Treatise on Process Metallurgy

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

• Publisher: Elsevier Inc.
• Year: 2014
• Tongue: English
• Leaves: 957
• Category: Library

✦ Table of Contents

Cover Page
Title Page
Copyright
Dedication
Preface
Editor in Chief
Contributors to volume 1
Acknowledgement
The Review Committee
Process Metallurgy?An Argosy Through Time
Introduction
Alchemy and the Discovery of Metals
Development of Extraction Processes
References
Introduction to Metallurgical Processing
Recent Development Trends
Drivers for Change
Process Trends
Process Options
Process Stages and Aims
Alternative Process Routes
Alternative Process Routes for Selected Metals
Classification of Metallurgical Reactors
Gas/Solid Reactors
Shaft Furnaces
Rotary Kiln
Fluidized Beds
Entrained Flow Reactors
Moving and Fixed Grate Reactors
Liquid/Solid Reactors
In Situ Leaching
Heap Leaching
Percolation Leaching
Agitation Leaching
Crystallizers/Precipitation Reactors
Electrochemical Production Reactors
Ion Exchange Reactors
Liquid-Phase Reactors
Gas/Liquid Reactors
Bath Smelting Processes
Bath Refining Processes
Liquid/Liquid Reactions
Multistep Reactors
Blast Furnaces and Other Counter Current Reactors
Reverberatory Furnaces
Flash Smelting Processes
Multistage Smelting Processes
Solvent Extraction
Summary of General Characteristics of Metallurgical Reactors
Pyrometallurgy
Hydro- and Electrometallurgical Reactors
Reactor and Process Design Methodologies
Summary
Reference
Structure and Properties of Matter
State and Equilibrium
State of Matter
Solid
Liquid
Gas
Glass=Amorphous Solid
Plasma
Phase Transition
Glass Transition
Description of Structural Features of Liquid
Structural Features of Metallic and Oxide Melts
References
Structure and Properties of Molten Metals
Structure
Introduction
Levitation Methods
X-ray and Neutron Diffraction?Basics
Results
Pure Elements
Alloys
Properties
Experimental Techniques
Pyrometry
Thermal Expansion and Density
Maximum Bubble Pressure
Dilatometers
Capillary Dilatometers
Push-rod Technique
Levitated Drop
Thermal Properties
Differential Scanning Calorimetry
Drop Calorimetry
Modulation Calorimetry
Thermal Conductivity and Thermal Diffusivity
Electrical Conductivity
Mass diffusion
Surface Tension
Maximum Bubble Pressure
Sessile Drop
Oscillating Drop
Viscosity
Capillary Viscometer
Rotating Cup Viscometer
Oscillating Cup Viscometer
Oscillating Drop
Results
Pure Metals
Emissivity
Density and Thermal Expansion
Specific Heat
Thermal Conductivity
Electrical Resistivity
Self-diffusion
Viscosity
Surface Tension
Alloys
Structure-Property Relations and Interproperty Relations
Structure-Property Relations
Interproperty Relations
Summary
References
The Structure and Properties of Silicate Slags
Introduction
Structure of Slags and Glasses
Structure of Silicates
Structure of Aluminosilicates
The Effect of Fe2O3 and Cr2O3 on Silicate Structure
Effect of TiO2 and ZrO2 on Silicate Structure
Effect of CaF2 and B2O3 on Silicate Structure
Parameters to Represent the Structure of Slags
Basicity
NBO/T and Q
Optical Basicity 㼀
Concentrations of O0, O-, and O2-
Qn Values
Viscosity
Effect of Cations on Structure
Structural Characteristics
Nature of Structural Units
Coordination Number of Cations Ncoord
Topology, Bond Angles, Bond Energies
Configurational Entropy
Structural Information
Silicates
Aluminosilicates
Titano-Silicates
Silicates Containing Iron Oxides
Additions of CaF2
Methods of Determining Structure
X-ray, Electron, and Neutron Diffraction
Infrared, Ultraviolet, and Raman Spectroscopy
NMR Spectroscopy
Electron Spin Resonance
Mossbauer Spectroscopy
X-ray Absorption Spectroscopy XANES and EXAFS
X-ray Emission Spectroscopy
X-ray Photon Spectroscopy or ESCA
Effect of Structure on Properties
Effect of Silicate Structure on Properties of Slags
Silicates
Aluminosilicates
Effect of Cations on Slag Properties
Strength of the Ionic M+-O- Bond
Fraction of Ionic Bonding in the MO Bond
Size of the Cations
The Bridging of Cations
The Number of Cations
Mixed Alkali Effect
Effect of Temperature on Properties
Solid Slags
Liquid Slags
Properties of Slags Based on Silicate Network
Thermodynamic Properties
Liquidus Temperature Tliq
The Importance of Tliq in Industrial Processes
Factors Affecting Tliq
Measurement Methods
Tliq Data for Slags
Calculation of Tliq
Activity Coefficients and other Thermodynamic Properties
Why Thermodynamic Property Data are Needed
Factors Affecting Activities and Other Thermodynamic Functions
Heat Capacity Cp HT-H298, Entropy, Entropy of Fusion DeltaSfus
Factors Affecting Cp and Enthalpy
Measurement Methods
Acknowledgments
References
Introduction
Atomistic Computer Simulation Techniques
MC Method
Basic Approach
Statistical Ensembles
Micro-Canonical Ensemble for Isolated Systems
Canonical Ensemble for Closed Systems
Grand Canonical Ensemble for Open Systems
Isobaric Isothermic Ensemble
Sampling Procedures
Trial Moves and Boundary Conditions
Random Numbers and Accuracy Considerations
MD Method
Basic Approach
Ensembles
Constant Temperature Ensemble
Constant Pressure Ensemble
Accuracy Considerations
Ab initio Density Functional Theory
Basic Approach
Applications to Materials Science
Current Limitations and Future Directions
Special Techniques and Advanced Algorithms
Kinetic Monte Carlo Method
Reverse Monte Carlo Method
Hybrid MC Methods
The Gibbs Ensemble Method
Biased MC Schemes
Wang?Landau Formalism
Parallel Tempering Method
Determination of Physical Properties
Free Energy
Surface Tension
Wettability
Phase Diagrams and Critical Phenomena
Diffusion
Atomistic Interaction Potentials
Fundamentals
Beyond Pair Potentials
Development of Interatomic Potentials/Parameters
Interaction Potentials for Iron
Finnis?Sinclair Potential
Embedded-Atom Method
Analytic Bond-Order Potential
Models for Simulations on Liquid iron in the Earth's Outer Core: Sutton?Chen Potentials
Interaction Potentials for Other Metals
Finnis?Sinclair Potentials for Transition Metals
Modified Embedded-Atom Method Potentials for Cubic Materials and Impurities
EAM Potentials for Liquid Transition Metals
Sutton?Chen Potentials
Interatomic Potentials from First-Principles Calculations
Interaction Potentials for Covalently Bonded Group IV Elements
Silicon
Stillinger and Weber Potential
Tersoff Potential
Other Potentials
Carbon
Tersoff Potential
Brenner Potential
Nonbonded Macro-Molecular Potentials
Interaction Potentials/Parameters for Binary and Ternary Systems
Fe?C System
Interaction Potentials
References
Thermodynamic Aspects of Process Metallurgy: Introduction to Thermodynamics of Metallurgical
Processes
First, Second, and Third Laws of Thermochemistry
Thermodynamic Data Compilations
Ideal Gas
The First Law of Thermodynamics
Enthalpy and Heat Capacity
Enthalpy
Heat Capacity
Temperature Dependence of Heat Capacity
Temperature Dependence of Enthalpy
The Second and Third Laws of Thermodynamics and Entropy
Gibbs Energy
Combined Statement of the First and Second Laws of Thermodynamics
Changes in Gibbs Energy, Enthalpy, and Entropy Due to Reaction
Gibbs Energy Function
Appendix
References
Phase Rule
Intensive and Extensive Properties
Degree of Freedom
Phase
System
Condensed Phase-Vapor Equilibrium
Arbitrary Choice of System
Clapeyron Equation?Liquid Vapor Equilibrium
Temperature Dependence of Vapor Pressure
Solid?Liquid Equilibrium
Triple Point
Arbitrary Choice of System?Ionic Species
Critical Temperature and Pressure
Freedom Degree and Thermochemical Data?1
Freedom Degree and Thermochemical Data?2
Single-Phase Composition and Bulk Composition
Composition of Industrial Slag
References
Ellingham Diagram
Standard Gibbs Energy Change of Formation of Compounds
Equilibrium Oxygen Partial Pressure
Equilibrium CO/CO2 Ratio and the Boudouard Reaction
Influence of Activity of Condensed Phases on Gibbs Energy Change
References
Solution Thermochemistry
Partial Molar Quantities
Integral Molar Quantities
Relationship Between Partial Molar Quantities and Integral Molar Quantities
Relative Partial Molar Quantities and Integral Molar Quantities
Raoults Law and Ideal Solutions
Excess Thermodynamic Quantities
Integration of the Gibbs-Duhem Equation
Regular Solutions
Darkens Quadratic Formalism
References
Thermodynamic Basis for Phase Diagrams
Gibbs Energy of Binary Solutions
Binary Isomorphous System
Binary Eutectic System
Binary Monotectic and Peritectic Systems
Binary System Including an Intermediate Compound
Consistency of Phase Diagram and Thermochemical Data of the Binary System CaO?SiO2
Ternary Phase Diagram
References
Dilute Solutions
Henry's Law and Sieverts Law
Henrian Activities and the Conversion of Standard States
Description of Activities of Minor Solute Elements in Metallic Solution Wagner's Equation
Examples for the Calculation of Henrian Activities
Data Compilations for Dilute Liquid Alloys
The Thermodynamics of Liquid Iron Alloys
The Thermodynamics of Liquid Copper Alloys
The Thermodynamics of Liquid Cobalt Alloys
The Thermodynamics of Liquid Nickel Alloys
References
Thermodynamics of Slags
Phase Diagrams and Activities
Basicity and Refining Ability of Slags
Basicity of the Slags
Optical Basicity
Theoretical Optical Basicity
Capacity and Dissolution
Sulfide, Phosphate, and Carbonate Capacities [16]
Phosphide and Nitride Capacities
Other Capacities
Structure and Thermochemical Models for Slags
Temkin's and Flood et al.s Description of Ionic Melts [38]
Richardson's Theory of Ideal Mixing of Silicates [38]
Lumsden's Description of Silicates [38,43]
Slag Models [38]
Oxidation?Reduction Equilibrium in Slags
References
Examples of Steelmaking Thermochemistry
Fundamental Considerations Pertaining to Removal of Impurities from Molten Steel
Effect of Solute Elements on Silicon Deoxidation of Ferrous Alloys
Thermodynamics of Calcium Treatment of Al-Killed Steel
Equilibrium Between Solid Oxides and Highly Alloyed Steels
Thermodynamics of Calcium Treatment of Molten Iron
Chemical Potential Control by Gas Equilibria
CO+CO2+SO2+Ar Gas Mixture
H2+CO2 Gas Mixture
References
Thermodynamics of Aqueous Phases
Chemical Potentials and Electrochemical Potentials
Activity and Activity Coefficients
Mean Activity Coefficients
The Debye?Hückel Law [2]
Chemical Equilibrium and Gibbs Energy of Formation of Ions
Chemical Equilibrium in Aqueous Solutions
Acid?Base Reaction
Redox Reactions
Potential?pH Diagrams Pourbaix Diagrams [6]
References
Thermodynamic Basis of Electrolysis and Electrochemistry
Zinc Electrowinning
Copper Electrowinning
Copper Electrorefining
Electrochemistry in Leaching
Oxidation
Acidification
Reduction
References
Rate Phenomena in Process Metallurgy
Introduction
Importance of Transport Phenomena in Metallurgical Processing
Basic Methodologies in Transport Phenomena
Momentum Transfer
Flow Description
Steady and Unsteady Flows
Uniform and Nonuniform Flows
Streak Lines, Particle Paths, and Stream Lines
Eulerian and Lagrangian Points of View
Laminar and Turbulent Flows
Incompressible and Compressible Flows
Overall Energy Balance
The Concept of Viscosity
Steady-State Fully Developed Laminar Flow Through a Straight Pipe
Buckingham Pi Theorem and Its Application to Transport Phenomena
Reynolds Number
Friction Factor for Flow Through Pipes
Friction Losses from Pipe Fittings
Estimation of Friction Factor for Flow Through Conduits Having Noncircular Cross Section
Flow Through Packed Beds
Fluidized Beds
Minimum Fluidization Velocity, vmf
Voidage in Particulate Fluidized Bed
Voidage in Bubbling Fluidized Bed [21]
Flow Around Particles
Compressible Flow
Compressible Flow Through a Pipe of Constant Cross Section
Compressible Flow Through Convergent-Divergent de Laval Nozzle
Momentum Balance at Differential Scale
Equation of Continuity
Navier-Stokes Equation
Models of Turbulence
Generic Flow Features in Turbulent Flows
RANS Models
Mixing-Length Theory
κ- Model [29]
LES Models
Introduction to Heat Transfer
Conservation Equation as Applied to Thermal Systems
Conduction
Conduction Equation
Boundary Conditions
Prescribed Surface Temperature
Prescribed Heat Flux
Convective Boundary Condition
A Boundary Between Two Conducting Media
1D Steady-State Conduction
Conduction Through a Plane Wall
Conduction Through Radial Systems
Heat Transfer Through Extended Surfaces
1D Transient Conduction
Thermally Thin Bodies
Thermally Thick Bodies
Conduction in 1D
Slab
Long Cylinder and Sphere
Semi-infinite System
Convection
Boundary Layer Theory
Forced Convection: Heat Transfer Coefficient Correlations
External Flow
Flow over a Flat Plate
Flow Across Cylinder
References
Reaction Kinetics
Reaction Kinetics and Reaction Systems
Homogeneous Reactions
Heterogeneous Reactions
Reaction Rates and Rate-Limiting Processes
Case a: Mass Transfer in Phase I is Rate Limiting
Case b: Mass Transfer in Phase II is Rate Limiting
Case c: Mass Transfer in Both Phases I and II are Rate Limiting
Case d: Chemical Reaction at the Interface is Rate Limiting
Case e: Overall Rate Equation
Structure of the Chapter
References
Chemical Reaction Kinetics
Chemical Kinetics
Empirical Rate Equations
Reaction Rate Theory
Reactions at Interfaces
Electrochemical Reactions
Rate Equations
Electrochemical Cells
Half-Cell Reactions
Coupled Reactions
Reversible Processes
References
Chemical Reactions at Moving Surfaces: Shape Change, No Phase Change
Reaction Rates on Fluid/Condensed Phases Interfaces
Reactions with the Gas Phase
Thermodynamic Driving Force for the Reaction
Removal of Species from Solid Surfaces
Chemical Reactions on Moving Solid Surfaces
Chemical Reaction Rates on Moving Surfaces
The Influence of Atomic Roughness on Chemical Reactions Rates
Reactions with Accumulation at the Interface
Conditions for Instability Formation at Moving Interfaces
Oxide Surface Morphologies in Reactive Gas Atmospheres
Summary
References
Phase Formation Reactions
Classes of Phase Formation Reactions
Elementary Reaction Processes
Continuum Phase Formation Reactions Spinoidal
Heterogeneous Phase Formation Reactions Nucleation and Growth
Nucleation
Mechanisms of Growth
Introduction
Rates of Reconstructive Transformations
Growth of New Phases
Summary
References
Chemical Kinetics+Phase Changes+Shape Changes
Introduction
Chemical Reactions on Metal Surfaces
Metal Growth Morphologies
Dendritic Pore Formation
Metal Whisker Growth
Continuous and Discontinuous Metal Layer Growth
Coupled Growth
Analogies with Solid/Liquid and Solid/Solid Systems
Morphology Maps
Summary
References
Factors Influencing Reaction Area
Introduction
Reactant Characteristics
Fluid/Fluid Systems
Composition
Bulk Flow
Fluid/Solid Systems
Particle Characteristics
Reaction Induced Phenomena
Fluid/Fluid Systems
Emulsification
Gas Phase Formation
Fluid/Solid Systems
Product Structure
Reaction Micromodels for Nonplanar Interfaces
Reaction Time/Extent
Fluid/Fluid Systems
Fluid/Solid Systems
Summary
References
Reaction System Performance
Driving Forces for Reaction
Reaction Engineering and Process Models
Batch/Semibatch Discontinuous Reactors
Continuous Flow Reactors
Complex Reactor Models
Summary
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
Z