Treatise on Process Metallurgy

✍ Scribed by Seshadri Seetharaman, Alexander Mclean, Roderick Guthrie, Seetharaman Sridhar

• Publisher: Elsevier Inc.
• Year: 2014
• Tongue: English
• Leaves: 864
• Category: Library

✦ Table of Contents

Cover Page
Front Matter
Copyright
Dedication
Preface
Editor in Chief
Contributors to Volume 2
Acknowledgement
The Review Committee
Interfacial Phenomena in High Temperature Metallurgy
Surfaces and Interfaces
Definition of Surfaces and Interfaces
Gibbs Adsorption Isotherm
Langmuirs Isotherm
References
Surface Tension and Contact Angle
Surface Tension
Definition of Surface Tension
Temperature Dependence of Surface Tension
Contact Angle
Young's Equation
Smith's Equation
Effect of Surface Roughness
Wetting
References
Experiments
Sessile Drop
Maximum Bubble Pressure
Pendent Drop
Drop Weight
Detachment Method
Liquid Surface Contour Method
Capillary Rise Method
Levitating Drop
Software for Evaluation of Surface Tension from Sessile Drop
References
Surface Tension Models
Modeling of Surface Tension of Liquid Pure Metals and Molten Salts
Modeling of Surface Tension of Liquid Alloys
Modeling of Surface Tension of Molten Ionic Materials Including Molten Slag
Some Issues on the Evaluation of Molten Ionic Mixtures
Evaluation of Surface Tension of Molten Ionic Mixtures
Evaluation of Surface Tension of Molten SiO2 based Binary and Ternary Slag
Evaluation of Interfacial Tension Between Liquid Steel and Molten Slag
Application of Constrained Gibbs Energy Minimization Approach to Evaluate Surface Tension of Liquid Alloys
Basic Thermodynamic for Constrained Gibbs Energy Minimization Approach
Use of Gibbs Energy Minimizer for Surface Equilibria Calculations
Some Results
References
Interfacial Free Energy and Wettability
Wettability
Interfacial Free Energy Between Solid and Liquid Phases in Metals and Alloys
Interfacial Tension Between Liquid Steel and Molten Slag
References
Some Aspects of Electrochemistry of Interfaces
Basics of Electrochemistry of Interfaces
Electrochemical Equilibria
Electrochemical Double Layer
Electrocapillary Phenomena
Electrocapillary Equation
Adsorption and Electrocapillary Curves
Electrocapillarity at the Slag/Metal Interface
Some Practical Aspects of Electrocapillary Phenomena
Wettability and Wear of Refractory Materials
Clogging in Casting Processes
Emulsification of Metal and Slag
Separation Technology
References
Interfacial Convection and Its Effect on Material Processing
Some Basics of the Interfacial Convection
Effect of Interfacial Flow in Liquid?Liquid Reactions
Effect of Interfacial Flow in Liquid?Gas Reactions
Effect of Interfacial Flow in Liquid?Solid Reactions
Effect of Interfacial Flow in Solidification Processes and Crystal Growth
References
Stability of Interface Between Liquid Steel and Molten Slag
References
Applications of Interfacial Phenomena in Process Metallurgy
Marangoni Flow During the Welding Process
Engulfing of Small Droplets of Molten Slag into Liquid Steel
Erosion or Dissolution of Refractories
Separation of Metallic Droplets from Slags
Engulfing Nonmetallic Inclusions and Gas Bubbles into Solidified Interface
Gas Bubble Formation in Liquid Steel
Nucleation During Solidification
Slag Foaming
References
Metallurgical Process Phenomena
The Importance of Metallurgical Process Phenomena
Kinetics of Gas?Liquid and Liquid?Liquid Reactions
Introduction
Rate-Controlling Process
The Difference Between Thermodynamics and Kinetics
Gas-Phase Mass Transfer
Flux Equations
Properties of Gases and Mass Transfer Coefficient Relationships
Mass Transfer Correlation Relationships
Characteristics of GPMT-Controlled Reactions
Examples of GPMT
Coupled Mass Transfer
Reactions with Bulk Flow
Free Vaporization
Liquid-Phase Mass Transfer
Flux Equations and Correlations
An Example of LPMT Control
Two-Phase LPMT
Heat Transfer Control
Chemical Kinetics
Absorption of Surfaces
Rate Equations and Activated Complexes
Relationship Between Forward and Reverse Reaction
Examples of Gas?Metal Reactions
N2 Reaction with Liquid Iron
The CO2 Reaction on Iron?Carbon Alloys
The CO2 Reaction with Liquid Fe?C
The H2O Reaction with Liquid Iron?Carbon Alloys
The CO, H2, C2H6, and CH4 Reaction with Liquid Iron
Parallel Reaction and Mixed Control
Mixed Control
Chemical Kinetics?GPMT
Chemical Kinetics?LPMT
Gaseous Intermediates
Concluding Remarks
References
Bubbles in Process Metallurgy
Introduction
Bubble Formation
Quasi-Stationary Bubbling
Effect of Drag on Bubble Detachment Size
Bubble Breakup
Effect of Flow Conditions on Bubble Breakup and Coalescence
Bubble Shapes
Plume Shape
Mixing Time
Bubble Rupture
Bubbling?Jetting Transition
Effects of Temperature and Entrained Liquid on the Sonic Velocity
Jet Breakup
Modeling
References
Foams and Foaming
Foaming in Metallurgical Processes
Study of Slag Foaming
Foam Stability
Foam Drainage
Physical Model of Slag Foaming
Foaming Index
Theory
Experimental Measurements
Dimensional Analysis and Empirical Equations
Mass-Limited Foaming
Slag Foaming in Industrial Processes
Electric Arc Furnace
Bath Smelting Furnace
Basic Oxygen Furnace
Suppression of Foaming
References
Applications
Rate Phenomena in Direct Ironmaking
Ladle Desulfurization Kinetics
Principles and Equilibrium Relationships
Kinetic Effects
Desulfurization Mass Transfer Constant
Rate Phenomena in Vacuum Degassing
Rate Phenomena in AOD Stainless Steel Production
Inclusion Flotation in Argon-Stirred Steel
References
Some Applications of Fundamental Principles to Metallurgical Operations
Introductory Comments: Some Perspectives on the Process of Innovation
References
Some Metallurgical Considerations Pertaining to the Development of Steel Quality
Introduction
Generation of Steel Quality
Oxygen Control in Molten Steel
The Characterization of Refining Slags
Slag Chemistry and the Control of Sulfur
Water Vapor Dissolution in Molten Slags
Preservation of Steel Quality
Furnace to Ladle Transfer
Ladle to Tundish Transfer
Tundish to Mold Transfer
Evaluation of Steel Quality
Ferrous Oxide in Molten Slag
Activity Determinator for Ferrous Oxide
Application of Activity Determinator for Desulfurization Control
Application of Activity Determinator for Cleanliness Control
Application of Activity Determinator for Manganese Control
Continuous Monitoring of Metallurgical Processes
Online Sensors for Evaluation of Liquid Metal Cleanliness
Continuous Nonintrusive Monitoring of Steelmaking Operations
Summary
References
Refractory Corrosion During Steelmaking Operations
Introduction
Theoretical Considerations
Penetration of Melt into Refractories
Dissolution of Refractories into Melt
Corrosion Testing of Refractories [1]
Static Corrosion Tests
Dynamic Tests
Corrosion of Oxide-Carbon Refractories
Corrosion Mechanism of MgO?C
Local Corrosion of Refractories
Summary
References
Application of Slag Engineering Fundamentals to Continuous Steelmaking
Introduction
Continuous Steelmaking: An Overview
Review of Previously Proposed Technologies
Fundamental Challenges for Continuous Refining of Steel
Continuous Steelmaking Based on the Use of DRI
Direct Reduced Iron
Use of DRI in Steelmaking
DRI-Based Continuous Steelmaking
Process Characteristics
Process Requirements
Fundamental Considerations
Melting and Decarburization of DRI
Behavior of DRI in Slag
Reaction Mechanism and Kinetics
Stage I?Incubation Period
Stage II: Rapid Gas Evolution Period?Decarburization Within DRI Pellet
Stage III: Lull Period?Interface Replenishment
Stage IV: Continued Decarburization by Slag
Slag Oxidizing Power
Slag Foaming
Refractory Degradation
EAF Refractories and Their Degradation Mechanisms
Refractory Corrosion
Effect of Slag FeO on Refractory Degradation
Slag Design Steps
Thermodynamic Evaluation
Bench-Scale Experiments
Pilot Trials
Phase I
Phase II
Trials
State of Reactions Between Slag and Metal
Slag Foaming and Steel Nitrogen Content
Refractory Stability
Process Analysis
References
Kinetics of Assimilation of Additions in Liquid Metals
Introduction
Fundamentals of Assimilation
Routes of Assimilation
Route One
Route Two
Route Three
Route Four
Route Five
Route Six
Exothermic Phenomena During Assimilation
Microexothermic Phenomena
Macroexothermic Phenomena
Transport Phenomena During Exothermic Assimilation
Mathematical Formulation and Computational Approach
Initial Conditions
Boundary Conditions
Acceleration of Assimilation During Macroexothermic Phenomena
Dimensionless Heat Transfer Equations for Macroexothermic Phenomena
Recovery
Liquid Light Metals
Liquid Steel
Conclusions
References
Metallurgical Process Technology
Process Kinetics, Fluid Flow, and Heat and Mass Transfer, in Process Metallurgy
Theory of Fluid Flows
The Continuity and Momentum Equations
Newtonian Liquids
Electromagnetically Driven Flows
Physical Modeling
Physical and Computational Models
Computational Fluid Dynamics
References
Turbulence Modeling and Implementation
Introduction
Turbulence Models
Conclusions
References
Computational Fluid Mechanics
Introduction
Applications of CFD in Process Metallurgy
Blast Furnace
Direct Reduction
Direct Reduced Iron
The Basic Oxygen Furnace
Ladles
Tundish
Conclusions
References
Solidification
Application of Textured Copper Substrates for Enhancing Heat Fluxes
Solidification in Conventional Fixed-Mold Machines
Steel Shell Formation
References
Computational and Physical Modeling of Solidification in CCC and TSC
Proposed New Mechanism for the Formation of OMs
Conclusions
References
Single Phase, Two Phase, and Multiphase Flows, and Methods to Model these Flows
Introduction
Multiphase Flow Regimes
Gas?Liquid or Liquid?Liquid Flows
Gas?Solid Flows
Liquid?Solid Flows
Three-Phase Flows
Examples of Multiphase Flows in Process Metallurgical Operations
Choice of a Proper Multiphase Model
Euler?Euler Approach [1]
The VOF Method
Interpolation Near the Interface
The Mixture Model
The Eulerian Model
Euler?Lagrangian Approach [1]
Example: Modeling of Inert Gas Shrouding in a Tundish Three-Phase Flow Involving Gas Bubbles, Liquid Steel, and Slag
Modeling Procedures
Bubble Trajectories in the Tundish
Fluid Flow Patterns in the Tundish
Modeling of the Exposed Eye´´ Using the Multiphase VOF Model References The Design of a New Casting Process: From Fundamentals to Practice Continuous Casting Machines for the Steel Industry Conventional Continuous Casting Machines Thin Slab Casting, TSC Strip Casting, or Near Net-Shape Casting Fluid Flows, Solidification, and Heat Transfer in Moving Mold Machines Theoretical Heat Fluxes, Based on Perfect and Imperfect, Thermal Contact Solidification and Strip Microstructures in NNSC Horizontal Single-Belt Casting Processes Fluid Flows: Design of Metal Delivery Systems The Potential of the HSBC Caster: From Fundamentals to Practice Conclusions References Conclusion Computational Thermodynamics, Models, Software and Applications Thermodynamics Calphad Method Dilute Metallic Solution Liquid Fe Wagner Interaction Parameter Formalism Unified Interaction Parameter Formalism Modified Regular Solution Model Associate Model for Deoxidation Dilute Metallic Solution: Nonferrous Metals Model for Oxide Solid Solutions The Reciprocal Ionic Liquid Model Quasichemical Models The Cell Model Structure of the Slag Partition Function Degeneracy of the System Calculation of the Permutations Number Calculation of the Maximum Cells Permutation Number Degeneracy Calculation Energy of the System Formation Energy Interaction Energy Gibbs Energy Calculation of the Cell Mole Numbers Chemical Potentials CSIRO's Modification The Central Atoms Model and Generalized Central Atom Model Description of the Structure Parameters of the Model Formation Energy Parameters Interaction Energy Parameters Gibbs Free Energy and Chemical Potential Multicomponent Steels Sulfur-Bearing Systems Nitrogen-Bearing Systems Oxygen-Bearing System Multicomponent Slags The Modified Quasichemical Model Modified Quasichemical Model for Matte Thermodynamic Packages and Databases FactSage www.factsage.com Databases for Slags/Oxides for Pyrometallurgical Applications FToxid FTmisc Other Databases Databases for Other Applications MPE www.csiro.au Databases for Slags/Oxides for Pyrometallurgical Applications MTDATA www.npl.co.uk Databases for Slags/Oxides for Pyrometallurgical Applications NPLOX MTFEDLSL Databases for Other Applications Thermo-Calc www.thermocalc.com Databases for Slags/Oxides for Pyrometallurgical Applications SLAG3 TCOX Databases for Other Applications References Slag Viscosity Model FactSage Structural Viscosity Model for Multicomponent Slag Viscosity Model Basic Formula of the Viscosity Model Modification of the Model for Melts Containing Alkali Oxides Charge Compensation Effect for Alumino-Silicate System Addition of Fluoride in Oxide Slag Viscosity of Slags Nomenclature Explicit Models Model due to Urbain et al. [17,19,20] Model due to Mudersbach et al. [22] Model due to Tan and Vix [23] Model due to Riboud et al. [24,51] Model due to Koyama et al. [25] Model due to Kim et al. [26] Model due to Iida et al. [27-29] Model due to Reddy and Hebbar [30] KTH model [31,55,56] Modified Urbain Model by Jak and Kondratiev [32-35] Structural Models Model due to Nakamoto et al. [45] Model due to Zhang et al. [44,58,59] Model due to Jak et al. [36-43] Other Models Model due to Hanao et al. [48] Model due to Mills et al. [46] Model due to Pal et al. [47] Appendices Urbain's Model for Steelmaking Slags [17,20,21] Riboud's Model [24] Iida's Model [27-29] Koyama et al.s Model [25] Kim et al.'s Model [26] NPLs Model [46] Pal et al.'s Model [47] Tan and Vix's Model [23] Jak and Kondratiev Model [32] Nakamoto et al.'s model [45] Reddy and Hebbar's Model [30] Jak et al.s Model [42] References Applications 5.3.1.Applications to Steelmaking Processes 5.3.1.1.Overview of Steelmaking Processes and Chemistry 5.3.1.1.2.Overview of Chemistry 5.3.1.1.3.Chemical Reactions 5.3.1.2.Liquid Steel Desulfurization 5.3.1.2.1.Partitioning of Sulfur Between Slag and Metal Melts 5.3.1.2.1.1.Sulfide Capacity 5.3.1.2.1.2.Modeling 5.3.1.2.1.3.Desulfurization During Secondary Metallurgy Operations 5.3.1.2.2.Future Work 5.3.1.3.Ca Treatment 5.3.1.3.1.TheTheory´´
5.3.1.3.2.The Practice
5.3.1.4.Mold Flux Design
5.3.1.4.1.Solidification Behavior of Commercial Mold Flux
5.3.1.4.2.Mold Flux Design Using the Phase Diagrams
5.3.1.5.Slag Crystallization
5.3.1.5.1.Slag Liquidus Temperatures and Solid Proportions
5.3.1.5.2.Effect of Oxide Additions on Slag Liquidus Temperatures
5.3.1.5.3.Mineralogy of As-Solidified Slags
5.3.1.5.4.Heat Evolution During Solidification
5.3.1.6.Chemical Interaction of Refractory with Molten Slag, Steel, and Inclusion
5.3.1.6.1.Thermal Stability of Refractories
5.3.1.6.2.Slag/Refractories Reactions
5.3.1.6.2.1.Interaction with Various Slags
5.3.1.6.2.2.Interaction with Ladle Glaze
5.3.1.6.2.3.Interaction with RH Vacuum Degasser Slag
5.3.1.6.2.4.Interaction with Mold Flux
5.3.1.6.3.Metal/Refractory Interactions
5.3.1.6.3.1.Tundish Refractory
5.3.1.6.3.2.Effect of Antioxidant Additions to MgO-C on the Steel Cleanliness
5.3.1.6.3.3.Reaction of Refractories and High Mn Steels
5.3.1.6.4.Corrosion of Nozzle Refractories by Liquid Inclusion in High Oxygen Steels
5.3.1.6.4.1.Liquid Inclusion in High Oxygen Steel
5.3.1.6.4.2.Chemical Reaction Between Liquid Inclusion and Refractories
5.3.1.6.4.2.1.MgAl2O4-C Refractory
5.3.1.6.4.2.2.ZrO2-C Refractory
5.3.1.6.4.3.Corrosion Mechanism of Refractories by Liquid MnO-SiO2-FeO Inclusion
5.3.1.6.4.4.In Plant Tests
5.3.1.7.Inclusion Engineering
5.3.1.7.1.Mn/Si Deoxidation
5.3.1.7.2.Formation of Oxisulfide Inclusions
5.3.1.7.3.Inclusion Diagram of Al/Ti Deoxidation
5.3.1.7.4.Acicular Ferrite Formation
5.3.2.Application of Advanced Modeling in Nonferrous Metallurgy
5.3.2.1.Introduction
5.3.2.2.Generic Overview of Nonferrous Smelting Chemistry
5.3.2.2.1.Value Metals, Minerals, and Other Input Chemistry
5.3.2.2.2.Brief Generic Description of Some Nonferrous Pyrometallurgical Smelting Process and Common Process Stages
5.3.2.2.2.1.Oxidation+Reduction Routes
5.3.2.2.2.2.Smelting/Converting Route
5.3.2.2.2.2.1.Common Features of Base-Metal Sulfide Systems
5.3.2.2.3.Major Phases and Output Stream Chemistries
5.3.2.2.3.1.Value Stream Chemistries
5.3.2.2.3.2.Slag Chemistry
5.3.2.2.3.3.Common Solid Chemistry
5.3.2.2.3.4.Common Gas Chemistry
5.3.2.2.3.5.Dust Chemistry
5.3.2.2.4.Summary-Main Issues Assisted with Advanced Modeling in Nonferrous Pyrometallurgy
5.3.2.2.5.Selection of Multicomponent Sections
5.3.2.2.6.Suggestions on the Use of Advanced Thermodynamic Software Tools
5.3.2.3.Examples of Applications/Case Studies
5.3.2.3.1.Analysis of Slag Chemistry for Lead and Zinc Industrial Slags-Liquidus and Subliquidus ``Fluxing´´ Diagrams fo ...
Acknowledgments
References
Process Modeling
Production of Metallurgical Grade Silicon in an Electric Arc Furnace
Summary
Introduction
The Stoichiometric Reaction Approach
The Complex Equilibrium Approach
The Counter-Current Reactor Approach
Modeling TiO2 Production by Explicit Use of Reaction Kinetics
Introduction
Anatase?Rutile Transformation: A Simple Example of the Constrained Gibbs Energy Method
Model for the TiCl4-Burner: Comparison with the Image Component Technique
Non-equilibrium Modeling for the LD-Converter
Introduction
Process Model Development
Modeling Tool
Simulation Results
Conclusions
Simulation of the RH?OB and BOF Processes Using the Effective Equilibrium Reaction Zone Model
Concept of the Effective Equilibrium Reaction Zone Model
Calculation Procedure
Simulation of the RH?OB Process
Determination of the Reaction Zones
Model Validation
Simulation of the BOF Process
Determination of the Reaction Zones
Model Validation
Rotary Cement Kiln Model
Description of the Model
Results of the Rotary Kiln Model
Kinetic Simulation of Ladle Refining and Smelting Using Software
METSIM
Simulation of Ladle Refining at Two Ladle Metallurgy Furnaces
Description of the Kinetic Model
Simulation Results
Simulation of the Ferromanganese Smelting Process
Development of the Multistage Reactor Model for Ferromanganese Smelting
Results of the Kinetic Simulation
References
Index
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z