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Metals
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Selected Papers from 8th ICSTI 2018
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Selected Papers from 8th ICSTI 2018

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Extractive Metallurgy".

Deadline for manuscript submissions: closed (31 March 2019) | Viewed by 34618

Special Issue Editor

Prof. Dr. Johannes Schenk

E-Mail Website
Guest Editor
Ferrous Metallurgy Lehrstuhl für Eisen- und Stahlmetallurgie, Montanuniversität Leoben, Franz-Josef-Strasse 18, 8700 Leoben, Austria
Interests: ironmaking; crude steel production; characterization of raw materials; reduction kinetics of iron oxide; experimental process simulation; mathematical modelling of metallurgical processes
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Selected contributions of the 8th International Congress on Science and Technology in Ironmaking—8th ICSTI 2018 will be published in the Special Issue. The congress will be held form Sept. 25 to 27 2018 in Vienna and will bring together a wide range of experts, coming from plant operation and plant and equipment suppliers, as well as research institutes and universities, who share expertise in the field of ironmaking. The scope and topic of the contribution to the 8th ICSTI 2018 covers the topics cokemaking, iron ore production and handling, sintering, pelletizing, blast furnace ironmaking, direct reduction, smelting reduction, environmental control in coke and ironmaking, CO2 reduction and energy saving, recycling of in-plant residues, and automation and digitalization in coke and ironmaking, as well as modelling and simulation in coke and ironmaking.

Prof. Dr. Johannes Schenk
Guest Editor

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Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • ironmaking
  • cokemaking
  • sintering
  • pelletizing
  • blast furnace
  • direct reduction
  • smelting reduction
  • sustainable iron production
  • automation

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Published Papers (8 papers)

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Research

14 pages, 5148 KiB  
Article
Isothermal Kinetic Mechanism of Coke Dissolving in Hot Metal
by Wei Zhang, Fubo Hua, Jing Dai, Zhengliang Xue, Guojun Ma and Chengzhi Li
Metals 2019, 9(4), 470; https://doi.org/10.3390/met9040470 - 22 Apr 2019
Cited by 7 | Viewed by 3688
Abstract
The carburization of molten iron is close to saturation in the blast furnace process, while that in the flash ironmaking process is uncertain because there is no pressure from solid charge and no carburization reactions occurring between the deadman and hot metal. Some [...] Read more.
The carburization of molten iron is close to saturation in the blast furnace process, while that in the flash ironmaking process is uncertain because there is no pressure from solid charge and no carburization reactions occurring between the deadman and hot metal. Some experiments were conducted to reveal the kinetic mechanism of coke dissolving in carbon-iron melts. Reduced iron powder, electrolytic iron as well as chemical pure graphite were used as experiment materials. With high-purity argon injected as the protective gas, the specimens were heated up to 1873 K in a tubular resistance furnace to study the isothermal mechanism. The results show that the composition of the ferrous sample affects the dissolution rate. When the FeO content of the iron-bearing material rises from 0% to 4.76%, the apparent dissolution rate constant, kt, falls from 7.98 × 10−6 m/s to 5.48 × 10−6 m/s. There are some differences amongst the dissolution rate coefficients of different cokes despite interacting with similar carbon-iron melts, with coke 1 of 7.98 × 10−6 m/s, coke 2 of 5.17 × 10−6 m/s, and coke 3 of 3.77 × 10−6 m/s. Besides, this index decreases with the increase of the dissolution time and solely depends on the procedure of the mass transfer. A negative correlation is demonstrated between kt and the sulfur content in the iron bath as well. The content of silicon dioxide in the coke has a significant influence on kt. Additionally, the dissolution rate coefficient increases with the increase of the graphitization degree of coke. Full article
(This article belongs to the Special Issue Selected Papers from 8th ICSTI 2018)
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13 pages, 3524 KiB  
Article
Effect of Thermodynamic Melt Formation Characteristics on Liquid Phase Fluidity of Iron Ore in the Sintering Process
by Shengli Wu, Heping Li, Weili Zhang and Bo Su
Metals 2019, 9(4), 404; https://doi.org/10.3390/met9040404 - 2 Apr 2019
Cited by 17 | Viewed by 3429
Abstract
The liquid phase fluidity of iron ore is a vital index of fundamental sintering characteristics. In this paper, FactSage software and a visible microsintering test device were used to research the influence of the thermodynamic melt characteristics on the liquid phase fluidity under [...] Read more.
The liquid phase fluidity of iron ore is a vital index of fundamental sintering characteristics. In this paper, FactSage software and a visible microsintering test device were used to research the influence of the thermodynamic melt characteristics on the liquid phase fluidity under fixed CaO content conditions. The results show that the laws governing liquid phase fluidity of iron ore are significantly different with a fixed alkalinity and fixed CaO content of the sample. The liquid phase content at the sintering temperature is the most important thermodynamic melt formation characteristic affecting the liquid phase fluidity. In addition to the liquid phase content, other minerals also have a greater impact on liquid phase fluidity. Decreasing the viscosity of the liquid phase improves the liquid phase fluidity of the iron ore, and the effect of the SiO2 content of the iron ore on the mixed phase viscosity is greater than that of the Al2O3 content. Full article
(This article belongs to the Special Issue Selected Papers from 8th ICSTI 2018)
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12 pages, 3892 KiB  
Article
An Environment-Friendly Process Featuring Calcified Roasting and Precipitation Purification to Prepare Vanadium Pentoxide from the Converter Vanadium Slag
by Juhua Zhang, Wei Zhang and Zhengliang Xue
Metals 2019, 9(1), 21; https://doi.org/10.3390/met9010021 - 25 Dec 2018
Cited by 31 | Viewed by 4499
Abstract
Converter vanadium slag is a byproduct of the iron making process when the vanadium titanomagnetite is used as iron raw material. A cleaner process including calcified roasting, dilute acid leaching, precipitation purification, vanadium precipitation with ammonium salt, followed by thermal decomposition was proposed [...] Read more.
Converter vanadium slag is a byproduct of the iron making process when the vanadium titanomagnetite is used as iron raw material. A cleaner process including calcified roasting, dilute acid leaching, precipitation purification, vanadium precipitation with ammonium salt, followed by thermal decomposition was proposed to extract vanadium resource from this slag. And then vanadium pentoxide with purity over 98% was prepared, which can be used as additives for high strength low alloy steel production. A total vanadium recovery beyond 80% was achieved in this whole process. Since no sodium and potassium salt was introduced, wastewater generated was closed-circulating after removing the enriched impurities of P, Si, Ti and Cr with adding powder CaO. The content of V2O5 in residues after vanadium extraction was lower than 1.2 wt.%, while other valuable metals like Fe, Mn, Cr and Ti were concentrated. With no alkaline metal salts added in this process, the metal resources of Fe, Mn, Cr and Ti in the residues were more feasible to be recovered with pyrometallurgy processes. Full article
(This article belongs to the Special Issue Selected Papers from 8th ICSTI 2018)
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14 pages, 7225 KiB  
Article
Petrological Study of Ferrous Burden-Crucible Interaction in Softening & Melting Experiments: Implications for the Relevance of Pressure Drop Measurements
by James Small, Allert Adema, Kirill Andreev and Enno Zinngrebe
Metals 2018, 8(12), 1082; https://doi.org/10.3390/met8121082 - 19 Dec 2018
Cited by 6 | Viewed by 3531
Abstract
Numerous tests are used worldwide to investigate the advanced high temperature reduction, softening, and melting (S&M) of blast furnace ferrous burden material. Commonly, the curve of pressure drop (dP) against temperature, measured over the experimental charge, is taken as directly indicative of the [...] Read more.
Numerous tests are used worldwide to investigate the advanced high temperature reduction, softening, and melting (S&M) of blast furnace ferrous burden material. Commonly, the curve of pressure drop (dP) against temperature, measured over the experimental charge, is taken as directly indicative of the evolution of ferrous layer permeability. Previous authors have expressed concerns about the reproducibility and practical relevance of dP measurements due to narrow crucible diameter and wall effects. Petrological study of samples from interrupted Advanced Softening and Melting (ASAM) experiments, performed with ferrous burdens comprising a mixture of pellets (C/S 0.1–0.7) and highly basic sinter (C/S 2.4–3.5), sheds light on the nature and controlling mechanisms of systematic artefacts influencing the measurement of dP. The observations imply that the dP-T curves in ASAM, and likely other similar S&M, tests most immediately reflect the varying ease of gas flow in a sidewall bypass around the qualitatively impermeable ferrous burden layer, rather than through it. This is controlled by the formation of diverse oxide(-slag)-metal segregations at the exterior of the ferrous burden layer. The potential correlation of parameters derived from dP measurements with input burden characteristics is not in itself sufficient evidence that the measurements are indicative of the ferrous layer permeability. Full article
(This article belongs to the Special Issue Selected Papers from 8th ICSTI 2018)
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13 pages, 2574 KiB  
Article
The Potential of Recycling the High-Zinc Fraction of Upgraded BF Sludge to the Desulfurization Plant and Basic Oxygen Furnace
by Anton Andersson, Mats Andersson, Elsayed Mousa, Adeline Kullerstedt, Hesham Ahmed, Bo Björkman and Lena Sundqvist-Ökvist
Metals 2018, 8(12), 1057; https://doi.org/10.3390/met8121057 - 12 Dec 2018
Cited by 5 | Viewed by 4203
Abstract
In ore-based steelmaking, blast furnace (BF) dust is generally recycled to the BF via the sinter or cold-bonded briquettes and injection. In order to recycle the BF sludge to the BF, the sludge has to be upgraded, removing zinc. The literature reports cases [...] Read more.
In ore-based steelmaking, blast furnace (BF) dust is generally recycled to the BF via the sinter or cold-bonded briquettes and injection. In order to recycle the BF sludge to the BF, the sludge has to be upgraded, removing zinc. The literature reports cases of recycling the low-zinc fraction of upgraded BF sludge to the BF. However, research towards recycling of the high-zinc fraction of BF sludge within the ore-based steel plant is limited. In the present paper, the high-zinc fraction of tornado-treated BF sludge was incorporated in self-reducing cold-bonded briquettes and pellets. Each type of agglomerate was individually subjected to technical-scale smelting reduction experiments aiming to study the feasibility of recycling in-plant residues to the hot metal (HM) desulfurization (deS) plant. The endothermic reactions within the briquettes decreased the heating and reduction rate leaving the briquettes unreduced and unmelted. The pellets were completely reduced within eight minutes of contact with HM but still showed melt-in problems. Cold-bonded briquettes, without BF sludge, were charged in industrial-scale trials to study the recycling potential to the HM deS plant and basic oxygen furnace (BOF). The trials illustrated a potential for the complete recycling of the high-zinc fraction of BF sludge. However, further studies were identified to be required to verify these results. Full article
(This article belongs to the Special Issue Selected Papers from 8th ICSTI 2018)
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12 pages, 5203 KiB  
Article
The Macroscopic Flow direction and Microscopic Distribution of Mg in Sintered Products and Its Influence
by Shengli Wu, Weili Zhang, Mingyin Kou and Heng Zhou
Metals 2018, 8(12), 1008; https://doi.org/10.3390/met8121008 - 1 Dec 2018
Cited by 2 | Viewed by 2957
Abstract
Magnesium flux is an indispensable part of sintering materials. Its distribution and reaction behavior have an important influence on the quality of the sinter. Studying the macroscopic flow direction and microscopic distribution of MgO in sintered products is important for guiding the matching [...] Read more.
Magnesium flux is an indispensable part of sintering materials. Its distribution and reaction behavior have an important influence on the quality of the sinter. Studying the macroscopic flow direction and microscopic distribution of MgO in sintered products is important for guiding the matching of ore for sintering and adjusting sintering technical parameters. The macroscopic flow direction situation of MgO in all sintered products was studied using X-Ray diffractometer and X-Ray fluorescence analyzer. In addition, the microscopic distribution characteristics of Mg element in the main sintered products were studied using scanning electron microscope and energy dispersive spectrometer. The results of this research are as follows. The Mg contents of sintered products are in the following increasing order: sinter ore, sinter internal return ore, and blast furnace return ore. The Mg content of the 1 to 2 mm grain size is the highest in the sinter internal return ore and blast furnace return ore, which is related to the granular distribution of magnesium flux. Moreover, the Mg content of sintered minerals are in the following decreasing order: magnetite; silico-ferrites of calcium and aluminium (SFCA); and silicate and hematite, and the Mg dissolving in the SFCA has a tendency to make the SFCA morphology coarse. The diffusion range of Mg in a large dolomite particle is much narrower, and it mainly stays at the position where the dolomite is located. In the actual sintering process, Mg increases the viscosity of the sintering liquid phase and prevents the oxidation of magnetite, which is not conducive to the improvement of the strength of the sinter. Full article
(This article belongs to the Special Issue Selected Papers from 8th ICSTI 2018)
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14 pages, 7993 KiB  
Article
Multi-Objective Optimization of Cost Saving and Emission Reduction in Blast Furnace Ironmaking Process
by Shun Yao, Shengli Wu, Bo Song, Mingyin Kou, Heng Zhou and Kai Gu
Metals 2018, 8(12), 979; https://doi.org/10.3390/met8120979 - 23 Nov 2018
Cited by 10 | Viewed by 3233
Abstract
Due to the increasing environmental pressures, one of the most direct and effective way to achieve emission reduction is to reduce the CO2 emissions of the blast furnace process in the iron and steel industry. Based on the substance conservation and energy [...] Read more.
Due to the increasing environmental pressures, one of the most direct and effective way to achieve emission reduction is to reduce the CO2 emissions of the blast furnace process in the iron and steel industry. Based on the substance conservation and energy conservation of ironmaking process and the engineering method, the carbon loss model was firstly established to calculate the amount of solution loss. Based on this model, the blast furnace emission reduction optimization mathematical model with the cost and CO2 emissions as objective functions was then established using the multiple-objective optimization method. The optimized results were obtained by using the GRG (Generalized Reduced Gradient) nonlinear solving method. The optimization model was applied to the B# blast furnace of BayiSteel in China. The optimization model was verified by comparing the optimized results with the actual production data. The optimization model was then applied to analyze the effects of coke ratio, coal rate, blast temperature and other factors on the cost, CO2 emission and solution loss, and some measures to save cost, reduce emissions and reduce solution loss have been proposed. Full article
(This article belongs to the Special Issue Selected Papers from 8th ICSTI 2018)
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10 pages, 1527 KiB  
Article
Calculation Model for Activity of FeO in Quaternary Slag System SiO2-CaO-Al2O3-FeO
by Zhi Li, Guojun Ma, Mengke Liu and Jingjing Zou
Metals 2018, 8(9), 714; https://doi.org/10.3390/met8090714 - 12 Sep 2018
Cited by 11 | Viewed by 8207
Abstract
According to the coexistence theory of slag structure, a calculation model for the activity of FeO in the quaternary system SiO2-CaO-Al2O3-FeO of depleted copper slag was established. The model was used to calculate and analyze the effects [...] Read more.
According to the coexistence theory of slag structure, a calculation model for the activity of FeO in the quaternary system SiO2-CaO-Al2O3-FeO of depleted copper slag was established. The model was used to calculate and analyze the effects of temperature (T), basicity (B), and Al2O3 content on the activity of FeO (NFeO). The results show that temperature has little impact on NFeO. With increased basicity, NFeO first increased slightly, then increased sharply, and finally decreased. It is easier for CaO to combine with SiO2 than FeO to form calcium silicate, which replaces FeO in 2FeO·SiO2 and increases NFeO. However, when basicity is higher than 2.0, CaO not only reacts with SiO2, but also combines with FeO to form calcium ferrate compounds to decrease NFeO. In addition, the activity of FeO decreases with increased Al2O3 content because of the reaction between CaO and Al2O3. The results can be used as a theoretical basis to guide the carbothermal reduction process of copper slag. Full article
(This article belongs to the Special Issue Selected Papers from 8th ICSTI 2018)
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