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Publications (69)
Steel slag is a significant environmental liability generated by pyrometallurgical processes. Residue generation, such as granulated blast furnace slag and basic oxygen slag (BOF), is intrinsic in steel production. Blast furnace slag, generated in the carbothermal reduction of iron ore, is almost entirely used as a supplementary cement material in...
Basic oxygen furnace slag is considered a potential material for the replacement of natural aggregate in Portland cement concrete due to its similar physical characteristics. Therefore, in the present work, the slag was analyzed by Nitrogen sorption porosimetry, elemental analysis, mineralogical analysis, and volume stability. On the other hand, co...
Given the current huge generation of solid waste worldwide, alternative and innovative methodologies for incorporating these materials should be encouraged elsewhere. In this context, the objective of this research is to evaluate the use of glass waste as a substitute for sand as raw material in ceramics. Formulations containing from 0% to 20% of g...
Landfill leachate is a global problem that has attracted considerable attention from researchers in different areas. It is crucial to develop optimized treatment strategies for landfill leachate, given the need to minimize or eliminate negative environmental impacts resulting from the inadequate disposal of solid waste, as determined by legislation...
The reuse of industrial waste is an important tool to contribute to the sustainable development of different sectors. It is known that most companies do not have reuse policies, making the final disposal of waste in landfills or even inappropriately. In this context, the objective of this work was to study the reuse of the waste from the production...
This paper compares the thermal shock damage resistance and the slag corrosion resistance of a high-alumina and an alumina-containing andalusite refractory castable. Thermal shock damage resistance was analyzed through thermal cycling and thermal shock damage resistance parameters. Thermal shock cycling damage was analyzed using the dynamic modulus...
This paper describes the study of a lime kiln refractory failure analysis and the proposed solution. A postmortem
study was carried out on the lime kiln refractory lining. Three refractory failures were hypothesized: thermal shock, discrepancy in the material properties, and excessive abrasion wear. The following characterization techniques were us...
The contradictory properties required of castable refractories makes selecting castable refractories for industrial applications challenging. This paper seeks to describe the material selection for a blast furnace blowpipe application that is subjected to sudden temperature changes and must prevent heat loss. Three commercial high alumina castables...
Os objetivos principais são evidenciar a parceria e a interlocução entre as áreas de engenharia de materiais, design e comunicação social que foram possíveis por meio da colaboração entre o Centro Universitário Teresa D’Ávila (Unifatea) e a Escola de Engenharia de Lorena da Universidade de São Paulo (EEL-USP), no Departamento de Materiais, contribu...
Na siderurgia o alto-forno (AF) é basicamente divido em quatro regiões, sendo: cuba, ventre, rampa e cadinho. A região da cuba ainda pode ser dividida em três regiões: inferior, média e alta cuba. A alta cuba, corresponde a parte superior do AF e lugar onde ocorre a entrada das matérias primas percursoras do ferro gusa. Dessa maneira, os refratário...
As tintas (líquidas, pastosas ou em pó) são compostas por uma mistura de resinas, aditivos, pigmentos, cargas e solventes; capazes de formarem película após secagem ou cura. Os aditivos são adicionados às matrizes poliméricas em quantidade suficiente para conferir características específicas para determinadas aplicações. O objetivo do presente trab...
This is a study about the synthesis of SiC from rice husk. The SiC production was carried out in two stages, the first one being the rice husk carbonization under vacuum, at the temperature range from 270 to 650 °C, and the second stage was the pyrolysis of the carbonized rice husk, at the temperature range from 1300 to 1800 °C and 120 min isotherm...
The technology of refractory castables has generated products with higher density and less porosity to increase their resistance to high temperatures and abrasion; however, its permeability has also been reduced presenting a problem in the drying operation since it increased the risk of spalling and explosions that are theoretically a result of the...
Os objetivos principais são evidenciar a parceria e a interlocução entre as áreas de engenharia de materiais, design e comunicação social que foram possíveis por meio da colaboração entre o Centro Universitário Teresa D’Ávila (Unifatea) e a Escola de Engenharia de Lorena da Universidade de São Paulo (EEL-USP), no Departamento de Materiais, contribu...
This work has as its objective to evaluate the effect of mold flux waste incorporation in a red ceramic body. The mold flux waste came from an industry of additives for continuous casting of steel, in the municipal area of Guaratinguetá, State of São Paulo, Brazil. Initially, the mold flux waste was characterized in terms of chemical composition, p...
Este estudo compara a resistência ao dano por choque térmico e a resistência a corrosão de escória de alto forno entre dois refratários comerciais para aplicação em conjunto de porta ventos de alto forno, sendo um concreto rico em alumina e o outro em andaluzita, ambos de baixo teor de cimento. Para caracterizar a composição e a microestrutura dess...
The indirect selective laser sintering (SLS) process consists of a powder-based additive manufacturing (AM) technique. Recently, an attempt was carried out using the indirect-SLS method on ceramics to obtain complex geometric parts without the need to fabricate tools or molds. In this context, the ceramic particles employed in indirect-SLS must be...
A produção mundial de aço bruto em 2017 foi da ordem de 1700 milhões de toneladas, portanto,
a otimização do seu processo produtivo, pela diminuição de perdas e da redução do uso de
insumos, tem um impacto muito positivo na economia do setor. Nas aciarias, durante o
reaquecimento das placas de aço, etapa da laminação a quente, ocorre a formação de...
The basic oxygen furnace (BOF) slag use as raw material for cement production carries economic, environmental and technical benefits to the cement industry, reducing energy costs, material consumption and waste storage areas. This study evaluates the partial replacement of blast furnace slag by BOF slag in the production of slag portland cement. Sp...
The technological process of clinkerization is responsible for a high consumption of energy and the release of carbon dioxide (CO2) to the environment. It is estimated that the cement industry generates, for every tonne of cement produced, around 0.7–1 tonne of CO2, in order to be responsible for 5% of CO2 global emission, while in Brazil, this cor...
The main refractory lining of blast furnace hearth is composed by carbon blocks that operates in continuous contact with hot gases, liquid slag and hot metal, in temperatures above 1550 ºC for 24 hours a day. To fully understand the wear mechanism that acts in this refractory layer system it was performed a Post Mortem study during the last partial...
The maintenance of several steel-making equipment of the Companhia Siderúrgica Nacional (CSN/Brazil) builds up about 11 000 tons of refractory waste per year. Most of that refractory waste is disposed off in landfill sites without any application. That action permanently excludes an important alternative source of raw material from the productive c...
The ternary compound barium aluminosilicate BaAl2Si2O8, knoiun as celsian, a non-wetting additive that increases the corrosion resistance of refractory materials against molten aluminum, was incorporated into the matrix of a high-alumina low cement castable after its synthesis using harite and a low cost source of alumina and silica. This paper pre...
Titanium is a metal that has high melting point 1668 ° C, the boiling point of 3287° C, low density (4.54 g/cm3) and modulus of elasticity around 12.7 MPa x104. However, one of the most important properties is the biocompatibility, which makes this metal to be the most widely used in biomedical. Several alloys were developed using titanium such as...
In the last years it has been used statistical tools for industrial optimization processes, research and development, in order to minimize the amount of experiments and to establish the best relationships among representative variables. Obtaining the metallic materials route metallurgy powder, the sintering process is preponderant in the final prop...
The blast furnace is one the main systems used in steelmaking plants operating with iron ores. In addition to the production of pig iron and slag, the blast furnace operation also generates a considerable amount of wastes such as dust usually collected in the upwards flowing gas. The dust collecting stage, without separation procedures, produces a...
The microstructural and technological properties of clay ceramic incorporated with 10 and 20 wt% of elephant grass ashes were investigated at different firing temperatures of 650, 850 and 1050ºC. X-ray diffraction were used to obtain the minerals and phase compositions. The microstructure was analyzed by scanning electron microscopy. The technical...
The blast furnace sludge is a waste generated after the washing step of the blast furnace gas. The reuse of this waste in the steelmaking process itself is quite problematic. This study aims to analyze the possibility of the incorporation of a type of blast furnace sludge, benefited by a process that uses helical separators, into red ceramic. Speci...
The addition of industrial residues into common red clay ceramic has been, from many decades, an alternative of using other low cost raw materials and, more recently, as an environmentally correct destination for polluting substances. An important residue, known as yellow sludge, is that generated at the water clearing stage (WCS) of a treatment pl...
In this work it is presented a methodology applied by Companhia Siderúrgica Nacional (CSN, Brazil) in order to assess its blast furnace 3 carbon refractory hearth lining conditions. The aim of the investigation was the gathering of critical data base for blast furnace refractories life cycle follow up and eventual repair decision taking.
The sample...
This paper describes the main characteristics and advantages of convective heating system for refractory lining, compared with conventional heating systems. In addition the main results obtained are presented with its implementation in CSN Blast Furnace #2 and 3 Runners, in terms of cost and equipment availability, as well as the need for ceramic c...
The growing demand for steels with tighter compositional specifications led the Companhia Siderúrgica Nacional (CSN) to develop more efficient processes. To solve this problem this paper aims to identify the operational variables more impacting in the desulfurization process, specifically in torpedo car, as well as its causes and solutions. Then se...
CSN BF no. 2 has only three hot blast stoves. Owing to the operational risks as well as output losses associated with the BF operation with just two hot blast stoves, the revamping time of this equipment becomes a crucial issue, requiring special attention in each phase of the project from planning to execution so as to shorten the time as much as...
In this work is analyzed the synthesis of maghemite, γ - Fe 2O3, magnetite, Fe304, goethite, α - FeOOH, and hematite, α - Fe2O3, by application of excess of iron chlorate ionic aqueous solution from Continuous Pickling line (CPL) of Companhia Siderurgica Nacional (CSN), about of 500 m3/month, as a new production rote of inorganic pigments. The goet...
Blast furnace gas yield is essentially controlled by a gas-solid reaction phenomenon, which strongly influences hot metal manufacturing costs. As a result of rising prices for reducing agents on the international market, Companhia Siderúrgica Nacional decided to inject natural gas into its blast furnaces. With more gas inside the furnace, the burde...
One of the major problems facing Blast Furnaces is the occurrence of cracks in taphole mud, as the underlying causes are not easily identifiable. The absence of this knowledge makes it difficult the use of conventional techniques for predictability and mitigation. This paper will address the application of Probabilistic Neural Network using the Mat...
This paper reports on the characterization of a rare earth oxide obtained by hydrometallurgy of the mineral xenotime, an yttrium phosphate containing other rare earths, and comparison with mixtures of rare earth oxides prepared in different ways. The results indicated that hydrometallurgy from xenotime yielded a solid solution of the rare earth oxi...
This work has as its objective to evaluate the effect of incorporation of up to 20 wt.% of fine steel sludge, from an integrated siderurgic plant, on the microstructure of a kaolinitic clay used to the fabricate bricks and roofing tiles, as well as to evaluate the inertization of potentially toxic elements through solution and leaching tests in the...
The present paper has for objective to evaluate the effect of fine steel sludge waste incorporation on the properties and microstructure of a kaol initie clayey body used to the fabrication of bricks and roofing tiles. Compositions were prepared with additions of waste of 0, 5 and 10 wt.% in a kaolinitic clay from the county of Campos dos Goytacaze...
A post mortem study of Al2O3/SiC/C/MgAl2O4 (ASCMg) refractory lining used in Companhia Siderurgica Nacional (CSN) torpedo car was conducted in order to determine the corrosion equation developed during industrial application. Different samples were collected and characterized using the following techniques: Chemical Analysis by X-Ray Fluorescence,...
Over recent years, owing to the need to increase productivity, it has been necessary among other things to increase the hot metal temperature in the blast furnace hearth. As a result, refractory lining wear becomes more intense. While publications present a host of comparative tests for hearth refractories and their performance, hardly any informat...
This paper looked into hot metal corrosion behavior for graphite refractory used in blast furnace hearth, consisting of 50% graphite and 50% anthracite, impregnated with TiO2, ZrO2 carrying solutions. The method used for corrosion was the Finger Test, which was conducted in an induction furnace with 30 × 30 × 280 mm bar-shaped test specimens, and t...
This paper investigates corrosion behavior in graphite refractory hot metal impregnated with ZrO2 and CeO2 carrying solutions used in Blast Furnace hearth, consisting of 50% graphite and 50% anthracite. Corrosions tests were carried out by means of finger test method in an induction furnace, using bar-shaped 30X30X280 mm test specimens and hot meta...
The objective of this work was to manufacture and characterize silicon nitride crucibles and evaluate its corrosion behavior upon exposure to molten aluminium at 1150°C for 30 days. Crucibles with low porosity (<2%) and with good mechanical properties ( HV = 13.5 GPa and K IC > 5 MPa.m -1/2) were obtained by cold isostatic pressing followed by conv...
The protection mechanisms of refractory linings both at the slag and pig-iron levels associated with conventional techniques of titanium addition to the blast furnace burden were investigated. The results were derived from a post mortem study on CSN's Blast Furnaces 2 and 3, as well as laboratory simulations carried out using two different refracto...
Este trabalho apresenta a técnica de eletrodeposição de tântalo em meio de fluoretos fundidos, seguida de tratamento térmico para formação do carbeto de tântalo, como uma alternativa de pré-tratamento para tubos de grafite utilizados em determinações analíticas de espectrometria de absorção atômica em forno de grafite. Os experimentos de eletrodepo...
A espectrometria de absorção atômica com atomização eletrotérmica em forno de grafite, como método analítico, possui uma grande vantagem que é a sensibilidade na detecção, tendo assim grande aceitação como rotina analítica em laboratórios de aplicação e pesquisa. Apesar desta metodologia possuir grande poder de detecção, sua aplicação é limitada pe...
Este trabalho apresenta uma nova metodologia para a formação de uma camada de carbeto de tântalo em superfície de grafite, que consiste da imersão dos tubos de grafite em suspensões aquosas de tântalo e de óxido de tântalo, com posterior tratamento térmico a 2100 °C. Para facilitar a aderência dos compostos de tântalo sobre a superfície do tubo, ut...
Nos últimos anos vem sendo testados óxidos de terras raras pesadas como aditivos de sinterização, via fase líquida, do nitreto de silício (Si3N4). Este trabalho visou o estudo do comportamento da sinterização do Si3N4 aditivado com um concentrado de óxidos de ítrio e terras raras pesadas e sílica, nas quantidades de 14 e 21%. Os resultados obtidos...
O comportamento à corrosão de cerâmicas à base de Si3N4 contendo misturas de Y2O3/SiO2 e RE2O3/SiO2 como aditivos nas proporções de 14 e 21% em volume ambos na estequiometria dos dissilicatos Y2Si2O7 e RE2Si2O7, respectivamente, foi estudado em soluções aquosas de HCl 0,1N a 100 °C. A resistência à corrosão foi avaliada pela perda de massa das amos...