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.

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.

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.

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.

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.

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.

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.

Binding waste anthracite fines with Si-containing materials as an alternative fuel for foundry cupola furnaces.

An alternative fuel to replace foundry coke in cupolas was developed from waste anthracite fines. Waste anthracite fines were briquetted with Si-containing materials and treated in carbothermal (combination of heat and carbon) conditions that simulated the cupola preheat zone to form silicon carbide nanowires (SCNWs). SCNWs can provide hot crushing strengths, which are important in cupola operations. Lab-scale experiments confirmed that the redox level of the Si-source significantly affected the formation of SiC. With zerovalent silicon, SCNWs were formed within the anthracite pellets. Although amorphous Si (+4) plus anthracite formed SiC, these conditions did not transform the SiC into nanowires. Moreover, under the test conditions, SiC was not formed between crystallized Si (+4) and anthracite. In a full-scale demonstration, bricks made from anthracite fines and zerovalent silicon successfully replaced a part of the foundry coke in a full-scale cupola. In addition to saving in fuel cost, replacing coke by waste anthracite fines can reduce energy consumption and CO2 and other pollution associated with conventional coking.

Effect of root canal curvature on the failure incidence of ProFile rotary Ni-Ti endodontic instruments.

AIM: To investigate the effect of root canal curvature on the failure incidence and fracture mechanism of ProFile rotary Ni-Ti endodontic instruments. METHODOLOGY: Three hundred mesial root canals of mandibular molars were instrumented using the ProFile system in a crown-down technique up to size 25 0.06 taper. Root canals were classified according to the angle and radius of curvature to: straight (group A: 0 + 10°, radius 0 mm), moderately curved (group B: 30 ± 10°, radius 2 ± 1 mm) and severely curved (group C: 60 ± 10°, radius 2 ± 1 mm). After each use, instruments were cleaned ultrasonically and autoclaved. Instruments that prepared 20 root canals, fractured or were plastically deformed without fracture were retrieved and substituted. Kaplan-Meier estimator was used for survival analysis and post hoc test for determination of significant differences (a=0.05). All fractured instruments were subjected to fractographic analysis under SEM, and all used instruments were viewed under the metallographic microscope. RESULTS: Regardless of the size of instrument, fracture and overall failure were significantly more frequent (P<0.05) in group C. SEM examination of the fracture surfaces revealed mainly the characteristic pattern of ductile failure, whereas examination under the metallographic microscope revealed no sign of cracks. CONCLUSIONS: The abruptness of root canal curvature negatively affected the failure rate of ProFile rotary Ni-Ti instruments. The fractographic results confirmed that failure of Ni-Ti files was caused by a single overload during chemomechanical preparation.

Non-destructive techniques based on eddy current testing.

Non-destructive techniques are used widely in the metal industry in order to control the quality of materials. Eddy current testing is one of the most extensively used non-destructive techniques for inspecting electrically conductive materials at very high speeds that does not require any contact between the test piece and the sensor. This paper includes an overview of the fundamentals and main variables of eddy current testing. It also describes the state-of-the-art sensors and modern techniques such as multi-frequency and pulsed systems. Recent advances in complex models towards solving crack-sensor interaction, developments in instrumentation due to advances in electronic devices, and the evolution of data processing suggest that eddy current testing systems will be increasingly used in the future.

Performance quantification of applicators for microwave treatment of crushed mineral ore.

Exposure of crushed mineral ores to microwaves at high power density (-10(9) to 10(11) W/ m3(abs)) and for short exposure times (< 0.1 s) induces grain boundary fracture around the grains of the value minerals at economically viable energy inputs (-1 kWh/t). In subsequent processing steps, liberation of the value minerals is enhanced, improving the efficiency of the process. In this paper the performance of transverse E-field applicators for the continuous treatment of 30 t/h of crushed ore was quantified using damage maps. These provide the amount of microwave-induced grain boundary damage and the fraction of the load treated as a function of input power and throughput. The damage maps are created by combining the outputs from thermal stress simulations (for the determination of thermal damage) with those from electromagnetic simulations (for the determination of the 3d dissipation of power in the load). The results are to be used to select the optimal applicator structure and operating parameters (bed height and speed) for a given ore. Results from two applicator configurations for a coarser and finer-grained galena-calcite ore are used to exemplify the results. It is shown high the texture of the ore significantly reduces performance in terms of achievable throughput and required energy input. It is also shown that sub-optimal electromagnetic design also results in reduced throughput and increased energy requirement.

Impact resistance of guards on grinding machines.

Guards on machine tools are meant to protect persons from injuries caused by parts ejected with high kinetic energy from the machine's working zone. With respect to stationary grinding machines, Standard No. EN 13218:2002, therefore, specifies minimum wall thicknesses for guards. These values are mainly based on estimations and experience instead of systematic experimental investigations. This paper shows to what extent simple impact tests with standardizable projectiles can be used as basis for the evaluation of the impact resistance of guards, provided that not only the kinetic energy of the projectiles used but also, among others, their geometry corresponds to the abrasive product fragments to be expected.

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.

Silicon-substituted hydroxyapatite composite coating by using vacuum-plasma spraying and its interaction with human serum albumin.

The incorporation of silicon can improve the bioactivity of hydroxyapatite (HA). Silicon-substituted HA (Ca(10)(PO(4))(6-x )(SiO(4))( x )(OH)(2-x ), Si-HA) composite coatings on a bioactive titanium substrate were prepared by using a vacuum-plasma spraying method. The surface structure was characterized by using XRD, SEM, XRF, EDS and FTIR. The bond strength of the coating was investigated and XRD patterns showed that Ti/Si-HA coatings were similar to patterns seen for HA. The only different XRD pattern was a slight trend toward a smaller angle direction with an increase in the molar ratio of silicon. FTIR spectra showed that the most notable effect of silicon substitution was that -OH group decreased as the silicon content increased. XRD and EDS elemental analysis indicated that the content of silicon in the coating was consistent with the silicon-substituted hydroxyapatite used in spraying. A bioactive TiO(2) coating was formed on an etched surface of Ti, and the etching might improve the bond strength of the coatings. The interaction of the Ti/Si-HA coating with human serum albumin (HSA) was much greater than that of the Ti/HA coating. This might suggest that the incorporation of silicon in HA can lead to significant improvements in the bioactive performance of HA.

Internal fit evaluation of crowns prepared using a new dental crown fabrication technique: laser-sintered Co-Cr crowns.

STATEMENT OF PROBLEM: Difficulties encountered during casting of base metal dental alloys limit their use. Application of these alloys might be enhanced if new techniques are used. PURPOSE: The purpose of this study was to compare the internal fit of laser-sintered Co-Cr alloy crowns with base metal restorations prepared from another Co-Cr alloy and a Ni-Cr alloy using conventional casting techniques. MATERIAL AND METHODS: Internal fit of laser-sintered Co-Cr crowns was compared with the fit of conventionally cast Ni-Cr and Co-Cr alloy crowns. Twelve crown-shaped specimens were prepared on a stainless steel die representing a prepared maxillary right central incisor for each group. Fit of crowns was evaluated using 2 different techniques: (1) weighing the light-body addition silicone that simulated a cement material, and (2) measuring the internal gap width on a die for longitudinally sectioned specimens. One-way ANOVA followed by Tukey multiple comparison test was used for statistical analysis (alpha=.05). RESULTS: Significantly higher mean (SD) light-body silicone weights (P<.001) were observed in the laser-sintered Co-Cr alloy group (14.34 (1.67) mg) compared to the conventionally cast Ni-Cr alloy group (9.36 (1.97) mg) and Co-Cr alloy group (7.85 (1.19) mg). Mean internal gap widths (SDs) were 58.21 (19.92) microm, 50.55 (25.1) microm, and 62.57 (21.62) microm, respectively, for the cast Ni-Cr and Co-Cr alloy groups and the laser-sintered Co-Cr alloy group. No significant difference was observed between the 3 groups for internal gap widths (P=.42). CONCLUSIONS: Weighing the light-body addition silicone is a convenient method for evaluating the 3-dimensional internal fit of dental crowns. However, no significant difference was found among the 3 alloy groups evaluated for the internal gap width of sectioned crown specimens.

Large-area electron beam irradiation for surface polishing of cast titanium.

Cast titanium is a known hard-to-polish material, and its final polishing step is a perpetual challenge. The best way to tackle this challenge lies in automatic and non-mechanical polishing methods. Against this background, the suitability of large-area electron beam (EB) irradiation was examined in this study. In parallel, the optimum condition for efficient surface polishing was investigated. Cast titanium specimens were prepared, whereby their surface glossiness, surface roughness, and corrosion resistance were measured before and after EB irradiation. After EB irradiation, favorable results were observed: the cast titanium surface became smooth, the glossiness increased, and corrosion resistance was enhanced. These results were attributed to the low heat conductivity of titanium. With mechanical polishing, this property results in temperature rise and burnout reaction of the titanium surface with oxygen and the abrasives. However, during EB irradiation, the low heat conductivity of titanium was an advantage in raising the surface temperature to the melting point, such that a smooth surface was yielded after solidification. Based on the results obtained, automatic polishing by EB seemed to be a suitable polishing method for metal frameworks of removable dentures, and an efficient one too by saving time and effort.