| 1. |
- Akbarnejad, Shahin, 1978-
(författare)
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Mathematical and Experimental Study on Filtration of Solid Inclusions from Molten Aluminium and Steel
- 2023
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Doktorsavhandling (övrigt vetenskapligt/konstnärligt)abstract
- Aluminum and steel have been the most produced metal and alloy, respectively, for many years. Their extensive use in various industries, their fundamental role in our everyday life, and their excellent recycling characteristics are the major driving forces for development of their production towards more sustainable processes. A successful integration and application of molten metal filtration from unwanted inclusions in production processes could result in reducing scrap, rework and would provide a cleaner molten metal which could lead to production of metallic materials with enhanced mechanical properties. Filtration of aluminum melts by ceramic foam filters is an established process in aluminum industry. Ceramic filters are also used in steel foundries to remove inclusions from the melt prior to casting to the mold. However, the use of ceramic filters is either limited to specific types of alloys or casts or to specific filters with large pores and openings. As a result, utilization of ceramic filters in the steel industry has limitations in capturing inclusions, where specifically small size inclusions may not be captured. This research work aims at contributing to the global effort in developing the molten metal production processes to become more sustainable and to increase the quality of the final product. To be specific, it is aimed at shedding more light into filtration applications and the use of ceramic filters for removal of solid non-metallic inclusions from molten aluminum and steel. Thus, permeability characteristics of single 30, 50, and 80 Pore Per Inch (PPI) alumina Ceramic Foam Filter (CFF) grades as well as stacks of three 30, three 50, and three 80 PPI alumina CFF grades were both experimentally and numerically obtained and studied. This provides the information needed to estimate the pressure required to prime and/or push the molten aluminum through the filters. The pressure could either be built up by gravitational or other forces. It has been shown recently that it is possible to prime such filters with electromagnetic forces and filter solid inclusions from molten aluminum. Lastly, physical refining of molten steel from solid alumina inclusions through monolithic extruded square-celled alumina ceramic filter was investigated and studied with a developed mathematical Computational Fluid Dynamics (CFD) model as well as the particle trajectories of inclusions in the size range of 1 to 100 [µm]. The experimentally obtained permeability characteristics as well as the obtained pressure gradient profiles of the single 30, 50, and 80 PPI CFFs were compared to previous research findings from the literature. Overall, a good agreement between the current and previous findings was found. It was also shown that fluid bypassing should be avoided during permeability experiments, otherwise deviations as high as 60% may occur. It was also revealed that similar permeability characteristics for the stacked filters, compared to single filters, could be achieved. However, an about three times higher pressure gradient or pressure needs to be applied when using a stack of three identical PPI filters compared to using single filters. The numerical simulations also validated the experimental findings of the permeability experiments. The CFD simulations and particle trajectories of the solid alumina inclusions in molten steel through the monolithic alumina filter revealed that it was possible to capture all particles larger than 50 [µm]. However, it was not possible to capture all particles smaller than 50 [µm] due to the applied simulation approach as well as current simulation limitations in the software.
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| 2. |
- Bonechi, L., et al.
(författare)
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BLEMAB European project : muon imaging technique applied to blast furnaces
- 2022
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Ingår i: Journal of Instrumentation. - : IOP Publishing. - 1748-0221. ; 17:04, s. C04031-
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Tidskriftsartikel (refereegranskat)abstract
- The BLEMAB European project (BLast furnace stack density Estimation through on-line Muon ABsorption measurements), evolution of the previous Mu-Blast European project, is designed to investigate in detail the capability of muon radiography techniques applied to the imaging of a blast furnace???s inner zone. In particular, the geometry and size of the so called ???cohesive zone???, i.e. the spatial zone where the slowly downward moving material begins to soften and melt, that plays an important role in the performance of the blast furnace itself. Thanks to the high penetration power of the natural cosmic ray muon radiation, muon transmission radiography represents an appropriate non-invasive methodology for imaging large high-density structures such as blast furnaces, whose linear size can be up to a few tens of meters. A state-of-the-art muon tracking system, whose design profits from the long experience of our collaboration in this field, is currently under development and will be installed in 2022 at a blast furnace on the ArcelorMittal site in Bremen (Germany) for many months. Collected data will be exploited to monitor temporal variations of the average density distribution inside the furnace. Muon radiography results will also be compared with measurements obtained through an enhanced multipoint probe and standard blast furnace models.
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| 3. |
- Boström, M., et al.
(författare)
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Understanding ice and water film formation on soil particles by combining density functional theory and Casimir-Lifshitz forces
- 2023
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Ingår i: Physical Review B. - : American Physical Society (APS). - 2469-9950 .- 2469-9969. ; 108:12
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Tidskriftsartikel (refereegranskat)abstract
- Thin films of ice and water on soil particles play crucial roles in environmental and technological processes. Understanding the fundamental physical mechanisms underlying their formation is essential for advancing scientific knowledge and engineering practices. Herein, we focus on the role of the Casimir-Lifshitz force, also referred to as dispersion force, in the formation and behavior of thin films of ice and water on soil particles at 273.16 K, arising from quantum fluctuations of the electromagnetic field and depending on the dielectric properties of interacting materials. We employ the first-principles density functional theory (DFT) to compute the dielectric functions for two model materials, CaCO3 and Al2O3, essential constituents in various soils. These dielectric functions are used with the Kramers-Kronig relationship and different extrapolations to calculate the frequency-dependent quantities required for determining forces and free energies. Moreover, we assess the accuracy of the optical data based on the DFT to model dispersion forces effectively, such as those between soil particles. Our findings reveal that moisture can accumulate into almost micron-sized water layers on the surface of calcite (soil) particles, significantly impacting the average dielectric properties of soil particles. This research highlights the relevance of DFT-based data for understanding thin film formation in soil particles and offers valuable insights for environmental and engineering applications.
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| 4. |
- Deng, Tengfei, et al.
(författare)
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Experimental Design for the Mechanism Study of Lime Dissolution in Liquid Slag
- 2012
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Ingår i: Steel Research International. - : Wiley. - 1611-3683 .- 1869-344X. ; 83:3, s. 259-268
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Tidskriftsartikel (refereegranskat)abstract
- The applicability of rotating rod technique in the study of lime dissolution in slag was investigated. Both computational fluid dynamic (CFD) and cold model experiments showed that the mass transfer due to radial velocity introduced by forced convection was zero if the rod was long. The mass transfer by forced convection was also less important in comparison with natural convection and diffusion when the rod was half length of the height of the bath. This finding was in accordance with the criteria put forward by the original work that the method could only be applicable when a thin disk (instead of rod) with big diameter and big liquid bath were used. To study the lime dissolution by forced convection a new experimental technique was developed. A cube was placed in the slag that was eccentrically stirred. The whole system, viz. the sample along with the slag could be quenched. The new technique could study the effect of forced convection on the dissolution. The microscopic study on the quenched slag-lime samples could reveal the dissolution mechanism successfully.
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| 5. |
- Deng, Zhiyin, et al.
(författare)
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Effects of Temperature and Holding Time on the Sintering of Ladle Filler Sand with Liquid Steel
- 2016
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Ingår i: Steel Research International. - : Wiley. - 1611-3683 .- 1869-344X. ; 87:7, s. 921-929
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Tidskriftsartikel (refereegranskat)abstract
- In the present work the effects of temperature and holding time on the sintering of ladle filler sand are studied. Laboratory experiments are carried out using pellets made of chromite based filler sand and two steel grades containing different contents of Mn and Al. It is found that the liquid steel plays a major role in the sintering behavior. The results also show that the amount of liquid phase in the sintered sand pellets increases with the increase of temperature and holding time. The Al2O3 content increases substantially in the chromite phase (spinel), especially in the region close to the liquid phase, when the temperature is high enough or when the holding time is long enough. Higher content of dissolved Al would accelerate the formation of the alumina-rich chromite.
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| 6. |
- Deng, Zhiyin, et al.
(författare)
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Mechanism Study of the Blocking of Ladle Well Due to Sintering of Filler Sand
- 2015
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Ingår i: Steel Research International. - : Wiley-VCH Verlagsgesellschaft. - 1611-3683 .- 1869-344X.
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Tidskriftsartikel (refereegranskat)abstract
- The present work is aimed at a mechanism study of blocking of ladle well by filler sand. Laboratory experiments are carried out using two different chromite-based filler sands. The interaction between the liquid steel and the sand is also studied by using steels containing different contents of Mn and Al. The reaction between the silica phase and the chromite phase is found to be the main mechanism for the sintering of sand. The reaction results in a liquid oxide phase, which becomes the binding phase between the solid oxide grains. The amount of silica phase and its grain size are found to have great impact on the formation of the liquid oxide phase. Faster formation of the liquid oxide phase leads to more serious sintering of the sand. It is found that liquid steel can hardly infiltrate into sand. On the other hand, the presence of steel considerably increases the amount of liquid phase and enhances the sintering of the sand.
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| 7. |
- Franklin White, Jesse, 1971-, et al.
(författare)
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Towards Bio-carbon Substitutes in the Manufacture of Electrodes and Refractories for the Metallurgical Industries : A Science and Technology Review
- 2023
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Ingår i: Advances in Pyrometallurgy. - Cham : Springer Nature. ; , s. 151-152
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Konferensbidrag (refereegranskat)abstract
- The unique structural versatility and chemical and thermophysical properties of carbon make it essentially irreplaceable for non-reductant uses in many high-temperature metallurgical processes. At present, bio-carbon substitutes are not technically feasible for large-scale use in electrode and refractory materials that are vital consumables in the steel, aluminum, and non-ferrous metal industries. Carbon electrodes of all types (including Soderberg, prebaked, and anodes/cathodes for Al) as well as carbon lining pastes are all similar in that they are comprised of a granular carbon aggregate and a carbon-based binder. Similarly, refractories such as MgO-C utilize both natural (mined) graphite and carbon-based binders. Replacements of fossil materials with equivalent bio-carbon substitutes have the potential to dramatically reduce the carbon footprints of these products. However, there are still considerable materials engineering challenges that must be surmounted. The properties of bio-carbon materials and technological obstacles are explored, including catalytic graphitization and development of bio-pitch materials.
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| 8. |
- Frosin, C., et al.
(författare)
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Exploring the potential of muon radiography for blast furnace assessments: advancements in non-invasive imaging and structural analysis
- 2024
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Ingår i: Journal of Instrumentation. - : IOP Publishing. - 1748-0221. ; 19:2
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Tidskriftsartikel (refereegranskat)abstract
- The BLEMAB European project (BLast furnace stack density Estimation through online Muon ABsorption measurements), the evolution of the previous Mu-Blast European project, is designed to investigate in detail the capability of muon radiography techniques applied to the imaging of the inner zone of a blast furnace. In particular, the goal of this collaboration is to characterize the internal region (so-called cohesive zone) where the slowly downward-moving material begins to soften and melt, which plays an important role in the performance of the blast furnace itself. In this contribution, we describe the state-of-the-art of the muon tracking system which is currently being developed and installed at a blast furnace on the ArcelorMittal site in Bremen (Germany). Moreover, we will present the GEANT4 simulation framework devised for this application together with the simulation results. Finally, we will show the possible contribution of multiple scattering effects to such peculiar applications.
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| 9. |
- Glaser, Björn, 1975-
(författare)
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A Study on the Thermal State of Steelmaking Ladles
- 2012
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Doktorsavhandling (övrigt vetenskapligt/konstnärligt)abstract
- In the present thesis a study on the thermal state of steelmaking ladles was undertaken. The transient hot wire method was verified for thermal conductivity measurements on metallurgical slags and applied to ladle slag measurements. Temperature measurements on ladles in an industrial environment were carried out. The emissivities of the outer and inner shells of steelmaking ladles were investigated. Two dynamic models were developed to predict the heat transfer and fluid flow in a preheating and teeming ladle. The gathered thermal conductivity values for ladle slag were used to study the effect of the slag layer on the top surface of the melt on heat transfer and fluid flow in a teeming ladle.In the first stage, the transient hot-wire method was verified to measure the thermal conductivity of metallurgical slags at steelmaking temperatures. A numerical model was developed, cold model experiments were conducted and test measurements using a high temperature experimental setup were carried out. To minimize natural convection and to obtain more reliable measurements, the crucible diameter, the hot-wire diameter, the applied current, the position of the wire in the crucible and the cooling on the upper surface of the crucible were studied. Investigations into the choice of sheathing material of the circuit exposed to the slag were also made. It was found that only certain materials were suitable for slag measurements depending on slag composition and temperature. The electrical resistivity of the hot wire was measured to make the thermal conductivity calculation more reliable. The wire diameter also played a major role due to the heat generation per surface area. The thermal conductivity should be derived from the values measured during the first seconds. In this initial stage, the effect of the natural convection as a function of the wire position in the crucible, the cooling on the top surface and the diameter of the crucible are negligible. A compromise has to be made in choosing the electrical current, since higher current results in higher sensitivity but at the same time in more natural convection.In the second stage, the thermal conductivities of four different ladle slags were measured at 1773 K, 1823 K, 1873 K and 1923 K using the transient hot wire method. Very good reproducibility was obtained. The thermal conductivity did not vary substantially with the variation of slag composition at 1873 K and 1923 K, at which the slag samples were all entirely liquid. The thermal conductivities were low. It was found that the precipitation of solid phase resulted in a considerable increase of thermal conductivity.In the third stage, a two dimensional model was developed in order to predict the temperature distribution in the ladle wall during the preheating process. The model calculated the heat transfer and the velocity field in the gas phase inside the ladle as well as the heat transfer in the solid walls during the preheating process. Measurements of the temperature profiles in an industrial ladle were carried out using an infrared thermography. The measurements were made both inside and outside the ladle. The model predictions were found to be in reasonably good agreement with the measured temperatures. It was found that the preheating time could be minimized when the working lining became thinner. The effect ofthe distance between the lid and the ladle was also studied by the model. The results indicated that there was no significant temperature change on the upper side wall of the ladle. On the lower side wall and bottom the temperature changed slightly. The temperature difference in the lower part of the ladle could be explained by the larger flame distance from the bottom layer.In the fourth stage, a two dimensional axisymmetric model was developed to predict the heat flux in a steelmaking ladle during the teeming process. The model predicts dynamically the flow fields in both the liquid phase and the gas phase along with the movement of the liquid upper surface. The model also predicts the temperature distributions in the liquid metal, gas phase and all layers in the ladle wall. Again, industrial measurements were performed using an infrared thermography, both inside the ladle after teeming and at the wall outside the ladle during the whole process sequence. The model predictions were found to be in agreement with the measured data. It was found that the heat transfer to the surrounding atmosphere and the conductivity of the highly insulating layer were the most important factors for the heat loss. The decrease of the thickness of the working lining was found to have limited effect on the total heat flux.In the fifth and final stage, the effect of the slag layer on the top surface of the melt, on fluid flow and on heat transfer in a teeming ladle was investigated theoretically. The two dimensional axisymmetric model developed in the fourth stage was used. To predict the effect of the slag layer a stationary heat conduction boundary condition including thermal conductivity and slag layer thickness was employed. Different calculations with differing thermal conductivity values for the slag layer were carried out. The calculations showed that the effect of the slag layer was insignificant. This could be explained by the similarity of the thermal conductivity of slag and gas phase.
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| 10. |
- Glaser, Björn, et al.
(författare)
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Determination of Experimental Conditions for Applying Hot Wire Method to Thermal Conductivity of Slag
- 2013
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Ingår i: Steel Research International. - : Wiley. - 1611-3683 .- 1869-344X. ; 84:7, s. 649-663
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Tidskriftsartikel (refereegranskat)abstract
- In order to apply the hot wire method for metallurgical slags at steelmaking temperatures, a numerical model was developed, cold model experiments were conducted and test measurements using a high temperature experimental setup were carried out. To minimize natural convection and obtain more reliable measurements, the crucible diameter, the hot-wire diameter, the applied current, the position of the wire in the crucible, and the cooling on the upper surface of the crucible were studied. Investigations into the choice of sheathing material of the circuit exposed to the slag were also made. It was found that only certain materials were suitable for slag measurements depending on slag composition and temperature. The electrical resistivity of the hot wire was measured to make the thermal conductivity calculation more reliable. The wire diameter also played a major role, because of the heat generation per surface area. The thermal conductivity should be derived from the values measured during the first seconds. In this initial stage, the effect of the natural convection as a function of the wire position in the crucible, the cooling on the top surface, and the diameter of the crucible are negligible. A compromise has to be made in choosing the electrical current, since higher current results in higher sensitivity but at the same time in more natural convection.
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