A Review of Ferroalloy Tapping Models

Bublik, Sergey; Olsen, Jan Erik; Loomba, Varun; Reynolds, Quinn; Einarsrud, Kristian Etienne

doi:10.1007/s11663-021-02134-5

Cited by 13 publications

(7 citation statements)

References 39 publications

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“…Iron and ferroalloys (e.g., Fe–Mn, Fe–Cr, Fe–Si) 32 are the most produced technological metals and alloys on earth. They are the basic ingredients for the production of steel which finds applications everywhere.…”

Section: Pyrometallurgical Operations: Current Statementioning

confidence: 99%

Greener reactants, renewable energies and environmental impact mitigation strategies in pyrometallurgical processes: A review

Harvey

Courchesne

et al. 2022

MRS Energy & Sustainability

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Metals and alloys are among the most technologically important materials for our industrialized societies. They are the most common structural materials used in cars, airplanes and buildings, and constitute the technological core of most electronic devices. They allow the transportation of energy over great distances and are exploited in critical parts of renewable energy technologies. Even though primary metal production industries are mature and operate optimized pyrometallurgical processes, they extensively rely on cheap and abundant carbonaceous reactants (fossil fuels, coke), require high power heating units (which are also typically powered by fossil fuels) to calcine, roast, smelt and refine, and they generate many output streams with high residual energy content. Many unit operations also generate hazardous gaseous species on top of large CO2 emissions which require gas-scrubbing and capture strategies for the future. Therefore, there are still many opportunities to lower the environmental footprint of key pyrometallurgical operations. This paper explores the possibility to use greener reactants such as bio-fuels, bio-char, hydrogen and ammonia in different pyrometallurgical units. It also identifies all recycled streams that are available (such as steel and aluminum scraps, electronic waste and Li-ion batteries) as well as the technological challenges associated with their integration in primary metal processes. A complete discussion about the alternatives to carbon-based reduction is constructed around the use of hydrogen, metallo-reduction as well as inert anode electrometallurgy. The review work is completed with an overview of the different approaches to use renewable energies and valorize residual heat in pyrometallurgical units. Finally, strategies to mitigate environmental impacts of pyrometallurgical operations such as CO2 capture utilization and storage as well as gas scrubbing technologies are detailed. This original review paper brings together for the first time all potential strategies and efforts that could be deployed in the future to decrease the environmental footprint of the pyrometallurgical industry. It is primarily intended to favour collaborative work and establish synergies between academia, the pyrometallurgical industry, decision-makers and equipment providers. Graphical abstract Highlights A more sustainable production of metals using greener reactants, green electricity or carbon capture is possible and sometimes already underway. More investments and pressure are required to hasten change. Discussion Is there enough pressure on the aluminum and steel industries to meet the set climate targets? The greenhouse gas emissions of existing facilities can often be partly mitigated by retrofitting them with green technologies, should we close plants prematurely to build new plants using greener technologies? Since green or renewable resources presently have limited availability, in which sector should we use them to maximize their benefits?

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Section: Pyrometallurgical Operations: Current Statementioning

confidence: 99%

Greener reactants, renewable energies and environmental impact mitigation strategies in pyrometallurgical processes: A review

Harvey

Courchesne

et al. 2022

MRS Energy & Sustainability

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“…When the layer becomes thinner than 20 cm, tapping should stop to avoid significant metal losses. 26 A low interfacial tension between the slag and the metal means that the metal droplets will be less spherical as they are descending in the slag. This again gives a lower terminal velocity, and hence the metal droplets will be more easily trapped in the slag.…”

Section: Metal-slag Separation: Flow Through Tap Hole Runner and Into...mentioning

confidence: 99%

Conceptual Tapping Model of Mn-Ferroalloy Furnaces

Tangstad

Olsen

Ringdalen

et al. 2022

JOM

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The tapping process of submerged arc furnaces, like the Mn-ferroalloy production process, is when you drain the liquid metal and slag from the furnace. The optimal tapping process is when slag and metal is drained from the furnace at the same rate as it is produced, and the slag and metal is being separated in the post-tap hole process. Industrially, this is not always the case. Based on published articles, this paper discusses the total tapping process that contains the consecutive steps of flow from back electrodes to the tap electrode and flow from the tap electrode through the tap hole and runner, and into the ladle system. It focuses on an overall summary of which elements may affect the tapping; however, it should be noted that this is not a mathematical model. The main information is regarding materials and zones in the furnaces, as well as knowledge from computational fluid dynamics (CFD) modeling work.

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“…In general, the specific electrical resistance decreases with the increase of graphitization level. Also, the presence of carbon atoms in the amorphous phase or fatty side chains increases reactivity [ [8] , [9] , [10] ]. The reactivity of carbon materials affects the consumption of electrodes and the life of refractories by affecting the atmosphere of the furnace [ 11 ].…”

Section: Introductionmentioning

confidence: 99%