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

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.

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

Butlerov Communications ◽

10.37952/roi-jbc-01/20-61-2-145 ◽

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.

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

Izvestiya Ferrous Metallurgy ◽

10.17073/0368-0797-2018-10-794-799 ◽

2018 ◽

Vol 61 (10) ◽

pp. 794-799 ◽

Cited By ~ 1

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.

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

Butlerov Communications ◽

10.37952/roi-jbc-01/19-59-9-125 ◽

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.

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

KnE Materials Science ◽

10.18502/kms.v6i1.8136 ◽

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

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Carbon Monoxide Related Reductions

INEOS OPEN ◽

10.32931/io2017r ◽

2020 ◽

Vol 3 ◽

Author(s):

O. I. Afanasyev ◽

◽

D. Chusov ◽

Keyword(s):

Organic Chemistry ◽

Carbon Monoxide ◽

Reducing Agent ◽

Current Development ◽

Efficient Route ◽

Development Prospects

Carbon monoxide is a unique reducing agent that is only gaining popularity in organic chemistry. This review highlights the main approaches to the application of CO as a reducing agent, summarizes and critically analyzes the key trends in this field, and describes the current development prospects. Potentially the most selective and efficient route for the realization of these processes is demonstrated.

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Methane production from carbon monoxide and hydrogen over nickel–alumina xerogel catalyst: Effect of nickel content

Journal of Industrial and Engineering Chemistry ◽

10.1016/j.jiec.2010.12.015 ◽

2011 ◽

Vol 17 (1) ◽

pp. 154-157 ◽

Cited By ~ 70

Author(s):

Sunhwan Hwang ◽

Joongwon Lee ◽

Ung Gi Hong ◽

Jeong Gil Seo ◽

Ji Chul Jung ◽

...

Keyword(s):

Carbon Monoxide ◽

Methane Production ◽

Nickel Content ◽

Catalyst Effect

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Iron reduction from concentrates of hydrometallurgical dressing

Izvestiya Ferrous Metallurgy ◽

10.17073/0368-0797-2021-10-728-735 ◽

2021 ◽

Vol 64 (10) ◽

pp. 728-735

Author(s):

I. A. Rybenko ◽

O. I. Nokhrina ◽

I. D. Rozhikhina ◽

M. A. Golodova ◽

I. E. Khodosov

Keyword(s):

Experimental Study ◽

Thermal Decomposition ◽

Thermodynamic Modeling ◽

Iron Reduction ◽

Solid Phase ◽

Experimental Studies ◽

Statistical Processing ◽

Reducing Agent ◽

Volatile Components ◽

Software Complex

The article presents results of theoretical and experimental studies of the processes of iron solid-phase reduction from an iron-containing concentrate obtained as a result of hydrometallurgical dressing of ferromanganese and polymetallic manganese-containing ores with coals of grades D (long-flame) and 2B (brown). The method of thermodynamic modeling using TERRA software complex was used to study the reducing properties of hydrocarbons by calculating equilibrium compositions in the temperature range of 373 - 1873 K. The authors obtained the dependences of compositions and volume of the gas phase formed as a result of the release of volatile components during heating on the temperature for the coals of the grades under consideration. As a result of thermodynamic modeling, the optimal temperatures and consumption are determined, which ensure the complete iron reduction from an iron-containing concentrate. The results of experimental studies were obtained by modern research methods using laboratory and analytical equipment, as well as methods of statistical processing. Results of the coals analysis carried out using the Setaram LabSys Evo thermal analyzer showed that the process of thermal decomposition of coals of the studied grades proceeds according to general laws. The process of thermal decomposition of long-flame coal proceeds less intensively than of brown coal. The results of an experimental study of the processes of thermal decomposition of reducing agents have shown that volumes of the gas phases, formed when coals are heated to a temperature of 1173 K in an argon atmosphere, practically coincide with the calculated values. As a result of thermodynamic modeling and experimental study, the optimal consumption of D and 2B grades of coal is determined at a temperature of 1473 K. The best reducing agent with a minimum specific consumption is long-flame coal of D grade. When determining the optimal amount of reducing agent in charge mixtures during the study of metallization processes, it was found that with an excess of reducing agent, it is possible to achieve almost complete extraction (98 - 99 %) of iron from the concentrate.

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Modelling the reduction of zinc from oxide melt

Tsvetnye Metally ◽

10.17580/tsm.2021.04.03 ◽

2021 ◽

pp. 18-22

Author(s):

A. S. Vusikhis ◽

E. N. Selivanov ◽

L. I. Leontiev ◽

S. N. Tyushnyakov

Keyword(s):

Experimental Data ◽

Carbon Monoxide ◽

Basic Research ◽

Metallic Phase ◽

Thermodynamic Modelling ◽

Reduction Degree ◽

Similar Reduction ◽

Oxide Melt ◽

Higher Temperature

For predicting the results of sparging processes to understand how much metal can be reduced from oxide melt, a method of thermodynamic modelling has been developed that ensures approximation to real systems in which the metallic phase and gases are removed from the liquid at a certain interval. The key principle of this method is that equilibrium is determined for every single portion of introduced gas, and the concentration of oxides of the reduced metals in each cycle is taken from the previous data. Such approach enables a very close simulation of real processes so that one can have an idea about the quality of reactions taking place in pyrometallurgical units. When the thermodynamic modelling method was applied to the processes of iron and nickel reduction, the obtained results well matched the experimental data. A comparative analysis was carried out to understand how the temperature T and the amount of introduced gas VСО or VН2 influence the process of zinc reduction from oxide melt. For the purposes of modelling, a B2O3 – CaO – ZnO melt was used with the B2O3/CaO ratio equal to 3 (which corresponds to the eutectic composition) and with the initial ZnO concentration in the range from 3 to 12 %; the temperature range used was 1273–1673 K. The concentration of zinc oxide СZnO in the melt, as well as the reduction degree Zn were analyzed. The correlation dependences СZnO, φZn = f(C0, T, VCO or VH2) are presented in the form of second order polynomials. Reduction of zinc with hydrogen is a more intense process than when zinc is reduced with carbon monoxide. Therefore, less gas is required to reach a similar reduction degree. A higher temperature facilitates the reduction of zinc while less СО or Н2 is required to achieve the target reduction degree φZn. Irrespective of the initial composition of the melt, it takes 1.5 times less hydrogen that carbon monoxide to obtain the unit mass of zinc with the process temperature being the same. The obtained data explain the changing zinc distillation performance when changing the temperature. The established relationships between CZnO and φZn and the temperature and the amount of introduced gas are useful for predicting the zinc distillation performance and can be used as basic relationships for analyzing experimental data. This research was funded by the Russian Foundation for Basic Research under the Project No. 18-29-24093мк.

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