Search Results (657)

Under the background of “dual-carbon” strategy and global energy transition, the metallurgical industry, which accounts for 15–20% of industrial energy consumption, urgently needs to reduce the energy consumption and emission of DC power supply of electric furnaces. Aiming at the existing 400–800 V/≥3000 A industrial-frequency transformer-rectifier system with low efficiency, large volume, heat dissipation difficulties and other bottlenecks, this thesis proposes and realizes a high-frequency integrated DC power supply scheme for high-power electric furnaces: high-frequency transformer core and rectifier circuit are deeply integrated, which breaks through and reduces the volume of the system by more than 40%, and significantly reduces the iron consumption; multiple cores and three windings in parallel are used for the system. The topology of multiple cores and three windings in parallel enables several independent secondary stages to share the large current of 3000 A level uniformly, eliminating the local overheating and current imbalance; the combination of high-frequency rectification and phase-shift control strategy enhances the input power factor to more than 0.95 and cuts down the grid-side harmonics remarkably. The authors have completed the design of 100 kW prototype, magneto-electric joint simulation, thermal structure coupling analysis, control algorithm development and field comparison test, and the results show that the program compared with the traditional industrial-frequency system efficiency increased by 12–15%, the system temperature rise reduced by 20 K, electrode voltage increased by 10–15%, the input power of furnace increased by 12%, and the harmonic index meets the requirements of the traditional industrial-frequency system. The results show that the efficiency of this scheme is 12–15% higher than the traditional IF system, the temperature rise in the system is 20 K lower, the voltage at the electrode end is 10–15% higher, the input power of the furnace is increased by 12%, and the harmonic indexes meet the requirements of GB/T 14549, which verifies the value of the scheme for realizing high efficiency, miniaturization, and reliable DC power supply in metallurgy. Full article

In this study, the elastic modulus of CFRP rebars under high-temperature conditions was evaluated in accordance with ASTM D7205 and CSA S806, and the differences between the two standards were compared and analyzed. CFRP rebars with diameters of 10 mm and 13 mm were tested, and tensile specimens were prepared following the procedures specified in both standards. Tensile tests were conducted at temperatures ranging from 25 °C to 650 °C using an electric furnace. Fracture morphology before and after testing, as well as microstructural changes, were examined through scanning electron microscopy (SEM). The results revealed that the ASTM standard determines the elastic modulus based on the initial linear portion of the stress–strain curve before the transition point, whereas the CSA standard includes the post-transition segment. At temperatures below 325 °C, the ASTM-derived modulus exhibited a lower coefficient of variation (COV) compared to the CSA-derived values, indicating a more stable performance. By applying the experimentally obtained modulus values to various prediction models, the model with the lowest average error was identified. These findings confirm that the elastic modulus of CFRP rebars can be reasonably predicted under elevated-temperature conditions using calibrated models. Full article

Steel is an important product in many engineering sectors; however, steelmaking remains one of the largest ${\mathrm{CO}}_2$ emitters. Therefore, new governmental policies drive the steelmaking industry toward a cleaner and more sustainable operation such as the gas-based direct reduction–electric arc furnace process. To become carbon neutral, utilizing more scrap is one of the feasible solutions to achieve this goal. Addressing knowledge gaps regarding scrap heterogeneity (size, shape, and composition) is essential to evaluate the effects of increased scrap ratios in basic oxygen furnace (BOF) operations. This review systematically examines heat and mass transfer correlations relevant to scrap melting in BOF steelmaking, with a focus on low Prandtl number fluids (thick thermal boundary layer) and dense particulate systems. Notably, a majority of these correlations are designed for fluids with high Prandtl numbers. Even for the ones tailored for low Prandtl, they lack the introduction of the porosity effect which alters the melting behavior in such high temperature systems. The review is divided into two parts. First, it surveys heat transfer correlations for single elements (rods, spheres, and prisms) under natural and forced convection, emphasizing their role in predicting melting rates and estimating maximum shell size. Second, it introduces three numerical modeling approaches, highlighting that the computational fluid dynamics–discrete element method (CFD–DEM) offers flexibility in modeling diverse scrap geometries and contact interactions while being computationally less demanding than particle-resolved direct numerical simulation (PR-DNS). Nevertheless, the review identifies a critical gap: no current CFD–DEM framework simultaneously captures shell formation (particle growth) and non-isotropic scrap melting (particle shrinkage), underscoring the need for improved multiphase models to enhance BOF operation. Full article

Direct electrification and hydrogen utilization represent two key pathways for decarbonizing the glass industry, with their effectiveness subject to adequate furnace design and renewable energy availability. This study presents a techno-economic assessment for optimal solar energy integration in a representative 300 t/d oxyfuel container glass furnace with a specific energy consumption of 4.35 GJ/t. A mixed-integer linear programming formulation is developed to evaluate specific melting costs, carbon emissions, and renewable energy self-consumption and self-production rates across three scenarios: direct solar coupling, battery storage, and a hydrogen-based infrastructure. Battery storage achieves the greatest reductions in specific melting costs and emissions, whereas hydrogen integration minimizes electricity export to the grid. By incorporating capital investment considerations, the study quantifies the cost premiums and capacity requirements under varying decarbonization targets. A combination of 30 MW of solar plant and 9 MW of electric boosting enables the realization of around 30% carbon reduction while increasing total costs by 25%. Deeper decarbonization targets require more advanced systems, with batteries emerging as a cost-effective solution. These findings offer critical insights into the economic and environmental trade-offs, as well as the technical constraints associated with renewable energy adoption in the glass industry, providing a foundation for strategic energy and decarbonization planning. Full article

Vacuum degassing (VD) is a critical refining step in electric arc furnace (EAF) steelmaking for producing clean steel with reduced nitrogen and hydrogen content. This study develops an Effective Equilibrium Reaction Zone (EERZ) model focused on denitrogenation (de-N) by simulating interfacial reactions at the bubble–steel interface (Z1). The model incorporates key process parameters such as argon flow rate, vacuum pressure, and initial nitrogen and sulfur concentrations. A robust empirical correlation was established between de-N efficiency and the mass of Z1, reducing prediction time from a day to under a minute. Additionally, the model was further improved by incorporating a dynamic surface exposure zone (Z_eye) to account for transient ladle eye effects on nitrogen removal under deep vacuum (<10 torr), validated using synchronized plant trials and Python-based video analysis. The integrated approach—combining thermodynamic-kinetic modeling, plant validation, and image-based diagnostics—provides a robust framework for optimizing VD control and enhancing nitrogen removal control in EAF-based steelmaking. Full article

There are many advantages of the smelting of vanadium–titanium magnetite pellets by hydrogen-based shaft furnace pre-reduction and electric arc furnace process, including high reduction efficiency, low carbon dioxide emission and high recovery of titanium and so on. However, vanadium–titanium magnetite pellets are highly susceptible to severe reduction disintegration when reduced in the gas-based shaft furnaces. H₂ and CO are the primary reducing gas components in the gas-based shaft furnace process, which significantly influences the reduction behavior of vanadium–titanium magnetite pellets. In this study, the reduction disintegration behavior and reduction kinetics of vanadium–titanium magnetite under mixed H₂–CO atmospheres at low temperatures (450–600 °C) were investigated. The differences in the reduction capacities and rates of H₂ and CO on iron oxides and titanium–iron oxides were revealed, along with their impact on the reduction disintegration behavior of the pellets at low temperatures. At lower temperatures, CO exhibited a greater reducing capability for vanadium–titanium magnetite. As the reduction temperature increased, the reduction capacities of both H₂ and CO improved; however, the reduction capacity of H₂ was more significantly influenced by the temperature. The disparity in the reduction capacities of H₂ and CO for vanadium–titanium magnetite pellets caused an inconsistent expansion rate in different regions of the pellet, increasing internal stress, contributing to a more severe reduction disintegration of vanadium–titanium magnetite pellets in the mixed H₂–CO atmospheres. Full article

Barro Alto processes nickel laterite ore using rotary kilns and six-in-line rectangular electric arc furnaces. This study evaluated the briquetting of ferronickel ore to reduce kiln fines, improve furnace charge permeability, and enhance process safety. Binderless briquettes were produced from screened ore at two size fractions (−6.3 mm and −12.5 mm), with moisture contents of 16% and 24%, cured under closed and open conditions. The physical and metallurgical properties of the briquettes were assessed using ISO standard tests. The results confirmed successful agglomeration of the ore into binderless briquettes. Screening the run-of-mine (ROM) ore improved the feed quality, increasing the NiO grade from 2.0% to 2.2% in the −6.3 mm fraction. The briquettes from the −6.3 mm ore at 16% moisture exhibited the highest green strength (559 N). Higher moisture content reduced the briquette strength and increased both the reduction disintegration and decrepitation indices. The decrepitation index increased from 0.33% to 0.61% for the −6.3 mm briquettes when the moisture increased from 16% to 24%. The reduction levels were 33.4% and 39.2% for −6.3 mm and −12.5 mm briquettes with 16% moisture, respectively. This study concludes that optimal performance was achieved using −6.3 mm ore, 16% moisture, and open curing, thereby balancing reduction efficiency and mechanical stability. Full article

In this work, an approach has been developed for the accelerated aging of test specimens with an electrical furnace for tensile strength and hardness testing, manufactured using a 3D Fused Deposition Modeling (FDM) printer. A detailed study of the climatic conditions and temperature amplitudes of the city of Sofia, Bulgaria, over a period of one calendar year was conducted. The ASTM D3045 standard was used, and numerical expressions were compiled, which guided the authors in determining the period and temperature of heating. Eight types of FDM 3D printing materials with different properties and characteristics were used in this study. Full article

Phosphorous slag is an industrial by-product generated in the process of producing yellow phosphorus by electric furnace, which occupies a substantial number of land resources and causes serious environmental pollution. The comprehensive utilization of phosphorous slag is a major topic relevant to the sustainability of the yellow phosphorus industry. In this paper, we attempted to utilize phosphorous slag as a supplementary cementing material to prepare silica-aluminum based cementitious material (SAC-PHS). To determine how phosphorus influences the early-age hydration reaction process of silica-aluminum based cementitious material, three groups of samples, PHS₂₀, PHS₂₅, and PHS₃₀, with better mechanical properties were selected to deeply investigate their one-week hydration characteristics. Characterization results showed that the main hydration products of SAC-PHS were C-A-S-H gels and ettringite. PHS₂₅ specimen produced more C-A-S-H gels and ettringite than the other two samples after one-week hydration. Interestingly, the P/Si atomic ratio indicated that chemical bonds were formed between Si and P during the formation of C-A-S-H gels, which improved the strength of SAC-PHS. Our findings offer valuable insights for the application of phosphorous slag in construction and building materials and promote the efficient resource utilization of phosphorous residue. Full article

The amount of waste generated by society is constantly increasing. Consequently, there is a need to develop new and better methods of treating it. A significant part of municipal waste is biowaste, which can be treated as a source of valuable resources such as nutrients, organic matter, and energy. The present work aims to determine the properties of the tested household biowaste and the possibility of using it as feedstock in slow pyrolysis to obtain biochar. The slow pyrolysis process of the biowaste was carried out in an electrically heated Horizontal Tube Furnace (HTF) at temperatures of 400 °C, 500 °C, and 600 °C in a nitrogen atmosphere. The analysis showed that depending on the type and composition of the biowaste, its properties are different. All the biowaste tested has a high moisture content (between 63.51% and 81.53%), which means that the biowaste needs to be dried before the slow pyrolysis process. The characteristics of kitchen biowaste are similar to those of food waste studied by other researchers in different regions of the world. In addition, the properties of kitchen biowaste are similar to those of the typical biomasses used to produce biochar via slow pyrolysis, such as wood, almond shells, and rice husks. Both kinds of garden biowaste tested may have been contaminated (soil, rocks) during collection, which affected the high ash content of spring (17.75%) and autumn (43.83%) biowaste. This, in turn, affected all the properties of the garden biowaste, which differed significantly from both the literature data of other garden wastes and from the properties of typical biomass feedstocks used to produce biochar in slow pyrolysis. For all biowaste tested, it was shown that as the pyrolysis temperature increases, the yield of biochar decreases. The maximum mass yield of biochar for kitchen, spring garden, and autumn garden biowaste was 36.64%, 66.53%, and 66.99%, respectively. Comparing the characteristics of biowaste before slow pyrolysis, biochar obtained from kitchen biowaste had a high carbon content, fixed carbon, and a higher HHV. In contrast, biochar obtained from garden biowaste had a lower carbon content and a lower HHV. Full article

The (1−x)Ba_0.96Ca_0.04TiO₃-xBa(Mg_1/3Nb_2/3)O₃ (x = 0–0.20) lead-free ceramics were prepared through the chemical-furnace-assisted combustion synthesis (abbreviated as CFACS). The phase structure, microstructure, dielectric, and piezoelectric properties were systematically investigated. Phase analysis revealed the coexistence of orthorhombic and tetragonal phases in the vicinity of x = 0.07. More importantly, the composition with x = 0.07 exhibited optimal overall electrical properties, including a high piezoelectric coefficient (d₃₃) of 495 pC/N, the planar electromechanical coupling factor (K_p) of 41.9%, and the Curie temperature (T_c) of 123.7 °C. In addition, the average grain size was observed to progressively decrease with increasing x. Full article

This study focuses on developing a novel clinker-free cement, specifically comprising phosphorus slag-based cementitious materials (PSCMs), by utilizing lime and industrial byproducts, including granulated electric furnace phosphorus slag and fluidized bed combustion bottom ash. The optimal composition of PSCM was determined by investigating the effects of different proportions of activators (water glass and sodium sulfate) and retarder (potassium fluoride) on the setting time and the mechanical strength of PSCMs. Performance evaluations demonstrated that the compressive and flexural strengths of the optimal PSCM formulation at 28 days were 64.1 MPa and 7.5 MPa, respectively. Notably, concrete prepared with the optimal PSCM exhibited superior freeze–thaw resistance and sulfate resistance compared to Portland cement concrete of equivalent strength grades. The comprehensive characterization of selected PSCM compositions, conducted using X-ray diffraction (XRD), Fourier transform infrared spectroscopy (FTIR), thermogravimetric analysis (TGA), and scanning electron microscope–energy-dispersive spectrometry (SEM-EDS), provided in-depth insights into the interrelationship among mechanical properties, durability, and microstructural characteristics. SEM-EDS analysis confirmed that calcium aluminosilicate hydrate and sodium aluminosilicate hydrate are the predominant hydration products of PSCMs. FTIR and TG analyses elucidated the continuous hydration behavior of PSCMs during the curing process, while SEM observations revealed a densely compact microstructure in the hardened PSCM paste. Full article

This research paper provides new insights into the impact of accelerated mineralization of alkaline waste materials on the physical and mechanical behavior of low-carbon cement-based mortars. Standardized eco-cement mortars were prepared by replacing Portland cement with 7% and 20% proportions of three alkaline waste materials (white ladle furnace slag, biomass ash, and fine concrete waste fraction) that had been previously carbonated in a static reactor at predefined humidity and CO₂ concentration. The mortars’ physical (total/capillary water absorption, electrical resistivity) and mechanical properties (compressive strength up to 90 d of curing) were analyzed, and their microstructures were examined using mercury intrusion porosimetry and computed tomography. The results reveal that carbonated waste materials generate a greater heat of hydration and have a lower total and capillary water absorption capacity, while the electrical resistivity and compressive strength tests generally indicate that they behave similarly to mortars not containing carbonated minerals. Mercury intrusion porosimetry (microporosity) indicates an increase in total porosity, with no clear refinement versus non-carbonated materials, while computed tomography (macroporosity) reveals a refinement of the pore structure with a significant reduction in the number of larger pores (>0.09 mm³) and intermediate pores (0.001–0.09 mm³) when carbonated residues are incorporated that varies depending on waste material. The construction and demolition waste (CCDW-C) introduced the best physical and mechanical behavior. These studies confirm the possibility of recycling carbonated waste materials as low-carbon supplementary cementitious materials (SCMs). Full article

The electric arc furnace (EAF) process includes key stages: charging scrap metal, melting using electric arcs, refining through oxygen injection and slag formation, and tapping molten steel. Recently, EAF steelmaking has become increasingly important due to its flexibility with recycled materials, lower environmental impact, and reduced investment costs. This study focuses specifically on select aspects of the refining stage, analysing decarburization and the associated exothermic oxidation reactions following the removal of carbon with oxygen injection. Particular attention is given to FeO generation during refining, as it strongly affects slag chemistry, yield losses, and overall efficiency. Using a Computational Fluid Dynamics (CFD)-based refining simulator validated with industrial data from EVRAZ North America (showing an 8.57% deviation), this study investigated the impact of oxygen injection rate and burner configuration. The results in a three-burner EAF operation showed that increasing oxygen injection by 10% improved carbon removal by 5%, but with an associated increase of FeO generation of 22%. Conversely, reducing oxygen injection by 15% raised the residual carbon content by 43% but lowered FeO by 23%. Moreover, the impact of the number of burners was analysed by simulating a second scenario with 6 burners. The results show that by increasing the number of burners from three to six, the target carbon is reached 33% faster while increasing FeO by 42.5%. Moreover, by reducing the oxygen injection in the six-burner case, it is possible to reduce FeO generation from 42.5 to 28.5% without significantly impacting carbon removal. This set of results provides guidance for burner optimization and understanding the impact of oxygen injection on refining efficiency. Full article

To address the challenges of concrete construction in polar regions, this study investigates the feasibility of fabricating cement-based materials under severely low temperatures using electric-induced heating curing methods. Cement mortars incorporating fly ash (FA-CM), ground granulated blast furnace slag (GGBS-CM), and metakaolin (MK-CM) were cured at environmental temperatures of −20 °C, −40 °C, and −60 °C. The optimal carbon fiber (CF) contents were determined using the initial electric resistivity to ensure a consistent electric-induced heating curing process. The thermal profiles during curing were monitored, and mechanical strength development was systematically evaluated. Hydration characteristics were elucidated through thermogravimetric analysis (TG), X-ray diffraction (XRD), and Fourier-transform infrared spectroscopy (FTIR) to identify phase compositions and reaction products. Results demonstrate that electric-induced heating effectively mitigates the adverse effect caused by the ultra-low temperature constraints, with distinct differences in the strength performance and hydration kinetics among supplementary cementitious materials. MK-CM exhibited superior early strength development with strength increasing rates above 10% compared to the Ref. specimen, which was attributed to the accelerated pozzolanic reactions. Microstructural analyses further verified the macroscopic strength test results that showed that electric-induced heating curing can effectively promote the performance development even under severely cold environments with a higher hydration degree and refined micro-pore structure. This work proposes a viable strategy for polar construction applications. Full article