Applications of Process Engineering Principles in Materials Processing, Energy and Environmental Technologies (eBook)
571 Seiten
Springer International Publishing (Verlag)
978-3-319-51091-0 (ISBN)
The Minerals, Metals & Materials Society (TMS) is a member-driven international professional society dedicated to fostering the exchange of learning and ideas across the entire range of materials science and engineering, from minerals processing and primary metals production, to basic research and the advanced applications of materials. Included among its nearly 13,000 professional and student members are metallurgical and materials engineers, scientists, researchers, educators, and administrators from more than 70 countries on six continents.
The Minerals, Metals & Materials Society (TMS) is a member-driven international professional society dedicated to fostering the exchange of learning and ideas across the entire range of materials science and engineering, from minerals processing and primary metals production, to basic research and the advanced applications of materials. Included among its nearly 13,000 professional and student members are metallurgical and materials engineers, scientists, researchers, educators, and administrators from more than 70 countries on six continents.
Preface 5
Contents 7
About the Editors 13
Plenary Session 17
1 Applications of Process Engineering Principles in Materials Processing, Energy and Environmental Technologies—Contributions of Professor Ramana Reddy 18
Abstract 18
Biographical Overview 19
Significant Research Accomplishments 21
PROFESSIONAL AWARDS AND HONORS RECEIVED 28
2 Status of the Development of Flash Ironmaking Technology 30
Abstract 30
Introduction 30
Reduction Kinetics Determination 31
Reduction Kinetics in Temperature Range 1130–1350 °C 32
Reduction Kinetics in Temperature Range 1350–1600 °C 33
Laboratory Scale Flash Reactor 35
Mini-pilot Scale Flash Reactor 36
Conclusions 36
Acknowledgements 37
References 37
3 Innovations and Insights in Fluid Flow and Slime Adhesion for Improved Copper Electrorefining 39
Abstract 39
Introduction 39
Design and Simulation Results of an Innovative Electrolytic Cell 41
Control of the Adhesion and Sizes of Slime Particles 44
Conclusions 46
References 46
4 Molten Flux Design for Solid Oxide Membrane-Based Electrolysis of Aluminum from Alumina 48
Abstract 48
Introduction 48
Background 49
New Research Strategy 50
Results 52
Conclusion 57
References 57
5 Effect of Slag Phase on Mixing and Mass Transfer in a Model Creusot Loire Uddeholm (CLU) Converter 58
Abstract 58
Introduction 58
Experimental Measurements 60
Bath Mixing Intensity Measurements 60
Mass Transfer Experiments 60
Results and Discussion 61
Mixing Rates 62
Mass Transfer Rates 68
Conclusions 73
References 73
Electrometallurgy 75
6 Modeling of Aluminum Electrowinning in Ionic Liquid Electrolytes 76
Abstract 76
Introduction 77
Experimental Methods 78
Mathematical Formulation 79
Electrical Potential Modeling 79
Fluid Flow Modeling 80
Mass Transport in Bulk Electrolyte 81
Electrode-Electrolyte Interface 81
Boundary Conditions 82
Results and Discussion 85
Electrical Field Distribution 85
Concentration Profile 85
Current Density Distribution 86
Conclusions 87
Acknowledgements 88
Appendix 88
References 89
7 Electrochemical Processing of Rare Earth Alloys 91
Abstract 91
Introduction 91
Experimental 92
Results and Discussion 93
Summary and Concluding Remarks 98
Acknowledgements 98
References 98
8 Effect of Cobalt and Iron Concentration on the Potential for Oxygen Evolution from Pb–Ca–Sn Anodes in Synthetic Copper Electrowinning Electrolytes 99
Abstract 99
Introduction 99
Experimental 100
Results and Discussion 101
Conclusions 104
Acknowledgements 104
References 104
9 Cobalt Electrodeposition from Cobalt Chloride Using Urea and Choline Chloride Ionic Liquid: Effect of Temperature, Applied Voltage, and Cobalt Chloride Concentration on Current Efficiency and Energy Consumption 106
Abstract 106
Introduction 106
Experimental Procedure 108
Preparation of Urea and Choline Chloride Ionic Liquid 108
Cyclic Votammetry 108
Electrodeposition of Cobalt 109
Characterization of the Deposited Cobalt 109
Result and Discussion 109
Cyclic Voltammetry 109
Electrodeposition of Cobalt 112
The Effect of Temperature on the Electrodeposition of Co 112
Effect of the Applied Voltage on the Electrodeposition of Co 114
Effect of the Concentration of CoCl2 on the Electrodeposition of Co 118
Conclusion 121
Acknowledgements 121
References 121
10 METTOP-BRX Technology—Eliminating Concerns and Highlight Potentials of the Concept of Tankhouse Optimization 124
Abstract 124
Introduction 124
Theoretical Background and Functional Principle 126
Inhibitor Distribution 128
METTOP-BRX Technology—Hardware for Different Kinds of Application 129
Brownfield Approach—Parallel Flow Device (PFD) for Upgrading Existing Tankhouses 129
Greenfield Approach—Parallel Flow Plate for Optimized Tankhouse Performance 130
Considerations for Installation of the METTOP-BRX Technology 131
References of the Technology in Industrial Scale Use 132
Montanwerke Brixlegg AG, Austria—Upscaling an Existing Tankhouse [3, 7, 8] 132
Xiangguang Copper, China—Installation of a New Tankhouse 133
Economical Benefits of the METTOP-BRX Technology 135
Summary and Conclusion 135
References 136
11 Mathematical Modeling of Molten Salt Electrolytic Cells for Sodium and Lithium Production 137
Abstract 137
Introduction 138
Dimensions of the Anode/Cathode Pair 138
Mathematical Model 139
Standard k-? Turbulence Model 139
Discrete Phase Model (DPM) 140
Electrolytic Reaction Model 140
Parameters and Computing Method 141
Results and Discussion 141
Bubble Behavior and Flow Characteristics in LiCl Cell 141
Lithium Droplet Trajectories 143
Aspects of Lithium Distribution on the Top Surface 144
Electrolytic Process in NaCl Cell 145
Conclusion 145
References 146
Hydrometallurgy 147
12 P-CAC, A Unique Separation Technology for PGM Recovery 148
Abstract 148
Introduction 148
P-CAC Technology 149
Experimental Tests 152
Results and Discussion 154
Conclusions 156
Acknowledgements 156
References 157
13 The Physical Characteristics of Electrorefined Copper Starter Sheet Material 158
Abstract 158
Introduction 158
Experimental 159
Starter Sheet Materials 159
One-Point Bending Test 159
X-ray Diffraction 160
Results and Discussion 160
Commercial Starter Sheets 160
Laboratory Starter Sheets 160
Conclusions 166
Acknowledgements 167
References 167
14 Extraction of Copper from Sulfate-Chloride Solutions by Using Hydroxyoxime Extractants 168
Abstract 168
Introduction 168
Experimental 170
Results 170
Maximum Loading for LIX 84-IC and LIX 860 N-IC 170
Extraction Isotherms 171
Conclusions 174
Acknowledgements 174
References 175
15 Hydrometallurgical Processes for the Recovery of Rare Earths, Nickel and Cobalt in Chloride Medium 176
Abstract 176
Introduction 176
Mixed-Chloride Leaching Process for the Recovery of Rare Earth Elements 177
Mixed-Chloride Leaching Process for the Recovery of Nickel and Cobalt from Laterite 180
Conclusions 183
References 183
16 A Cr6+-Free Extraction of Chromium Oxide from Chromite Ores Using Carbothermic Reduction in the Presence of Alkali 185
Abstract 185
Introduction 185
Experimental 187
Results and Discussion 188
Carbothermic Reduction of Chromite Ore in the Presence of Alkali 188
Wet Magnetic Separation 189
Treatment of the Non-magnetic Fraction 191
Proposed Process Flowsheet 192
Conclusions 193
Acknowledgements 194
References 194
Pyrometallurgy I 195
17 Market Dynamics, Recycling and Recovery of Magnesium from Aluminum Alloy Scrap 196
Abstract 196
Introduction 196
Aluminum and Magnesium Production and the Scrap Industry 196
Commercial Significance—Mg Recovery from Al Scrap Is Important Now 198
Magnesium Recovery Potential 198
Magnesium and Aluminum Scrap North American Materials Flow 199
Current State-of-the-Art and Available Technology 200
Need for a New Technology 201
New Technology—Re-12™ Electrorefining Process 201
Experimental and Analytical Results 202
Markets for RE-12™ Process Implementation 202
Production of AA 6111 Automotive Closure Sheet from New Stamping Plant Scrap 203
Low Mg–Al Foundry Alloys 356, 380, 319 203
Production of Can Body Sheet from Used Beverage Can (UBC) Scrap 204
Results and Conclusions 204
Path Forward 204
Acknowledgements 205
References 205
18 Alternative Ways of Using Nonferrous Slags as Feed Material in the Ferrous Production Industry 206
Abstract 206
Introduction 207
Thermodynamics Considerations 207
Iron Recovery 208
Copper Removal 211
Conclusions 212
References 212
19 Insulating or Conductive Lining Designs for Electric Furnace Smelting? 214
Abstract 214
Introduction 214
Background 215
Tools Available to Conduct Desktop Study 217
Consequences of Philosphy Selected 221
Conclusion 223
Acknowledgments 224
References 224
20 The Influence of Phosphorous Additions on Phase Evolution in Molten Synthetic Coal Slag 226
Abstract 226
Introduction 226
Materials and Methods 227
Results and Discussion 228
Conclusions 233
Acknowledgements 233
References 234
21 The Recovery of Copper from Smelting Slag by Flotation Process 235
Abstract 235
Introduction 235
Experimental 236
Materials 236
Flotation Tests 237
Results and Discussion 237
Characterization of the Slag 237
Flotation Results 238
Conclusions 240
Acknowledgements 240
References 240
22 Reaction Mechanisms in the Silicothermic Production of Magnesium 242
Abstract 242
Introduction 242
Experimental and Thermodynamic Calculation Conditions 243
Use of CaF2 as the Catalyst 244
Use of B2O3 as the Catalyst 248
Conclusions 251
References 251
23 Influences of CaO/SiO2/MgO/Al2O3 on the Formation Behavior of FeO-Bearing Primary-Slags in Blast Furnace 253
Abstract 253
Introduction 253
Experimental 254
Experimental Method 254
Results and Discussion 256
Softening and Melting Properties of Base Case 256
Effects of the Samples Composition on Softening and Melting Properties 257
Conclusions 259
Acknowledgements 260
References 260
24 Desulfurization of High Sulfur Coal Leached with H2O2 and NaOH by Microwave Irradiation 261
Abstract 261
Introduction 261
Experimental 263
Coal Sample 263
Desulfurization Experiments by Microwave Irradiation 263
Desulfurization Experiments Leached with H2O2 and NaOH by Microwave Irradiation 263
ATR-FTIR Analysis 264
Results and Discussion 265
Effects of Irradiation Time on Desulfurization Rates 266
Effects of Irradiation Power on Desulfurization Rates 267
Effects of Particle Size on Desulfurization Rates 268
Effects of the Concentration Ratio on Desulfurization Rates 268
Analysis of the ATR-FTIR Spectra 268
Conclusions 269
Acknowledgements 270
References 270
Pyrometallurgy II 272
25 Chloridizing Roasting of Bismuthinite with Sodium Chloride–Oxygen 273
Abstract 273
Introduction 273
Experimental Work 274
Results 274
Effect of Temperature 275
Effect of Partial Pressure of Oxygen 276
Characterization of the Reaction Products 277
Bismuthinite Oxidation with and without Sodium Chloride 279
Conclusions 281
Acknowledgements 281
REFERENCES 281
26 Natural Gas Utilization in Blast Furnace Ironmaking: Tuyère Injection, Shaft Injection and Prereduction 282
Abstract 282
Introduction 282
Limits to Tuyère Injection Rates 283
Using Pre-reduced Feed 285
Shaft Injection 285
Calculation Approach 286
Results and Discussion 288
Coke Replacement Ratios and CO2 Intensity 288
Costs 290
Conclusion 290
Acknowledgements 290
References 290
27 Selective Sulfation Roasting of Rare Earths from NdFeB Magnet Scrap 292
Abstract 292
Introduction 292
NdFeB Magnets 292
Sulfation Roasting 293
Experimental 294
Sample Preparation 294
Experimental Procedure 294
Results 295
Weight Change 295
XRD Spectra 296
Discussion 297
Conclusions 298
Acknowledgements 298
References 298
28 Gold Solubility in Smelting Slags for the Recycling of Industrial and Mining Wastes 299
Abstract 299
Introduction 299
Experimental Procedure 301
Results and Discussion 301
Conclusions 304
Acknowledgements 304
References 304
29 Solid State Reduction of Iron, Manganese and Chromium Oxide Ores with Methane 305
Abstract 305
Introduction 305
Experimental Procedure 307
Results and Discussion 310
Reduction of Mustavaara Titano Magnetite Ore 310
Reduction of Mamatwan Manganese Ore 311
Reduction of LG-6 Chromite Ore 312
Conclusions 315
Acknowledgements 315
References 316
30 Stibnite Chloridizing with Calcium Chloride-Oxygen at Roasting Temperatures 317
Abstract 317
Introduction 317
Experimental Work 318
Materials and Procedure 318
Results 319
Effect of the Partial Pressure of Oxygen in the Reaction Atmosphere 320
Characterization of the Reaction Products 323
Conclusions 324
Acknowledgements 324
References 324
31 Investigations on Rotary Tool Near-Dry Electric Discharge Machining 325
Abstract 325
Introduction 325
Experimental Setup 327
Materials and Methods 327
Experimental Procedure 328
Results and Discussions 329
Effect of Process Parameters on MRR 329
Effect of Process Parameters on Overcut 330
Conclusions 331
References 331
32 Dependence of Ti2O3 and Temperature on Electrical Conductivity of TiO2– FeO–Ti2O3 Slags 333
Abstract 333
Introduction 333
Experimental 334
Apparatus for Electrical Conductivity 334
Samples Preparation 335
Procedure for Electrical Conductivity 336
Results and Discussion 337
XRD Analysis of Slag 337
Theoretical Phases Calculation by FactSage 338
Conclusions 339
Acknowledgements 339
References 339
Materials Processing and Plasma Processing 340
33 DuraStell PTA Cladding for Wear Application 341
Abstract 341
Introduction 341
Test Sample Preparation and Characterization 344
Results and Discussion 344
Tungsten Carbide-Ni Alloy Composite Cladding on SA-210 A1 Boiler Tubes 344
Tungsten Carbide-Ni Alloy Composite Cladding on SA-213 TP347H Boiler Tubes 348
Conclusions 350
Acknowledgements 351
References 351
34 Production of SiMn-Alloys by Natural Gas and Carbon Black 352
Abstract 352
Introduction 352
Experimental 354
Results and Discussions 355
Methane as Reductant 355
Carbon Black as Reductant 357
Conclusions 358
Acknowledgements 358
References 359
35 Effect of Flux Ratio on the Products of Self Propagating High Temperature Synthesis-Casting in the WO3–Si–Al System 360
Abstract 360
Introduction 360
Experimental 361
Results and Discussion 362
Thermodynamic Investigation 362
SHS-Product Characteristics 363
Conclusions 366
Acknowledgements 367
References 367
36 Synthesis of Chrysin Based Cationic Lipids: Plasmid Delivery and Transgene Expression 368
Abstract 368
Introduction 368
Experimental 369
Synthesis 369
Synthesis of Lipid 2: (Scheme 1) 370
Hydrodynamic Diameter and Zeta Potential of Lipids 371
Transfection Biology 372
Toxicity Assay 372
Discussion 372
Chemistry 372
Nanosizes and Global Surface Charges of the Lipoplexes 373
In Vitro Transfection Studies 373
Toxicity Studies 375
Conclusions 375
Acknowledgements 375
References 376
Energy Storage and Engineering Issues 377
37 Corrosion Mechanism of Haynes 230 Alloy with Ni Crucible in MgCl2–KCl 378
Abstract 378
Introduction 378
Experimental Procedure 379
Results and Discussion 380
Weight Loss and EDS Analysis 380
Thermodynamic Calculation of Ni–Cr Alloy 381
Galvanic Corrosion with CrCl3 Diffusion 382
Calculation of Exchange Current Density of CrCl3/Cr in MgCl2–KCl 383
Calculation of Corrosion Potential and Corrosion Rate 384
Conclusions 385
References 386
38 Conceptualization of Doped Black P Thin Films for Potential Use in Photovoltaics with Validation from First Principle Calculations 388
Abstract 388
Introduction 388
Experimentation 389
Results and Discussion 390
Conclusions 392
References 392
39 Energy Efficiency and Sustainability in Steel Production 393
Abstract 393
Introduction 393
Carbon Dioxide Emissions 395
Concluding Remarks 400
References 401
40 Application of Surface Effect on Metallurgical Processes 403
Abstract 403
Introduction 403
A New Theoretical Formula for Melting Point Depression 404
A New Technique for Measuring the Melting Rang of Glass Materials 405
Discussion and Conclusion 407
Acknowledgements 408
References 408
Modeling and Simulation 410
41 Metal Silicides for High-Temperature Thermoelectric Application 411
Abstract 411
Introduction 411
Materials and Methods 416
Arc-Melting and SHS Method 417
X-Ray Diffraction and Lattice Constants 418
Hardness and Thermoelectric Properties 418
Gibbs Energy Minimization 419
Results and Discussion 419
Change in Gibbs Energy of Metal Silicides 419
Synthesis of Mn4Si7 420
Lattice Constants of Mn4Si7 421
Hardness Testing of Mn4Si7 422
Thermoelectric Properties of Mn4Si7 422
Conclusions 423
Acknowledgements 423
References 424
42 CFD Modeling of Slag-Metal Reactions and Sulfur Refining Evolution in an Argon Gas-Stirred Ladle Furnace 425
Abstract 425
Introduction 425
Model Description 426
CFD Model 426
Reaction Model 427
Numerical Procedure 429
Results and Discussion 429
Conclusions 432
References 432
43 Numerical Study of the Fluid Flow and Temperature Distribution in a Non-transferred DC ARC Thermal Plasma Reactor 434
Abstract 434
Introduction 434
Experimental Method 435
Geometry and Computational Mesh 436
Fluid Flow and Heat Transfer Model 437
Boundary Conditions 437
Grid Independence Study 438
Model Verification 438
Results and Discussion 439
Temperature and Velocity Distribution 439
Plasma Input Power Effect 440
Plasma Gas Flow Rate Effect 441
Conclusions 441
Acknowledgments 441
References 442
Thermodynamics and Kinetics 444
44 Thermodynamic Studies on the Mg-B System Using Solid State Electrochemical Cells 445
Abstract 445
Introduction 445
Experimental 447
Materials Preparation 447
Solid State Electrochemical Cell 448
Results and Discussion 448
Conclusions 451
Acknowledgements 451
References 451
45 An Investigation on the Kinetics and Mechanism of Alkali Reduction of Mine Waste Containing Titaniferous Minerals for the Recovery of Metals 453
Abstract 453
Introduction 454
Alkali Reduction of Ilmenite 455
Experimental 456
Results and Discussion 456
Phase Analysis 456
Microstructure Analysis 457
Thermogravimetric Analysis 458
Arrhenius Plot and Activation Energy 460
Conclusions 461
Acknowledgements 461
References 461
46 Empirical Activation Energies of MnO and SiO2 Reduction in SiMn Slags Between 1500 and 1650 °C 463
Abstract 463
Introduction 464
Theoretical Considerations 464
Experimental Procedures 466
Results and Discussions 466
Conclusions 470
Acknowledgements 471
References 471
47 Experimental Evaluation of Thermodynamic Interactions Between Tellurium and Various Elements in Molten Iron 472
Abstract 472
Introduction 472
Experimental 473
Principle 474
Results 475
Discussion 475
Conclusions 479
References 479
48 Thermodynamics of Simultaneous Desulfurization and Dephosphorization of Silicomanganese Alloy 481
Abstract 481
Introduction 481
Experimental Procedure 482
Results and Discussion 483
Conclusions 484
References 485
49 Reduction Behavior of CaO–Fe2O3–8 wt%SiO2 System at 1123, 1173 and 1223 K with CO–N2 Gas Mixtures 486
Abstract 486
Introduction 486
Experimental 487
Materials 487
TGA 488
Thermal Analysis Kinetics 488
Results and Discussion 490
Reduction Degree and Reduction Rate 490
Apparent Activation Energy for Samples Reduction 491
Model Function Results 492
Conclusions 493
Acknowledgements 494
References 494
50 A Review of Some Studies on Impurity Capacity Predictions in Molten Melts 496
Abstract 496
Introduction 496
Theoretical Consideration 497
Reddy-Blander (RB) Model 497
Neural Network Model 498
Result and Discussions 499
Conclusions 503
Acknowledgments 503
References 503
Poster Session 505
51 Application of Sharp Analysis on Reduction Kinetics of Vanadium Titanium Magnetite Sintering Ore 506
Abstract 506
Introduction 506
Experimental 507
Materials 507
Procedure 507
Results and Discussion 508
TG Analysis 508
Kinetics Model of VTM Sintering Ore Reduction 510
Conclusions 511
Acknowledgments 511
References 511
52 High Temperature Properties of Molten Nitrate Salt for Solar Thermal Energy Storage Application 513
Abstract 513
Background 514
Experimental Methodology 515
Results and Discussion 516
Conclusions 519
References 519
53 Influence of Diluents Dosage on the Performance of High Solid Anti-corrosion Coating by Converter Dust 522
Abstract 522
Experimental Method 523
Results and Discussion 523
Influence of Diluents Dosage on Coatings Viscosity 523
The Influence of Diluents Dosage on Coating Surface 524
Influence of Diluents Dosage on Adhesion and Hardness of Films 525
Influence of Diluents Dosage on the Anti-corrosion Performance of the Film 526
Film Resistance of Salt Water 526
Film Corrosion Resistance to Acid 527
Conclusion 527
Acknowledgements 528
References 528
54 Permselectivity Study of Ion-Exchange Membranes in the Presence of Cu-HEDP Complexes from a Copper Plating Wastewater Treatment 529
Abstract 529
Introduction 529
Materials and Methods 530
Ion-Exchange Membranes 530
Ageing 530
Permselectivity 531
Results 532
Ageing 532
Permselectivity 533
HDX 100 533
HDX 200 533
Conclusion 534
References 534
55 Treatment of Blast Furnace Gas Washing Water by Utilization of Coagulation Associated with Microwave 535
Abstract 535
Introduction 536
Experimental 536
Experimental Samples 536
Experimental Device and Treatment Chemical Agent 537
Experimental Procedure 537
Experimental Methodology 537
Results and Discussion 538
Conclusion 543
Acknowledgements 543
References 543
Author Index 544
Subject Index 547
| Erscheint lt. Verlag | 7.2.2017 |
|---|---|
| Reihe/Serie | The Minerals, Metals & Materials Series | The Minerals, Metals & Materials Series |
| Zusatzinfo | XVI, 571 p. 293 illus., 1 illus. in color. |
| Verlagsort | Cham |
| Sprache | englisch |
| Themenwelt | Technik ► Maschinenbau |
| Schlagworte | electrometallurgy • environment and energy • Hydrometallurgy • materials processing • Process Modeling • Pyrometallurgy |
| ISBN-10 | 3-319-51091-6 / 3319510916 |
| ISBN-13 | 978-3-319-51091-0 / 9783319510910 |
| Informationen gemäß Produktsicherheitsverordnung (GPSR) | |
| Haben Sie eine Frage zum Produkt? |
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