Production of Aluminum-silicon Alloy and Ferrosilicon and Commercial Purity Aluminum by the Direct Reduction Process. Special Technical Report PDF Download
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Languages : en
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As part of a contract to develop a process for the carbothermic reduction of aluminum-silicon alloys, the technical feasibility of an atmospheric combustion-heated reactor was investigated. Potentially, such a reactor could have lower energy and capital requirements than current processes for producing aluminum and silicon. Reduction reactions were modelled using two chemical equilibrium computer programs which predicted the aluminum recovery in the reduction zone and the carbon rate needed to meet the energy requirements of the process.
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Languages : en
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Book Description
As part of a contract to develop a process for the carbothermic reduction of aluminum-silicon alloys, the technical feasibility of an atmospheric combustion-heated reactor was investigated. Potentially, such a reactor could have lower energy and capital requirements than current processes for producing aluminum and silicon. Reduction reactions were modelled using two chemical equilibrium computer programs which predicted the aluminum recovery in the reduction zone and the carbon rate needed to meet the energy requirements of the process.
Author: Marshall J. Bruno
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ISBN:
Category :
Languages : en
Pages : 431
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Author:
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Category :
Languages : en
Pages :
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The primary objective of the three year program is to demonstrate technical feasibility of a pilot sized direct reduction process for producing aluminum and aluminum-silicon alloy. The process includes three major tasks, reduction to produce impure alloy, alloy purification and purification to commercial grade aluminum. Goals for the first year are to establish the effects of process operating and design variables in bench scale units, to design the three main pilot units plus auxiliary equipment, and to prepare the sites for installation of the pilot units. Progress toward these goals is reported.
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Category : Aeronautics
Languages : en
Pages : 788
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Author: Marshall J. Bruno
Publisher:
ISBN:
Category :
Languages : en
Pages :
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Author:
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Category :
Languages : en
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Progress on the program to demonstrate the technical feasibility of a pilot-sized Direct Reduction Process for producing aluminium and aluminium-silicon alloy is reported for Phase C. Progress is reported on reduction including the following tasks: supply burden material; burden beneficiation; effects of pilot operating parameters; pilot modifications; reactor scale-up design; calculating heat and mass balance; processing mathematical modeling; effects of process variables; information on supportive analytical, phase identification, and mechanical engineering data. Progress on alloy purification is reported in the following tasks: pilot unit installation; effects of pilot operating parameters; pilot unit modifications; and supportive mechanical engineering. Progress on purification to commercial grade aluminum is reported on: pilot unit installation; effects of pilot operating parameters; pilot unit modifications; support pilot operations; and supportive expended man-hours. Plans for Phase D are noted. (MCW).
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Languages : en
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Operation of the bench AF-reactor on burden with all reducing carbon exterior to the ore pellet resulted in low metal alloy product yields and prematurely terminated runs, indicating the need for intimate contact between alumina and carbon to produce oxycarbide liquid prior to reaction with solid silicon carbide. Carbon solubility tests made on 60Al-40Si alloys at 2200°C in graphite crucibles indicated continued reaction to form SiC for one hour. Efficiency of reduction to SiC ranged from 68 to 100%. The A-C two-electrode submerged arc reactor pilot, SAR-II, was successfully operated on both alumina-clay-coke and alumina-silicon carbide-coke (from the VSR prereduction) burdens. Metal alloy was produced and tapped in each of four runs. The pilot crystallizer was operated to evalute the two-stage (stop and go) crystallization technique on obtaining high yields of Al in Al-Si eutectic, with a limit of 1.0% Fe and 0.1% Ti in the alloy product. 18 figures, 19 tables. (DLC).
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Category : Power resources
Languages : en
Pages : 1634
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Category :
Languages : en
Pages :
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Experimental runs were made to determine the effect of a cooler product reservoir on metal alloy yield and recovery. The reservoir temperature had no significant effect. Difficulties were experienced with operation of an oxygen injected bench scale reactor. Many tests were terminated by burden bridging or flooding of the oxygen tuyeres with metal and slag. Runs were made in which refluxing vapors were condensed in a liquid slag. The addition of CaO decreased the tendency for formation of thick, strong burden bridges but did not completely eliminate bridging. Reduction of flame temperatures did not affect the volatilization rate in the bench reactor. Operation of VSR-1 pilot reactor with O injection was achieved after resolving reactor shell leakage problems, by replacing the permeable ceramic shell with impermeable fused silica. Various combustion parameters were investigated, including coke size, burden height and oxygen flow rate. Steady state operation of the oxygen-coke system was attained with smooth burden movement and a 2000°C bed temperature in the raceway vicinity. To further reduce heat losses from the raceway area. VSR-1 was redesigned to facilitate locating an induction coil below the oxygen inlets. Further evaluation of effects of impurities on alloy purification in the bench scale unit indicated a 50% decrease in product yield for starting charges containing Fe greater than 5%. Site installation for the entire alloy purification complex was completed. Operations were continued in the bench scale units to obtain design information for the pilot commercial grade Al purification unit. Procurement of construction material was established.
Author: Marshall J. Bruno
Publisher:
ISBN:
Category :
Languages : en
Pages : 60
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