P Elaboration BellotV1 - Métallurgie 2012 - … · Iron-ore Agglomerate As-cast steel alloy ......
Transcript of P Elaboration BellotV1 - Métallurgie 2012 - … · Iron-ore Agglomerate As-cast steel alloy ......
PROCEDES D’ELABORATION
J.P. BellotIJL, UMR CNRS-UL 7198
DAMAS, Labex ULEcole des Mines de Nancy
ANF Métallurgie Fondamentale
22-25 octobre 2012
What is the meaning:
(Procédés d’élaboration)
Materials Processing?
(Génie des Procédés d’élaboration)
Materials Process Engineering?
What is the Materials Processing?
Minerals Raw Materials
Metallic alloy
Materials
Extraction/Separation
Elaboration Materials transformation, forming, surface
treatments
Secondary resource (recycled)
Product
Elaboration and Treatments
solidification
= Materials Processing
Iron-ore Agglomerate As-cast steelalloy
Car metalsheet, gear, packaging
Extraction
Elaboration and Treatments
Elaboration Materials transformation, forming,
surface treatment
Iron Scraps
Functions
What is the Materials Processing?
= Materials Processing
What is the Materials Process Engineering?
Car metal sheet, gear, packaging
FunctionsElaboration CompositionStructure
Properties
• Analysis• Control• Optimization
• Analysis of the main physical phenomena• Set up measurements and experimental studies • Modeling (numerical)• Simulation of the process and optimization of the operating parameters
New challenges in 21st Century?
• Improvement of Inclusion cleanliness and alloy purity
• Energy: efficiency and vector
• Environmental impact: assessment and reduction
• Waste stream (Matières Premières Secondaires): Processing technologies for metals and minerals extraction
from waste streamsAdditional stress on the purification processes
• The main processing routes in metallurgy
• The main stages of the elaboration
• Materials Processing Fundamentals
• Illustrations: Modeling and simulation
• What about experiments?
Summary
Main Processing RoutesHydrometallurgy
Pyrometallurgy
Low Energy costSmall unitsRecycling processes
No environmentally friendly
Hydrometallurgy
1st Stage: Leaching: Dissolving the metals (as one of its salts)
2nd Stage: Purification: Separating the waste from the aqueous solution to an other phase by precipitation, crystallization, cementation
3nd Stage: Elaboration of the solid metal: Electrolysis or solvent extraction
Applications: Au, Zn, Co, Cr, Cu, Mn…
Fundamentals in hydrometallurgy:
Chemical, Electrochemical and Chemical Engineering
Production of primary aluminum
Al alloysOresBauxite
alumina Liquidalumimium
Bay
er p
roce
ss
elec
trol
ysis
Cas
ting
shop
Rol
ling,
hea
t tre
atm
ent …
elaborationhydrometallurgy
électrolytique
Injection de l’alumine
Production of primary Copper
OresCu2S
CuFeS2
Aq. SolutionCuSO4
Leaching
H2SO4
Extraction by org. solvent
Electrowinning(électroextraction)
Cu metal
R2Cu
Electro-refining
converterCu Blister Anode
Cu metal
T>T fus+ O2
RoastingCu Matte
CuxFey +S+ Sintering
OresCu2S
CuFeS2
Pyrometallurgy
Hydrometallurgy
Zinc Recycling: Dust produced by the EAF (iron scarp remelting)
Dust emission
N
dp
QS
20 kg of dust/ t steel
Zn 25 %Pb 5 %Salts 5 %Cd 2 %
Leaching with NaOH
90°C – 1h
Fe, Lime
Zn, PbCementation Pb
ZnElect Zn metalZn powder
Main Processing Routes
Hydrometallurgy
Pyrometallurgy
Low Energy costSmall unitsRecycling processes
No environmentally friendly
PyrometallurgyThe main stages
Metallic oxide Metal+ C
Reduction Liquid alloy
Alloying of the metal &
purification
Solid alloy
Casting
Converter Liquid metalCO O2
Steel makingAluminium makingTitanium making
Steel making
Iron oxides Pig Iron(C + P + S)
Liquid steel alloy
Alloying of the metal &
purification
Liquidsteel
Solid alloy
Casting
Blast Furnace
CO
Converter
O2
Iron ores
Sintering
Steel making
Iron oxides Pig Iron(C + P + S)
Blast Furnace Liquid steel alloy
Alloying of the metal &
purification
Solid alloy
Casting
Converter LiquidsteelCO O2
Iron ores
Sintering
Elec
tric A
rc F
urna
ceIron scraps
Ladletreatments
Gas-stirring ladle
cored wires
vessel refractoycrucible
vacuum pump
Refining of liquid steel
Stages
Degassing
Final AdditionsCa, Al …
Inclusion separation
Al alloysOresBauxite
alumina Liquidalumimium
Bay
er p
roce
ss
elec
trol
ysis
Cas
ting
shop
Rol
ling,
hea
t tre
atm
ent …
elaborationhydrometallurgy
Aluminum making
Al scraps
Rotary kiln
Titanium making
Metallic oxideTiO2
TiCl4Reduction Liquid
alloy
Alloying of the metal &
purification
Solid alloy
Casting
Ti spongeCl2 + C
Carbochloration
Mg
ReductionKroll Process
pyrometallurgy
sponge
recycledscrap
Primaryelectrode forging
&forming
TitaniumTitanium makingmaking
master alloy
EBM alternative
VAR route
Chemical Engineering History
WW2
1970
1990
Unit Operations
Process DesignControl System
Transport Phenomena, R.B. Bird, 1960, Unified approach
Computer Science
Chemical Engineering ‘Science’AIChE (American Institute of Chemical Engineering)
MIT, IC
Application to Materials Engineering, J. Szekely
Materials Process Engineering (Génie des Procédésd’Elaboration, A. Vigne, D. Ablitzer)
‘Voie Royale’J. Villermaux
Chemical Engineering Reactors, O. Levenspiel
Materials Processing Fundamentals
Process EngineeringSystem Analysis
• Unit operation / Idealreactor
• Chemical kinetics/Mass Transfers
• Thermodynamics
• System dynamic (unit control, automatic)
MechanisticAnalysis
• Fluid mechanic
• Thermal & thermochemistry
• Transport phenomena
• Chemical kinetics
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Laboratory experiments
Trials on industrialplants
Numerical simulation of the process
Modeling of the mechanisms
Elementary Phenomena
Materials Processing
" Microscopic scale"
"Macroscopic scale"
Research approach
Gas-stirring ladle
1st Example: Refining of liquid steel
cored wires
vessel refractoycrucible
vacuum pump
1st Stage
Modeling of Liquid/gas bubblesTurbulent Fluid flow
2nd Stage
Modeling of inclusion behavior
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Example of the hydrodynamics of an industrial ladle (60 t)
Isosurface of the 1% gas volume fraction
Velocity of the liquid steel (m/s)
Two porous plugs
Settling step (weak gas flow)
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Mixing time
2 m
Addition of copper platelets as a tracer
Tracer : 60 kg of copper (0,1 wt%) Introduction duration : 3 s
?
?
?
Deep-sampling time interval: 50 sTotal time : 3 min
trajectory & dissolution behaviour?
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Initial tracer location: pts 1 to 3
Location of the Sampling (pt S)
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S
3
S
32
1
0,050
0,075
0,100
0,125
0,150
0,175
0,200
0,225
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300Temps (s)
Tene
ur e
n C
uivr
e (%
)
Point 1 Point 2 Point 3 MesuresIntroduction
of Cu
Mixing time
Cop
per
con
ten
t (w
t%)
Measurements
Discrepency between real and idealPSR (Perfectly Stirred Reactor)
Inclusion behavior: Development of a 0D, 3D or 1D model
Coupling of 1D and 0D reactorsHomogeneous ladle 0D
0D1DVitesse du panache
Vitesse du liquide (exemple)
0D
Heterogeneous ladle 3D
1
10
100
1000
10000
100000
00.
02
0.05
0.07 0.
1
0.12
0.14
0.17
0.19
0.22
0.24
0.38 6.
913
.4
19.9
26.5 33
39.5 46
52.5
59.1
65.6
72.1
78.6
85.2
Taux de dissipation eps (m2/s3)
Freq
uenc
e
Série1
Zone homogèneZone des panaches
Fréq
uenc
e/no
mbr
e de
cel
lule
s
2 3( / )m sε
Averaging of the hydrodynamics properties
Two modes: bimodal distribution
Aggregation/agglomeration Floatation
Modeling of the inclusion behavior
SettlingCapture
l il l i l i i b i i
N d iv ( u N ) ( B D ) Z St
∂α+ α = α − − −
∂
Macroscopic transport mesoscopic interactions
Ni nb of inclusions of the i class / m3 of liquid
ibiiiil SZDB
tN
−−−=∂
∂αResolution of the PBE
Numerical Resolution
0)( =+∂
∂illl
ill Ndivt
N uραραTransport of scalars
Time splitting technique :[ ]1,i M∀ ∈
CFD (Fluent)
Method of Classes (UDF)
Fixed Pivot (Cell average - Kumar, 2006)
0 20 40 60 80 100Taille des particules (microns)Inclusion size (μm)
Incl
usio
n nu
mbe
r co
ncen
trat
ions
NiDiscretizationNi: number density#part (size i) /m3
Bellot,Rimbert, AEM, 2011
Method of Moments (QMOM)
OD
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Laboratory experiments
Trials on industrialplants
Num. Sim. of the process
Modeling of the mechanisms
Elementary Phenomena
Materials Processing
" Microscopic scale"
"Macroscopic scale"
Research approach
d10 (m)
G X 1500– Détail d’une inclusion Ø 35µm
Spectre 2 Spectre 1
Dip sampling and inclusion counting
Coke Oven
Power PlantBlast
Furnace
Basic Oxygen Furnace
Hot Rolling
Sintering Plant Coke Oven
Power PlantBlast
Furnace
Basic Oxygen Furnace
Hot Rolling
Sintering Plant
Classical integrated Steelmill
1 ton of hot rolled coiled
~2 tons of CO2
released in the atmosphere
2nd Example: Environmental assessment using LCALife Cycle Analysis
1 ton of hot rolled coiled
~?? of CO2
released in the atmosphere
2nd Example: Environmental assessment using LCALife Cycle Analysis
Réduction Directe à l’H2
LCA• Select the best alternative
• Communicate on your environmental performances
• Compare the different alternatives• Compare with a reference
Objectives
Results
Methodology
Goal and scopedefinition
Inventory analysis (LCI)
Impact assessment
Interpretation of the results
• For processesthat do not existyet, no data are available
• We need to calculate thosedata
Methodology
Experimental approach
High temperature
Liquid reactivity
How to see through opaque liquid materials?
Numerical simulation
Pyrometallurgy:• Worcester Polytechnic Intitute, MA, USA (M. Makhlouf)• Mac Gill University, Canada (R. Guthrie)• University of British Columbia, BC, Canada (A. Mitchell)• University of Illinois (Urbana Champaign), USA (B. Thomas)• University of Birmingham, UK (M. Ward)• University of Illmenau, Germany (C. Karcher)• University of Leoben, Austria (S. Michelic)• University of Sendaï, Japan (S. Tanigushi)•…
IJL ICMPELorraine Ile de France
SIMAPRhône Alpes
UMR
Instituts de Recherche
Centres de Recherche Privés
Réseau National de Plateformes d’Elaboration d’alliages métalliques par passage à l’état liquide
Difficultés pour maintenir les compétences techniques et scientifiques sur les procédés
Un manque critique de petites expérimentations soignées
Equipements d’élaboration lourds de qualité
Des spécialistes sont encore présents mais la pyramide d’âge est inquiétante
Les points faibles:
Les points forts:
Développer des projets de recherche communs
Coordonner l’usage et la maintenance
Renforcer les savoir-faire et la transmission des compétences
Assurer la visibilité
Le constat Les objectifs
IRT
To make advances in the understanding and the control of the purification phenomena during liquid materials processing
Multiphase & Multiscale modelingInterface mass transferThermochemistry
To develop integrated analysis on a whole processing route so as to compare energy consumption and environmental impacts.
Experiments at the laboratory scalefocused on a mechanism
- high energy beamline- Confocal microscope…
Among the future challenges
(1) Some perspectives on the mathematical modelling of materialsprocessing operations, Julian Szekely and Gerardo Trapaga 1994 Modelling Simul. Mater. Sci. Eng. 2 pp.809-828, doi:10.1088/0965-
0393/2/4/002
(2) Transport Phenomena, R. Byron. Bird, Warren E. Stewart, Edwin N. Lightfoot, Wiley, New York, 2nd Edition, 2006
(3) Elaboration des matériaux et génie des procédés, Ecole d’été du CNRS, St Pierre d’Oléron, juin 2005, Publié sous la direction de Denis Ablitzer et Jean-Pierre Petitet
Main References