The emerging bottom blown copper smelting (SKS) technology has attracted growing interest since it came into production. To further reveal the agitation behavior inside the bath and optimize the variable parameters, CFD simulation was conducted on a scaled down SKS furnace model with different tuyere arrangements. The Multi-Fluid VOF model was used for the first time in SKS furnace simulation and the

Oxidative ladle refining (OLR) is the most used refining method in industrial production of metallurgical grade silicon. OLR is performed by purging the liquid alloy with oxygen-enhanced air at 1823 K to 1873 K, reacting with silicon and the primary slag forming impurities to a SiO\(_{2}\)-CaO-Al\(_{2}\)O\(_{3}\) slag. To further increase our capability to control this process, it is paramount to understand

To alleviate macrosegregation, it is the first time that an electromagnetic nozzle swirling flow is applied with a mold electromagnetic stirrer (M-EMS) during continuous casting of square and round billets. Compared with those by only M-EMS, the carbon ranges in square and round billets can be reduced to 0.022 and 0.046 pct, respectively, and the equiaxed crystal ratios are 18 and 33 pct, respectively

A tapping process model of the steel from the basic oxygen furnace (BOF) addressing the reactions in the ladle is proposed. In the model, the effective equilibrium reaction zone (EERZ) method is applied to describe the steel/slag interfacial reaction. The equilibrium reactions in the bulk steel (steel/inclusion/lining wear) and slag (liquid slag/slag additions/lining wear) are considered. The thermodynamic

A procedural model is urgently required for optimization of slag foaming in metallurgical processes. Through physical modeling following the similarity criterion of the Morton number (Mo), this paper investigates the effects of superficial gas velocity, dynamic viscosity, and surface tension on the foaming height. From the physical modeling results, several dimensionless numbers relevant to the slag

Recent inclusion models are mainly focused on the compositional evolution of inclusion, steel and slag. Due to the importance of inclusion size distribution to steel properties, the evolution of inclusion size distributions should also be accounted for. As the first step to establish a model to predict the evolution of inclusion size distribution, the nucleation, growth and removal of alumina inclusions

Casting powders or mold fluxes, as they are more commonly known, are used in the continuous casting of steel to prevent the steel shell from sticking to the copper mold. The powders first melt and create a pool of liquid flux above the liquid steel in the mold, and then the liquid mold fluxes penetrate into the gap between water-cooled copper mold and steel shell, where crystallization of solid phases

Oxygen blowing refining is an effective method for the removal of the main Al and Ca metallic impurities from metallurgical-grade silicon (MG-Si). However, the removal of impurities in silicon melt is affected and restricted by the kinetics of the refining process. In this work, the oxidation mechanism and kinetics of impurity removal from silicon melt by oxygen blowing refining were investigated experimentally

The evolution of non-metallic inclusions (> 10 µm) for the Al-killed steel in the stainless steelmaking is described. The effects of the slag basicity at the AOD/VOD process, Ca treatment, raw materials (dolomite and spent refractory), reoxidation and vacuum condition on the evolution of the non-metallic inclusion were investigated using the thermo-chemical program (FactSageTM) and the SEM-EDS analysis

A novel integrated cell with O2-|YSZ|Pt|O2(air) reference and counter electrodes was constructed using a short yttria-stabilized zirconia solid electrolyte (YSZ) tube. Combining with cyclic voltammetry and potentiostatic electrolysis methods, green electrochemical preparation of Si from solid SiO2 in CaCl2 melt at 1173 K was studied via an experimental apparatus containing the novel integrated cell

New continuous cooling transformation (CCT) equations have been optimized to calculate the start temperatures and critical cooling rates of phase formations during austenite decomposition in low-alloyed steels. Experimental CCT data from the literature were used for applying the recently developed method of calculating the grain boundary soluble compositions of the steels for optimization. These compositions

To improve the recycling efficiency of rejected electrolytic manganese metal (EMM) scrap that contains excessive sulfur, a high-temperature experiment and mathematical model reflecting the mechanism of sulfur transfer from the molten manganese metal to the molten slag were elaborated. A MoSi2 electrical resistance furnace filled with argon protective gas was first employed to perform the desulfurization

The technical viability of the marble waste as raw material in the iron ore pelletizing sector was investigated. The effects of binary basicity (0.15 to 0.45), fixed carbon (0.5 to 1.1 wt pct), and bentonite percentages (0.5 to 0.7 wt pct) on the pellet properties were also investigated. The physical properties of the pellets were determined for drop number, tumble strength, porosity, green pellet

The valorization of Basic Oxygen Furnace (BOF) slag is important as the global annual production of this slag amounts to about 200 million tonnes. Al2O3 can be added to modify the composition and mineralogy of the slag. Al2O3 dissolution can provide long term volumetric stability to the solidified slag and tailor its microstructure/mineralogy for high-added value non-binder applications e.g., aggregates

A correction to this paper has been published: https://doi.org/10.1007/s11663-021-02137-2

A grid-filtered scale interface-resolved volume of fluid (VoF) model coupling a sub-grid scale large eddy simulation (LES) was used to directly simulate bubble behavior and the evolution of multiphase interfaces and free surfaces in a bubble–metal–slag multiphase system. The model has been applied to an industrial 150-ton gas-stirred ladle. The results show transient behavior of the slag eye, with

The study has aimed at understanding the key factors involved in the synthesis of porous Ti-based β-Ti-35Nb-7.9Sn alloy by electro-deoxidation of compacted and sintered TiO2-Nb2O5-SnO2 mixed oxide disks in molten calcium chloride. Processing parameters assessed were the sintering temperature, and thus, the open porosity, of the oxide precursor as well as the temperature, voltage, and time of electro-deoxidation

The vaporization of vanadium pentoxide from CaO-SiO2-VOx ternary slags using different gas treatment regimens and parallel vacuum gas extirpation to treat V-bearing slags at 1873 K has been developed in the present study. The novelty of the present study is to monitor the effect of parallel alumina dissolution on the vaporization phenomenon. Vanadium pentoxide has high vapor pressure at the temperatures

The performance of the blast furnace is strongly affected by the position and thickness of the cohesive zone, which is largely influenced by the high-temperature properties of the iron-bearing materials. During its reduction, softening and melting, ferrous materials undergo major microstructure changes and its understanding is essential to develop new raw-materials, technologies, and models. In this

A mathematical model coupled with the penetration theory, the ion and molecule coexistence theory, and thermodynamic equilibrium was proposed for predicting the composition evolution of inclusions in the molten steel during the electroslag remelting process. The model was used to evaluate the transformation of composition of inclusions in a plain carbon steel and the mechanism of the transformation

Currently, recycled metal is diluted with primary metal to keep the concentration of alloying elements within specification. This will be more difficult in the future, when a larger proportion of the metal is made from scrap. Particularly, there is a need for a process that can remove elements more noble than aluminum from the scrap metal. While electrolytic refining in a three-layer cell (the Hoopes

To investigate the effect of Si on Al and AlN precipitation in ferritic Fe, high-temperature thermochemical equilibrium experiments were conducted on Fe-Si-Al foils and Ag-Si-Al alloys at 1373 K, 1423 K, and 1473 K. Using the activity coefficient in the infinite dilute solution and the self-interaction parameter of Si in ferritic Fe, the interaction parameter between Si and Al in solidified ferritic

Desulfurization phenomenon of Ni-base superalloy using a solid CaO was identified by adjusting the temperature of melt. Ni-base superalloy and NiS powder were heated together at 1400 °C, 1500 °C, and 1600 °C. Dense and porous CaO rods were inserted into the melts individually. After the rods were pulled out, CaO, CaS, and calcium aluminates were detected on the rods by X-ray diffraction analysis. Electron

This study investigates the development of the microstructure in the interconnection zone of an IN718/Al/IN718 couple obtained by the Transient Liquid Phase Bonding (TLPB) process at 1000 °C. The crystal structure, composition and orientation of the phases formed during joining were examined by SEM-EDS EBSD. The results showed that the interconnection zone is a multilayered region, constituted mainly

Pulsed electric current is used to control the interface structure between Al-C nozzle material and the molten steel containing rare earth in this work. In the absence of a pulsed electric current, the interface shows a loose, rough structure with nodules, and interconnected holes are observed in the interface layer. Furthermore, inclusions CeAlO3/LaAlO3 adhere to the surface of the nozzle. However

Organic substances are used in refractory bricks manufacture as binders. In this work, two commercial binder systems currently employed in MgO-C bricks for steelmaking industry were first analyzed separately from the other components of the refractory. A resol phenolic resin alone and mixed with an ecobinder produced by treatment of tar pitch were studied by several techniques (XRD, FTIR, Raman spectroscopy

Corner transverse cracks are frequently observed on microalloyed steel slabs during continuous casting. As a solution to this problem, double phase-transformation technology could improve the ductility of the shell surface and avoid corner cracks. However, this technology requires a high cooling rate, which is difficult to reach in traditional flat plate molds (TFMs). Therefore, a novel convex structure

The deformation of inclusions in the steel was affected by the thermal history during the physical simulation of steel processing. After plain strain compression with a reduction of 30 pct, the average aspect ratio of inclusions in the steel sample cooled down to 1673 K from semi-solid state was 1.89, which was significantly higher than 1.29 in the steel sample heated persistently up to the same temperature

The solid-state reaction and diffusion behaviors of CaFe2O4 and TiO2 were investigated using a diffusion couple method at 1373 K to 1473 K under air atmosphere, and an in situ XRD method was used to analyze the solid-state reaction process. The reactions between calcium ferrite and TiO2 in the solid state are displacement reactions that produce perovskite and Fe2O3. The diffusion interface was divided

The effect of lanthanum addition on the grain refinement of CrMnFeCoNi high-entropy alloys (HEAs) was investigated experimentally. When 9.3 pct lanthanum was added, the equiaxed zone faction enlarged sharply from 41.17 to 76.58 pct. The number of grains < 200 µm increased obviously, and the mean grain size in the equiaxed zone decreased from 331 to 144 μm. Compositional undercooling induced by lanthanum

The effects of an axial static magnetic field (ASMF) on the carbides and mechanical properties of electroslag-remelted (ESR) Cr12MoV die steel were investigated. The superimposition of a 30 mT ASMF induced unidirectional rotation in the molten slag pool, resulting in a more uniform temperature distribution at the front of the dendrite solid–liquid interface. The size of the grains and carbides in the

The microstructure and thermal conductivity of the CaO-Al2O3-based (CA-based) mold slags are crucial for casting high aluminum steel. Herein, the microstructure and thermal conductivity of the CA-based mold slags were systematically investigated by using molecular dynamics (MD). Moreover, the effects of the CaO/Al2O3 mole (C/A) ratio and CaO/SiO2 mole (C/S) ratio on the microstructure and thermal conductivity

A correction to this paper has been published: https://doi.org/10.1007/s11663-021-02109-6

A multi-scale approach for simulating hot tearing during the DC casting of aluminum alloys is presented. The novelty of this approach lies in the combination of a macro-scale finite element simulation of the DC casting process with direct prediction of hot tears via a meso-scale multi-physics granular model. This approach is capable of simulating hot tearing initiation, growth, and propagation within

Due to the poor separability and low reducibility of fayalite in iron extracting from smelting waste slag, the composition of the original slag was modified for the nickel matte smelting process. Based on molecular dynamics simulation, thermodynamic calculation and experimental analyses, the influence mechanism of Fe/SiO2 ratio on physicochemical properties, Fe-containing phases and microstructure

Ladle slag entrainment during the last stages of ladle draining contaminates the liquid steel in the tundish. Another effect of ladle slag is that it contaminates the tundish covering and hinders it to perform its intended functions. Affected area of tundish covering by ladle slag entrainment was quantified using a first principle-based mechanistic model in this study. Ladle slag hits the bottom of

The non-isothermal kinetic method was used in this manuscript to obtain the reaction models by fitting the reduction ratio of low-grade phosphate ore and the volatilization ratio of phosphorus. And the reaction mechanism of vacuum carbothermal reduction of low-grade phosphate was investigated by combining XRD, SEM, EDS, chemical analysis, and FactSage7.2. Ca5(PO4)3F first reacted with a small amount

The degradation mechanism of a MgO-C refractory was studied at 1973 K using an induction furnace under an Ar atmosphere. Cylindrical specimens were analyzed by X-ray computed tomography according to time. The degradation proceeded from the outer surfaces towards the core. Analysis of the degradation kinetics indicated the cylindrical shrinking core model could adequately describe the degradation behavior

Basic Oxygen Furnace (BOF) dust is a secondary resource with high total iron (TFe) content produced in metallurgical steelmaking process. It is the most economical way to recycle BOF dust by adding binders to prepare cold-bonded pellets and returning to BOF for steelmaking. Nevertheless, the digestion reaction of dead-burned MgO and CaO contained in BOF dust causes expansion and cracking of the pellets

Metallurgical grade alumina is produced worldwide through the well-known Bayer process, which unavoidably generates bauxite residue (BR, also known as red mud) in almost equal amounts to alumina. This study aims the valorization of BR through a smelting-reduction process to obtain calcium aluminate slags that can be a proper feed for alumina recovery via the Pedersen process. It investigates the thermodynamics

2A97 is the third-generation aluminum-lithium (Al-Li) alloy developed by China. However, the fine equiaxed zone (FEQZ) of weld is the weakest area of its joint, which severely limits its practical application in the aerospace field. In this study, the macro- and microscopic characteristics of weld and the formation mechanism of the microstructure under the condition of non-autogenous laser welding

The clogging behavior of a submerged entry nozzle for the casting of sulfur-containing Ca-treated Al-killed Ti-bearing steel was ex situ investigated. The surface of clogging consisted of CaO-TiOx phase, Al2O3-MgO phase, and Al2O3-CaO-SiO2 phase. The TiOx in the clogging was originated from the adhesion of inclusions in molten steel. The silicate inclusions were formed by the reaction between low-melting-point

The intrinsic factor of crack defect in continuous casting slab is determined by the high-temperature mechanical properties of slab itself. At present, the measurement for the thermal mechanical properties is mostly achieved by Gleeble Hot-Tensile test. However, the uneven temperature distribution in the specimen during the test will definitely affect the accuracy of the measured mechanical properties

Basic oxygen steelmaking has been the interest of research for several decades due to its complex and fast process dynamics. To predict the evolution of slag–metal composition and temperature, it is important to control the process efficiently. The framework developed by Sarkar et al. (Metall Mater Trans B 46:961–976, 2015) is advanced further to estimate the evolution of chemical composition and temperature

To further clarify the evolution of inclusions in Si-Mn-killed steel grades, industrial samples were taken during the LF (ladle furnace) refining process, and laboratory experiments were carried out to investigate the effects of alloy additions, refining slags, and refractory materials on the evolution of inclusions. It is found that the inclusions transform along the route of “MnO-SiO2-based inclusions

The effects of basicity and anionic species on the solubility of Ni in CaO-MgO-Al2O3-SiO2 slags were investigated based on the thermodynamic evaluation and structural analysis of the coordination number of Al ions via 27Al 500-MHz solid-state nuclear magnetic resonance spectroscopy. Depending on slag basicity, Ni dissolution followed two mechanisms, involving Ni2+ and NiO22− as ionic species. The solubility–basicity

Silicon sulfide (SiS2) was synthesized from Si, SiC, Si3N4, and a eutectic Al-Si liquid. An Ar-CS2 gas mixture, after bubbling through liquid CS2, was passed over pulverized Si, SiC, Si3N4, or a eutectic Al-Si alloy liquid. White, needle-shaped SiS2 was precipitated as a single phase on the colder downstream surface when Si powder in a SiO2 liner was heated over 1273 K. This deposition mechanism involves

Pressurized electroslag remelting (PESR) has been widely used for preparation of high-quality high nitrogen steels. However, desulfurization might be limited by the pressurized-nitrogen atmosphere in the process. In this paper, the desulfurization behaviors of electroslag remelting in air and nitrogen pressure were investigated and further an appropriate method to improve the sulfur removal in PESR

Physics-based Finite Element Methods models can be used to investigate the electrical conditions in submerged arc furnaces (SAFs). However, their explicit solution may be very demanding in terms of time and computational resources. This makes these models difficult to employ during control operations and in fast prototyping. To obviate these inconveniences, we developed metamodels that are grounded

The formation and removal of exogenous inclusions in a real-size two-strand tundish is simulated by the proposed unsteady 3D comprehensive numerical model of the respective fluid-structure interaction, which takes into account the impacting and washing effects on the refractory wear. A large eddy simulation is employed to describe the molten steel vortex flow. Thus, the thermal profiles of the molten

In the current study, the transient fluid flow pattern in steel continuous casting molds with varied dimensions was evaluated using nail board measurement and onsite top flux observation. Effects of steel throughput, argon flow rate, submergence depth of the submerged entry nozzle, and mold dimension on the flow pattern inside the mold were investigated. The top flux under lower steel throughput, higher

Isothermal reduction experiments at 1400 °C, which used carbon-bearing pellets mainly made from Bayan Obo complex iron ore and pulverized coal, could effectively separate rare earth (RE) slag and iron. Different instruments were used to study the precipitation of RE slag and the growth behavior of the RE phase in RE slag during the process of cooling from 1400 °C. The experimental results show the

The distributions of precious metals (gold, silver, platinum, and palladium) between copper matte and silica-saturated FeOx-SiO2/FeOx-SiO2-Al2O3/FeOx-SiO2-Al2O3-CaO slags were investigated at 1300 °C and \( P_{{{\text{SO}}_{ 2} }} \) = 0.5 atm. The experiments were carried out in silica crucibles under flowing CO-CO2-SO2-Ar gas atmosphere. The concentrations of precious metals in matte and slag were

The mechanical properties of steels can be deteriorated by the formation of type II sulfide inclusions. The addition of alloying elements Al, C, and Si is generally considered to promote the transition from type II to type III sulfides. However, the mechanism of how alloying elements, especially Al, affect the transition is still unclear. In this work, the effect of aluminum on the divorced eutectic

A thermodynamic model, based on SimuSage, was developed to simulate refractory corrosion between a magnesia-based refractory material and ferronickel (FeNi) slags. The model considers a theoretical cross-section of a refractory material to simulate a ferronickel smelter application. The current model is structured into 10 zones, which characterize different sectors in the brick (hot to cold side) perpendicular

Numerical simulations of a gas-particle jet through a Laval nozzle are performed using a modified point-particle Euler–Lagrange approach. By excluding the particle-occupied fluid fraction when solving the fluid phase equations and accounting for gas-particle and inter-particle interactions in the mathematical framework, the particle motion behaviors in gas stream and their impact on gas stream structure

The nitrogen isotope exchange reaction was applied to measure the interfacial reaction rate constant of nitrogen with liquid cobalt at 1823 K, 1873 K, and 1923 K. Measured values increased with increasing temperature, with average values of 1.3×10−7 mol cm−2 s−1 atm−1 at 1823 K, 3.3×10−7 mol cm−2 s−1 atm−1 at 1873 K, and 6.2×10−7 mol cm−2 s−1 atm−1 at 1923 K. Compared with liquid iron, the rate on

To develop an effective method for removing sulfur from spent refining slag at high temperature, the slag was treated in argon atmosphere using desulfurization ash as desulfurization reagent. Experimental results revealed that at 1773 K, molar ratio of CaS to CaSO4 + CaSO3 of 3:1, and reaction time of 2 hours, sulfur removal efficiency reached a maximum of 67.9 pct. The optimal ratio indicates the

Plain medium carbon steel with multiscale ferrite (α) + cementite (θ) lamellar structure was produced by warm rolling and subsequently annealing. The effect of annealing time on microstructural evolution was studied via scanning electron microscope and electron backscatter diffraction. The obtained results showed that the feature of multiscale lamellar microstructure remained virtually the same with