Smelting Research Articles

Method for Calculating the Unbalanced Current in Ungrounded Double Wye C-Type Harmonic Filters

This paper presents a methodology to calculate the neutral unbalanced current in C-type filters with an ungrounded double Wye topology; this equipment is widely used in the steel sector to mitigate the harmonic content in electrical installations caused by electric furnaces used in metal smelting processes. A common failure in these filters is the current unbalance caused by the degradation of the capacitor and inductor modules, leading to dangerous surges that affect these components, possible harmonic resonances, and deficient filtering by the equipment. Currently, there are no documented strategies for calculating the neutral current that allow for the proper adjustment of neutral protection in this type of equipment, resulting in catastrophic failures, costly unscheduled shutdowns, and potential harm to plant personnel. In this paper, we propose a methodology for calculating the unbalanced current in double Wye C-type harmonic filters, considering the natural degradation of capacitor and inductor modules and based on on-site measurements of the impedances for each element of the equipment. This allows for the predictive maintenance of these devices and the precise adjustment of neutral overcurrent protection. First, we review the operating principle of C-type harmonic filters and the neutral protection scheme. Then, the calculation methodology is proposed and validated in two practical case studies. In the first case, a 45 Mvar C-type second harmonic filter connected to a 34.5 kV bus is analyzed. In the second case, an 18.5 Mvar C-type second harmonic filter, part of a ±80 Mvar STATCOM system, connected to a 34.5 kV bus is examined. In both cases, these filters reduce the harmonic content in two steel plants: the first connected to a 400 kV bus and the second to a 230 kV bus. The results obtained with the proposed methodology were implemented in the protection device for a neutral current imbalance, considering different degradation values of the capacitors, and compared with the manufacturer’s suggested settings. The discussion highlights the good performance of the proposed methodology, particularly in terms of the protection device’s response speed to a risky unbalanced current.

Iron extraction from dust from scrap metal smelting in electric arc furnaces by magnetic separation

Iron extraction from dust from scrap metal smelting in electric arc furnaces by magnetic separation

From Waste to Strength: A Comprehensive Review on Using Fly Ash in Composites with Enhanced Mechanical Properties

This article explores the diverse applications of fly ash (FA), a by-product generated during the combustion of coal. The introductory segment thoroughly comprehends the origins, composition, and widespread occurrence of FA. FA, which comprises an estimated 38% of worldwide power generation, frequently encounters disposal and storage obstacles on account of its classification as non-hazardous waste in the majority of countries. The environmental issues linked to the dispersal of FA are underscored in the problem statement, which further emphasizes the urgency for sustainable alternatives. Due to the fugitive emissions and potential health hazards associated with metal melting in FA, it is critical to investigate novel applications and disposal techniques immediately. Environmental sustainability is a primary focus of research, with the development of synthetic FA composites being one such alternative. The analysis presents significant findings that underscore the wide-ranging applications of FA. These applications include its utilization as a filler in composites, as well as its incorporation into cement and geo-polymerization processes. Notably, (10-20) wt. % Nano-FA enhances epoxy-based composites, showcasing remarkable improvements in tensile strength, flexural strength, and impact resistance. In thermoplastic composites, substantial enhancements occur within the (5–10) wt. % FA range, but exceeding optimal ranges weakens matrix-fiber interaction, leading to diminishing returns. The article emphasizes the criticality of FA in improving the mechanical and thermodynamic characteristics of substances, specifically within the domain of composites. The investigation into FA nanoparticles, including their processing techniques and surface treatments, unveils encouraging prospects for enhancing material characteristics.

Nonlinear Theory of the Growth of New Phase Particles in Supercooled Metal Melts

Nonlinear Theory of the Growth of New Phase Particles in Supercooled Metal Melts

Towards High-Quality Investment Casting of Ti-6Al-4V with Novel Calcium Zirconate Crucibles and Optimized Process Control

The investment casting of titanium and its alloys relies on a high resistance of the crucibles and shell molds in terms of temperature and reactivity. The availability of ceramic crucibles that offer sufficient resistance to the titanium melt enables vacuum induction melting (VIM). CaZrO3 prepared from a mixture of CaO and ZrO2 as a raw material for refractory ceramics shows a high corrosion resistance against metallic melts even under very high temperatures up to 1800 °C. Crucibles and shell molds of CaZrO3 were successfully produced and used in subsequent casting trials. This study is focused on the refractory crucibles suitable for casting Ti-6Al-4V (Ti-64) using a tilt casting machine. In order to evaluate the crucible reaction and, therefore, the quality of the castings, chemical analyses, investigations of the microstructures and hardness measurements were carried out. Careful control of the melting duration is mandatory to avoid crucible reactions that otherwise result in contamination of the cast with oxygen and zirconium. This was achieved by modified coil geometries. Under optimized casting conditions, the oxygen and zirconium impurity limits of ASTM B367-09 for titanium castings were met. Based on the correlations found, optimized casting parameters with regard to material quantity, coil geometry and heating power could be determined in order to provide guidance for a high-quality casting process with VIM.

CFD Modeling of HBI/SCRAP Melting in Industrial EAF and the Impact of Charge Layering on Melting Performance

The melting of scrap and hot briquetted iron (HBI) in an AC electric arc furnace (EAF) is simulated by an advanced 3D computational fluid dynamics (CFD) model that captures the arc heating, the scrap/HBI melting process, and the solid collapse mechanisms. The CFD model is used to simulate a scenario where charge layering and EAF power profiles are provided by a real EAF operation. CFD simulation of the EAF operation shows proper prediction of the charge melting when compared with standard industry practice. Namely, the CFD model predicts a 32.5%/67.5% ratio of solid/liquid steel at the beginning of refining, which approaches the 30%/70% ratio used in standard practice. Based on this prediction, the melting rate in the CFD results differs by 8.3% from actual EAF operation. The impact of charge layering on melting is also investigated. CFD results show that distributing charge material into a greater number of layers in the first bucket (10 layers as compared to 4) enhances the melting rate by 12%. However, including dense material at the bottom of the furnace deteriorates melting performance, reducing the impact of the number of layers of the charge. The CFD platform can be used to optimize the use of HBI/scrap in real EAF operations and to determine best recipe practices.

Identification and Evaluation of Synergy Between Carbon Emissions and Air Pollutants in Inter-Industrial Trade Among Provinces in China

With the vigorous promotion in China of efforts to reduce pollution and carbon emissions, examining their synergies becomes increasingly crucial. This study used the multi-regional input–output (MRIO) table to build the consumption-based industrial emissions inventories of CO2 and three major air pollutants (PM2.5, NOx, and SO2) and constructed synergistic emission indices of the intensity and magnitude to identify and evaluate the synergy between carbon emissions and air pollutants in inter-industrial trade among 30 provinces in mainland China. The results show that more than 85% and 40% of inter-provincial and inter-industrial trades have synergistic emissions between CO2 and air pollutants, respectively. We identified 77 inter-provincial trades and 84 inter-industrial trades among provinces with strong synergistic emissions. They are mainly reflected in the demand of the construction industry in Zhejiang and Guangdong for the nonmetal mineral products manufacturing industry in Henan, and the metal smelting and processing industry in Hebei, along with the demand of the service industry in Beijing for the electric power, steam, and hot water production and supply industry in Inner Mongolia. Our study provides new insights into the synergistic reduction of CO2 and air pollutants within the supply chain, thereby enriching the discourse on regional and industrial synergies in achieving sustainable development goals.

Graphene reinforced magnesium metal matrix composites by infiltrating coated-graphene preform with melt

Graphene’s exceptional mechanical, electrical, and thermal conductivity capabilities make it an ideal reinforcement for metal matrix composites. However, graphene is hard to be dispersed in the melt metal due to its high surface energy, non-wetting nature, and strong van der Waals interactions between graphene sheets, which weaken the reinforcing efficiency of composites. A novel process by infiltrating the coated-graphene preform with melt magnesium was proposed to improve the dispersion of graphene in the magnesium matrix. Graphene preforms with oriented pores were prepared by a directional freeze-drying method. Magnesium oxide coatings were deposited on the surface of graphene inside the graphene preform using the evaporation of magnesium atoms to enhance the strength as well as the wettability between the preform and magnesium matrix. Magnesium matrix composites were fabricated by liquid-solid pressure infiltrating coated-graphene preform with molten magnesium. The microstructure of graphene preforms and composites and mechanical properties of the composites were characterized. The results show that graphene is uniformly dispersed in the matrix and presents a reticular structure, and the hardness, elastic modulus, and compressive strength of the composite were improved apparently compared to the matrix. This study suggests that the method of preparing composites by infiltration provides a novel strategy for fabricating nano-material reinforced magnesium matrix composites.

Study of regularities and features of simultaneous contact interaction of active and inert metal melts with zirconia

ABSTRACT The mutual influence of interface processes during simultaneous contact of zirconia ceramic plate with adhesion-active Cu–Ga–Ti melt (on one side of the plate) and inert to oxides liquid copper (on other side of the plate) was studied. Wetting of ceramic with metal melts was studied by sessile drop method, the structure of the interfaces was determined using SEM. Due to the dissolution of ceramic oxygen in Cu–Ga–Ti, non-stoichiometric zirconia (ZrO2-x) is formed, then ‘surplus’ zirconium from the ZrO2-x structure dissolves in the copper melt, the stoichiometry of zirconia is restored and an additional amount of oxygen dissolves in the Cu–Ga–Ti melt. It leads to a decrease in the adhesion of Cu–Ga–Ti to ceramics, while improving the wetting of ZrO2 ceramics with copper. The ZrO2–Cu–Ga–Ti interface contains copper–titanium–oxygen intermetallides with zirconia inclusions, which does not provide adhesion of metals with solid oxides. If the contact of Cu–Ga–Ti with ZrO2 is formed before contact with liquid copper, then the interface layer contains oxidized titanium, which promotes adhesion of metal to ceramic. Thus, the design of the sample affects the processes in the studied systems in the same way as the heating mode and the amount of the active component.

Integrating a high-energy activation method for the sustainable treatment of iron smelting slag, phosphogypsum, and arsenic-contaminated water

Metallurgy is one of the pillar industries in China, but metallurgy inevitably produces a large amount of industrial solid waste and heavy metal pollution. Phosphogypsum (PG) is a by-product of the production of wet-process phosphoric acid, and after the preliminary fieldwork, there is a very small amount of arsenic [As(V)] in some of the phosphorus ores, and there is a risk of heavy metal pollution. In the present study, the preparation of arsenic adsorbent (PG/IS) by doping iron smelting slag (IS) with PG as a base material was proposed and the preparation conditions were optimized by Response Surface Methodology. PG/IS was systematically characterized and its adsorption properties were investigated with respect to a variety of factors. PG/IS exhibits spontaneous endothermic chemical adsorption characteristics for As(V)，its adsorption process is more consistent with the pseudo-second-order kinetic model. Coordination complexation and chemical precipitation are the primary mechanisms by which PG/IS removes As(V). This study provides a new approach for phosphorus chemical enterprises to achieve green development and reduce industrial solid waste and As(V) emissions.

Characterization of Industrial Carbon Emission Dynamics and Network Structure Evolution in China

Given that industry is the major source of carbon emissions, clarifying the carbon transfer regularity triggered by industry production linkage is of great importance in realizing the synergistic development of industry to reduce pollution and carbon emissions. Based on the perspective of responsibility allocation, the study accounted for the industry carbon emissions and constructed a carbon transfer weighted directed network model and applied the social network analysis method to explore the structure of the industry carbon transfer network and its evolution characteristics from 2005 to 2020. The results showed that： ① The overall carbon emissions of industries from 2005 to 2020 presented a rapid growth trend and large differences occurred in emissions between industries. ② The scale of the carbon transfer network was expanding rapidly and the characteristics of the small-world network were significant. ③ The community structure of the carbon transfer network was obvious, including four optimal associations： high carbon emission, carbon transmission, carbon endogenous, and high spillover. ④ The construction industry and the metal smelting and rolling processing industry were the core of the carbon transfer network structure, with strong network control. In view of the above characteristics, we proposed countermeasures and suggestions in terms of implementing the allocation of carbon emission reduction responsibilities and differentiated emission reduction measures for associations as well as focusing on the management of core nodes of the network, with the intent of providing cross-sectoral synergistic emission reduction ideas for the development of sustainable low-carbon transformation in China's industry sector.

Pollution of Heavy Metals in Topsoil of Remote Mountainous Areas in Western Yunnan-Guizhou Plateau

Heavy metals from anthropogenic emissions have had a negative impact on the ecological environment in remote regions. A total of 69 topsoil samples were collected from 13 remote mountainous areas in the western Yunnan-Guizhou Plateau at altitudes of 2 563-4 037 m, and the concentrations of ten heavy metals in the samples were determined. Enrichment characteristics and pollution sources of heavy metals in topsoil were discussed by referencing the enrichment factor （EF）, positive matrix factorization （PMF）, and Pb isotopes. The results showed that the average concentrations of Al, Fe, Cu, V, and Zn in the topsoil were lower than the soil background values in Yunnan Province； the average concentrations of Ni and Pb were similar to the background values； and the average concentrations of Cd, Cr, and Hg were 1.8-3.6 times higher than the background values. The average EF values of Pb, Cr, and Ni were 3.8, 3.4, and 2.3, respectively, showing moderate enrichment according to the EF classification criteria； the average EF values of Cd and Hg were 15.2 and 10.0, reflecting significant enrichment； and the average EF values of the other metals ranged from 1.1 to 1.9, displaying none-weak enrichment. Combining the comparisons of heavy metal concentrations and ratios in topsoil and bedrock and the EF and PMF results, Al, Fe, V, Cr, Cu, Ni, and Zn in topsoil were considered primarily from detrital sources, and the spatial concentration variations of the metals should have been mainly regulated by the parent material. Cadmium, Hg, and Pb were obviously polluted by anthropogenic emissions, and the main sources were non-ferrous metal smelting and coal combustion. The areas with relatively high Cd, Hg, and Pb pollution were mainly distributed in the Jiaozi snow mountain, Bitahai watershed, Luoji Mountain, and Laojun Mountain areas. Anthropogenic emissions contributed 23.8% of the accumulation of heavy metals in the topsoil.

Molecular dynamics research on the effect of selective laser melting parameters on porosity and properties of parts

Selective laser melting (SLM) is considered as a new production technology which has the potential to produce amorphous alloy parts. However, pores are often observed in parts prepared by SLM, which seriously affect the properties and life of the parts. In this work, an atomic model for SLM forming of Cu50Zr50 amorphous alloy is established. The effects of laser power and scanning speed on the porosity and mechanical properties of parts fabricate by SLM are researched using molecular dynamics methods. The results indicate that increasing laser power or reducing laser scanning speed could enhance the laser energy input of the molten pool and increase the molten pool temperature, which could improve the fluidity of the metal melt and prolong the existence time of the molten pool. The molten metal could fully fill the gaps between powders, which reduces the porosity and is beneficial to obtain dense parts. The tensile strength of samples formed by SLM is positively correlated with their porosity. Stress concentration occurs in the system with through holes and internal pores. Defects expand and interconnect rapidly under stress concentration, which leads to a decrease in strength and plasticity. The porosity could be reduced by adjusting the process parameters, thus improving the mechanical properties of the parts. This study provides a theoretical reference for a deeper understanding of the formation mechanism of SLM pores and the development of advanced alloys with high density.

Analysis of noise characteristics of metal processing equipment

The management and prevention of industrial injuries among workers are crucial in the work environment. Industrial injuries occur in various forms and have diverse causes, and noise-induced hearing loss accounts for a significant proportion of workplace injuries. Therefore, this study aimed to measure the factory noise during engine-component (metal) processing for automobiles, where substantial noise-induced hearing loss is prevalent. The measurement results revealed that the 24-h equivalent continuous noise level (Leq) was approximately 83.8 dB(A), and the noise at two points was higher than the noise exposure standard of 89 dB(A). These points were identified as locations where 2,200- to 3,500-ton casting machines were positioned on both sides to melt iron to produce components. The noise generated from each machine is assumed to have combined at these points, resulting in elevated noise levels. The results were plotted on a noise rating (NR) curve. The NR values ranged from 81 to 83, surpassing the standard NR range of 60 to 70 that is commonly used in typical workplaces. The frequency band that determined the NR was 2 kHz. Therefore, measures such as the use of porous sound-absorbing materials should be considered to attenuate the frequency range based on the noise characteristics.

Source apportionment and health-risk assessment of PM2.5-bound elements in indoor/outdoor residential buildings in Chinese megacities

Particulate matter with a diameter of 2.5 μm or smaller (PM2.5) in indoor environments originates from both indoor and outdoor sources, influencing associated human health risks through different compositions. This study simultaneously collected and analyzed indoor and outdoor PM2.5 samples in three major Chinese megacities—Beijing, Shanghai, and Shenzhen—to characterize PM2.5 sources and assess their health impacts. A total of seven distinct sources, both indoor and outdoor, were identified for PM2.5: indoor activities, metal smelting, industrial activities, soil dust, vehicle emissions, coal combustion, and fuel oil combustion. Indoor activities accounted for approximately 20% of the residential indoor PM2.5, with the remainder predominantly due to outdoor PM2.5 infiltration. The contributions of indoor activities to noncarcinogenic and carcinogenic risks ranged from 3.6% to 28.5%, whereas outdoor PM2.5 sources posing greater health risks. The cumulative noncarcinogenic risks for adults in Beijing, Shanghai, and Shenzhen were 0.99, 1.15, and 0.72, respectively, slightly higher than those for children. The cumulative carcinogenic risks for adults were approximately five times those for children, with values of 6.90 × 10−5, 6.34 × 10−5, and 6.83 × 10−5, respectively, all surpassing the acceptable limit. Noncarcinogenic risks were predominantly attributed to Ni, Co, and Mn, contributing over 80% to the total risk, while Cr was the primary contributor (>89%) to carcinogenic risks. Indoor exposure accounting for over 80% of noncarcinogenic and carcinogenic risks for adults, and exceeding 90% for children. This study provides significant insights into the effective control of PM2.5 pollution and the reduction of health risks from a source perspective.

Study on the dynamic characteristics of rising bubbles under the influence of viscosity based on VOF method

Abstract In order to study the buoyancy-driven rising bubbles in liquids in various types of problems such as oil pipeline transportation, combustible ice mining, ship drag reduction, and the use of bubbles to deliver drugs in blood, this paper establishes a model for the rising bubbles in liquids based on the Volume of Fluid Function (VOF) method, and investigates the change rule of the larger-size bubbles under the influence of viscosity in different viscous silicone oils. It provides theoretical and technical support for various natural and industrial processes such as deep-sea oil extraction and metal smelting.

Acoustic emission monitoring of a laser powder bed fusion process

Additive manufacturing (AM) metal parts offers opportunities for various industrial applications. From individual production of spare parts for unique mechanical components to prototyping of complex structures, the possibilities of production using the additive manufacturing process are manifold. One common AM technique is the Laser Powder Bed Fusion (PBF-LB/M) process, where a laser is used to selectively melt metal powder and create the parts layer wise as designed in a model. During manufacturing certain defects like pores, cracks and lack of fusion may be created in the built parts. As AM parts often have complex geometries, a postprocess non-destructive testing is difficult or even not possible. Thus, different optical monitoring techniques are applied to detect flaws during the build process with the aim to detect and repair defects right away during the manufacturing process. However, optical monitoring system require a clear view of the melt pool and quite expensive equipment. Acoustic monitoring by AE sensors attached to the built plate would be a cheaper alternative which also can be used without visual contact to the building chamber. This paper shows a first approach of an AE based process monitoring. The build plate of a PBF-LB/M machine therefore was adapted to hold four AE sensors that are then used to monitor the process. The build process itself creates AE signals caused by the melting and cooling and the mechanical application of powder. The formation of pores and cracks is expected to create additional acoustic emissions that will be distinct from the AE pattern from the printing process. This AE signals can be linked to the different layers of the printed part or in the long run to the laser position. Results from the first tests in a customized LPBF machine will be shown as well as the implementation of AE into the PBF-LB/M machine.

Numerical investigation of arc characteristics and metal properties in ELAMF-assisted WAAM with wire retraction

In this study, a multi-physics integrated model of wire arc additive manufacturing (WAAM) with wire retraction and external longitudinal alternating magnetic field (ELAMF) assistance is proposed and validated, and the effect of ELAMF on the arc plasma characteristics and metal properties are systematically and quantitatively investigated. The model comprehensively takes the arc plasma heating, wire dynamic retraction, droplet transfer, the formation and diffusion of metal vapor, the melting and solidification of molten metal, and the stirring effect of ELAMF into account. The simulated results show that ELAMF has compressed the arc morphology, and decreased the temperature, potential, current density and static pressure, which are most pronounced when the wire is at an elevated position and the transient current is at its peak phase. Meanwhile, the formation of low-temperature and low-velocity cavities in the center of arc column are promoted by ELAMF, consequently diminishing the energy transferred from the arc plasma to molten pool through thermal conduction and mitigating the squeezing of the arc plasma on the surface of molten pool. The results also demonstrate that the ELAMF has reduced the temperature gradient of liquid metal inside the molten pool, and intensified the forced convection for the occurrence of multiple circulations.

Methods of Processing Dental Chromium-Cobalt Alloys for Production of Metal Frameworks Faced with Ceramics to Obtain the Best Mechanical Properties.

BACKGROUND Modern prosthetic technologies make it possible to fabricate prosthetic restorations without material loss and to make prosthetic restorations with complex geometric shapes in a relatively simple way. One such technology is selective laser melting (SLM), or additive manufacturing of metal materials, better known as 3D printing from metal or selective laser melting, but currently the most commonly used method is casting. The present study investigated use of dental chromium-cobalt alloys for prosthetic bridges and compared methods of processing dental chromium-cobalt alloys to obtain the best mechanical properties. MATERIAL AND METHODS We used dental chromium-cobalt alloy (SCHEFTNER GMBH) for laser melting StarbondCoSEeasy Powder with grain size of 10-30 µm and StarbondCoS alloy casting, made in accordance with the European standard EN ISO 22674. SLM-made specimens and induction melted alloy castings were prepared for the study. A centrifugal casting system with induction current melting of the metal alloy was used to produce the samples. The melting and casting process is automatic and limits changes in chemical composition. RESULTS The results show that none of the samples changed their chemical composition, while the samples made by SLM had better mechanical properties. CONCLUSIONS The SLM technique makes it possible to produce restorations faster and cheaper without any loss of quality compared to restorations made with the casting technique. Casting technology reduces mechanical properties, but still provides good mechanical properties.

The Impacts of Carbon Policy and “Dual Carbon” Targets on the Industrial Resilience of Ferrous Metal Melting and Rolling Manufacturing in China

The Impacts of Carbon Policy and “Dual Carbon” Targets on the Industrial Resilience of Ferrous Metal Melting and Rolling Manufacturing in China