Treatise on Process Metallurgy, Volume 2: Process Phenomena

Dedication

Preface

Editor in Chief

Co-Editors-in-Chief

Contributors to Volume 2

Acknowledgement

The Review Committee

Chapter 1. Interfacial Phenomena in High Temperature Metallurgy

Chapter 1.1. Surfaces and Interfaces

Abstract

1.1.1 Definition of Surfaces and Interfaces

1.1.2 Gibbs Adsorption Isotherm

1.1.3 Langmuir’s Isotherm

References

Chapter 1.2. Surface Tension and Contact Angle

Abstract

1.2.1 Surface Tension

1.2.2 Contact Angle

1.2.3 Wetting

References

Chapter 1.3. Experiments

Abstract

1.3.1 Sessile Drop

1.3.2 Maximum Bubble Pressure

1.3.3 Pendent Drop

1.3.4 Drop Weight

1.3.5 Detachment Method

1.3.6 Liquid Surface Contour Method

1.3.7 Capillary Rise Method

1.3.8 Levitating Drop

Appendix A Software for Evaluation of Surface Tension from Sessile Drop

References

Chapter 1.4. Surface Tension Models

Abstract

1.4.1 Modeling of Surface Tension of Liquid Pure Metals and Molten Salts

1.4.2 Modeling of Surface Tension of Liquid Alloys

1.4.3 Modeling of Surface Tension of Molten Ionic Materials Including Molten Slag

1.4.4 Evaluation of Interfacial Tension Between Liquid Steel and Molten Slag

1.4.5 Application of Constrained Gibbs Energy Minimization Approach to Evaluate Surface Tension of Liquid Alloys

References

Chapter 1.5. Interfacial Free Energy and Wettability

Abstract

1.5.1 Wettability

1.5.2 Interfacial Free Energy Between Solid and Liquid Phases in Metals and Alloys

1.5.3 Interfacial Tension Between Liquid Steel and Molten Slag

References

Chapter 1.6. Some Aspects of Electrochemistry of Interfaces

Abstract

1.6.1 Basics of Electrochemistry of Interfaces

1.6.2 Electrocapillary Phenomena

References

Chapter 1.7. Interfacial Convection and Its Effect on Material Processing

Abstract

1.7.1 Some Basics of the Interfacial Convection

1.7.2 Effect of Interfacial Flow in Liquid–Liquid Reactions

1.7.3 Effect of Interfacial Flow in Liquid–Gas Reactions

1.7.4 Effect of Interfacial Flow in Liquid–Solid Reactions

1.7.5 Effect of Interfacial Flow in Solidification Processes and Crystal Growth

References

Chapter 1.8. Stability of Interface Between Liquid Steel and Molten Slag

Abstract

References

Chapter 1.9. Applications of Interfacial Phenomena in Process Metallurgy

Abstract

1.9.1 Marangoni Flow During the Welding Process

1.9.2 Engulfing of Small Droplets of Molten Slag into Liquid Steel

1.9.3 Erosion or Dissolution of Refractories

1.9.4 Separation of Metallic Droplets from Slags

1.9.5 Engulfing Nonmetallic Inclusions and Gas Bubbles into Solidified Interface

1.9.6 Gas Bubble Formation in Liquid Steel

1.9.7 Nucleation During Solidification

1.9.8 Slag Foaming

References

Chapter 2. Metallurgical Process Phenomena

Chapter 2.1. The Importance of Metallurgical Process Phenomena

Abstract

Chapter 2.2. Kinetics of Gas–Liquid and Liquid–Liquid Reactions

Abstract

2.2.1 Introduction

2.2.2 Rate-Controlling Process

2.2.3 The Difference Between Thermodynamics and Kinetics

2.2.4 Gas-Phase Mass Transfer

2.2.5 Free Vaporization

2.2.6 Liquid-Phase Mass Transfer

2.2.7 Heat Transfer Control

2.2.8 Chemical Kinetics

2.2.9 Mixed Control

2.2.10 Concluding Remarks

References

Chapter 2.3. Bubbles in Process Metallurgy

Abstract

2.3.1 Introduction

2.3.2 Bubble Formation

2.3.3 Bubble Shapes

2.3.4 Plume Shape

2.3.5 Mixing Time

2.3.6 Bubble Rupture

2.3.7 Bubbling–Jetting Transition

2.3.8 Modeling

References

Chapter 2.4. Foams and Foaming

Abstract

2.4.1 Foaming in Metallurgical Processes

2.4.2 Foaming Index

2.4.3 Slag Foaming in Industrial Processes

References

Chapter 2.5. Applications

Abstract

2.5.1 Rate Phenomena in Direct Ironmaking

2.5.2 Ladle Desulfurization Kinetics

2.5.3 Rate Phenomena in Vacuum Degassing

2.5.4 Rate Phenomena in AOD Stainless Steel Production

2.5.5 Inclusion Flotation in Argon-Stirred Steel

References

Chapter 3. Some Applications of Fundamental Principles to Metallurgical Operations

Abstract

3.0 Introductory Comments: Some Perspectives on the Process of Innovation

References

Chapter 3.1. Some Metallurgical Considerations Pertaining to the Development of Steel Quality

Abstract

Acknowledgments

3.1.1 Introduction

3.1.2 Generation of Steel Quality

3.1.3 Preservation of Steel Quality

3.1.4 Evaluation of Steel Quality

3.1.5 Summary

References

Chapter 3.2. Refractory Corrosion During Steelmaking Operations

Abstract

3.2.1 Introduction

3.2.2 Theoretical Considerations

3.2.3 Corrosion Testing of Refractories

3.2.4 Corrosion of Oxide–Carbon Refractories

3.2.5 Summary

References

Chapter 3.3. Application of Slag Engineering Fundamentals to Continuous Steelmaking

Abstract

3.3.1 Introduction

3.3.2 Continuous Steelmaking: An Overview

3.3.3 Continuous Steelmaking Based on the Use of DRI

3.3.4 Fundamental Considerations

3.3.5 Slag Design Steps

3.3.6 Process Analysis

References

Chapter 3.4. Kinetics of Assimilation of Additions in Liquid Metals

Abstract

List of Nomenclature

Greek symbols

Subscripts

Superscripts

3.4.1 Introduction

3.4.2 Fundamentals of Assimilation

3.4.3 Routes of Assimilation

3.4.4 Exothermic Phenomena During Assimilation

3.4.5 Recovery

3.4.6 Conclusions

References

Chapter 4. Metallurgical Process Technology

Chapter 4.1. Process Kinetics, Fluid Flow, and Heat and Mass Transfer, in Process Metallurgy

Abstract

4.1.1 Theory of Fluid Flows

4.1.2 The Continuity and Momentum Equations

4.1.3 Newtonian Liquids

4.1.4 Electromagnetically Driven Flows

4.1.5 Physical Modeling

4.1.6 Physical and Computational Models

4.1.7 Computational Fluid Dynamics

References

Chapter 4.2. Turbulence Modeling and Implementation

Abstract

Nomenclature

4.2.1 Introduction

4.2.2 Turbulence Models

4.2.3 Conclusions

References

Chapter 4.3. Computational Fluid Mechanics

Abstract

Nomenclature

4.3.1 Introduction

4.3.2 Applications of CFD in Process Metallurgy

4.3.3 Conclusions

References

Chapter 4.4. Solidification

Abstract

4.4.1 Application of Textured Copper Substrates for Enhancing Heat Fluxes

4.4.2 Solidification in Conventional Fixed-Mold Machines

References

Chapter 4.5. Computational and Physical Modeling of Solidification in CCC and TSC

Abstract

4.5.1 Proposed New Mechanism for the Formation of OMs

4.5.2 Conclusions

References

Chapter 4.6. Single Phase, Two Phase, and Multiphase Flows, and Methods to Model these Flows

Abstract

Nomenclature

4.6.1 Introduction

4.6.2 Multiphase Flow Regimes

4.6.3 Example: Modeling of Inert Gas Shrouding in a Tundish (Three-Phase Flow Involving Gas Bubbles, Liquid Steel, and Slag)

References

Chapter 4.7. The Design of a New Casting Process: From Fundamentals to Practice

Abstract

4.7.1 Continuous Casting Machines for the Steel Industry

4.7.2 Fluid Flows, Solidification, and Heat Transfer in Moving Mold Machines

4.7.3 Theoretical Heat Fluxes, Based on Perfect and Imperfect, Thermal Contact

4.7.4 Solidification and Strip Microstructures in NNSC

4.7.5 Horizontal Single-Belt Casting Processes

4.7.6 Fluid Flows: Design of Metal Delivery Systems

4.7.7 The Potential of the HSBC Caster: From Fundamentals to Practice

4.7.8 Conclusions

References

Chapter 4.8. Conclusion

Abstract

Chapter 5. Computational Thermodynamics, Models, Software and Applications

Chapter 5.1. Thermodynamics

Abstract

5.1.1 Calphad Method

5.1.2 Dilute Metallic Solution

5.1.3 Model for Oxide Solid Solutions

5.1.4 The Reciprocal Ionic Liquid Model

5.1.5 Quasichemical Models

5.1.6 The Cell Model

5.1.7 The Central Atoms Model and Generalized Central Atom Model

5.1.8 The Modified Quasichemical Model

5.1.9 Modified Quasichemical Model for Matte

5.1.10 Thermodynamic Packages and Databases

References

Chapter 5.2. Slag Viscosity Model

Abstract

5.2.1 FactSage Structural Viscosity Model for Multicomponent Slag

5.2.2 Viscosity of Slags

5.2.3 Appendices

References

Chapter 5.3. Applications

Abstract

List of Symbols

Acknowledgments

5.3.1 Applications to Steelmaking ProcessES

5.3.2 Application of Advanced Modeling in Nonferrous Metallurgy

References

Chapter 5.4. Process Modeling

Abstract

List of Symbols for Section 5.4.3

5.4.1 Production of Metallurgical Grade Silicon in an Electric Arc Furnace

5.4.2 Modeling TiO₂ Production by Explicit Use of Reaction Kinetics

5.4.3 Non-equilibrium Modeling for the LD-Converter

5.4.4 Simulation of the RH–OB and BOF Processes Using the Effective Equilibrium Reaction Zone Model

5.4.5 Rotary Cement Kiln Model

5.4.6 Kinetic Simulation of Ladle Refining and Smelting Using Software

References

Index