ANNUAL REPORT 2005 OF PROCESS METALLURGY · a Cupola Furnace 22 3.1.5 Phase Transformations in...

ANNUAL REPORT 2005� LABORATORY OF PROCESS METALLURGYDepartment of Process and Environmental Engineering

ANNUALREPORT2005

ANNUAL REPORT 2005 �

DEPARTMENT OF PROCESS AND

ENVIRONMENTAL ENGINEERING

Laboratory of Process Metallurgy

ANNUAL REPORT 2005

Editor: TIMO FABRITIUS

UNIVERSITY OF OULULABORATORY OF PROCESS METALLURGY

P.O. BOX 4300

FI-90014 UNIVERSITY OF OULU

OULU UNIVERSITY PRESS

OULU 2006

ANNUAL REPORT 2005�

PREFACE

The year 2005 was exceptionally hectic for Oulu University and subsequently the Laboratory of Process Metallurgy: The university has been preparing for a new salary system, that has employed the entire staff in two successive waves. The preparation of the new salary system has not progressed particularly easily within the university, on the contrary an abundance of irregularities have had to be clarified. This has negatively influenced our researchers motivation. Our department has over the last year also been a pilot unit in the university’s quality control project. A great common challenge within the entire university world, has been the teaching renovation in accordance with the Bologna declaration. In practice all Process Metallurgy courses have been revised or will need to be re-vised within the following year. This creates extreme pressure for all with teaching responsibilities. The Department of Process and Environmental Engineering, was the only unit in Oulu, to receive national quality teaching status that will continue for another three years. This illustrates well our department’s and laboratory’s extensive association with the development of teaching. The quality teaching status is the result of our long term work for the benefit of teaching. For this reason I wish to extend special thanks to our entire personnel.

The year 2005 has been more laborious than the previous year in respect to obtaining research funding. Of the laboratory’s budget, approximately 3/4 comes from competitive marketing outside of the university’s normal budget. The Finnish Academy’s successful application rate is about 10% and The National Technology Agency of Finland’s (TEKES) project contribution is approximately in the region


of 20% - 25%. Because of this our researchers have been employed with application requests, more than ever. The Laboratory of Process Metallurgy’s key area has focused once again on reactive thermody-namics and kinetics, transfer processes and material mineralogy. For retention and further development of this key area we have continued with a multi scholarly approach. Our research teams are composed of chemists, physicists, mathematicians, geoligists and our department’s experts in the material transfer and reactivity areas. Our laboratory has worked within research networks both nationaly and interna-tionaly in the same manner as last year. Cross scientific collaboration within the scientific faculty in Oulu has increased in accordance with our strategy. Our working method of seeking solutions from the sci-entific boundaries has produced remarkable results and germinates international recognition. The research springboard is good. Capable researchers are responsible for the development of key areas. I wish to thank all for their efforts in the research, whose best fruits still await publishing.

Jouko HärkkiHead of the laboratory


TABLE OF CONTENTS Page

PREFACE 4

TABLE OF CONTENTS 6

1 LABORATORY STAFF AND STUDENTS 8

2 EDUCATIONAL ACTIVITIES 12 2.1 University Courses Held by the Laboratory (The Old Study System) 12 2.1.1 Metallurgical Processes 12 2.1.2 Metallurgical Thermodynamics 13 2.1.3 Theory of Pyrometallurgical Processes 13 2.1.4 Laboratory Exercises in Process Metallurgy 13 2.1.5 Casting and Solidification 14 2.1.6 Construction Materials of High Temperature Processes 14 2.1.7 Steel Industry’s Challenges 14 2.1.8 Environmental Effects of the Metallurgical Industry 15 2.2 University Courses Held by the Laboratory (The New Study System) 15 2.2.1 Introduction to Process Engineering 15 2.2.2 Thermodynamic Equilibria 16 2.2.3 Structure of Solid Materials 16 2.2.4 Thermodynamics of Pyrometallurgical Solutions 16 2.2.5 Thermodynamics of Hydrometallurgical Solutions 16 2.2.6 Surfaces and Phase boundaries in Pyrometallurgy 17 2.2.7 Melting and Solidification 17 2.2.8 Oxidation and Reduction in Pyrometallurgy 17 2.2.9 Slag and Slag Formation in Pyrometallurgy 17 2.2.10 Laboratory Exercises of Metallurgy 18 2.2.11 Environmental Load of Metallurgical Industry 18 2.2.12 Seminar in Metallurgy 18

3 RESEARCH ACTIVITIES 19 3.1 Reduction metallurgy 19 3.1.1 Development of the Steel Belt Sintering Technology for Ferroalloys11 19 3.1.2 Stabilised Iron Making Production 20 3.1.3 FunSmart-Functional Smart Materials for the Blast Furnace 21 3.1.4 Coke: The Behaviour and Properties of Coke in a Blast Furnace and in a Cupola Furnace 22 3.1.5 Phase Transformations in Metallurgical Coke 24 3.2 Refining metallurgy 26 3.2.1 Metal: Increasing Efficiency of the Decarburization in the Last Stage of the AOD-process 26 3.2.2 Vista: CFD-Thermochemical Model for Gas-to-liquid Blow Reactor 27 3.2.3 The Lifespan of Refractory Lining and the Properties of the Slag in Steelmaking Converter, KOVUKE 28


Page

3.2.4 High Quality Steel Production by Modern Process Metallurgy – VAATIVA 28 3.2.5 Hot-Link - Product Driven Metallurgy 29 3.2.6 Electromagnetic Forces in Melts 30 3.2.7 Electromagnetic Forces in Melts 31 3.3 Environmental research 32 3.3.1 CIRU – Centre: Today’s Residues are Tomorrow’s Products. 32 3.3.2 POHA Control Removals Generated in Harjavalta Smelter and Pori Refinery 33 3.3.3 ReGenGas 34

4 RESEARCH DEVICES AND ANALYTIC INSTRUMENTS 35 4.1 High-temperature Devices 35 4.1.1 DSC-TGA-MS 35 4.1.2 DTA-TGA 35 4.1.3 TGA 35 4.1.4 High Temperature Viscometer 35 4.1.5 Finger Test Device 35 4.1.6 Optical Dilatometer 36 4.1.7 Gradient Furnace 36 4.1.8 Pressure Furnace 36 4.1.9 High Temperature microscope stage 36 4.1.10 Blast Furnace Gas Phase Simulator 36 4.1.11 High Speed TGA 36 4.1.12 Induction Furnace 37 4.1.13 Chamber Furnace 37 4.2 Other Devices and Tools 37 4.2.1 Watermodels 37 4.2.2 Computational Fluid Dynamics Software 37 4.2.3 Thermodynamic Calculation Programmes 37 4.2.4 Gas Chromatograph 37 4.2.5 Microscopes 37 4.2.6 Materialographic Surface Preparation of Solid Materials 38 4.3 Other Available Facilities 38

5 PUBLICATIONS 2004 39 5.1 Papers 39 5.2 Conferences, Seminars and Symposiums 39 5.3 Reports 41

6 THESIS 42 6.1 Diploma Engineer Theses (Master of Science in Technology) 42

7 CONFERENCE VISITS 43

8 CONTACT INFORMATION 45


1 LABORATORY STAFF AND STUDENTS

Academic StaffHärkki, Jouko D.Sc. (Tech.), Professor, Head of the Laboratory, Senior Scientist

Fabritius, Timo D.Sc. (Tech.), Senior Researcher

Taskinen, Pekka D.Sc. (Tech.), Docent in Thermodynamics, Outokumpu Research Oy, Pori

Seppänen, Matti D.Sc. (Tech.), Docent in Process Metallurgy, Rautaruukki Steel, Raahe

Heinänen, Kyösti D. Phil (Geol Min.), Docent in Mineralogy, Rautaruukki Steel, Raahe

Jonsson, Lage D.Sc. (Tech.), Docent in Macro Modeling, Luleå , Sweden

Dahl, Olli D.Sc. (Tech.), Docent in Environmental Engineering, Helsinki University of Technology

Heikkinen, Eetu-Pekka Lic. (Tech.), Senior Assistant

Himanka, Tuomas Student, Part-time Teacher

Paananen, Timo M.Sc. (Tech.), Assistant

Luomala, Matti D.Sc. (Tech.), Part-time Teacher

Heino, Jyrki Lic (Tech.), Part-time Teacher

Hekkala, Lauri M.Sc. (Math.), Part-time Teacher

Kokkonen, Tommi M.Sc. (Chem.), Part-time Teacher

Makkonen, Hannu M.Sc. (Geol Min.), Part-time Teacher

Mattila, Riku M.Sc. (Tech.), Part-time Teacher

Tanskanen, Pekka M.Sc. (Geol Min.), Part-time Teacher

Ikäheimonen, Topi M.Sc. (Tech.), Part-time Teacher

Leinonen, Virpi M.Sc. (Tech.), Part-time Teacher

Angerman, Mikko Student, Part-time Teacher


Teachers from the IndustryHooli, Paavo M.Sc. (Tech.), Part-time Teacher, Outokumpu Stainless Oy, Tornio

Petäjäjärvi, Marko M.Sc. (Tech.), Part-time Teacher, Outokumpu Stainless Oy, Tornio

Päätalo, Mika M.Sc. (Tech.), Part-time Teacher, Outokumpu Stainless Oy, Tornio

Vaara, Niina M.Sc. (Tech.), Part-time Teacher, Outokumpu Stainless Oy, Tornio

Co-lecturers: Researchers from the laboratory, Rautaruukki Steel and Outokumpu Stainless

ResearchersAngerman, Mikko Student, Project Manager

Fabritius, Timo D.Sc. (Tech.), Senior Researcher, Research Manager

Gornostayev, Stanislav Ph.D. (Geol. Min.)

Heikkinen, Eetu Lic.Sc. (Tech.), Senior Assistant

Heino, Jyrki Lic.Sc. (Tech.), Doctoral Thesis Worker

Hekkala, Lauri M.Sc. (Math.)

Holappa, Sanna M.Sc. (Tech.)

Huttunen, Satu M.Sc. (Chem.)

Ikäheimonen, Topi M.Sc. (Tech.)

Isokääntä, Simo M.Sc. (Tech.)

Kärnä, Aki Researcher

Leinonen, Virpi M.Sc. (Tech.)

Luomala, Matti D.Sc. (Tech.), Project Manager

Makkonen, Hannu M.Sc. (Geol.Min.), Project Manager

Mattila, Olli M.Sc. (Tech.), Project Manager

Mattila, Riku M.Sc. (Tech.)

Paananen, Timo M.Sc. (Tech.), Project Manager

Petäjäjärvi, Marko M.Sc. (Tech.)

Pääkkönen, Juha M.Sc. (Tech.)

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Pyykkänen, Juha M.Sc. (Tech.)

Rantakeisu, Pauliina M.Sc. (Tech.)

Riipi, Jaana M.Sc. (Tech.)

Tang, Yong D.Sc. (Tech.)

Tanskanen, Pekka M.Sc. (Geol.), Project Manager

Tuominen, Petri M.Sc. (Tech.)

Vaara, Niina M.Sc. (Tech.)

Valo, Jenny M.Sc. (Tech.)

Virtanen, Esa M.Sc. (Tech.), Manager

Research AssistantsAntila, Antti Student

Pitsinki, Anna-Leena Student

Diploma Thesis Workers Kangas, Ossi Student

Karppinen, Anni Student

Mansikka, Jukka Student

Pieskä, Vesa Student

Pyykkönen, Juha Student

Rytioja, Petri Student

Tarkka, Terttu Student

Tuominen, Petri Student

Technical StaffKokkonen, Tommi M.Sc. (Chem.), Researcher

Mattila, Riku M.Sc. (Tech.), Laboratory Manager

Penttinen, Jorma Special Laboratory Technician, part-time

Virkkala, Jouko Special Laboratory Technician

ANNUAL REPORT 2005 11

AdministrationZinovjev, Berith Project Secretary, Financial Manager

Heikkinen, Kaisa Secretary, Web-master, part time

Postgraduate StudentsHeikkinen, Eetu-Pekka

Heino, Jyrki

Huttunen, Satu

Kivilompolo, Laura

Kokkonen, Tommi

Leinonen, Virpi

Leinonen, Mervi

Makkonen, Hannu

Mattila, Olli

Paananen, Timo

Petäjäjärvi, Marko

Riipi, Jaana

Tanskanen, Pekka

Virtanen, Esa

New students from 31.10.2005 Dunder, Marko

Haapakangas, Juho

Hakkarainen, Ville

Helkomaa, Jussi

Hulkkonen, Jussi

Karassaari, Olli-Pekka

Pekkala, Olli

Peuranen, Eliisa

Ruokanen, Jussi

Savolainen, Jari

Syrjänen, Antti


2 EDUCATIONAL ACTIVITIESEetu-Pekka Heikkinen

The new study system based on the Bologna Declaration was implemented into the academic education in 2005. In the Department of Process and Environmental Engineering this lead to some considerable changes, the most noticeable being new ECTS points (instead of old credits), a new study system based on two degrees (3 years - B.Sc.Eng. and 2 years - M.Sc.Eng.) and some major changes in the courses organised by the department. This meant that the education held by the Labora-tory of Process Metallurgy also experienced significant alterations. Since there were changes in nearly every course of metallurgy, it was considered to be necessary to present both the old and the new courses in this chapter.

However, the primary goals of the Laboratory of Process Metallurgy were not changed even though the courses are now organised in a new - and hopefully more meaningful - way. The primary goal is still to educate people with master’s and doctoral degrees (M.Sc.Eng. and D.Sc.Tech.) into the service of the metallurgical industry. As a part of the Department of Process and Environmental Engineering, the laboratory also organizes its education in a way that serves the educational objectives of the whole department (i.e. to understand and to control the phenomena occuring in the industrial processes). Therefore because of this it is not the laboratory’s only goal to teach people to understand the metallurgical processes of iron, steel and ferroalloys production as thoroughly as possible, but it is equally important to give students different viewpoints and perspectives to the phenomena and problems concerning metallurgical processes, as well as other challenges which a freshly graduated M.Sc.Eng. may encounter in his or her future career. This means that the students have the abilities to understand, model and control the phenomena inside the processes no matter what the process in question is.

Organised planning of the education has also been noticed since the Department of Process and Environmental Engineering has been credited as a national high quality teaching unit by The Finnish Higher Education Evaluation Council since 2004.

ANNUAL REPORT 2005 1�

2.1 UNIVERSITY COURSES hELD BY ThE LABORATORY ACCORDINg TO ThE OLD STUDY SYSTEm

2.1.1 metallurgical ProcessesMetallurgical processes is the only course of the old system which is still organ-ised (until 2006). The aim of the course is to teach students the fundamentals of metallurgical unit operations and metal production in Finland as well as the basics of thermodynamics and its applications in metallurgy. Some environmental aspects are considered too. Although the emphasis of the laboratory’s education is on the production of iron, steel and ferroalloys, the production of other metals (e.g. copper, nickel, zinc and aluminium) is also considered during this course.

The course is carried out with lectures, exercises and an industrial excursion which in 2005 was directed at Outokumpu’s stainless steel works in Tornio. The course was lectured by assistant Timo Paananen (M.Sc.Eng.) and part-time teacher Tuomas Himanka (student of process metallurgy). Additional lectures were held by professor Jouko Härkki (D.Sc.Tech.) and researcher Jyrki Heino (Tech.Lic.).

2.1.2 metallurgical ThermodynamicsThis course was organised in 2004-05 for the last time. In 2005-06 it was divided into two parts: Thermodynamics of pyrometallurgical solutions and Thermodynamic of hydrometallurgical solutions.

The aim of the course was to equip the students with tools that are needed while examining the phenomena inside metallurgical processes in the forthcoming courses. After this course the students were required to have a sufficient knowledge of physical chemistry for thermodynamic calculations which involve gas and liquid (slag and metal) phases. The most important topics were thermodynamics of solutions, phase diagrams and the use of commercial software in thermodynamic equilibria calculations.

The course was lectured in 2004-2005 by senior assistant Eetu-Pekka Heikkinen (Tech.Lic.) and part-time teacher Maija Kärkkäinen (M.Sc.Eng.).

2.1.3 Theory of Pyrometallurgical ProcessesThis course was no longer lectured in 2005. The main contents of this course are in the new study system presented in the courses of Surfaces and Phase Boundaries


in Pyrometallurgy, Melting and Solidification, Oxidation and Reduction in Pyrometal-lurgy and Slags and Slag formation in Pyrometallurgy.

2.1.4 Laboratory Exercises in Process metallurgyThe purpose of the course is to teach students how experimental laboratory scale research is carried out by using the experimental equipment at the university and industry’s research centers. In addition to this, some safety aspects are considered during the lectures. In 2006 the course will be replaced by the course of Laboratory Exercises of Metallurgy. The content of the course will remain the same.

In 2005 the course was lectured by senior researcher Timo Fabritius (D.Sc.Tech.), researcher Tommi Kokkonen (M.Sc.Chem.) as well as chief engineer Riku Mattila (M.Sc.Eng.). The exercises were supervised by researchers Timo Paananen (M.Sc.Eng.) and Timo Fabritius. The course also contained two industrial excursions which were directed at Rautaruukki’s and Outokumpu’s steel works in Raahe and Tornio.

2.1.5 Casting and SolidificationThis course was no longer lectured in 2005. The main contents of this course are in the new study system presented in the course Melting and Solidification.

2.1.6 Construction materials of high Temperature ProcessesThis course was organised in 2005 for the last time. The course was focused on ceramic refractory and insulation materials and their use as construction materials in metallurgy and other high temperature processes. The aim of the course was to present different kind of refractory materials, their physical and chemical properties as well as interaction mechanisms between refractories and metallurgical melts (slag and metal).

The course was lectured in 2005 by professor Jouko Härkki (D.Sc.Tech.).

2.1.7 Steel Industry’s ChallengesThis course was organised in 2005 for the last time and it is now replaced by the course of Environmental Load of Metallurgical Industry.

The aim of the course was to represent metallurgical processes and industry as a part of a larger economic-technical environment in which environmental aspects


are also considered. The contents featured e.g. main ideas of technology roadmaps, challenges of metallurgical research and development, review of development state of alternative metallurgical processes, steel industry’s effects on the environment and visions of future business environment of the steel industry.

In 2005 the course was co-ordinated by researcher Matti Luomala

(D.Sc.Tech.) and lectured by several lecturers from the laboratory and the industrial field (Jouko Härkki, Seppo Haimi, Marko Mäkikyrö, Veikko Heikkinen, Mikko Angerman, Toni Hemminki, Matti Seppänen, Kyösti Karjalahti, Mikko Korteniemi). The profitability calculation exercises were supervised by docent Matti Seppänen (D.Sc.Tech.) from Rautaruukki. The use of visiting lecturers ensures that the contents of the course are always updated and close to practice.

2.1.8 Environmental Effects of the metallurgical IndustryIn the old study system this course was organized for the students of industrial environmental engineering. In the new study system it is replaced by the course of Environmental Load of Metallurgical Industry which is directed also to the students of process metallurgy. This course was not organised in 2005.

2.2 UNIVERSITY COURSES hELD BY ThE LABORATORY ACCORDINg TO ThE NEW STUDY SYSTEm

2.2.1 Introduction to Process EngineeringThis course was organised in 2005 for the first time and it is the first course of proc-ess engineering for all the students of process and environmental engineering. The aim of the course is to help the students to understand the essential phenomena in industrial processes in a conceptual level and to know how to associate these phe-nomena to the industrial unit processes. In addition, the terminology of the process engineering is introduced during the lectures.

The course is divided into four parts. The first one deals with flow chart diagrams, material and mass balances, energy balances, homogenous chemical equilibrium, kinetics of the homogenous reactions and reactors. The second one handles sieving and sorting, mixing, mechanical separation, filtering and grinding. The third part which is lectured by the personnel of the Laboratory of Process Metallurgy concentrates on agglomeration and granulation, structure and properties of the solid materials, phase transitions, oxidation and reduction and heterogeneous phase equilibria. The


last part deals with momentum transfer, heat transfer, mass transfer and catalysis.

The course was organised in 2005 by senior assistant Eetu-Pekka Heikkinen (Tech.Lic.). The lectures were held by the teachers from the laboratories of Chemical Process Engineering (Juha Ahola and Juha Tanskanen), Fibre and Particle Engineer-ing (Jouko Niinimäki and Ari Ämmälä), Process Metallurgy (Timo Paananen, Jouko Härkki and Eetu-Pekka Heikkinen) and Mass and Heat Transfer Engineering (Eero Tuomaala, Kaisu Ainassaari and Riitta Keiski).

2.2.2 Thermodynamic EquilibriaThis course will be organised for the first time in 2006 and it is directed to all the students of process and environmental engineering. The goal of the course will be that the student knows the principles of physical chemistry to be able to study thermodynamical equilibria in industrial processes.

2.2.3 Structure of Solid materialsThis course will be organised for the first time in 2007 and it is directed to all the students of process engineering. The goal of the course will be that the student knows the structure of solid materials and its effects on material properties when processing and/or using the materials. The student also understands the meaning of structural examination when studying properties of solid materials.

2.2.4 Thermodynamics of Pyrometallurgical SolutionsThis is the first course to replace the old course of Metallurgical Thermodynamics. The aim of the course is that the student knows how to examine the pyrometallurgical processes in the perspective of thermodynamics using solution models, equilibrium diagrams and computer-aided thermodynamical equilibrium software.

The course was organised for the first time in 2005 and it was lectured by senior assistant Eetu-Pekka Heikkinen (Tech.Lic.).

2.2.5 Thermodynamics of hydrometallurgical SolutionsThis is the second course to replace the old course of Metallurgical Thermodynamics. The aim of the course is that the student knows how to examine the hydromet-allurgical processes in the perspective of thermodynamics using solution models,


equilibrium diagrams and computer-aided thermodynamical equilibrium software.

The course was organised for the first time in 2006 and it was lectured by senior assistant Eetu-Pekka Heikkinen (Tech.Lic.).

2.2.6 Surfaces and Phase Boundaries in PyrometallurgyThe aim of this course is that students understand the properties of different phases and the interphases (gas-solid, gas-liquid, solid-solid, solid-liquid, liquid-liquid) in the high temperature processes. The course was organised for the first time in 2005 and it was lectured by professor Jouko Härkki (D.Sc.Tech.).

2.2.7 melting and SolidificationThe goal of this course is that the students will understand the melting and solidi-fication phenomena for pure and multicomponent systems. In addition to this, the continuous casting of steels is considered during the lectures.

The course was lectured for the first time in 2005. The lecturers were assistant Timo Paananen (M.Sc.Eng.) and researcher Pekka Tanskanen (M.Sc.Geol.Min.) as well as visiting lecturers from Outokumpu Stainless Oy (Paavo Hooli, Marko Petäjäjärvi, Mika Päätalo).

2.2.8 Oxidation and Reduction in PyrometallurgyThe aim of this course is that students have an understanding about the oxida-tion and reduction reactions in pyrometallurgy. The purpose is to give the student the knowledge about gas-solid and gas-liquid reactions in high temperatures. The contents include reduction of iron oxides, reduction reactions in the blast furnace, pyrocorrosion, oxidation and reduction reactions with liquid steel as well as roasting reactions for sulphides.

The course was organised for the first time in 2005. The lecturer was assistant Timo Paananen (M.Sc.Eng.) with additional lectures given by professor Jouko Härkki (D.Sc.Tech.), researcher Lauri Hekkala (M.Sc.), senior researcher Timo Fabritius (D.Sc.Tech.), docent Matti Seppänen (D.Sc.Tech.) and senior assistant Eetu-Pekka Heik-kinen (Tech.Lic.).


2.2.9 Slags and Slag Formation in PyrometallurgyThis course will be organised for the first time in 2006. The goal of the course will be that the student understands the properties and behaviour of slags in high tem-perature processes, especially in metallurgy. The lectures will be given by professor Jouko Härkki (D.Sc.Tech.).

2.2.10 Laboratory Exercises of metallurgyThis course will replace the old course of Laboratory Exercises in Process Metal-lurgy in 2006. The purpose of the course is to teach students how experimental laboratory scale research is carried out by using the experimental equipment at the university and industry’s research centers.

2.2.11 Environmental Load of metallurgical IndustryThis course replaces the old course of Environmental Effects of Metallurgical Indus-try and it was organised for the first time in 2005. The aim of the course is to give students understanding of the environmental impact of the metallurgical industry and also knowledge about the factors effecting environmental impact and its con-trol. The course is implemented as a research seminar to which the students can participate. In 2005 the seminar was the third Nordic Recycling Day that was held in Oulu in November.

2.2.12 Seminar in metallurgyThis course was not yet organised in 2005. In the future it will be organised in co-operation with other units of metallurgy in different Nordic universities (HUT, KTH, LTU, NTNU).


3 RESEARCh ACTIVITIESTimo Fabritius

Main research activities of Laboratory of Process Metallurgy have traditionally fo-cused on the ironmaking and steelmaking processes and phenomena that occur at the high temperature processes. The research actions in the Laboratory of Process Metallurgy have divided into three divisions: reduction metallurgy, refining metallurgy and environmental engineering at high temperature processes. During the last few years research activities on the field of high temperature chemistry of recycling and waste treatments have increased. During 2005 about a third of total research volume concentrated on recycling and industrial residual utilisation.

Total funding of the laboratory was balanced on the level of 1.5 M euro per year. The main part of funding is naturally directed at research activities. The laboratory employs about 30 personnel on average including diploma thesis workers. In practice, almost all research activities are based on co-operation with industrial partners. The role of Tekes (National Technology Agency of Finland) as a financer was large although the laboratory has also acquired more funding from Academy of Finland as a form of research projects and Graduate School vacancies. Furthermore, short-term service research directly to the industry increased during the last year.

3.1 REDUCTION mETALLURgY

3.1.1 Development of Steel Belt Sintering Technology for Ferroalloys II

Project Manager: Timo FabritiusResearcher: Lauri HekkalaResearch Assistant: Juha Pyykkönen

The aim of the project was to develop a detailed mathematical model that predicts gas flow, temperature and composition distribution in the bed of chromite pellets and the atmosphere. Furthermore, the purpose was that the effects of operational parameters as well as constructional changes on belt sintering process can be simu-lated by the model. Computational fluid dynamics programme Fluent was used in the flow simulations.

Many different reactions (oxidation of coke, oxidation and reduction of iron cations

ANNUAL REPORT 2005�0

in chromite) in the chromite pellets set hard challenges for the relevant descrip-tion of the sintering process. Sub-models were developed and implemented in the calculations to described reactions. Sub-models were developed first for pellets scale and after that extrapolated for pellet bed. Study was focused on three main reactions: 1) drying of pellet, 2) oxidation and reduction behaviour of iron cations in chromite and 3) oxidation of coke.

3.1.2 Stabilised Iron making Production

Control and Optimization of Efficiency and Energy Consumption by Burden Material. (STARA)Project Manager: Timo PaananenResearchers: Timo Paananen, Pekka Tanskanen, Eetu-Pekka HeikkinenTechnician: Tommi Kokkonen

The purpose of the project was to discover the reason for seasonal variation of iron making production and to develop a strategy for eliminating that using the research based on experimental study and phenomena. The contribution of the Laboratory of Process Metallurgy concentrates mainly on quality of sinter and the factors ef-fecting that. That includes phase transformations and oxidation/reduction reactions of minerals forming/formed in sinter.

The behaviour of sinters most important minerals during sintering variation of bacisity and impurity content will be defined in the research. In addition, reduction behaviour of the minerals will be studied.

Tools for the study are thermodynamical calculations (FactSage) and experimental sintering and reduction tests. Analyzing is made using optical and electron micros-copy (SEM-EDS + EPMA) and X-ray diffractometer (XRD). Pilot-experiments will be executed by Ruukki. Ruukki is acting as an industrial partner and financier in this project. Duration time of the project is 1.3.2005 – 28.2.2007.


3.1.3 FunSmart - Functional Smart materials for the Blast Furnace

Project Manager: Pekka TanskanenResearcher: Pekka Tanskanen

FunSmart Project, 1.1.2004-31.12.2007, is funded by The Academy of Finland. The project aims to decrease the problematic alkali circulation phenomena in the blast furnace by selective capture of the alkalis into the crystal lattices of stable mineral phases inserted as a part of iron burden materials. A hydrothermally modified in-dustrial by-product is tested as the alkali capturer. The second target is to increase the alkali retention capacities of the liquid slags evolving in the blast furnace.

The conventional mineralogical and metallurgical research methods and equipment (optical microscopy, SEM, XRD, XRF, DTA, TGA, optical dilatometer, and thermody-namic calculation) will be used together with newly developed equipment, called blast furnace gas phase simulator (BFS). The latter piece of equipment makes it possible to expose both solid and liquid materials to contemporaneous or separated alkali and sulphur gas attack in a controlled T-t-gas composition conditions.

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3.1.4 Coke: The Behaviour and Properties of Coke in a Blast Furnace and in a Cupola Furnace

Project Manager: Olli MattilaResearcher: Stanislav Gornostayev 1.1.2003-31.7.2004Research Assistant: Tommi Kokkonen

This project was started on 1.5.2002 and ended 31.7.2005.

The main target of this project was to increase coke production and improvement of cost-effectiveness of coke production and decrease the reducing agent (coke, oil) consumption in BF. Additional targets were to increase knowledge in Finland and in Northern countries in the field of coke structures and the behaviour of coke in BF and to develop methods to analyse coke behaviour straight from the process data.

Laboratory of Process Metallurgy’s focus was to study the structural changes of coke and the main factors causing those changes as the coke moves downwards in the BF process. Necessary methods were developed in the project and used to produce information of the most important phenomenon coke faces in the upper part of blast furnace process. Samples obtained via tuyere drilling experiments were studied in detail and compared to the feed material. Despite being the very first coke related research project in the Laboratory of Process Metallurgy novel information about coke reactions and phenomena in coke faces in the BF process was created. Two laboratories and two industrial partners were involved in the project: Labora-tory of Process Metallurgy, Laboratory of Heat Engineering, Rautaruukki Oyj and Paroc Group Oyj respectively. Coke research in Sweden was monitored through Jernkontoret’s meetings.


Picture: Simulator GUI.

Picture: Coke intrinsic reactivity setup.


3.1.5 Phase Transformations in metallurgical CokeResponsible Scientist: Stanislav Gornostayev, PhDThe interdisciplinary (metallurgy - mineralogy) project is funded by the Academy of Finland (08.2004 - 07.2006) and includes laboratory studies and theoretical inves-tigations of natural and synthetic phases found in samples of feed and tuyere coke from Ruukki Steel Works, Raahe, Finland. Detailed laboratory studies include EDS and WDS (microprobe) analyses, optical and electron microscopy. The research is focused on chemical and physical changes of mineral phases under coking and blast furnace conditions and on the influence of these changes on properties of coke.

Results:

At coking temperatures, pure SiO2 has several polymorphs and transformations from one to another are accompanied by volume changes in the mineral matter that can cause the formation of cavities and cracks in a coke matrix. These can weaken the coke physical strength and lead to a higher circulation of gases within coke pieces. The grain size of the primary quartz crystals in a coal blend is also important for the estimation of coke strength: the larger the crystals that occur in a coal, the larger the cavities and cracks that will ensue. The occurrence of any given SiO2 polymorph indicates the temperature of its formation and can be used to correlate other changes in coke-forming compounds with certain temperatures. A high amount of free quartz in a coal blend can be considered a negative factor for coking (Gornostayev, Kerk-konen and Härkki 2006).

“The processes involved in the formation of glassy aluminosilicate spherules and irregular segregations of slag are not destructive with respect to a coke matrix, but further heating of these compounds can lead to the appearance of crack-generating crystalline phases. Data on the expansion properties, temperature of formation and crystalline features of these phases, including those of refractory ones, can be em-ployed to estimate coke strength during coking and the coke consumption processes. A high concentration of Al- and especially Mg-bearing compounds in coking coals in particular will detract from coke strength, since it may lead to the crystallization of spinel, accompanied by the formation of cracks in the coke matrix” (Gornostayev and Härkki, 2006).

Publications and presentations relevant to the project:


Picture: Crystallization of spinel from spherule and formation of crack in the coke matrix.

Picture: The model for evolution of mineral particles with formation of spherules, crystallization of spinel and formation of cracks in the coke matrix.

Gornostayev S. (2004) Mineral matter in coke. Blast Furnace Seminar, March 30-31, 2004, University of Oulu, Finland, http://cc.oulu.fi/~pometwww/BF04/

Gornostayev S., Kerkkonen O. and Härkki J. (2005) Occurrence and composition of some mineral phases in the tuyere coke. ISIJ International, 45, 1, 1-7.

Gornostayev S. and Härkki J. (2005) Spinel crystals in tuyere coke. Metallurgical and Materials Transactions, 36B, 2, 303-305.

Gornostayev S. and Härkki J. (2006) Mineral matter crystallization and crack forma-tion in tuyere coke. Fuel, 85, 7-8, 1047-1051.

Gornostayev S., Kerkkonen O. and Härkki J. (2006) Importance of mineralogical data for influencing properties of coke: A reference on SiO2 polymorphs. Steel Research International (accepted).


3.2 REFININg mETALLURgY

3.2.1 mETAL: Increasing Efficiency of the Decarburization in the Last Stage of the AOD-process

Project Manager: Timo FabritiusResearchers: Yong Tang and Aki Kärnä

The aim of the project is to decrease tap-to-tap time of AOD-process by intensifying blowing especially at the final stage of decarburization period. Effects of operational parameters as well as constructional changes on AOD process can be simulated by the model.

The study includes theoretical calculations, numerical fluid flow simulations and proc-ess tests. Fluid flow simulations are made by Fluent programme and thermodynamic data will be implemented into the simulation model. The model will be verified by process tests and water model tests. Water model is used for validating behaviour of gas plume in liquid bath during high-intensity gas injection.

The project is funded by Tekes and Outokumpu Stainless Oy. Research will be done in co-operation with Outokumpu Stainless Oy. This three-year project will continue until the end of 2006.

Picture: Penetration of gas jet into the water bath with 120l/min gas injection rate.


3.2.2 VISTA: CFD-Thermochemical model for gas-to-liquid Blow Reactor

Project Manager: Timo FabritiusResearcher: Jaana Riipi

This is the part of the “Multi-phase Chemistry in Process Simulations” project, which is a multi-partner National Agency of Technology funded project. The aim of this part project is to minimise consumption of argon in AOD converter blowing with the production of different steel grades. This will be made by optimising the switch point from nitrogen to argon during decarburisation period. The model pursues an economical way to optimize processing practices and to allow improved control of nitrogen content in liquid steel before tapping.

Several phenomena will be investigated:

- heat transfer between gas and molten steel - thermodynamic conditions at the interface between bubble and liquid steel - the influence of flow turbulence on the species transfer and gas dissolution - bubble sizes and interface areas - pressure inside bubbles - flow pattern in the liquid steel bath- bioreactors: reactor

Picture: Mole fraction and proportional surface area of steel melt surface phase at T=1973 K with [O]=400ppm ja [S]=250ppm.


The project is funded by Tekes and Outokumpu Stainless Oy. Research will be done in co-operation with Outokumpu Stainless Oy. This three-year project will continue until the end of 2007.

3.2.3 The Lifespan of Refractory Lining and the Properties of the Slag in Steelmaking Converter, KOVUKE

Project Manager: Matti LuomalaResearcher: Marko Petäjäjärvi

KOVUKE started on the 1.10.2003 and will be concluded on the 30.6.2006. The project is funded by the TEKES (National Technology Agency of Finland) and Rau-taruukki Oyj. Additional partners in KOVUKE are Outokumpu Stainless Oyj and Bet-Ker Oy. Multiple goals have been set for the project; 1) to extend significantly the lifespan of refractory linings of Rautaruukki’s converter vessels, 2) to ensure work-able bottom stirring for the whole campaign length, and 3) to find out optimal slag composition for the slag splashing operation. Versatile means will be applied in order to achieve the above-mentioned targets; laboratory experiments, optical dilatometer, viscosimeter, thermodynamic equilibrium calculations etc. Sticking characteristic of the slag is studied by so-called dipping method. The method enables multiple dip-ping and varying temperature (both slag and specimen), atmosphere, dipping time and dipping interval

3.2.4 high Quality Steel Production by modern Process metallurgy – VAATIVA

Project Manager: Matti LuomalaResearchers: Petri Tuominen and Sanna Holappa

VAATIVA is part of the national technology programme NewPro - Advanced Met-als Technology - New Products 2004 – 2009. The project is funded by Rautaruukki Oyj, Oy Ovako Ab, Outokumpu Stainless Oy and TEKES (National Technology Agency of Finland). The project started on the 1.11.2004 and will be concluded on the 31.12.2007.

The goal of this project is to enable new steel products to be produced that meet high demands on quality by exploiting the technology of modern process metallurgy


to its limit. Activities are focused on making steel production more cost effective, improving quality assurance, and increasing the reliability of delivery. The project comprises more than 10 related tasks, each having a goal specific to the participat-ing company. Two subprojects are going on in the Laboratory of Process Metallurgy viz. 1) physical model study of Rautaruukki’s mould flows and wave motion and 2) improvement of inclusion control in Outokumpu Stainless’ practice.

1) Water Modelling of Slab Casting MouldThe purpose of physical model study is to investigate the effect of submergence depth of SEN (Submerged Entry Nozzle) and the width of mould on the flow behaviour in the mould and wave motion on the surface. Secondly, this study aims to clarify the effect of argon gas on fluid flow in the SEN and mould. Furthermore, different SEN designs and pressure distribution in SEN will be studied. The Experiments will be carried out with a 1:2 water model of the slab casting mould in Rautaruukki’s smelting plant.

2) Improvement of Surface Quality and Other Properties of Special Stainless Steels The purpose of this subproject is 1) to study the effect of aluminium alloying on inclusions and castability, 2) make the production of titanium stabilised steels and inclusion control more effective, and 3) to investigate the factors contributing to the MgO content in inclusions. Thermodynamic calculations by commercial software (FactSage) will be done to predict the formation of aluminium and titanium inclusions (mostly oxides and nitrides). Also, the effect of MgO will be studied.

3.2.5 hOT-LINK - Product Driven metallurgyProject Manager: Matti LuomalaResearcher: Simo Isokääntä

Hot-Link is a 3-year project which started on 1st of January 2004 and will end on 31st of December 2007. The project is part of the national technology programme “New Pro” and it is financed by TEKES (National Technology Agency of Finland), Ruukki, Outokumpu Stainless and Imatra Steel.

The properties of molten metal and casting procedures directly influence final product quality and the satisfaction of customer requirements.

ANNUAL REPORT 200530

The aim of the project is to develop new computational tools in order to improve the properties and quality of various types of steel. The goal is to model processes and phenomena and to integrate these models to create real-time on-line models, which will be integrated into existing predictive methods. Adapting the results of the project to the steel industry processes will improve accuracy and cost-effectiveness of the processes. The results will be used to develop new steel grades and prod-ucts. Examples of these products and steel grades are ultra clean silicon deoxidated spring- and bearing steels, deformable low silicon steels to automotive application and Ti-alloyed high temperature corrosion proof steels.

The interest of the research at the University of Oulu has been focused on the estimation of inclusion behavior at the interfaces (slag-steel and steel-refractory) using mathematical modeling and laboratory scale experiments. Also influences of electrical charges to inclusion separation will be examined.

Partners: Helsinki University of Technology Laboratories of Metallurgy and Materials Processing, VTT Processes, Ruukki (Rautaruukki Oyj), Outokumpu Stainless, Imatra Steel Oy Ab and TEKES (National Technology Agency of Finland).

The duration time of the project is about three years and it will be finished at the end of 2007.

3.2.6 Electromagnetic Forces in melts Project Manager: Matti LuomalaResearchers: Sanna Holappa, Topi Ikäheimonen, Olli Mattila, Riku Mattila

On April 2003 a new branch of research was started in the Laboratory of Process Metallurgy. Electromagnetic Forces in Melts was a 3-year project, where the aim was to understand the possibilities of applying electric and magnetic forces to steelmaking. The project concentrated on electro-wetting and thermo voltage tests as an electric phenomena and inclusion control as a magnetic phenomena.

In discussion about electro-wetting, it was shown that when applying potential to synthetic ladle slag the contact angle with platinum surface can be changed. The effect of alternating and direct voltages ranging from 0.25 to 10 V was investigated.

ANNUAL REPORT 2005 �1

Picture: Induced force field and generated flow pattern of liquid tin in the one half of crucible with coil current of 700 A and with 3 kHz coil frequency.

3.2.7 Electromagnetic Forces in melts

Reseach Visit to Tohoku UniversityTopi IkäheimonenDuring the year 2005 an 11 month research visit to the Graduate School of Envi-ronmental Studies at Tohoku University was realized. There, under kind supervision of professor Taniguchi, the basics of EPM and magnetic phenomena were studied.

The research done in the Taniguchi Laboratory consisted of theoretical studies of fluid flow calculations in inductively stirred metal baths and laboratory experiments of electromagnetic separation of silicon carbide particles in a liquid tin system. In the numerical calculations it was shown that the coil current and used frequency had a great influence on the metal bath system basically allowing the possibility to choose desired fluid velocity and flow pattern for a given situation. The visit was funded by TEKES (National Technology Agency of Finland).


3.3 ENVIRONMENTAL RESEARCH

3.3.1 CIRU – Centre: Today’s Residues are Tomorrow’s Products.

Manager Esa VirtanenThe Laboratory of Process Metallurgy have established CIRU - Centre (Centre for Industrial Residue Utilisation) in the year 2004 together with the Laboratory of Water Resources and Environmental Engineering and with the Laboratory of Environmental Technology within process industry from Helsinki University of Technology.

CIRU – Centre is an umbrella organisation which includes all our environmental projects. The main focus of CIRU is to gather information, coordinate research and be a link between environmental authorities, industry and end users. In the beginning our research is focused on pyro- and hydrometallurgical residues and utilization of those. In the future we are going to expand our action to all the fields of process industry by covering all kind of inorganic residues. CIRU – Centre has about 10 researchers working in environmental research projects.

Our first year (2005) was time for activity growth. We have extended our action wider in the process industry mainly to roasting processes. CIRU - Centre participated also in establishing new material efficiency agency (FRAME) in Finland, of which start up funding was applied from EU’s Life-funding. Other participants of FRAME -project were Motiva Oy, Lahti Science and Business Park Ltd, Efeko Ltd, Finnish Environ-ment Institute, University of Oulu and Wuppertal Insititute for Climate, Environment Energy from Germany.

Today’s residues are tomorrow’s products.

ANNUAL REPORT 2005 ��

3.3.2 POhA Control Removals generated in harjavalta Smelter and Pori Refinery

Project Managers: Professors Jouko Härkki and Olli Dahl (Helsinki University of Technology)Researchers: Virpi Leinonen, Jyrki Heino and Eetu-Pekka Heikkinen (Part-Time)Diploma Thesis Worker: Anna-Leena Pitsinki Diploma Thesis Supervisors: Doc. Kauko Kujala and Prof. Jouko Härkki

In the study, both national and EU waste and product policy targets were analysed so that all the copper and nickel slags will fulfil the regulation from the authority. Because of the equal EU product policy it was also utilised for the iron sand exami-nation experiences from Boliden Rännskär copper plant.

The main target was to find out means of how to remove substances, which can prevent reuse of slags to increase the raw material efficiency of copper and nickel manufacture. It was also an aim to find new feasible utilisation targets in the conven-tional usage environment in the area of earthworks, road construction and coating of the dumping areas, etc. Also attempts were made to discover ways of improving the nickel slag quality already utilised in sand blasting and roofing felt industry.

Personnel working with research, development and production have participated in the survey in a very fruitful way. Especially important was the contribution of the operating staff, because the utilisation of slags as a part of the production must be integrated in an optimal way within the nickel and copper production.

The main experimental work was done to determine the technical properties of water-cooled and granulated nickel slag. The assessment of environmental applicability of nickel slag was also studied, based on previous tests. The thermodynamic calcula-tions were applied to simulate the gas phase reactions of harmful components in the gas cooling system of a copper smelter. During the study of harmful compounds, a large dust sampling campaign was also executed in the copper smelter.

The project was introduced in many internal and external meetings and seminars. The results of the study were reported in ten internal reports and in a diploma thesis. At the end of the project all the results were also collected into two final reports.


Partners in the project were Boliden Harjavalta Oy, Outokumpu Research Centre and Environmental Technology within Process Industry at Helsinki University of Technology. The project was financed by Boliden Harjavalta Oy and TEKES (National Technology Agency of Finland). The duration of the project was about two years and it concluded at the end of 2005.

3.3.3 Regengashybrid Reformer Setup to Recycle and Regenerate greenhouse gases for Reduction and Combustion ProcessesProject Manager: Jari Ruuska (PYOS)Researchers: Mikko AngermanResearch Assistant and Other Personnel: Jarmo Murto, Markus Harju

ReGenGas is continuing work done earlier in “CO2H2”-project by trying to verify and validate promising results gained in gas recycling calculations. For the purpose, a novel laboratory test facility is to be built.

Planning and designing of the test equipment was the major activity of the project and lead to an implementation phase at the end of the year. Actual tests are sched-uled to be run in 2006 and reported thereafter. Objectives and expected results include verified design models for the concept as well as simulation models for the system.

Project partners are the Laboratories of Process Metallurgy, Control Engineering and Heat and Mass Transfer from University of Oulu and Laboratory of Heat Technol-ogy from Åbo Akademi. The project will end at the end of 2006. Total budget is 525 000 euro, funded by TEKES (National Technology Agency of Finland), Outokumpu


4 RESEARCh DEVICES AND ANALYTIC INSTRUmENTS AVAILABLE IN ThE LABORATORY OF PROCESS mETALLURgY

4.1 hIgh TEmPERATURE DEVICES

4.1.1 DSC-TgA-mSThe Netzsch models STA 409PC and QMS 403C measures weight change (TGA) and heat flow (DSC) and evaporated gas mass spectrometry (MS) on the same sample at the same time from ambient to 1550 ºC. The device was purchased in 2003.

4.1.2 DTA–TgAThe TA-instruments model SDT 2960 provides simultaneous measurement of weight change and differential temperature on the same sample from ambient to 1500 ºC. The device was purchased in 1996.

4.1.3 TgAThe Device measures weight changes in a material as a function of temperature and time in a controlled atmosphere. The device was built in 1998.

4.1.4 high Temperature ViscometerThe device measures viscosities of melts as a function of shear rate, temperature and time in controlled atmosphere. Device is Haakes model VT550 and the furnace Carbolites model PVT 18/75/350 its maximum temperature is 1750° C. Haake was purchased in 1996 and Carbolite 1999.

4.1.5 Finger Test DeviceThe measurement method is to dip (and rotate) refractory material piece “finger” at constant speed in slag or metal and then measure the corrosion rate and analyze the infiltration. The furnace is a Lenton model CSC 17/90/250 and its maximum temperature is 1700 °C. The furnace was purchased in 1997.


4.1.6 Optical DilatometerThe device indicates material dimension changes as a function of temperature and time in controlled atmosphere. With the device a sessile drop contact angle and all parameters for surface tension calculations can be determinated. The device was built during 1996-1998.

4.1.7 gradient FurnaceThe funace is an Entech model ETF 75/17V with a maximum temperature of 1750 °C. It is a double chamber tube furnace with a maximum tube inside diameter of 200 mm. The purpose of the device is to measure material properties in a control-led temperature gradient. The furnace was purchased in 2000.

4.1.8 Pressure FurnaceThe maximum pressure of the furnace is 10 bar and maximum temperature is 1500 °C. The inner pipe diameter is 90 mm. The furnace was purchased in 2000.

4.1.9 high Temperature microscope StageThe device is Linkam model ts1500, maximum temperature is 1500 °C. The stage was purchased in 2005.

4.1.10 Blast Furnace gas Phase SimulatorThe simulator has programmable time dependent temperature and atmosphere for N2, CO, CO2, H2, H2O, K, S2. gases for the sample point. Sample weight, temperature and gases mass flow controllers data are collected into simple text database. The inner diameter of the steel tube is 90 mm and the maximum temperature is 1150 °C or with ceramic tube up to 1800 °C. The device was built during 2002-2004.

4.1.11 high speed TgA equipped with Land Lancom Series II gas analyzerFurnace reaches 1000 ̊ C in 4 minutes starting from room temperature. Gas analyzer detects CO, CO2, O2 gases. The device was built in 2004.


4.1.12 Induction furnace The induction furnace has a crucible size of 150 ml.

4.1.13 Chamber furnace Nabertherm type HT08/18.

4.2 OThER DEVICES AND TOOLS

4.2.1 WatermodelsThe models visualize phenomenon taking place inside a converter, ladle and continu-ous caster, like steel / slag flow and wearing of refractory materials.

4.2.2 Computational Fluid Dynamics SoftwareThe Fluent and Phoenics programme is for gas and liquid flow model. The Comsol multiphysics programme is for simple model tasks.

4.2.3 Thermodynamic Calculation ProgrammesHSC, Chemsage and Fact Sage programmes are for thermodynamic equilibrium calculations.

4.2.4 gas ChromatographThe device is an Agilents model 6890 with thermal conductivity detector. The device was purchased in 2001.

4.2.5 microscopesAn Olympus polarizing microscope BX51P and Olympus research stereomicroscope SZX9 with DP-12 camera and DP-software. The microscopes were purchased in 2001.


4.2.6 materialographic Surface Preparation of Solid materialsStruers Epovac vacuum impregnation equipment. Grinding and polishing is done with Struers LaboForce-1 and LabPol-1. The ready samples go through ultrasonic cleaning before use. The device was purchased in 2002.

4.3 OThER AVAILABLE FACILITIES

Within the University of Oulu

Department DevicesThe Micromeritics ASAP 2020 Gas sorption analyzer, measures surface area and determinates pore size distribution. A high speed camera Hisis2002. An AAS Perkin Elmer 600 and 4100. A multi-wavelength particle size analyzer, Beckman coulter LS 13320.

Institution of Electron Optics (EOL)The EOL facilities are based on the use of seven instruments: EFTEM, SEM, FESEM, STEM, EPMA, XRD and XRF. They provide three basic kinds of information: images, chemical analyses and crystal structures.

Trace Element LaboratoryPlasma atomic emission spectrometry (DCP-AES, ICP-AES) and plasma mass spectrometry (ICP-MS). These equipment provide chemical analyses of difficult samples.

At Ruukki in Raahe WorksThere is for example XRF, XRD, OES and SEM.

At Outokumpu Stainless in Tornio WorksThere is for example XRF, OES and SEM.


5 PUBLICATION

5.1 PAPERS

Fabritius, Timo Matti Juhani; Kurkinen, P.T.; Mure, P.T. & Härkki, Jouko Vibration of Argon-oxygen Decarburisation Vessel During Gas Injection, Ironmaking and Steelmaking, 2005, Vol.32, No.2, s. 113-119.

Gornostayev, Stanislav & Härkki, Jouko Spinel Crystals in Tuyere Coke. Communications, Metallurgical and Materials Transac-tions. B, 2005, vol. 36, s. 303-305. http://www.tms.org/pubs/journals/MT/MT.html

Gornostayev, Stanislav; Kerkkonen, O. & Härkki, Jouko Occurrence and Composition of Some Mineral Phases in the Tuyere Coke, ISIJ In-ternational, 2005, vol. 45, nro 1, s. 1-7.

Tang, Yong; Fabritius, Timo & Härkki, Jouko Mathematical Modelling of the Argon Oxygen Decarburization Converter Exhaust Gas System at the Reduction Stage, Applied Mathematical Modelling, 2005, vol. 29, s. 497-514.

5.2 CONFERENCES, SEmINARS AND SYmPOSIUmS

Angerman, Mikko Plant wide simulations – an example utilizing multiple software tools, Finnish Automa-tion Society, Simulation in Process Planning- seminar, Helsinki, 7-8 April 2005.

Angerman, Mikko Analysing Material Efficiency and Recycling Scenarios with Factory Simulation Tool, Finnish Forum of Industrial Ecology, seminar, Oulu 2-3 December 2005.

Heikkinen, Eetu-Pekka; Makkonen, Hannu; Heino, Jyrki; Heikkinen, Juha & Seppänen, MattiA computational study on the formation of Zn-, Pb-, Sn-, Cd-, As- and alkali com-pounds while recycling the integrated steel plant dusts and other iron-containing

ANNUAL REPORT 2005�0

residues. International Conference on Clean Technologies in the Steel industry. 6-8 June 2005. Balatonfured, Hungary. OMBKE. s. 112-121.

Heikkinen, Eetu-Pekka; Makkonen, Hannu; Leinonen, Virpi; Paananen, Timo; Virtanen, Esa & Heino, Jyrki. Industrial ecology and carbon steel making - Iron bearing residues as raw materials in carbon steel making. Securing the future - International Conference on Mining and the Environment Metals and Energy Recovery. 27. 6. - 1. 7.2005. Skellefteå, Sweden. s. 380-388.

Ahola, Juha; Heikkinen, Eetu-Pekka; Hiltunen, Jukka; Jaako, Juha; Luhtaanmäki, Saara & Puikkonen, Marita Pedagoginen malli tutkinnonuudistustyölle Oulun yliopiston prosessi- ja ympäristöte-kniikan osastolla. - ReflekTori 2005. Tekniikan opetuksen symposium 20-21.10.2005, Teknillinen korkeakoulu, Dipoli, Espoo, Finland. Sessio 17. Tutkintorakenteen uudis-tuksen malleja ja prosesseja. 2005. s. 1-5. http://www.dipoli.tkk.fi/ok/p/reflektori/php/esitykset_pdf/refl05-s17 jaako.juha.Reflektori2005_1.pdf

Ahola, Juha; Heikkinen, Eetu-Pekka; Hiltunen, Jukka; Jaako, Juha; Luhtaanmäki, Saara & Puikkonen, Marita Tutkinnonuudistustyön organisointi Oulun yliopiston prosessi- ja ympäristötekniikan osastolla. - ReflekTori 2005. Tekniikan opetuksen symposium 20-21.10.2005, Teknillinen korkeakoulu, Dipoli, Espoo, Finland. Teemasessio 10. Opetustyöyhteisön kehittäminen. 2005. s. 1-5. http://www.dipoli.tkk.fi/ok/p/reflektori/php/esitykset_pdf/refl05-s10-jaako.juha.Reflektori2005_2.pdf

Tanskanen P., Makkonen H., Härkki J.Characterization and optimisation of by-products and their properties using applied mineralogy and petrology. Proceedings of The 7th Nordic-Japan Symposium. Science and Technology of Process Metallurgy. Jernkontoret, Stockholm, 15-16 September 2005. 9 pp.


Tanskanen, P. A., and Makkonen H. T, Applied Mineralogy and Petrology – examples of useful methods for slag composi-tion and property design. Proceedings of the 4th European Slag Conference, Oulu, Finland, 20-21 June 2005. 10 pp.

5.3 REPORTS

Tanskanen, A., P., Paananen, T., T., Huttunen, S., M., Härkki, J., J.Panama, Masuunin panosmateriaalien uudenlainen analysointi ja optimointi kustan-nus- ja tuotantotehokkaan raakaraudan valmistamiseksi -projekti, Oulun yliopiston Prosessimetallurgian laboratorion tutkimusosuuden loppuraportti. Oulun yliopisto, Oulu, 98 s.

Ikäheimonen, Topi Sähkömagneettiset voimat sulametallurgiassa. Kirjallisuusselvitys. University of Oulu, Department of Process and Environmental Engineering. Report nro 312. Oulu, 2004. 40 s.

Makkonen, Hannu Tapani & Tanskanen, Pekka AnteroOutokumpu Chrome Oy:n ferrokromikuonan minerologia ja liukoisuusominaisuudet. University of Oulu, Department of Process and Environmental Engineering. Report nro 313. Oulu, 2005. 26 s.

Ylönen, Reeta & Heikkinen, Eetu-Pekka,Vihreä kemia ja kuparin liekkisulatus. University of Oulu, Department of Process and Environmental Engineering. Report nro 314. Oulu, 2005. 25 s.

Fabritius, Timo Reagoivan kaasun puhallus nesteeseen. Kirjallisuusselvitys. University of Oulu, Depart-ment of Process and Environmental Engineering. Report nro 316. Oulu, 2005. 23 s.

Turpeinen, Esa; Mäki, Timo; Angeman, Mikko & Ruuska, JariClosed gas loop principles in reduction and combustion processes. Part I: Gas reforming principles and case studies with steel plant process gases. University of


Oulu, Department of Process and Environmental Engineering. Report nro 317. Oulu, 2005. 85 s.

Fabritius, Timo; Himaka, Tuomas & Kärnä, AkiCO2-injektio NaOH-liuokseen vesimallissa. University of Oulu, Department of Proc-ess and Environmental Engineering. Report nro 319. Oulu, 2005. 25 s.

Pitsinki, Anna-LeenaRaekuonan tekniset ominaisuudet ja ympäristökelpoisuus. Oulun yliopisto, Prosessi- ja ympäristötekniikan osasto, Prosessimetallurgian laboratorio. Oulu 2005. 88 s.

6 ThESIS

6.1 DIPLOmA ENgINEERINg ThESISKangas, Ossi Development of Descaling Practise for Plate

Rolling

Linnala, Kati The Oxidation of Iron in a Chromite Pellet

Mansikka, Jukka Continuous Dust Monitoring of Exhaust Gases

Pieskä, Vesa Valokaariuuni Controlled Utilization of Chemical Energy of Charge in EAF2

Pyykkönen, Juha Formation of Gaseous Pollutants in the Sintering Process of Chromite

Tarkka, Terttu Temperature Modelling for Steel Slabs on Direct Charging

Tuominen, Petri Development of Temperature Control for the Ladle Furnace and Vacuum Treated Heats

Vatanen, Jukka Reduction of Chromite in CO/CO2 Atmosphere


7 CONFERENCE VISITS

Fabritius, Timo4th European Slag Conference of EUROSLAG, - 21 June 2005 in Oulu, Finland

The 7th Nordic-Japan Symposium. Science and Technology of Process Metallurgy. 15-16 September 2005, Jernkontoret, Stockholm, Sweden.

Nordic Waste Recycling Day, 09 November 2005, University of Oulu, Oulu, Fin-land.

Waste Minimization and Utilization in Oulu Region: Drivers and Constraints, RESOPT Closing Seminar, 17 June 2005, University of Oulu, Finland

CIRU-seminaari, 16.03.2005, Oulun yliopisto, Oulu, Finland.

CFD-mallinnus terästeollisuuden tarpeisiin –seminaari, 05.04.2005, Oulun yliopisto, Oulu, Finland.

Suomen teollisen ekologian foorumin –seminaari, Ekotehokkuus teollisuudessa, 1.-2.12.2005, Oulun yliopisto, Oulu, Finland.

Heikkinen, Eetu-PekkaInternational Conference on Clean Technologies in the Steel industry, 6 8 June 2005, Balatonfured, Hungary.

Waste Minimization and Utilization in Oulu Region: Drivers and Constraints, RESOPT Closing Seminar, 7 June 2005, University of Oulu, Finland.

4th European Slag Conference of EUROSLAG, - 21 June 2005 in Oulu, Finland

Securing the Future - International Conference on Mining and the Environment Metals and Energy Recovery, 27.6.-1.7.2005, Skellefteå, Sweden.

UNITECR ’05 - 9th Biennial Worldwide Congress on Refractories. 8-11 November 2005, Orlando, Florida, USA.

Leinonen, Virpi4th European Slag Conference of EUROSLAG, - 21 June 2005 in Oulu, Finland

CIRU –seminaari 16.3.2005, Oulun yliopisto, Oulu, Finland (Oral presentation)

Waste Minimization and Utilization in Oulu Region: Drivers and Constraints, RESOPT Closing Seminar, 7 June 2005, University of Oulu, Finland.

Securing the Future - International Conference on Mining and the Environment


Metals and Energy Recovery, 27.6.-1.7.2005, Skellefteå, Sweden.

Nordic Waste Recycling Day, 09 November 2005, University of Oulu, Oulu, Finland. (Oral presentation)

Analytiikka päivät 14. - 15.11.2005, KETEK, Kokkola, Finland

Suomen teollisen ekologian foorumin –seminaari, Ekotehokkuus teollisuudessa, 1.-2.12.2005, Oulun yliopisto, Oulu, Finland.

Luomala, MattiUNITECR ’05 - 9th Biennial Worldwide Congress on Refractories. 8-11 November 2005, Orlando, Florida, USA.

Mattila, OlliSeminar of High Temperature Properties of Blast Furnace Coke, 18 May, 2005, Åbo Akademi, Turku, Finland.

Tanskanen, PekkaThe 7th Nordic-Japan Symposium. Science and Technology of Process Metallurgy. 15-16 September 2005, Jernkontoret, Stockholm, Sweden.

Virtanen, EsaKemianpäivät Suomi, 26.04-28.04, Helsinki, Fnland.

International Conference on Clean Technologies in the Steel Industry, 5-8 June 2005, Balatonfured, Hungary.

Euroslag, 4th European slag conference 20. - 21 June 2005, Pohto, Oulu, Finland

The 7th Nordic-Japan Symposium. Science and Technology of Process Metallurgy. 15-16 September 2005, Jernkontoret, Stockholm, Sweden.

Securing the Future - International Conference on Mining and the Environment Metals and Energy Recovery, 27.6.-1.7.2005, Skellefteå, Sweden.

Nordic Waste Recycling Day, 09 November 2005, University of Oulu, Oulu, Fin-land.

The 1st Global Slag Conference, ‘From Problem to Opportunity’, Hilton Hotel, 14-15 November 2005, Dusseldorf ,Germany.


8. CONTACT INFORmATIONAddress:

UNIVERSITY OF OULU

Department of Process and Environmental EngineeringLaboratory of Process Metallurgy

P.O. Box �300FI-9001� UNIVERSITY OF OULU

FINLANDFax: +35� � 553 �339

Email:[email protected]

e.g. [email protected]

Internet:http://cc.oulu.fi/~pometwww/

Contact Persons:Professor Mr. Jouko Härkki

[email protected] +358 8 553 2424

Research Manager Mr. Timo [email protected] +358 8 553 2421

Laboratory Manager Mr. Riku [email protected]

tel +358 8 553 2425

Senior Assistant Mr. Eetu-Pekka [email protected] +358 8 553 2559

Project Secretary Ms. Mari [email protected]

tel +358 8 553 2553


LABORATORY OF PROCESS METALLURGYDepartment of Process and Environmental Engineering

P.O. Box �300

FI-9001� UNIVERSITY OF OULU

FINLAND

Fax: +35� � 553 �339

Internet: http://cc.oulu.fi/~pometwww

E-mail: [email protected]

ANNUAL REPORT 2005 OF PROCESS METALLURGY · a Cupola Furnace 22 3.1.5 Phase Transformations in...

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