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Number of results: 8
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Abstract

Iron black commonly employs in thermal insulation riser sleeves due to its ability to react with aluminum powder, generating heat. However, the complex production process and unstable composition of iron black lead to high production costs. The potential of using arc furnace flue ash (AFFA) as a complete substitute for iron black and MnO2 and KNO3 oxidizing agents in conventional riser sleeves was investigated in this study. Waste material can be transformed into a valuable resource, while production costs can be reduced by utilizing arc furnace flue ash. The research examined the impact of varying types and amounts of arc furnace flue ash on riser sleeve temperature and holding time by conducting single-factor and orthogonal optimization experiments. The orthogonal optimization experiment determined that the optimum ratio of each oxidant was 6 % arc flue ash, 3 % MnO2 and 6 % KNO3. At this time, the highest temperature was 1512 ℃ and the holding time was 244 s. Results indicated that different types of arc furnace flue ash used as an oxidizing agent demonstrated superior holding capacity and heat generation performance compared to iron black. Additionally, a comparative analysis of factory casting experiments using ductile iron 600-3 (IS) revealed that both arc furnace flue ash and iron black risers effectively countered shrinkage. However, arc furnace flue ash risers exhibited improved mechanical properties, as evidenced by the hardness of the castings.
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Bibliography

[1] Lu, J.J., Qian, J.B., Yang, L. & Wang, H.F. (2023). Preparation and performance optimization of organosilicon slag exothermic insulating riser. Archives of Foundry Engineering. 23(1), 75-82. DOI: 10.24425/afe.2023.144283.
[2] Vasková, I., Conev, M. & Hrubovčáková, M. (2017). The influence of using different types of risers or chills on shrinkage production for different wall thickness for material EN-GJS-400-18LT. Archives of Foundry Engineering. 17(2), 131-136. DOI: 10.1515/afe-2017-0064.
[3] Sowa, L., Skrzypczak, T. & Kwiatoń, P. (2019). The influence of riser shape on feeding effectiveness of solidifying casting. Archives of Foundry Engineering. 19(4), 91-94. DOI: 10.24425/afe.2019.129636.
[4] Krajewski, P.K., Gradowski, A. & Krajewski, W.K. (2013). Heat exchange in the system mould - riser - ambient. part ii: surface heat emission from open riser to ambient. Archives of Metallurgy and Materials. 58(4), 1149-1153. DOI: 10.2478/amm-2013-0140.
[5] Xu, X. Hui,G,D. Ma, B, H . et al. (2017). Research on high efficiency heat insulation risers for casting. Casting technology. 38(03), 726-728. (in Chinese).
[6] Zhang, S.L., Wu, B., Qin, Z.G.,et al .(2010). Ignition temperature of 2Al/Fe2O3 aluminum thermite. Energy Containing Materials. 18(02), 162-166. (in Chinese).
[7] Duan, W. H., Li, G., Zu. C.S., et al (2017). Control of critical characteristics of heat-insulating riser sleeves and countermeasures for application problems. China Casting Equipment and Technology, 2017(06), 20-24. (in Chinese).
[8] Sambo, A. & Szymanek, A. (2014). Analysis of the distribution of chemical compounds from fly ash exposed to weather. Chemical and Process Engineering. 35(3), 265-275. DOI: 10.2478/cpe-2014-0020.
[9] Chen, J. (2022). Application of steelmaking electric arc furnace ash in sintered bricks[J]. Brick and Tile, 2020 (7): 25-27. DOI:10.16001/j.cnki.1001-6945.2020.07.011.
[10] Wang, J., Zhang, Y.Y., Cui, K.K., Fu. T., Gao, J.J. Shahid Hussain, Tahani Saad AlGarni. (2021). Pyrometallurgical recovery of zinc and valuable metals from electric arc furnace dust – A review. Journal of Cleaner Production. 298, 126788. DOI:10.1016/j.jclepro.2021.126788.
[11] Donald, J.R. & Pickles, C.A. (1996). Reduction of electric arc furnace dust with solid iron powder. Canadian Metallurgical Quarterly. 35(3), 255-267. DOI:10.1016/0008-4433(96)00009-2.
[12] Lin, X.L. Peng. Z.W., Yan. J.X., Li. Z., Z. Hwang, J.Y. Zhang, Y.B., Li, G.H., Jiang, T. (2017). Pyrometallurgical recycling of electric arc furnace dust. Journal of Cleaner Production. 149, 1079-1100. DOI:10.1016/j.jclepro.2017.02.128.
[13] Abhilash T. Nair, Aneesh Mathew, Archana A R, M Abdul Akbar.(2022). Use of hazardous electric arc furnace dust in the construction industry: A cleaner production approach. Journal of Cleaner Production. 377, 134282, 0959-6526. DOI:10.1016/j.jclepro.2022.134282
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Authors and Affiliations

Junjie Zhu
1
ORCID: ORCID
Jian Feng
2
ORCID: ORCID
Ling Liu
1
ORCID: ORCID
Huafang Wang
1
ORCID: ORCID
Jijun Lu
1
ORCID: ORCID

  1. School of Mechanical Engineering and Automation, Wuhan Textile University, China
  2. CRRC Corporation Limited, China
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Abstract

In this study, solidification/stabilization (S/S) of electric arc furnace dust (EAFD) which is generated during the production of steel from scrap metals and classified as hazardous waste were investigated by using different ratios of cement and low grade MgO (LG MgO) as binding agents. Type I PC 42.5 R portland cement and LG MgO which contains 70–80% MgO were used. S/S blocks that contain different ratios of binding agents which have 1/0.5 – 1/1 – 1/2 – 1/3 – 1/4 – 1/5 cement/LG MgO ratio and S/S blocks which contain only cement and no LG MgO agents were prepared. These blocks, which contain 3 different waste ratios according to weight, 20%, 30% and 40% respectively, were produced and exposed to 28-day water purification. At the end of the purification process, S/S blocks were extracted using TCLP (Toxicity Characteristic Leaching Procedure) tests in order to determine the leaching behavior of Zn, Pb, and Cd in S/S blocks. By the end of this study, it was concluded that the recovery of EAFD is possible and applicable by immobilization. The findings of the study concluded that environmental performances or structural properties of blocks contain 30% waste by weight are suitable. This method is a proper one for recovering and treatment of EAFD with mixture of cement and LG MgO.

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Authors and Affiliations

Ahmet Can Bayraktar
Edip r Avşa
İsmail Toröz
Kadir Alp
Asude Hanedar
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Abstract

Dust generated at an electric arc furnace during steel production industry is still not a solved problem. Electric arc furnace dust (EAF) is a hazardous solid waste. Sintering of well-prepared briquetted mixtures in a shaft furnace is one of possible methods of EAFD utilisation. Simultaneously some metal oxides from exhaust gases can be separated. In this way, various metals are obtained, particularly zinc is recovered. As a result, zinc-free briquettes are received with high iron content which can be used in the steelmaking process. The purpose of the research was selecting the appropriate chemical composition of briquettes of the required strength and coke content necessary for the reduction of zinc oxide in a shaft furnace. Based on the results of the research the composition of the briquettes was selected. The best binder hydrated lime and sugar molasses and the range of proper moisture of mixture to receive briquettes of high mechanical strength were also chosen and tested. Additionally, in order to determine the thermal stability for the selected mixtures for briquetting thermal analysis was performed. A technological line of briquetting was developed to apply in a steelworks.

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Authors and Affiliations

Aneta Magdziarz
Monika Kuźnia
Michał Bembenek
Paweł Gara
Marek Hryniewicz
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Abstract

This paper presents new directions in the modeling of electric arc furnaces. This work is devoted to an overview of new approaches based on random differential equations, artificial neural networks, chaos theory, and fractional calculus. The foundation of proposed solutions consists of an instantaneous power balance equation related to the electric arc phenomenon. The emphasis is mostly placed on the conclusions that come from a novel interpretation of the equation coefficients.
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Authors and Affiliations

Dariusz Grabowski
1
ORCID: ORCID
Maciej Klimas
1
ORCID: ORCID

  1. Faculty of Electrical Engineering, Silesian University of Technology, Akademicka 10 str., 44-100 Gliwice, Poland
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Abstract

An economical alternative for the steel industry which uses a separate ferrosilicon and aluminum for the deoxidization of steel is a complex deoxidizer in the form of FeSiAl alloys. The effectiveness of complex deoxidizers is higher and they have a positive effect on quality improvement and also for mechanical properties of the finished steel. It is associated with a smaller number of non-metallic inclusions and a more favorable its distribution in the structure of steel. Noteworthy are the waste from the mining industry simultaneously contains SiO2 and Al2O3 oxides with a few of dopants in the form of CaO, MgO, FeO, TiO2 oxides. These wastes are present in large quantities and can be a cheap raw material for obtaining complex FeSiAl ferroalloys by an electrothermal method. “Poor” hard coal grades which so far did not apply as a reducing agent in the ferroalloy industry because of the high ash content can also be a raw material for the electrothermal FeSiAl process. The electrothermal FeSiAl melting process is similar to the ferrosilicon process in the submerged arc furnace. For this reason, a model based on Gibbs’ free enthalpy minimization algorithm was used to analyze the simultaneous reduction of SiO2 and Al2O3 oxides, which was originally elaborated for the ferrosilicon smelting process. This is a system of two closed reactors: the upper one with the lower temperature and the lower one with the higher temperature. Between the reaction system and the environment, and between the reactors inside the system, there is a cyclical mass transfer in moments when the state of equilibrium is reached in the reactors. Based on the model, the basic parameters of the electrothermal reduction process of SiO2 and Al2O3 oxides were determined and a comparative analysis was made towards the ferrosilicon process.
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Authors and Affiliations

B. Machulec
W. Bialik
S. Gil
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Abstract

Zinc is present in electric arc furnace dust (EAFD) mainly in two basic minerals, namely as franklinite ZnFe2O4 and/or zincite ZnO. While zincite is relatively reactive and easily treatable, franklinite is considerably refractory, which causes problems during EAFD processing. In this work EAFD containing 18.53% Zn was leached in water solution of ammonium carbonate. This leaching solution selectively leaches zincite, while franklinite is refractory and stable against leaching in this case. The temperature dependence of zinc leaching from EAFD was studied and the activation energy EA was determined by two methods: 1.) classically based on zinc chemical analyses from the leaching solution and 2.) by using of X-Ray diffraction qualitative phase analyses of leaching residues. The determined values of activation energies 37.41 and 38.55 kJmol–1 match perfectly, which show the excellent possibility of using X-Ray diffraction toward the study of leaching kinetics at properly chosen experimental conditions. The important result is the determination of the amount zincite and franklinite in EAFD, which is not possible by using of classical chemical methods.
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Authors and Affiliations

T. Havlik
G. Maruskinova
A. Miskufova
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Abstract

The post-processing slags containing about 0.8 wt.% of copper were subjected to the treatment of a complex reagent. The chemical composition of the complex reagent has been elaborated and patented in frame of the Grant No. PBS3/A5/45/2015. The slags had an industrial origin and were delivered by the Smelter and Refinery Plant, Głogów, as a product of the direct-to-blister technology performed in the flash furnace assisted by the arc furnace. An agglomeration of copper droplets suspended in the liquid slag, their coagulation, and deposition on the bottom of furnace were observed after the treatment this post-processing slag by the mentioned reagent. The treatment of the post-processing slags by the complex reagent was performed in the arc furnace equipped with some additional electrodes situated at the furnace bottom (additional, in comparison with the arc furnace usually applied in the Smelter and Refinery Plant, Głogów). The behaviour of the copper droplets in the liquid slag within the competition between buoyancy force and gravity was studied from the viewpoint of the required deposition of coagulated copper droplets. The applied complex reagent improves sufficiently the surface free energy of the copper droplets. In the result, the mechanical equilibrium between coagulated copper droplets and surrounding liquid slag is properly modified. Eventually, sufficiently large copper droplets are subjected to a settlement on the furnace bottom according to the requirements. The agglomeration and coagulation of the copper droplets were significantly improved by an optimized tilting of the upper electrodes and even by their rotation. Moreover, the settlement was substantially facilitated and improved by the employment of both upper and lower system of electrodes with the simultaneous substitution of the variable current by the direct current.

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Authors and Affiliations

W. Wołczyński
A.W. Bydałek
P. Migas
A. Tarasek
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Abstract

Higher active power of a submerged arc furnace is commonly believed to increase its capacity in the process of ferrosilicon smelting. This is a true statement but only to a limited extent. For a given electrode diameter d, there is a certain limit value of the submerged arc furnace active power. When this value is exceeded, the furnace capacity in the process of ferrosilicon smelting does not increase but the energy loss is higher and the technical and economic indicators become worse. Maximum output regarding the reaction zone volumes is one of parameters that characterize similarities of furnaces with various geometrical parameters. It is proportional to d3 and does not depend on the furnace size. The results of statistical analysis of the ferrosilicon smelting process in the 20 MVA furnace have been presented. In addition to basic electrical parameters, such as active power and electrical load of the electrodes, factors contributing to higher resistance of the furnace bath and resulting lower reactive power Px demonstrate the most significant effect on the electrothermal process of ferrosilicon smelting. These parameters reflect metallurgical conditions of ferrosilicon smelting, such as the reducer fraction, position of the electrodes and temperature conditions of the reaction zones.

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Authors and Affiliations

B. Machulec
W. Bialik
S. Gil

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