Search results for: furnace

Authors: Galiya Zhanzakovna Alzhanova, Yelaman Kanatovich Aibuldinov, Zhanar Baktybaevna Iskakova, Gaziz Galymovich Abdiyussupov, Madi Toktasynuly Omirzak, Aizhan Doldashevna Gazizova

Abstract:

The sustainable use of industrial waste has recently increased due to increased environmental problems in landfills. One of the best ways to utilise waste is as a road base material. Industrial waste is a less costly and more efficient way to strengthen local soils than by introducing new additive materials. This study explored the feasibility of utilising red mud, blast furnace slag, and lime production waste to develop environmentally friendly construction materials for stabilising natural loam. Four different ratios of red mud (20, 30, and 40%), blast furnace slag (25, 30, and 35%), lime production waste (4, 6, and 8%), and varied amounts of natural loam were combined to produce nine different mixtures. The results showed that the sample with 40% red mud, 35% blast furnace slag, and 8% lime production waste had the highest strength. The sample's measured compressive strength for 90 days was 7.38 MPa, its water resistance for the same period was 7.12 MPa, and its frost resistance for the same period was 7.35 MP; low linear expansion met the requirements of the Kazakh regulations for first-class building materials. The study of mineral composition showed that there was no contamination with heavy metals or dangerous substances. Road base materials made of red mud, blast furnace slag, lime production waste, and natural loam mix can be employed because of their durability and environmental performance. The chemical and mineral composition of raw materials was determined using X-ray diffraction, X-ray fluorescence, scanning electron microscopy, energy dispersive spectroscopy, atomic absorption spectroscopy, and axial compressive strength were examined.

Keywords: blast furnace slag, lime production waste, natural loam stabilizing, red mud, road base material

Procedia PDF Downloads 63

Authors: Maha Bakkari, Fatiha Lemmeni, Rachid Tadili

Abstract:

In this work, we present some characteristics of the furnace studied, its operating principle and the experimental measurements of the evolutions of the temperatures inside and outside the walls of the This work deals with the problem of energy consumption of pottery kilns whose energy consumption is relatively too high. In this work, we determined the sources of energy loss by studying the heat transfer of a pottery furnace, we proposed a recovery system to reduce energy consumption, and then we developed a numerical model modeling the transfers through the walls of the furnace and to optimize the insulation (reduce heat losses) by testing multiple insulators. The recovery and reuse of energy recovered by the recovery system will present a significant gain in energy consumption of the oven and cooking time. This research is one of the solutions that helps reduce the greenhouse effect of the planet earth, a problem that worries the world.

Keywords: recovery lost energy, energy efficiency, modeling, heat transfer

Procedia PDF Downloads 46

Authors: M. Bahgat, H. A. Hanafy, S. Lakdawala

Abstract:

Clustering phenomenon of pellets was observed frequently in shaft processes operating at higher temperatures. Clustering is a result of the growth of fibrous iron precipitates (iron whiskers) that become hooked to each other and finally become crystallized during the initial stages of metallization. If the pellet clustering is pronounced, sometimes leads to blocking inside the furnace and forced shutdown takes place. This work clarifies further the relation between metallic iron whisker growth and iron ore mineralogy. Various pellet sizes (6 – 12.0 & +12.0 mm) from three different ores (A, B & C) were (completely and partially) reduced at 985 ^oC with H₂/CO gas mixture using thermos-gravimetric technique. It was found that reducibility increases by decreasing the iron ore pellet’s size. Ore (A) has the highest reducibility than ore (B) and ore (C). Increasing the iron ore pellet’s size leads to increase the probability of metallic iron whisker formation. Ore (A) has the highest tendency for metallic iron whisker formation than ore (B) and ore (C). The reduction reactions for all iron ores A, B and C are mainly controlled by diffusion reaction mechanism.

Keywords: shaft furnace, cluster, metallic iron whisker, mineralogy, ferrous metallurgy

Procedia PDF Downloads 426

Authors: B. M. Patil, S. R. Dharwadkar

Abstract:

Zirconolite (CaZrTi2O7) is one of the three major phases in the synthetic ceramic 'SYNROC' which is used for immobilization of high-level nuclear waste and also acts as photocatalytic and photophysical properties. In the present work the nanocrystalline CaZrTi2O7 was synthesized from Calcium Zirconyl Titanate tartrate precursor (CZTT) employing two different heating techniques such as Conventional heating (Muffle furnace) and Microwave heating (Microwave Oven). Thermal decomposition of the CZTT precursors in air yielded nanocrystalline CaZrTi2O7 powder as the end product. The products obtained by annealing the CZTT precursor using both heating method were characterized using simultaneous TG-DTA, FTIR, XRD, SEM, TEM, NTA and thermodilatometric study. The physical characteristics such as crystallinity, morphology and particle size of the product obtained by heating the CZTT precursor at the different temperatures in a Muffle furnace and Microwave oven were found to be significantly different. The microwave heating technique considerably lowered the synthesis temperature of CaZrTi2O7. The influence of microwave heating was more pronounced as compared to Muffle furnace heating. The details of the synthesis of CaZrTi2O7 from CZTT precursor are discussed.

Keywords: CZTT, CaZrTi2O7, microwave, SYNROC, zirconolite

Procedia PDF Downloads 130

Authors: Sewon Kim, Changyeop Lee

Abstract:

A noble low NOx combustion technology, based on partial oxidation combustion concept in a fuel rich combustion zone, is successfully applied in this research. The burner is designed such that a portion of fuel is heated and pre-vaporized in the furnace then injected into a fuel rich combustion zone so that a partial oxidation reaction occurs. The effects of equivalence ratio, thermal load, and fuel distribution ratio on the emissions of NOx and CO are experimentally investigated. This newly developed combustion technology is successfully applied to industrial furnace, and showed extremely low NOx emission levels.

Keywords: low NOx, combustion, burner, fuel rich

Procedia PDF Downloads 386

Authors: A. A. Dare, E. U. Iniegbedion

Abstract:

Industrial furnaces generally involve enclosures of fire typically initiated by the combustion of gases. The fire leads to temperature distribution inside the enclosure. A proper understanding of the temperature and velocity distribution within the enclosure is often required for optimal design and use of the furnace. This study was therefore directed at numerical modeling of temperature distribution inside an enclosure as typical in a furnace. A mathematical model was developed from the conservation of mass, momentum and energy. The stream function-vorticity formulation of the governing equations was solved by an alternating direction implicit (ADI) finite difference technique. The finite difference formulation obtained were then developed into a computer code. This was used to determine the temperature, velocities, stream function and vorticity. The effect of the wall heat conduction was also considered, by assuming a one-dimensional heat flow through the wall. The computer code (MATLAB program) developed was used for the determination of the aforementioned variables. The results obtained showed that the transient temperature distribution assumed a uniform profile which becomes more chaotic with increasing time. The vertical velocity showed increasing turbulent behavior with time, while the horizontal velocity assumed decreasing laminar behavior with time. All of these behaviours were equally reported in the literature. The developed model has provided understanding of heat transfer process in an industrial furnace.

Keywords: heat source, modelling, enclosure, furnace

Procedia PDF Downloads 228

Authors: Udaya Kumar

Abstract:

The aim of this paper is to discuss recent research conducted in experimental studies related to the process of the iron smelting. The paper will discuss issues related to the selection of iron ore, structure of furnace, making of tuyeres, fashioning of blowers and firing temperatures through experiments conducted recently and scientific analyses of experimental work. Experiments were conducted in order to investigate iron smelting techniques used at the Early Historic site of Nathara-Ki-Pal. (73°47’E; 24°16N is located about 70 km south-east of Udaipur city). Geographically, Nathara-Ki-Pal has located the foot hills of Aravalli’s. Iron ore and iron slag can be seen on the surface of the site. The remains of 4 broken furnaces were recovered during excavations (2007 and 2008) and the site was excavated by Prof. Pandey from the Department of Archaeology of the Institute of Rajasthan studies, Rajasthan Vidyapeeth University. This shows that the site of Nathara-Ki-Pal was a center of iron smelting. Results of experiments performed both in the field reconstruction of a bloomery furnace and in the laboratory are discussed.

Keywords: experimental studies, furnace, smelting techniques, making of tuyeres

Procedia PDF Downloads 157

Authors: Jagannath Prasad Tegar, Zeeshan Ahmad

Abstract:

The Ordinary Portland Cement (OPC) is a major constituent of concrete, which is being used extensively since last half century. The production of cement is impacting not only environment alone, but depleting natural materials. During the past 3 decades, the scholars have carried out studies and researches to explore the supplementary cementatious materials such as Ground granulated Blast furnace slag (GGBFS), silica fumes (SF), metakaolin or fly ash (FA). This has contributed towards improved cementatious materials which are being used in construction, but not the way it is supposed to be. The alkali activated slag concrete is another innovation which has constituents of cementatious materials like Ground Granuled Blast Furnace Slag (GGBFS), Fly Ash (FA), Silica Fumes (SF) or Metakaolin. Alkaline activators like Sodium Silicate (Na₂SiO₃) and Sodium Hydroxide (NaOH) is utilized. In view of evaluating properties of alkali activated slag concrete blended with polypropylene shredding and accelerator, research study is being carried out. This research study is proposed to evaluate the effect of polypropylene shredding and accelerating admixture on mechanical properties of alkali-activated slag concrete. The mechanical properties include the compressive strength, splitting tensile strength and workability. The outcomes of this research are matched with the hypothesis and it is found that 27% of cement can be replaced with the ground granulated blast furnace slag (GGBFS) and for split tensile strength 20% replacement is achieved. Overall it is found that 20% of cement can be replaced with ground granulated blast furnace slag. The tests conducted in the laboratory for evaluating properties such as compressive strength test, split tensile strength test, and slump cone test. On the aspect of cost, it is substantially benefitted.

Keywords: ordinary Portland cement, activated slag concrete, ground granule blast furnace slag, fly ash, silica fumes

Procedia PDF Downloads 152

Authors: Charles Horace Ampong

Abstract:

Non-linear models have been found to be useful in modeling the elasticity (measure of degree of responsiveness) of a dependent variable with respect to a set of independent variables ceteris paribus. This constant elasticity principle was applied to the dependent variable (Compressive Strength of Concrete in MPa) which was found to be non-linearly related to the independent variable (Water-Cement ratio in kg/m3) for given Ages of Concrete in days (3, 7, 28) at different levels of admixtures Superplasticizer (in kg/m3), Blast Furnace Slag (in kg/m3) and Fly Ash (in kg/m3). The levels of the admixtures were categorized as: S1=Some Plasticizer added & S0=No Plasticizer added; B1=some Blast Furnace Slag added & B0=No Blast Furnace Slag added; F1=Some Fly Ash added & F0=No Fly Ash added. The number of observations (samples) used for the research was one-hundred and thirty-two (132) in all. For Superplasticizer, it was found that Compressive Strength of Concrete was more elastic with regards to Water-Cement ratio at S1 level than at S0 level for the given ages of concrete 3, 7and 28 days. For Blast Furnace Slag, Compressive Strength with regards to Water-Cement ratio was more elastic at B0 level than at B1 level for concrete ages 3, 7 and 28 days. For Fly Ash, Compressive Strength with regards to Water-Cement ratio was more elastic at B0 level than at B1 level for Ages 3, 7 and 28 days. The research also tested for different combinations of the levels of Superplasticizer, Blast Furnace Slag and Fly Ash. It was found that Compressive Strength elasticity with regards to Water-Cement ratio was lowest (Elasticity=-1.746) with a combination of S0, B0 and F0 for concrete age of 3 days. This was followed by Elasticity of -1.611 with a combination of S0, B0 and F0 for a concrete of age 7 days. Next, the highest was an Elasticity of -1.414 with combination of S0, B0 and F0 for a concrete age of 28 days. Based on preceding outcomes, three (3) non-linear model equations for predicting the output elasticity of Compressive Strength of Concrete (in %) or the value of Compressive Strength of Concrete (in MPa) with regards to Water to Cement was formulated. The model equations were based on the three different ages of concrete namely 3, 7 and 28 days under investigation. The three models showed that higher elasticity translates into higher compressive strength. And the models revealed a trend of increasing concrete strength from 3 to 28 days for a given amount of water to cement ratio. Using the models, an increasing modulus of elasticity from 3 to 28 days was deduced.

Keywords: concrete, compressive strength, elasticity, water-cement

Procedia PDF Downloads 268

Authors: V. E. Messerle, A. L. Mosse, O. A. Lavrichshev, A. N. Nikonchuk, A. B. Ustimenko

Abstract:

One of the most serious environmental problems today is pollution by biomedical waste (BMW), which in most cases has undesirable properties such as toxicity, carcinogenicity, mutagenicity, fire. Sanitary and hygienic survey of typical solid BMW, made in Belarus, Kazakhstan, Russia and other countries shows that their risk to the environment is significantly higher than that of most chemical wastes. Utilization of toxic BMW requires use of the most universal methods to ensure disinfection and disposal of any of their components. Such technology is a plasma technology of BMW processing. To implement this technology a thermodynamic analysis of the plasma processing of BMW was fulfilled and plasma-box furnace was developed. The studies have been conducted on the example of the processing of bone. To perform thermodynamic calculations software package Terra was used. Calculations were carried out in the temperature range 300 - 3000 K and a pressure of 0.1 MPa. It is shown that the final products do not contain toxic substances. From the organic mass of BMW synthesis gas containing combustible components 77.4-84.6% was basically produced, and mineral part consists mainly of calcium oxide and contains no carbon. Degree of gasification of carbon reaches 100% by the temperature 1250 K. Specific power consumption for BMW processing increases with the temperature throughout its range and reaches 1 kWh/kg. To realize plasma processing of BMW experimental installation with DC plasma torch of 30 kW power was developed. The experiments allowed verifying the thermodynamic calculations. Wastes are packed in boxes weighing 5-7 kg. They are placed in the box furnace. Under the influence of air plasma flame average temperature in the box reaches 1800 OC, the organic part of the waste is gasified and inorganic part of the waste is melted. The resulting synthesis gas is continuously withdrawn from the unit through the cooling and cleaning system. Molten mineral part of the waste is removed from the furnace after it has been stopped. Experimental studies allowed determining operating modes of the plasma box furnace, the exhaust gases was analyzed, samples of condensed products were assembled and their chemical composition was determined. Gas at the outlet of the plasma box furnace has the following composition (vol.%): CO - 63.4, H2 - 6.2, N2 - 29.6, S - 0.8. The total concentration of synthesis gas (CO + H2) is 69.6%, which agrees well with the thermodynamic calculation. Experiments confirmed absence of the toxic substances in the final products.

Keywords: biomedical waste, box furnace, plasma torch, processing, synthesis gas

Procedia PDF Downloads 492

Authors: Serkan Kocapinar, Gülay Altay

Abstract:

This study investigates the efficiency of two different industrial intumescent coatings which have different types of certifications, in the fire protection performance in steel beams in the case of ISO 834 fire for 2 hours. A better understanding of industrial intumescent coatings, which assure structural integrity and prevent a collapse of steel structures, is needed to minimize the fire risks in steel structures. A comparison and understanding of different fire protective intumescent coatings, which are Product A and Product B, are used as a thermal barrier between the steel components and the fire. Product A is tested according to EN 13381-8 and BS 476-20,22 and is certificated by ISO Standards. Product B is tested according to EN 13381-8 and ASTM UL-94 and is certificated by the Turkish Standards Institute (TSE). Generally, fire tests to evaluate the fire performance of steel components are done numerically with commercial software instead of experiments due to the high cost of an ISO 834 fire test in a furnace. Hence, there is a gap in the literature about the comparisons of different certificated intumescent coatings for fire protection in the case of ISO 834 fire in a furnace experiment for 2 hours. The experiment was carried out by using two 1-meter UPN 200 steel sections. Each one was coated by different industrial intumescent coatings. A furnace was used by the Turkish Standards Institute (TSE) for the experiment. The temperature of the protected steels and the inside of the furnace was measured with the help of 24 thermocouples which were applied before the intumescent coatings during the two hours for the performance of intumescent coatings by getting a temperature-time curve of steel components. FIN EC software was used to determine the critical temperatures of protected steels, and Abaqus was used for thermal analysis to get theoretical results to compare with the experimental results.

Keywords: fire safety, structural steel, ABAQUS, thermal analysis, FIN EC, intumescent coatings

Procedia PDF Downloads 72

Authors: S. Yousefi Oderji, B. Chen, M. A. Yazdi, J. Yang

Abstract:

This study investigates the influence of water-binder ratio, mineral admixtures (silica fume and ground granulated blast furnace slag), and copper coated steel fiber on fluidity diameter, compressive and flexural strengths of reactive powder concrete (RPC). The test results show that the binary combination of silica fume and blast-furnace slag provided a positive influence on the mechanical properties of RPC. Although the addition of fibers reduced the workability, results indicated a higher mechanical strength in the inclusion of fibers.

Keywords: RPC, steel fiber, fluidity, mechanical properties

Procedia PDF Downloads 271

Authors: Hemant Upadhyay, Tarun Kumar Kundu

Abstract:

It is utmost important for a blast furnace operator to understand the mechanisms governing the liquid flow, accumulation, drainage and heat transfer between various phases in blast furnace hearth for a stable and efficient blast furnace operation. Abnormal drainage behavior may lead to high liquid build up in the hearth. Operational problems such as pressurization, low wind intake, and lower material descent rates, normally be encountered if the liquid levels in the hearth exceed a critical limit when Hearth coke and Deadman start to float. Similarly, hot metal temperature is an important parameter to be controlled in the BF operation; it should be kept at an optimal level to obtain desired product quality and a stable BF performance. It is not possible to carry out any direct measurement of above due to the hostile conditions in the hearth with chemically aggressive hot liquids. The objective here is to develop a mathematical model to simulate the variation in hot metal / slag accumulation and temperature during the tapping of the blast furnace based on the computed drainage rate, production rate, mass balance, heat transfer between metal and slag, metal and solids, slag and solids as well as among the various zones of metal and slag itself. For modeling purpose, the BF hearth is considered as a pressurized vessel, filled with solid coke particles. Liquids trickle down in hearth from top and accumulate in voids between the coke particles which are assumed thermally saturated. A set of generic mass balance equations gives the amount of metal and slag intake in hearth. A small drainage (tap hole) is situated at the bottom of the hearth and flow rate of liquids from tap hole is computed taking in account the amount of both the phases accumulated their level in hearth, pressure from gases in the furnace and erosion behaviors of tap hole itself. Heat transfer equations provide the exchange of heat between various layers of liquid metal and slag, and heat loss to cooling system through refractories. Based on all that information a dynamic simulation is carried out which provides real time information of liquids accumulation in hearth before and during tapping, drainage rate and its variation, predicts critical event timings during tapping and expected tapping temperature of metal and slag on preset time intervals. The model is in use at JSPL, India BF-II and its output is regularly cross-checked with actual tapping data, which are in good agreement.

Keywords: blast furnace, hearth, deadman, hotmetal

Procedia PDF Downloads 154

Authors: Mamdouh Omran, Timo Fabritius

Abstract:

A growing interest in microwave heating has emerged recently. Many researchers have begun to pay attention to microwave energy as an alternative technique for processing various primary and secondary raw materials. Compared to conventional methods, microwave processing offers several advantages, such as selective heating, rapid heating, and volumetric heating. The present study gives a summary on our recent works related to the use of microwave energy for the recovery of valuable metals from primary and secondary raw materials. The research is mainly focusing on: Application of microwave for the recovery and recycling of metals from different metallurgical industries wastes (i.e. electric arc furnace (EAF) dust, blast furnace (BF), basic oxygen furnace (BOF) sludge). Application of microwave for upgrading and recovery of valuable metals from primary raw materials (i.e. iron ore). The results indicated that microwave heating is a promising and effective technique for processing primary and secondary steelmaking wastes. After microwave treatment of iron ore for 60 s and 900 W, about a 28.30% increase in grindability.Wet high intensity magnetic separation (WHIMS) indicated that the magnetic separation increased from 34% to 98% after microwave treatment for 90 s and 900 W. In the case of EAF dust, after microwave processing at 1100 W for 20 min, Zinc removal from 64 % to ~ 97 %, depending on mixture ratio and treatment time.

Keywords: dielectric properties, microwave heating, raw materials, secondary raw materials

Procedia PDF Downloads 55

Authors: Reina Kawase

Abstract:

Japan set the goal of 80% reduction in GHG emissions by 2050. To consider countermeasures for reducing GHG emission, the production estimation of energy intensive materials, such as steel, is essential. About 50% of steel production is exported in Japan, so it is necessary to consider steel production including export. Steel productions from 2005-2050 in Japan were estimated under various global assumptions based on combination of scenarios such as goods trade scenarios and steel making process selection scenarios. Process selection scenarios decide volume of steel production by process (basic oxygen furnace and electric arc furnace) with considering steel consumption projection, supply-demand balance of steel, and scrap surplus. The range of steel production by process was analyzed. Maximum steel production was estimated under the scenario which consumes scrap in domestic steel production at maximum level. In 2035, steel production reaches 149 million ton because of increase in electric arc furnace steel. However, it decreases towards 2050 and amounts to 120 million ton, which is almost same as a current level. Minimum steel production is under the scenario which assumes technology progress in steel making and supply-demand balance consideration in each region. Steel production decreases from base year and is 44 million ton in 2050.

Keywords: goods trade scenario, steel making process selection scenario, steel production, global warming

Procedia PDF Downloads 349

Authors: T. Kuchukhidze, N. Jalagonia, T. Korkia, V. Gabunia, N. Jalabadze, R. Chedia

Abstract:

In this work, obtaining methods of ultrafine alumina powdery composites and high temperature pressing technology of matrix ceramic composites with different compositions have been discussed. Alumina was obtained by solution combustion synthesis and sol-gel methods. Metal carbides containing powdery composites were obtained by homogenization of finishing powders in nanomills, as well as by their single-step high temperature synthesis .Different types of matrix ceramics composites (α-Al2O3-ZrO2-Y2O3, α-Al2O3- Y2O3-MgO, α-Al2O3-SiC-Y2O3, α-Al2O3-WC-Co-Y2O3, α-Al2O3- B4C-Y2O3, α-Al2O3- B4C-TiB2 etc.) were obtained by using OXYGON furnace. Consolidation of powders were carried out at 1550- 1750°C (hold time - 1 h, pressure - 50 MPa). Corundum ceramics samples have been obtained and characterized by high hardness and fracture toughness, absence of open porosity, high corrosion resistance. Their density reaches 99.5-99.6% TD. During the work, the following devices have been used: High temperature vacuum furnace OXY-GON Industries Inc (USA), Electronic Scanning Microscopes Nikon Eclipse LV 150, Optical Microscope NMM- 800TRF, Planetary mill Pulverisette 7 premium line, Shimadzu Dynamic Ultra Micro Hardness Tester DUH-211S, Analysette 12 Dynasizer.

Keywords: α-alumina, consolidation, phase transformation, powdery composites

Procedia PDF Downloads 320

Authors: A. Yönetken, A. Erol, A. Yakar, G. Peşmen

Abstract:

The microstructure, mechanical properties and metalgraphic characteristics of Ni plated AlN-Astaloy Cr-M powders were investigated using specimens produced by tube furnace sintering at 1000-1400 °C temperature. A uniform nickel layer on AlN powders was deposited prior to sintering using electroless plating technique. A composite consisting of ternary additions, metallic phase, Ni and ceramic phase AlN within a matrix of Astaloy Cr-M had been prepared under Ar shroud and then tube furnace sintered. The experimental results carried out by using XRD (X-Ray Diffraction) and SEM (Scanning Electron Microscope) for composition (10% AlN-Astaloy Cr-M) 10% Ni at 1400 °C suggest that the best properties as 132.45HB and permittivity were obtained at 1400 °C.

Keywords: composite, electroless nickel plating, powder metallurgy, sintering

Procedia PDF Downloads 249

Authors: Chung-Hao Wu, Tung-Dju Lin, Ming-Chin Ho, Minehiro Nishiyama

Abstract:

This paper discusses reported fire tests of concrete beams and columns, future fire tests of beam/column frames, and an innovative concept for designing a beam/column furnace. The proposed furnace could be designed to maximize the efficiency of fire test procedures and minimize the cost of furnace construction and fuel consumption. ASTM E119 and ISO 834 standards were drafted based on prescriptive codes and have several weaknesses. The first involves a provision allowing the support regions of a test element to be protected from fire exposure. The second deals with the L/30 deflection end point instead of the structural end point (collapse) in order to protect the hydraulic rams from fire damage. Furthermore, designers commonly use the measured fire endurances of interior columns to assess fire ratings of edge and corner columns of the same building. The validity of such an engineering practice is theoretically unsound. Performance-Based Codes (PBC) require verification tests of structural frames including the beam/column joints to overcome these weaknesses but allow the use of element test data as reference only. In the last 30 years, PBC have gained global popularity because the innovative design and flexibility in achieving an ultimate performance goal.

Keywords: fire resistance, concrete structure, beam/column frame, fire tests

Procedia PDF Downloads 297

Authors: David E. Esezobor, Friday I. Apeh, Harrison O. Onovo, Ademola A. Agbeleye

Abstract:

Available indigenous refractory bricks in Nigeria can only be used in the lining of furnaces for melting of cast iron operating at less than 1,400°C or in preheating furnaces due to their low refractoriness less than 1,500°C. The bricks crack and shatter on heating at 1350 to 1450°C. In this paper, a simple and adaptable technology of manufacturing high-quality refractory bricks from selected Nigerian clays for furnace linings was developed. Fireclays from Onibode, Owode-Ketu in Ogun State and Kwoi in Kaduna State were crushed, ground, and sieved into various grain sizes using standard techniques. The pulverized clays were blended with alumina in various mix ratios and indurated in the furnace at 900 – 16000C. Their chemical, microstructure and mineralogical properties were characterized using atomic absorption spectrophotometry, scanning electron microscopy and x-ray diffraction spectrometry respectively. The mineralogical and spectrochemical analyses suggested that the clays are of siliceous alumino-silicate and acidic in nature. The appropriate blending of fireclays with alumina provided the tremendous improvement in the refractoriness of the bricks and other acceptable service properties comparable with imported refractory bricks. The change in microstructure from pseudo-hexagonal grains to equiaxed grains of well – ordered sequence of structural layers could be responsible for the improved properties.

Keywords: alumina, furnace, industry, manufacturing, refractoriness

Procedia PDF Downloads 223

Authors: Heba Al-Kelesh

Abstract:

Day after day, high-grade iron ores are consumed. Because of the strong global demand for iron and steel, it has necessitated the utilization of various low-grade iron ores, which are not suitable for direct exploitation in the iron industry. The low-grade ores cannot be dressed using traditional mineral processing methods because of complicated mineral compositions. The present work is aimed to investigate the reducibility of some Egyptian iron ores and concentrates by conditions emulate different blast furnace areas. Representative specimens are collected from El-Gedida–Baharia oasis, Eastern South Aswan, and Eastern desert-wadi Kareem (EDC). Some mineralogical and morphological characterizations are executed. The reactivity arrangement of green samples is Baharia>Aswan>EDC. The presence of magnetite decreased reactivity of EDC. The reducibility of the Aswan sample is lower than Baharia due to the presence of agglomerated metallic grain surrounded by semi-melted phases. Specimens are annealed at 1000ᵒC for 3 hours. After firing, the reducibility of Aswan becomes the lowest due to the formation of fayalite and calcium phosphate phases. The relative attitude for green and fired samples reduced at different conditions are studied. For thermal and top areas, the reactivity of fired samples is greater than green ones, which were confirmed by morphological examinations.

Keywords: reducibility, low grade, iron industry, blast furnace

Procedia PDF Downloads 95

Authors: Alena Sicakova

Abstract:

Air-cooled Blast furnace slag aggregate (BFSA) is usually referred to as a material providing for unique properties of concrete. On the other hand, negative influences are also presented in many aspects. The freeze-thaw resistance of concrete is dependent on many factors, including regional specifics and when a concrete mix is specified it is still difficult to tell its exact freeze-thaw resistance due to the different components affecting it. An important consideration in working with BFSA is the granularity and whether slag is sorted or not. The experimental part of the article represents a comparative testing of concrete using both the sorted and unsorted BFSA through the freeze-thaw resistance as an indicator of durability. Unsorted BFSA is able to be successfully used for concretes as they are specified for exposure class XF4 with providing that the type of cement is precisely selected.

Keywords: blast furnace slag aggregate, concrete, freeze-thaw resistance

Procedia PDF Downloads 367

Authors: A. Yonetken, A. Erol, M. Cakmakkaya

Abstract:

Intermetallic materials are among advanced technology materials that have outstanding mechanical and physical properties for high temperature applications. Especially creep resistance, low density and high hardness properties stand out in such intermetallics. The microstructure, mechanical properties of %88Ni-%10Cr and %2Mn powders were investigated using specimens produced by tube furnace sintering at 900-1300°C temperature. A composite consisting of ternary additions, a metallic phase, Fe ,Cr and Mn have been prepared under Ar shroud and then tube furnace sintered. XRD, SEM (Scanning Electron Microscope), were investigated to characterize the properties of the specimens. Experimental results carried out for composition %88Ni-%10Cr and %2Mn at 1300°C suggest that the best properties as 138,80HV and 6,269/cm3 density were obtained at 1300°C.

Keywords: composite, high temperature, intermetallic, sintering

Procedia PDF Downloads 379

Authors: G. S. Ryu, K. T. Koh, H. Y. Kim, G. H. An, D. W. Seo

Abstract:

Geopolymer mortar is produced by alkaline activation of pozzolanic materials such as fly ground granulated blast-furnace slag (GGBFS) and fly ash (FA). Its unique reaction pathway facilitates rapid strength development in comparison with hydration of ordinary Portland cement (OPC). Geopolymer can be fabricated using various types and dosages of alkali-activator, which effectively gives a wider control over the performance of the final product. The present study investigates the effect of types of precursors and curing conditions on the fresh state and strength development characteristics of geopolymers, thereby comparatively exploring the effect of precursors from various sources of origin. The obtained result showed that the setting time and strength development of the specimens with the identical mix proportion but different precursors displayed significant variations.

Keywords: alkali-activated material, blast furnace slag, fly ash, flowability, strength development

Procedia PDF Downloads 214

Authors: Gökhan Polat, Dicle Kocaoğlu Yılmazer, Muhlis Nezihi Sarıdede

Abstract:

Iron oxides are the main input to produce iron in integrated iron and steel plants. During production of iron from iron oxides, some wastes with high iron content occur. These main wastes can be classified as basic oxygen furnace (BOF) sludge, flue dust and rolling scale. Recycling of these wastes has a great importance for both environmental effects and reduction of production costs. In this study, recycling experiments were performed on basic oxygen furnace sludge, flue dust and rolling scale which contain 53.8%, 54.3% and 70.2% iron respectively. These wastes were mixed together with coke as reducer and these mixtures are pressed to obtain cylindrical briquettes. These briquettes were pressed under various compacting forces from 1 ton to 6 tons. Also, both stoichiometric and twice the stoichiometric cokes were added to investigate effect of coke amount on reduction properties of the waste mixtures. Then, these briquettes were reduced at 1000°C and 1100°C during 30, 60, 90, 120 and 150 min in a muffle furnace. According to the results of reduction experiments, the effect of compacting force, temperature and time on reduction ratio of the wastes were determined. It is found that 1 ton compacting force, 150 min reduction time and 1100°C are the optimum conditions to obtain reduction ratio higher than 75%.

Keywords: Coke, iron oxide wastes, recycling, reduction

Procedia PDF Downloads 303

Authors: Mario Sergio de Andrade Zago, Javier Mazariegos Pablos, Eduvaldo Paulo Sichieri

Abstract:

This research project accomplished a study on the technical feasibility of recycling industrial solid waste generated by the discharge of casting sand agglomeration with clay, blast furnace slag and sugar cane bagasse ash. For this, the plan proposed a methodology that initially establishes a process of solid waste encapsulation, by using solidification/stabilization technique on Portland cement matrices, in which the residuals act as small and large aggregates on the composition of concrete, and later it presents the possibility of using this concrete in the manufacture of concrete pieces (concrete blocks) for paving. The results obtained in this research achieved the objective set with great success, regarding the manufacturing of concrete pieces (blocks) for paving urban roads, whenever there is special vehicle traffic or demands capable of producing accentuated abrasion effects (surpassing the 50 MPa required by the regulation), which probes the technical practicability of using waste from sand casting agglomeration with clay and blast furnace slag used in this study, unlocking usage possibilities for construction.

Keywords: industrial solid waste, solidification/stabilization, Portland cement, reuse, bagasse ash in the sugar cane, concrete

Procedia PDF Downloads 274

Authors: Abdul Khaliq Amiri, Shigeyuki Date

Abstract:

This study investigates the effect of using carbon-free fly ash (CfFA) and ground granulated blast-furnace slag (GGBFS) on the compressive strength of mortar. The CfFA used in this investigation is high-quality fly ash and the carbon content is 1.0% or less. In this study, three types of blends with a 30% water-binder ratio (w/b) were prepared: control, binary and ternary blends. The Control blend contained only Ordinary Portland Cement (OPC), in binary and ternary blends OPC was partially replaced with CfFA and GGBFS at different substitution rates. Mortar specimens were cured for 1 day, 7 days and 28 days under two curing conditions: steam curing and water curing. The steam cured specimens were exposed to two different pre-curing times (1.5 h and 2.5 h) and one steam curing duration (6 h) at 45 °C. The test results showed that water cured specimens revealed higher compressive strength than steam cured specimens at later ages. An increase in CfFA and GGBFS contents caused a decrease in the compressive strength of mortar. Ternary mixes exhibited better compressive strength than binary mixes containing CfFA with the same replacement ratio of mineral admixtures.

Keywords: carbon-free fly ash, compressive strength, ground granulated blast-furnace slag, steam curing, water curing

Procedia PDF Downloads 106

Authors: Ahmet Yonetken, Ayhan Erol

Abstract:

Intermetallic materials advanced technology materials that have outstanding mechanical and physical properties for high temperature applications. Especially creep resistance, low density and high hardness properties stand out in such intermetallics. The microstructure, mechanical properties of %80Cr-%10Ti and %10WC powders were investigated using specimens produced by tube furnace sintering at 1000-1400°C temperature. A composite consisting of ternary additions, a metallic phase, Ti,Cr and WC have been prepared under Ar shroud and then tube furnace sintered. XRD, SEM (Scanning Electron Microscope), were investigated to characterize the properties of the specimens. Experimental results carried out for composition %80Cr-%10Ti and %10WC at 1400°C suggest that the best properties as 292HV and 5,34g/cm3 density were obtained at 1400°C.

Keywords: ceramic-metal, composites, powder metallurgy, sintering

Procedia PDF Downloads 435

Authors: Jin-Lung Guan, Jyh-Cherng Gu, Chun-Wei Huang, Hsin-Hung Chang

Abstract:

This investigation develops a revisable method for estimating the estimate value of equivalent 10 Hz voltage flicker (DV10) of a DC Electric Arc Furnace (EAF). This study also discusses three 161kV DC EAFs by field measurement, with those results indicating that the estimated DV10 value is significantly smaller than the survey value. The key point is that the conventional means of estimating DV10 is inappropriate. There is a main cause as the assumed Qmax is too small. Although DC EAF is regularly operated in a constant MVA mode, the reactive power variation in the Main Transformer (MT) is more significant than that in the Furnace Transformer (FT). A substantial difference exists between estimated maximum reactive power fluctuation (DQmax) and the survey value from actual DC EAF operations. However, this study proposes a revisable method that can obtain a more accurate DV10 estimate than the conventional method.

Keywords: voltage flicker, dc EAF, estimate value, DV10

Procedia PDF Downloads 420

Authors: Mokhtari Karchegani Amir, Maboudi Samad, Azadi Reza, Dastanian Raoof

Abstract:

Marun's petrochemical cracking furnaces have a very comprehensive operating control system for combustion and related equipment, utilizing advanced instrument circuits. However, after several years of operation, numerous problems arose in the pyrolysis furnaces. A team of experts conducted an audit, revealing that the furnaces were over-designed, leading to excessive consumption of air and fuel. This issue was related to the burners' shutter settings, which had not been configured properly. The operations department had responded by increasing the induced draft fan speed and forcing the instrument switches to counteract the wind effect in the combustion chamber. Using Fluent and Gambit software, the furnaces were analyzed. The findings indicated that this situation elevated the convection part's temperature, causing uneven heat distribution inside the furnace. Consequently, this led to overheating in the convection section and excessive cracking within the coils in the radiation section. The increased convection temperature damaged convection parts and resulted in equipment blockages downstream of the furnaces due to the production of more coke and tar in the process. To address these issues, corrective actions were implemented. The excess air for burners and combustion chambers was properly set, resulting in improved efficiency, reduced emissions of environmentally harmful gases, prevention of creep in coils, decreased fuel consumption, and lower maintenance costs.

Keywords: furnace, coke, CFD analysis, over cracking

Procedia PDF Downloads 36

Authors: Guneet Saini, Uthej Vattipalli

Abstract:

In a world with increased demand for sustainable construction, waste product of one industry could be a boon to the other in reducing the carbon footprint. Usage of industrial waste such as fly ash and ground granulated blast furnace slag have become the epicenter of curbing the use of cement, one of the major contributors of greenhouse gases. In this paper, empirical studies have been done to develop alkali activated self-compacting geopolymer concrete (GPC) using ground granulated blast furnace slag (GGBS), incorporated with 2% nano-silica by weight, through evaluation of its fresh and hardening properties. Experimental investigation on 6 mix designs of varying molarity of 10M, 12M and 16M of the alkaline solution and a binder content of 450 kg/m³ and 500 kg/m³ has been done and juxtaposed with GPC mix design composed of 16M alkaline solution concentration and 500 kg/m³ binder content without nano-silica. The sodium silicate to sodium hydroxide ratio (SS/SH), alkaline activator liquid to binder ratio (AAL/B) and water to binder ratio (W/B), which significantly affect the performance and mechanical properties of GPC, were fixed at 2.5, 0.45 and 0.4 respectively. To catalyze the early stage geopolymerisation, oven curing is done maintaining the temperature at 60˚C. This paper also elucidates the test results for fresh self-compacting concrete (SCC) done as per EFNARC guidelines. The mechanical properties tests conducted were: compressive strength test after 7 days, 28 days, 56 days and 90 days; flexure test; split tensile strength test after 28 days, 56 days and 90 days; X-ray diffraction test to analyze the mechanical performance and sorptivity test for testing of permeability. The study revealed that the sample of 16M concentration of alkaline solution with 500 Kg/m³ binder content containing 2% nano silica produced the highest compressive, flexural and split tensile strength of 81.33 MPa, 7.875 MPa, and 6.398 MPa respectively, at the end of 90 days.

Keywords: alkaline activator liquid, geopolymer concrete, ground granulated blast furnace slag, nano silica, self compacting

Procedia PDF Downloads 115