Ida Kero

Particle Size Distributions of Particulate Emissions from the Ferroalloy Industry Evaluated by Electrical Low Pressure Impactor (ELPI)

The present article presents a comprehensive evaluation of the potential use of an Electrical Low Pressure Impactor (ELPI) in the ferroalloy industry with respect to indoor air quality and fugitive emission control. The ELPI was used to assess particulate emission properties, particularly of the fine particles (Dp ≤ 1 μm), which in turn may enable more satisfactory risk assessments for the indoor working conditions in the ferroalloy industry. An ELPI has been applied to characterize the fume in two different ferroalloy plants, one producing silicomanganese (SiMn) alloys and one producing ferrosilicon (FeSi) alloys. The impactor classifies the particles according to their aerodynamic diameter and gives real-time particle size distributions (PSD). The PSD based on both number and mass concentrations are shown and compared. Collected particles have also been analyzed by transmission and scanning electron microscopy with energy dispersive spectroscopy. From the ELPI classification, particle size distributions in the range 7 nm – 10 μm have been established for industrial SiMn and FeSi fumes. Due to the extremely low masses of the ultrafine particles, the number and mass concentration PSD are significantly different. The average aerodynamic diameters for the FeSi and the SiMn fume particles were 0.17 and 0.10 μm, respectively. Based on this work, the ELPI is identified as a valuable tool for the evaluation of airborne particulate matter in the indoor air of metallurgical production sites. The method is well suited for real-time assessment of morphology (particle shape), particle size, and particle size distribution of aerosols.

Refining Kinetics of Selected Elements in the Industrial Silicon Process

An industrial oxidative ladle refining process of metallurgical grade silicon has been experimentally examined. An extensive industrial sampling campaign has been performed and samples of silicon and slag have been analyzed by inductively coupled plasma mass spectroscopy (ICP-MS). The elemental concentrations of 45 elements have been evaluated with respect to sampling time during the refining process. Major elements, such as Ca and Al, as well as trace elements are studied. The refining kinetics is discussed and groups of elements with different behaviors are distinguished. For 21 elements, which are responsive to the refining process, kinetic parameters are established. The alkaline and alkaline earth elements are identified as having the highest refining rates, whereas the rare earth elements are slower and most transition metals are quite unresponsive to the oxidative refining operation.

Trace Elements Behavior During the Oxidation of Liquid SiMn Alloy

During the tapping and casting of manganese ferroalloys, fumes are generated and released to the working environment. The fumes are mostly composed of metallic oxides generated due to reaction between high temperature molten metal and ambient oxygen in the air. From an environment perspective, it is important to limit these emissions. However, to do so, it is important to understand fuming mechanisms and kinetics as well as fume compositions, i.e. element behavior during the oxidation process of liquid manganese ferroalloys. Silicomanganese alloys are composed of a minimum of 65 wt% Mn and 17 wt% Si, 2 wt% C as well as minor and trace elements. These elements include Fe, Mg, Al and other elements originating from ores and reductants. Trace elements behavior in fume from liquid silicomanganese generated under an impinging air jet in the temperature range of 1450–1700 °C has been investigated in this work. The thermodynamic and kinetic conditions governing the generation mechanisms are discussed.

Active Oxidation and Fume Formation from Liquid SiMn

Dust, or airborne particulate matter, from metal smelting can be either mechanically or thermally generated and it negatively affects the indoor air quality as well as the fugitive emissions from the plant. The thermally generated dust is often referred to as fume and it is typically generated whenever liquid metal comes into contact with air. For practical reasons, such as vehicle access, etc. it is often difficult to collect 100% of the fume. It is therefore highly desirable to develop processes and optimize operational procedures so that fuming can be kept to a minimum. In this series of experiments, the mechanism of active oxidation and fume formation from liquid silicomanganese under an impinging air jet in the temperature range 1400–1600°C has been explored. Characteristic properties of the fume have been established; particle diameter, shape, size distribution, and elemental composition are reported. The oxidation process is described in terms of vaporization, oxidation and agglomeration. In the boundary layer, two competing mechanisms seem to be operative in parallel: a direct oxidation of Mn vapor, and a two-step oxidation of silicon. The thermodynamic and kinetic conditions governing the two mechanisms are discussed.

The Influence of Water Vapour on the Fuming Rate in a Ferromanganese System

During the casting of ferromanganese alloys, a considerable amount of dark fumes, consisting primarily of manganese oxides, are generated when the Mn vapour oxidises in the atmosphere. Previous studies indicate that these fumes can be reduced by increasing the humidity above the melt. However, the reduction mechanism is not fully understood. In an attempt to understand the reduction mechanism, the influence of a humidity change on the fuming rate was studied. Laboratory scale experiments were conducted where an impinging jet blew air with a varying humidity onto the melt where dust was captured to determine relative mass fluxes. When the wet air experiments’ fume fluxes were compared to the dry air experiment, it was found that the increase in humidity resulted in a significant fume reduction (between 33 and 79%), confirming industrial observations. Dust composition from the experiments as well as dust reduction mechanisms are presented and discussed.

Cellular responses of human astrocytoma cells to dust from the Acheson process: An in vitro study

HighlightsThe toxicity of Acheson dust collected from work place in a Silicon Carbide facility was investigated in a human astrocytoma cell line.Toxicity of the dust was determined using both low occupationally comparable and high doses.ROS production indicated no effects with low doses, whereas the highest dose induced a significant increase in ROS and DNA damage.The results showed that low doses of the Acheson dust were not neurotoxic in the astrocytoma cell line used. ABSTRACT Silicon carbide (SiC) is largely used in various products such as diesel particulate filters and solar panels. It is produced through the Acheson process where aerosolized fractions of SiC and other by‐products are generated in the work environment and may potentially affect the workers’ health. In this study, dust was collected directly on a filter in a furnace hall over a time period of 24 h. The collected dust was characterized by scanning electron microscopy and found to contain a high content of graphite particles, and carbon and silicon containing particles. Only 6% was classified as SiC, whereof only 10% had a fibrous structure. To study effects of exposure beyond the respiratory system, neurotoxic effects on human astrocytic cells, were investigated. Both low, occupationally relevant, and high doses from 9E‐6 &mgr;g/cm2 up to 4.5 &mgr;g/cm2 were used, respectively. Cytotoxicity assay indicated no effects of low doses but an effect of the higher doses after 24 h. Furthermore, investigation of intracellular reactive oxygen species (ROS) indicated no effects with low doses, whereas a higher dose of 0.9 &mgr;g/cm2 induced a significant increase in ROS and DNA damage. In summary, low doses of dust from the Acheson process may exert no or little toxic effects, at least experimentally in the laboratory on human astrocytes. However, higher doses have implications and are likely a result of the complex composition of the dust.

Modeling microstructure development during hot working of an austenitic stainless steel

A number of physically based models are combined in order to predict microstructure development during hot deformation. The models treat average values for the generation and recovery of vacancies and dislocations, recrystallization and grain growth and the dissolution and precipitation of second phase particles. The models are applied to a number of laboratory experiments made on 304 austenitic stainless steel and the model parameters are adjusted from those used for low alloyed steel mainly in order to obtain the right kinetics for the influence of solute drag on climb of dislocations and on grain growth. The thermodynamic data are obtained using Thermo-Calc© to create solubility products for the possible secondary phases. One case of wire rolling has been analyzed mainly concerning the evolution of recrystallization and grain size. The time, temperature and strain history has been derived using process information. The models are shown to give a fair description of the microstructure development during hot working of the studied austenitic stainless steel.

Model of Silicon Refining During Tapping: Removal of Ca, Al, and Other Selected Element Groups

A mathematical model for industrial refining of silicon alloys has been developed for the so-called oxidative ladle refining process. It is a lumped (zero-dimensional) model, based on the mass balances of metal, slag, and gas in the ladle, developed to operate with relatively short computational times for the sake of industrial relevance. The model accounts for a semi-continuous process which includes both the tapping and post-tapping refining stages. It predicts the concentrations of Ca, Al, and trace elements, most notably the alkaline metals, alkaline earth metal, and rare earth metals. The predictive power of the model depends on the quality of the model coefficients, the kinetic coefficient, τ, and the equilibrium partition coefficient, L for a given element. A sensitivity analysis indicates that the model results are most sensitive to L. The model has been compared to industrial measurement data and found to be able to qualitatively, and to some extent quantitatively, predict the data. The model is very well suited for alkaline and alkaline earth metals which respond relatively fast to the refining process. The model is less well suited for elements such as the lanthanides and Al, which are refined more slowly. A major challenge for the prediction of the behavior of the rare earth metals is that reliable thermodynamic data for true equilibrium conditions relevant to the industrial process is not typically available in literature.