Applications of Process Engineering Principles in Materials Processing, Energy and Environmental Technologies: An EPD Symposium in Honor of Professor Ramana G. Reddy

549 Pages·2017·60.241 MB·English

by  Shijie Wang, Michael L Free, Shafiq Alam, Mingming Zhang, Patrick R. Taylor (eds.)

APPLICATIONS OF
PROCESS ENGINEERING
PRINCIPLES IN MATERIALS
PROCESSING, ENERGY
AND ENVIRONMENTAL
TECHNOLOGIES
An EPD Symposium in Honor of
Professor Ramana G. Reddy
EDITED BY Shijie Wang • Michael Free
Shafiq Alam • Mingming Zhang
Patrick R. Taylor
The Minerals, Metals & Materials Series
Shijie Wang Michael L. Free
(cid:129)
fi
Sha q Alam Mingming Zhang
(cid:129)
Patrick R. Taylor
Editors
Applications of Process
Engineering Principles
in Materials Processing,
Energy and Environmental
Technologies
An EPD Symposium in Honor of Professor
Ramana G. Reddy
123
Editors
Shijie Wang Mingming Zhang
RioTinto Kennecott UtahCopper ArcelorMittal Global R&D
Magna, UT EastChicago, IN
USA USA
Michael L. Free Patrick R. Taylor
University of Utah ColoradoSchool ofMines
Salt Lake City,UT Golden,CO
USA USA
Shafiq Alam
TheUniversity of Saskatchewan
Saskatoon, SK
Canada
ISSN 2367-1181 ISSN 2367-1696 (electronic)
TheMinerals, Metals& Materials Series
ISBN978-3-319-51090-3 ISBN978-3-319-51091-0 (eBook)
DOI 10.1007/978-3-319-51091-0
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Preface
The Professor Ramana Reddy Honorary Symposium on Applications of Process
Engineering Principles in Materials Processing and Energy and Environmental
Technologies has been proposed and designed as a tribute to Prof. Reddy and his
distinguished career asprofessor, teacher,and researcherovera periodof 35years
at the University of Nevada, Reno, and the University of Alabama, Tuscaloosa,
Alabama. Professor Reddy has advised and worked with over 100 Ph.D. and
M.S. graduatestudents, research scholars, and visitingscientists. He has published
morethan 378researchpapers and26books(4CDs)includingoneundergraduate
student textbook in thermodynamics. He has also delivered more than 268 invited
lectures and research presentations in 26 nations. As an ACIPCO Endowed
Professor, Prof. Reddy holds many leadership positions and honors and awards as
well. The extent of Prof. Reddy’s contribution to energy, environmental, and
materials science and process engineering is underlined in the biographical sketch
provided in these proceedings.
Theresponsetothesymposiumhasbeenmostgratifying.Whenacallforpapers
wentout,78abstractsweresubmittedforinclusionintheconferenceprogram.The
netresulthasbeenthatthenumberofpapersofferedforpresentationhasexceeded
the time allocation and a Poster Session has been included in the program and
accommodated in the proceedings. The international nature of the symposium is
attested to by the fact that the selected papers are drawn from 17 countries.
The symposium has been named “Applications of Process Engineering
Principles in Materials Processing, Energy and Environmental Technologies:
An EPD Symposium in Honor of Ramana Reddy.” It is little bit longer but covers
the most papers, which are presented at the symposium.
The symposium program encompasses 10 sessions with each session being
precededbyaplenarylecture.Thesessionscoverarangeoftopicswithinmaterials
processing, energy, and environmental:
(1) Plenary Session
(2) Electrometallurgy
(3) Hydrometallurgy
v
vi Preface
(4) Pyrometallurgy I
(5) Pyrometallurgy II
(6) Materials Processing and Plasma Processing
(7) Energy Storage and Engineering Issues
(8) Modeling and Simulation
(9) Thermodynamics and Kinetics
(10) Poster Session
Within these topic areas, the individual papers represent a diversity of subjects.
Whatisevidentisathrusttowardbridgingthegapbetweentheoryandpracticevia
contributionsdealingwithprocessmodelingandsimulation,processandequipment
design,thedevelopmentofnovelprocesses,andthegenerationofnewdataforthe
better understanding of current process technology. The environmental challenges
facing metallic and nonmetallic industries are also addressed.
ThesymposiumshouldbeafittingsalutetoProf.Reddyforhiscontributionsto
extractive metallurgy, materials science, and energy and environmental technolo-
gies over the breadth of his distinguished career. It is hoped that the symposium
volume will provide not only a record of a meeting but also a basis for further
excellent work in the applications of process engineering principles in materials
processing and energy and environmental technologies.
This symposium will provide a forum where industrial, research institutes and
university professionals can interact and exchange with other stakeholders to
facilitate the advancement of materials processes and engineering.
Shijie Wang
Michael L. Free
Shafiq Alam
Mingming Zhang
Patrick R. Taylor
Contents
Part I Plenary Session
Applications of Process Engineering Principles in Materials
Processing, Energy and Environmental Technologies—Contributions
of Professor Ramana Reddy.. ..... .... .... .... .... .... ..... .... 3
Shijie Wang
Status of the Development of Flash Ironmaking Technology. ..... .... 15
H.Y. Sohn, Y. Mohassab, M. Elzohiery, D.-Q. Fan and A. Abdelghany
Innovations and Insights in Fluid Flow and Slime Adhesion
for Improved Copper Electrorefining ... .... .... .... .... ..... .... 25
Weizhi Zeng, Michael L. Free and Shijie Wang
Molten Flux Design for Solid Oxide Membrane-Based Electrolysis
of Aluminum from Alumina.. ..... .... .... .... .... .... ..... .... 35
Uday Pal, Shizhao Su and Thomas Villalon
Effect of Slag Phase on Mixing and Mass Transfer in a Model
Creusot Loire Uddeholm (CLU) Converter... .... .... .... ..... .... 45
A. Chaendera and R.H. Eric
Part II Electrometallurgy
Modeling of Aluminum Electrowinning in Ionic Liquid Electrolytes....... 65
Mingming Zhang and Ramana G. Reddy
Electrochemical Processing of Rare Earth Alloys.. .... .... ..... .... 81
Karen Sende Osen, Ana Maria Martinez, Henrik Gudbrandsen,
Anne Støre and Ole Kjos
Effect of Cobalt and Iron Concentration on the Potential
for Oxygen Evolution from Pb–Ca–Sn Anodes in Synthetic
Copper Electrowinning Electrolytes. .... .... .... .... .... ..... .... 89
C.E. Abbey and M.S. Moats
vii
viii Contents
Cobalt Electrodeposition from Cobalt Chloride Using Urea
and Choline Chloride Ionic Liquid: Effect of Temperature,
Applied Voltage, and Cobalt Chloride Concentration
on Current Efficiency and Energy Consumption .. .... .... ..... .... 97
Andrea R. Kim and Ramana G. Reddy
METTOP-BRX Technology—Eliminating Concerns and Highlight
Potentials of the Concept of Tankhouse Optimization .. .... ..... .... 115
A. Filzwieser, I. Filzwieser, S. Wallner and M.B. Hanel
Mathematical Modeling of Molten Salt Electrolytic Cells
for Sodium and Lithium Production.... .... .... .... .... ..... .... 129
Donghui Li, Kinnor Chattopadhyay, Lei Gao, Boyd Davis,
Rüdiger Schwarze, Amjad Asad and Christoph Kratzsch
Part III Hydrometallurgy
P-CAC, A Unique Separation Technology for PGM Recovery .... .... 141
Shijie Wang and Tracy Morris
The Physical Characteristics of Electrorefined Copper
Starter Sheet Material .. .... ..... .... .... .... .... .... ..... .... 151
Daniel Majuste, Paul Laforest and Michael Moats
Extraction of Copper from Sulfate-Chloride Solutions by Using
Hydroxyoxime Extractants... ..... .... .... .... .... .... ..... .... 161
M.C. Ruiz, I. Gonzalez, J. Salgado and R. Padilla
Hydrometallurgical Processes for the Recovery of Rare Earths,
Nickel and Cobalt in Chloride Medium . .... .... .... .... ..... .... 169
V.I. Lakshmanan, R. Sridhar, D. Tait and M.A. Halim
A Cr6+-Free Extraction of Chromium Oxide from Chromite Ores
Using Carbothermic Reduction in the Presence of Alkali ... ..... .... 179
L. Escudero-Castejon, S. Sanchez-Segado, S. Parirenyatwa, Y. Hara
and A. Jha
Part IV Pyrometallurgy I
Market Dynamics, Recycling and Recovery of Magnesium
from Aluminum Alloy Scrap . ..... .... .... .... .... .... ..... .... 191
A.J. Gesing and S.K. Das
Alternative Ways of Using Nonferrous Slags as Feed Material
in the Ferrous Production Industry. .... .... .... .... .... ..... .... 201
Mario Sánchez, Fernando Parada and José Palacios
Contents ix
Insulating or Conductive Lining Designs for Electric
Furnace Smelting? . .... .... ..... .... .... .... .... .... ..... .... 209
J.D. Steenkamp, G.M. Denton and D.A. Hayman
The Influence of Phosphorous Additions on Phase Evolution
in Molten Synthetic Coal Slag ..... .... .... .... .... .... ..... .... 221
HaniAbuElHawa,JinichiroNakano,AnnaNakanoandJamesP.Bennett
The Recovery of Copper from Smelting Slag by Flotation Process. .... 231
Jiaqi Fan, Hongxu Li, Liangtian Wei, Chao Li and Shi Sun
Reaction Mechanisms in the Silicothermic Production
of Magnesium . .... .... .... ..... .... .... .... .... .... ..... .... 239
M. Chen, B.J. Zhao, Y.H. Chen, F.L. Han and L.E. Wu
Influences of CaO/SiO /MgO/Al O on the Formation
2 2 3
Behavior of FeO-Bearing Primary-Slags in Blast Furnace... ..... .... 251
Dongdong Wang, Kaihui Ma, Yang Xu, Jian Xu and Liangying Wen
Desulfurization of High Sulfur Coal Leached with H O
2 2
and NaOH by Microwave Irradiation... .... .... .... .... ..... .... 259
Pengqi Zhang, Shengfu Zhang, Lixiong Shao, Mingcheng Bing,
Shuxing Qiu and Qingyun Zhang
Part V Pyrometallurgy II
Chloridizing Roasting of Bismuthinite with Sodium
Chloride–Oxygen... .... .... ..... .... .... .... .... .... ..... .... 273
R. Padilla, L. Salinas and M.C. Ruiz
Natural Gas Utilization in Blast Furnace Ironmaking:
Tuyère Injection, Shaft Injection and Prereduction.... .... ..... .... 283
P. Chris Pistorius, Jorge Gibson and Megha Jampani
Selective Sulfation Roasting of Rare Earths from NdFeB
Magnet Scrap . .... .... .... ..... .... .... .... .... .... ..... .... 293
B.N. Carlson and P.R. Taylor
Gold Solubility in Smelting Slags for the Recycling of Industrial
and Mining Wastes. .... .... ..... .... .... .... .... .... ..... .... 301
Jun-Gil Yang, Joo Hyun Park and Hyun-Sik Park
Solid State Reduction of Iron, Manganese and Chromium Oxide
Ores with Methane. .... .... ..... .... .... .... .... .... ..... .... 307
R.H. Eric, A. Bhalla, P. Halli and P. Taskinen
Stibnite Chloridizing with Calcium Chloride-Oxygen at Roasting
Temperatures . .... .... .... ..... .... .... .... .... .... ..... .... 319
R. Padilla, I. Moscoso and M.C. Ruiz
x Contents
Investigations on Rotary Tool Near-Dry Electric Discharge
Machining .... .... .... .... ..... .... .... .... .... .... ..... .... 327
Vineet Kumar Yadav, Pradeep Kumar and Akshay Dvivedi
Dependence of Ti O and Temperature on Electrical
2 3
Conductivity of TiO –FeO–Ti O Slags.. .... .... .... .... ..... .... 335
2 2 3
Shengping Li, Xuewei Lv, Gangqiang Fan, Wei Lv and Yingyi Zhang
Part VI Materials Processing and Plasma Processing
DuraStell PTA Cladding for Wear Application ... .... .... ..... .... 345
Qingjun Zheng and Robert Vasinko
Production of SiMn-Alloys by Natural Gas and Carbon Black.... .... 357
Xiang Li and Merete Tangstad
Effect of Flux Ratio on the Products of Self Propagating High
Temperature Synthesis-Casting in the WO –Si–Al System .. ..... .... 365
3
S. Niyomwas and T. Chanadee
Synthesis of Chrysin Based Cationic Lipids: Plasmid Delivery
and Transgene Expression... ..... .... .... .... .... .... ..... .... 373
Bhavani Kedika, Venkatagiri Noole, Krishna Thotla
and Krishna Reddy Chepyala
Part VII Energy Storage and Engineering Issues
Corrosion Mechanism of Haynes 230 Alloy with Ni Crucible in
MgCl –KCl ... .... .... .... ..... .... .... .... .... .... ..... .... 385
2
Yuxiang Peng and Ramana G. Reddy
Conceptualization of Doped Black P Thin Films for Potential Use
in Photovoltaics with Validation from First Principle Calculations. .... 395
Sayan Sarkar, Prashant K. Sarswat, Weizhi Zeng and Michael L. Free
Energy Efficiency and Sustainability in Steel Production.... ..... .... 401
L.E.K. Holappa
Application of Surface Effect on Metallurgical Processes.... ..... .... 411
K.C. Chou
Part VIII Modeling and Simulation
Metal Silicides for High-Temperature Thermoelectric Application. .... 421
M.R. Bogala and Ramana G. Reddy
CFD Modeling of Slag-Metal Reactions and Sulfur Refining
Evolution in an Argon Gas-Stirred Ladle Furnace. .... .... ..... .... 435
Q. Cao, L. Nastac and A. Pitts