Search results for: ladle furnace slag

Authors: Chanchal Biswas, Anrin Bhattacharyya, Gopes Chandra Das, Mahua Ghosh Chaudhuri, Rajib Dey

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Boiler coals with low fixed carbon and higher ash content have always challenged the metallurgists to develop a suitable method for their utilization. In the present study, an attempt is made to establish an energy effective method for the reduction of iron ore fines in the form of nuggets by using ‘Syngas’. By devolatisation (expulsion of volatile matter by applying heat) of boiler coal, gaseous product (enriched with reducing agents like CO, CO2, H2, and CH4 gases) is generated. Iron ore nuggets are reduced by this syngas. For that reason, there is no direct contact between iron ore nuggets and coal ash. It helps to control the minimization of the sulphur intake of the reduced nuggets. A laboratory scale devolatisation furnace designed with reduction facility is evaluated after in-depth studies and exhaustive experimentations including thermo-gravimetric (TG-DTA) analysis to find out the volatile fraction present in boiler grade coal, gas chromatography (GC) to find out syngas composition in different temperature and furnace temperature gradient measurements to minimize the furnace cost by applying one heating coil. The nuggets are reduced in the devolatisation furnace at three different temperatures and three different times. The pre-reduced nuggets are subjected to analytical weight loss calculations to evaluate the extent of reduction. The phase and surface morphology analysis of pre-reduced samples are characterized using X-ray diffractometry (XRD), energy dispersive x-ray spectrometry (EDX), scanning electron microscopy (SEM), carbon sulphur analyzer and chemical analysis method. Degree of metallization of the reduced nuggets is 78.9% by using boiler grade coal. The pre-reduced nuggets with lesser sulphur content could be used in the blast furnace as raw materials or coolant which would reduce the high quality of coke rate of the furnace due to its pre-reduced character. These can be used in Basic Oxygen Furnace (BOF) as coolant also.

Keywords: alternative ironmaking, coal gasification, extent of reduction, nugget making, syngas based DRI, solid state reduction

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Authors: Nils Mueller, Gregor Herz, Erik Reichelt, Matthias Jahn

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In the context of climate change, the reduction of greenhouse gas emissions in all economic sectors is considered to be an important factor in order to meet the demands of a sustainable energy system. The steel industry as one of the large industrial CO₂ emitters is currently highly dependent on fossil resources. In order to reduce coke consumption and thereby CO₂ emissions while still being able to further utilize existing blast furnaces, the possibility of including a direct reduction process (DRP) into a fully integrated steel mill was investigated. Therefore, a blast furnace model, derived from literature data and implemented in Aspen Plus, was used to analyze the impact of DRI in the blast furnace process. Furthermore, a state-of-the-art DRP was modeled to investigate the possibility of substituting the reducing agent natural gas with hydrogen. A sensitivity analysis was carried out in order to find the boundary percentage of hydrogen as a reducing agent without penalty to the DRI quality. Lastly, the two modeled process steps were combined to form a route of producing pig iron. By varying boundary conditions of the DRP while recording the CO₂ emissions of the two process steps, the overall potential for the reduction of CO₂ emissions was estimated. Within the simulated range, a maximum reduction of CO₂ emissions of 23.5% relative to typical emissions of a blast furnace could be determined.

Keywords: blast furnace, CO₂ mitigation, DRI, hydrogen

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Authors: Sebastiano Candamano, Antonio Iorfida, Patrizia Frontera, Anastasia Macario, Fortunato Crea

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Alkali-activated materials are promising binders obtained by an alkaline attack on fly-ashes, metakaolin, blast slag among others. In order to guarantee the highest ecological and cost efficiency, a proper selection of precursors and alkaline activators has to be carried out. These choices deeply affect the microstructure, chemistry and performances of this class of materials. Even if, in the last years, several researches have been focused on mix designs and curing conditions, the lack of exhaustive activation models, standardized mix design and curing conditions and an insufficient investigation on shrinkage behavior, efflorescence, additives and durability prevent them from being perceived as an effective and reliable alternative to Portland. The aim of this study is to develop alkali-activated cements mortars containing high amounts of industrial by-products and waste, such as ground granulated blast furnace slag (GGBFS) and ashes obtained from the combustion process of forest biomass in thermal power plants. In particular, the experimental campaign was performed in two steps. In the first step, research was focused on elucidating how the workability, mechanical properties and shrinkage behavior of produced mortars are affected by the type and fraction of each precursor as well as by the composition of the activator solutions. In order to investigate the microstructures and reaction products, SEM and diffractometric analyses have been carried out. In the second step, their durability in harsh environments has been evaluated. Mortars obtained using only GGBFS as binder showed mechanical properties development and shrinkage behavior strictly dependent on SiO2/Na2O molar ratio of the activator solutions. Compressive strengths were in the range of 40-60 MPa after 28 days of curing at ambient temperature. Mortars obtained by partial replacement of GGBFS with metakaolin and forest biomass ash showed lower compressive strengths (≈35 MPa) and shrinkage values when higher amount of ashes were used. By varying the activator solutions and binder composition, compressive strength up to 70 MPa associated with shrinkage values of about 4200 microstrains were measured. Durability tests were conducted to assess the acid and thermal resistance of the different mortars. They all showed good resistance in a solution of 5%wt of H2SO4 also after 60 days of immersion, while they showed a decrease of mechanical properties in the range of 60-90% when exposed to thermal cycles up to 700°C.

Keywords: alkali activated cement, biomass ash, durability, shrinkage, slag

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Authors: Mohamed Lyes Kamel Khouadjia, Bouzidi Mezghiche

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The evolution in the civil engineering and carried out more consumption of aggregates and particularly the sand. Due to the depletion of natural reserves of sand, it is necessary to focus on the use of local materials such as crushed sand, river sand and dune sand, mineral additions. The aim of this work is to improve the state of knowledge on the compressive strengths of crushed sands with several mixtures (dune sand, river sand, pozzolan, and slag). The obtained results were compared with numerical results obtained with the software Béton Lab Pro 3.

Keywords: crushed sand, river sand, dune sand, pouzzolan, slag, compressive strengths, Béton Lab Pro 3

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Authors: Sewon Kim, Changyeop Lee

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A new concept of in-furnace partial oxidation combustion is successfully applied in this research. The burner is designed such that liquid fuel is prevaporized 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, injection distance and fuel distribution ratio on the NOx and CO are experimentally investigated. This newly developed burner showed very low NOx emission level, about 15 ppm when light oil is used as a fuel.

Keywords: burner, low NOx, liquid fuel, partial oxidation

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Authors: Jeffrey Cacho, Sherwin Reyes

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The research targeted enhancing energy utilization and reducing waste in roasting processes, particularly in Camarines Norte, where Bounty Agro Ventures Incorporated dominates through brands such as Chooks-to-Go, Uling Roaster, and Reyal. Competitors like Andok’s and Baliwag Lechon Manok also share the market. A staggering 90% of these businesses use traditional glass-type roasting furnaces fueled by wood charcoal, leading to significant energy loss and inefficiency due to suboptimal heat conservation. Only a mere 10% employ electric ovens. Many available furnaces, typically constructed from industrial materials through welding and other metal joining techniques, are not energy-efficient. Cost-prohibitive commercial options compel some micro-enterprises to fabricate their furnaces. The study proposed developing an eco-friendly, cost-effective roasting furnace with excellent heat retention. The distinct design aimed to reduce cooks' heat exposure and overall fuel consumption. The furnace features an angle bar frame, a combustion chute for fuel burning, a heat-retaining clay-walled chamber, and a top cover, all contributing to improved energy savings and user safety.

Keywords: biomass roasting furnace, heat storage, combustion chute, start-up roasting business

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Authors: Ravindra N. Singh, Dheerendra P. Singh

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Recent discoveries of Bronze Age artefacts, tin slag, furnaces and crucibles, together with new geological evidence on tin deposits in Tosham area of Bhiwani district in Haryana (India) provide the opportunity to survey the evidence for possible sources of tin and the use of bronze in the Harappan sites of north western India. Earlier, Afghanistan emerged as the most promising eastern source of tin utilized by Indus Civilization copper-smiths. Our excavations conducted at Khanak near Tosham mining area during 2014 and 2016 revealed ample evidence of metallurgical activities as attested by the occurrence of slag, ores and evidences of ashes and fragments of furnaces in addition to the bronze objects. We have conducted petrological, XRD, EDAX, TEM, SEM and metallography on the slag, ores, crucible fragments and bronze objects samples recovered from Khanak excavations. This has given positive indication of mining and metallurgy of poly-mettalic Tin at the site; however, it can only be ascertained after the detailed scientific examination of the materials which is underway. In view of the importance of site, we intend to excavate the site horizontally in future so as to obtain more samples for scientific studies.

Keywords: archaeometallurgy, problem of tin, metallography, indus civilization

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Authors: Changyeop Lee, Sewon Kim

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Reburning is a useful technology in reducing nitric oxide through injection of a secondary hydrocarbon fuel. In this paper, an experimental study has been conducted to evaluate the effect of fuel lean reburning on NOx/CO reduction in LNG flame. Experiments were performed in flames stabilized by a co-flow swirl burner, which was mounted at the bottom of the furnace. Tests were conducted using LNG gas as the reburn fuel as well as the main fuel. The effects of reburn fuel fraction and injection manner of the reburn fuel were studied when the fuel lean reburning system was applied. The paper reports data on flue gas emissions and temperature distribution in the furnace for a wide range of experimental conditions. At steady state, temperature distribution and emission formation in the furnace have been measured and compared. This paper makes clear that in order to decrease both NOx and CO concentrations in the exhaust when the pulsated fuel lean reburning system was adapted, it is important that the control of some factors such as frequency and duty ratio. Also it shows the fuel lean reburning is also effective method to reduce NOx as much as reburning.

Keywords: fuel lean reburn, NOx, CO, LNG flame

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Authors: Maha Bakkari, Fatiha Lemmeni, Rachid Tadili

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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

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

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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

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Authors: Harkaranjit Singh, Arun Kumar

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Depletion of natural resources is a common phenomenon in developing countries like India due to rapid urbanization and industrialization involving construction of infrastructure and other amenities. In view of this, people have started searching for suitable other viable alternative materials for concrete so that the existing natural resources could be preserved to the possible extent for the future generation. In this process, different industrial waste materials such as fly ash, blast furnace slag, quarry dust, tile waste, bricks, broken glass waste, waste aggregate from demolition of structures, ceramic insulator waste, etc. have been tried as a viable substitute material to the conventional materials in concrete and has also been succeeded. This paper describes the studies conducted on strength characteristics of concrete made with utilizing of crushed tiles as a coarse aggregate. The waste crushed tiles can be used as coarse aggregates with the replacement ratio of 0, 50, 75 and 100% were used. Mechanical and physical tests were conducted on specimens. It was found that, the concrete made of waste ceramic tile aggregate produced more strength in compression, and flexure.

Keywords: compressive strength, flexural strength, waste crushed tile, concrete

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

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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

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Authors: Girts Zageris, Vadims Geza, Andris Jakovics

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Gasification processes are of great interest due to their generation of renewable energy in the form of syngas from biodegradable waste. It is, therefore, important to study the factors that play a role in the efficiency of gasification and the longevity of the machines in which gasification takes place. This study focuses on the latter, aiming to optimize an entrained-flow gasifier by reducing slag formation on its walls to reduce maintenance costs. A CFD mathematical model for an entrained-flow gasifier is constructed – the model of an actual gasifier is rendered in 3D and appropriately meshed. Then, the turbulent gas flow in the gasifier is modeled with the realizable k-ε approach, taking devolatilization, combustion and coal gasification into account. Various such simulations are conducted, obtaining results for different air inlet positions and by tracking particles of varying sizes undergoing devolatilization and gasification. The model identifies potential problematic zones where most particles collide with the gasifier walls, indicating risk regions where ash deposits could most likely form. In conclusion, the effects on the formation of an ash layer of air inlet positioning and particle size allowed in the main gasifier tank are discussed, and possible solutions for decreasing a number of undesirable deposits are proposed. Additionally, an estimate of the impact of different factors such as temperature, gas properties and gas content, and different forces acting on the particles undergoing gasification is given.

Keywords: biomass particles, gasification, slag formation, turbulence k-ε modelling

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Authors: Hilary Rutto

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The investigation was aimed at determining the extent at which the zinc will be extracted from secondary sources generated from galvanising process using dilute sulphuric acid under controlled laboratory conditions of temperature, solid-liquid ratio, and agitation rate. The leaching experiment was conducted for a period of 2 hours and to total zinc extracted calculated in relation to the amount of zinc dissolved at a unit time in comparison to the initial zinc content of the zinc ash. Sulphuric acid was found to be an effective leaching agent with an overall extraction of 91.1% when concentration is at 2M, and solid/liquid ratio kept at 1g/200mL leaching solution and temperature set at 65ᵒC while slurry agitation is at 450rpm. The leaching mechanism of zinc ash with sulphuric acid was conformed well to the shrinking core model.

Keywords: leaching, kinetics, shrinking core model, zinc slag

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Authors: Sewon Kim, Changyeop Lee

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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

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

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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

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Authors: Mokhtar Nikgoo

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Definition of Concrete and Concreting: Concrete (in French: Béton) in a broad sense is any substance or combination that consists of a sticky substance with the property of cementation. In general, concrete refers to concrete made by Portland cement, which is produced by mixing fine and coarse aggregates, Portland cement and water. After enough time, this mixture turns into a stone-like substance. During the hardening or processing of the concrete, cement is chemically combined with water to form strong crystals that bind the aggregates together, a process called hydration. During this process, significant heat is released called hydration heat. Additionally, concrete shrinks slightly, especially as excess water evaporates, a phenomenon known as drying shrinkage. The process of hardening and the gradual increase in concrete strength that occurs with it does not end suddenly unless it is artificially interrupted. Instead, it decreases more over long periods of time, although, in practical applications, concrete is usually set after 28 days and is considered at full design strength. Concrete may be made from different types of cement as well as pozzolans, furnace slag, additives, additives, polymers, fibers, etc. It may also be used in the way it is made, heating, water vapor, autoclave, vacuum, hydraulic pressures and various condensers.

Keywords: concrete, RCC, batching, cement, Pozzolan, mixing plan

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

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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

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Authors: Young Cheol Choi, Eun-Jin Moon, Sung-Won Yoo, Sang-Hwa Jung, In-Hwan Yang

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Stainless steel slag (STS) is a by-product generated from the stainless steel refining process. The recycling of STS produced in Korea for construction applications is limited due to its poor hydraulic properties. On the other hand, STS has high carbonation reactivity to CO2 as it contains gamma-C2S content. This material is ideal for mineral carbonation which is one of the techniques proposed for carbon emission reduction. The objective of this study is to investigate the feasibility of developing a zero-cement STS binder activated by carbonation as alternative cementitious material. The quantitative analyses for CO2 uptake of STS powder and STS blended cement were investigated using thermogravimetric analysis (TGA), X-ray diffraction (XRD). In addition, the compressive strength and microstructure of STS pastes after CO2 curing were evaluated. Test results showed that STS can be activated by carbonation to gain a sufficient strength as alternative cementitious material.

Keywords: gamma-C2S, CO2 uptake, carbonation, stainless steel slag

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Authors: Serkan Kocapinar, Gülay Altay

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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

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Authors: C. Lanzerstorfer

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The off-gas from the basic oxygen furnace (BOF), where pig iron is converted into steel, is treated in the primary ventilation system. This system is in full operation only during oxygen-blowing when the BOF converter vessel is in a vertical position. When pig iron and scrap are charged into the BOF and when slag or steel are tapped, the vessel is tilted. The generated emissions during charging and tapping cannot be captured by the primary off-gas system. To capture these emissions, a secondary ventilation system is usually installed. The emissions are captured by a canopy hood installed just above the converter mouth in tilted position. The aim of this study was to investigate the dependence of Zn and other components on the particle size of BOF secondary ventilation dust. Because of the high temperature of the BOF process it can be expected that Zn will be enriched in the fine dust fractions. If Zn is enriched in the fine fractions, classification could be applied to split the dust into two size fractions with a different content of Zn. For this air classification experiments with dust from the secondary ventilation system of a BOF were performed. The results show that Zn and Pb are highly enriched in the finest dust fraction. For Cd, Cu and Sb the enrichment is less. In contrast, the non-volatile metals Al, Fe, Mn and Ti were depleted in the fine fractions. Thus, air classification could be considered for the treatment of dust from secondary BOF off-gas cleaning.

Keywords: air classification, converter dust, recycling, zinc

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Authors: Mohammadjavad Yaghoubi, Arul Arulrajah, Mahdi M. Disfani, Suksun Horpibulsuk, Myint W. Bo, Stephen P. Darmawan

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Utilising waste materials, such as fly ash (FA) and slag (S) stockpiled in landfills, has drawn the attention of researchers and engineers in the recent years. There is a great potential for usage of these wastes in ground improvement projects, especially where deep deposits of soft compressible soils exist. This paper investigates the changes in the strength development of a high water content soft soil stabilised with alkaline activated FA and S, termed as geopolymer binder, to use in deep soil mixing technology. The strength improvement and the changes in the microstructure of the mixtures have been studied. The results show that using FA and S-based geopolymers can increases the strength significantly. Furthermore, utilising FA and S in ground improvement projects, where large amounts of binders are required, can be a solution to the disposal of these wastes.

Keywords: alkaline activation, fly ash, geopolymer, slag, strength development

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Authors: Zong-Xian Qiu, Ta-Wui Cheng, Wei-Hao Lee, Yung-Chin Ding

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The greenhouse effect is an important issue since it has been responsible for global warming. Carbon dioxide plays an important part of role in the greenhouse effect. Therefore, human has the responsibility for reducing CO₂ emissions in their daily operations. Except iron making and power plants, another major CO₂ production industry is cement industry. According to the statistics by EPA of Taiwan, production 1 ton of Portland cement will produce 520.29 kg of CO₂. There are over 7.8 million tons of CO₂ produced annually. Thus, trying to development low CO₂ emission green concrete is an important issue, and it can reduce CO₂ emission problems in Taiwan. The purpose of this study is trying to use marble wastes and slag as the raw materials to fabricate geopolymer green concrete. The result shows the marble based geopolymer green concrete have good workability and the compressive strength after curing for 28 days and 365 days can be reached 44MPa and 53MPa in indoor environment, 28MPa and 40.43MPa in outdoor environment. The acid resistance test shows the geopolymer green concrete have good resistance for chemical attack. The coefficient of permeability of geopolymer green concrete is better than Portland concrete. By comparing with Portland cement products, the marble based geopolymer not only reduce CO₂ emission problems but also provides great performance in practices. According to the experiment results shown that geopolymer concrete has great potential for further engineering development in the future, the new material could be expected to replace the Portland cement products in the future days.

Keywords: marble, slag, geopolymer, green concrete, CO₂ emission

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Authors: Mamdouh Omran, Timo Fabritius

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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

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Authors: Reina Kawase

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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

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

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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

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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

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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

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Authors: Jeeja Menon, M. S. Ravikumar

Abstract:

With the advent of green technology and the concept of zero energy buildings, there is an emerging trend in the utilization of indigenous materials like soil as a construction material. However, fine soils like clays and sand have undesirable properties and stabilization of these soils is essential before it is used to develop a building unit. Eco cement or Ground Granulated Blast Furnace Slag (GGBS), a waste byproduct formed during the manufacture of iron has cementitious properties and has the potential of replacing cement which is the most common stabilizer used for improving the geotechnical properties of soil. This paper highlights the salient observations obtained by the investigations into the effect of GGBS as a stabilizer for clayey sand. The index and engineering properties of the soil on the addition of different percentages (0%, 2%, 4%, 5% & 6% of the dry weight of the soil) of GGBS are tested to arrive at the optimum binder content. The criteria chosen for evaluation are the unconfined compressive strength values of different soil- binder composition. The test results indicate that there are significant strength improvements by the addition of GGBS in the soil, and the optimum GGBS content was determined as 5%. Moreover, utilizing waste binders for developing an ecofriendly, less energy induced building units as well as for stabilizing soil will also contribute to the solid waste management, which is the current environmental crisis of the world.

Keywords: eco cement, GGBS, index properties, stabilization, unconfined compressive strength

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Authors: Ryoko Yoshida, Jyunpei Yoshida, Hua Fang Yu, Yasushi Sasaki, Tetsuya Nagasaka

Abstract:

Phosphorous is an important element for agriculture and industry and is a non-renewable resource. Especially, yellow phosphorus is an essential material in advanced industrial technology, but phosphorus resources were not produced in Japan at all, and all depend on imports. It has been suggested, however, that the remaining accessible reserves of phosphate ore will be depleted within 50 years. Therefore, alternative resources for phosphate ore must be found. In this research, we have developed a process that enables the production of high-purity yellow phosphorus from domestic unused phosphorus resources such as steelmaking slags. The process consists of two parts: (1) the production of crude phosphoric acid from wastes such as steelmaking slag; (2) producing high-purity yellow phosphorus by low-temperature carbothermic reduction of phosphoric acid (H₃PO₄). The details of the carbothermic reduction of phosphoric acid are presented in this paper. Yellow phosphorus is commercially produced by carbothermic reduction of phosphate ore in an electric arc furnace at more than 1673K. In the newly developed system, gaseous P₄O₁₀ evaporated from H₃PO₄ is successfully reduced to yellow phosphorus by using carbon packed bed at less than 1273K. To meet the depletion of phosphate ore, the proposed process in this study to produce yellow phosphorus by carbothermic reduction of H₃PO₄ that are extracted from dephosphorization slags will be one of the effective and economical solutions.

Keywords: carbothermic reduction, phosphoric acid, dephosphorization slags, yellow phosphorus

Procedia PDF Downloads 92