significant, among which the molasses binder cannot meet the technological requirements. In this paper, coal tar pitch binder and BJ additive were used in briquetting and carbonizing process of coal powder. The results showed that BJ effectively activated cold state cohesiveness of the pitch and make it bond the coke particles to a firm briquette at room temperature .Carbonizations of coal and coal tar pitch achieved obvious constriction and formed a carbonized skeleton. The drop resistance of wet briquettes reached over 50 times/1meter. When cured at 1000 °C for 1h under nitrogen atmosphere, the compressive strength of carbonized briquettes came to 6.43 Mpa.

Jan 1, 2016

By D. F. Suarez

Spontaneous nodulation leading to growth of well developed glossy spheroids (generally hemispheres) of up to 0.06 cm width in 120 min has been observed during copper electrodeposition with certain levels of glue, thiourea and C1-. Thiourea alone can produce spontaneous nodulation but addition of glue and/or Cl- is required for rapid and sustained growth. In most cases once the glossy nodules develop they consume the majority of the copper deposited; thus, the specific current densities (and hence copper electrodeposition rates) on the glossy nodules are about an order of magnitude or, more greater than on the adjacent planar surfaces. The texture of the adjaoent planar surfaces is not glossy in appearance but is well faceted showing the usual deposition grain structure for such additives. Cathode potentials when spontaneous nodulation occurs are about TOO my more negative than with usual copper electroplating. This fact associated with evidence of extremely high levels of cathode surface passivation based on cyclic voltammograms indicates that the conditions which lead to spontaneous nodulation result from a very tightly adsorbed additive surface film. This film breaks down in specific points initiating the glossy nodules which then grow at extremely rapid rates. Current density is also important in spontaneous nodulation. At equal deposition times a current density of 21.5 mA/cm produced much larger glossy nodules than at 48 mA/cm2. The surface concentration of the glossy nodules was much greater in the latter case, however. The role of current density is still not well understood. The role of it as well as the relative roles of the three additives, thiourea, glue and Cl- in spontaneous nodulation is presented. Preliminary results and some possible correlations of these to help explain spontaneous nodulation are presented. It is believed that tankhouse upsets where cathode nodulation occurs may be related to this phenomenon.

Jan 1, 1987

By Guanghui Li

In the paper, the recovery technology of gallium from zinc-leaching residue by cold-bonded coal-based direct reduction process following magnetic separation was developed. The results show that the scattered metal Ga can be concentrated obviously after the reduction of zinc-leaching residue briquette and magnetic separation of reduced product. At the same time, the volatilization of Zn in the residue is enhanced during the reduction. When the residue, bear¬ing 18.60% Zu.21.18% Fe and 527 g/t Ga, was reduced with coal at 1100°C for 150 min, the results of Zn volatilization of 9842% and Ga recovery of 89. 10% were obtained in reduction. After magnetic separation of the reduced product, the concentration of Ga in sponge iron is 2164 g/t, and the separation recovery of Ga reaches 92.42%. The enriched mechanism of Ga during reduction -separation process was studied by using electron microscope, scanning elec¬tron microscope, energy spectrum and mineralogical analysis. The investigations show that there is no formation of independent phase of Ga during reduction process. The Ga occurs mainly in metallic iron phase (the concentration of Ga in metallic iron phase is 0.04%-0,4%), in addition, there exists a little Ga in poorly crystalline sulphide (o.08%-0./5Y& Ow). But Go does not exist in most of glass and silicate phase. The affinity of Ga for metallic iron is the enrichment basis of Go in reduction, and it is also in favor of recovering Go during magnetic separation. Key Words: Gallium Zinc-leaching Residue Cold- Bonded Direct Reduction

Jan 1, 2003

By Rudolf Keller

"EMEC Consultants is developing a process to extract oxygen, aluminum and silicon from lunar anorthositic soil. The process will provide oxygen in space for propulsion, aluminum as a structural material, and possibly silicon for the construction of solar cells.The evolution of the process concept in the course of our present NASA-sponsored SBIR effort is discussed. A molten salt electrolysis producing aluminum and oxygen is the central step; inert anode technology is to be employed. Silicon will be produced by reducing the anorthite, CaAI2Si20S' with aluminum. In a steady-state operation, all components of the ore added have to be removed from the process, and the removal of calcium is a major topic of our experimental studies.Utilization of Lunar ResourcesUtilization of lunar resources may play an essential role in the exploration of the solar system and the conquest of space. High costs are involved in overcoming Earth's gravity to supply missions in space. Even at a low projected cost of $ 300 for transporting a pound of payload into Earth orbit -- today's costs are many times higher -- it appears attractive to use resources in space to produce needed materials. Processing of lunar resources on the lunar surface is an obvious possibility.Oxygen is a product of major interest. It is required for support of human life in space. Even greater quantities may be needed for propulsion, to conduct further missions into space. To satisfy this demand for oxygen through lunar processing requires a quite different solution than to supply oxygen on Earth, where oxygen gas is abundant and easy to extract from air or water. On the lunar surface, solid oxide materials have to be used. Hydrogen reduction of ilmenite and subsequent electrolysis of the resulting water is being studied [1]. Other suggestions include fluorination of lunar soil [2], reduction with lithium and electrolytic decomposition of the resulting lithium oxide [3], and aqueous HF leaching [4]."

Jan 1, 1988

By Yuanbo Zhang, Guanghui Li, Zhenyu Fan, Tao Jiang, Xiaohui Fan

"Iron ore sintering process is the main source of SO2 generated in the steel industry, of which the discharge amount of SO2 emission accounts for about 60% of the total. Aiming at the features of sintering flue gases and existing problems during the flue gas desulphurization, a technical route of flue gas circulation sintering (FGCS) for iron ores has been put forward. Under the simulated experimental conditions, effects of FGCS process on the main output and quality indexes and SO2 emission rule are researched using simulating flue gases. Compared the novel FGCS with conventional sintering process, SO2 in the final sintering flue gas is obviously enriched and the total exhaust gases can be reduced evidently. The decreasing of oxygen content in circulating gases has bad effect on the sintering indexes. Increasing the oxygen potential is beneficial to obtain high quality sinters. This investigation shows that the FGCS process is promising.IntroductionSteel is a kind of essential material for modern society, but steel-making process is characterized by high energy-consumption and emission as well as heavy environmental pollution. Chinese steel industry has developed rapidly in the last decade, and the environmental problem caused by ironmaking and steelmaking have also aroused the greatest concern, especially the atmospheric pollution caused by SO2, CO2, etc. Iron ore sintering process is the main source of SO2 generated in the steel industry, of which the discharge amount of SO2 emission accounts for about 60 % of the total. The development of the desulfurization process for sintering flue gases to reduce SO2 emission in sintering process is not only the requirements of sustainable development but also the most important environmental tasks for steel industry [1-5]."

Jan 1, 2011

By Pengfu Tan

A thermo-chemical model of the copper P-S converter and a viscosity model for the converter slag have been developed to predict the behavior of magnetite in the converter slag, amounts of slag and matte, compositions of slag and matte, volume of the bath, bath temperature, slag blow endpoint determination, SEMTECH OPC signals, and the viscosity of converter slags. The predictions of bath temperature, slag and matte compositions, and magnetite content in the slag have been validated by the industrial data. The effects of fluxing strategy, returns and skim charges, oxygen enrichment, and temperature on the magnetite formation in the slag have been predicted and discussed. The effect of oxygen potential, SiO2/Fe in slag, detection of slag blow endpoint, and temperature on Fe3O4 content in converter slag, slag viscosity, liquidus temperature of converter slag and skimming operation has been modeled and discussed as well. Some applications of the industrial operations have been presented.

Jan 1, 2009

By Thomas P. Battle

Modern-day direct reduction of iron first developed as a small-scale, low capital and operating cost alternative to the blast furnace. Since commercialization of continuous DR technology in the late 1960s, the market for the products of direct reduction has grown to more than 74 million tonnes in 2012. The initial advantages of DR plants over BF facilities have grown over the years, for several reasons, including the increased size of DR modules, lower energy and emissions (particularly CO2), along with the flexibility to use a number of different reductants. The development of DR technology over the past forty years will be emphasized in this presentation, including recent developments that allow for even more direct sustainability comparisons with the iron blast furnace – and even combine the two technologies for improved synergies. Also briefly discussed will be the possibilities of using direct reduction for non-ferrous ores.

Jan 1, 2014

By Ulises Crossa Archiopoli

We describe a technique that allows rapid imaging of the thermal diffusivity of the sample by a modified photo-thermal technique. The thermal diffusivity in hardened steels strongly correlates to the hardness. Hence in a noncontact manner and with optical microscope resolution, a 2D map exhibiting the crystallographic phases and hardness of the sample can be retrieved. Two almost collinear laser beams scan the surface, one as a modulated pump and a second as a CW probe. The deflection of the probe carries information on the thermal expansion of the sample and with it, on the thermal diffusivity. It is shown that a single determination of the time delay of the modulation of the probe beam can be used to retrieve the thermal diffusivity.

Jan 1, 2010

By N. B. Gray, A. E. Guerra, D. E. Morton

"The formation of splash in pyrometallurgical operations that involve the injection of gases into a liquid has been the subject of a number of studies over the last few decades. Given the complexity of the phenomena, there have been some advances in understanding the microscale formation of splash but the ability to accurately predict the amount and character of the splash formed is still in its infancy. First, the macroscale mechanisms for splash formation is very varied. Second, the timescales for splash formation are very small, usually less than 100 milliseconds, making experiments elucidating the formation of splash difficult and costly. Work at the GKW CRC has shown that the microscale mechanism of splash formation is primarily is due to the Kelvin-Helmholtz instability. Substantial progress has been made in understanding the behaviour of large bubbles in effecting splash formation and a simple model has been developed to estimate the behaviour of splash formed from a top submerged lance. Direct numerical computation of splash formation using the GKMAC codes developed at the Centre has been successful in simulating the impact of liquid drops onto a liquid bath.IntroductionInjection of gases into melts is used in the metallurgical industry to promote mixing to ensure acceptable heat and mass transfer rates, conveying solids for alloying, provide efficient contact for gas-melt reactions, and as a reactant. High gas injection rates bring about the formation of splash and slop. Extensive splash formation leads to loss of valuable product, creation of safety hazards, formation of accretion on refractory lining and exhaust ducts, and increased load on dust removal equipment. Many operators and researchers have claimed that splash formation is the limiting factor in many gas injected processes. The problems listed above lead to loss of production and increased maintenance, adding to the cost of processing base metals. Over the last five years, the GKW CRC has been studying the formation of splash from a number of sources. They include the impingment of drops on liquids[ l·2.31, slopping of bath liquidI4.51, breakup of gas bubbles at the liquid-gas interfacel61, shearing of liquids by gases[7·81, and impact of packets of fluids on solidsl81. Theoretically, the extreme deformation of fluid shape and the influence of surface tension makes the simulation of flow resulting from only a drop impacting on a liquid surface a very challenging computational fluid dynamics problem. Recently, we have been successful in simulating the formation of the Rayleigh jet resulting from a drop impact showing the effect of drop Froude number on the shape of the Rayleigh jet."

Jan 1, 1996

By P. Kerr

Iron segregation is pre-dated by copper and nickel segregation processes for which the experimental methodology and reaction chemistry were established. The accepted reaction sequence for segregation involves the generation of hydrogen chloride, the chloridization and volatilization of the metal chloride, and precipitation of the metal from the metal chloride in the vicinity of carbon. Iron segregation roasting offers a potential extraction solution for processing oxide deposits with complex mineralogy or waste streams such as Minette-type iron deposits, nickel laterites, ilmenite, red mud, electric arc furnace (EAF) dust, mill scale and slag. After subsequent magnetic separation, one is left with a high grade metallic iron powder which can be marketed for powder metallurgy or briquetted to serve as a direct reduced iron (DRI) product. The non-magnetic product is typically concentrated oxides including rutile, alumina, or oxides of V, P, and rare earths, etc. that may be economically recoverable with subsequent processing. While operating conditions vary for different metals, they share the requirements of an elevated operating temperature and a mixture of oxide ore, carbonaceous additive and a chloride additive in varying amounts all in a closed reactor to allow for reducing conditions and contain the volatile chlorides. This process is then followed by some form of physical separation. Testwork performed by the authors shows promising results that may aid in future development of the process. Segregation roasting of iron will likely never displace traditional beneficiation and ironmaking technologies; however, it has great potential in niche markets where traditional technologies have failed or current technologies generate substantial waste.

By Jean-François Boulanger

The production of rare earth elements from ore usually consists of three steps; the separation of a concentrate of REE bearing minerals; the cracking of the REE minerals to liberate the REE into an aqueous solution and separation of REE into individual elements. This paper describes the results of laboratory tests conducted on a carbonate-rich REE ore containing bastnaesite and monazite. The tests cover the whole processing sequence of beneficiation, preparation of the REE solution using a caustic leach followed by acid leach to break monazite and bastnaesite and liberate REE into an aqueous solution and the partial separation of the REE using solvent extraction. Details on the product quality and process performances (recovery and impurities removal) are given for each studied step. The paper also discusses the economic advantage of separating the REE rather than producing a mixed REO product to be sold to a refinery for REE separation. A mini-pilot plant version of the process is currently planned.