Search Results (11)

As the energy consumption problem of an electric arc furnace (EAF) is becoming more and more prominent, improving the furnace charge resistivity becomes the key to reducing the energy consumption of metallurgical-grade silicon smelting. This study systematically examines the impact mechanism of the particle size of raw materials on the electrical resistivity of metallurgical-grade silicon furnace burden. The results show that in the range of 700–1300 °C, the size of the furnace charge consisting of coal and silica ore decreases from 6–9 mm to 0.25–0.3 mm, and the resistivity of the furnace charge increases from 0.9–1366.7 Ω·m to 2.5–2060.5 Ω·m. The effects of particle size on furnace charge resistivity are clarified by investigating how particle size influences the resistivity of coal and silica ore, along with an analysis performed within the context of furnace charge resistivity modeling. Research shows that particle size plays a crucial role in affecting the resistivity of the furnace charge. This impact is largely due to alterations in the graphitization-like degree of coal and changes in the contact resistance between particles. Together, these factors significantly influence the overall resistivity of the furnace charge. During this process, the particle size increased dramatically from 0.25–0.3 mm to 6–9 mm. The coal I_D/I_G ratio (degree of graphitization-like) was reduced from 1.36 to 1.32. The resistivity of the coal decreased by 29%, while the contact resistance of the charge was reduced by a factor of 2. The resistivity of the charge itself was also reduced by 64%. This transformation highlights the significant changes in the coal’s properties aimed at optimizing operational efficiency. This study is of great significance in clarifying the scheme of regulating furnace charge resistivity through particle size optimization, which is an important guide for energy saving and carbon reduction in the industrial silicon smelting process. Full article

Red mud is a by-product of alumina production, which is largely stored in landfills that can endanger the environment. Red mud, or bauxite residue, is a mixture of inorganic compounds of iron, aluminum, sodium, titanium, calcium and silicon mostly, as well as a large number of rare earth elements in small quantities. Although certain methods of using red mud already exist, none of them have been widely implemented on a large scale. This paper proposes a combination of two methods for the utilization of red mud, first by carbothermic reduction and then, by leaching under high pressure in an autoclave in order to extract useful components from it with a focus on titanium. In the first part of the work, the red mud was reduced with carbon at 1600 °C in an electric arc furnace, with the aim of removing as much iron as possible using magnetic separation. After separation, the slag is leached in an autoclave at different parameters in order to obtain the highest possible yield of titanium, aiming for the formation of titanium oxysulfate and avoiding silica gel formation. A maximal leaching efficiency of titanium of 95% was reached at 150 °C using 5 mol/L sulfuric acid with 9 bar oxygen in 2 h. We found that high-pressure conditions enabled avoiding the formation of silica gel during leaching of the slag using 5 mol/L sulfuric acid, which is a big problem at atmospheric pressure. Previously silica gel formation was prevented using the dry digestion process with 12 mol/L sulfuric acid under atmospheric pressure. Full article

This article describes elements of the know-how of using carbon electrodes produced using the technology of molding around a rod when smelting silicon metal. Application of our know-how will dramatically increase the competitiveness of silicon metal production. Experts’ concerns regarding the use of such electrodes were that such electrodes have a through axial hole. This significantly reduces the mechanical strength of such electrodes, which can presumably lead to problems associated with the breakage of the working side of the electrode, which is immersed in the smelting space of the furnace under the charge layer. Industrial testing of such electrodes was carried out in a 30 MVA furnace of “Tau-Ken Temir” LLP. During testing, we used an approach previously developed by our team for working with a furnace in the process of smelting silicon metal. In particular, we used an interval between top treatments of about 30 min and adhered to the principles of balanced smelting, i.e., provided a balance between the intensity of the uniform supply of the charge into the furnace and the current active electrical power. Industrial testing carried out over four weeks confirmed the stability of the operation of cheaper carbon electrodes with a through axial hole. The recovery of silicon into finished products was also improved to 88–89% and the specific energy consumption was reduced to 11.2–12.1 MWh/t of silicon metal from the initial value 14,752 MWh/t. Thus, we received additional evidence for the effectiveness of our approach in furnace operating compared to an approach based on the ultimate provision of gas and permeability of the furnace top due to excessively intense processing of the top and an uncontrolled, uneven supply of charge to the furnace. Full article

Biomaterials are currently a unique class of materials that are essential to improving the standard of human life and extending it. In the assent of the appearance of biomaterials that contain non-toxic elements, in this study, we examine a system of Ti25Mo7Zr15TaxSi (x = 0, 0.5, 0.75, 1 wt.%) for future medical applications. The alloys were developed in a vacuum electric arc furnace and then studied from a structural, mechanical and in vivo assessment (on rabbits) perspective. The effect of the silicon addition was clearly seen in both the structural and the mechanical characteristics, standing out as beta alloys with a dendritic structure and lowering the mechanical properties as a result of the silicon addition. In experimental rabbits, the proliferation of mesenchymal stem cells was observed in the periosteum and peri-implant area, differentiating into osteoblasts and then into osteocytes. Osteoclasts were discovered within the cartilaginous islands that provide structural support to newly formed bone, playing a primary role in bone remodeling. The newly formed spongy tissue adhered to the fibrous capsule that surrounds the alloy, ensuring good osseointegration of metallic implants. The overexpression of Osteopontin, Metalloproteinase-2 (also known as gelatinase A), and Metallopeptidase-9 (also known as gelatinase B) underscores the processes of osteogenesis, bone mineralization, and normal bone remodeling. Full article

Reported are the synthesis and structural characterization of a series of quaternary lithium-alkaline earth metal alumo-silicides and alumo-germanides with the base formula A₂LiAlTt₂ (A = Ca, Sr, Ba; Tt = Si, Ge). To synthesize each compound, a mixture of the elements with the desired stoichiometric ratio was loaded into a niobium tube, arc welded shut, enclosed in a silica tube under vacuum, and heated in a tube furnace. Each sample was analyzed by powder and single-crystal X-ray diffraction, and the crystal structure of each compound was confirmed and refined from single-crystal X-ray diffraction data. The structures, despite the identical chemical formulae, are different, largely dependent on the nature of the alkaline earth metal. The differing cation determines the structure type—the calcium compounds are part of the TiNiSi family with the Pnma space group, the strontium compounds are isostructural with Na₂LiAlP₂ with the Cmce space group, and the barium compounds crystallize with the PbFCl structure type in the P4/nmm space group. The anion (silicon or germanium) only impacts the size of the unit cell, with the silicides having smaller unit cell volumes than the germanides. Full article

A hybrid scheme integrating the current waste heat recovery system (WHRS) for a silicon arc furnace with plasma gasification for medical waste is proposed. Combustible syngas converted from medical waste is used to drive the gas turbine for power generation, and waste heat is recovered from the raw syngas and exhaust gas from the gas turbine for auxiliary heating of steam and feed water in the WHRS. Meanwhile, the plasma gasifier can also achieve a harmless disposal of the hazardous fine silica particles generated in polysilicon production. The performance of the proposed design is investigated by energy, exergy, and economic analysis. The results indicate that after the integration, medical waste gave rise to 4.17 MW net power at an efficiency of up to 33.99%. Meanwhile, 4320 t of the silica powder can be disposed conveniently by the plasma gasifier every year, as well as 23,040 t of medical waste. The proposed design of upgrading the current WHRS to the hybrid system requires an initial investment of 18,843.65 K$ and has a short dynamic payback period of 3.94 years. Therefore, the hybrid scheme is feasible and promising for commercial application. Full article

Waelz slag is an iron-containing waste generated during electric arc furnace (EAF) dust processing in a rotary kiln named the Waelz process. This study focuses on the reduction smelting of the Waelz slag to produce iron-based alloy. The thermodynamic simulation using FactSage 8.0 software was carried out to predict temperatures of the metal and slag obtained as well as their compositions. Based on the simulation results, reduction smelting experiments were performed on a laboratory scale using two approaches, with and without preliminary froth flotation of carbon, respectively. The experiments have confirmed the technological possibility of reduction smelting of the Waelz slag from EAF dust processing. The approach using preliminary flotation of carbon and reduction smelting at 1500 °C resulted in high-copper cast iron production, while the approach without flotation, where the Waelz slag was smelted at 1650 °C with the addition of SiO₂ flux, led to obtaining low-silicon ferrosilicon with high Cu content, as well as slag attractive for construction industry. Full article

This paper presents studies on the possibility of utilization of technogenic waste from the metallurgical industry by the method of complex processing in order to reduce the anthropogenic load on the environment of the region with the example of the zinc silicate-magnetite-carbon system. The selected sample of clinker dump from welting was subjected to chemical and scanning electron microscopic analyses and thermodynamic modeling. Thermodynamic studies were carried out in the temperature range 1600–2200 K and pressure p = 0.1 MPa, modeling the process of electric melting of clinker from welting in an arc furnace using the software application Astra 4 developed at the Bauman Moscow State Technical University (Moscow, Russian Federation). As a result of the thermodynamic modeling, the optimal temperature range was established, which was 1800–1900 K. Thermodynamic studies established that it is possible to drive away zinc from the system under study by 99–100% in the entire temperature range under study. The maximum degree of silicon extraction (α_Si) in the alloy is up to 69.44% at T = 1900 K, and the degree of iron extraction (α_Fe) in the alloy is up to 99.996%. In particular, it was determined and proved that clinker waste from welting can act as a secondary technogenic raw material when it is processed as a mono mixture to produce iron silicides with a silicon content of 18 to 28%. Full article

The subject of this study was the dust collected from an electric arc furnace at an unidentified-waste treatment site in southern Taiwan. The dust underwent an in situ vitrification (ISV) process and was tested using the toxicity characteristic leaching procedure (TCLP), at the end of which the final product was analyzed for its stability and weather resistance. This study then examined the above results to determine whether the ISV process helps to enhance the efficiency and economic benefits of said waste-treatment site. A TCLP test conducted on the dust that had been treated with ISV revealed that concentrations of various heavy metals were not only far below those of the unprocessed sample dust but also fell below the limit stipulated in the TCLP regulation of Taiwan’s Environmental Protection Administration. The results show that after undergoing ISV treatment, heavy metals in the dust were either encapsulated or bound in silicon lattices and thus barely leached from the dust. Analyses using scanning electron microscopy (SEM) and an energy dispersive spectrometry (EDS) indicate that the surface of the dust appeared more compacted after going through the ISV process. In addition, the highly contaminated dust that underwent ISV treatment saw a pronounced decrease in or elimination of wave crests. Another analysis applying X-ray diffraction (XRD) showed that the SiO₂ crests disappeared in the processed dust, suggesting that the crystal structure was replaced with quasi-vitreous products after ISV treatment. In the event that pollutants were extant, they were usually characterized by smaller size, high stability, excellent weather resistance, an innocuous nature, and recyclability. Full article

The production of ferroalloys and alloys like ferronickel, ferrochromium, ferromanganese, silicomanganese, ferrosilicon and silicon is commonly carried out in submerged arc furnaces. Submerged arc furnaces are also used to upgrade ilmenite by producing pig iron and a titania-rich slag. Metal containing resources are smelted in this furnace type using fossil carbon as a reducing agent, which is responsible for a large amount of direct CO₂ emissions in those processes. Instead, renewable bio-based carbon could be a viable direct replacement of fossil carbon currently investigated by research institutions and companies to lower the CO₂ footprint of produced alloys. A second option could be the usage of hydrogen. However, hydrogen has the disadvantages that current production facilities relying on solid reducing agents need to be adjusted. Furthermore, hydrogen reduction of ignoble metals like chromium, manganese and silicon is only possible at very low H₂O/H₂ partial pressure ratios. The present article is a comprehensive review of the research carried out regarding the utilization of bio-based carbon for the processing of the mentioned products. Starting with the potential impact of the ferroalloy industry on greenhouse gas emissions, followed by a general description of bio-based reducing agents and unit operations covered by this review, each following chapter presents current research carried out to produce each metal. Most studies focused on pre-reduction or solid-state reduction except the silicon industry, which instead had a strong focus on smelting up to an industrial-scale and the design of bio-based carbon for submerged arc furnace processes. Those results might be transferable to other submerged arc furnace processes as well and could help to accelerate research to produce other metals. Deviations between the amount of research and scale of tests for the same unit operation but different metal resources were identified and closer cooperation could be helpful to transfer knowledge from one area to another. Life cycle assessment to produce ferronickel and silicon already revealed the potential of bio-based reducing agents in terms of greenhouse gas emissions, but was not carried out for other metals until now. Full article

Due to the increasing demand for battery raw materials, such as cobalt, nickel, manganese, and lithium, the extraction of these metals, not only from primary, but also from secondary sources, is becoming increasingly important. Spent lithium-ion batteries (LIBs) represent a potential source of raw materials. One possible approach for an optimized recovery of valuable metals from spent LIBs is a combined pyro- and hydrometallurgical process. The generation of mixed cobalt, nickel, and copper alloy and lithium slag as intermediate products in an electric arc furnace is investigated in part 1. Hydrometallurgical recovery of lithium from the Li slag is investigated in part 2 of this article. Kinetic study has shown that the leaching of slag in H₂SO₄ takes place according to the 3-dimensional diffusion model and the activation energy is 22–24 kJ/mol. Leaching of the silicon from slag is causing formation of gels, which complicates filtration and further recovery of lithium from solutions. The thermodynamic study presented in the work describes the reasons for the formation of gels and the possibilities of their prevention by SiO₂ precipitation. Based on these findings, the Li slag was treated by the dry digestion (DD) method followed by dissolution in water. The silicon leaching efficiency was significantly reduced from 50% in the direct leaching experiment to 5% in the DD experiment followed by dissolution, while the high leaching efficiency of lithium was maintained. The study takes into account the preparation of solutions for the future trouble-free acquisition of marketable products from solutions. Full article