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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records

Exploring high temperature phenomena related to post-detonation using an electric arc

We report a study of materials recovered from a uranium-containing plasma generated by an electric arc. The device used to generate the arc is capable of sustaining temperatures of an eV or higher for up to 100 μs. Samples took the form of a 4 μm-thick film deposited onto 8 pairs of 17 μm-thick Cu electrodes supported on a 25 μm-thick Kapton backing and sandwiched between glass plates. Materials recovered from the glass plates and around the electrode tips after passage of an arc were characterized using scanning and transmission electron microscopy. Recovered materials included a variety of crystalline compounds (e.g., UO{sub 2}, UC{sub 2}, UCu{sub 5},) as well as mixtures of uranium and amorphous glass. Most of the materials collected on the glass plates took the form of spherules having a wide range of diameters from tens of nanometers to tens of micrometers. The composition and size of the spherules depended on location, indicating different chemical and physical environments. A theoretical analysis we have carried out suggests that the submicron spherules presumably formed by deposition during the arc discharge, while at the same time the glass plates were strongly heated due to absorption of plasma radiation mainly by islands of deposited metals (Cu, U). The surface temperature of the glass plates is expected to have risen to ∼2300 K thus producing a liquefied glass layer, likely diffusions of the deposited metals on the hot glass surface and into this layer were accompanied by chemical reactions that gave rise to the observed materials. These results, together with the compact scale and relatively low cost, suggest that the experimental technique provides a practical approach to investigate the complex physical and chemical processes that occur when actinide-containing material interacts with the environment at high temperature, for example, during fallout formation following a nuclear detonation.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Optical emission from a small scale model electric arc furnace in 250-600 nm region

Optical emission spectroscopy has been for long proposed for monitoring and studying industrial steel making processes. Whereas the radiative decay of thermal excitations is always taking place in high temperatures needed in steel production, one of the most promising environment for such studies are electric arc furnaces, creating plasma in excited electronic states that relax with intense characteristic emission in the optical regime. Unfortunately, large industrial scale electric arc furnaces also present a challenging environment for optical emission studies and application of the method is not straightforward. To study the usability of optical emission spectroscopy in real electric arc furnaces, we have developed a laboratory scale DC electric arc furnace presented in this paper. With the setup, optical emission spectra of Fe, Cr, Cr{sub 2}O{sub 3}, Ni, SiO{sub 2}, Al{sub 2}O{sub 3}, CaO, and MgO were recorded in the wavelength range 250-600 nm and the results were analyzed with the help of reference data. The work demonstrates that using characteristic optical emission, obtaining in situ chemical information from oscillating plasma of electric arc furnaces is indeed possible. In spite of complications, the method could possibly be applied to industrial scale steel making process in order to improve its efficiency.

36 MATERIALS SCIENCE↗

Some features of horizontally oriented low-current electric arc in air

The properties of an electric arc operating in open air at currents of lower than 1 A were studied experimentally. The rod cathode was oriented horizontally. Cylindrical rods and plane plates either installed strictly vertically in front of the cathode end or tilted at a certain angle served as the anode. It is shown that, with such an electrode configuration, it is possible to form a discharge channel much longer than the electrode gap length. Regimes of regular oscillations are revealed, and conditions for their appearance are established. The electric field strength in the arc column and the electron temperature near the anode are calculated.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

Optimization of Scrap Melting Using an Electric Arc in Steel Manufacturing

Steel industry is crucial to the national economy and security. Around 67% of crude steel in the U.S is produced in electric arc furnaces (EAF), which is energy intensive. Around 140 EAFs operate in the U.S., consuming about 8.6x10 7 MMBtu/year of electricity. One of major challenges for EAFs includes maximizing the efficiency of the electrical energy provided in the form of electric arcs to melt various scrap mixes. To address this issue, a computational fluid dynamics (CFD) methodology is chosen to analyze scrap melting using the electric arc. Due to complex furnace phenomena and the wide variety of potential scenarios, high performance computing (HPC) is essential to yield comprehensive and detailed CFD analyses and systematic parametric studies for optimized EAF operation. The objectives are to 1) simulate scrap melting using electric arc, 2) evaluate electrode/arc position for optimum scrap melting and 3) establish reduced order model for CFD data-base for fast model calculation.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Waste Heat Recovery from High Temperature Off-Gases from Electric Arc Furnace

This article presents a study and review of available waste heat in high temperature Electric Arc Furnace (EAF) off gases and heat recovery techniques/methods from these gases. It gives details of the quality and quantity of the sensible and chemical waste heat in typical EAF off gases, energy savings potential by recovering part of this heat, a comprehensive review of currently used waste heat recovery methods and potential for use of advanced designs to achieve a much higher level of heat recovery including scrap preheating, steam production and electric power generation. Based on our preliminary analysis, currently, for all electric arc furnaces used in the US steel industry, the energy savings potential is equivalent to approximately 31 trillion Btu per year or 32.7 peta Joules per year (approximately $182 million US dollars/year). This article describes the EAF off-gas enthalpy model developed at Oak Ridge National Laboratory (ORNL) to calculate available and recoverable heat energy for a given stream of exhaust gases coming out of one or multiple EAF furnaces. This Excel based model calculates sensible and chemical enthalpy of the EAF off-gases during tap to tap time accounting for variation in quantity and quality of off gases. The model can be used to estimate energy saved through scrap preheating and other possible uses such as steam generation and electric power generation using off gas waste heat. This article includes a review of the historical development of existing waste heat recovery methods, their operations, and advantages/limitations of these methods. This paper also describes a program to develop and test advanced concepts for scrap preheating, steam production and electricity generation through use of waste heat recovery from the chemical and sensible heat contained in the EAF off gases with addition of minimum amount of dilution or cooling air upstream of pollution control equipment such as bag houses.

EAFs↗

Formation Mechanisms and Leachability of Hexavalent Chromium in Cr{sub 2}O{sub 3}-Containing Refractory Castables of Electric Arc Furnace Cover

Cr (III)-containing refractories are widely used as electric-arc furnace cover because of their excellent corrosion resistance properties. However, the formation of hexavalent chromium [Cr(VI)] remains a matter of concern during the service and subsequent disposal of the spent refractories. Moreover, the Cr(VI) formation mechanism and total amount of Cr(VI) generated are not clearly understood. In this study, samples from different parts of a spent electric arc furnace cover were collected from a local integrated steel plant. The phase composition, microstructure, formation and leachability of Cr(VI) were investigated using X-ray photoelectron spectroscopy, X-ray diffraction, scanning electron microscopy with energy dispersive X-ray spectroscopy, and TRGS 613 leaching test (Technische Regeln für Gefahrstoffe-TRGS 613-October 2002)/multiple leaching tests. A Cr(VI)-containing phase namely CaCrO{sub 4} existed in the sample at a medium temperature range, while another Cr(VI)-containing phase namely hauyne (Ca{sub 4}Al{sub 6}CrO{sub 16}) and a Cr(III)-containing phase (Al{sub 2}O{sub 3}–Cr{sub 2}O{sub 3} solid solution) formed in the high temperature region. Concentrations of Cr(VI) in the leachates (as in the TRGS 613 procedure) exceeded the European permissible limit. During the leaching tests in an acid condition, Cr(VI) was reduced by Fe{sup 2+}, which was primarily derived from the dissolution of FeO in the samples, while more Cr(VI) leached out with distilled water. Formation of an Al{sub 2}O{sub 3}–Cr{sub 2}O{sub 3} solid solution can inhibit Cr(VI) generation.

36 MATERIALS SCIENCE↗

Modeling of Radiative Heat Transfer in an Electric Arc Furnace

Radiation is an important means of heat transfer inside an electric arc furnace (EAF). To gain insight into the complex processes of heat transfer inside the EAF vessel, not only radiation from the surfaces but also emission and absorption of the gas phase and the dust cloud need to be considered. Furthermore, the radiative heat exchange depends on the geometrical configuration which is continuously changing throughout the process. The present paper introduces a system model of the EAF which takes into account the radiative heat transfer between the surfaces and the participating medium. This is attained by the development of a simplified geometrical model, the use of a weighted-sum-of-gray-gases model, and a simplified consideration of dust radiation. The simulation results were compared with the data of real EAF plants available in literature.

42 ENGINEERING↗

Preliminary Results from Electric Arc Furnace Off-Gas Enthalpy Modeling

This article describes electric arc furnace (EAF) off-gas enthalpy models developed at Oak Ridge National Laboratory (ORNL) to calculate overall heat availability (sensible and chemical enthalpy) and recoverable heat values (steam or power generation potential) for existing EAF operations and to test ORNL s new EAF waste heat recovery (WHR) concepts. ORNL s new EAF WHR concepts are: Regenerative Drop-out Box System and Fluidized Bed System. The two EAF off-gas enthalpy models described in this paper are: 1.Overall Waste Heat Recovery Model that calculates total heat availability in off-gases of existing EAF operations 2.Regenerative Drop-out Box System Model in which hot EAF off-gases alternately pass through one of two refractory heat sinks that store heat and then transfer it to another gaseous medium These models calculate the sensible and chemical enthalpy of EAF off-gases based on the off-gas chemical composition, temperature, and mass flow rate during tap to tap time, and variations in those parameters in terms of actual values over time. The models provide heat transfer analysis for the aforementioned concepts to confirm the overall system and major component sizing (preliminary) to assess the practicality of the systems. Real-time EAF off-gas composition (e.g., CO, CO2, H2, and H2O), volume flow, and temperature data from one EAF operation was used to test the validity and accuracy of the modeling work. The EAF off-gas data was used to calculate the sensible and chemical enthalpy of the EAF off-gases to generate steam and power. The article provides detailed results from the modeling work that are important to the success of ORNL s EAF WHR project. The EAF WHR project aims to develop and test new concepts and materials that allow cost-effective recovery of sensible and chemical heat from high-temperature gases discharged from EAFs.

Electric Arc Furnace↗

Improving the Modeling of Slag and Steel Bath Chemistry in an Electric Arc Furnace Process Model

An improvement to the thermochemical module of the electric arc furnace (EAF) process model developed by Meier based on the work of Logar, Dovžan, and Škrjanc is presented. Different models for the calculation of activities in melt and slag are implemented, and separate reaction zones are defined for the interaction of slag and melt, the injection of oxygen, and the injection of carbon. For each zone, equilibrium compositions and reaction rates are calculated. Furthermore, diffusion of species is considered as a rate-limiting factor in reactions between slag and melt, and diffusion rates are calculated from the bulk melt to the reaction zone where reactions with the slag take place. Oxygen and sulfur dissolved in the melt and CaS in the slag are added as new species not previously considered in the EAF model. The treatment of carbon is revised to reduce model complexity and improve accuracy. The improved model is validated using extensive data from an industrial EAF, and results are compared to measured data as well as results obtained with the unmodified model. The different models for the determination of thermodynamic activities and their impacts on the duration of the simulation as well as its results are evaluated.

36 MATERIALS SCIENCE↗

Thermal Analysis on the Pyrolysis of Tetrabromobisphenol A and Electric Arc Furnace Dust Mixtures

The pyrolysis of Tetrabromobisphenol A (TBBPA) mixed with electric arc furnace dust (EAFD) was studied using thermogravimetric analysis (TGA) and theoretically analyzed using thermodynamic equilibrium calculations. Mixtures of both materials with varying TBBPA loads (1:1 and 1:3) were prepared and pyrolyzed in a nitrogen atmosphere under dynamic heating conditions at heating rates of 5 and 10 °C/min. The mixtures degraded through several steps, including decomposition of TBBPA yielding mainly HBr, bromination of metal oxides, followed by their evaporation in the sequence of CuBr{sub 3}, ZnBr{sub 2}, PbBr{sub 2}, FeBr{sub 2}, MnBr{sub 2}, KBr, NaBr, CaBr{sub 2}, and MgBr{sub 2}, and finally reduction of the remaining metal oxides by the char formed from decomposition of TBBPA. Thermodynamic calculations suggest the possibility of selective bromination of zinc and lead followed by their evaporation, leaving iron in its oxide form, while the char formed may serve as a reduction agent for iron oxides into metallic iron. However, at higher TBBPA volumes, iron bromide forms, which can also be evaporated at a temperature higher than those of ZnBr{sub 2} and PbBr{sub 2}. Results from this work provide practical insight into selective recovery of valuable metals from EAFD while at the same time recycling the hazardous bromine content in TBBPA.

36 MATERIALS SCIENCE↗

Recovery of Cs-137 from Electric Arc Furnace Dust - 20562

The present work proposes the Cs-137 recovery from Electric Arc Furnace Dusts (EAFD) by leaching, in order to reduce the volume of radioactive waste to be managed. Leaching tests were performed on different samples of EAFD contaminated with Cs-137. Two leaching methodologies were tested: dynamic and static using as medium distilled water and in some cases NaOH. The results indicate the possibility of recovering Cs-137 from EAFD using the dynamic method; however, the recovery efficiencies of Cs-137 depend on EAFD's chemical composition. The leachates of Cs-137 were quantitatively adsorbed on exchange resins, showing its great potential to isolate or contain the Cs-137 recovery from EAFD. This study shows the feasible to apply the dynamic leaching methodology to recover Cs-137 from EAFD and the use of ion exchange resins for the isolation of removed Cs-137. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Assessment of Physicochemical Properties of Electrical Arc Furnace Slag and Their Effects on Foamability

The composition of slags of an electric arc furnace (EAF) in a commercial melt shop was systematically analyzed with a focus on slag foaming. Basic behavior of FeO in an EAF slag was confirmed using fundamental thermodynamics. Monoxide ([Mg,Fe,Mn]O = M’O) and spinel ([Mg,Fe]Al{sub 2}O{sub 4}) phases in EAF slag were confirmed by X-ray diffraction analysis, and these results were interpreted in the context of equilibrium cooling calculation using FactSage™ software. Furthermore, the distribution of MgO with respect to the M’O-saturation limit at different basicity ratios (=CaO/SiO{sub 2}=C/S) and temperatures was evaluated. In particular, the relationship between MgO and FeO for C/S ratios ranging from 1.3 to 1.6 was considered with reference to phase equilibria. Foam height was affected by slag viscosity (η) and gas generation according to changes in C/S ratio and FeO content. Foaming index (Σ) decreased with the increasing C/S ratio and FeO content. The measured foam heights were relatively higher than the calculated values, and the result indicates that the effect of M’O on slag foaming in commercial process is remarkable. Therefore, slag chemistry should be optimized based on thermodynamic considerations and thermophysical properties to achieve good foaming characteristics.

36 MATERIALS SCIENCE↗

Advancing Temperature Monitoring of the Bottom Anode in a Direct Current Electric Arc Furnace Operations with Distributed Optical Fiber Sensors.

The bottom anode in the Direct Current Electric Arc Furnace (DC EAF) is critical for completing the electrical circuit necessary for sustaining the arc within the furnace. For pin-type bottom anodes, monitoring of the temperature of select pins instrumented with thermocouples is performed to track bottom wear in the EAF and inform the operator when the furnace should be removed from service. Furthermore, this work presents the results from a plant trial using distributed temperature monitoring of bottom anode pins in a 165-ton DC EAF over a two-month service period utilizing two optical fiber sensing techniques: fiber Bragg grating (FBG) and Rayleigh backscattering (RBS). The early detection of temperature anomalies along the length of the anode pin through distributed sensing enhances operational safety, providing a robust alternative to traditional thermocouples.

42 ENGINEERING↗

Electrical Arc Fault Particle Size Characterization

In this investigation a series of small-scale tests were conducted, which were sponsored by the Nuclear Regulatory Commission (NRC) Office of Nuclear Regulatory Research (RES) and performed at Sandia National Laboratories (SNL). These tests were designed to better understand localized particle dispersion phenomena resulting from electrical arcing faults. The purpose of these tests was to better characterize aluminum particle size distribution, rates of production, and morphology (agglomeration) of electrical arc faults. More specifically, this effort characterized ejected particles and high-energy dispersion, where this work characterized HEAF electrical characteristics, particle movement/distributions, and morphology near the arc. The results and measurements techniques from this investigation will be used to inform an energy balance model to predict additional energy from aluminum involvement in the arc fault. The experimental setup was developed based on prior work by KEMA and SNL for phase-to-ground and phase-to-phase electrical circuit faults. The small-scale tests results should not be expected to be scale-able to the hazards associated with full-scale HEAF events. Here, the test voltages will consist of four different levels: 480V, 4160V, 6900V and 10kV, based on those realized in nuclear power plant (NPP) HEAF events.

36 MATERIALS SCIENCE↗

TATB Sensitivity to Shocks from Electrical Arcs

Use of insensitive high explosives (IHEs) has significantly improved ammunition safety because of their remarkable insensitivity to violent cook–off, shock and impact. Triamino–trinitrobenzene (TATB) is the IHE used in many modern munitions. Previously, lightning simulations in different test configurations have shown that the required detonation threshold for standard density TATB at ambient and elevated temperatures (250 °C) has a sufficient margin over the shock caused by an arc from the most severe lightning. In this paper, the Braginskii model with Lee–More channel conductivity prescription is used to demonstrate how electrical arcs from lightning could cause detonation in TATB. The steep rise and slow decay in typical lightning pulse are used in demonstrating that the shock pressure from an electrical arc, after reaching the peak, falls off faster than the inverse of the arc radius. For detonation to occur, two necessary detonation conditions must be met: the Pop–Plot criterion and minimum spot size requirement. The relevant Pop–Plot for TATB at 250 °C was converted into an empirical detonation criterion, which is applicable to explosives subject to shocks of variable pressure. The arc cross–section was required to meet the minimum detonation spot size reported in the literature. Furthermore, one caveat is that when the shock pressure exceeds the detonation pressure the Pop–Plot may not be applicable, and the minimum spot size requirement may be smaller.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

Study on the Fluid Flow Characteristics of Coherent Jets with CO{sub 2} and O{sub 2} Mixed Injection in Electric Arc Furnace Steelmaking Processes

As an efficient oxygen supplying technology, coherent jets are widely applied in electric arc furnace (EAF) steelmaking processes to strengthen chemical energy input, speed up smelting rhythm, and promote the uniformity of molten bath temperature and compositions. Recently, the coherent jet with CO{sub 2} and O{sub 2} mixed injection (COMI) was proposed and demonstrated great application potentiality in reducing the dust production in EAF steelmaking. In the present study, based on the eddy dissipation concept model, a computational fluid dynamics model of coherent jets with COMI was built with the overall and detailed chemical kinetic mechanisms (GRI-Mech 3.0). Compared with one-step combustion reaction, GRI-Mech 3.0 consists of 325 elementary reactions with 53 components and can predict more accurate results. The numerical simulation results were validated by the combustion experiment data. The jet behavior and the fluid flow characteristics of coherent jets with COMI under 298 K and 1700 K (25 °C and 1427 °C) were studied and the results showed that for coherent jets with COMI, the chemical effect of CO{sub 2} significantly weakened the shrouding combustion reactions of CH{sub 4} and the relative importance of the chemical effect of CO{sub 2} increases with CO{sub 2} concentration increasing. The potential core length of coherent jet decreases with the volume fraction of CO{sub 2} increasing. Moreover, it also can be found that the potential core length of coherent jets was prolonged with higher ambient temperature.

36 MATERIALS SCIENCE↗

Effect of Direct Reduced Iron (DRI) on Dephosphorization of Molten Steel by Electric Arc Furnace Slag

We investigated the effect of direct reduced iron (DRI) addition on dephosphorization of molten steel by electric arc furnace (EAF) slag at 1823 K (1550 °C). Various phenomena such as CO gas evolution and slagmaking by gangue oxides in DRI were experimentally observed at each reaction step. Thermodynamic behaviors of phosphorus, oxygen, and carbon were strongly dependent on DRI content. Basicity, which is the thermodynamic driving force of dephosphorization, decreased with the increasing DRI content because SiO{sub 2} concentration in the slag was proportional to DRI addition. The excess free energy of P{sub 2}O{sub 5} increased with the increasing SiO{sub 2} content in slag. A higher DRI content made dephosphorization difficult by decreasing the basicity and stability of P{sub 2}O{sub 5} in the slag. Therefore, when using DRI in EAF process, it is very important to control the basicity of slag.

36 MATERIALS SCIENCE↗

Modeling and Simulation of the Off-gas in an Electric Arc Furnace

The following paper describes an approach to process modeling and simulation of the gas phase in an electric arc furnace (EAF). The work presented represents the continuation of research by Logar, Dovžan, and Škrjanc on modeling the heat and mass transfer and the thermochemistry in an EAF. Due to the lack of off-gas measurements, Logar et al. modeled a simplified gas phase under consideration of five gas components and simplified chemical reactions. The off-gas is one of the main continuously measurable EAF process values and the off-gas flow represents a heat loss up to 30 pct of the entire EAF energy input. Therefore, gas phase modeling offers further development opportunities for future EAF optimization. This paper presents the enhancement of the previous EAF gas phase modeling by the consideration of additional gas components and a more detailed heat and mass transfer modeling. In order to avoid the increase of simulation time due to more complex modeling, the EAF model has been newly implemented to use an efficient numerical solver for ordinary differential equations. Compared to the original model, the chemical components H{sub 2}, H{sub 2}O, and CH{sub 4} are included in the gas phase and equilibrium reactions are implemented. The results show high levels of similarity between the measured operational data from an industrial scale EAF and the theoretical data from the simulation within a reasonable simulation time. In the future, the dynamic EAF model will be applicable for on- and offline optimizations, e.g., to analyze alternative input materials and mode of operations.

42 ENGINEERING↗