Dissertationen zum Thema „Sintering furnace“

Manganese furnace dust is made up of volatiles and fine particles of the raw materials collected from the off-gas during smelting of manganese alloys. Impediments to the recycling of the manganese furnace dust back to the ferroalloy furnaces are handling due to the presence of tar, and the potential accumulation of zinc in the furnaces, which can cause irregularities in their operation. The aim of the thesis was to establish conditions for zinc removal from the dust and assess the feasibility of the dust recycling in the Tasmanian Electrometallurgical Company sinter plant. Major findings are: - Manganese furnace dust taken from the settling ponds contained water, carbonaceous materials (tar), and metal oxides. The carbon content of the dried furnace dust was about 20% and the average manganese and zinc contents were 33.4 and 1.29%, respectively. Moisture content was 30-60%. - The tar components were aliphatic hydrocarbons and polyaromatic hydrocarbons, their derivatives, and sulphur- and oxygen-containing compounds with a wide range of carbon number (15-28) and boiling point (230-530oC). Light hydrocarbons were not detected. - If manganese furnace dust was recycled to ferroalloy furnaces through the sintering plant, the overall zinc input had increased by 51-143%. Sustainable utilisation of manganese furnace dust should include enhanced zinc removal. - Reduction of zinc oxide from manganese furnace dust pellets started at 800oC. Zinc oxide was reduced to zinc vapour by tar in the dust. Temperature and gas atmosphere were key parameters affecting the zinc removal from the dust. The zinc removal rate increased with increasing temperature and was close to completion at 1100oC. - Optimal conditions for removal of zinc from the furnace dust include: temperature in the range 1000-1150oC, inert gas atmosphere and furnace dust fraction in the furnace dust-manganese ore mixture above 60%. - Zinc removal in the processing of manganese furnace dust in the sinter plant was low because of zinc reoxidation in the sinter bed. This makes the sinter plant unsuitable for recycling of the dust. More suitable conditions for utilisation of manganese furnace dust exist in the rotary hearth furnace, which development is recommended for further study.

To be able to supervise the quality of a sintering process, furnace control pieces are therefore used. The current furnace control piece is not sensitive enough small variations during insert production. The goal of the project was to find and evaluate a new suitable cemented carbide grade, which better captures temperature variations during sintering process, likewise, evaluate the alternative placing in the production furnace and methods to supervise and follow the status of the sintering process. The cemented carbide grade 592, which is a DQ-grade, captured larger temperature variations during the sintering compared to the current furnace control piece. The process charge for 592 that captured the largest variations also had the highest charge weight, which indicates that the new grade is also sensitive to the charge weight. The purpose of the project was fulfilled when a more suitable cemented carbide grade, 592, was evaluated for both sintering temperatures 1410 ℃ and 1450 ℃.

Este trabalho tem por objetivo estudar o aproveitamento do pó de aciaria elétrica (PAE) na sinterização de minério de ferro visando a eliminação de zinco. Primeiramente, foi feita uma caracterização física e química do resíduo através de análises químicas, granulométricas, morfológicas e de difração de raios-X. O minério de ferro, principal componente do processo de sinterização, foi caracterizado através de análise química, granulométrica e de umidade. Em seguida, foram fabricadas micropelotas de 3,0 a 5,0mm de diâmetro compostas por 70% de PAE e 30% de moinha de coque, que foram classificadas por peneiramento e secas em esfufa. Depois de aglomerado, o resíduo foi incorporado na sinterização de minério de ferro em diferentes proporções, condições de processo e formas de adição (micropelotas, undersize da micropelotização com granulometria entre 1,0 e 2,0mm, ou mistura de PAE e coque em pó). A cada processo de sinterização foram retiradas amostras de sínter, os materiais foram analisados através de Microscópio Eletrônico de Varredura (MEV), macroscopia e análises químicas por espectrofotometria de absorção atômica para verificar o teor de zinco. Amostras de misturas não sinterizadas também foram submetidas a análises químicas para determinar a quantidade inicial de zinco, ou seja, verificar a quantidade de zinco contido na mistura antes do processo de sinterização. Mediante a comparação do teor de zinco das amostras não sinterizadas com os sínteres, foi possível determinar a eliminação de zinco nos ensaios realizados. Aproximadamente 92% de zinco foi eliminado (junto com os gases de saída) com a incorporação de 10% de micropelotas na mistura a sinterizar. Os resultados mostraram que a eliminação do metal no processo é proporcional à relação redutor/resíduo.
The aim of this work was to study the use of electric arc furnace dust (EAFD) in iron ore sintering process aiming zinc elimination. Firstly, physical and chemical characterizations of the waste were made using X-ray diffraction, microscopy, chemical and size analyses. Iron ore is the main component of the sintering process, this material was characterized by chemical, size and humidity analyses. After, micropellets composed of EAFD 70% and coke breeze 30% with diameters of 3.0-5.0 mm were produced, then they were dried in kiln and classified by sieving. The pellets were incorporated into the iron ore sintering charge using differents proportions, process conditions and addition forms (micropellets, undersize with diameters of 1.0-2.0 mm, or a mixture of EAFD and coke breeze). Sintered samples were collected in each sintering process. These materials were analyzed by scanning electron microscopy (SEM), macroscopy and chemical analysis using atomic absorption spectrophotometry in order to determine the zinc content. Samples of not sintered mixtures were also characterized by chemical analysis aiming the determination the initial amounts of zinc, i.e. in order to check the zinc amounts present in the mixture before the sintering process. The comparation between the zinc contents of sintered samples and not sintered allowed to determine the elimination of zinc during the experiments. About 92% of zinc was eliminated (along with the output gas) with the incorporation of 10% of micropellet in the sintering mixture. Results showed that the zinc elimination in the process is proportional to the ratio reducer/waste.

Höganäs AB has a customer center where they perform their cutomers production processes usingtheir own metal powder, thereby gaining knowledge of how the powder behaves and how it can be improved. The powder is usually pressed, and then sintered in a sintering furnace where temperature and atmosphere composition gives the component its desired characteristics. Höganäs AB didn’t save the parameters from these process’s in a easily accessible way, some values were not saved at all. To increase understanding of these parameters impact on the produced detail they wanted these parameters collected and stored in the cloud. They also wanted solution ideas and concepts for implementation of weight measuring on both the in- and output side of the furnace. This project used Ulrich & Eppinger’s product development method, modified by performing continous testing parallell to the design process. The project was also separated into three parts worked on simultaneously. Computer architecture, physical casing and weight measuring. To compile and upload to the cloud a Raspberry Pi 3 B+, a micro processor, was used. It connected via WiFi to upload files to OneDrive. The measured values from the furnace were gathered from the furnace’s PLC via OPCUA and a gas measuring unit via serial communication. Because of the use of metal powder there was conductive dust in the air which could lead to leakage currents and short circuiting if it were to gather on the processor unit. Hence the dust had to be keptaway. The casing was therefore designed to be relatively airtight. The casing was made with 3D-printed PETG. The seal utilized PETG’s elasticity to elastically deform an elevated seal, and thereby sealing the casing, without having to produce more components than a bottom and a lid. The cable feedthrough used the cables elastic deformation to seal. A screen was implemented to start and stop logging processes, which was also sealed using an overlapping lip around it’s rim. The logging of the furnace parameters was split in two logs, a day-log and a job-log. The daylog took measurements continously over a day in long intervals, 30 minutes. At the end of the day a log was uploaded for that day, hence the name. The job-log had to be started manually via the screen and was used to take measurements with higher frequency during a production series. Log files of both types were uploaded to a OneDrive folder. The product was tested with a number of final tests, both for the casing and the software. The casing was tested primarily for the numerical requirements set in the requirements specification. While the software was tested over a longer period of time to ensure functionality.The final product was a sealed, robust, easily disassembled and cable strain relieved 3D-printed box with a 3.5 inch touchscreen and a connected keyboard. It collected the desired data and compiled it to log files readable by programs such as Microsoft Excel. The weight measuring concept produced was a self-made solution with load cells under the loading ramp. The weight is then measured automatically during the regular loading process without disrupting it. Two backup solutions were also put forward.

O pó de forno elétrico a arco (FEA) é gerado durante a fusão de sucata ferrosa nos fornos elétricos a arco e coletado predominantemente através de filtros de mangas. Esta substância é listada como resíduo sólido perigoso de fonte específica, K061, conforme a Norma ABNT NBR 10004:2004. As maiores empresas siderúrgicas semi-integradas do mundo têm adotado para o tratamento de pó de FEA, fundamentalmente três rotas: a recuperação de zinco e chumbo, através de dois processos complementares, um piro-metalúrgico, o Wäelz kiln e outro hidro-metalúrgico, o processo de dupla lixiviação Óxido de Wäelz; a inertização através da blendagem com a cal, aditivos e água, de forma a alcançar o pH da mistura >11, o que garante que metais pesados como o chumbo, cádmio e o zinco, presentes no pó de forno elétrico, não possam se tornar solúveis, evitando consequentemente, a sua lixiviação e a disposição em aterros industriais de resíduos sólidos perigosos. Sob a perspectiva da sustentabilidade, deve ser considerada a rota da recuperação de zinco e chumbo, que para ser viável necessita reunir a geração de pó de FEA de varias plantas, o que para um país com dimensões continentais pode ser um fator de insucesso. Esse trabalho trata da reciclagem do pó de FEA através do processo de sinterização de um compósito constituído de pó de FEA aglomerado com coque, carepa e fluorita cerâmica em pelotas, aplicável a uma planta unitária. Como resultado deste processo foram obtidos dois coprodutos, o aglomerado pré-fundido, APF, com teor de óxido de ferro superior a 70%, objeto do processo de sinterização e o concentrado de zinco, com teor de óxido de zinco maior que 50%, resultante da volatilização deste metal durante o processo de sinterização e coletado através de filtro de mangas. Complementarmente foi extraído aproximadamente 90% dos óxidos de chumbo e cádmio contidos no pó de FEA inicial. A produção do APF ocorreu em escala experimental dividida em três fases, a primeira fase foi efetuada com oito formulações distintas e comprovou através de análises químicas de espectrometria por fluorescência de raios X e difratometria de raios X, a viabilidade técnica da utilização somente de resíduos sólidos industriais para fabricação do APF. A segunda fase, também com oito formulações, definidas conforme planejamento de experimentos com delineamento fatorial, teve como objetivo identificar os principais efeitos das interações entre os componentes do APF, para obtenção da mistura com formulação ótima. A terceira fase testou a intensidade das variáveis, coque e fluorita cerâmica, para a extração do zinco. As duas primeiras fases dos testes de produção em escala experimental foram realizadas em uma planta piloto de sinterização de fluxo descendente e a terceira fase em uma planta piloto de fluxo ascendente, ambas instaladas na usina ArcelorMittal Piracicaba. O APF, com a formulação ótima, foi produzido em escala industrial na planta de sinterização Metalflexi, também instalada na usina ArcelorMittal Piracicaba, e testado em alto-forno de pequeno porte. O concentrado de zinco foi caracterizado quimicamente para se avaliar o uso em segmentos industriais que utilizem este elemento.
The electric arc furnace (EAF) dust is generated during melting of steel scrap in electric arc furnaces and collected mainly through bag filters. The EAF dust is listed as hazardous waste from specific source, K061, according to ABNT 10004:2004. The major semi-integrated steel companies in the world have adopted for the treatment of EAF dust, basically three routes: the recovery of zinc and lead, through two complementary processes, a pyro-metallurgy, Waelz kiln and other hydro-metallurgical the leaching process of double oxide Waelz; the blanketing by blending with lime, water and additives in order to achieve the pH of the mixture>11, which ensures that heavy metals like lead, cadmium and zinc, present in furnace residue, can not become soluble, thereby avoiding the leaching and disposal in landfills of hazardous waste. This work suggests recycling of the EAF dust by sintering of a composite consisting of EAF dust agglomerate to coke particles (carbon source), mill scale (iron source) and ceramic fluorite (adictive agent used like fluxant) into pellets, a process known as sintering. As a result of the process is expected to obtain two by-products, the pre-cast agglomerated, PCA, with iron oxide content exceeding 70%, object of the process of sintering and zinc dust, containing more than 50% zinc oxide resulting from volatilization of this metal during the sintering process and collected by bag filter. Addition is expected to extract approximately 90% of lead and cadmium oxide contained in the initial EAF dust. The production of the PCA occurred in experimental scale divided into three stages, the first stage was performed with eight different formulations and checked by chemical analysis by X-ray fluorescence spectrometer and X-ray diffraction, the technical viability of using only solid waste industrial manufacturing PCA. The second phase, also with eight formulations, defined as planning experiments with factorial design, was tested the main effects and the double and triple interactions between the components of the PCA, to obtain the optimal formulation. The third phase was checked the intensity of the variables, coke fluorite ceramics, for removing zinc of PCA. The first two stages of the production tests were carried out on a pilot scale in a pilot plant sintering downstream and the third phase in a pilot plant xii upstream, both installed in the plant ArcelorMittal Piracicaba. The PCA, with the optimal formulation was produced on an industrial scale in the sinter plant Metalflexi also installed at the plant ArcelorMittal Piracicaba, and tested in small blast furnace. The zinc dust was characterized chemically for application in industries that use this element.

Ce travail a pour objectif d’élaborer de manière contrôlée différentes microstructures de (K0,5Na0,5)NbO3 non dopées par différentes mises en forme, bien caractérisées structuralement et microstructuralement, afin d’étudier et d’éclaircir l’influence de la densification et de la taille des grains sur les propriétés piézoélectriques. Il s’agit pour cela de produire des microstructures, avec une composition maitrisée, ayant d’abord des grains de taille micrométrique, ensuite millimétrique et enfin si possible des grains centimétriques de KNN et d’atteindre des densifications allant de 80 % à plus de 95 %. Au-delà de l’ingénierie des microstructures de KNN, l’obtention de monocristaux du composé (K0,5Na0,5)NbO3 de plusieurs mm3, de bonne qualité cristalline et bien caractérisés structuralement et microstructuralement permettrait de caractériser l’ensemble des tenseurs élastiques, diélectriques et piézoélectriques ainsi que de valider des méthodes de caractérisation originales développées au sein du laboratoire GREMAN
The purpose of this work is to elaborate different controlled microstructures of undoped (K0,5Na0,5)NbO3 by different methods, with full structural and microstructural characterization in order to study and to elucidate the influence of the densification and grain size effect on the piezoelectric properties. For this, it is necessary to produce KNN microstructures with controlled composition, starting with micrometer grain size, then millimeter and if possible centimeter grain size and to attain densification ranging from 80 % up to 95 % of the theoretical one. Beyond the KNN microstructure engineering, the growth of large (K0,5Na0,5)NbO3 single crystals about several mm3 with good crystallinity and full structural and microstructural characterization would enable the elastic, dielectric and piezoelectric tensors to be fully characterized as well as to validate the original characterization methods developed within the GREMAN laboratory

Abstract When producing ferrochrome, a submerged arc furnace (SAF) is used. The charge of an SAF consists of chromite pellets, coke, lumpy ore and quartzite as a slag modifier. The charge is pre-heated before it descends into the SAF where the charge eventually reduces and melts. The electrical conductivity of the charge is important because, among other things, it affects the productivity of the furnace. The electrical conductivity of the charge should ideally be low on the higher parts of the furnace and high near the electrode tip. This is to ensure that the electric current path travels through the metal bath via arcing, which provides the most effective heat transfer. Another option for the current path would be through the solid feed material via ohmic conduction, but since this zone is less reactive, the heat energy would be mostly wasted. This work brings forth new information about the electrical behaviour of coke and chromite pellet is produced. The electrical conductivity was measured at room temperature for different simulated process conditions (different coke textures, different reduction degrees of chromite pellets, sulphur in atmosphere and replacing the coke used in chromite pellet production with charcoal). It was found out that unlike gasification with a CO/CO2 mixture, heat treatment at 950°C increased the degree of graphitization and changed the electrical behaviour of coke. Furthermore, it was observed that increasing the chromite pellets’ reduction degree reduced the electrical conductivity measured at room temperature. In the case of chromite pellets and sulphur in the atmosphere it was found that sulphur has an effect on the pellets’ electrical behavior and structure during reduction, which - in turn - has an effect on the SAF performance when raw materials with varying sulphur contents are used. Lastly, it was found that substituting coke with charcoal when producing chromite pellets affects the sintering behaviour, cold compression strength, and electrical conductivity of the chromite pellets
Tiivistelmä Uppokaariuuni on osa ferrokromin valmistusprosessia. Uppokaariuuniin panostetaan kromiittipellejä, koksia, palarikastetta ja kvartsiittia. Etukuumennusuunista panos laskeutuu uppokaariuuniin, jossa se pelkistyy ja lopulta sulaa. Uppokaariuunin panoksen sähkönjohtavuus on tärkeää uunin toiminnan kannalta, koska se vaikuttaa suoraan esimerkiksi tuottavuuteen. Jotta virran kulku tapahtuisi optimaalisesti sulan metallin kautta, panoksen sähkönjohtavuuden tulee olla pieni uunin yläosissa ja suuri alaosassa lähellä elektrodien päitä. Mikäli virran kulku tapahtuu uunin yläosassa, hukataan lämpöenergiaa ja uunin toiminta hankaloituu. Tässä työssä on selvitetty koksin ja kromiittipellettien sähköisiä ominaisuuksia. Sähkönjohtavuutta on tutkittu useilla simuloiduilla prosessiolosuhteilla (koksin eri tekstuurit, kromiittipellettien eri pelkistysasteet, rikin pitoisuus atmosfäärissä ja kromiittipellettien valmistuksessa on korvattu koksi puuhiilellä). Nämä mittaukset on tehty huonelämpötilassa. Huomattiin, että toisin kuin koksin kaasutus, koksin lämpökäsittely (950°C) nosti grafitoitumisastetta ja vaikutti sähköisiin ominaisuuksiin. Kromiittipelletin pelkistymisasteen noustessa huonelämpötilassa mitattu sähkönjohtavuus laski. Kun kromiittipelletit altistetaan atmosfäärille, jossa on rikkiä, pellettien sähköiset ominaisuudet muuttuvat samoin kuin rakenne pelkistyksen aikana. Tämä vaikuttaa uppokaariuunin toimintaan, kun käytetään raaka-aineita, joissa rikkipitoisuus vaihtelee. Kun kromiittipellettien valmistuksessa käytettävä koksi korvataan puuhiilellä, tämä vaikuttaa sintrausprosessiin, kylmälujuuteen ja sähköisiin ominaisuuksiin

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Tese (Doutoramento)
IPEN/T
Instituto de Pesquisas Energeticas e Nucleares - IPEN/CNEN-SP

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O carbeto de silício (SiC) é um material que apresenta baixa expansão térmica, altas resistências mecânica e ao choque térmico e alta condutividade térmica. Em razão disto é empregado na confecção de mobília de fornos de sinterização. O SiC no entanto sofre degradação a altas temperaturas quando submetido a atmosferas agressivas. A utilização de recobrimentos protetores evita a exposição direta da superfície do material à atmosfera dos fornos; a mulita pode ser um recobrimento protetor apropriado em razão de sua alta estabilidade em temperaturas elevadas e seu coeficiente de expansão térmica compatível com o do SiC (4x10-6/°C e 5,3x10-6/°C, respectivamente). No presente trabalho foi estudada a obtenção de recobrimento de mulita, para refratário de SiC, a partir da utilização de polímero precursor cerâmico e alumínio particulado. Foram preparadas composições com 10, 20, 30 e 50% (vol.) de alumínio adicionado ao polímero, sendo utilizados pós de alumínio de diferentes distribuições de tamanhos de partículas. As composições foram submetidas a diversos ciclos térmicos para determinação da condição mais adequada à obtenção de alto teor de mulita. A composição que apresentou melhor resultado foi a contendo 20% do pó de Al de menor tamanho de partículas. A partir desta, foi preparada e aplicada suspensão para ser aplicada sobre o refratário de SiC. A suspensão aplicada, após seca, reticulada e tratada termicamente a 1580°C, originou um recobrimento de mulita. Foram realizados ciclos de choque térmico em amostras com e sem recobrimento para comparação, num total de 26 ciclos. As condições foram 600°C/30 min. seguida de resfriamento ao ar até a temperatura ambiente. Após cada choque térmico, as amostras foram caracterizadas por microscopia óptica e eletrônica e determinado o módulo de elasticidade. Os recobrimentos apresentaram boa adesão e não foram detectados danos significativos após os choques térmicos.
Tese (Doutorado em Tecnologia Nuclear)
IPEN/T
Instituto de Pesquisas Energéticas e Nucleares - IPEN-CNEN/SP

碩士
國立高雄應用科技大學
機械與精密工程研究所
103
ABSTRACT This study is related to evaluate the gas protected sintering furnace by using finite element software to do thermal field and flow field simulation. We compared simulated values (by using mathematical models to evaluate the temperature distribution and flow field status in each region of sintering furnace) and experimental values for verification. We built a finite element mathematical model by using thermodynamics and fluid dynamics module of the finite element software (Ansys-CFX). Then we take varied parameters to do simulation (temperature and flow field) by using the finite element mathematical model. In this study, we also take varied set points of temperature to simulate temperature change of sintering furnace. Results showed that by using Ansys-CFX to do simulation, which can keep 8% (the maximum) deviation between the simulated value and experimental value. We can speculate the temperature curve and do temperature experimental plan by putting varied parameter in this mathematical model.

碩士
明新科技大學
電機工程研究所
99
In this thesis, a high vacuum degreasing sintering furnace that is to be applied to Metal Powder Injection Molding (MIM) process is going to be completely designed and manufactured. HMI is used to integrate control interface, Mitsubishi Q series PLC is adopted as control core, and GX Developer software is used for control procedure editing. Meanwhile, the entire MIM degreasing sintering process is summarized into 12 actions and events, then the communication interface of the temperature controller is used to call the event implemented and edited by PLC, by doing so, the smoothness of the entire degreasing and sintering process can then be reached, and more diversified process action can be made accordingly. In this article, nine points analog signal digital recorder is adopted, then accompanied with nine K Type thermocouples and two W Type thermocouples, one TTR91 thermister vacuum gauge, and one PTR225 cold cathode ionized vacuum gauge. The detailed data in the test process is completely recorded, then through detailed data recording correction system, the room temperature to 1500℃ heating rate of this system is then successfully tuned to 13.2℃/minute, which is superior to the 12℃/minute of the spec. The nine point average temperature is 1000±3℃, which is superior to the spect of 1000±5℃; the vacuum can reach 10-2 Torr Range in nineteen minutes, which is superior to the spec of 30 minutes; the vacuum leak rate of the system is 6.33×10-4 L‧Torr/sec, which is much superior to the spec of 5 x 10-1 L‧Torr/sec.

碩士
國立成功大學
環境工程學系碩博士班
94
Blast furnace (BF) slurry, a solid by-product with high iron and carbon contents, could originally be recycled in the steel making process. Limited that the zinc and lead contents might evaporate in elevated temperature; the recycling of BF slurry is constrained. Nevertheless, iron content in BF slurry is basic material of ferrite, and carbon could provide reduced atmosphere and convert iron to ferrite in high temperature ferrite process. In this study, quantitative X-ray diffraction analysis was performed to investigate the influence of sintering conditions including atmosphere, sintering temperature and isothermal time on the ferrite process of BF slurry. When the sintering temperature was increased from 600ºC to 900ºC under air atmosphere, Relative Intensity to Reference (RIR) of α-Fe2O3 in sintered BF slurry increased accordingly. The result supports that the oxide number of iron oxide is raised under the air atmosphere during the sintering process. On the other hand, as the sintering temperature was in the range from 700ºC to 800ºC under nitrogen atmosphere, the RIR of Fe3O4 reached maximum value. Afterward, as the temperature or the isothermal time was further increased, the RIR of FeO increased and the RIR of Fe3O4 decreased. The results indicate that the oxide number is reduced in elevated temperatures under the reduced atmosphere created by carbon in BF slurry and nitrogen atmosphere. Summarized from the experiments performed, the optimal sintering condition for ferrite process of the BF slurry is palletized sintering at 800 ºC for 5 hours under nitrogen atmosphere.

碩士
正修科技大學
營建工程研究所
102
Firstly this article has processed waste LCD glass,basic oxygen furnace slag(BOFS) and mudstone ground into powder, BOFS dosage is set to 25% and 35%,,flux is set to 3%, 6% and 9% etc. three kinds, swell agent is set to 0%,1% and 3%, the sintering temperature is set at 950℃, 1000℃ and 1020℃, material is mixed and pressed into the body, and then fired into the red brick,base mechanics features of the brick through tests of compressive strength, water absorption and scanning electron microscopy etc. tests, and then investigates brick sintering manufacture technique and engineering characteristics. Experimental results have proven that: (1)At the same flux (iron oxide, sodium bicarbonate) the amount was increased from 3% to 9% and swell agent (boric acid) fixed at 0%, 1% and 2% usage , BOFS dosage is set to 25%, the sintering temperature is set at 950℃, 1000℃ and 1020℃, when the sintering temperature of 1000 ° C, the compressive strength and water absorption are requirements of the three kinds of brick. (2) At the same swell agent(boric acid or sodium carbonate) fixed at 0%, 1% and 2% usage , flux (iron oxide, sodium bicarbonate) the amount is fixed at 3%, 6% and 9% usage , BOFS dosage is set to 25%, the sintering temperature is set at 950℃, 1000℃ and 1020℃, when the sintering temperature of 1000 ° C, the compressive strength and water absorption are requirements of the three kinds of brick. (3)In the same usage amount of swell agent and flux, compressive strength increases with increasing temperature, and decreases with increasing BOFS dosage, BOFS dosage of 25% is the best. (4)Swell agent is used boric acid, flux is used iron oxide, compressive strength increases with increasing temperature , iron oxide and boric acid addition amount. (5)With the increased amount 3% of swell agent or flux, sintered body showed internal molten lumps, small bubbles exists and increases degree of densification. (6)BOFS dosage is 25%, swell agent is used 2% boric acid, flux is used iron oxide which the amount was increased from 3% to 9%, sintered body showed internal molten lumps and small bubbles exists. Keyword: Basic Oxygen Furnace Slag (BOFS), Compressive, Scanning Electron Microscopy, Flux, Swell.

In South Africa, the ferrochromium industry produces approximately 100,000 t bag house filter dust and slurry, while the stainless steel industry produces 24,000 t of dust annually [17,39]. The toxic substances in these wastes potentially pose a threat to the environment and human health, especially Cr (VI) due to its toxic, carcinogenic, highly soluble and strongly oxidizing properties. Therefore, the existence and treatment of wastes from stainless steel and ferrochrome production remain a challenge and an issue of concern. The increase of environmental legislation globally and the trend towards sustainable development are drives for alternatives to landfill. In the present thesis, the characteristics, formation mechanisms, leachability and stabilisation of the Cr (VI)-containing electric furnace dust and filter cake were investigated using various techniques such as XRD, XRF, TG/DTA, XPS, SEM-EDS, FT-IR, Raman spectrometer and UV/Vis spectrometer. The electric furnace dust and filter cake are very fine particles. Stainless steel dust forms by the entrainment of charge materials, evaporation or volatilisation of elements and ejection of slag and metal by spitting or the bursting of gas bubbles. It was found that ferrochrome dust is formed by the ejection of slag and metals droplets from the electrode hole, the entrainment of charge materials, vaporisation as well as the formation and precipitation of compounds from vaporised species in the off-gas duct. Filter cake contains crystal phases (CaF2 and CaSO4 ) and metal rich amorphous phases. It is formed due to super saturation and precipitation. Leaching experiments on the wastes showed that Cr (VI) rapidly leaches out by distilled water. Bricks were produced by mixing wastes (stainless steel plant dust, ferrochrome dust and filter cake) and clay. The optimum sinter parameter was found to be 1100oC and 5 hours for a 50wt% SPD-50wt% AS mixture in the brick. The leachability of Cr(VI) is strongly influenced by the mass%CaO/mass%SiO2 ratio and alkali metal oxides content in the wastes. The emission factors from the stabilised wastes (SPD, FCD1, FCD2 and FC) are similar to those reported for the cement industry. Semi-dynamic leaching tests indicated that the predominant leaching mechanisms of chromium species are initial surface wash-off followed by matrix diffusion.
Thesis (PhD (Metallurgical Engineering))--University of Pretoria, 2007.
Materials Science and Metallurgical Engineering
unrestricted

碩士
明新科技大學
管理研究所碩士在職專班
105
Today, the wiring in the machine are much more complicated compared to the past ones. Thus, using the old techniques for wiring is not suitable anymore. At present, the domestic machinery factories place high value on the improvements of main hardware and software programs in the machine, but they don’t pay much attention on improving the electrical control wiring. The goal of this research is to improve the system of wiring. To shorten the time of maintenance, and to decrease the error rate of wiring, the cause-effect chain analysis method in the TRIZ theory was used to find out the main parts needed to be focused for improvements. There were four parts. First, the data for the vacuum sintering furnace is lack of systemization. Second, the manual containing electrician regulations is too thick to read for electricians during working. Third, it is time-consuming for checking whether the internal three-phase contact point) functions properly or not. Last, it needs a lot of time for the external wiring because the connections between external components and the machine are complicated. After I found out the main parts, I used the method of resolving technology contradictions to seek out feasible improvements for the problems. I got four projects for improvements. They were establishing a line number system, sticking related regulations on the commonly-used instruments, using the Molex power connector’s (莫士端子) plug(公座) and receptacle(母座) match connect set on wiring of motor, and creating SOPs for common wirings. We found out that these four projects may reduce the repair time into one-fourth to one-sixth times, and may save NT$ 32100 in cost of maintenance for each Vacuum Sintering Furnace. It may also save 6 working days in connecting external wiring and NT$16800 for each Vacuum Sintering Furnace in cost of wiring. Although the regulations and industrial electrical wiring rules for electricians are written in the manual, but the manual is too thick, so that few electricians learnt these regulations by the manual. Most of them learn these regulations from the experienced electricians. Learning in this way lacks of systematization, and is difficult for new entrants to get used to work quickly. We think that making table lists for the arrangements of wiring based on the past experience will help new staff get used to work in a short time. Since the new entrants get used to work quickly, they will make less errors in the work, and this will improve the work efficiency, and will decrease the cost of the wiring.

A dissertation submitted to the School of Chemical and Metallurgical Engineering at the University of the Witwatersrand, in partial fulfilment of the degree Master of Science in Engineering, 2020
A study was undertaken to evaluate sintering as a potential cause of duct blockage for a submerged arc furnace applied in silicomanganese production. Within the broader aim of the study, four research questions were of principal interest. The research questions were as follows:  Is there a potential for dust to sinter in the off-gas duct?  If so, what mechanism of sintering is applicable, under the given conditions?  Does the firing temperature have an effect on sinter formation and the compressive strength of the dust, given a fixed PSD?  Does PSD have an effect on sinter formation and the compressive strength of the dust, given a fixed firing temperature? In order to address the aforementioned research questions, several plant-based, laboratory-based, and desktop-based activities were undertaken. The activities were divided into five chronological stages as follows:  Stage 1: Smelter based activities –entailed the collection of dust samples from the three streams in the baghouse and the measurement of the furnace duct temperatures. From this exercise, a total of 505 kg of dust across the three streams was collected. The duct temperature was found to vary between 600‒1300°C.  Stage 2: Laboratory dust samples preparations–entailed sample preparation, and PSD and chemical characterisation of each dust stream.  Stage 3: Laboratory pellet-pressing and firing tests –entailed the pressing of pellets at a pressure of 5 MPa pressure, followed by oven drying, and then firing in a muffle furnace at 600‒1300°C (the measured duct temperature) in an air atmosphere. For each temperature and dust stream, forty one pellets were fired.  Stage 4: Fired dust examination: the fired pellets were examined for sintering using observations of their: physical appearance, compressive strength, bulk chemistry, bulk phase chemical composition.  Stage 5: Chemical thermodynamic evaluation: thermodynamic calculations were performed using FactSageTM, to determine the amount of liquid formed from bulk mixtures, as well phases that were observed to have sintered together. Following the testwork, the following research outcomes were found:  There was sound evidence of sintering in the off-gas duct of the smelter in question.  Both solid-and liquid-state sintering were observed. The former was more localised‒ observed only in some areas in the sample‒and most prominent at firing temperatures of 600‒900°C. The latter was observed between 600‒1100°C; it was prevalent at 1100°C‒ where long networks of sintered materials were observed.  The firing temperature was found to have an effect on sinter formation and the compressive strength.  The PSD was also found to have an effect on sinter formation and the compressive strength of the formed sinters
CK2021

The effect of replacing fine ore by coarse ore on sintering reactions was investigated using an infrared furnace on laboratory scale and sinter pots on pilot plant scale. Five sinter mixes were prepared by changing the percentage coarse ore from 0% to 100% in 25% increments. Coarse ore fraction, sintering temperature, holding time and oxygen partial pressure were selected as sintering parameters, and two-level factorial design was used for identification of parameters that significantly influence the formation of sinter phases. Experimental results showed that the coarse ore fraction has a higher effect on the sintering process compared to those of other parameters. The experiment design also enabled to set these parameters to their optimum values. The porosity of compacted pellets was measured using a helium pycnometer. The replacement of fine ore by coarse ore resulted in a decrease in porosity (increase in packing density) of compacted pellets. The particles are closer to each other in pellets consisting of more coarse particles than fine particles. Laboratory experiments were performed at 1300°C in air, using a high heating rate (15°C/s). The holding time was set to 2.5 minutes. X-ray diffraction (XRD), reflected light microscopy (RLM), scanning electron microscopy (SEM) and energy dispersive spectrometry (EDS) were used to characterize sintering reactions and sinter phases. XRD analysis revealed that sintered pellets consisted of hematite, SFCA, SFCA-I and calcium silicate. The proportions of SFCA slightly increased when the fraction of coarse ore varied from 0% to 25%, but decreased with a further increase in percentage coarse ore. At 25% coarse ore fraction, the porosity of the compacted pellets decreased, resulting in an increase in packing density and sintering rate. More hematite reacted, resulting in the formation of high amounts of SFCA. Above 25% coarse ore fraction, the amount of hematite increased, and the concentrations of columnar SFCA decreased despite a further decrease in porosity. This was attributed to the decrease in reaction surface area for coarse ore, and the short reaction time, which limited the extent of reaction of the coarse particles. The variation of SFCA-I and calcium silicate was not significant under laboratory conditions. Reflected light microscopy and SEM analysis easily identified two major sinter phases: hematite and SFCA. A clear distinction between the different types of SFCA could not be made using EDS analysis. Sinter pot tests were carried out in order to examine the effect of coarse ore fraction on physical and metallurgical properties of sinters. The tumbler and reduction disintegration indexes increased with increasing coarse ore fraction in the sinter bed. This was presumably due to the increase in amounts of hematite and decrease in surface area for reaction. Consequently, the reducibility of sinter decreased as the percentage coarse ore increased. This study has concluded that the presence of 25% coarse ore in the sinter mix led to enhance sintering reactions. The amounts of SFCA increased, and sinter quality was improved. It is recommended that in future work, sintering reactions should further be investigated by also measuring the permeability of the sinter bed and the reaction surface area of solid particles. Copyright
Dissertation (MSc)--University of Pretoria, 2012.
Materials Science and Metallurgical Engineering
unrestricted