<p>Steel heating and melting processes consume the majority of the energy used in advanced short-process steelmaking practices. Economic and environmental pressures from energy consumption drive the research to improve the furnace operation efficiency and energy efficiency. The goal of this research is to utilize computational fluid dynamics (CFD) modeling to provide useful tools and recommendations on the steel heating and melting practices in the steelmaking process. The steel slab reheating process, the steel scrap preheating process and the steel scrap melting process are studied.</p> <p> </p> <p>A transient three-dimensional (3-D) CFD model was developed to simulate the flow characteristics, combustion process and multi-scale, multi-mode heat transfer inside the reheating furnace. The actual geometry of an operating industrial furnace was used and typical operating conditions were simulated. Specific walking speeds of slabs in production were modeled using a dynamic mesh model which is controlled by a user-defined function (UDF) solved using ANSYS Fluent. Fuel variations at different zones with respect to time were also considered. The model was validated with instrumented slab trials conducted at the SSAB Mobile (Alabama) mill. The temperature field in the furnace and the temperature evolution of a slab predicted by the CFD model are in good agreement with those obtained from the instrumented slab trials. Based on the simulation results, the slab reheating process and the temperature uniformity of a slab at discharge were able to be properly evaluated. In addition, a comprehensive two-dimensional (2-D) numerical heat transfer model for slab reheating in a walking beam furnace was developed using the finite difference method. An in-house code was developed. The model is capable of predicting slab temperature evolution during a reheating process based on real time furnace conditions and steel physical properties. The model was validated by using mill instrumented slab trials and production data. The results show that the temperature evolution predicted by the model is in good agreement with that measured by the thermocouples embedded in the instrumented slab. Compared with 3-D CFD simulation of a reheating process, this 2-D heat transfer model used for predicting slab temperature evolution requires less computing power and can provide results in a few seconds. A graphical user interface was also developed to facilitate the input and output process. This is a very convenient and user-friendly tool which can be used easily by mill metallurgists in troubleshooting and process optimization.</p> <p> </p> <p>CFD models for steel scrap preheating and melting processes by the combined effects of the heat source from both oxy-fuel combustion and electric arc were also developed. The oxy-fuel burners firing natural gas (NG) are widely used in EAF operation during the scrap preheating and melting stages. In order to understand the role of oxy-fuel combustion and potentially increase the energy input from NG while decreasing the electricity consumption, numerical simulation of scrap preheating by oxy-fuel combustion in an EAF was firstly conducted. A 3-D CFD model was developed with detailed consideration of gas flow, oxy-fuel combustion, heat transfer between gas and solid scrap and scrap oxidation. The model was validated by a small-scale experimental study and applied onto a real-scale EAF.</p> <p> </p> <p>Scrap melting in bath is comprehensively studied with a CFD model developed to simulate the melting in bath process under given operating conditions. Two sub-models were developed for model integration: steel melting model and coherent jet model. The multiphase volume of fluid (VOF) model and the enthalpy-porosity technique are applied to describe the steel melting process. The coherent jet model calculates the gas jet momentum and is integrated into the flow model to calculate its effect on the fluid flow in the bath. The electric arc was treated as a heat flux to represent the heat transfer from the electric arc during the melting process. Model validations were conducted for each sub-model to ensure their accuracy. Parametric studies were also carried out to obtain useful information for real practice. </p><p>Overall, the CFD models developed in this research work have demonstrated value in improving energy efficiency in the energy-intensive steelmaking processes. The developed CFD models also provide insights for better understanding of the multi-physics processes.<br></p> <p> </p>

The objective of this study was to utilize an electric arc furnace ¡]EAF¡^in a steel mill to melt municipal incinerator fly ash ¡]MIFA¡^of different sources ¡]Plants K1 and K2¡^ and evaluate its effectiveness in aspects of environment and economy. The results of full-scale tests have shown that slag thus generated by the EAF was found to be non-hazardous based on the TCLP result and also met the standard of CNS 14602. However, EAF dust thus obtained remained hazardous as it was originally a listed waste by Taiwan EPA. Test results have indicated that this novel treatment technology would not deteriorate the quality of steel billets and bars produced. Moreover, when melting MIFAs from Plant K1¡]with 2.00 wt¢H of MIFA¡^ and Plant K2 ¡]with 3.28 wt¢H of MIFA¡^, the air quality in the steel mill surroundings and off-gas from the stack were all below the regulatory limits. Thus, it would not cause additional pollution problems from this practice. Based on the total capacity of EAFs in Taiwan, it was estimated that these EAFs would be capable of melting fly ash generated by municipal incinerators in Taiwan. From the economic perspective, this melting practice would not lower the production rate of EAF steel-making and increase the tap-to-tap cycle time, consumption of electrical energy, consumption of oxygen, and consumption of graphite electrodes. Furthermore, through this novel practice, the contents of MIFA have turned out to be able to replace some portions of quick-lime and coke powder required for steel-making. Test results have also shown that 1 wt¢H of MIFA injection would generate additional 8.93 kg of slag and 2.76 kg of EAF dust. It was found that an additional cost of NT¢C318 per ton of MIFA treated would be resulted through this practice. This treatment cost is very low as compared with NT¢C8,000 per ton of waste treated by solidification and followed by landfilling. Assuming a melting cost of NT¢C5,000 per ton of MIFA is charged by EAFs, it would save more than ten million NT¢C per year for a municipal incinerator with an annual generation of 5,840 tons of MIFA. On the other hand, for a mini-mill with an annual capacity of 264,000 tons of billets, it would have an additional income of 37 million NT¢C if 3 wt¢H of MIFA is melted while making steel.

This report deals with the mathematical model of the transient behaviour of an existing ethane dehydrogenation furnace which is composed of two main sections: a preheating convection section and a radiant-heated section. The correlation of pressure drop with time has been found from the available data. The fractional carbon deposition and the multiplier coefficient of a pressure drop equation have been determined by the direct search optimization technique of Hooke and Jeeves. An optimal policy for the cyclic operation of the furnace was determined by considering plant temperature profile and hydrocarbon/ steam ration as parameters for maximizing average ethylene produced per day. The effect of temperature profile on the distribution of carbon deposited along the reactor was also predicted and discussed. / Thesis / Master of Engineering (ME)

Thesis: Sc. D., Massachusetts Institute of Technology, Department of Materials Science and Engineering, 1980 / Vita. / Includes bibliographical references. / by Balkishan Agrawal. / Sc. D. / Sc. D. Massachusetts Institute of Technology, Department of Materials Science and Engineering

L’artisanat verrier forestier moderne connaît un développement particulièrement important dans la région languedocienne qui bénéficie d’une tradition ancrée depuis le XIIIe s. Pour autant, les modes et structures de production sont encore peu documentés et l’historiographie en livre généralement l’image d’un modeste réseau d’officines isolées. Fondée sur la complémentarité des sources écrites, archéologiques et archéométriques, cette étude privilégie l’analyse de ces fabriques à partir de huit ateliers fouillés. Elle livre une approche des divers acteurs comme de l’environnement qui contribuent à la structuration formelle de cet art du feu. Une centaine de centres de production modernes a été recensée, le plus souvent rassemblés en foyers. Si leur développement demeure limité, ils font en revanche état d’une certaine autonomie dans la production. De la plus petite unité forestière aux grands établissements assimilés à des centres villageois, chaque site assure le cycle complet de la production du verre. Les ateliers bénéficient en général d’infrastructures relativement simples, rassemblées autour de deux à trois fours à vocation complémentaire : préparation des matières, fusion et recuit. Leur morphologie ainsi que les usages combinés qui en sont faits varient en fonction des époques et de l’importance de la fabrique. Terre propice à l’établissement de l’industrie verrière pour ses nombreuses ressources naturelles, le Languedoc moderne produit principalement du verre creux destiné à alimenter la province. Toutefois, à partir du premier tiers du XVIIIe s., cet artisanat forestier s’étiole progressivement au profit de grandes manufactures alimentées au charbon de terre. / The modern woodlands glassmaking enjoys a particularly siginifant development in the Lower Languedoc region which benefits from a deeply rooted tradition from the thirteenth century on. However, the ways and structures of production are as yet very poorly documented and the historiography generally gives a picture of a modest network of workshops producing objects for daily use.Based on the additionnal information of written archaeological and archeometrical sources, this study favours the analysis of these factories from eight excavated sites. At first place it gives an approach of the people as well as the surrounding area which shows the formal structuring of this ceramic skillset. About a hundred moderns production centres emerged, grouped together in a number of zones with several workshops near each other. Their extent is limited, on the other hand they indicate a certain autonomy in production. From the smallest unit in the woodlands to the big establishments which resembledl proper village settlements, each site ensured the complete cycle of the operational chain of glass production. Generally, the workshops were a relatively simple infrastructure assembled around two or three furnaces with complementary functions: frit, fusion and annealing furnaces.As a region favourable to the establishment of glassmaking due to the rich resources in raw materials, modern Languedoc produced mainly hollow, concave glass.. Basically their production supplied the province which was the biggest of the kingdom. It is only from the first third of the eighteenth century that this woodland craft industry declined progressively as big coal-fired factories took over.

<p>The main objectives of this study were to investigate (i) anovel wetland treatment technology and (ii) selected bed filtermedia for the removal of contaminants from landfill leachate. Areview of the literature concerning experiences of the use ofconstructed wetlands (CW) for the removal of nitrogen fromlandfill leachate, showed that at least three groups oftreatment systems are in practice: sub-surface flow wetlands,hybrid systems (a combination of vertical and horizontal flowwetlands) and, compact constructed wetland (CCW). Most of thesetypeswere generally effective in reducing nitrogen (N,<i>e.g.</i>NH₄-N, dominant N species in leachate) down toeffluent concentrations of about 10 mg L^-1. Unfortunately, very little evidence ofresponsible mechanisms for the removal of N was presented,although some data indicated denitrification. The treatmentperformance of a compact constructed wetland (CCW) applied atthe Tveta Landfill, Södertälje, Sweden, wasevaluated. Chemically purified leachate and untreated leachatewere applied in periods of 7 day submergence and 7 day drainageto different sections of the CCW. The removal efficiency variedbetween 40 and 82%, and a mass removal rate of up to 5.1 g m²d^-1was achieved. The chemical pre-treatment had adecisive role for the highest removal efficiencies obtained andit was unclear whether that treatment enhanced the efficiencybecause of lower toxicity and/or content of fewer competingcations. The possible combination of bed filter media and CCWas an ecotechnological treatment method for landfill leachatewas investigated by bench-scale laboratory column experiments.Reactive filter media (sorbents) was selected from their knownor suggested capacities for removal of heavy metals, nitrogenand phosphorus. Quartz sand or natural sand from an esker wasused as reference medium. Peat was used as an additionalcomponent in mixtures with the reactive media Polonite^®(product from the bedrock opoka) and blastfurnace slag (BFS). A small column study also involved zeolite.Phosphorus was efficiently removed by Polonite^®and NH₄-N to some extent. Concerning metal removal, thebest performance was found as well for Polonite^®, especially for Mn, Fe, Zn and Cu. The BFSshowed good removal efficiency for Cu, Ni and Mo. The removalof different elements was suggested to be a combination ofseveral factors,<i>e.g.</i>precipitation, ion exchange and adsorption. Priorto full-scale application of reactive filters at a landfillsite, matrix selection, filter design and operationalprocedures must be developed.</p><p><b>Keywords:</b>Blast furnace slag; Compact constructedwetland; Metals; Nitrogen; Polonite; Sorbents</p>

This research investigated the fire performance of unprotected timber floors, focussing on composite joist floors, composite box floors and timber-concrete composite floors. The study of these floors was conducted using the finite element software ABAQUS using a thermo-stress analysis in three dimensions, and with experimental fire tests of floor assemblies. The major goal of this research was to develop a simplified design approach for timber floors, validated against the numerical and experimental work. Four furnace tests were conducted on unprotected timber floor systems in the full-scale furnace at the BRANZ facilities in New Zealand. The tested floors were one-way strip floors with pinned support conditions exposed to the ISO 834 standard fire for varying durations of 30 – 105 minutes. The floors were loaded under standard office loading conditions of 3.0kPa live and 1.0kPa superimposed dead loading. The charring rates of the LVL timber members were found to range from 0.66 – 0.86 mm/min across all specimens. When designed to resist a similar load level both the composite joist and box floor types had a similar response to the fire loads, however the joist floors exhibited increased upward burning through the beam members in the latter stages of testing which may contribute to earlier failure times for smaller floor geometries. A sequentially coupled thermal-stress analysis was conducted to determine the effects of a fire on floor assemblies under load. Firstly a thermal analysis was performed to determine the temperature profile of the floor assemblies for the duration of modelling, and then a stress analysis was performed using the temperature profile as input into the structural model. With regards to the thermal modelling, a proposed set of effective values was used to account for the mass transfer processes occurring in the timber. The thermal modelling predicted the charring damage of the floors tested in the experiments to within a few millimetres of precision, and the simplified assumptions made in relation to fire inputs, boundary conditions, mesh refinement and effective material parameters were accurate to the desired level of precision. A sensitivity study was conducted comparing different mesh sizes, time step sizes, material model approaches and software suites to determine any shortfalls which may be encountered in the analysis. It was found that a material model adopting a latent heat approach was the most adequate for modelling timber in fires using these effective values, and mesh sizes of up to 6 mm produced relatively precise results. The structural modelling predicted the displacement response and failure times of the floors to within 20% of the experimental data, and the simplified assumptions made in relation to fire inputs, boundary conditions, mesh refinement and effective material properties were once again accurate to the desired level of precision. A modification to the reduction in tension strength at elevated temperatures was proposed to better predict the observed behaviour. A sensitivity study concluded that the material model definition plays a vital role in the output of the modelling. Non-standard fire exposures were also modelled for completeness. A simplified design method to estimate the fire resistance of unprotected floor assemblies was also developed. The method uses a bi-linear charring rate the assumption of a zero strength layer in the timber. The method was compared to the experimental data from this research and others around the world. The results were also compared to other charring rate methodologies from around the world.

No description available.

Os reatores nucleares de potência refrigerados à água pressurizada (Pressurized Water Reactor - PWR) comumente utilizam pastilhas de dióxido de urânio como o seu combustível nuclear, estas por sua vez são montadas e empilhadas em tubos e tampões de ligas de zircônio (M5, Zirlo, Zircaloy, etc), Na usinagem desses componentes são geradas grandes quantidades de cavacos que estão contaminados com fluido de corte, o armazenamento destes cavacos apresenta riscos de segurança e ambientais por ser um material pirofórico e apresentarem alta área específica. Estas são ligas importadas e por isso é mostrado interesse pela indústria de reciclagem na sua reutilização. Este trabalho apresenta o estudo de um processo de reciclagem e os resultados para buscar, eficiência no processo de limpeza; controle de qualidade; obtenção de eletrodos prensados e a fusão em um forno a arco elétrico sob vácuo (Vacuum Arc Remelting - VAR). O processo de reciclagem se inicia com uma separação magnética de possíveis materiais ferromagnéticos presentes, lavagem do fluido de corte, que é solúvel em água, lavagem com um desengraxante industrial, seguido por um enxágue com fluxo contínuo de água em alta pressão e uma secagem por fluxo de ar quente. A primeira avaliação do processo foi feita por uma análise de fluorescência de raios X por dispersão de energia mostrando impurezas provenientes da mistura com cavacos da usinagem de aços inoxidáveis. Os cavacos foram prensados para a obtenção de eletrodos, para fusão em forno VAR, e para isso foi desenvolvida uma matriz para obtenção de eletrodos. Os eletrodos foram fundidos em um forno VAR de laboratório no Laboratório de Fusão do CECTM IPEN. A fusão dos cavacos é possível e viável em um forno VAR o que reduz em até 40 vezes o volume de armazenamento desse material. / The Pressurized Water Reactor commonly uses uranium dioxide pellets as the nuclear fuel, which are then assembled and stacked in zirconium alloy tubes (M5, Zirlo, Zircaloy) and end capped, in the machining of these components large amounts of chips are generated which are contaminated with cutting fluid. Its storage poses security and environmental risks due to a pyrophoric material. These are imported alloys and so it is shown interest by the recycling industry in its reuse. This paper presents the study of a recycling process and its results to seek efficiency in the cleaning process; quality control; obtaining of the electrodes and melting in a Vacuum Arc Remelting (VAR) furnace. The recycling process begins with a magnetic separation of possible ferromagnetic alloys present, washing out the water-soluble cutting fluid, washing with an industrial degreaser, followed by a rinse with continuous high pressure water flow and a flow drying of hot air. The first evaluation of the process was done by an energy dispersive X-ray fluorescence analysis showing the presence of impurities from the mixture with stainless steel machining chips. The chips were pressed to obtain electrodes to be melted in VAR furnace and for this a matrix was developed to obtain electrodes. The electrodes were melted in a laboratory VAR furnace in the Melt Laboratory at CECTM - IPEN. The melting of the chips is possible and feasible in a VAR furnace that reduces the storage volume of this material by up to 40 times, however, it is necessary to correct the composition of the alloy for the melting of these ingots.

Os cimentos de escória apresentam boas possibilidades de mercado, especialmente em aplicações em que o cimento Portland não possa ser utilizado ou onde o seu uso provoque uma elevação dos custos. A confecção de matrizes para fibras sensíveis aos álcalis e a produção de cimentos com baixo calor de hidratação são exemplos. Neste trabalho, a escória foi ativada com silicato de sódio e cal hidratada. O ativador foi formulado de maneira a proporcionar teores de Na2O de 2,5% e 5%, SiO2 de 0% a 14,8% e Ca(OH)2 de 0%, 2,5% e 5%. O aumento dos teores de Na2O e de SiO2, dentro de determinados limites, propicia um notável crescimento da resistência à compressão. Este crescimento da resistência está associado a uma diminuição da porosidade, para um mesmo fator/água aglomerante. Certamente a diminuição da porosidade é devida a um menor grau de organização cristalina dos produtos hidratados, decorrente do aumento da velocidade de precipitação de hidratados e de gel de N-C-S-H. A adição de Ca(OH)2 diminui a velocidade de perda da trabalhabilidade. Os cimentos de escória ativada com silicatos de sódio podem apresentar resistência à compressão de até 100 MPa, superior à dos cimentos Portland, com calor de hidratação da mesma ordem de grandeza. A velocidade de carbonatação destes cimentos é equivalente a dos cimentos Portland de mesma resistência. No entanto, estes cimentos apresentam maior retração hidráulica. / Binders based on ground granulated blast furnace slag (BFS) are suitable for the building industry, mainly if the use of Portland cement is expensive or may cause problems, such as: alkali sensitive fibre-reinforced cement and concretes and low heat-hydration concretes. BFS is activated by sodium silicates and hydrated lime. The compound\'s proportions are: Na2O - 2.5 and 5.0%; SiO2 from 0 to 14.8%; CaOH2 - 0, 2.5 and 5%. The increase of Na2O and SiO2 amounts allows a considerable improvement of binder strength, with values up to 100 MPa. This increase of the strength is related to the decrease of the porosity for a constant water-binder ratio. The porosity is affected certainly by the reduction of the degree of cristalynity of the hydrated compounds, due to the increase of the speed of precipitation of the hydrates or the N-C-S-H gel. It is possible to obtain BFS binders stronger than the Portland cement, with similar hydration heat. The carbonation rate of these new binders is equivalent to those of Portland cement specimens with similar strength. However these BFS binders have higher drying shrinkage.