scholarly journals Thermodynamic modeling of nickel and iron reduction from multicomponent silicate melt in bubbling process. Report 2. Reducing agent – a mixture OF Н2 – Н2О

2018 ◽  
Vol 61 (10) ◽  
pp. 794-799 ◽  
Author(s):  
A. S. Vusikhis ◽  
L. I. Leont’ev ◽  
D. Z. Kudinov ◽  
E. N. Selivanov
Keyword(s):  
Carbon Monoxide ◽  
Iron Oxide ◽  
Nickel Oxide ◽  
Thermodynamic Modeling ◽  
Iron Reduction ◽  
Nickel Content ◽  
Reduction Process ◽  
Gas Mixture ◽  
Degree Of Reduction ◽  
Oxide Melt

A number of technologies in ferrous and non-ferrous metallurgy  are based on bubbling processes. For prediction of melting parameters  including the reduction of metals from oxide melt by a reducing gas  in a bubbling layer in industrial aggregates, a thermodynamic modeling technique is proposed based on calculation of the equilibrium in  oxide-melt-metal-gas system. Originality of the technique is that equilibrium is determined for each unit dose of gas introduced into the  working body, with the contents of oxides of metals being reduced in  each subsequent design cycle equal to the equilibrium in the previous  one. For the analysis NiO (1.8  %) – FeO (17.4  %) – CaO (13.5  %)  –  MgO  (1.9  %) – SiO2 (58.0  %) – Al2O3 (7.4  %) oxide system was  taken, closely corresponding to composition of oxidized nickel ore.  The ratio of Н2О/Н2 in gas mixture varies between 0 and 1.0. (1823  K),  amount and composition of formed metal (ferronickel), as well as the  indices (the ratio of slag and metal, the degree of reduction of metals)  are important in implementation of the process under commodity conditions. The increase in hydrogen consumption monotonously reduces  the content of nickel oxide in the melt, while the content of iron oxide  initially increases, and then decreases.  When H2 is introduced in an  amount of about 50 m3 per ton of the melt, the content of nickel oxide  in it is reduced to 0.017  %, and of iron oxide to 16.7  %. Resulting ferronickel contains 61  % Ni, ratio of slag and metal – 42  units. Further  increase in H2 consumption leads to preferential iron reduction. An increase in H2O/H2 ratio worsens the results of reduction of metals from  the melt: decrease in degree of reduction of nickel and iron, increase  in nickel content in the alloy, and the ratio of slag and metal. However,  even with a H2 / H2O ratio of 1.0, which corresponds to 50  % of H2O  in the gas mixture, reduction process does not stop. For comparison,  the work presents data on change in content of nickel and iron oxides,  when metals are restored from similar melts with carbon monoxide.  At a nickel recovery rate of 98  %, indicators are close in case of using  both H2 and CO. However, to achieve them, it is required 2.5  times less hydrogen, and 1.36 times less mixture in which H2O/H2  =  0.11  (H2  –  90  %) than carbon monoxide.

scholarly journals Metal reduction by hydrogen from the B2O3-СaO-Ni(Zn, Pb, Cu)O melts thermodynamic modeling

2020 ◽  
Vol 61 (2) ◽  
pp. 145-151
Author(s):  
Alexander S. Vusikhis ◽  
◽  
Evgeny N. Selivanov ◽  
Stanislav N. Tyushnyakov ◽  
Viktor P. Chentsov ◽  
...  
Keyword(s):  
Carbon Monoxide ◽  
Thermodynamic Modeling ◽  
Reduction Process ◽  
Reducing Agent ◽  
Metal Reduction ◽  
Oxide Melt ◽  
Reduction Processes ◽  
Lead And Zinc ◽  
Nickel Copper ◽  
Copper Lead

Thermodynamic modeling is used to describe the metal reduction processes by hydrogen from oxide melt in the B2O3-CaO- MeO (Me – Ni, Zn, Pb, Cu) system. Open systems approximation with periodic removal of metal particles and gases from the working melt composition is used in the method. By this work we present the thermodynamic modeling results of metal reduction processes (Ni, Cu, Pb, Zn) by Hydrogen. The reducible metals oxides content in the all melts was 3 mass %, and the mass ratio of B2O3/CaO was taken as 3 to be close to eutectic composition. The calculations made it possible to determine such parameters as oxide melt compositions and elements reduction degree depending on the induced gas quantity. of the Nickel, Copper, Lead and Zinc reduction process simulation from B2O3-CaO-MeO melts proved the reduction process by Hydrogen is similar to that which was earlier established when Carbon monoxide was used as the reducing agent. When Copper is reduced from CuO, the process occurs with intermediate Cu2O oxide formation (CuO → Cu2O → Cu). The Nickel (NiO → Ni), Lead (PbO → Pbs + Pbg) and Zinc (ZnO → Zng) recovery have been realized by one stage. The non-ferrous metals change content in the oxide melt and the degrees of its reduction depending on temperature and reducing agent quantity introduced are described by the second-order polynomial functional equations. Comparison of the Carbon monoxide and Hydrogen used for Nickel, Copper, Lead, and Zinc reducing to 90% metallization degree proved much less Hydrogen consumption.

scholarly journals Thermodynamic Modeling of Iron and Nickel Reduction from B2O3-CaO-FeO-NiO Melts

2020 ◽  
Author(s):  
A.S. Vusikhis ◽  
L.I. Leontiev ◽  
E.N. Selivanov ◽  
V.P. Chentsov
Keyword(s):  
Carbon Monoxide ◽  
Thermodynamic Modeling ◽  
Open System ◽  
Iron Reduction ◽  
Nickel Extraction ◽  
Residual Content ◽  
Oxide Melt ◽  
Closed Systems ◽  
Joint Reduction ◽  
Gas Bubbling

At present, during solving theoretical and applied problems of metallurgical technologies improving, thermodynamic modeling (TDM) methods are widely used to calculate multicomponent and multiphase systems. However, existing methodology TДM are intended for the balance analysis in the ”closed” systems. The authors of [9] proposed a technique that allows, using TDMs, to describe metal reduction processes during gas bubbling of multicomponent oxide melts in approximation to “open” real systems. The applicability of the methods is estimated using the example of joint Nickel and Iron reduction modeling in the B2O3-CaO-FeO-NiO system by Carbon monoxide for ”open” and ”closed” systems. The data obtained comparison for ”open” and ”closed” systems show that the consecutive output of products (gas and metal) from working medium promotes achievement of the best parameters for Nickel extraction to alloy and to its residual content in oxide melt. Using this technique, the TДM process of joint reduction of Nickel and Iron in system B2O3-CaO-FeO-NiO by Carbon monoxide in ”open” system was undertaken at various temperatures in the 1273-1773K interval. Keywords: thermodynamic modeling, ”closed” system, ”open” system, joint reduction, Carbon monoxide, oxide melt, gas bubbling

scholarly journals Thermodynamic modeling of metals reduction from B2O3-CaO-FeO-NiО melts by carbon monoxide and hydrogen

2020 ◽  
Vol 63 (9) ◽  
pp. 99-104
Author(s):  
Alexander S. Vusikhis ◽  
◽  
Evgeny N. Selivanov ◽  
Stanislav N. Tyushnyakov ◽  
Viktor P. Chentsov ◽  
...  
Keyword(s):  
Carbon Monoxide ◽  
Thermodynamic Modeling ◽  
Nickel Content ◽  
Component Composition ◽  
Reducing Agent ◽  
Oxide Melt ◽  
Oxide Component ◽  
Useful Components ◽  
Nickel Metallization ◽  
Neutral Conditions

Thermodynamic modeling method have been used to describe the process of Iron and Nickel joint reduction from oxide melt of the B2O3-CaO-FeO-NiO system by Carbon monoxide and Hydrogen. Fractional inducing of reducing agent and periodic removal of metal gases from working body composition are applied in the method. The equilibrium states are determined for each unit portion of gas, and oxide component composition of the working body in each calculation cycle is taken from the previous data. Such approach is originality of the method. The approach gives possibility to bring the simulated processes closer to real technologies as well as to estimate reactions completeness in pyrometallurgical aggregates. The calculations were carried out accounting disproportionation of FeO into Fe and Fe3O4. It was shown that as a result of FeO disproportionation under neutral conditions (Ar), the resulting metallic Iron interacts with Nickel oxide to form ferronickel. As a result, the initial composition of the B2O3-CaO-FeO-NiO system variation, take place. Additionally, Fe3O4 appears in the working body. The relationship of Iron and Nickel oxides contents in oxide melt, degrees of its reducing and composition of ferronickel formed depending on temperature and induced reducing agent are revealed. The Hydrogen quantity consumed for metal reducing, at which the same degree of Nickel metallization is achieved, is much less comparing to CO. However, the resulting ferroalloy has less Nickel content, which is associated with increase of reduced Iron content. The obtained information is useful for prognoses of thermal extraction processes acting during useful components extraction from oxide melts, for example, nonferrous metallurgy slag.

scholarly journals Thermodynamic modeling of nickel and iron reduction from B2O3 – CaO – Fe2O3 – NiO melt by СО – СО2 and Н2 – Н2О mixtures

2021 ◽  
Vol 64 (5) ◽  
pp. 353-359
Author(s):  
A. S. Vusikhis ◽  
L. I. Leont’ev ◽  
E. N. Selivanov
Keyword(s):  
Thermodynamic Modeling ◽  
Iron Reduction ◽  
Selective Reduction ◽  
Gas Composition ◽  
Oxide Melt ◽  
Second Stage ◽  
Maximum Value ◽  
Working Medium ◽  
Third Stage ◽  
Successive Calculation

To predict the conditions for metals reduction from an oxide melt by gas in bubbling processes, a thermodynamic modeling technique has been developed that provides an approximation to real systems. The main difference between the accepted method and the well-known one is in conducting successive calculation cycles with withdrawal of the generated gases and the metal phase from the working medium. This paper presents the results of thermodynamic modeling of nickel and iron reduction processes from B2O3 – CaO– Fe2O3 – NiO melts by mixtures of CO– CO2 and H2 – H2O containing 0 – 60 % CO2 (H2O) in the temperature range of 1273 – 1673 K. The calculations evaluated the content of nickel and iron oxides in the melt and the degree of their reduction. It is shown that, regardless of the gas composition, this process proceeds in several stages. At the first stage, Fe2O3 is reduced to Fe3O4 and FeO. СFe2O3 values decrease to almost zero, while СFe3O4 and CFeO increase simultaneously. By the end of the phase, СFeO reaches its maximum value. At the second stage, the Fe3O4 → FeO transition occurs, when СFe3O4 values reach maximum, nickel and iron begin to reduce to metal. At reduction by CO– CO2 mixture, an increase in temperature reduces the metallization of both nickel and iron. Similarly, an increase in the CO2 content of the introduced gas affects. During interaction of the oxide melt with a gas containing 60 % CO2 , the third stage is absent. At reduction by H2 – H2O mixture, an increase in temperature reduces the metallization of nickel, but increases metallization of iron. With increasing water vapor content in the introduced gas, the degree of metallization of both nickel and iron decreases. The obtained data are useful for creating technologies for selective reduction of metals and formation of ferronickel of the required composition.

scholarly journals Effect of Cobalt on Nickel Oxide Toward Reduction Behaviour in Hydrogen and Carbon Monoxide Atmosphere

2020 ◽  
Vol 1010 ◽  
pp. 373-378
Author(s):  
Norliza Dzakaria ◽  
Maratun Najiha Abu Tahari ◽  
Salma Samidin ◽  
Tengku Shafazila Tengku Saharuddin ◽  
Fairous Salleh ◽  
...  
Keyword(s):  
Carbon Monoxide ◽  
Nickel Oxide ◽  
Reduction Process ◽  
Xrd Analysis ◽  
X Ray Diffraction ◽  
X Ray ◽  
Reduction Behaviour ◽  
One Step ◽  
Temperature Programmed ◽  
Co Doped

The reduction behaviour of cobalt doped with nickel oxide and undoped nickel oxide (NiO) by hydrogen (H2) in nitrogen (20%, v/v) and carbon monoxide (CO) in nitrogen (40%, v/v) atmospheres have been investigated by temperature programmed reduction (TPR). The phases formed of partially and completely reduced samples were characterized by X-ray diffraction spectroscopy (XRD). TPR results indicate that the reduction of Co doped and undoped nickel oxide in both reductants proceed in one step reduction (NiO → Ni) without intermediate. TPR results also suggested that by adding Co metal into NiO, the reduction to metallic Ni by both reductant gaseous give different intensity of the peak. The reduction process of Co and undoped NiO become faster when H2 was used as a reductant. Furthermore, in H2 atmosphere, Co-NiO give complete reduction to metallic Ni at 700 °C. Meanwhile, XRD analysis indicated that NiO without Co composed better crystallite phases of NiO with higher intensity.

scholarly journals Thermodynamic modeling of reduction of metals from B2O3-CaO-Ni(Zn,Pb,Cu)O melts carbon monoxide

2019 ◽  
Vol 59 (9) ◽  
pp. 125-131
Author(s):  
Alexander S. Vusikhis ◽  
◽  
Evgeny N. Selivanov ◽  
Stanislav N. Tyushnyakov ◽  
Victor P. Chentsov ◽  
...  
Keyword(s):  
Carbon Monoxide ◽  
Thermodynamic Modeling ◽  
Equilibrium Composition ◽  
Metal Phase ◽  
Oxide Melt ◽  
Reducing Ability ◽  
Lead And Zinc ◽  
Nickel Copper ◽  
Reducing Gases ◽  
Copper Lead

Thermodynamic modeling technique is used to describe the metal reduction from oxide melt by carbon monoxide. The B2O3-CaO-MeO (Me – Ni, Zn, Pb, Cu) system, was used with periodic output of the metal phase and gases from the working body. The approach originality is that the equilibrium is determined for each single portion of the gas injected into the working body, and the metal oxides content being reduced in each calculation cycle is taken from the previous data. This approach gives qualitative possibility to make simulated processes closer to real ones. The proposed method calculations allow determining, such parameters as the oxide melt and metal phase compositions, degree of elements reduction, oxide and metal phases mass ratio, equilibrium composition of the gas, reducing ability of gas utilization degree, and others, depending on the introduced gas quantities. Reducing process modeling of Nickel, Copper, Lead and Zinc from B2O3-CaO-MeO melts gives opportunity to determine the process for each metal. Copper reducing from CuO, goes with intermediate oxide (CuO → Cu2O → Cu) formation. Reduction of Nickel (NiO → Ni), Lead (PbO → Pbs + Pbg) and Zinc (ZnO → Zng) proceeds in one stage. The temperature dependence of the non-ferrous metals content in the oxide melt, its reduction degree and reducing agent quantity introduced are described by the second-order polynomial equations. The information obtained may be useful for thermo-extraction processes prognosis during the Nickel, Copper, Lead, and Zinc extraction from non-ferrous metallurgy slag in bubbling process of oxide melt by reducing gases.

The Reduction Behaviour of Cerium Doped Iron Oxide in Hydrogen and Carbon Monoxide Atmosphere

2016 ◽  
Vol 840 ◽  
pp. 381-385
Author(s):  
Tengku Shafazila Tengku Saharuddin ◽  
Alinda Samsuri ◽  
Fairous Salleh ◽  
Rizafizah Othaman ◽  
Mohammad Kassim ◽  
...  
Keyword(s):  
Carbon Monoxide ◽  
Iron Oxide ◽  
Metallic Iron ◽  
Reduction Process ◽  
Xrd Analysis ◽  
Temperature Programmed Reduction ◽  
X Ray Diffraction ◽  
X Ray ◽  
Reduction Behaviour ◽  
Temperature Programmed

The reduction behaviour of 3% cerium doped (Ce-Fe2O3) and undoped iron oxide (Fe2O3) by hydrogen in nitrogen (10%,v/v) and carbon monoxide in nitrogen (10%,v/v) atmospheres have been investigate by temperature programmed reduction (TPR). The phases formed of partially and completely reduced samples were characterized by X-ray diffraction spectroscopy (XRD). TPR results indicate that the reduction of Ce doped and undoped iron oxide in both reductants proceed in three steps reduction (Fe2O3 → Fe3O4 → FeO → Fe) with Fe3O4 and FeO were the intermediate. TPR results also suggested that by adding Ce metal into iron oxide the reduction to metallic Fe by using both reductant gaseous give better reducibility compare to the undoped Fe2O3. The reduction process of Ce and undoped Fe2O3 become faster when CO was used as a reductant instead of H2. Furthermore, in CO atmosphere, Ce-Fe2O3 give complete reduction to metallic iron at 700 0C which about 200 0C temperature lower than other samples. Meanwhile, XRD analysis indicated that Ce doped iron oxide composed better crystallite phases of Fe2O3 with higher intensity and a small amount of FeCe2O4.

scholarly journals Recovery Of Nickel From Spent Nickel-Cadmium Batteries Using A Direct Reduction Process

2015 ◽  
Vol 60 (2) ◽  
pp. 1365-1370 ◽  
Author(s):  
D.J. Shin ◽  
S.-H. Joo ◽  
J.-P. Wang ◽  
S.-M. Shin
Keyword(s):  
Iron Oxide ◽  
Nickel Oxide ◽  
Direct Reduction ◽  
Base Material ◽  
Reduction Process ◽  
Smelting Process ◽  
Low Grade ◽  
Direct Reduction Process ◽  
Ni Alloy ◽  
Pre Treatment

Abstract Most nickel is produced as Ferro-Nickel through a smelting process from Ni-bearing ore. However, these days, there have been some problems in nickel production due to exhaustion and the low-grade of Ni-bearing ore. Moreover, the smelting process results in a large amount of wastewater, slag and environmental risk. Therefore, in this research, spent Ni-Cd batteries were used as a base material instead of Ni-bearing ore for the recovery of Fe-Ni alloy through a direct reduction process. Spent Ni-Cd batteries contain 24wt% Ni, 18.5wt% Cd, 12.1% C and 27.5wt% polymers such as KOH. For pre-treatment, Cd was vaporized at 1024K. In order to evaluate the reduction conditions of nickel oxide and iron oxide, pre-treated spent Ni-Cd batteries were experimented on under various temperatures, gas-atmospheres and crucible materials. By a series of process, alloys containing 75 wt% Ni and 20 wt% Fe were produced. From the results, the reduction mechanism of nickel oxide and iron oxide were investigated.

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