scholarly journals A Combined Pyro- and Hydrometallurgical Approach to Recycle Pyrolyzed Lithium-Ion Battery Black Mass Part 1: Production of Lithium Concentrates in an Electric Arc Furnace

Metals ◽  
2020 ◽  
Vol 10 (8) ◽  
pp. 1069
Author(s):  
Marcus Sommerfeld ◽  
Claudia Vonderstein ◽  
Christian Dertmann ◽  
Jakub Klimko ◽  
Dušan Oráč ◽  
...  
Keyword(s):  
Raw Materials ◽  
Maximum Yield ◽  
Lithium Ion ◽  
Melting Process ◽  
Electric Arc Furnace ◽  
Electric Arc ◽  
Arc Furnace ◽  
Mineralogical Characterization ◽  
Secondary Sources ◽  
Cobalt Nickel

Due to the increasing demand for battery raw materials such as cobalt, nickel, manganese, and lithium, the extraction of these metals not only from primary, but also from secondary sources like spent lithium-ion batteries (LIBs) is becoming increasingly important. One possible approach for an optimized recovery of valuable metals from spent LIBs is a combined pyro- and hydrometallurgical process. According to the pyrometallurgical process route, in this paper, a suitable slag design for the generation of slag enriched by lithium and mixed cobalt, nickel, and copper alloy as intermediate products in a laboratory electric arc furnace was investigated. Smelting experiments were carried out using pyrolyzed pelletized black mass, copper(II) oxide, and different quartz additions as a flux to investigate the influence on lithium-slagging. With the proposed smelting operation, lithium could be enriched with a maximum yield of 82.4% in the slag, whereas the yield for cobalt, nickel, and copper in the metal alloy was 81.6%, 93.3%, and 90.7% respectively. The slag obtained from the melting process is investigated by chemical and mineralogical characterization techniques. Hydrometallurgical treatment to recover lithium is carried out with the slag and presented in part 2.

Electromechanical Coupled Response of the AC Electric Arc Furnace Structures During the Scrap Melting Process

2012 ◽  
Author(s):  
Eugenio G. M. Brusa ◽  
Nicola Bosso ◽  
Nicolò Zampieri ◽  
Stefano Morsut ◽  
Maurizio Picciotto
Keyword(s):  
Flexible Structures ◽  
Electric Circuit ◽  
Melting Process ◽  
Electric Arc Furnace ◽  
Electric Arc ◽  
Design Parameters ◽  
Vertical Position ◽  
Arc Furnace ◽  
Hydraulic Actuator ◽  
Scrap Melting

Prediction of structural dynamics of the Electric Arc Furnace (EAF) is rather difficult, because of a number of phenomena occurring during the scrap melting process. Three large electrodes, corresponding to each phase of a AC circuit, are lowered by the main mast towards the scrap to activate the melting process, induced by the electric arc. Electric current fed to each electrode produces a strong magnetic field and applies an electromechanical force on the other electrodes. Arc voltage looks irregular upon time, even because of the scrap motion within the vessel and temperature growth. The vertical position of the mast is controlled by an hydraulic actuator. Nevertheless, a heavy vibration of the structures affects the regularity of the melting process. A fully coupled model of the whole system is herein proposed, through a multi-physics approach. A first analytical approach, describing the electric circuit of the whole system, is implemented into a Multi Body Dynamics (MBD) model of the EAF, while a reduced Finite Element Method (FEM) model of the flexible structures is used for a preliminary optimization of the design parameters. Electromechanical forces due to the mutual induction among the electrodes are computed and the dynamic response of the system is investigated. Proposed model allows a first refinement of the EAF design, although a complete experimental validation on the real machine has to be performed, in spite of problems due the extremely difficult accessibility of structures during the melting process.

scholarly journals Phase Equilibrium Diagram for Electric Arc Furnace Slag Optimization in High Alloyed Chromium Stainless Steelmaking

Metals ◽  
2020 ◽  
Vol 10 (6) ◽  
pp. 826 ◽  
Author(s):  
Marcus Kirschen ◽  
In-Ho Jung ◽  
Gernot Hackl
Keyword(s):  
Raw Materials ◽  
Equilibrium Diagram ◽  
Electric Arc Furnace ◽  
Electric Arc ◽  
Special Focus ◽  
Arc Furnace ◽  
Monitoring And Control ◽  
Refractory Wear ◽  
Slag Refining ◽  
Electric Arc Furnace Slag

The electric arc furnace (EAF) process for steelmaking of Cr and Ni high alloyed stainless steel grades differs significantly from the steelmaking process of carbon steel due to the special raw materials and generally lower oxygen consumption. The special slag chemistry in the EAF process affects slag foaming and refractory wear characteristics due to an increased content of CrOx. A special slag diagram is presented in order to improve monitoring and control of slag compositions for Cr alloyed heats, with special focus on saturation to MgO periclase and dicalcium silicate C2S in order to minimize MgO losses from the refractory lining and to improve slag refining capability by avoidance of stable C2S. With the same diagram different EAF process strategies can be efficiently monitored, either at elevated CaO and basicity with lower spinel concentration and more liquid process slags near C2S saturation or at lower CaO content and basicity with increased spinel concentration and stiffer slags at MgO saturation but certainly no C2S stability. Examples for three industrial EAFs are given.

scholarly journals ENERGY EFFICIENT WATER-COOLED ELEMENTS FOR FOUNDRY CLASS ELECTRIC ARC STEELMAKING FURNACES

2021 ◽  
pp. 55-58
Author(s):  
S. Timoshenko ◽  
E. Nemtsev ◽  
M. Gubinski
Keyword(s):  
Energy Efficiency ◽  
Energy Efficient ◽  
Melting Process ◽  
Electric Arc Furnace ◽  
General Purpose ◽  
Electric Arc ◽  
Oxidation Potential ◽  
Low Energy ◽  
Specific Power ◽  
Arc Furnace

Possibility of a wide choice of original charge and variation of oxidation potential in melting process makes the electric arc furnace (EAF) a general-purpose unit in foundries. Energy-intensive classical technology with insufficient specific power of the transformer, irregular operation with forced downtime predetermine a low energy efficiency of foundry class furnaces [1,2]. Flat and shallow bath of the EAF enhances the problem.

Analysis of Stiffening Effect and Rupture in Dynamics of Graphite Electrodes of the Electric Arc Furnace

2014 ◽  
Author(s):  
Eugenio G. M. Brusa
Keyword(s):  
Numerical Model ◽  
Dynamic Behavior ◽  
Position Control ◽  
Melting Process ◽  
Integrated Approach ◽  
Electric Arc Furnace ◽  
Electric Arc ◽  
Vertical Position ◽  
Arc Furnace ◽  
Stiffening Effect

Prediction of dynamic behavior of electrodes of the Electric Arc Furnace (EAF) fed by AC current is rather difficult because of several phenomena superposed, particularly during the first step of melting process, i.e. the so-called perforation, and in case of melting of metallic scrap. Unexpected ruptures of electrodes are often observed as a consequence of vibration. Dynamic excitation is applied by the vertical position control of the mast supporting the electrodes and by the Lorentz’s forces generated by the magnetic flux provided by each electric phase. Moreover, the irregular distribution of stiffness along the electrode, being due to the sensitivity of material properties upon temperature, affects quite a lot the dynamic response of the structure. To identify the origin of the observed ruptures and to suitably predict the dynamic behavior of the whole system a modeling activity was performed. A numerical model of the EAF structures was built, by resorting to an integrated approach based on the Finite Element Method and on the Multi Body Dynamics, then it was preliminarily validated on an existing plant. It demonstrated that stiffening effect upon the graphite electrode induced by temperature distribution makes dangerous the action of the vertical position control, when it is applied too fast and excites the flexural modes of the electrode. Numerical model allowed refining the design of the electrode and improving the safety factor as well as finding some design requirement to suitably limit the operation of the position control system.

Effect of Feldspar Content on Electric Arc Furnace Slag (EAFS) Added Tiles

2014 ◽  
Vol 1024 ◽  
pp. 235-238 ◽  
Author(s):  
Mohamad Hasmaliza ◽  
Anasyida Abu Seman ◽  
Wei Long Gan
Keyword(s):  
Raw Materials ◽  
Strength Properties ◽  
Electric Arc Furnace ◽  
Electric Arc ◽  
Arc Furnace ◽  
Ceramic Tiles ◽  
Ceramic Tile Production ◽  
Ball Clay ◽  
Electric Arc Furnace Slag ◽  
Furnace Slag

Electric arc furnace slag (EAFS) is a solid waste from steel making industrial. Previously, EAFS was deposited, recycled or used as fertilizer. In present study, EAFS is used as one of the raw materials in ceramic tile production. EAFS added tiles samples have been prepared by mixing of EAFS with ball clay, quartz and feldspar. The feldspar content was varied at various weight percentages (0, 10 and 20 %) to observe their effect on the produced samples. The raw materials mixture was pressed and then sintered at temperature range 1100°C-1175°C for 1 hour. In general, results shows that, sample with higher content of feldspar require shorter vitrification range and having relatively higher density and good strength properties. In addition, MOR value was increasing as the sintering temperature was increasing. However when the temperature reached 1175°C, the MOR was dropped which may be due to the early vitrification of the compositions, resulting in over firing, grain growth and recrystallization. Whereas the density values are relatively higher than the conventional vitreous ceramic tiles due to the presence of high amount of iron oxide from the EAFS.

Energy Savings in the Melting Process of an Electric Arc Furnace

2000 ◽  
Vol 33 (13) ◽  
pp. 561-566
Author(s):  
Luís Gomes ◽  
Anikó Costa ◽  
Dirk Tilsner ◽  
Carlos Soares ◽  
Carmen Morgado
Keyword(s):  
Energy Savings ◽  
Melting Process ◽  
Electric Arc Furnace ◽  
Electric Arc ◽  
Arc Furnace

scholarly journals Investigation on the Chemical and Thermal Behavior of Recycling Agglomerates from EAF by-Products

2020 ◽  
Vol 10 (22) ◽  
pp. 8309
Author(s):  
Thomas Willms ◽  
Thomas Echterhof ◽  
Stefan Steinlechner ◽  
Matti Aula ◽  
Ahmed Abdelrahim ◽  
...  
Keyword(s):  
Thermal Behavior ◽  
Raw Materials ◽  
Central Element ◽  
Steel Production ◽  
Electric Arc Furnace ◽  
Electric Arc ◽  
Arc Furnace ◽  
Electric Steel ◽  
Crude Steel ◽  
By Products

In addition to the blast furnace converter route, electric steel production in the electric arc furnace (EAF) is one of the two main production routes for crude steel. In 2019, the global share of crude steel produced via the electric steel route was 28%, which in numbers is 517 million metric tons of crude steel. The production and processing of steel leads to the output of a variety of by-products, such as dusts, fines, sludges and scales. At the moment, 10–67% of these by-products are landfilled and not recycled. These by-products contain metal oxides and minerals including iron oxide, zinc oxide, magnesia or alumina. Apart from the wasted valuable materials, the restriction of landfill space and stricter environmental laws are additional motivations to avoid landfill. The aim of the Fines2EAF project, funded by the European Research Fund for Coal and Steel, is to develop a low-cost and flexible solution for the recycling of fines, dusts, slags and scales from electric steel production. During this project, an easy, on-site solution for the agglomeration of fine by-products from steel production has to be developed from lab scale to pilot production for industrial tests in steel plants. The solution is based on the stamp press as the central element of the agglomeration process. The stamp press provides the benefit of being easily adapted to different raw materials and different pressing parameters, such as pressing-force and -speed, or mold geometry. Further benefits are that the stamp press process requires less binding material than the pelletizing process, and that no drying process is required as is the case with the pelletizing process. Before advancing the agglomeration of by-products via stamp press to an industrial scale, different material recipes are produced in lab-scale experiments and the finished agglomerates are tested for their use as secondary raw materials in the EAF. Therefore, the tests focus on the chemical and thermal behavior of the agglomerates. Chemical behavior, volatilization and reduction behavior of the agglomerates were investigated by differential thermogravimetric analysis combined with mass spectroscopy (TGA-MS). In addition, two melts with different agglomerates are carried out in a technical-scale electric arc furnace to increase the sample size.

scholarly journals Heat balance analysis in electric arc furnace for process improvement

2020 ◽  
Vol 170 ◽  
pp. 02012
Author(s):  
Sandeep Ohol ◽  
Mathew VK ◽  
Savita Shinde ◽  
G. Balachandran
Keyword(s):  
Heat Balance ◽  
Process Analysis ◽  
Exothermic Reaction ◽  
Melting Process ◽  
Electric Arc Furnace ◽  
Electric Arc ◽  
Process Efficiency ◽  
Balance Model ◽  
Arc Furnace ◽  
Reaction Heat

The current study deals with optimizing the melting process used in electric arc furnace by heat balance equations. Heat balance is a very important aspect in an arc furnace in which the energy input consists of electrical energy [65%], chemical energy [25%] and exothermic reaction heat [10%]. This energy is optimized with the charge mix, charge quantity, fluxes, fuel used, and O2 used in the burners. The present model considers all these aspects and gives heat distribution in the process. The model spreadsheet gives a reasonable prediction in terms of metal yield, composition, and energy consumption. The model also predicts the amount of iron oxidized in the process. The mass and heat balance model is a useful tool for process analysis and improves the process efficiency of electric arc furnace steelmaking.

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