Life cycle assessment of carbonaceous pellets used in blast furnaces in the context of "double carbon".

As the sole carbonaceous renewable energy source, biomass is distinguished by its abundant yield, widespread distribution, and carbon neutrality. It is integral to the achievement of zero and negative carbon production via conventional carbonaceous pellet technology. This study introduces a cradle-to-gate life cycle assessment methodology for biomass preparation in carbonaceous pellets. We prepare high-quality biochar through a process combining hydrothermal carbonization and pyrolytic carbonization. Biomass high molecular weight extracts are obtained via organic pyrolytic extraction, while biomass high-temperature binders result from the modification and treatment of biochar. Biomass carbonaceous pellets are then formed using hot press technology. The ReCiPe model facilitates a comprehensive life cycle assessment of biomass carbonaceous pellets used in blast furnace production. The study leverages two comprehensive evaluation indicators - renewability, and environmental performance - to enhance the environmental performance of the process system and to maximize energy-saving and emission reduction potential.

Recent developments on the removal of zinc from electric arc furnace dust by using microwave heating.

Electric arc furnace dust (EAFD) is a hazardous by-product of steel production. As global steel output increases, substantial amounts of EAFD are produced, which causes significant environmental issues. EAFD contains quantities of Fe and Zn, which could be reused as raw materials in the steelmaking process. However, zinc oxides can be reduced and vaporized during this process, forming zinc vapor that contaminates equipment surfaces and causes damage. Consequently, various pyrometallurgical methods have been proposed for zinc removal from EAFD. Due to the extensive usage of carbonaceous materials, these methods contribute to significant CO2, raising concerns about greenhouse gas emissions. Microwave heating offers an efficient, energy-saving, and environmentally friendly alternative to pyrometallurgical approaches. EAFD can generate heat under microwave irradiation without carbon addition, which means the CO2 emissions can be reduced by replacing the reductant in the microwave heating process. Furthermore, microwaves enhance zinc removal reactions to a certain extent, resulting in higher efficiency. Thus, employing microwave heating for EAFD processing has significant potential for future development. This paper reviews recent research on using microwave heating for zinc removal from EAFD, focusing on the heating behavior of EAFD in microwaves and the mechanisms of zinc removal. This review will be crucial for researchers working on processing EAFD using microwave heating and could help guide the development of more sustainable and efficient methods.

A Coupled CFD-DEM Study on the Effect of Basset Force Aimed at the Motion of a Single Bubble.

The physical meaning of Basset force is first studied via polynomial approximation and the Fourier series representation method. After compiling the Basset force into the coupling interface with Visual C, a dynamic mathematical model is set up to describe the upward motion behavior of a single bubble by adopting the CFD-DEM method. Afterwards, the coupling interface with Basset force proposed in this study is verified experimentally and shows very good agreements. The initial velocity, releasing depth, bubble size, density ratio and viscosity ratio are studied qualitatively due to their great importance to Basset force. The ratio of Basset force to the sum of Basset force and drag force and to buoyancy, F→Ba/(F→D+F→Ba) and |F→Ba/F→B|, are employed to quantify the contribution of Basset force quantitatively. In addition, some instructive outlooks and recommendations on a further development of appropriate and justifiable use of Basset force are highlighted at last.

A Novel Method of Si and Si3N4 Powder Resources Recycling: Cold Bonding Briquettes.

Silicon nitride (Si3N4) and silicon powder (Si) are two kinds of harmful solid waste in industrial production. As an environmental and low-consumption method, the cold-bonding technique is a novel method to utilize the problem of powder resource cycling. In this experiment, mechanical and high-temperature properties of Si and Si3N4 briquettes were studied after cold bonding. The results are as follows: (1) The compressive strength of the Si and Si3N4 briquettes increased with the improvement of molding pressure. With the same binder (1 wt.%) and water (10 wt.%) addition, the compressive strength of the Si3N4 briquette arrived at 12,023.53 N under 40 Mpa molding pressure, which is much higher than that of the Si briquette (942.40 N). The Si particles are uneven and irregular, which leads to an intense arch bridge effect in the Si briquette and the compressive strength decrease. Compared with Si powder, the particle size and shape of Si3N4 is small, uniform, and regular. The influence of the arch bridge effect is smaller than that in the Si briquette. (2) After being treated at 1473 K for 1 h, the compressive strength of the Si briquette increased to 5049.83 N, and the compressive strength of the Si3N4 briquette had a slight change. The surface of the briquettes was contacted with oxygen and reacted to form an outer shell which mainly contains SiO2 in the high-temperature treatment. FT-IR results have shown there were no extra impurities in cold-bonded briquettes when using the organic binder. (3) The microstructure of the cross section of the Si and Si3N4 briquettes after high-temperature treatment presented that oxygen entered the briquette through the pores and continued to react with the Si and Si3N4. The outer shell of the Si briquette grew and thickened continuously with the oxygen spreading in the Si briquette. However, because of the smaller particle size and regular shape, little oxygen diffused in the Si3N4 briquette. The outer shell of the Si3N4 briquette is fairly thin, so the compressive strength did not change too much.

Numerical Analysis of the Relationship between Friction Coefficient and Repose Angle of Blast Furnace Raw Materials by Discrete Element Method.

In recent years, the discrete element method (DEM) has been widely used to study the factors affecting the repose angle and calibrate particle parameters for simulations. In this paper, DEM is used to study the effects of the coefficient of rolling and static friction of pellet, sinter and coke particles on the repose angle. By comparison of the results of simulations and physical experiments, the coefficients of rolling and static friction suitable for simulation work are determined. The results demonstrate that repose angle increases with the coefficient of rolling and static friction, but the rate of increase gradually decays, when the coefficient of rolling friction exceeds 0.4 or the coefficient of static friction exceeds 0.35. The coefficient of static friction has a greater impact on the repose angle than the coefficient of rolling friction. The rougher of the base surface, the larger the repose angle of the formed particle piled. It can be concluded that appropriate coefficient of rolling and static friction for simulations can be obtained by the outlined procedure.

Interfacial Area Transport Equation for Bubble Coalescence and Breakup: Developments and Comparisons.

Bubble coalescence and breakup play important roles in physical-chemical processes and bubbles are treated in two groups in the interfacial area transport equation (IATE). This paper presents a review of IATE for bubble coalescence and breakup to model five bubble interaction mechanisms: bubble coalescence due to random collision, bubble coalescence due to wake entrainment, bubble breakup due to turbulent impact, bubble breakup due to shearing-off, and bubble breakup due to surface instability. In bubble coalescence, bubble size, velocity and collision frequency are dominant. In bubble breakup, the influence of viscous shear, shearing-off, and surface instability are neglected, and their corresponding theory and modelling are rare in the literature. Furthermore, combining turbulent kinetic energy and inertial force together is the best choice for the bubble breakup criterion. The reviewed one-group constitutive models include the one developed by Wu et al., Ishii and Kim, Hibiki and Ishii, Yao and Morel, and Nguyen et al. To extend the IATE prediction capability beyond bubbly flow, two-group IATE is needed and its performance is strongly dependent on the channel size and geometry. Therefore, constitutive models for two-group IATE in a three-type channel (i.e., narrow confined channel, round pipe and relatively larger pipe) are summarized. Although great progress in extending the IATE beyond churn-turbulent flow to churn-annual flow was made, there are still some issues in their modelling and experiments due to the highly distorted interface measurement. Regarded as the challenges to be addressed in the further study, some limitations of IATE general applicability and the directions for future development are highlighted.

Numerical Analysis on Erosion and Optimization of a Blast Furnace Main Trough.

The main trough of a blast furnace (BF) is a main passage for hot metal and molten slag transportation from the taphole to the torpedo and the slag handling. Its appropriate working status and controlled erosion ensure a safe, stable, high-efficiency and low-cost continuous production of hot metal. In this work, the tapping process of a main trough of a BF in the east of China was numerically studied with the help of a CFD library written in C++, called OpenFOAM, based on the use of the Finite Volume Method (FVM). The results show that turbulence intensity downstream of the hot metal impact position becomes weaker and the turbulence area becomes larger in the main trough. During the tapping, thermal stress of wall refractory reaches the maximum value of 1.7 × 107 Pa at the 4 m position in the main trough. Furthermore, baffles in the main trough placed between 5.8 m and 6.2 m were found to control and reduce the impact of the turbulence on the refractory life. The metal flowrate upstream of the baffles can be decreased by 6%, and the flow velocity on the upper sidewall and bottom wall decrease by 9% and 7%, respectively, compared with the base model. By using baffles, the minimum fatigue life of the refractory in the main trough increases by 15 tappings compared with the base model, so the period between the maintenance stops can be prolonged by about 2 days.

Study of an Organic Binder of Cold-Bonded Briquettes with Two Different Iron Bearing Materials.

The aim of this study was to investigate the properties of an organic binder used in cold-bonded briquettes (CBBs) prepared from two different iron bearing materials. The applied binder is a type of starch as indicated by chemical analysis, iodine-starch staining and Fourier transform infrared analyses. Thermogravimetric differential scanning calorimetry showed that the binder pyrolysis undergoes four stages: moisture desorption, ash volatilization, pyrolysis of organic matter and decomposition of materials with high activation energy. The difference between the dry and heat-treated samples during the macroscopic failure process is the instability propagation of the crack. The CBB shows a low decrepitation index at 700 °C. The returned fines of CBBs used with the organic binder were applied in two blast furnaces. The industrial trials showed that the CBBs do not influence the performance of the blast furnace and can reduce the fuel consumption rate. The curing rate of the binder decreases, and the growth rate of compressive strength decreases during the curing process. Iron ore particles are bonded together and exist in the form of aggregation after mixing with water and binder. The edges and corners of the particles become blurred, and the original surfaces of the particles are covered with binder film, the surface of which is covered with fine particles. The multi-branched structure of amylopectin provides omnibearing adhesion sites, thus forming binder agglomeration and film leading to a strong adhesion between binder and iron ore particles. Binder film and binder agglomeration work together to make the CBB perform well.

A Novel Approach for Measuring the Thickness of Refractory of Metallurgical Vessels.

The advancement of metallurgical vessels, such as blast furnaces, shaft furnaces, and torpedo ladles, can be better controlled and expanded for a greater lifespan if the thickness of the refractory lining wear is known and predicted. In the past, various methods including radioactive tracers, infrared (IR) thermography, electromagnetic waves, ultrasonic tomography, and temperature field have been tested to determine the thickness of the refractory wall. However, for various reasons, these methods have failed to be effective. This paper presents a novel method-electromotive force (EMF)-for predicting the thickness of refractory lining wear in vessels, including a small-scale vessel in the laboratory, an industrial torpedo ladle, and in the two refining hearths of blast furnaces. The experimental results show that the magnitude of the EMF signal increases with a decrease in wall thickness. Prediction values of the refractory wall thickness are consistent with measured ones. The relative error of EMF measurement for the torpedo ladle is around 6.8%. The EMF measurement of blast furnace hearths is quite accurate, and the relative error is less than 11%.

Microwave catalyzed carbothermic reduction of zinc oxide and zinc ferrite: effect of microwave energy on the reaction activation energy.

Recently, more attention has been paid to the use of microwave (MW) energy in accelerating chemical reactions. The effect of microwave energy on the reduction of zinc oxide and zinc ferrite was investigated. The results indicated that the temperatures required to initiate zinc oxide and zinc ferrite reduction under MW heating were 550 and 450 °C, respectively, while under conventional thermal (CT) heating, were 950 and 850 °C, respectively. Apparently, the MW reaction had a negative standard Gibbs free energy (ΔG) at a lower temperature (∼400 °C) when compared to the CT reaction. Additionally, the activation energy (E a) substantially decreased from 223.7 and 221.1 kJ mol-1 under CT heating to 64.8 and 32.9 kJ mol-1 under MW heating for Zn oxide and zinc ferrite, respectively. The enhancement in zinc reduction under MW energy was due to the rapid and bulk heating phenomena of MWs as well as the interactions occurring between the electromagnetic MW pattern and the molecules of heated materials.

Mass separation of deuterium and helium with conventional quadrupole mass spectrometer by using varied ionization energy.

Deuterium pressure in deuterium-helium mixture gas is successfully measured by a common quadrupole mass spectrometer (model: RGA200) with a resolution of ∼0.5 atomic mass unit (AMU), by using varied ionization energy together with new developed software and dedicated calibration for RGA200. The new software is developed by using MATLAB with the new functions: electron energy (EE) scanning, deuterium partial pressure measurement, and automatic data saving. RGA200 with new software is calibrated in pure deuterium and pure helium 1.0 × 10(-6)-5.0 × 10(-2) Pa, and the relation between pressure and ion current of AMU4 under EE = 25 eV and EE = 70 eV is obtained. From the calibration result and RGA200 scanning with varied ionization energy in deuterium and helium mixture gas, both deuterium partial pressures (P(D2)) and helium partial pressure (P(He)) could be obtained. The result shows that deuterium partial pressure could be measured if P(D2) > 10(-6) Pa (limited by ultimate pressure of calibration vessel), and helium pressure could be measured only if P(He)/P(D2) > 0.45, and the measurement error is evaluated as 15%. This method is successfully employed in EAST 2015 summer campaign to monitor deuterium outgassing/desorption during helium discharge cleaning.

First results on disruption mitigation by massive gas injection in Korea Superconducting Tokamak Advanced Research.

Massive gas injection (MGI) system was developed on Korea Superconducting Tokamak Advanced Research (KSTAR) in 2011 campaign for disruption studies. The MGI valve has a volume of 80 ml and maximum injection pressure of 50 bar, the diameter of valve orifice to vacuum vessel is 18.4 mm, the distance between MGI valve and plasma edge is ~3.4 m. The MGI power supply employs a large capacitor of 1 mF with the maximum voltage of 3 kV, the valve can be opened in less than 0.1 ms, and the amount of MGI can be controlled by the imposed voltage. During KSTAR 2011 campaign, MGI disruptions are carried out by triggering MGI during the flat top of circular and limiter discharges with plasma current 400 kA and magnetic field 2-3.5 T, deuterium injection pressure 39.7 bar, and imposed voltage 1.1-1.4 kV. The results show that MGI could mitigate the heat load and prevent runaway electrons with proper MGI amount, and MGI penetration is deeper under higher amount of MGI or lower magnetic field. However, plasma start-up is difficult after some of D(2) MGI disruptions due to the high deuterium retention and consequently strong outgassing of deuterium in next shot, special effort should be made to get successful plasma start-up after deuterium MGI under the graphite first wall.