Appendix

Block diagrams for the production of several important materials.

Steel

Coal

512

Coke oven gas

Coke

Iron ore pellets, lump or

sinter Limestone

Air

Oxygen steelmaking

Ladle metallurgy

Steel

Casting

Waste gas

Slag, to waste

Ingot (or billet or slab)

Finishing operations

Sale

Ingo

t S

oaki

ng

pit

For

ging

fo

r sa

le

Con

tinuo

us

cast

ing

elim

inat

es

oper

atio

ns to

le

ft 01

thi

s lin

e

Bea

ms,

ra

ilroa

d,

etc,

fo

r sa

le

Bar

s ro

unds

, ec

l. fo

r sa

le

See

mle

ss

pipe

m

ill

See

mle

ss p

ipe

for

sale

Coa

ting Wel

ded

pipe

for

sale

Nai

l pr

oduc

tion

Nai

ls f

or

sale

Sal

e

Wire

fo

r sa

le

"'U

-,

o a.

c () .....

0"

:::J o -+0

cn

.....

CD

CD =r

o 3 :::J

(0

o .....

.....

o "T

l :::

J 00"

::::T

CD

a.

"'U

-,

o a.

c () .....

» "'0

"'

0

CD

::::l

0. x'

(JI .....

Co)

514 Appendix

Aluminum

Bauxite

Co ne NaOH soln

Evaporation • ",_--,

Dilution/ preeip.

"Red mud," to waste

.,, __ Water

AI(OHb

NaOH '-. ___ _

"'----- soln ..

Carbon .----__ '-1

anodes ~--v

Sale

Casting

Steam

Copper (fram Sulfide Ores, Traditional Route)

Sulfide concentrate

[S02 frequently converted into sulfuric acid]

Anode slimes to minor metal

recovery

Sale

Melting furnace

Casting

Appendix 515

Slag, to waste

Spent anodes

Remelting

516 Appendix

Copper (fram Oxide Ores, Representative Hydrametallurgical Route)

Oxide ~--'" ore

Spent electrolyte

Casting

Sale

Solid, to waste

Zinc

Sulfide concentrate

Zn L---v

Cathodes Sale "' __ ---1

Leaching

Solution pur­ification by cementation

Appendix 517

Precipitated impurities

~-----''' Cemented �._-----,/ impurities

518 Appendix

Gold

Ground ore

Air

Sodium cyanide

soln

Deaeration

L..----:I Cementation

Zn power

Drying/ roasting

Melting/ casting

Sale

Solid, to waste

Appendix 519

Production of Advanced Ceramic Parts

Parts would be evaluated by nondestructive techniques at various points in this scheme (e.g., following green machining). Granulation (e.g., by spray drying) sometimes fol­lows wet milling.

Reagents

~J D Binder Powder removal (first

production stage of firing) (chemical

steps)

~r ~J. Ceramic powder Binders Densification and (next stage of

additives Milling (foll- firing-might be owed by drying two-step e.g. sin-if milling is wet) tering followed by HIP)

~Fermixure ~}.Sintered part

Shape Final forming machining

~J. Green compact ~J. Green Final proof

machining testing

-I ~ Machined

compact Part for assembly/sale

Ele

ctro

de

....

--v C

O (

was

te)

HC

I,H 2

to s

crub

ber

Dis

tilla

tion

colu

mn

H2S

iCI 2

+

HS

iCI 3

P

urili

catio

n

"-•••••

' H2~iC12

HS

iCI 3

to

CV

D

reac

tor

Flu

idiz

ed

bed

reac

tor

Sol

id i

mpu

rity

ch

lorid

es

(dis

char

ged

inte

rmitt

ently

)

SiC

I 4

• _

__

•• v

by p

rodu

ct

lr--

----

-oI1

Com

min

utio

n .1

00..

----

-,/1

• _

__

..

' S

i par

ticle

s

HS

iCI 3

"J

+

H2S

iCI 2

HC

I ga

s

SiC

I 4, H

SiC

I 3

__

.--.

__

.' H

2SiC

I 2, H

2 +H

CI

Pol

ycry

stal

line

Si

(dis

char

ged

inte

rmitt

ently

) --

---,

H2S

iCI 2

+ H

SiC

I 3

and

SiC

I 4

Con

dens

er

... _

__

..

' H

2+H

CI

Sin

gle

cyst

al

grow

n S

ingl

e-cy

stal

ingo

ts

,.

'\.

01 s

ilico

n to

r sa

le o

r (e

.g.,

Czo

chra

lski

) tu

rthe

r pr

oces

sing

NaO

Haq

NaC

I

For

rec

ycle

~ t

o C

VD

rea

ctor

Cf)

U

I

S"

N

0 CO

CD

() ~

~ "0

CD

.....

. :::

J

Q)

0..

x·

C

f)

er

0 :::J

......... <

0)"

Cf)

Ci)" 3 CD

:::J

Cf)

-U a 0 CD

C

f)

Cf)

....

......

INDEX

("CD" refers to the compact disc of thermodynamic data and worked examples pro­vided by Prof. Arthur Morris and distributed with this text)

A Abundance of elements 13, 24 Acheson process 374 Activation energy 86-88, 178 Activity 48-54, 84 Activity coefficient 49-51 Actual available heat 231 Adiabatic flame temperature CD Adsorption of gases 125,126 Aerogel 371 Agglomerates 11 0 Agglomeration 26 Aggregates 111 Agitation leaching 284, 285 Air agitation 284, 285 Alkemade lines 200 Alkoxides 370 Aluminum 3,9, 11, 15, 104,212,

308-312,339,340 Aluminum deposition 488 Aluminum-lithium alloys 11 Aluminum nitride 495 Aluminum oxide (alumina) 379, 495,

496 Aluminum oxide reduction 263, 264 Ambipolar diffusion 191 Amorphous metals 479 Annealing gas CD

Anode slimes 315 Anodes 267,302,308,309,312-315 Anodizing 351 Anticipatory controller action 234 Argon degassing 273,323 Argon-oxygen decarburization 328, 329 Arrhenius equation 86 Arrhenius plot 87,88,99 Atrnosphere controI463-466, 470, CD Atomization ofliquid metals 479,480 Attrition mill 359 Auger spectroscopy 142, 144 Austenite CD Available heat 227-230

B BOF BOP see Basic oxygen furnace Back-mixed operations 214-216 Balance equation 217 Ball mill 20-22 Balling drums 26 Barium carbide 495 Barium titanate 495 Basic oxygen furnace (BOF) 271, 272 Basic slag 270 Basis of a balance 218 Batch operations 212 Bauxite 9, 15

521

522 Index

Bayer process 289,309,379, CD Bayer-Hall process 212 BET measurements 125, 126 Bias sputtering 504 Billet mills 344, 346, 347 Billets 344, 346 Bimodal partic1e size packing 386, 387 Binary phase diagrams 194-197 Binder removal398, 461, 462 Binders 26 Biot number 475 Bipolar electrode 315 Block diagram 211,212 Blooms 345 Body centered cubic packing 384 Boron carbide 495 Boron nitride 376, 488, 491 Bosh region of iron blast fumace

257-259 Bottom blown oxygen steelmaking 272,

273 Bronze 6 Bronze age 6 Brownian motion 124

C Calcining 250,251,462, CD Calcite 265, CD Carbon dioxide - monoxide equilibrium

65, CD Carbonyls 377 Carbothermic reduction 263, CD Carburizing 7, CD Cast iron production 262 Casting 336-340

as method of powder consolidation 395-399

near net shape 480 Catalytic reforming 252 Cathodes 302 Cementation 290, 296 Central zone ESR 342 Centrifugal atomization 479 Centrifuge 327, 328 Ceramic superconductors 462 Chalcolithic period 4

Chalcosphere 12,13 Chemical beam epitaxy (CBE) 501, 509 Chemical potential 40-42 Chemical precipitation 289 Chemical step controlled kinetics 95-97,

99 Chemical vapor deposition (CVD)

487-491 reactors for 489 Chemical vapor infiltration (CV1) 491,492 Chlorination 312, CD Chromium oxide reduction 262, 263 Cleaner cells 25 Closed system 31 Coarsening 428, 445 Coarsening rate 453 Coatings 377 Co-current operations 222 Coke 252 Cold plasmas 503 Cold working 6, 343 Collectors 24 Collision cross section in plasmas

501,502 Colloid partic1e, effective charge on,

156, 157 Colloids 111, 134, 135, 146-167

re-dispersion of 162, 167 stabilization ofby polymers 158-162 steric stabilization of 159-162

Combined blowing (in oxygen steelmaking) 273

Combustion 226-230, 267, CD Component (in phase rule) 192 Composites 387, 429-433, 441, 488 Composites from liquid metals 494-497 Concentrate 25 Concentration cell 298, CD Condensation CD Conditioners 24 Conduction of heat 226 Consolidation relationship in pressing

389,390 Constitutional supercooling 334, 335 Consumable electrode 341 Contact angle 126, 127,434,435

Continuous casting 338, 339, 344, 348 Continuous operations 212, 213 Control volumes 217 Controller gain 233, 234 Controllers 231-235 Convection 91-94, 226 Conversion between units 291, CD Converting (in processing sulfides)

265-267 Copper production 264-269, 282, 288,

291,300-303,308,314,315 Copper sulfides 15, 16,23,24 Coulter counter 123 Countercurrent operations 222 Creep and densification, relationship

between 422-424 Creep ofporous so lids 422-425 Creep rate 422-424 Creep viscosity 422-425

grain size compensated 426 Critical ceramic powder volume 398 Critical flocculation temperature 160 Critical nuc1eus size 201-203 Critical porosity 456 Critical pressures of some solvents 372 Critical process temperature 228,229 Critical temperature of some solvents

372 Cross-current operations 223 Crushing 19, 20 Cullet 274, 275 Current density 308, 310, 350 Current efficiency 303-305, 310 Curvature

and chemical potential 206 and sintering stress 406-409 ofpore walls 412-414

Cutting tools 11 Cyanide leaching of goldlsilver 282 Czochralski crystal growth 482, 483

D Debye length 149, 151 Decarburizing 8 Defect chemistry 179-183

conservation rules 180

Index 523

Degassing ofmetals 322-324, 326 Degrees of freedom (in phase rule) 193 Dendrites 333-335 Densification 205-207,421-433,450,

451,495 of composites 429-433, 441 at constant heating rate 451-453 and creep, relationship between 422-

424 differential 429-433 by grain boundary diffusion 418-421 non-isothermal 451-453 power law 448 viscosity 421,425 by volume diffusion 421,422

Densifying/non-densifying mechanisms 406,407,425,426,451

Deoxidizing agents 324, 325 Dephosphorization of steel 326 Derivative controller action 234 Desulfurization of steel 326 Diamond films 508 Die compaction 390-394 Dielram materials for hot pressing 469,

470 Die wall friction 390-393 Differential densification 429-433 Diffraction of electrons 138-141 Diffusion 89-91,170-178,183-191

ofcharged speciesl88-191 coefficient 90, 175, 178, 186 driving forces for 172, 184-187 in liquids 178 marker movement 186-188 mechanisms for 176-178 multi-component 186-188 temperature dependence 178 thermodynamic factor 185

Diffusion controlled kinetics 10 1,103, 104,251

Diffusivity 90, 175, 178, 186 Dihedral angle 443,444 Direct chill (DC) casting 339, 340 Direct reduction ofiron oxides 461, 462,

CD Directed oxidation for production of

524 Index

composites 494-497 Direct1y reduce iron (DRI) 272-274 Disappearing solid 99, 100 Distribution coefficient (in solvent

extraction) 223 Dolomite 8 Double layer 146-149 Dredging 17 Dry bag tooling 395 Dry grinding 357, 358 Drying 26 Drying control additives 372 Dump leaching 283

E Earth,zonesof12,13 Economics 1-3 Effective charge on colloid partic1e 156,

157 Eh 287,288 Electric furnace steelmaking 273, 274 Electric smelting of sulfides 268 Electrical energy consumption in

electrometallurgy 307,308,310-312, 314

Electrical generation ofheat 230 Electricity 9 Electrochemical potential 146, 147,292 Electrochemical sensors 191, CD Electrodeposition

of copper 306 ofmetals 306 oftin on steel strip 349, 350 ofzinc 30

Electrogalvanizing 351 Electrolysis ofmolten salts 307-314 Electrolytic cells 300-303 Electromagnetic casting 339, 340 Electromagnetic stirring 338,339 Electrometallurgy 281,291-316 Electron scattering from surfaces 137 Electron temperature in plasma 503,504 Electrophoresis 154 Electrophoretic mobility 156, 157 Electroplating of steel strip 349-351 Electrorefining 281,314-316

Electroslag remelting (ESR) 341, 342 Electrothermic reduction of ZnO 254,

255 Electrowinning 281, 302-314

Cells 302-314 effect of impurities 306

Ellingham diagram 56-61, CD for chlorides 249, 250 nomographic scales 61 for oxides 56-61, 241, 252, 253, 258,

259,262,263,269 for sulfides 241, 242

Elutriation 247 Employment 3,277 Encapsulation 464 End capping 393 Energy consumption 3 Enthalpy balances 217,218,226 Entropy 31-35

as disorder or uncertainty 33-35 Environmental considerations 265-267,

277,281,289 Epitaxy 497-501

chemical beam (CBE) 500 liquid-phase 497 -499 molecular beam (MBE) 499-502

Equilibrium 37-58, 66, 67 Equilibrium constant 43-48, 54, 55 Equilibrium potential 300 ESCA 144 Eutectic transformation 194-197, 204,

205 Evaporation/condensation mechanism of

sintering 425-429 Evaporation of solutions 361 Evaporative decomposition 364 Expansion work 35 Extrinsic defects 179 Extrusion 398, 399

F Face centered cubic packing 383 Faraday's constant 146, 291 Faraday's law 303-305 Feedback contro1230-235 Ferro-alloys 262, 263

Ferrochromium 263 Ferromanganese 263 Ferrosilicon 263 Fick's first law 90, 174 Filtering 25, 328 Fining agents 276 Finishes for steel strip 349-351 Firing 4 First law oftherrnodynamics 34 Flame spraying CD Floating zone refining 486 Flocculation 153 Flocs 162 Flotation 23-25 Flowsheets 212

see also Appendices Fluidized bed roaster 247,248,277 Fluidized beds 247, 248, 277, 481, CD Flux, definition of 90 Fluxing agents 245, 246, 262 Forging 343-345, 471 Free energy, Gibbs 34-40, 54, 58, 299 FREED CD Freeze drying 366, 367 Frenke1 disorder 180,181 Frothers 24 Fuel combustion 226-230,267, CD Fuel oi1226, 259, CD Fugacity 49 Furnace temperatures 227-240

G Gallium arsenide films 488 Galvanic cell 295, 296 Galvanized steel strip 349-351 Gangue 18, 19, 104,244,286 Gas temperature in plasmas 503, 504 Gases in metals 66, 67, 322-324 Gates-Gaudin-Schuhmann distribution

116 Gibbs free energy 34-40, 54, 58, 202,

299 Gibbsite CD Glass-ceramics 203 Glass making 274-276 Glow dis charge plasmas 503

Index 525

Goal seek CD Gold 4, 183,237,238,266,282 Grain boundaries 178,406,441,496

effect on pore shapes and growth 412-418

Grain boundary diffusion 418-421 mobility 443 stress 415

Grain growth 404,441-448,470 abnorrnaVnorrnm442 in porous compacts 444-448

Grain structure from solidification 337 Gram equivalent weight 303,304 Granules 111 Gravity separation 22 Green pellets 26 Grinding 19-21,356-359

autogeneous 21 effects of detergents 358, 359 medium 20, 356

Gross available heat 228-230, CD Growth ofphases 201-205, 360, 361,

441,478

H Half cell re action 291 Hall, Charles 9 Hall-Heroult cell 308-312 Heap leaching283, 286 Heat balances 226, CD Heat capacity CD Heat content CD Heat exchangers CD Heat induration 26 Heat losses 227, 257, 311, 463 Heat of solution 67 Heat transport 79,251 Heavy medium separation 22 Hematite CD Henry's law 51 Heroult, Paul 9 Heteroepitaxy 498 Heterogeneities, effects on sintering 207,

429 Heterogeneity in partic1e packing 386

526 Index

Heterogeneous nuc1eation203, 488 Heterogeneous reactions 74-78, 84, 85,

89, 94-105 Hexagonal c10se packing 383,384 Homogeneous nuc1eation 201,367 Homogeneous reaction 74,76,79-81 Homologous temperature 428 Hoopes cell 316 Hot extrusion 347,467,473 Hot forging 467,471 Hot isostatic pressing (HIP) 471-473

containerless 472 Hot pressing 467-470 Hot swaging 473 Hot topping 337 Hot working 342, 343 Hydraulic dredges 17 Hydrocarbon injection, iron blast

furnace 259 Hydrocyc1one 20, 22 Hydrolytic stripping 373 Hydrophilie surfaces 24 Hydrophobie surfaces 23 Hydrospherel2, 13

I Ideal solutions 50 Imperial Smelting furnace 255, 256, CD Imports 1-3 Impurities in metals 321-328 Impurity removal by reaction 289,324 In-situ leaching 18,283, 286 Inc1usion, non-metallic 3, 326-328 Ingot casting 336-338 Injection molding 400 Ink bottle pores 128 Integral controller action 234, 235 Interaction parameters 51, 70 Interaction potentials (energy) 152, 153 Interdiffusivity 18 8 Interstitial mechanism of diffusion 177 Interstitialcy mechanism of diffusion

177 Interstitials 176 Intrinsic defects 179 Intrinsic diffusivities 186

Ion exchange 290 Ion plating 505, 506 Ions in solution 291-298

Iron age 6 Iron blast furnace 256-261

bosh region of 25 8 higher blast temperature 258 higher top pressure 259 hydrocarbon injection 259 oxygen enrichment in 259 stack region of 257

Irreversible changes 29-31 Isoelectric point 156 Isolated system 31 Isostatic compacting (pressing) 394, 395

JANAF Tables 36 Jaw crusher 19,21

J

K Kelvin equation 408, 443 Killed steel 324 Kiln 245,247,248,250 Kinetics

chemical step controlled 95,96 mass transfer controlled 95-97

Kirkendall effect 186-188 Knudsen cells 499 Kroger-Vink defect notation 179, 180,

209

L Ladle metallurgy 324 Langmuir-Hinshelwood kinetics 85, 86 Lanxide corporation 494-496, 498 Laplacian operator 176 Leaching 15,18,104,281-289,356

Chemistry 287-289 ofcopperl04,282,284,290 of gold 282 ofzinc 282

Lead blast furnace 246 Lead production 246, 255, 256 LEED 140-142 Lehr 276

Lever rule 196,200,205 Liberation 19-22 Light scattering 124 Lime 4, 78, 226, 245, 250, 265, 270, CD Lime pIaster 4 Limelight 9 Limestone 4, 78, 79, 250, 257-260, 262,

265,269,274,358 Linz-Donawitz (LD) converter 271

see also Basic Oxygen Furnace Liquid metal intrusion 494 Liquid-phase epitaxy (LPE) 497, 498 Liquid phase sintering 433-436 Lithosphere 12, 13

composition of 13 LIX reagents 105,290,291,373 Lixiviants 281,283 Log-normal distribution 116-118, 385 London-Van der Waals forces 151 Low-pressure chemical vapor deposition

(LPCVD) 489, 490 Lubricants, in die compaction 393

M Macrosegregation 330,331,333,336,

339,341,361,376,478,486 Magnetherm process 264 Magnesium chloride production 312,

313,360 Magnesium oxide (magnesia) 8, 60, 264,

313,379,465, CD reduction 264, CD

Magnetic separation 22,23,250 Malachite 5 Manganese oxide reduction 59,63,64,

262 Mass transfer 92-94,247,248,255,272

accompanying reaction 94-105 coefficient 93 controlled kinetics 95, 98-100, 103,

105,284,377 in electrogalvanizing 351 temperature effects 98, 99, 101

Mass balances, see Material balances

Mass transport 89,91-104,170, 188,

Index 527

206,271,272,310,324,330,331, 436

Material balances 217-220, 223, 225, CD

Matte 264-266, 268, 269 Mean free path 174, 175

ofelectrons 501, 502 Mean partic1e diameter 117 Mechanical agitation 284,285 Mercury penetration porosimetry

126-129 Mesh sizes 118, 120 Metal organic chemical vapor deposition

(MOCVD) 489, 490 Metal powder production 376,377

from carbonyls 75, 376-378 by reduction of oxides 376,377

Methanol 372, CD Microscopy 119, 137-139, 164 Microsegregation 335, 336 Microstructure 170,205,335,343,370,

404,405,440-458,478 Microstructure evolution 404 Microwave heating 463 Micro-plasma assisted chemical vapor

deposition (MPACVD) 507, 508 Migration of charged species 189, 190 Mineral beneficiation 18 Mineral processing 18-27 Mineralization 13 -1 7 Minimum operating temperature 227,

229 Mining 17, 18,283,286 Mitsubishi continuous smelter 268, 269 Mixer-settlers 222-225 Mixing 91, 214, 215, 360, 361, 364, 388

see also Agitation 214,284-286,310, 338

Molality 293 Molarity 293 Molecular beam epitaxy (MBE) 499-502 Molybdenun 24,276,463,471, CD Monozised partic1es 118, 13 8, 164, 371,

384-387,429,446 Morphology ofreactions 250-252,462 Multi-component diffusion 188

528 Index

Multiple hearth furnace 247-249 Mushy zone 333

N Native copper 5 Near net shape 480, 496 Neck growth between particles 417, 428 Neolithic period 4-6 Nemst equation 292, 293, 298, 306, CD Non-metallic inc1usions 3, 4, 326-328,

341,342 Non-stoichiometry in cobalt oxide 182,

183 Noranda process 268 Normal distribution 115-118 Nuc1eating agents 337 Nuc1eation 201-203,360,361,367,478,

479,488

Offset 233-235 On-off control 232

o

Open arc fumace 262, 273, 274, 328, 329

Open hearth fumace 271-273 Optical fiber production 492-494 Ore bodies 13, 16 Osmotic pressure 150, 151 Outokumpu flash smelter 267,268 Overburden 17 Oxidation potentials 295 Oxidation ofmetals 186,494, CD Oxidation ofsulfides 244,245,247,265 Oxide films 187, 191

semiconducting properties 191 Oxide ores 244 Oxygen 242, 243, 258, 259, 268, 269-

274,286,326,328,329 concentration cell, CD emichment in fuel combustion 229 emichment in iron blast fumace 258,

259 steelmaking 271-273,298

P Packing 383-389

bimodal partic1e size386, 387 body center cubic 384 density 383-387, 429 centered cubic 384 heterogeneity in 386 hexagonal c10se 384 partic1e 383-389 random 384 simple cubic 384

Palladium CD Partic1e

Packing 383-389 Shape 118, 166,384 size distributions 111-119, 122, 123,

355,361 Particles in metals 326-328 Partition ratio 331 Pellet wheel 26 Pelletizing 26 Perfect1y mixed units 214-217,360 Phase

Change 32,45, 193, 196,202 Diagrams 193-200,270,329,330,332 aluminum-chromium 197 CaO-FeO-SiO 270 Carbon 193 Si-AI-O-N 198 silicon dioxide 194 equilibria, in phase rule, 181 stability CD

Phase rule 192, 193 Photoelectron spectroscopy 141, 144

see also ESCA Pickling of steel strip 350 Pidgeon process 264 Placer deposits 16 Plane of slippage 155 Plasma assisted chemical vapor

deposition (PACVD) 490 Plasma processing 501-504 Plasmas, glow discharge 503 Plastic deformation 342,343,346,471,

472 Plasticity 165 Plate glass 276 Plate mill 346

Plug flow operations 213-216, 360, 361 Point defects 176, 179 Poisson's equation 148, 155 Porcelain 6, 8 Pore breakaway 453-457 Pore coalescence 458 Pore co ordination number 415,417 Pore elimination 406 Pore evolution during densification

448-453 Pore isolation 404,417,434,447,448,

450,453,454,457 Pore movement 453-458 Pore stability conditions 414 Pore volume distribution function 127,

128 Porosity, open to c10sed transition

448-450 Potline 310 Pottery 4, 5, 8 Pourbaix diagram 61-66, 287-289

of copper-oxygen-sulfur 287 Poured density 384 Powder compaction 383-401 Powder production 355-382

by gas-solid and solid-solid reaction 374-376

by mechanical methods 355-359 from solution 360-373

Prebaked anodes 309 Precipitation from solutions 15,289,

360,361,367-369 Predominance diagram 63-66, 243, 250,

251,287, CD for copper-sulfur-oxygen 242 for lead-sulfur-oxygen 251 for iron oxides with CO/C02 65 for nickel-sulfur-oxygen 64

Pressure casting 397 Pressure leaching 286 Primary partic1es 110, 111, 113 Process analysis CD Process controI230-235, CD Process economics 235,286 Production statistics 2 Productivity 98, 105,258-260, 272-274,

Index 529

284-286, 307 Proportional bandwidth 233 Proportional contro1232-234 Pseudoplasticity 165 Puddling 8 Pycnometry 129

Q Q-BOP 273 Quatemary phase diagrams 200 Quenching 255,256,264,376

R Radiation ofheat 226,275,463 Radiation shields 463 Random packing of particles 384 Raoult's law 50 Raoultian solutions 50 Rapid solidification 201,477-480 Rate constant 79,81,86,87,203,448

forward and backwards 85 Rate controlling step 95-97 Rate equations 77-86

determination of 80-84 Ratio controlled sintering 453 Reaction order 79,81 Reaction rate, definition of 76, 77 Reactive sputtering 504 Recovery ofheat 230 Recovery of metal values from solution

300-316 Recyc1es 219-221 Re-dispersion of colloids 162 Reducing agents 61, 241, 252, 326 Reduction of oxides 252-264

ofiron oxides 256-262, CD Regression CD Remelting technology 340-342 Reservoir engineering 283 Reset controller action 234 Residence time 213, 214, 216, 217, 285,

286 distribution 214

Retort fumace for zinc 254 Reverberatory smelters 264-266 Reversibility of changes 29-32

530 Index

Reversing mills 346 Rheology of suspensions 164-167 Ring mechanism of diffusion 177, 178 Roasting 245-252, 364, CD

comparison ofunits 248 ofmercury sulfides 248, 249

Rod mill20, 356 Rolled steel products 345-349 Rolling mills 345, 346 Rosin-Rammler distribution 116, 117 Rougher cells 24, 25

S Saturation vapor pressure 67 Scanning tunneling microscopy 139, 140 Scavenger cells 25 Schottky disorder 81 Seamless pipe production 347,349 Secondary ion mass spectroscopy

(SIMS) 141, 144 Sedimentation 119-123 Segregation 329-333,335,361,363,

366,371,376,478 Segregation roasting 249 Selectivity 244 Selfbaking anodes 309 Self diffusion 184, 185 Self similarity in grain growth 442 Sensible heat 226-229 Sensors, electrochemical191, CD Separation systems 24, 25 Sessile drop 435 Set point 231-235 Shape change 445

see also Shrinkage Shear thickening/thinning 164-166 Shrinkage

during sintering 206, 372 during solidification 335-337,339

Shrinking core reactions 79, 100-104 Siderosphere 12, 13 Siemens process 480-486, CD Sievert's law 67, 322 Sieving 113, 115, 118, 119 Silicon

metallurgical grade 262-264

semiconductor grade 480-488, 492, 493, CD

Silicon carbide 10,374,375,441,461, 462,465,466,494,495, CD

Silicon -chlorine-hydro gen equilibrium 481,482,488, CD

Silicon dioxide reduction 262, 263 Silicon nitride 10,375,465,466,491 Silver 58,59,282,315,316 Simple cubic packing 384 Sink-float separation 22, 24 Sinter 26,246,248,261,262 Sinter strand 26, 244 Sintering

aids 457, 462 driving forces for 372, 406-418 free 463-466 by grain boundary diffusion 406, 407,

418-421,424-426,428,448 iquid-phase 433-437 mechanisms 406 maps 429 pressure assisted 466-473 pressureless 463-466 Protective atmosphere 467, CD ratio controlled 453

Sintering stress 406, 409, 413-415, 417, 422,425,427,430,452

and pore size distribution 409 Size c1assification 20, 22 Slabs 338, 345, 346 Slag 255,257-260,262,264-266,268-

273,326,342 Slip casting 395-397 Slips 395-397 Smelting 5, 255, 256, 264-269 Smokestack industries 277 SNIF 328 Soaking pit 344 Soderberg anodes 309 Sol-gel reactions 369-372 Solidification 201,204,205,329-342,

477-480,486,494 Solubility product 67 Solute distribution on solidification 332,

333,478

Solution complexation 371 Solution mining 18 Solution purification 289-291 Solutions, ideal 50 Solvent extraction 105, 221-225, 290,

291,373 Specialty mills 346, 348 Specific surface area 125, 126 Speed of gas moleeules 174 Spelter 350 Spontaneous changes 31 Spray degassing 323 Spray drying 361-366 Spray roasting 364 Spraying ofliquid metals 376, 479, 480 Sputtering 504, 505 Stabilization of colloids by polymers

158, 159 Stack region ofiron blast furnace 257 Staged operations 221-225 Stainless steels 328-329 Standard electrode potential 292, 293,

296,298-300 and Gibb's free energy 298-300

Standard free energy of formation 44, 45,56, CD

of species in aqueous solution 300 Standard free energy ofreaction 48,

55-58, 299, CD Standard heat (enthalpy) of formation

45, CD Standard heat (enthalpy) ofreaction 48 Standard hydrogen electrode 293, 294 Standard reduction potentials 294,300 Standard state 44, 49, 292, 293 Starter sheets 302, 308, 314 Steady state operations 213 Steelmaking 8, 9, 104,269-274, 324,

326 Stereological characterization of

evolving pore network 450 Steric stabilization of colloids 159-162 Stern layer 149 Stoichiometry 218,219 Stoker furnaces 465 Stokes law 119, 156,326,327

Index 531

Strain rate of sintering solid 421, 422, 424,452,453

Stress distribution on grain boundary during sintering 419, 420

Stress intensification factor 415,421 relation to porosity 416

Stress/strain curve for metal 343 Submerged are furnace 263 Substitutionals 176 Sulfide ores 16,23,24,244,245,264 Sulfur dioxide 64, 243, 267, CD Sulfur recovery from roaster gas CD Sulfuric acid 267, 284, 350 Superconductors 10, 462, 480 Supercritical drying 371, 372 Superheat 334 Superlattices 500 Supersaturated solutions 360, 366 Supply ofheat to units 226-230 Surface area measurement 125, 126 Surface charge 135, 146, 149, 151, 154,

156, 157 Surface chemistry 23,24, 111, 164 Surface diffusion 178,406,428,447 Surface modification 497-508 Surface potential 149, 155 Surface structure 135-146 Surface tension 126, 127,409,413,415,

434,435

T Tailings 25 Tap density 284,285,387 Tape casting 397 Tempering 7 Terminal velocity 119, 122,327 Ternary phase diagrams 197-200 Texture formation 470,471,473 THERBALCD Thermal debinding 461 Thermal decomposition (stability) of

oxides 58, 59, CD Thickeners 286 Third law ofthermodynamics 32 Thixotropy 165 Tin 6, 276, 306, 349, 350

532 Index

Tinning 349, 350 Titanates 10 Titanium diboride 376, 488 Titanium nitride 495 Titanium production 11, 340, 341 TLK surfaces 136 Tacer diffusion 184, 185 Tracer measurement of residence time

214-217 Transport mechanism 177, 206 Traveling grate furnace 245, 246, 248 Trendline CD Trichlorosilane 480-482, 484, 486, CD Tundish 338 Tungsten carbide 376, 494 Tuning ofprocess controllers 235 Turbidity 122 Twin roll caster 480, 481 Types ofpartic1es 110,111

U Undercooling 202, 203 Unit operations 211-213 Unsteady state operations 213 Uranium 18,283,290 Useful work 34-36,38

V Vacancies 176-178, 182 Vacancy mechanism of diffusion 177 Vacuum arc remelting (VAR) 340-342 Valuable mineral 19, 20, 22, 25 Van der Waals attraction 151, 152 Van't Hoff's relationship 151 Vapor pressure 50, 67, 93, 427, 428, CD

Vaporization equilibrium 66, CD Vat leaching 284, 286 Vibro mi11359 Viscosity, intrinsic 165, 166 Viscosity ofsuspension 395 Void formation during solidification 322,

335,336

W Wet bag tooling 394 Wet grinding 357, 358 Whiskers 387-389, 432, 465, 466 Wrought iron 6

X X-ray line broadening 123, 124 Xeroge1371

Y Yellowcake 290 Yield point 342, 343, 395 Young's equation 435

Z Zeta potential 154-158, 166 Zinc 61, 252-256, 264, 282, 290, 293,

295,300,305,306,308,349-351, CD Zirconia 10, 369, 379

stabilized and partially stabilized 369 Zirconium 496 Zirconium boride 496 Zirconium carbide 496 Zirconium nitride 495 Zone leveling 486 Zone refining 486, 487

-100

-200

-300

-400

-600

-700_

-800 _

-900

-1000

o 200

-200

400

o 200

MgCh

M9+CI,~

600 800

400 600

1000 1200

TIK)

Tee) 800 1000 1200 1400 1600 1800 2000

2Cu + CI:!" = t CU 8CI3

*Sb+CI2""~SbCI3

Cu -I- CI '" 2C~_Sn + CI;: "" Sn CI2

2H + CI, ~ 2HCI -50

B

. CI ~ 2LiCI CI ~ BaCI,

2Lt + 2 Ba+ 2

-150

Metal Chloride -200

Melting point M @I

BOiling point ® Transition POint ('j)

SUblimation POint s ®

1800 2000 2200 1400 1600

-250

2400

CD Containing Thermodynamic Data and Examples of the Use of Excel©

prepared by Dr. Arthur E. l\1orris, Thermart Software

The CD contains data and descriptive material for making detailed calculations involving materials processes. The contents of the CD are de­scribed in the text file CDjNTRODUCTION.PDF, which you should read and print before trying to use the material on the CD.

There are two Excel© workbooks on the disk: DATATABLES.xLS and Xl\1PLES.XLS. They contain thermodynamic data and examples of their use by Excel to solve problems and examples similar to those in the text. The CD contains a document describing these examples, Xl\1PLEDESCRIPTION.PDF, which is in Portable Document Format (PDF).

You will need Adobe Acrobat Reader to view and print these files; if you do not have Reader, you can install it using the appropriate installer contained on the CD, or it can be downloaded from the following location:

http://www.trns.org/AdobeAcrobat.html