Three-dimensional computational fluid dynamics analysis of an electric submerged arc furnace

A computational fluid dynamics (CFD) method is proposed to analyze the operation of a submerged electric arc furnace (SAF) used in ferronickel production. A three-dimensional mathematical model was used for the time-dependent solution of the fluid flow, heat transfer and electromagnetic phenomena. The slag's physical properties, which play a crucial role in the SAF operation, were previously determined using classical molecular dynamics simulations and empirical relationships. The analysis revealed that the main slag properties affecting SAF operation are density, viscosity and electrical conductivity-the latter two being mutually dependent. The high electrical conductivity values of the slag favor melting via the high Joule heat produced within the slag region. Calculation of the dimensionless Péclet and Reynolds numbers revealed that the slag velocities play a decisive role in heat transfer and further indicate that the slag flow is laminar. The average slag velocity calculated 0.0001 m/s with maxima in the vicinity of the electrodes.

Pragmatic analysis of the electric submerged arc furnace continuum

A transient mathematical model was developed for the description of fluid flow, heat transfer and electromagnetic phenomena involved in the production of ferronickel in electric arc furnaces. The key operating variables considered were the thermal and electrical conductivity of the slag and the shape, immersion depth and applied electric potential of the electrodes. It was established that the principal stimuli of the velocities in the slag bath were the electric potential and immersion depth of the electrodes and the thermal and electrical conductivities of the slag. Additionally, it was determined that, under the set of operating conditions examined, the maximum slag temperature ranged between 1756 and 1825 K, which is in accordance with industrial measurements. Moreover, it was affirmed that contributions to slag stirring due to Lorentz forces and momentum forces due to the release of carbon monoxide bubbles from the electrode surface were negligible.

A XAFS study of plain and composite iron(III) and chromium(III) hydroxides

Reduction of hexavalent Cr(VI) to the trivalent state is the common strategy for remediation of Cr(VI) contaminated waters and soils. In the presence of Fe the resulting compounds are usually mixed Fe(III)-Cr(III) phases, while, under iron-free conditions, reduction leads to formation of plain Cr(III) hydroxides. Environmental stability of these compounds depends on their structure and is important to understand how different precipitation conditions affect the local atomic order of resulting compounds and thus their long term stability. In current study, typical Cr(VI) environmental remediation products, i.e. plain and mixed Fe(III)-Cr(III) hydroxides, were synthesized by hydrolysis and redox reactions and their structure was studied by X ray diffraction and X ray absorption fine structure techniques. Plain Cr(III) hydroxide was found to correspond to the molecular formula Cr(OH)3·3H2O and was identified as crystalline in XRD. However, the same compound when examined by EXAFS did not exhibit any clear local order in the range of EXAFS detectable distances, i.e. between 0 and 5Å. Namely, EXAFS spectroscopy detected only contribution from the first nearest neighboring (Cr-O) shell, suggesting that CrO6 octahedra interconnection is loose, in accordance with the suggested anti-bayerite structure of this compound. Mixed Fe(III)-Cr(III) systems resembled 2-line ferrihydrite irrespective of the synthesis route. Analysis of Fe-K-EXAFS and Cr-K-EXAFS spectra indicated that FeO6 octahedra are bonded by sharing both edges and corners, while CrO6 octahedra seem to prefer edge sharing linkage. EXAFS data also suggest that Fe-Cr hydroxide produced by hydrolysis presents a better arrangement of CrO6 octahedra compared to the redox product.

Synthesis, characterization and stability of Cr(III) and Fe(III) hydroxides

Chromium is a common contaminant of soils and aquifers and constitutes a major environmental problem. In nature, chromium usually exists in the form of two oxidation states, trivalent, Cr(III), which is relatively innocuous for biota and for the aquatic environment, and hexavalent, Cr(VI) which is toxic, carcinogenic and very soluble. Accordingly, the majority of wastewater and groundwater treatment technologies, include a stage where Cr(VI) is reduced to Cr(III), in order to remove chromium from the aqueous phase and bind the element in the form of environmentally stable solid compounds. In the absence of iron the final product is typically of the form Cr(OH)3·xH2O whereas in the presence of iron the precipitate is a mixed Fe(1-x)Crx(OH)3 phase. In this study, we report on the synthesis, characterisation and stability of mixed (Fex,Cr1-x)(OH)3 hydroxides as compared to the stability of Cr(OH)3. We established that the plain Cr(III) hydroxide, abiding to the approximate molecular formula Cr(OH)3·3H2O, was crystalline, highly soluble, i.e. unstable, with a tendency to transform into the stable amorphous hydroxide Cr(OH)3(am) phase. Mixed Fe0.75Cr0.25(OH)3 hydroxides were found to be of the ferrihydrite structure, Fe(OH)3, and we correlated their solubility to that of a solid solution formed by plain ferrihydrite and the amorphous Cr(III) hydroxide. Both our experimental results and thermodynamic calculations indicated that mixed Fe(III)-Cr(III) hydroxides are more effective enhancers of groundwater quality, in comparison to the plain amorphous or crystalline Cr(III) hydroxides, the latter found to have a solubility typically higher than 50μg/l (maximum EU permitted Cr level in drinking water), while the amorphous Cr(OH)3(am) phase was within the drinking water threshold in the range 5.7<pH<11. In comparison, the mixed Fe0.75Cr0.25(OH)3 hydroxides studied were of extended stability in the 4.8<pH<13.5 range.

Atomic order and cluster energetics of a 17 wt% Si-based glass versus the liquid phase

Aerodynamic levitation of a multicomponent 17 wt% Si glass formed by rapid quenching of the melt phase was studied by high resolution x-ray diffraction (XRD) and reverse Monte Carlo (RMC) modelling. The main local atomic order features comprised interactions between Si, Fe and Mg polyhedra, the stereochemistry of which was on a par with the literature. Both the glass and the liquid state appeared to consist of the same fundamental Si-O, Fe-O and Mg-O clusters, with only the relative number of each varying between the two. Transition from liquid to glass involved a three-fold decrease in uncoordinated O (to within the first minimum of the total g(r)) and a marked increase of Fe-Si-Mg polyhedra bridging O. Octahedral Fe coordination was not suggested by the RMC data. All-electron open-shell density functional theory (DFT) calculations of the most prominent clusters suggested independence between the Fe oxidation state and its polyhedra O-coordination. Of secondary thermodynamic importance were indications of network-forming Fe(2+) and Fe(3+) distorted trigonal and tetrahedral polyhedra. In all occasions, the Fe ferrous and ferric states involved comparable binding energies within similar clusters which indicate a dynamic equilibrium between the two.