Sticking of iron ore pellets in direct reduction with hydrogen and carbon monoxide: Behavior and prevention简

A series of reduction experiments of iron ore pellets with hydrogen,carbon monoxide and their mixture were carried out in a laboratory scale shaft furnace.The sticking behavior accompanying reduction of iron ore pellets was investigated.And morphology of the sticking interface forming during reduction was analyzed by SEM equipped with EDS.In order to evaluate the effects of the temperature and gas composition on sticking properties,reduction of iron ore pellets were conducted at 800-1000 ℃.The results show that the sticking strength of the pellets increases with temperature,however,decreases with hydrogen content in reducing gas.For an efficient shaft furnace operation in direct reduction（DR）,relative prevention of sticking such as coating of pellets was also developed to solve sticking problem.The results show that CaO is a suitable material for the coating method.     

Utilization of waste polyethylene terephthalate as a reducing agent in the reduction of iron ore composite pellets

The increasing consumption of plastics inevitably results in increasing amounts of waste plastics. Because of their long degradation periods, these wastes negatively affect the natural environment. Numerous studies have been conducted to recycle and eliminate waste plastics. The potential for recycling waste plastics in the iron and steel industry has been underestimated; the high C and H contents of plastics may make them suitable as alternative reductants in the reduction process of iron ore. This study aims to substitute plastic wastes for coal in reduction melting process and to investigate their performance during reduction at high temperature. We used a common type of waste plastic, polyethylene terephthalate （PET）, because of its high carbon and hydrogen contents. Composite pellets containing PET wastes, coke, and magnetite iron ore were reduced at selected temperatures of 1400 and 1450℃ for reduction time from 2 to 10 min to investigate the reduction melting behavior of these pellets. The results showed that an increased temperature and reduction time increased the reduction ratio of the pellets. The optimum experimental conditions for obtaining metallic iron （iron nuggets） were reduction at 1450℃ for 10 min using composite pellets containing 60% PET and 40% coke.     

Correlation between aggregation structure and tailing mineral crystallinity

Direct reduction is an emerging technology for the utilization of refractory iron ore. With this technology, iron oxides in the ore can be reduced to recoverable elemental iron. The structure of granular aggregates in direct reduction products was investigated by X-ray diffraction （XRD）. The results show that iron is mainly generated as a shell in the outer edge of the aggregates. The thermal conductivity of the iron shell is higher than that of other minerals. Thus, minerals close to the iron shell cool faster than those in the inner shells and do not crystallize well. These minerals mainly become stage 2 tailings. Hence the XRD intensity of stage 2 tailings is lower than that of stage 1 tailhags. When iron is mainly generated in the interior of the aggregates, the crystallinity of stage 2 tailings will be higher than that of stage 1 tailings. This indicates that the crystallinity of tailings can be used as a marker for the aggregate structure.     

Ferronickel enrichment by fine particle reduction and magnetic separation from nickel laterite ore

Ferronickel enrichment and extraction from nickel laterite ore were studied through reduction and magnetic separation. Reduction experiments were performed using hydrogen and carbon monoxide as reductants at different temperatures （700-1000℃）. Magnetic separa- tion of the reduced products was conducted using a SLon-100 cycle pulsating magnetic separator （1.2 T）. Composition analysis indicates that the nickel laterite ore contains a total iron content of 22.50wt% and a total nickel content of 1.91wt%. Its mineral composition mainly con- sists of serpentine, hortonolite, and goethite. During the reduction process, the grade of nickel and iron in the products increases with in- creasing reduction temperature. Although a higher temperature is more favorable for reduction, the temperature exceeding 1000℃ results in sintering of the products, preventing magnetic separation. After magnetic separation, the maximum total nickel and iron concentrations are 5.43wt% and 56.86wt%, and the corresponding recovery rates are 84.38% and 53.76%, respectively.     

Swelling behavior of hot preheated pellets in reduction roasting process

One kind of facile coal-based direct reduction process is using hot preheated pellets for reduction in grate kiln. In this work, effects of reduction parameters on swelling index of hot preheated pellets were investigated by photographic technique under isothermal conditions. Experimental results show that swelling index of pellets is firstly increased then gradually decreased with increasing reduction time, while that is found to be an obvious decrease from 175 % to 30% with the variation of temperature from 900 °C to 1100 °C. Results of XRD combined with SEM reveal that swelling behavior of pellets is decided by structure of newly formed metal iron grains. The formation and growth of fibers iron grains promote the increase in volume. Low temperature and low CO content are favored to the formation and orientated growth of metal iron grains in the one step process.     

Carbothermal reduction process of the Fe-Cr-O system

Understanding the reduction behaviors and characteristics of the end products of Fe-Cr-O systems is very important not only for maximizing the recovery of metals from stainless steel dust but also for the subsequent reuse in metallurgical process. The present work first predicted the possible products thermodynamically when FeCr204 was reduced by C. The reduction behaviors by graphite of three kinds of Fe-Cr-O systems, i.e., FeCr204, Fe203q-Cr203, and Feq-Cr203, were then investigated in 1350-1550℃. Further, the microstructures of final products and element distribution conditions were examined. The results suggest that, thermodynamically, the mass of products for the carbothermal reduction of FeCr204 is a strong function of temperature, and the initial carbon content is used. More Fe-Cr-C solution and less residual carbon content are obtained at higher temperatures and lower no：no ratios （the initial molar ratio of C to O in the sample）. Experimental data show that the sample amount tends to affect the reduction rate, and the residual carbon content strongly depends on nc：no. With regard to the phases present in products during the reaction process, metal carbides tend to form in the initial stage, whereas Fe-Cr-C solution forms when the degree of reduction is sufficiently high.     

Recovery of Ferric Oxide from Bayer Red Mud by Reduction Roasting-Magnetic Separation Process

A great amount of red mud generated from alumina production by Bayer process was considered as a low-grade iron ore with a grade of 5wt% to 30wt% iron.We adopted the reduction roastingmagnetic separation process to recover ferric oxide from red mud.The red mud samples were processed by reduction roasting,grinding and magnetic separating respectively.The effects of different parameters on the recovery rate of iron were studied in detail.The optimum techqicalparameters were proposed with 700 ℃roasting for 20 min,as 50wt% carbon and 4wt% additive were added.The experimentalresults indicated that the iron recovery and the grade of totaliron were 91% and 60%,respectively.A novelprocess is applicable to recover ferric oxide from the red mud waste fines.     

Numerical simulation of the temperature field of titania-bearing BF slag heated in a microwave oven

Considering the characteristic of selective heating of microwave and the treatment of titania-bearing BF slag, a mathematical model for the heating of a slag specimen is developed. The temperature distribution in the specimen is studied by numerical simulation. The temperature in the center of the cylindrical slag specimen is the highest and the temperature decreases when the radius increases rapidly. In this case, the temperature rising rate decreases with heating time rapidly, and it tends to zero when the heating time is up to 150 s.     

Thermal-rheology effect and temperature field of engineering polymers

The formation and evolution laws of the defect temperature field,heat dissipation in the process of defect evolution were studied.On the basis,the formation and evolution laws of the defect temperature field were investigated,the interaction among defects in the process of defect evolution was carried out.The numerical simulation of the temperature field of ABS was made.The results show that the process of defect evolution is one of energy dissipation,in which the defect temperature field forms due to that its heat dissipation possesses fractal property and its fractal dimension not only relates to the interaction among the defects,but also is the function of time,this incarnates the efficiency of coordinated actions of striding over the different gradations in the process of defect evolution and among gradations.The increase of the local temperature with the increase of deformation-induced heating effect in ABS is obvious.Moreover,the shape of plastic zone and inner heat source density function has big effect on the temperature field.     

Diffusion process for efficiency improvement with high sheet resistance on traditional production lines of solar cell

By optimizing the diffusion temperature and time,four groups of samples with different sheet resistances are achieved.The front screen printing pattern and firing temperature are fine-tuned according to the needs.The performance of the low-and-plateau-temperature doping recipe(as recipe A)is better than that of the low-and-multiple-temperature doping recipe(as recipe B).And the 19.24%efficiency of volume production of monocrystalline solar cells with 238.95 mm2 and 80?/sq sheet resistance is obtained in the traditional process line.0.48%more efficiency is achieved than 60?/sq due to the reduction of the phosphorus surface doping and shallow junction by the low-and-plateau-temperature diffusion recipe.The module test shows that by using two drive-in zones,not only do we have a higher efficiency,but also have a stabler and lower power loss in encapsulation manufacture.It is showed that power of a large improvement will be gotten by statistical analysis and PC1D simulation.     

Pilot scale test of producing nickel concentrate from low-grade saprolitic laterite by direct reduction-magnetic separation

The enrichment of Ni from a low-grade saprolitic laterite ore,which has been pre-treated by high pressure grinding roller（HPGR） to be 74% passing 0.074 mm and contains 0.92% Ni,18.47% Fe,10.61% MgO and 42.27% SiO2,was conducted by using pelletizing,rotary kiln reduction and magnetic separation process on a semi industrial scale,and the effects of reduction duration,mass ratio of coal to pellets（C/P）,the types of magnetic separator,the sections of grinding-separation and the grinding fineness on the recovery of Ni and Fe were examined.It is shown that nickel concentrate containing 3.13 % Ni and 59.20 % Fe was achieved at recoveries of 84.36 % and 71.51% for Ni and Fe,respectively under the following conditions：reducing at （1120±40） ℃ for 120 min,C/P being 1.0,wet grinding of reduced pellets up to 70%-87% passing 0.074 mm and a magnetic field intensity of 238.8 kA/m during the first section of grinding-magnetic separation,and a grinding fineness of 84%-91% passing 0.045 mm and a magnetic intensity of 39.8 kA/m during the second section of grinding-magnetic separation.The enriched Ni containing concentrate has a low content of S and P,and can be used for further processing to produce high-grade ferronickel alloy.     

Preparation and visible-light photocatalytic property of nanostructu- red Fe-doped TiO2 from titanium containing electric furnace molten slag

Nanostructured Fe-doped titanium dioxide was synthesized from titanium containing electric furnace molten slag （TCEFMS） by using an alkali fusion, followed by a hydrolyzation-acidolysis-cMcination route. The effects of Mkali/slag mass ratio, calcinating temperature, calcinating time, and water/slag mass ratio on the extraction efficiency and purity of products were systematically studied in this paper. It is indicated that the best extraction efficiency of nanostructured Fe- doped titanium dioxide is 99.35%, when the molten slag is calcinated at 700℃ for 1 h with the mass ratio of alkali/molten slag of 1.5：1. The influence of alkali/slag mass ratio on the photocatalytic activity of final products was evaluated by the photodegradation of methyl blue under visible light irradiation. A maximum photodegradation efficiency of 88.12% over 30 min was achieved under the optimum conditions.     

Martensitic transformation and magnetic properties of aged Ni-Fe-Ga-Ti shape memory alloy

This article reports the effect of ageing on the microstructure, martensitic transformation, magnetic properties, and mechanical properties of Ni51FelsGa27Ti4 shape memory alloy. There are five specimens of this alloy aged at 573 up to 973 K for 3 h per each. This range of ageing temperature greatly affects the microstructure of the alloy. As the ageing temperature increased from 573 up to 973 K, the microstructure of Ni51FelsGa27Ti4 alloy gradually changed from the entirely martensitic matrix at 573 K to the fully austenitic microstructure at 973 K. The volume fraction of precipi- tated Ni3Ti particles increased with the ageing temperature increasing from 573 to 773 K. Further increasing the ageing temperature to 973 K decreased the content of Ni3Ti in the microstructure. The martensitic transformation tempera- ture was decreased steadily by increasing the ageing temperature. The magnetization saturation, remnant magnetization, and coercivity increased with the ageing temperature increasing up to 773 K. A further increase in ageing temperature decreased these raagnetic properties. Moreover, the hardness values were gradually increased at first by increasing the ageing temperature to 773 K, and then dramatically decreased to the lowest value at 973 K.     

Microstructural and mechanical properties of A1-4.5wt% Cu rein- forced with alumina nanoparticles by stir casting method

The microstructure and mechanical properties of A1-4.5wt% Cu Mloy reinforced with different volume fractions （1.5vo1%, 3vo1%, and 5vo1%） of alumina nanoparticles, fabricated using stir casting method, were investigated. CMculated amounts of alumina nanoparticles （about ~50 nm in size） were ball-milled with aluminum powders in a planetary ball mill for 5 h, and then the packets of milled powders were incorporated into molten Al-4.5wt% Cu alloy. Microstructural studies of the nanocomposites reveal a uniform distribution of alumina nanoparticles in the A1-4.5wt% Cu matrix. The results indicate an outstanding improvement in compression strength and hardness due to the effect of nanoparticle addition. The aging behavior of the composite is also evaluated, indicating that the addition of alumina nanoparticles can accelerate the aging process of the Mloy, resulting in higher peak hardness values.     

Preparation of CaO-Al2O3-SiO2 system glass from molten blast furnace slag

To use the potential heat of molten blast furnace slag completely, a CaO-Al2O3-SiO2 system glass （MSG） was prepared from the molten industrial slag. The corresponding method proposed in this study utilized both slag and its potential heat, improving the production rate and avoiding the environmental pollution. Using appropriate techniques, an MSG with uniform color and superior performances was produced. Based on the experimental results and phase diagram, the chemical composition of MSG by mass is obtained as follows：CaO 27%-33%, SiO2 42%-51%, Al2O3 11%-14%, MgO 6%-8%, and Na2O＋K2O 1%-4%. Thermodynamic processes of MSG preparation were analyzed, and the phases and microstructures of MSG were investigated by X-ray diffraction （XRD） and scanning electron microscopy （SEM）. The results show that alkali metal oxides serve as the fluxes, calcium oxide serves as the stabilizer, and alumina reinforces the Si-O network. XRD and SEM analyses show that, the prepared MSG displays the glass-feature patterns, the melting process is more complete, and the melt viscosity is lowered with an increase in calcium oxide content;however, a continuous increase in slag content induces the crystalli-zation of glass, leading to the formation of glass subphase. The optimum content of molten slag in MSG is 67.37wt%. With respect to bend-ing strength and acid/alkali resistance, the performance of MSG is better than that of ordinary marble.     

Effect of some operational variables on bubble size in a pilot-scale mechanical flotation machine简

This work aims to provide a relationship of how the key operational variables of frother type and impeller speed affect the size of bubble （D32）. The study was performed using pilot-scale equipment （0.8 m^3） that is up to two orders of magnitude larger than equipment used for studies performed to date by others, and incorporated the key process variables of frother type and impeller speed. The results show that each frother family exhibits a unique CCC95-HLB relationship dependent on n （number of C-atoms in alkyl group） and m （number of propylene oxide group）. Empirical models were developed to predict CCC95 from HLB associated with other two parameters a and ft. The impeller speed-bubble size tests show that D32 is unaffected by increased impeller tip speed across the range of 4.6 to 9.2 m/s （representing the industrial operating range）, although D32 starts to increase below 4.6 m/s. The finding is valid for both coalescing and non-coalescing conditions. The results suggest that the bubble size and bubble size distribution （BSD） being created do not change with increasing impeller speed in the quiescent zone of the flotation.     

Feasibility of developing composite action between concrete and cold-formed steel beam

Cold-formed steel structures are steel structure products constructed from sheets or coils using cold rolling, press brake or bending brake method. These structures are extensively employed in building construction industry due to their light mass, ductility by economic cold forming operations, favorable strength-to-mass ratio and other factors. The utilization of cold formed steel sections with concrete as composite can hugely reduce the construction cost. However, the use of cold formed steel members in composite concrete beams has been very limited. A comprehensive review of developments in composite beam with cold formed steel sections was introduced. It was revealed that employing cold-formed steel channel section to replace reinforcement bars in conventional reinforced concrete beam results in a significant cost reduction without reducing strength capacity. The use of composite beam consisting of cold-formed steel open or close box and filled concrete could also reduce construction cost. Lighter composite girder for bridges with cold-formed steel of U section was introduced. Moreover, types of shear connectors to provide composite action between cold-formed steel beam and concrete slab were presented. However, further studies to investigate the effects of metal decking on the behavior of composite beam with cold-formed steel section and introduction of ductile shear connectors were recommended.     

Effects of Sr2＋ substitution on the structural,dielectric, and piezoelectric properties of PZT-PMN ceramics

This study described the structural, dielectric, and piezoelectric behavior of Pb1-xSrx[（Zr0.52Ti0.48）0.95（Mn1/3Nb2/3）0.05]O3 ceramics （PSZT-PMN, x=0, 0.025, 0.050, and 0.075）, prepared by a semi-wet route. X-ray diffraction, dielectric, and piezoelectric investigations were carried out to analyze the crystal structure. The relative dielectric constant and dielectric loss were both calculated as the functions of temperature. The room-temperature dielectric constant reaches a maximum for a Sr2＋-modified PZT-PMN ceramic with an x value of 0.050, which corresponds to the morphotropic phase boundary （MPB）. Raman spectroscopy studies also confirm the existence of this MPB for x=0.050. The piezoelectric strain coefficients （d33） value shows a maximum response for this composition. In addition, the phase transition temperature decreases significantly when the Sr2＋concentration increases in the PZT-PMN ceramics.     

Pyrolysis characteristics of rubber compositions in medical waste

Thermogravimetric study of rubber compositions （operating glove and catheter） in medical waste was carried out using the thermogravimetric analyser （TGA）,at the heating rate of 20 ℃/min in a stream of N2.The results indicate that the decomposition process of operating glove appears an obvious mass loss stage at 250-485 ℃,while catheter has two obvious stages at 240-510 ℃ and 655-800 ℃,respectively; both samples present endothermic pyrolysis reaction; the decomposition of operating glove and the first mass loss stage of catheter are in agreement with natural rubber pyrolysis; the second mass loss stage of catheter corresponds to CaCO3 decomposition.Based on the experimental results,a novel two-step four-reaction model was established to simulate the whole continuous processes,which could more satisfactorily describe and predict the pyrolysis processes of rubber compositions,being more mechanistic and conveniently serving for the engineering.     

Low temperature sintering and dielectric properties of Ca-Ba-Al-B-Si-O glass/Al2O3 composites for LTCC applications

The effects of various SiO2 contents on both the microstructures and properties of Ca-Ba- A1-B-Si-O glass/Al2O3 cotrtposites were investigated by FTIR, DSC, XRD and SEM. The experimental results show that increasing SiO2 content in the glass leads to the increase of [SIO4] units, increases the continuity of glass network, and decreases the trend to crystallization of composites. The shrinkage of samples rises rapid around the glass softening temperature and the final shrinkage of samples decreases with increasing SiO2 content in the glass. Borosilicate glass/Al2O3 composites with 60wt% SiO2 sintered at 875 ℃ for 15 min show better properties： a bulk density of 3.10 g,cm-3, a porosity of 0.23 %, a er value of 7.55 and a tan 8 value of 0.00053 （measured at 10 MHz） and a well matching with Ag electrodes.