Extensive computer predictions have been carried out by the author to study flow, addition dispersion and particle motion during central gas injection into cylindrical vessels. In conjunction with numerical computations, experiments were conducted in a 0.30 scale water model of a 150 ton steel processing ladle, using a Froude number scaling criterion. Two typical gas injection configurations (i.e., conventional central injection and C.A.S. alloy addition procedure) were investigated. / Flow visualization studies were carried out using a suspended network of silken threads, mean velocity vectors and overall flow patterns were determined by video recording techniques, while mean velocity vectors and associated turbulence level were also measured with laser doppler velocimetry. These measurements show very reasonable agreement with equivalent numerical predictions. / To simulate the subsurface motion of additions, spherical wooden balls of various densities were dropped from typical heights, and their subsurface trajectories, immersion times, etc., recorded by means of a video recorder. Frame by frame analysis of the video tapes showed trends which are in good accord with computed trajectories. / Mixing times of simulated molten additions were measured by the conductivity measurement technique. These were compared with prediction from an equivalent tracer dispersion model and excellent agreement achieved. / For industrial application, flow, particle motion, and mixing times in a 150 ton steel processing ladle have been predicted and their technological significance discussed.

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Thesis (MScIng)--University of Stellenbosch, 2003. / ENGLISH ABSTRACT: The pneumatic injection of reagent powder into molten iron has become the preferred way to carry out iron and steel desulphurisation. It is therefore essential to not only understand the thermodynamic implications, but also the kinetic principles that govern the desulphurisation process. Key variables that influence the kinetics of the procedure are the condition and composition of the top slag and the melt as well as the injection conditions. Notable injection parameters include reagent flowrate, injection-lance depth and carrier gas flowrate. Owing to sampling restrictions, the subsequent data from Saldanha Steel®, South Africa does not provide adequate insight into the kinetic behaviour of the desulphurisation process and it was therefore the focus of this research to provide an improved quantitive comprehension of the calcium carbide injection procedure at Saldanha Steel. For this purpose a one-dimensional quasi-steady state model for momentum, heat- and mass transfer in rising gas-liquid-powder plumes has been developed for conditions relevant to the Saldanha Steel refining process. Combined with a model predicting the contribution of the topslag to the process, the overall rate of desulphurisation as a function of time can be determined, thus affording the ability to quantitatively explore and analyse the influence of the afore-mentioned injection parameters, as well as the nature of both the topslag and the melt, on the kinetics of the desulphurisation process. Sensitivity analyses concluded that individual increases in the calcium carbide flowrate, the depth of injection and the amount of carry-over slag will result in a reduction in the injection time, while a decrease in the reagent particle diameter and the initial mass of iron in the ladle will have the same effect. Molten iron temperature losses brought about by prolonged injection needs to be electrically recovered within a steelmaking furnace at a high cost. Owing to the high cost of the desulphurising agent, any reduction in the required injection time, while still maintaining product specifications, will therefore result in diminishing overall production costs. Although all the results contained in this study is of particular interest to the Saldanha Steel scenario, it also provides invaluable information and insights into the important variables and parameters playing a role in injection desulphurisation processes in general, along with the influence that changing conditions can have on the end result of such a procedure. / AFRIKAANSE OPSOMMING: Die pneumatiese inspuiting van reagentpoeier is die populêrste ontswawelingsmetode in die yster- en staal bedryf. Dit is dus van groot belang dat die gepaardgaande termodinamiese en kinetiese beginsels betrokke by die ontswawelingsreaksies baie goed verstaan word. Die kondisie en samestelling van die bo-slak en die vloeibare yster, asook die inspuitingkondisies is twee van die belangrikste veranderlikes wat die kinetika van die ontswawelingsproses beïnvloed. Beperkte monsternemingsgeleenthede het veroorsaak dat die relevante data, soos voorsien deur Saldanha Staal®, nie die nodige kinetiese insig in verband met die ontswawelingreaksie weergee nie. Dit is dus die doel van hierdie werkstuk om ‘n verbeterde kwantitatiewe begrip van die ontswawelingsproses by Saldanha Staal daar te stel. Vir hierdie doeleinde is ‘n een-dimensionele, kwasi-gestadigde toestand model vir stygende gas-vloeistof pluime ontwikkel. Die model inkorporeer momentum-, hitte- en massaoordragsprinsiepe en is verteenwoordigend van die ontswawelingsproses by Saldanha Staal. ‘n Tweede model simuleer die bydrae wat die bo-slak tot die algehele ontswawelingsproses maak en saam gee hierdie twee modelle die algehele ontswawelingstempo weer as ‘n funksie van tyd. Die modelle word ook gebruik om die invloed van die bogenoemde inspuitingsveranderlikes op die proses te ondersoek. Deeglike sensitiwiteitsanalise het gewys dat ‘n verhoging in die kalsium karbied vloeitempo, asook die inspuitingsdiepte van die lans en die hoeveelheid slak wat vanaf die boogoond na die ontswawelingseenheid oorgedra word, ‘n vermindering in die vereisde inspuitingstyd te weeg bring. Verkleining in die kalsium kardied partikels se gemiddelde diameter en vermindering van die hoeveelheid yster in die torpedokarre aan die begin van die proses, het dieselfde uitwerking op die vereisde inspuitingstyd. Geweldig baie geld moet aan elektrisiteit spandeer word om die temperatuur wat verlore gaan as gevolg van onnodige lang inspuitingstye, in die staalmaakoonde te herwin. Gekombineerd met die feit dat die kalsium karbied reagent baie duur is, beteken dit dat reduksies in die vereisde ontswaweling inspuitingstyd groot besparings te weeg kan bring. Alhoewel die saamgevatte resultate van spesifieke belang is vir die Saldanha Staal proses, verskaf hierdie studie waardevolle informasie oor die belangrikheid van verskeie veranderlikes, asook die rol wat veranderende toestande op die eindresultate van die ontswawelingproses kan hê.

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M. Tech. Metallurgical Engineering / Martensitic stainless steel (MSS) metal matrix composite coatings that can accommodate most applications were developed using TiC and stellite 6 as reinforcement powders and Nd: YAG solid state laser for surface alloying. The alloyed surfaces were characterized by means of optical microscopy (OM), scanning electron microscopy (SEM/EDS) and x-ray diffraction (XRD). The microstructures of the alloyed zones show even distribution and super saturation of titanium carbide and other complex carbides of chromium (Cr23C6), niobium (Nb6C5), and iron (Fe7C3) in the matrix of the MSS A significant increase in the hardness was achieved by the addition of stellite 6, although with cracks in the alloyed layer. The cracks formation was due to high heat build-up during the laser alloying process. As a result of the addition of TiC powder in the form of premixed ratio, the heat build-up in the work-piece was minimized. This is due to the high absorptance of laser irradiation by the TiC powder. The alloyed zone of the premixed ratio was free from cracks with microhardness increase of more than 150% of that of the substrate. Multiple tracks of 50% and 75% overlap were fabricated. Three-body abrasive wear study of the overlapped coatings revealed the wear mechanism of the laser coatings to be adhesion, mild abrasive and less degree of deformation showing less plastic ploughing and cutting compared to the as-received. The wear mechanism of the as-received is adhesion, severe abrasive and plastic deformation, showing distinct grooves and damaged spots in the form of craters. The wear resistance of the MMC obtained by alloying with the TiC powder was significantly improved with the 75% overlap, about 90% better than the native material.