Model-based estimation of liquid flows in the blast furnace hearth and taphole

This thesis presents a set of methods and models for estimation of iron and slag flows in the blast furnace hearth and taphole. The main focus was put on predicting taphole flow patterns and estimating the effects of various taphole conditions on the drainage behavior of the blast furnace hearth. All models were based on a general understanding of the typical tap cycle of an industrial blast furnace. Some of the models were evaluated on short-term process data from the reference furnace. A computational fluid dynamics (CFD) model was built and applied to simulate the complicated hearth flows and thus to predict the regions of the hearth exerted to erosion under various operating conditions. Key boundary variables of the CFD model were provided by a simplified drainage model based on the first principles. By examining the evolutions of liquid outflow rates measured from the furnace studied, the drainage model was improved to include the effects of taphole diameter and length. The estimated slag delays showed good agreement with the observed ones. The liquid flows in the taphole were further studied using two different models and the results of both models indicated that it is more likely that separated flow of iron and slag occurs in the taphole when the liquid outflow rates are comparable during tapping. The drainage process was simulated with an integrated model based on an overall balance analysis: The high in-furnace overpressure can compensate for the resistances induced by the liquid flows in the hearth and through the taphole. Finally, a recently developed multiphase CFD model including interfacial forces between immiscible liquids was developed and both the actual iron-slag system and a water-oil system in laboratory scale were simulated. The model was demonstrated to be a useful tool for simulating hearth flows for gaining understanding of the complex phenomena in the drainage of the blast furnace.

Puristussylinterien valmistuksen kehittäminen

Tässä diplomityössä kehitettiin yksitoimisten puristussylinterien valmistusta Rautessa. Sylinterien valmistuksessa haastavin vaihe on sylinteriputken ja pohjan välinen hitsaus. Hitsauksen avuksi suunniteltiin sylinterin sisäpuolinen juuritukilaite. Hitsauskokeita suoritettiin hitsin pohjan jauhekaarihitsaukselle ja MAG-hitsaukselle. Juuritukilaitteen toimivuutta testattiin koehitsauksilla. Puristussylinterien materiaali on S355J2-terästä, jonka ainevahvuus on 20 – 60 mm. Paksujen rakenneterästen hitsauksessa täytyy ottaa huomioon hitsausliitoksen mekaanisten ominaisuuksien muuttuminen sekä eri halkeamien synty. Hitsauksen laatuun ja laadunhallintaan voidaan vaikuttaa monien eri tekijöiden avulla. Hitsausohjeen avulla, ja muut laatutekijät huomioiden, voidaan hitseille asetetut laatukriteerit täyttää. Juurituen käyttö nopeuttaa puristussylinterien hitsausta vähintään 50 %. Jauhekaarihitsaus kuparista juuritukea vasten synnyttää vaikeasti poistettavan kuonan juuren puolelle. Perinteinen MAG-hitsaus kuparista juuritukea vasten sisältää liian monta muuttujaa, mikä tekee siitä epäluotettavan pohjapalon hitsaukseen. Työssä suunnitellun juuritukilaitteen käyttö tuotannossa vaatii lisää hitsauskokeita.

Lounais-Suomen viemäröinti : Laajentamisalueet ja priorisointi

Varsinais-Suomen ELY-keskus on tehnyt selvityksen Lounais-Suomen viemäröintialueiden laajentamisesta. Samalla priorisoitiin tärkeimmät toteutuskohteet. Työssä päivitettiin vanha, vuonna 2006 tehty, Varsinais-Suomen ja Satakunnan potentiaaliset viemäröintialueet selvitys. Työssä tarkasteltiin nykyisten vesihuoltolaitosten toiminta-alueiden ja muiden rakennettujen viemäriverkostojen ulkopuolisia alueita, joille viemäriverkko olisi mahdollista ulottaa. Tiettyjen kriteerien ja laskentaperusteiden perusteella on arvioitu, millä alueilla viemäröinti olisi kiinteistökohtaisiin järjestelmiin verrattuna kannattava vaihtoehto. Priorisoinnin avulla on saatu tärkeimmät viemäröintialueet nostettua kiireellisimmin toteutettaviksi. Päivitetty selvitys toimii kunnille, maakuntien liitoille, vesihuoltolaitoksille ja Varsinais-Suomen ELY-keskukselle työkaluna mm. vesihuollon kehittämisessä, kaavoituksessa ja avustusten kohdentamisessa. Kyläyhteisöille ja haja-asutusalueiden asukkaille selvitys tarjoaa tietoa viemäröinnin kustannuksista ja eri jätevesien käsittelyvaihtoehdoista. Selvitys ei ole toteutussitoumus eikä siinä oteta kantaa siihen, mikä taho viemäröinnin toteuttaa.

Utilization of steelmaking waste materials for production of calcium carbonate (CaCO3)

The steel industry produces, besides steel, also solid mineral by-products or slags, while it emits large quantities of carbon dioxide (CO2). Slags consist of various silicates and oxides which are formed in chemical reactions between the iron ore and the fluxing agents during the high temperature processing at the steel plant. Currently, these materials are recycled in the ironmaking processes, used as aggregates in construction, or landfilled as waste. The utilization rate of the steel slags can be increased by selectively extracting components from the mineral matrix. As an example, aqueous solutions of ammonium salts such as ammonium acetate, chloride and nitrate extract calcium quite selectively already at ambient temperature and pressure conditions. After the residual solids have been separated from the solution, calcium carbonate can be precipitated by feeding a CO2 flow through the solution. Precipitated calcium carbonate (PCC) is used in different applications as a filler material. Its largest consumer is the papermaking industry, which utilizes PCC because it enhances the optical properties of paper at a relatively low cost. Traditionally, PCC is manufactured from limestone, which is first calcined to calcium oxide, then slaked with water to calcium hydroxide and finally carbonated to PCC. This process emits large amounts of CO2, mainly because of the energy-intensive calcination step. This thesis presents research work on the scale-up of the above-mentioned ammonium salt based calcium extraction and carbonation method, named Slag2PCC. Extending the scope of the earlier studies, it is now shown that the parameters which mainly affect the calcium utilization efficiency are the solid-to-liquid ratio of steel slag and the ammonium salt solvent solution during extraction, the mean diameter of the slag particles, and the slag composition, especially the fractions of total calcium, silicon, vanadium and iron as well as the fraction of free calcium oxide. Regarding extraction kinetics, slag particle size, solid-to-liquid ratio and molar concentration of the solvent solution have the largest effect on the reaction rate. Solvent solution concentrations above 1 mol/L NH4Cl cause leaching of other elements besides calcium. Some of these such as iron and manganese result in solution coloring, which can be disadvantageous for the quality of the PCC product. Based on chemical composition analysis of the produced PCC samples, however, the product quality is mainly similar as in commercial products. Increasing the novelty of the work, other important parameters related to assessment of the PCC quality, such as particle size distribution and crystal morphology are studied as well. As in traditional PCC precipitation process, the ratio of calcium and carbonate ions controls the particle shape; a higher value for [Ca2+]/[CO32-] prefers precipitation of calcite polymorph, while vaterite forms when carbon species are present in excess. The third main polymorph, aragonite, is only formed at elevated temperatures, above 40-50 °C. In general, longer precipitation times cause transformation of vaterite to calcite or aragonite, but also result in particle agglomeration. The chemical equilibrium of ammonium and calcium ions and dissolved ammonia controlling the solution pH affects the particle sizes, too. Initial pH of 12-13 during the carbonation favors nonagglomerated particles with a diameter of 1 μm and smaller, while pH values of 9-10 generate more agglomerates of 10-20 μm. As a part of the research work, these findings are implemented in demonstrationscale experimental process setups. For the first time, the Slag2PCC technology is tested in scale of ~70 liters instead of laboratory scale only. Additionally, design of a setup of several hundreds of liters is discussed. For these purposes various process units such as inclined settlers and filters for solids separation, pumps and stirrers for material transfer and mixing as well as gas feeding equipment are dimensioned and developed. Overall emissions reduction of the current industrial processes and good product quality as the main targets, based on the performed partial life cycle assessment (LCA), it is most beneficial to utilize low concentration ammonium salt solutions for the Slag2PCC process. In this manner the post-treatment of the products does not require extensive use of washing and drying equipment, otherwise increasing the CO2 emissions of the process. The low solvent concentration Slag2PCC process causes negative CO2 emissions; thus, it can be seen as a carbon capture and utilization (CCU) method, which actually reduces the anthropogenic CO2 emissions compared to the alternative of not using the technology. Even if the amount of steel slag is too small for any substantial mitigation of global warming, the process can have both financial and environmental significance for individual steel manufacturers as a means to reduce the amounts of emitted CO2 and landfilled steel slag. Alternatively, it is possible to introduce the carbon dioxide directly into the mixture of steel slag and ammonium salt solution. The process would generate a 60-75% pure calcium carbonate mixture, the remaining 25-40% consisting of the residual steel slag. This calcium-rich material could be re-used in ironmaking as a fluxing agent instead of natural limestone. Even though this process option would require less process equipment compared to the Slag2PCC process, it still needs further studies regarding the practical usefulness of the products. Nevertheless, compared to several other CO2 emission reduction methods studied around the world, the within this thesis developed and studied processes have the advantage of existing markets for the produced materials, thus giving also a financial incentive for applying the technology in practice.

Ryssen i Karistrakten 1713 – slaget vid Landsbro och dess följder

Artikel i årsskrift.

Optimal Recycling Combination of Ash in South-East Finland

The present world energy production is heavily relying on the combustion of solid fuels like coals, peat, biomass, municipal solid waste, whereas the share of renewable fuels is anticipated to increase in the future to mitigate climate change. In Finland, peat and wood are widely used for energy production. In any case, the combustion of solid fuels results in generation of several types of thermal conversion residues, such as bottom ash, fly ash, and boiler slag. The predominant residue type is determined by the incineration technology applied, while its composition is primarily relevant to the composition of fuels combusted. An extensive research has been conducted on technical suitability of ash for multiple recycling methods. Most of attention was drawn to the recycling of the coal combustion residues, as coal is the primary solid fuel consumed globally. The recycling methods of coal residues include utilization in a cement industry, in concrete manufacturing, and mine backfilling, to name few. Biomass combustion residues were also studied to some extent with forest fertilization, road construction, and road stabilization being the predominant utilization options. Lastly, residues form municipal solid waste incineration attracted more attention recently following the growing number of waste incineration plants globally. The recycling methods of waste incineration residues are the most limited due to its hazardous nature and varying composition, and include, among others, landfill construction, road construction, mine backfilling. In the study, environmental and economic aspects of multiple recycling options of thermal conversion residues generated within a case-study area were studied. The case-study area was South-East Finland. The environmental analysis was performed using an internationally recognized methodology — life cycle assessment. Economic assessment was conducted applying a widely used methodology — cost-benefit analysis. Finally, the results of the analyses were combined to enable easier comparison of the recycling methods. The recycling methods included the use of ash in forest fertilization, road construction, road stabilization, and landfill construction. Ash landfilling was set as a baseline scenario. Quantitative data about the amounts of ash generated and its composition was obtained from companies, their environmental reports, technical reports and other previously published literature. Overall, the amount of ash in the case-study area was 101 700 t. However, the data about 58 400 t of fly ash and 35 100 t of bottom ash and boiler slag were included in the study due to lack of data about leaching of heavy metals in some cases. The recycling methods were modelled according to the scientific studies published previously. Overall, the results of the study indicated that ash utilization for fertilization and neutralization of 17 600 ha of forest was the most economically beneficial method, which resulted in the net present value increase by 58% compared to ash landfilling. Regarding the environmental impact, the use of ash in the construction of 11 km of roads was the most attractive method with decreased environmental impact of 13% compared to ash landfilling. The least preferred method was the use of ash for landfill construction since it only enabled 11% increase of net present value, while inducing additional 1% of negative impact on the environment. Therefore, a following recycling route was proposed in the study. Where possible and legally acceptable, recycle fly and bottom ash for forest fertilization, which has strictest requirements out of all studied methods. If the quality of fly ash is not suitable for forest fertilization, then it should be utilized, first, in paved road construction, second, in road stabilization. Bottom ash not suitable for forest fertilization, as well as boiler slag, should be used in landfill construction. Landfilling should only be practiced when recycling by either of the methods is not possible due to legal requirements or there is not enough demand on the market. Current demand on ash and possible changes in the future were assessed in the study. Currently, the area of forest fertilized in the case-study are is only 451 ha, whereas about 17 600 ha of forest could be fertilized with ash generated in the region. Provided that the average forest fertilizing values in Finland are higher and the area treated with fellings is about 40 000 ha, the amount of ash utilized in forest fertilization could be increased. Regarding road construction, no new projects launched by the Center of Economic Development, Transport and the Environment in the case-study area were identified. A potential application can be found in the construction of private roads. However, no centralized data about such projects is available. The use of ash in stabilization of forest roads is not expected to increased in the future with a current downwards trend in the length of forest roads built. Finally, the use of ash in landfill construction is not a promising option due to the reducing number of landfills in operation in Finland.

Behaviour of laterised normal and self compacting concrete subjected to elevated temperatures

Concrete is a universal material in the construction industry. With natural resources like sand and aggregate, fast depleting, it is time to look for alternate materials to substitute these in the process of making concrete. There are instances like exposure to solar radiation, fire, furnaces, and nuclear reactor vessels, special applications like missile launching pads etc., where concrete is exposed to temperature variations In this research work, an attempt has been made to understand the behaviour of concrete when weathered laterite aggregate is used in both conventional and self compacting normal strength concrete. The study has been extended to understand the thermal behaviour of both types of laterised concretes and to check suitability as a fire protection material. A systematic study of laterised concrete considering parameters like source of laterite aggregate, grades of Ordinary Portland Cement (OPC) and types of supplementary cementitious materials (fly ash and GGBFS) has been carried out to arrive at a feasible combination of various ingredients in laterised concrete. A mix design methodology has been proposed for making normal strength laterised self compacting concrete based on trial mixes and the same has also been validated. The physical and mechanical properties of laterised concretes have been studied with respect to different variables like exposure temperature (200°C, 400°C and 600°C) and cooling environment (air cooled and water cooled). The behaviour of ferrocement elements with laterised self compacting concrete has also been studied by varying the cover to mesh reinforcement (10mm to 50mm at an interval of 10mm), exposure temperature and cooling environment.

Efectos fisiológicos de la termorregulación en trabajadores expuestos a altas temperaturas en una Siderúrgica en Colombia.

La exposición a altas temperaturas en ambientes laborales conlleva a cambios fisiológicos que se manifiestan como mecanismos de compensación a la alteración del equilibrio homeostático corporal. El propósito del presente estudio fue determinar los cambios y el comportamiento de variables fisiológicas a través de frecuencia cardiaca, densidad urinaria, temperatura corporal y tasa de sudoración, en dos escenarios con condiciones térmicas ambientales diferentes definidas por la exposición (grupo expuesto y no expuesto). Adicional, en dos áreas de trabajo diferentes correspondientes al proceso de fundición del acero, una de ellas, Horno electrico donde se hace la fusión de la chatarra y demás materias primas, obteniendo así el acero liquido, el cual se vuelca en el Horno Cuchara y en este, libre ya de escoria se realiza el afino y ajuste definitivo de la composición química del acero. Objetivos: Identificar la relación de las respuestas fisiológicas a carga física y térmica, comparar las respuestas funcionales registradas en el grupo expuestos y no expuestos y contribuir a la introducción de nuevos indicadores para evaluar carga e intensidad de trabajo con fines de normalización ergonómica. Método: Investigación experimental en una muestra de 30 trabajadores evaluados en dos condiciones ambientales diferentes. La temperatura oral se registró al inicio de la jornada y con intervalos de toma de 3 horas. La frecuencia cardiaca (HR) se registró durante las 8 horas de trabajo continuas con pulsometría. Igualmente, se estimó la sudoración por pérdida de masa corporal entre el inicio y el final de la jornada laboral teniendo en cuenta ingestas y perdidas. El procesamiento estadístico se realizó con el programa SPSS v. 20.0, calculándose medidas de tendencia central y dispersión, prueba de wilconxon para las variables dependientes y correlación para identificar asociaciones. Para todos los cálculos se asumió p <0,05. Resultados: No se observaron diferencias significativas frente a la variación de la frecuencia cardiaca (media y máxima), la tasa de sudoración y la densidad urinaria. A pesar de que no hubo diferencias significativas en la variación de la temperatura corporal en horno cuchara, si se observó una diferencia significativa en el horno eléctrico Conclusión: Aunque no se encontraron diferencias estadísticamente significativas en la mayoría de las variables, es un hecho que la exposición a temperaturas elevadas extremas tiene un impacto en el comportamiento fisiológico del organismo. Futuros estudios deben considerar la posibilidad de estandarizar protocolos que permitan la exposición térmica basada en el perfil particular de cada trabajador.

Matemáticas, juego y vida cotidiana

Se exponen algunas experiencias llevadas a cabo en el aula de dos a tres años del centro Gregori Mayans de Gandia, basadas en la relación entre las matemáticas y la vida cotidiana y entre las matemáticas y otros lenguajes. Se explican los principios metodológicos y se describen dos tipos de actividades. Una relacionada con el agua y otra con el cuidado de los animales que hay en el aula: un pez y dos caracoles.

Los títeres van a la escuela.

El juego con títeres en educación infantil es una fuente de curiosidad, descubrimiento, iniciativa y satisfacción. Para los niños y niñas los títeres traen consigo la oportunidad de expresar sentimientos y emociones y posibilitan la descarga de energía y tensiones. Además se favorece la comunicación y adquisición del lenguaje, el desarrollo cognitivo, las posibilidades expresivas y el desarrollo afectivo de los niños. Las diferentes actividades con títeres se proponen en función de las necesidades del grupo, en el juego con marionetas cualquier objeto puede ser susceptible de transformación y adquirir una nueva función diferente a la habitual. La evaluación se realiza a través de la observación individual y del grupo con la valoración de los resultados concretos de los talleres.

¿Cuántas patas tiene un caracol?

Se explican diversos proyectos de trabajo realizados con niños de Educación Infantil, en los que se utilizan las matemáticas como herramienta fundamental para ayudar a los niños a estructurar su pensamiento, a organizarse y a conocer el entorno que les rodea. Las actividades propuestas se centran en temas concretos de interés para los niños, a los que se aplican las matemáticas. Algunos ejemplos son los botes de colecciones y la clasificación de los objetos, los caracoles, el esqueleto del dinosaurio, el agua (mediante experimentos para estudiar sus propiedades de peso, volumen, cambio de estado) y otros materiales cotidianos.

Trace element partitioning and soil particle characterisation around mining and smelting areas at Tharsis, Riotinto and Huelva, SW Spain

Trace elements may present an environmental hazard in the vicinity of mining and smelting activities. However, the factors controlling trace element distribution in soils around ancient and modem mining and smelting areas are not always clear. Tharsis, Riotinto and Huelva are located in the Iberian Pyrite Belt in SW Spain. Tharsis and Riotinto mines have been exploited since 2500 B.C., with intensive smelting taking place. Huelva, established in 1970 and using the Flash Furnace Outokumpu process, is currently one of the largest smelter in the world. Pyrite and chalcopyrite ore have been intensively smelted for Cu. However, unusually for smelters and mines of a similar size, the elevated trace element concentrations in soils were found to be restricted to the immediate vicinity of the mines and smelters, being found up to a maximum of 2 kin from the mines and smelters at Tharsis, Riotinto and Huelva. Trace element partitioning (over 2/3 of trace elements found in the residual immobile fraction of soils at Tharsis) and soil particles examination by SEM-EDX showed that trace elements were not adsorbed onto soil particles, but were included within the matrix of large trace element-rich Fe silicate slag particles (i.e. 1 min circle divide at least 1 wt.% As, Cu and Zn, and 2 wt.% Pb). Slag particle large size (I mm 0) was found to control the geographically restricted trace element distribution in soils at Tharsis, Riotinto and Huelva, since large heavy particles could not have been transported long distances. Distribution and partitioning indicated that impacts to the environment as a result of mining and smelting should remain minimal in the region. (c) 2006 Elsevier B.V. All rights reserved.

Croig Cave: a late Bronze Age ornament deposition and 3,500 years of coastal foraging in NW Mull, Scotland

Activity within caves provides an important element of the later prehistoric and historic settlement pattern of western Scotland. This contribution reports on a small-scale excavation within Croig Cave, on the coast of north-west Mull, that exposed a 1.95m sequence of midden deposits and cave floors that dated bewteen c 1700 BC and AD 1400. Midden analysis indicated the processing of a .... 950 BC, a penannular copper bracelet a discrete ritual episode within the cycle of otherwise potentially mundane activities. Lead isotope analysis indicates an Irish origin for the copper ore. A piece of iron slag within later midden deposits, dated to c 400 BC, along with high frequencies of wood charcoal, suggest that smithing or smelting may have occurred within the cave. High zinc levels in the historic levels of the midden c AD 1200 might indicate intensive processing of seaweed.

Fracture and fatigue of natural fiber-reinforced cementitious composites

This paper presents the results of an experimental study of resistance-curve behavior and fatigue crack growth in cementitious matrices reinforced with eco-friendly natural fibers obtained from agricultural by-products. The composites include: blast furnace slag cement reinforced with pulped fibers of sisal, banana and bleached eucalyptus pulp, and ordinary Portland cement composites reinforced with bleached eucalyptus pulp. Fracture resistance (R-curve) and fatigue crack growth behavior were studied using single-edge notched bend specimens. The observed stable crack growth behavior was then related to crack/microstructure interactions that were elucidated via scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS). Fracture mechanics models were used to quantify the observed crack-tip shielding due to crack-bridging. The implications of the results are also discussed for the design of natural fiber-reinforced composite materials for affordable housing. (C) 2009 Elsevier Ltd. All rights reserved.

Catecholase and DNase activities of copper(II) complexes containing phenolate-type ligands

Three new homodinuclear complexes containing substituted phenolate-type ligands based on the N(5)O(2) donor (2-(N,N-Bis(2-pyridylmethyl)aminomethyl)-6-(N`,N`-(2-hydroxybenzyl)(2-pyridylmethyl))aminomethyl)-4-methylphenol (H(2)L-H) were synthesized and characterized by X-ray crystallography. Potentiometric titration studies in 70% (v/v) aqueous ethanol show that all three complexes exhibit a common {Cu(II)(mu-phenoxo)(mu-OH)Cu(II)(OH)} core in solution. Kinetic studies on the oxidation reaction of 3,5-di-tert-butylcatechol revealed that the catalytic activity of the metal complexes increases toward the ligand containing an electron-donating group. In addition, these complexes also carried out DNA cleavage by hydrolytic and oxidative pathways. Copyright (C) 2010 John Wiley & Sons, Ltd.