Search Results (22)

A new method of producing metal powders for additive manufacturing by the atomization of free-falling melt streams using pulsed cross-flow gaseous shock or detonation waves is proposed. The method allows the control of shock/detonation wave intensity (from Mach number 4 to about 7), as well as the composition and temperature of the detonation products by choosing proper fuels and oxidizers. The method is implemented in laboratory and industrial setups and preliminarily tested for melts of three materials, namely zinc, aluminum alloy AlMg5, and stainless steel AISI 304, possessing significantly different properties in terms of density, surface tension, and viscosity. Pulsed shock and detonation waves used for the atomization of free-falling melt streams are generated by the pulsed detonation gun (PDG) operating on the stoichiometric mixture of liquid hydrocarbon fuel and gaseous oxygen. The analysis of solidified particles and particle size distribution in the powder is studied by sifting on sieves, optical microscopy, laser diffraction wet dispersion method (WDM), and atomic force microscopy (AFM). The operation process is visualized by a video camera. The minimal size of the powders obtained by the method is shown to be as low as 0.1 to 1 μm, while the maximum size of particles exceeds 400–800 μm. The latter is explained by the deficit of energy in the shock-induced cross-flow for the complete atomization of the melt stream, in particular dense and thick (8 mm) streams of the stainless-steel melt. The mass share of particles with a fraction of 0–10 μm can be at least 20%. The shape of the particles of the finest fractions (0–30 and 30–70 μm) is close to spherical (zinc, aluminum) or perfectly spherical (stainless steel). The shape of particles of coarser fractions (70–140 μm and larger) is more irregular. Zinc and aluminum powders contain agglomerates in the form of particles with fine satellites. The content of agglomerates in stainless-steel powders is very low. In general, the preliminary experiments show that the proposed method for the production of finely dispersed metal powders demonstrates potential in terms of powder characteristics. Full article

The modern metallurgical industry produces approximately 90% of the volume of all produced steel; for this, integrated technology based on fossil materials such as coal, fluxes, and especially iron ore is used. This industry generates large amounts of waste and by-products at almost all stages of production. Alternative iron and steel production technologies based on iron ore, methane, or pure hydrogen are also not waste-free. To ensure sustainable waste management, efforts are made to seal processes as well as capture and recycle dusty waste. This work presents the results of research on the processing of sludge resulting from the dedusting of the basic oxygen furnace (BOF) process and landfilling in a lagoon. The work discusses the treatment of fine dusty sludge hydrated to 26–60% H₂O, to which various amounts of caking agents were added; also discussed are the rheological characteristics of the tested suspension systems, the possibility of forming these systems into larger fractions, and rapid drying using 100–600 W microwaves with a drying time of 1–9 min. The aim was to identify, describe, and characterize the parameters of the agglomeration process and obtain a product that was durable enough to transport and dose into slag baths in order to reduce iron oxides in liquid phases. During the research, completely dried briquettes with an appropriate strength were obtained. The study demonstrates that microwave drying at 300 W for 6 min achieved complete drying with a weight loss of 35%, whereas a higher-power treatment at 750 W for 2 min enhanced compressive strength by up to 95% and reached 15 N/psc, which was comparable with green iron ore pellets. This approach offers a sustainable alternative to traditional methods, but with a reduced drying time. Full article

The management of waste, especially ferrous waste, poses great problems in the steel industry due to strict regulations on preventing, reducing, or even eliminating the factors that generate a high degree of environmental pollution (landfills resulting from the steel industry and adjacent industries—mining, energy, etc.). The present paper presents a synthesis of the specialized literature regarding the processes used, both worldwide and nationally, regarding the transformation of raw materials (ores or concentrates) and iron-containing waste (steel mill dust, mill scale and scale, sludge from agglomeration factories, sideritic waste, etc.) into by-products that can be used in the steel industry. For technological reasons, the option of pelletizing powdered waste was applied—in laboratory conditions, according to its own recipes, with results that justify the application of the technology on an industrial scale (appearance after hardening; drop resistance). The aim of the paper was to identify a practical solution; based on this solution, original conceptual models of organizational strategies (management and processing, respectively, recovery of ferrous waste within steel companies) were developed, such as a concentration strategy, diversification, vertical integration, etc. Within graphical representations of the proposed strategies, other processing variants were mentioned: agglomeration; briquetting. Full article

Sintering is a commonly used agglomeration process to prepare iron ore fines for blast furnace. The quality of sinter significantly impacts the blast furnace ironmaking process. In the vast majority of sintering plants, the judgment of sintering quality still relies on the intuitive observation of the cross section at sintering machine tail by operators, which is susceptible to the external environment and the experience of operators. In this paper, we propose a new sintering state recognition method using deep learning based feature selection and ensemble learning. First, features from the infrared thermal images of sinter cross section at the tail of the sinterer are extracted based on ResNeXt. Then, to eliminate the irrelevant, redundant and noisy features, an efficient feature selection method based on binary state transition algorithm (BSTA) is proposed to find the truly useful features. Subsequently, an ensemble learning (EL) method based on group decision making (GDM) is proposed to recognize the sintering states. Novel combination strategies considering the varying performance of the base learners are designed to further improve recognition accuracy. Industrial experiments conducted at a steel plant verify the effectiveness and superiority of the proposed method. Full article

New results on the effect of TiO₂ on Pd/La₂O₃-CeO₂-Al₂O₃ systems for catalytic oxidation of methane in the presence of H₂O and SO₂ have been received. Low-temperature N₂-adsorption, XRD, SEM, HRTEM, XPS, EPR and FTIR techniques were used to characterize the catalyst. The presence of Ce³⁺ on the catalytic surface and in the volume near the lantana was revealed by EPR and XPS. After aging, the following changes are observed: (i) agglomeration of the Pd-clusters (from 8 nm to 12 nm); (ii) transformation of part of the TiO₂ from anatase to larger particles of rutile; and (iii)—the increase in PdO/Pd—ratio above its optimum. The modification by Ti of the La₂O₃-CeO₂-Al₂O₃ system leads to higher resistance towards the presence of SO₂ most likely due to the prevailing formation of unstable surface sulfites instead of thermally stable sulfates. Based on kinetic model calculations, the reaction pathway over the Pd/La₂O₃-CeO₂-TiO₂-Al₂O₃ catalyst follows the Mars–van Krevelen mechanism. For evaluation of the possible practical application of the obtained material, a sample of Pd/La₂O₃-CeO₂-TiO₂-Al₂O₃, supported on rolled aluminum-containing stainless steel (Aluchrom VDM^®), was prepared and tested. Methane oxidation in an industrial-scale monolithic reactor was simulated using a two-dimensional heterogeneous reactor model. Full article

In order to solve the problem of the low removal efficiency of fine particles in the flue gases of the metallurgy process, a chemical agglomeration pretreatment method was studied. The coagulant solution of xanthan gum, konjac gum, and their mixtures was selected to research the reunion effects of and the efficiency of gravitational dust removal of fine dust in the gas of the converter flue using a self-built experimental platform. Moreover, the effects of wetting agent type, dust concentration, pressure, and flue gas velocity on the fine grain removal efficiency were investigated. The results showed that the mixed solution of 1 g/L mixed gum and 0.5 g/L SDS had the most obvious effect on the particle size increasing of fine dust particles and the best removal effect when the flue gas velocity was 10 m/s. There was a peak particle size of 85.32 μm increased about eight times larger, and the removal efficiencies reached 51.46% for PM₂.₅ and 53.13% for PM₁₀. The Box–Behnken experimental design combined with a response surface analysis method was used to optimize the parameters of the mixed gum concentration, pressure, and flue gas velocity. The optimal removal conditions were 1 g/L, 0.4 MPa, and 10 m/s. The results of this study can provide efficient methods and technical support for pre-processing and efficient removal of fine particles in heavy-polluting industries such as steel making. This will promote the green development of the metallurgical industry. Full article

In order to study the effects of rare earth La–Ce alloying treatment on the characteristics of inclusions in non-oriented silicon steels, industrial experiments were conducted studying the composition, morphology, size and quantity of inclusions in W350 non-oriented silicon steel during the RH (Ruhrstahl-Hereaeus) refining process and tundish process, after rare earth treatment. The products were analyzed by means of ICP-MS (inductively coupled plasma mass spectrometry), SEM/EDS (scanning electron microscope-energy dispersive spectrometry), and ASPEX (automated SEM/EDS inclusion analysis). The research results showed that the types of inclusions in experimental steel changed significantly after rare earth treatment. The types of inclusions after RE (rare earth) treatment are typically rare earth composite inclusions that are mainly composed of (La, Ce)Al₂O₃, and conventional inclusions. The addition of rare earth promotes the agglomeration of inclusions; the morphologies of the inclusions are mostly blocky, and some are distributed in long strips. After rare earth treatment during the RH refining process, the number of inclusions with sizes of 1.0~3.5 μm in the experimental steel is increased, and the average size of the inclusions is 2.66 μm. In addition, the number of inclusions larger than 4 μm in the specimens increases due to the collision and growth of inclusions caused by the RH circulation. After rare earth treatment during the tundish process, the number of micro inclusions with sizes of 1.0~2.5 μm in the specimen steels decreases, while the number of inclusions larger than 5 μm increases. The size distribution of micro inclusions in hot-rolled sheets after rare earth treatment was studied using TEM (transmission electron microscopy). In the specimens without rare earth, the content of micro inclusions (≤1 μm) is 51,458.2/mm² and the average size is 0.388 μm. In the specimens with rare earth added, the content of micro inclusions (≤1 μm) is 24,230.2/mm² and the average size is 0.427 μm. Compared to sheet produced by the original process, the iron loss of the 0.35 mm finished experimental sheet is reduced by 0.068 W/kg, and the magnetic induction is increased by 0.007 T. The iron loss of the 0.50 mm finished experimental sheet is reduced by 0.008 W/kg, and the magnetic induction is increased by 0.004 T. After rare earth treatment, the average size of micro inclusions increases and the magnetic properties are obviously improved. Full article

Several studies have been conducted to improve the mechanical and other value-added properties of glass fiber-reinforced epoxy (GFRE) composites by the addition of different fillers. In this work, waste iron filings (WIFs) obtained from the steel industry were incorporated into GFRE composite samples in varying amounts of up to 50% (%w) to improve their mechanical and electrical properties. The results showed that, with increasing WIF loading from 0 w% to 50 w%, the resultant composite density gradually increased from 1.4 to 2.1 g/cm³. Surface hardness, Young’s modulus, and tensile strength also increased significantly with the addition of up to 9 w% of WIF followed by a significant drop with more WIF addition due to agglomeration. Overall, Young’s modulus of the GFRE samples with any WIF content was higher than that of the GFRE composite with no WIF. The elongation at break results showed that the GFRE samples were less ductile upon WIF addition, which decreased from 2% to 0.6% upon loading the composite with 50% WIF. In terms of electrical conductivity, the GFRE samples with WIF content of 15% or more were electrically conductive and their electrical conductivity increased with WIF content. It was clear that more WIF was needed to establish a percolated network in the GFRE composites to render them conductive. The electrical conductivity of the GFRE samples containing 15% WIFs was around 2.9 kS/m and increased to 35 kS/m upon the addition of 50% WIFs. These novel electrically conductive GFRE composites could be promising for structural dynamic monitoring systems in the construction industry. They also support the efforts for the utilization of waste materials towards a circular economy. Full article

The iron and steel industry is an important foundation of the national economy. It is the inevitable choice, to achieve high-quality development in the new era of the iron and steel industry, to speed up the green development of the iron and steel industry. This paper studies the effect of steel industry agglomeration on regional economic growth and air pollution. Through the analysis of the characteristics of iron and steel industry agglomeration, and the empirical analysis of the relationship between iron and steel industry agglomeration, regional economic growth, and air pollution, it is found that: (1) Iron and steel industry agglomeration helps to promote economic growth; (2) Iron and steel industry agglomeration has an obvious spatial correlation effect and obviously drives the development of surrounding areas; (3) Iron and steel industry agglomeration will cause air pollution. The marginal effect of air pollution will decline rapidly with the development of iron and steel industry agglomeration. (4) The impact of green process innovation investment on air pollution presents an inverted U-shaped effect, which has a positive effect on air recovery after exceeding the critical point. (5) The air self-purification capacity represented by precipitation, helps to reduce air pollution. Based on the above conclusions, this paper puts forward some policy suggestions, such as making a scientific development plan for the iron and steel industry, accelerating green process innovation, effectively improving regional precipitation and precipitation times, vigorously promoting high-quality development of the regional economy, and comprehensively promoting coordinated development of the iron and steel industry, so as to cope with the dilemma of the coordinated development of the iron and steel industry, regional economic growth, and smog pollution, and strive for international development in the future. In the competition, we should gain the first opportunity and obvious competitive advantage. Full article

Research shows that monolithic Al alloy has very attractive properties required in the production of aerospace, automotive, electrical and electronic, sports and recreational components/equipment. However, its low strength and low wear resistance have challenged its applications in some other critical industrial utilities. Nonetheless, the invention of metal composites has removed such barriers. The addition of one or more reinforcements to Al has helped in the creation of aluminium matrix composites (AMCs), which has not only increased the global utilization of Al alloy, but has been a major source of global revenue and job. This review was, therefore, aimed at studying recent works on AMCs with the aim of ascertaining the recent innovations in the development of advanced Al composites, which can replace steel components in most industrial applications at a cheaper rate. It was observed from the study that AMCs can be developed via solid and liquid fabrication techniques. Powder metallurgy was reported as the most effective method of producing hybrid Al nanocomposites, with spark plasma sintering as the best technique. In the liquid process, stir casting was reported as the most cost effective, but was challenged by agglomeration. It was recommended that agglomeration be ameliorated by cryogenic ball milling and an in situ fabrication technique. It was also recommended that more cost effective agro-waste nanoparticles should be developed to replace more costly conventional reinforcements. In summary, it was recommended that more research on the exploration of Al alloy at a cheaper rate should be carried out. Full article

Submerged arc welding joins metal by the heating of the electrode, base metal, and flux in the arc plasma, while the weld pool is protected under the granular flux and molten slag. Due to complex chemical reactions occurring between the arc plasma, weld pool, and molten slag (flux), flux essentially affects the weld metal composition, which, in turn, dictates the mechanical properties of the weldment. Therefore, fine-tuning the weld metal composition is essential to ensure a sound weld, and efforts worldwide have been focused on the control mechanism of flux on the weld metal composition. Recently, agglomerated fluxes have been widely applied due to low energy consumption during manufacture. The Cr₂O₃-bearing agglomerated flux is one of the most commonly used flux types in fields of heavy industrial applications. However, few works concern the element transfer behavior when Cr₂O₃-bearing agglomerated fluxes are used. Within this framework, typical agglomerated CaF₂-SiO₂-Na₂O-Cr₂O₃ fluxes with varying Cr₂O₃ content from 10 to 50 wt.% are designed and applied to Q345A steel. The influence of Cr₂O₃ content upon the transfer behaviors of essential elements, including O, Cr, and Mn, is quantified and interpreted from the point of thermodynamics. By incorporating a gas-slag-metal equilibrium consideration, the assumptions made in previous studies are justified. Additionally, evidence regarding the loss of Cr and Mn to the arc plasma is provided, and a possible thermodynamic approach to predict element transfer levels is proposed. It is revealed that the gas-slag-metal equilibrium consideration is able to qualitatively analyze the transfer behaviors involved in the submerged arc welding system, even under high temperatures. Based on the quantitative data, the practical implications as well as limitations of the gas-slag-metal equilibrium model are proposed. Full article

Laser cutting is used in many industrial settings to achieve precise cuts of metal sheets. Laser operators may be exposed to particles formed during cutting when opening the cabinet or when metal sheets are exchanged. To characterise the potential exposure, particles formed during laser cutting were studied with scanning electron microscopy equipped with an energy dispersive X-ray detector and an energy backscatter diffraction detector. The total concentration of particles (11–615 nm) was determined online with a scanning mobility particle sizer. The chemical composition of the particles formed during the cutting of the different metal sheets was determined by inductively coupled plasma mass spectrometry (ICP-MS). X-ray diffraction was applied to determine the phase composition. The occupational exposure was assessed gravimetrically and by ICP-MS for five laser operators handling different laser cutters, and materials and were found to be low. Agglomerates and aggregates of condensation particles were formed during laser cutting, independent of the sheet type. Iron, present as both magnetite and α-Fe, was the main element found in the particles formed when cutting steel sheets. The size of the particles generated was mainly below 300 nm. Open laser cutters may lead to higher metal exposures, which is especially relevant when cutting metal sheets containing heavy metals. Full article

This review focuses on the usability of iron ore ultra-fines for hydrogen-based direct reduction. Such technology is driven by the need to lower CO₂ emissions and energy consumption for the iron and steel industry. In addition, low operational and capital expenditures and a high oxide yield because of the direct use of ultra-fines can be highlighted. The classification of powders for a fluidized bed are reviewed. Fluid dynamics, such as minimum fluidization velocity, entrainment velocity and fluidized state diagrams are summarized and discussed regarding the processing of iron ore ultra-fines in a fluidized bed. The influence of the reduction process, especially the agglomeration phenomenon sticking, is evaluated. Thus, the sticking determining factors and the solutions to avoid sticking are reviewed and discussed. The essential theoretical considerations and process-relevant issues are provided for the usability of iron ore ultra-fines for hydrogen-based fluidized bed direct reduction. Full article

Ultra-high twinning-induced plasticity (TWIP) steel is receiving increasing attention in the automobile industry. Self-designed Fe–19Mn–0.6C TWIP steel was subjected to reveal the relationship between microstructures, which were related to recrystallization starting/ending temperature and cold rolling. The results indicated that initial deformation twins, secondary deformation twins, and nano-twins were successively generated in rolled TWIP steel with the increase of cold rolling, deformation twins, and dislocations, as well as with the elongation of grains. The elements remained uniformly dispersed rather than agglomerated in the twin crystals and grain boundaries. The recrystallization starting temperature changes of TWIP steel were 500–525, 400–425, 400–415, and 400–410 °C at cold rolling deformations of 25%, 50%, 75%, and 88%, respectively. Furthermore, the obtained corresponding recrystallization ending temperature changes were 580–600, 530–550, 520–540, and 500–520 °C, respectively. The linear relationship between cold deformation and hardness suggests that cold rolling can increase dislocation density and thus facilitate improving the hardness of TWIP steel. Full article

Industrial and urban dusts were characterized by investigating their magnetic properties. Topsoil composed of technogenic magnetic particles (TMP) originating from areas affected by three ironworks, street dust mainly composed of traffic-related pollution, and particulate matter (PM) from urban agglomeration in Warsaw, Poland were investigated. Several magnetic methods, namely magnetic susceptibility, thermomagnetic curves, hysteresis loops, decomposition of isothermal remanent magnetization acquisition curves, and first-order reversal curves, were performed to evaluate the magnetic fraction of dust. Magnetite was the main magnetic phase in all types of samples, with a small amount of high-coercive hematite within ironworks and street dust samples. Significant differences were observed in the domain structure (grain size) of industrial and traffic-related magnetic particles. The grain size of TMP obtained from steel production was in the range of 5–20 µm and was predominated by a mixture of single-domain (SD) and multidomain (MD) grains, with the prevalence of SD grains in the topsoil affected by Třinec ironwork. The traffic-related dust contained finer grains with a size of about 0.1 µm, which is characteristic of the pseudo-single-domain (PSD)/SD threshold. Street dusts were composed of a slightly higher proportion of MD grains, while PM also revealed the typical behavior of superparamagnetic particles. Full article