The steel industry is aiming to reduce CO2 emissions by different means; in the short-term, by replacing fossil coal with highly reactive carbonaceous material like bio-coal (pretreated biomass) and, in the longer term, by using hydrogen. The use of bio-coal as part of top charged briquettes also containing iron oxide has the potential to lower the thermal reserve zone temperature of the Blast furnace (BF) and, due to improved gas efficiency, thereby give a high replacement ratio to coke. In order to select a suitable bio-coal to be contained in agglomerates with iron oxide, the current study aims at investigating the devolatilization behavior and related kinetics of different types of bio-coals. In addition, the aim is to investigate the self-reduction behavior of bio-coal-containing iron ore composite under inert condition and simulated blast furnace thermal profile. In the BF the temperature of the top-charged material will increase rather quickly during the descent in the upper part. Ideally, all the carbon and hydrogen contained in the top-charged bio-coal should contribute to the reduction. The devolatilization of bio-coal is thus important to understand and to compare between different types of bio-coal. To explore the devolatilization behavior for different materials, a thermogravimetric analyzer equipped with a quadrupole mass spectrometer was used to monitor the weight loss and off-gases during non-isothermal tests for bio-coals having different contents of volatile matter. The samples were heated in an inert atmosphere up to 1200°C at three different heating rates: 5, 10 and 15°C/min. The thermogravimetric data were evaluated by using the Kissinger–Akahira–Sonuse (KAS) iso-conversational model and the activation energy was determined as a function of the conversion degree. Bio-coals with both low and high content of volatile matter can produce reducing gases that can contribute to the reduction of iron oxide in bio-agglomerates. Bio-coals containing a higher content of catalyzing components such as CaO and K2O will enhance the devolatilization and release of volatile matter at a lower temperature.  The self–reduction of composites was investigated by thermogravimetric analyses in argon atmosphere up to 1100°C and evolved gases were monitored by means of quadrupole mass spectroscopy. Composites with and without 10% bio-coal and sufficient coke breeze to keep the C/O molar ratio equal to one were mixed and Portland cement was used as a binder. To explore the effect of added bio-coals, interrupted vertical tube furnace tests were conducted in a nitrogen atmosphere at temperatures selected based on thermogravimetric results, using a similar thermal profile as for the thermogravimetric analyzer. The variation between fixed carbon, volatile matter contents and ash composition for different types of bio-coal influences the reduction of iron oxide. The results showed that the self-reduction proceeds more rapidly in the bio-coal-containing composite and that the volatile matter could have contributed to the reduction. The self-reduction of bio-coal-containing composites started at 500°C, while it started at 740°C with coke as the only carbon source. The hematite was successfully reduced to metallic iron at 850°C with bio-coal present as a reducing agent, but not until 1100°C when using coke. Use of bio-coal with high content of volatile matter but low content of catalyzing elements as potassium, sodium and calcium in bio-agglomerates for the BF can be recommended because it enhances the self-reduction of iron oxide, e.g., wustite was detected by XRD analysis in samples treated up to 680°C. Bio-coal with low content of volatile matter, low alkalis, low phosphorous and high content of fixed carbon will also be suitable to use in the BF.

After carbon, phosphorus is the most commonly detected element in archaeological iron. The typical phosphoric iron range is 0.1wt% to 1wt%P. The predominant source of phosphorus in iron is the ore smelted. Around 60% of economic UK rock iron ore formations contain over 0.2%P. Under fully reducing conditions, both in liquid-state (cast iron) and solid-state bloomery smelting (direct reduction) processes, such rock ores would be predicted to produce phosphoric iron, and bog iron ores even more so. Ore-metal-slag phosphorus ratios for bloomery iron are derived here, by means of: laboratory experiments; full-scale experimental bloomery smelting; and analysis of remains from three Medieval and two Late Roman-Iron Age iron production sites in England and the Netherlands. Archaeological ore, slag, metal residues (gromps), and iron artefacts were analysed by metallography, SEM-EDS, EPMA, and XRD. The effects of forging and carburising on phosphoric iron were studied by experiment and artefact analysis. The ore to slag %P ratio for solid-state reduction was determined to range from 1:1.2 to 1: 1.8. The ore to metal %P ratio varied from 1:0.2 to 1:0.7 ¿ 1.4, depending on furnace operating conditions. Archaeological phosphoric iron and steel microstructures resulting from non-equilibrium reduction, heat treatment, and mechanical processing are presented to define the technology of early phosphoric iron. Microstructures were identified by a combination of metallography and chemical analysis. The phosphoric iron artefacts examined appear to be fully functional objects, some cold-worked and carburised. Modern concepts of 'quality' and workability are shown to be inapplicable to the archaeological material.

The ladle metallurgical furnace (LMF) is a very flexible and common unit operation found in most steelmaking melt shops, and enables the adjustment and fine-tuning of molten steel's composition and temperature prior to casting. Despite the importance of ladle metallurgy to the overall steel making process very little has been achieved in the way of advanced ladle control. Limited sensors are available to monitor heat progress during refining and current control methods involve manual procedures. This thesis represents part of an ongoing study on the modelling of a full-scale LMF in real-time with the forward goal of improved control and optimization. The first part of this thesis details a vision-based sensor for analyzing ladle eye dynamics online using a multivariate image analysis (MIA) technique based on principal component analysis (PCA). Predictive capabilities of the developed model are demonstrated using previously published cold model data over a wide range of operating variables. Further, preliminary work has confirmed the ability of the sensor for potential use in an industrial setting. The second part of this study concerns the development of metallurgical models for assessing the state of a ladle metallurgical furnace. Specifically, a multi-component kinetic model in combination with developed slag and steel thermodynamic solution models were used to quantitatively describe the kinetics of slag-metal reactions within 41 industrially sampled heats at ArcelorMittal Dofasco's LMF#2. Metal phase mass transfer coefficients for all elements in steel were assumed to follow the empirical relation derived from measured sulphur contents, while slag phase mass transfer coefficients were calculated by fitting the ratio of k^Mm/ k^MxOysl to the experimental results. On the basis of the fitted results, slag phase mass transfer coefficient correlations were evaluated using linear regression. Computed results from the model using these slag phase mass transfer coefficient correlations were found to be consistent with the experimental data. In regard to the developed thermodynamic solution models, original contributions to the modified interaction parameter formalism and cell model are presented. As process model predictions are invariably uncertain, the final part of this work involves the use of a stochastic model (extended Kalman filter) to account for process disturbances, model-mismatch and other sources of uncertainty that may result in significant error propagation causing poor process control and plant economics. Several case studies were performed to illustrate the effectiveness of the extended Kalman filter and its application to optimal sensor selection was introduced. / Thesis / Doctor of Philosophy (PhD)

With the unstable cost and supply of rare earth materials used in permanent magnet electric machines, many alternative machine types are being studied which are suitable for different applications. The focus of this thesis is the design of a novel 6/14 switched reluctance machine which can be fitted in a residential heating, ventilation, and air-conditioning (HVAC) application based on measured performance characteristics of an existing surface mount permanent-magnet synchronous (SMPS) machine. Residential electric motor applications are reviewed and in particular - furnace blower motor appliances. The fundamentals of switched reluctance machines are discussed, including the mechanism, operation, and control strategy. A SMPS motor which is commercially available for retrofitting into residential HVAC systems is analyzed to find its performance characteristics through disassembly, inspection, and dynamometer bench testing. The design of a novel 6/14 SRM optimization process is outlined to investigate the effect of changing the geometry values within the motor on the performance characteristics, while keeping within the size constraints of the original motor. A novel 6/14 SRM design is presented which is capable of achieving the target goals in the desired operating conditions. Further suitability testing is performed in terms of thermal analysis of the motor in the peak and continuous operating condition and mechanical stress analysis of the rotor under various rotational speeds. The full CAD assembly of the motor is designed including components from the original SMPS motor to allow for fitting in the same HVAC application. / Thesis / Master of Applied Science (MASc) / With the unstable cost and supply of rare earth materials used in permanent magnet electric motors, many alternative machine types are being studied which are suitable for different applications. The focus of this thesis is the design of a novel 6/14 switched reluctance machine which can be fitted in a residential heating, ventilation, and air-conditioning (HVAC) application based on measured performance characteristics of an existing surface mount permanent-magnet synchronous (SMPS) machine. Switched reluctance machines have a number of benefits over permanent magnet machines including that they do not have permanent magnets, are less sensitive to high heat scenarios, have lower manufacturing costs, are more robust, and are generally capable of higher operating speeds. Residential electric motor applications are reviewed and in particular - furnace blower motor appliances. The fundamentals of switched reluctance machines are discussed, including the mechanism, operation, and control strategy. A SMPS motor which is commercially available for retrofitting into residential furnace systems is analyzed to find its performance characteristics through disassembly, inspection, and dynamometer bench testing. The design of a novel 6/14 SRM optimization process is outlined to investigate the effect of changing the geometry values within the motor on the performance characteristics, while keeping within the size constraints of the original motor. A novel 6/14 SRM design is presented which is capable of achieving the target goals in the desired operating conditions. Further suitability testing is performed in terms of thermal analysis of the motor in the peak and continuous operating condition and mechanical stress analysis of the rotor under various rotational speeds. The full 3D CAD assembly model of the motor is designed including components from the original SMPS motor to allow for fitting in the same HVAC application.

No description available.

In an effort to answer broad, contextual questions concerning early 19th Century American industrial history, it is often necessary to supplement generally accepted premises with observations of particular instances. This study of Cloverdale Furnace constitutes such an observation. Particular attention has been paid to details of person, place and practice as gained from Botetourt County Records and the correspondence between such furnace owners as the Breckenridge, Tayloe and Anderson families. The ultimate fate of charcoal-fired iron furnaces is so well known as to require little or no comment. That Cloverdale continued into, and beyond the period of the United States Civil War, depended upon a variety of causes. It probably would have ceased operation in 1859 - 1860, but for crisis of the Union. Other causes for Cloverdale's success and perseverance included: availability of capital, labor, raw materials and managerial talent. Not all of these were distinctive, but some were enough so to deserve special note. The study is chronologic. It begins with the establishment of the furnace in 1789, and ends with the final mining activity of 1889. During this period, there were two separate furnaces located within eight miles of each other. Each was named Cloverdale and each produced high grade charcoal-smelted "gun metal." The operation of Cloverdale Number 1 was based on craft techniques and linked to a local market. The owners were largely absentee investors who utilized their existing slave force for labor. Cloverdale Number 2 was based on a regional market and incorporated a more advanced technology in furnace construction. Under the ownership of John T. Anderson, and later, Joseph R. Anderson, Cloverdale Number 2 achieved a reputation second to none in the eastern part of the United states for producing quality "gun metal" and supplied the Tredegar Works in Richmond with the same. Unfortunately, the reputation was not enough to protect the firm from collapse due to depleted timber reserves and natural resources. / Master of Arts

Yes / In all industrial petrochemical plants and refineries, the furnace is the source of heat resulting from fuel combustion with air. The model-based furnace simulation is considered one of the efficient methods help to reduce the energy loss and maintain fixed refinery revenues, conserving energy, and finally reducing external fuel consumption and total fuel cost. In this paper, a model-based simulation is carried out for a natural air draught industrial scale furnace related to Liquified Petroleum Gas (LPG) production plant in Libya to thoroughly investigate the most responsible factors in lowering the furnace butane exit temperature, which is supposed to be two degrees Fahrenheit higher than inlet temperature. Therefore, to resolve this industrial problem, Aspen Hysys V10, coupling with EDR (exchanger design and rating) is used to carry out rigorous model-based simulation. This is specifically used to assess the impact of heat loss from inside the firebox to the surrounding medium and heat loss from the furnace stack and walls, besides the effect of excess air on the furnace efficiency. Furthermore, this research intends to verify whether the operating conditions, such as furnace tubes inlet flow rate, temperature and pumping pressure, are conforming to the upstream process design specifications or need to be adjusted. The results confirm that increasing furnace outlet temperature two degrees Fahrenheit from off specification 190 °F instead of 184 °F is successfully achieved by decreasing upstream stream flowrate 25% below the operating value and cutback excess air gradually until 20%. Also, the results clarify the necessity of increasing the flue gas temperature by 7% over design condition, to gain a significant reduction of heat loss of 31.6% and reach as low as 35.5 MBtu/hr. This improvement is achieved using optimum operating conditions of an excess air of 20%, and flue gas oxygen content of 3.3% delivered to stack. Accordingly, the furnace efficiency has been increased by 18% to hit 58.9%. Furthermore, the heat loss from the furnace walls can be also reduced by 68% from 5.41 MBtu/hr to 1.7 MBtu/hr by increasing the refractory wall thickness to 6 in., which entails an increase in the furnace efficiency by 3.66% to reach 58.96%. Decreasing the heat loss fraction through the refractory wall, pip doors, expansion windows and refractory hair cracks would also increase the efficiency by 21% to reach a high of 59.7%. Accordingly, a significant reduction in daily fuel consumption is observed, which costs 1.7 M$ per year. The outcomes of this research clearly show the potential of reducing the operation and maintenance costs significantly.

Artefacts relating to tin smelting from tin mills or ¿blowing houses¿ in Devon and Cornwall, plus material from smelting sites that cover a range of dates from the Bronze Age through to the 19th Century, were examined: these include metallic tin, furnace linings, ore samples and slag. Analysis of tin slags from over forty sites was carried out, to determine microstructure and chemical composition. Techniques employed included optical and scanning electron microscopy, X-ray fluorescence and ICP mass spectrometry. Analysis indicates that slag appearance and composition are heavily influenced by local geology. Composition, particularly iron content, is shown to have a strong effect on slag melting point and viscosity, and the implications for the purity of metal produced are discussed. Bringing together the evidence provided by slag chemistry, documentary sources and smelting remains in the archaeological record, changes in tin smelting technology through time, and the consequences thereof, are considered. / R. F. Tylecote Memorial Fund, administered by the Historical Metallurgy Society, and the Francis Raymond Hudson Memorial Fund.

Expansive clays undergo a large swell when they are subjected to water. Thus, expansive clay is one of the most abundant problems faced in geotechnical engineering applications. It causes heavy damages in structures, especially in water conveyance canals, lined reservoirs, highways, airport runways etc., unless appropriate measures are taken. In this thesis, Granulated Blast Furnace Slag (GBFS), GBFS - Lime combinations and GBFS Cement (GBFSC) were utilized to overcome or to limit the expansion of an artificially prepared expansive soil sample (Sample A). GBFS and GBFSC were added to Sample A in proportions of 5 to 25 percent. Different GBFS-Lime combinations were added to Sample A by keeping the total addition at 15 percent. Effect of stabilizers on grain size distribution, Atterberg limits, swelling percentage and rate of swell of soil samples were determined. Effect of curing on swelling percentage and rate of swell of soil samples were also determined. Leachate analysis of GBFS, GBFSC and samples stabilized by 25 percent GBFS and GBFSC was performed. Use of stabilizers successfully decreased the amount of swell while increasing the rate of swell. Curing samples for 7 and 28 days resulted in less swell percentages and higher rate of swell.

O arroz é um dos alimentos mais consumidos no mundo, caracterizando-se como a base da alimentação para mais da metade da população mundial. De acordo com a Organização Mundial da Saúde (WHO), a ingestão de alimentos contaminados é uma das principais vias de absorção de elementos potencialmente tóxicos pelo ser humano. Por esse motivo, órgãos de fiscalização têm estabelecidos limites máximos permitidos desse tipo de elemento nos alimentos. Nesse sentido, o desenvolvimento de métodos e aplicações visando à determinação de elementos com caráter tóxico, tais como o Al, As, Cd e Pb em alimentos é de suma importância. Nesse projeto, foram desenvolvidos métodos para determinações diretas de Al, As, Cd e Pb em arroz por espectrometria de absorção atômica com forno de grafite e amostragem direta de sólidos (SS-GF AAS) que tem se mostrado uma técnica promissora especialmente devido à sua elevada sensibilidade e detectabilidade, além de dispensar morosos processos de decomposição de amostra. A adequada otimização do programa de aquecimento aliado ao uso de modificadores químicos adequados possibilitou o uso de calibração aquosa. Parâmetros importantes como o tamanho de partícula, massa de amostra e segregação de analito foram investigados. Observou-se que partículas inferiores a 100 µm geravam resultados precisos. A massa mínima ideal de amostra de arroz a ser utilizada na análise foi em torno de 300 µg. A massa máxima recomendada foi 500 µg. Segregação de Al e Cd não foram observadas na amostra de arroz. A segunda parte do projeto envolveu a aplicação do método de análise desenvolvido em amostras de arroz comercializadas na cidade de São Paulo. Investigou-se também a influência dos processos de lavagem e cozimento dos grãos sobre a concentração de Al, As, Cd e Pb. Todas as 17 amostras de diversos tipos e marcas de arroz analisadas apresentaram concentrações de As, Cd e Pb abaixo dos limites estabelecidos por lei. Com relação ao Al, não há regulamentado o valor de limite máximo. As maiores concentrações desse elemento foram observadas nos grãos de arroz integral. O processo de lavagem removeu significativamente a concentração de Al e Pb na maioria das amostras, entretanto, o mesmo não foi observado para o Cd. O processo de cozimento diminuiu a concentração de Cd e Pb em parte das amostras, e um pequeno aumento na concentração do Al foi observado, o qual pode ser atribuído à contaminação pelo ambiente. O cozimento do arroz em frascos de vidro ou panelas a base de alumínio não alterou a concentração desse elemento no arroz, nem mesmo quando a panela de alumínio foi polida com palha de aço / Rice is a staple food for more than 40% of the world\'s population. Considering that the main reason of contamination by potentially toxic element occurs by food ingestion, World Health Organization (WHO) has been controlling the levels of some contaminants. In this context, development of methods and applications associated to determination of potentially toxic elements such as Al, As, Cd and Pb in food are important. In this work, methods for direct determination of Al, As, Cd and Pb in rice by solid sampling graphite furnace atomic absorption spectrometry (SS-GF AAS) were developed. Solid sampling-GF AAS has shown as a promising technique especially due to its high sensitivity and detectability and the possibility to practice direct analysis of solid samples, dismissing tedious and error prone sample preparation step. The adequate heating program optimization associated to the use of chemical modifier allowed direct rice analysis against aqueous calibration. The influence of some parameters, such as particle size, sample mass size and analyte segregation on the analytical results were investigated. Results showed that particle size smaller than 100 µm generated accurate results. The minimum sample mass size recommended for analysis was around 300 µg and the maximum sample mass size was around 500 µg. Segregation of Cd and Al was not observed in the rice sample. The second part of the work involved the analysis of 17 rice samples commercially available in São Paulo city. Influence of rice washing and cooking procedure on the Al, As, Cd and Pb concentrations was also investigated. Concentration of all analytes were lower than the maximum allowed by WHO in all samples. The highest concentrations of Al were found in coarse rice. The washing process reduced significantly the concentrations of Al and Pb in most samples, however, the same was not observed for Cd. Cooking process reduced the concentration of Cd and Pb for most samples, probably by volatilization. On the other hand, an increase in Al concentration was observed. This fact could be attributed to the sample contamination during cooking process. Rice cooked in glass or aluminum container presented the same concentration of Al, even when polished aluminum container was used. These results indicated that there is no translocation of Al from container to food