Characterizing the emissions of polybrominated dibenzo-p-dioxins and dibenzofurans (PBDD/Fs) from electric arc furnaces during steel-making.

The amount of steel produced using electric arc furnaces (EAFs) has been increasing in recent years. In this study, stack gases from EAFs in steelmaking plants were analyzed to determine if they are also dominant sources of polybrominated dibenzo-p-dioxin and dibenzofuran (PBDD/F) emissions in China. Isotope dilution high-resolution gas chromatography high-resolution mass spectrometry for qualitative and quantitative analysis of PBDD/F congeners revealed that the mean PBDD/F mass concentrations were 271.1-9467.8 pg Nm-3 for the preheating stages (PS) of three EAF plants and that the corresponding toxic equivalents (TEQs) were 10.8-971.2 pg TEQ Nm-3. The PBDD/F mass concentration from the smelting stage (SS) at plant E3 was 261.9 pg Nm-3 (4.5 pg TEQ Nm-3). The PBDD/F emission factors (EF) during the preheating stage for the three plants were 0.0356-1.51 µg TEQ t-1, and the EF was 0.0359 µg TEQ t-1 during the E3 smelting stage. PBDD/Fs were found to contribute 2.39-67.85% to the total mass and 2.84-57.68% to the total dioxin TEQ. These wide fluctuations were caused by differences in the composition of feeding materials and the working temperature of bag filters. Overall, the results indicate that PBDD/F emissions from EAF steelmaking should receive increased attention. The PBDD/F congener patterns among the three EAF plants were variable, possibly because of differences in raw materials. The results presented herein will facilitate assessment of the contribution of EAFs to total PBDD/F emissions in China and investigations of PBDD/F emissions at different stages of steelmaking processes using EAFs.

Blowpipes and their metalworking applications: New evidence from Mayapán, Yucatán, Mexico.

This study presents evidence of two tuyères, or blowpipe tips, used in metalworking at the Postclassic period city of Mayapán. Blowpipe technology has long been hypothesized to be the production technique for introducing oxygen to furnaces during the metal casting process on the basis of ethnohistorical depictions of the process in ancient Mesoamerica. To our knowledge, the tuyères recovered at Mayapán are the first archaeologically documented tuyères for pre-Hispanic Mesoamerica. The dimensions, internal perforation, vitrification, and presence of copper prills within the ceramic fabric, suggest that they were used in pyrotechnological production, likely metalworking, and is consistent with previous evidence for small-scale metalworking at Mayapán. Blowpipe use in metallurgical production is a logical extension of a much longer tradition of blowgun use in hunting, which was likely already present in Mesoamerica by the time metal was introduced to West Mexico from South America. Furthermore, the dimensions of the Mayapán tuyères are consistent with the internal diameter of ethnohistorically-documented blowguns from Jacaltenango in the southwest Maya region. We conducted replication experiments that suggest that when combined with wooden blowpipes, the Mayapán tuyères would have been ideal for small-scale, furnace-based metallurgy, of the type identified at Mayapán from Postclassic period contexts.

A direct metal laser sintering (DMLS) root analogue implant placed in the anterior maxilla. Case report.

BACKGROUND: Modern cone beam computed tomography (CBCT) acquisition and three-dimensional (3D) image processing, combined with direct metal laser sintering (DMLS), allows custom-made, root-analogue implants (RAIs). PURPOSE: To demonstrate how DMLS permits customized titanium RAI production, with immediate insertion and restoration in a fresh extraction socket of the anterior maxilla. MATERIALS AND METHODS: A titanium RAI perfect copy of the radicular unit needed for replacement was created by customized DMLS, and inserted into a fresh extraction socket of the esthetic area of the anterior maxilla. RESULTS: Follow-up after 1 year: the DMLS RAI implant showed a satisfactory functional and esthetic integration, with no bone resorption or soft tissue recessions. CONCLUSIONS: The production of customized DMLS RAIs opens new interesting perspectives for immediate implantation. KEY WORDS: Direct metal laser sintering, Root analogue implant.

Safety of stationary grinding machines - impact resistance of work zone enclosures.

Guards on machine tools are intended to protect persons from being injured by parts ejected with high kinetic energy from the work zone of the machine. Stationary grinding machines are a typical example. Generally such machines are provided with abrasive product guards closely enveloping the grinding wheel. However, many machining tasks do not allow the use of abrasive product guards. In such cases, the work zone enclosure has to be dimensioned so that, in case of failure, grinding wheel fragments remain inside the machine's working zone. To obtain data for the dimensioning of work zone enclosures on stationary grinding machines, which must be operated without an abrasive product guard, burst tests were conducted with vitrified grinding wheels. The studies show that, contrary to widely held opinion, narrower grinding wheels can be more critical concerning the impact resistance than wider wheels although their fragment energy is smaller.

Analysis of workers' compensation claims data for machine-related injuries in metal fabrication businesses.

BACKGROUND: Metal fabrication workers are at high risk for machine-related injury. Apart from amputations, data on factors contributing to this problem are generally absent. METHODS: Narrative text analysis was performed on workers' compensation claims in order to identify machine-related injuries and determine work tasks involved. Data were further evaluated on the basis of cost per claim, nature of injury, and part of body. RESULTS: From an initial set of 4,268 claims, 1,053 were classified as machine-related. Frequently identified tasks included machine operation (31%), workpiece handling (20%), setup/adjustment (15%), and removing chips (12%). Lacerations to finger(s), hand, or thumb comprised 38% of machine-related injuries; foreign body in the eye accounted for 20%. Amputations were relatively rare but had highest costs per claim (mean $21,059; median $11,998). CONCLUSIONS: Despite limitations, workers' compensation data were useful in characterizing machine-related injuries. Improving the quality of data collected by insurers would enhance occupational injury surveillance and prevention efforts. Am. J. Ind. Med. 59:656-664, 2016. © 2016 Wiley Periodicals, Inc.

A sustainable process for the recovery of valuable metals from spent lithium-ion batteries.

In this work, an eco-friendly and hydrometallurgical process for the recovery of cobalt and lithium from spent lithium-ion batteries has been proposed, which includes pretreatment, citric acid leaching, selective chemical precipitation and circulatory leaching. After pretreatment (manual dismantling, N-methyl pyrrolidone immersion and calcination), Cu and Al foils are recycled directly and the cathode active materials are separated from the cathode efficiently. Then, the obtained cathode active materials (waste LiCoO2) was firstly leached with 1.25 mol l(-1) citric acid and 1 vol.% H2O2 solution. Then cobalt was precipitated using oxalic acid (H2C2O4) under a molar ratio of 1:1.05 (H2C2O4: Co(2+)). After filtration, the filtrate (containing Li(+)) and H2O2 was employed as a leaching agent and the optimum conditions are studied in detail. The leaching efficiencies can reach as high as 98% for Li and 90.2% for Co, respectively, using filter liquor as leaching reagent under conditions of leaching temperature of 90°C, 0.9 vol.% H2O2 and a solid-to-liquid ratio of 60 ml g(-1) for 35 min. After three bouts of circulatory leaching, more than 90% Li and 80% Co can be leached under the same leaching conditions. In this way, Li and Co can be recovered efficiently and waste liquor re-utilization is achievable with this hydrometallurgical process, which may promise both economic and environmental benefits.

Selective autocatalytic reduction of NO from sintering flue gas by the hot sintered ore in the presence of NH3.

In this paper, the selective autocatalytic reduction of NO by NH3 combined with multi-metal oxides in the hot sintered ore was studied, and the catalytic activity of the hot sintered ore was investigated as a function of temperature, NH3/NO ratio, O2 content, H2O and SO2. The experimental results indicated that the hot sintered ore, when combined with NH3, had a maximum denitration efficiency of 37.67% at 450 °C, 3000 h(-1) gas hourly space velocity (GHSV) and a NH3/NO ratio of 0.4/1. Additionally, it was found that O2 played an important role in removing NOx. However, high O2 content had a negative effect on NO reduction. H2O was found to promote the denitration efficiency in the absence of SO2, while SO2 inhibited the catalytic activity of the sintered ore. In the presence of H2O and SO2, the catalytic activity of the sintered ore was dramatically suppressed.

Assessment of heavy metals exposure, noise and thermal safety in the ambiance of a vacuum metallurgy separation system for recycling heavy metals from crushed e-wastes.

Vacuum metallurgy separation (VMS) is a technically feasible method to recover Pb, Cd and other heavy metals from crushed e-wastes. To further determine the environmental impacts and safety of this method, heavy metals exposure, noise and thermal safety in the ambiance of a vacuum metallurgy separation system are evaluated in this article. The mass concentrations of total suspended particulate (TSP) and PM10 are 0.1503 and 0.0973 mg m(-3) near the facilities. The concentrations of Pb, Cd and Sn in TSP samples are 0.0104, 0.1283 and 0.0961 µg m(-3), respectively. Health risk assessments show that the hazard index of Pb is 3.25 × 10(-1) and that of Cd is 1.09 × 10(-1). Carcinogenic risk of Cd through inhalation is 1.08 × 10(-5). The values of the hazard index and risk indicate that Pb and Cd will not cause non-cancerous effects or carcinogenic risk on workers. The noise sources are mainly the mechanical vacuum pump and the water cooling pump. Both of them have the noise levels below 80 dB (A). The thermal safety assessment shows that the temperatures of the vacuum metallurgy separation system surface are all below 303 K after adopting the circulated water cooling and heat insulation measures. This study provides the environmental information of the vacuum metallurgy separation system, which is of assistance to promote the industrialisation of vacuum metallurgy separation for recovering heavy metals from e-wastes.

Femtosecond fiber laser welding of dissimilar metals.

In this paper, welding of dissimilar metals was demonstrated for the first time, to the best of our knowledge, by using a high-energy high-repetition-rate femtosecond fiber laser. Metallurgical and mechanical properties were investigated and analyzed under various processing parameters (pulse energy, repetition rate, and welding speed). Results showed that the formation of intermetallic brittle phases and welding defects could be effectively reduced. Strong welding quality with more than 210 MPa tensile strength for stainless steel-aluminum and 175 MPa tensile strength for stainless steel-magnesium has been demonstrated. A minimal heat affected zone and uniform and homogenous phase transformation in the welding region have been demonstrated. This laser-welding technique can be extended for various applications in semiconductor, automobile, aerospace, and biomedical industries.

Microstructure formation and fracturing characteristics of grey cast iron repaired using laser.

The repairing technology based on laser rapid fusion is becoming an important tool for fixing grey cast iron equipment efficiently. A laser repairing protocol was developed using Fe-based alloy powders as material. The microstructure and fracturing feature of the repaired zone (RZ) were analyzed. The results showed that regionally organized RZ with good density and reliable metallurgical bond can be achieved by laser repairing. At the bottom of RZ, dendrites existed in similar direction and extended to the secondary RZ, making the grains grow extensively with inheritance with isometric grains closer to the surface substrate. The strength of the grey cast iron base material was maintained by laser repairing. The base material and RZ were combined with robust strength and fracture resistance. The prevention and deflection of cracking process were analyzed using a cracking process model and showed that the overall crack toughness of the materials increased.

The aluminum smelting process and innovative alternative technologies.

OBJECTIVE: The industrial aluminum production process is addressed. The purpose is to give a short but comprehensive description of the electrolysis cell technology, the raw materials used, and the health and safety relevance of the process. METHODS: This article is based on a study of the extensive chemical and medical literature on primary aluminum production. RESULTS: At present, there are two main technological challenges for the process--to reduce energy consumption and to mitigate greenhouse gas emissions. A future step may be carbon dioxide gas capture and sequestration related to the electric power generation from fossil sources. CONCLUSIONS: Workers' health and safety have now become an integrated part of the aluminum business. Work-related injuries and illnesses are preventable, and the ultimate goal to eliminate accidents with lost-time injuries may hopefully be approached in the future.

A bioactive metallurgical grade porous silicon-polytetrafluoroethylene sheet for guided bone regeneration applications.

The properties of porous silicon make it a promising material for a host of applications including drug delivery, molecular and cell-based biosensing, and tissue engineering. Porous silicon has previously shown its potential for the controlled release of pharmacological agents and in assisting bone healing. Hydroxyapatite, the principle constituent of bone, allows osteointegration in vivo, due to its chemical and physical similarities to bone. Synthetic hydroxyapatite is currently applied as a surface coating to medical devices and prosthetics, encouraging bone in-growth at their surface and improving osseointegration. This paper examines the potential for the use of an economically produced porous silicon particulate-polytetrafluoroethylene sheet for use as a guided bone regeneration device in periodontal and orthopaedic applications. The particulate sheet is comprised of a series of microparticles in a polytetrafluoroethylene matrix and is shown to produce a stable hydroxyapatite on its surface under simulated physiological conditions. The microstructure of the material is examined both before and after simulated body fluid experiments for a period of 1, 7, 14 and 30 days using Scanning Electron Microscopy. The composition is examined using a combination of Energy Dispersive X-ray Spectroscopy, Thin film X-ray diffraction, Attenuated Total Reflectance-Fourier Transform Infrared Spectroscopy and the uptake/release of constituents at the fluid-solid interface is explored using Inductively Coupled Plasma-Optical Emission Spectroscopy. Microstructural and compositional analysis reveals progressive growth of crystalline, 'bone-like' apatite on the surface of the material, indicating the likelihood of close bony apposition in vivo.

A planar Bézier profiled horn for reducing penetration force in ultrasonic cutting.

An ultrasonic planar horn with a Bézier profile is developed. The first longitudinal displacement mode of the horn is exploited for high displacement amplification in order to reduce the penetration force required to enter and cut materials. The displacement amplification and stress distribution characteristics of the Bézier horn and the commonly used catenary horn are examined. The penetration force by the Bézier horn is nearly 75% of that by the catenary horn with a penetration speed of 0.25 mm/s during cutting a tissue stimulant. At a penetration speed of 0.5 mm/s, the penetration force by the Bézier horn is nearly 85% of that by the catenary horn for cutting a polymethylmethacrylate (PMMA) material. The decrease in the penetration force by the Bézier horn is attributed to the fact that the displacement amplification of the Bézier horn is 30% higher than that of the traditional catenary horn with the same length and end surface widths.

Dynamic ultrasonic contact detection using acoustic emissions.

For a non-contact ultrasonic material removal process, the control of the standoff position can be crucial to process performance; particularly where the requirement is for a standoff of the order of <20 µm. The standoff distance relative to the surface to be machined can be set by first contacting the ultrasonic tool tip with the surface and then withdrawing the tool to the required position. Determination of this contact point in a dynamic system at ultrasonic frequencies (>20 kHz) is achieved by force measurement or by detection of acoustic emissions (AE). However, where detection of distance from a surface must be determined without contact taking place, an alternative method must be sought. In this paper, the effect of distance from contact of an ultrasonic tool is measured by detection of AE through the workpiece. At the point of contact, the amplitude of the signal at the fundamental frequency increases significantly, but the strength of the 2nd and 3rd harmonic signals increases more markedly. Closer examination of these harmonics shows that an increase in their intensities can be observed in the 10 µm prior to contact, providing a mechanism to detect near contact (<10 µm) without the need to first contact the surface in order to set a standoff.

On-line flatness measurement in the steelmaking industry.

Shape is a key characteristic to determine the quality of outgoing flat-rolled products in the steel industry. It is greatly influenced by flatness, a feature to describe how the surface of a rolled product approaches a plane. Flatness is of the utmost importance in steelmaking, since it is used by most downstream processes and customers for the acceptance or rejection of rolled products. Flatness sensors compute flatness measurements based on comparing the length of several longitudinal fibers of the surface of the product under inspection. Two main different approaches are commonly used. On the one hand, most mechanical sensors measure the tensile stress across the width of the rolled product, while manufacturing and estimating the fiber lengths from this stress. On the other hand, optical sensors measure the length of the fibers by means of light patterns projected onto the product surface. In this paper, we review the techniques and the main sensors used in the steelmaking industry to measure and quantify flatness defects in steel plates, sheets and strips. Most of these techniques and sensors can be used in other industries involving rolling mills or continuous production lines, such as aluminum, copper and paper, to name a few. Encompassed in the special issue, State-of-the-Art Sensors Technology in Spain 2013, this paper also reviews the most important flatness sensors designed and developed for the steelmaking industry in Spain.

Hypersensitivity pneumonitis due to metalworking fluids: how to find the antigens.

Most surveys of outbreaks of hypersensitivity pneumonitis (HP) in subjects with occupational exposure to water-based metalworking fluids (MWFs) were unable to detect a clear link between symptoms and the precise causative agents. We studied the case of a male 41-year-old industrial knife grinder with exposure to water-based MWFs since 12 years. The diagnosis of HP was made by typical work-related symptoms, the demonstration of high lymphocyte numbers in bronchoalveolar lavage and elevated IgG antibody concentrations to various molds in the patient's serum, and complete recovery after early exposure cessation. Whereas an environmental survey showed only low numbers of mold contamination in one sump sample, high antigenic activity was demonstrated in the same sample by antigen-specific IgG inhibition tests. We conclude that the detection of antigenic molds in water-based MWFs by culture methods may be limited. The link between occupational exposure to specific molds in MWFs and hypersensitivity pneumonitis can be established by the demonstration of antigenic activity by antigen-specific IgG inhibition tests.

Effect of electric arc, gas oxygen torch and induction melting techniques on the marginal accuracy of cast base-metal and noble metal-ceramic crowns.

OBJECTIVES: The aim of this study was to identify the most appropriate alloy composition and melting technique by evaluating the marginal accuracy of cast metal-ceramic crowns. METHODS: Seventy standardised stainless-steel abutments were prepared to receive metal-ceramic crowns and were randomly divided into four alloy groups: Group 1: palladium-gold (Pd-Au), Group 2: nickel-chromium-titanium (Ni-Cr-Ti), Group 3: nickel-chromium (Ni-Cr) and Group 4: titanium (Ti). Groups 1, 2 and 3 were in turn subdivided to be melted and cast using: (a) gas oxygen torch and centrifugal casting machine (TC) or (b) induction and centrifugal casting machine (IC). Group 4 was melted and cast using electric arc and vacuum/pressure machine (EV). All of the metal-ceramic crowns were luted with glass-ionomer cement. The marginal fit was measured under an optical microscope before and after cementation using image analysis software. All data was subjected to two-way analysis of variance (ANOVA). Duncan's multiple range test was run for post-hoc comparisons. The Student's t-test was used to investigate the influence of cementation (α=0.05). RESULTS: Uncemented Pd-Au/TC samples achieved the best marginal adaptation, while the worst fit corresponded to the luted Ti/EV crowns. Pd-Au/TC, Ni-Cr and Ti restorations demonstrated significantly increased misfit after cementation. CONCLUSIONS: The Ni-Cr-Ti alloy was the most predictable in terms of differences in misfit when either torch or induction was applied before or after cementation. Cemented titanium crowns exceeded the clinically acceptable limit of 120µm. CLINICAL SIGNIFICANCE: The combination of alloy composition, melting technique, casting method and luting process influences the vertical seal of cast metal-ceramic crowns. An accurate use of the gas oxygen torch may overcome the results attained with the induction system concerning the marginal adaptation of fixed dental prostheses.

Enriching blast furnace gas by removing carbon dioxide.

Blast furnace gas (BF gas) produced in the iron making process is an essential energy resource for a steel making work. As compared with coke oven gas, the caloric value of BF gas is too low to be used alone as fuel in hot stove because of its high concentrations of carbon dioxide and nitrogen. If the carbon dioxide in BF gas could be captured efficiently, it would meet the increasing need of high caloric BF gas, and develop methods to reusing and/or recycling the separated carbon dioxide further. Focused on this, investigations were done with simple evaluation on possible methods of removing carbon dioxide from BF gas and basic experiments on carbon dioxide capture by chemical absorption. The experimental results showed that in 100 minutes, the maximum absorbed doses of carbon dioxide reached 20 g/100 g with ionic liquid as absorbent.

Operating condition influences on PCDD/Fs emissions from sinter pot tests with hot flue gas recycling.

This study was designed to clarify the influence of operating conditions on the formation and emissions of polychlorinated-p-dibenzodioxins and dibenzofurans (PCDD/Fs) from a sintering process with hot flue gas recycling. A pilot scale sinter pot with simulated flue gas recycling was developed, and four key operational parameters, including temperature, oxygen content of the simulated waste flue gas, the coke rate of the sintering mixture, and the quicklime quality, were selected for exploring PCDD/Fs formation. The results showed that the temperature of the recycled flue gas had a major affect on PCDD/Fs formation, and a high temperature could significantly increase their formation during sintering. A clear linear correlation between the temperature of recycling flue gas and PCDD/Fs emission (r = 0.93) was found. PCDD/Fs could be reduced to a certain extent by decreasing the level of oxygen in the recycled flue gas, while sintering quality was unchanged. The coke rate had no significant influence on the formation of PCDD/Fs, but the quality of quicklime used in the sintering mixture could affect not only the amount of PCDD/Fs emissions but also the sintering productivity. Compared with a benchmark sinter pot test, PCDD/Fs emissions markedly decreased with improvements to quicklime quality. However, the reduction in PCDD/Fs emissions realized by using high-quality quicklime was limited by the temperature of the inlet gas. The highest reduction achieved was 51% compared with conventional quicklime when the temperature of the inlet gas was 150 degrees C.