钢铁研究学报(英文版)
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2019年 26卷 6期
刊出日期：2019-06-25
综述
论著
综述
547
Cong-cong Yang, Jian Pan, De-qing Zhu, Zheng-qi Guo, Xiao-ming Li
Pyrometallurgical recycling of stainless steel pickling sludge: a review
Stainless steel pickling sludge (SSPS), generated from the lime neutralization process of spent pickling liquor, is classified as a hazardous waste consisting of abundant metals like Fe, Cr and Ni, and other elements like F, S and Na, etc. Rather than a common disposal in landfill, recovering these metals and other valuable components from SSPS can not only create economic benefits, but also eliminate its adverse impacts on human health and the environment. A review of the formation mechanism and basic properties of SSPS was made, and the technical features, advantages and limitations of a series of pyrometallurgical treatment processes were summarized. Based on these, the main challenges for recycling of SSPS through the existing techniques are demonstrated. The traditional pelletizing/sintering-blast furnace process can only be used as a partial solution. Direct use of SSPS as flux in an argon–oxygen decarburization converter or electric arc furnace is a promising way, but low S sludges are preferred. The STAR process shows excellent recovery for metals, but it also has a low tolerance to the S and F contents in SSPS. And the INMETCO process is highly flexible in treatment of various wastes, whereas it exhibits relatively low Cr recovery and produces poor-quality pig iron. In addition, the feasibility of the rotary kiln-electric furnace, solid-state reduction of chromite and reduction-magnetic separation processes requires further studies. An urgent task at present is to develop a system for scientific classification and separate collection of SSPS in terms of chemical composition, notably S and F contents.
2019 Vol. 26 (6): 547-557 [
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558
Xiao-hui Fan, Yan-nan Wang, Min Gan, Zhi-yun Ji, Yang Zhou, Xu-ling Chen
Thermodynamic analysis and reaction behaviors of alkali metal elements during iron ore sintering
Reaction thermodynamics and behaviors of alkali metal compounds were studied by FactSage7.1 and sinter pot trials. Main transformation behavior of alkali metal compounds was divided into three parts: part of alkali metal chloride was gasified and emitted into the flue gas, and most of alkali metal chloride turned into sulfate, which was remained in the finished sinter, through reacting with sulfur oxide; KAlSi3O8 and NaAlSi3O8 were transformed into KAlSi2O6, NaAlSi2O6 and alkali metal oxides by reacting with calcium oxide. Moreover, newly formed alkali metal oxides turned into sulfate and silicate, entering finished sinter finally. Only a small amount of KAlSi3O8 and NaAlSi3O8 were reduced into gaseous alkali metals in ambient strong reduction atmosphere and removed into the flue gas. 21.67% of potassium and 14.56% of sodium entered flue gas. In finished sinter, alkali metal elements existed in the form of alkali metal sulfate, silicate and aluminosilicate. The influences on alkali metal elements distribution, basicity (mass ratio of CaO to SiO2 in sinter), sulfur content, chloride content and coal ratio of raw materials indicated that increasing basicity level, rising coal ratio and adding CaCl2 promoted the removal of alkali metal elements into the flue gas. However, with sulfur content increasing in raw materials, alkali metal elements distribution ratio in the finished sinter rose.
2019 Vol. 26 (6): 558-566 [
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567
Xing-sheng Zhang, Zong-shu Zou, Zhi-guo Luo
Numerical simulation on characteristics of COREX shaft furnace with central gas distribution
A three-dimensional steady-state mathematical model, considering the chemical reactions and transfers of momentum, heat and mass between the gas and solid phases, was developed to investigate the characteristics of the shaft furnace with the central gas distribution (CGD) device. The model was verified by the practical production data of a COREX-3000 shaft furnace, and then, it was used to study the inner characteristics of the shaft furnace with CGD. The results show that, compared with the COREX shaft furnace without CGD, the gas utilization rate (UR) and solid metallization rate (MR) increase from 33.66% to 34.18% and 60.4% to 61.8%, respectively. Especially, the standard deviation of solid MR decreases from 6.9% to 0.8%, which means that the MR of direct reduced iron from the furnace with CGD is more uniform than that without CGD. Additionally, the effects of operational conditions and CGD design on gas UR, solid MR and direct reduced iron uniformity were further discussed and the optimized conditions were suggested.
2019 Vol. 26 (6): 567-577 [
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578
Ding Tian, Xiao-yi Shen, Yu-chun Zhai, Penny Xiao, Paul Webley
Extraction of iron and aluminum from high-iron bauxite by ammonium sulfate roasting and water leaching
High iron content is one of the challenges in utilizing the refractory bauxites in China. An improved method for treating the high-iron bauxite by roasting with (NH4)2SO4 was proposed, which offers a possible alternative method for utilizing the high-iron bauxite. The influences of the roasting time, roasting temperature, material ratio, and ore particle size on the extraction ratios of Fe and Al were studied, and the orthogonal test was used to optimize the reaction conditions. The optimized reaction conditions were proposed as follows: roasting temperature of 450 C, roasting time of 120 min, material ratio of (NH4)2SO4 to ore of 2.5:1.0, and ore particle size below 80 lm. The roasting mechanism and kinetic parameters including the apparent activation energy and reaction rate constant were investigated. The results showed that the control step of the roasting process was the internal diffusion on the product layer and the apparent activation energy was 19.22 kJ mol-1 in the reaction temperature range. The kinetic equation was obtained finally.
2019 Vol. 26 (6): 578-584 [
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585
Kai Feng, An-jun Xu, Peng-fei Wu, Dong-feng He, Hong-bing Wang
Case-based reasoning model based on attribute weights optimized by genetic algorithm for predicting end temperature of molten steel in RH
Temperature control is the key of Ruhrstahl-Heraeus (RH) process in steelmaking plant. The accuracy of RH control model greatly affects the molten steel temperature fluctuation. To obtain RH control model with higher accuracy, an improved case-based reasoning (CBR) model based on attribute weights optimized by genetic algorithm (GA) was proposed. The fitness function in GA was determined according to the prediction accuracy of end temperature of molten steel in RH; then, GA is used to optimize all the attribute weights based on known case base. An improved CBR model that contains the optimized attribute weights was applied to predict end temperature of molten steel in RH, and the prediction accuracy was calculated. Four methods, CBR based on attribute weights optimized by GA (CBR–GA), ordinary CBR, back propagation neural network (BPNN) and multiple linear regression (MLR) method were employed for comparison. The results show that in the error range of [- 3 °C, 3 °C], [- 5 °C, 5 °C], [- 7 °C, 7 °C] and [- 10 °C, 10 °C], the prediction accuracy of CBR–GA was improved by 19.99%, 28.19%, 27.11% and 16.3%, respectively, than that of MLR. Compared with BPNN, the prediction accuracy increased by 3.22%, 7.44%, 5.29% and 2.40%, respectively. Compared with ordinary CBR, the accuracy increased by 5.43%, 5.80%, 4.66% and 2.27%, respectively.
2019 Vol. 26 (6): 585-592 [
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593
Zhi-bing Chu, Zhan-yuan Xue, Duo Zhang, Huan-zhu Wang, Wei Li, Ren-huai Liu, Qing-xue Huang
Parameters of cold pilgering of seamless steel tube
As the process parameters of pilger cold-rolled seamless steel tubes are basically based on experience leading to the generation of defects, 304 stainless steel was chosen and the important process parameters including the feed, rotation angle and Q value (the ratio of the length of the deformation section to that of the finishing section) were selected to analyze the effect of different process parameters on the tube forming process and rules. The results show that during the cold rolling process, the rolling force, the equivalent stress of the tube, the residual stress and the springback of the external diameter increased with the increase in the feed rate and the rotation angle and the decrease in Q value. Increasing the feed quantity and decreasing Q value will lead to the decrement in the roundness of the pipe. After comprehensive evaluation of the advantages and disadvantages, a set of optimal parameters are selected to carry out the experiment. The residual stress and the outer diameter of the finished products were measured. The results of the measurement and the numerical simulation results are within reasonable range, and the accuracy of the numerical simulations and the influence of the process parameters on the pilger cold rolling are further verified.
2019 Vol. 26 (6): 593-601 [
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602
Hong-bin Li, Xiao-ping Zheng, De-cheng Wan, Lian-sheng Chen
Effect of time interval on microstructure evolution of medium carbon steel during warm deformation
The thermal mechanical simulator system (Gleeble-3500) was used to carry out the double passes compression tests. The microstructure evolution of medium carbon steel with different time intervals during warm deformation was investigated by scanning electron microscopy, transmission electron microscopy and electron back-scattered diffraction. The results show that the effects of time interval on microstructure evolution are very important. The low-angle boundaries transform into high-angle boundaries (HABs) during interval. The fraction of HABs and homogeneity of particle carbides increase with increasing time interval. In addition, the homogeneity of carbides also increases with the strain. However, the effects of time interval on the microstructure evolution are negligible when it exceeds 100 s.
2019 Vol. 26 (6): 602-610 [
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611
Xiang-yu Xu, Long Tian, Yun Zhou, Ming-yu Sun, Xue-min Wang, Cheng-jia Shang, R.D.K. Misra
Effect of Nb on corrosion behavior of inner bottom plate of cargo oil tankers
The effect of Nb on the corrosion resistance of steels in simulating an oil-corrosion environment was investigated by means of microstructure observation, electrochemical test, dissolved Nb content measurement and Nb segregation observation. The results show that the microstructure of the experimental steels is mainly ferrite with a little pearlite. The dissolved Nb contents of the experimental steels are 0.0235 and 0.0458 wt.%, respectively, while the undissolved Nb content is nearly the same. In addition to enhancing mechanical properties of the steel, dissolved Nb improves the corrosion resistance by enriching Nb in the rust layer. Nb oxides in the rust layer cause a decrease in the corrosion rate due to a decrease in the anodic reaction kinetics. The segregation of Nb at the grain boundaries suppresses the corrosion. Moreover, Nb is enriched at the bottom of the corrosion pit and prevents any further corrosion.
2019 Vol. 26 (6): 611-620 [
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621
Jian-feng Xiao, Hai-tao Cui, Hong-jian Zhang, Wei-dong Wen
A united tension/compression asymmetry micro-mechanical model for nickel-base single-crystal alloys
In recent years, the micro-deformation mechanisms of the tension/compression behavior for nickel-base single-crystal superalloys have been studied extensively and general agreements have been derived. Based on these researches, a new model called united tension/compression asymmetry micro-mechanical model (UTCAM) has been proposed, which can effectively estimate the initial yield strength of nickel-base single-crystal (SC) superalloys under different loading directions. Considering the combined effects of octahedral slip system and cubic slip system, slip control factor is introduced in the UTCAM to determine the type of the open slip system of nickel-base single-crystal superalloys during deformation, thus making this model cover a rather wide range of application. Furthermore, the UTCAM is applied to hot tension and compression tests of three typical nickel-base SC superalloys (PWA1480-593 C, RENE N4-760 C and DD407-760 C). The predicted initial yield strengths of the nickel-base SC superalloys are in good agreement with the experimental results, and the UTCAM proves to be effective.
2019 Vol. 26 (6): 621-630 [
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631
Guo-chao Li, Xu Cheng, Hua-ming Wang
Improvement of proof-ultimate strength difference in laser additive manufactured Ti–6Al–2V–1.5Mo–0.5Zr–0.3Si alloy by tuning basketweave structure
After annealed at 1000 °C, a special basket-weave structure is obtained in laser additive manufactured Ti–6Al–2V–1.5Mo– 0.5Zr–0.3Si alloy. The unit of the special basket-weave structure is a lamellas clusters, which consist of lamellar primary a (ap), crab-like structures at the edges of ap and lamellar secondary a (as) on both sides of ap. As the units of basket-weave structures, the width of the clusters is much larger than that of a lamellas in as-deposited alloy. The formation temperature and process of the special basket-weave structure are studied, and the room temperature properties are tested and compared with the as-deposited alloy. The results show that the formation of the special basket-weave structure finishes within about 30 s and crab-like structures form earlier than lamellar a s. The yield strength of the alloy is decreased by about 75 MPa compared to that of the as-deposited alloy. Besides, the proof-ultimate strength difference of the alloy is two times higher than that of the as-deposited alloy with about 34% improvement for the impact toughness. It is because a colony size shows a positive correlation to the width of the unit forming basket-weave structure. The enhancement in proof-ultimate strength difference could significantly improve the toughness of the alloy, and thus effectively increase the safety of the alloy.
2019 Vol. 26 (6): 631-636 [
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637
Hui-bin Wang, Fei-long Wang, Gen-hao Shi, Yu Sun, Jiang-cheng Liu, Qing-feng Wang, Fu-cheng Zhang
Effect of welding heat input on microstructure and impact toughness in CGHAZ of X100Q steel
The coarse-grained heat-affected zones (CGHAZs) of X100Q steel were reproduced via simulating their welding thermal cycles with the varying heat input (Ej) from 10 to 55 kJ/cm in Gleeble3500 system. The microstructures were characterized, and the impact toughness was estimated from each simulated sample. The results indicate that the microstructure in each simulated CGHAZ was primarily constituted of lath-like bainite. With the decreased heat input and accordingly the lowered Ar3 (the onset temperature for this transition), the prior austenite grain and the bainitic packet/block/lath substructure were refined remarkably, and the impact toughness was enhanced due to the microstructure refinement. The bainitic packet was the microstructural unit most effectively controlling the impact properties in CGHAZ of X100Q steel, due to their close correlation with the 50% fracture appearance transition temperatures, their size equivalent to the cleavage facet and their boundaries impeding the crack propagation.
2019 Vol. 26 (6): 637-646 [
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647
Xiao-fei Zheng, Yong-lin Kang, Jian Zhou
Influence of coating and dew point on hearth roll pickup
Thermal spray coatings have been widely used on hearth rolls in a continuous annealing line to improve steel sheet quality and prolong the roll service life. One of the common defects formed on a working hearth roll is the oxide pickup. The most common cause of the pickup formation is that the active Mn oxide reacts with coating. The potentials of two different coatings, CoCrAlYTa–Al2O3 (No. 1) and CoCrYNi–Y2O3 (No. 2), to duplicate pickups by reacting with Fe and Mn oxides were studied. There are three stages during pickup producing and growing. No. 2 coating effectively reduced the corrosion of Mn oxide. The characterization and modification of the surface oxide formed can be changed with different dew points. The results indicate that the dew point from - 53 to - 10 C can change the depth of Mn oxide, such that an alteration can prevent the first stage and second stage and is good for preventing the pickup growing.
2019 Vol. 26 (6): 647-652 [
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653
Hai-chen Wu, Xiao-fang Bi
Characterization of thermal-induced distorted face-centered cubic structure in pure titanium
After 900 C high-vacuum annealing and air cooling, a special band was observed in pure titanium. Energy-dispersive spectrum showed that the composition of the band and the matrix is the same. By tilting the band to different zone axes and taking selected-area electron diffraction (SAED) patterns, we found that the structure of the band is distorted face-centered cubic (fcc) with the lattice constants a, b, and c deviating slightly from each other on the basis of the analyses of the SAED patterns together with the tilting angles. The lattice constants a, b, and c are calculated based on the measurement of interplanar spacing according to high-resolution transmission electron microscopy (HRTEM) images. The orientation relation between the hexagonal-close-packed (hcp) matrix and the distorted fcc band is [1120]hcp//[110]fcc and (0001)hcp// (111)fcc according to SAED analysis. The phase boundary between the matrix and the band was observed to demonstrate serrated configuration composed of two kinds of micro-steps: (111)//(0002) and (111)//(1011) on the basis of Cs-corrected HRTEM characterization. The distorted fcc band is deduced to be a thermal-induced metastable phase transformed from the high-temperature body-centered cubic (bcc) structure during the allotropic transformation from bcc to hcp based on orientation relation analysis.
2019 Vol. 26 (6): 653-658 [
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