Treatise on Process Metallurgy

Volume 3: Industrial Processes

2nd Edition - March 12, 2024
Editors: Seshadri Seetharaman, Roderick Guthrie, Alexander McLean, Sridhar Seetharaman, H. Y. Sohn
Language: English
Hardback ISBN:
9 7 8 - 0 - 3 2 3 - 8 5 3 7 3 - 6
eBook ISBN:
9 7 8 - 0 - 3 2 3 - 8 5 8 9 6 - 0

Treatise on Process Metallurgy: Volume Three, Industrial Processes provides academics with the fundamentals of the manufacturing of metallic materials, from raw materials into fini… Read more

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Treatise on Process Metallurgy: Volume Three, Industrial Processes provides academics with the fundamentals of the manufacturing of metallic materials, from raw materials into finished parts or products. In these fully updated volumes, coverage is expanded into four volumes, including Process Fundamentals, encompassing process fundamentals, structure and properties of matter; thermodynamic aspects of process metallurgy, and rate phenomena in process metallurgy; Processing Phenomena, encompassing interfacial phenomena in high temperature metallurgy, metallurgical process phenomena, and metallurgical process technology; Metallurgical Processes, encompassing mineral processing, aqueous processing, electrochemical material and energy processes, and iron and steel technology, non-ferrous process principles and production technologies, and more.

The work distills the combined academic experience from the principal editor and the multidisciplinary four-member editorial board.

Cover image
Title page
Table of Contents
Copyright
Obituary
Contributors
Editors’ Biographies
Preface to the 2nd Edition
Preface to the 1st Edition
Section 1: Iron and Steel Technology
Chapter 1.1 Iron and Steelmaking—Introduction
Abstract
Chapter 1.2 Ironmaking
Abstract
Acknowledgments
1.2.1 Introduction
1.2.2 Raw Materials and Their Preparation
1.2.3 The Ironmaking Blast Furnace: Facilities and Processes
1.2.4 Blast Furnace Reactions
1.2.5 Energy Consumption, Process Performance, and Environmental Control
1.2.6 Future Trends and Sustainable Developments in Ironmaking
1.2.7 Modeling and Simulation of Ironmaking Processes
References
Suggested Readings
Chapter 1.3 The Direct Reduction of Iron
Abstract
1.3.1 Introduction
1.3.2 Raw Materials
1.3.3 Direct Reduction Processes
1.3.4 Applications of Direct Reduced Iron
1.3.5 Energy and Emissions
1.3.6 Concluding Remarks
References
Further Reading
Chapter 1.4 Hot Metal Pretreatment
Abstract
1.4.1 Introduction
1.4.2 Desulfurization
1.4.3 Dephosphorization
1.4.4 Desiliconization
1.4.5 Influence of Hot Metal Pretreatment on Scrap Melting Capacity
1.4.6 Hot Metal Heating Device
References
Chapter 1.5 Converter Steelmaking
Abstract
ACKNOWLEDGMENTS
1.5.1 INTRODUCTION
1.5.2 HISTORICAL DEVELOPMENT OF CONVERTER STEELMAKING
1.5.3 BASIC OXYGEN STEELMAKING
1.5.4 ARGON-OXYGEN DECARBURIZATION
1.5.5 VACUUM OXYGEN DECARBURIZATION
1.5.6 OUTLOOK ON CONVERTER METALLURGY
References
Chapter 1.6 Electric Furnace Steelmaking
Abstract
1.6.1 INTRODUCTION TO ELECTRIC STEELMAKING
1.6.2 RAW MATERIALS, AVAILABILITY, SCRAP CLASSES, SCRAP TRADING
1.6.3 FURNACE CONSTRUCTION
1.6.4 MELTING PRACTICE AND METALLURGY
1.6.5 ENERGY BALANCE OF EAF PROCESS, ELECTRIC ENERGY, CHEMICAL HEATING, PREHEATING, POSTCOMBUSTION
1.6.6 SPECIAL FURNACE CONSTRUCTIONS
1.6.7 ENVIRONMENTAL AND SAFETY ISSUES
1.6.8 FUTURE ASPECTS
References
Chapter 1.7 Secondary Steelmaking
Abstract
1.7.1 INTRODUCTION
1.7.2 FURNACE TAPPING
1.7.3 DEOXIDATION
1.7.4 DESULFURIZATION
1.7.5 DEGASSING
1.7.6 VACUUM DECARBURIZATION
1.7.7 DEPHOSPHORIZATION
1.7.8 HEATING
1.7.9 ALLOYING
1.7.10 SUMMARIZING DISCUSSION
References
Chapter 1.8 Inclusion Engineering
Abstract
1.8.1 Introduction
1.8.2 Nonmetallic Inclusions in Steel
1.8.3 Formation, Growth, and Removal of Inclusions
1.8.4 Inclusion Engineering in Practical Steelmaking – A Case of Ball-Bearing Steel
1.8.5 Special Methods for Ultra-Clean Steels
1.8.6 Quantification and Characterization of Nonmetallic Inclusions
1.8.7 Future Trends
References
Chapter 1.9 Tundish Technology
Abstract
1.9.1 Introduction
1.9.2 Sequential Casting
1.9.3 Nonmetallic Inclusions
1.9.4 Minimization of Exogenous Inclusions From Reoxidation and Slag Entrainment
1.9.5 Minimization of Exogenous Inclusions From Refractory Wear
1.9.6 Removal of Inclusions
1.9.7 Thermal Conditions in Tundish
1.9.8 Summarizing Discussion
References
Chapter 1.10 Continuous Casting of Steel
Abstract
1.10.1 Introduction
1.10.2 Types of Continuous Casting Machines
1.10.3 Basic Equipment in Continuous Casting
1.10.4 Fundamentals of Solidification in Continuous Casting
1.10.5 Modeling of Microstructures
1.10.6 Defects
References
Chapter 1.11 How Mold Fluxes Work
Abstract
Symbols, Units, and Abbreviations
1.11.1 Introduction
1.11.2 Lubrication of Shell by Mold Flux
1.11.3 Heat Transfer in the Mold
1.11.4 Using Mold Fluxes to Adjust Process Variables
1.11.5 Effect of Casting Variables on Mold Flux Performance
1.11.6 Properties of Mold Fluxes
1.11.7 Selection of Mold Fluxes
1.11.8 Using Mold Fluxes to Minimize Defects and Process Problems
References
Chapter 1.12 Production of Ferroalloys
Abstract
Acknowledgments
1.12.1 Classification, Manufacture, and Use of Ferroalloys
1.12.2 Thermodynamics in the Production of Main Ferroalloys
1.12.3 Ferrochromium Smelting Technology
1.12.4 Reduction of Manganese Oxides and Production of Manganese Alloys
1.12.5 General Process Description
References
Section 2: Nonferrous Process Principles and Production Technologies
Chapter 2.1 Nonferrous Process Principles
Chapter 2.1.1 Pyrometallurgical Principles
Abstract
2.1.1.1 Introduction
2.1.1.2 Reduction of Oxides
2.1.1.3 Roasting of Sulfide Minerals
2.1.1.4 Smelting of Sulfide Minerals
2.1.1.5 Refining
2.1.1.6 Concluding Remarks
References
Chapter 2.1.2 Hydrometallurgical Principles
Chapter 2.1.2.1 Physical Chemistry of Aqueous Processing
Abstract
2.1.2.1.1 Introduction
2.1.2.1.2 Leaching
2.1.2.1.3 Physicochemical Aspects of Leaching
2.1.2.1.4 Kinetics of Leaching
2.1.2.1.5 Treatment of Leach Liquor
2.1.2.1.6 Recovery of Metals from Leach Liquor
References
Chapter 2.1.2.2 Processing Principles
Abstract
2.1.2.2.1 Introduction to Hydrometallurgical Processing
2.1.2.2.2 Application of Hydrometallurgical Fundamentals
2.1.2.2.3 Gold Processing
2.1.2.2.4 Gold Refining
2.1.2.2.5 Copper Processing
2.1.2.2.6 Zinc Processing
References
Chapter 2.1.3 Principles of Biohydrometallurgy
Abstract
2.1.3.1 Principles of Biohydrometallurgy
Glossary
References
Chapter 2.1.4 Electrometallurgical Principles
Abstract
2.1.4.1 Introduction
2.1.4.2 Principles
2.1.4.3 Electrowinning
2.1.4.4 Electrorefining
References
Chapter 2.2 Copper Production
Abstract
Chapter 2.2.1 Principles of Copper Production
Abstract
2.2.1.1 ELLINGHAM DIAGRAM FOR SULFIDES
2.2.1.2 HIGH-TEMPERATURE PREDOMINANCE-AREA DIAGRAMS
2.2.1.3 THREE POSSIBLE PATHS FROM CHALCOPYRITE TO LIQUID METAL
2.2.1.4 MATTE SMELTING AND CONVERTING STEPS
2.2.1.5 DISPOSAL OF SO2 AND ACIDMAKING
2.2.1.6 SLAGS USED IN COPPER SMELTING
2.2.1.7 MINOR ELEMENT BEHAVIOR
2.2.1.8 RATE PROCESSES
2.2.1.9 COMBINED REACTION AND FLUID FLOW MODELING AND COMPUTER SIMULATION
References
Chapter 2.2.2 Industrial Technologies for Copper Production
Abstract
2.2.2.1 Matte Smelting Processes
2.2.2.2 Converting Processes
2.2.2.3 Mitsubishi Continuous Copper Smelting Process
2.2.2.4 Slag Cleaning
2.2.2.5 Industry Trends
References
Chapter 2.3 Nickel and Cobalt
Abstract
2.3.1 Synopsis
2.3.2 Occurrences
2.3.3 Extraction of Nickel and Cobalt from Laterite Ores
2.3.4 Extraction of Nickel and Cobalt from Sulfide Ores
2.3.5 Production of Nickel and Cobalt from Sulfide Intermediates
2.3.6 Cobalt from Central African Copper-Cobalt Ores
2.3.7 Recovering Nickel and Cobalt from End-of-Use Scrap
2.3.8 Summary
References
Chapter 2.4 Lead and Zinc Production
Abstract
2.4.1 Lead Production
2.4.2 Zinc Production
References
Chapter 2.5 Aluminum Production
Abstract
2.5.1 Hydrometallurgy of the Bayer Process
2.5.2 Electrometallurgy of Aluminum
2.5.3 Aluminum Recycling
References
Chapter 2.6 Silicon Production
Abstract
2.6.1 Introduction
2.6.2 Polysilicon Production Processes
2.6.3 Conclusions and Future Trends
References
Chapter 2.7 Rare Earth, Titanium Group Metals, and Reactive Metals Production
Abstract
2.7.1 Rare Earth Metals
2.7.2 Titanium Group Metals (Ti, Zr, and Hf)
2.7.3 Reactive Metals
References
Chapter 2.8 Platinum Group Metals Production
Abstract
2.8.1 Introduction
2.8.2 Uses of PGMs [8,9]
2.8.3 Sources of Raw PGMs
2.8.4 Material Flow of PGMs
2.8.5 Smelting and Refining of PGMs
2.8.6 Recycling of PGMs
2.8.7 Conclusions
References
Nomenclature
List of Symbols Thermodynamics (2nd Edition)
Notation for Thermodynamic Properties (Exemplified by G, the Gibbs Energy)
Notation for Quantities
Notation for Substances
List of Symbols Rate Phenomena (2nd Edition)
Special symbols
Accent is a mark appearing directly above the letter or symbol
Subscripts
Superscripts
Equations
Index

Seshadri Seetharaman

Seshadri Seetharaman is Professor Emeritus at the Royal Institute of Technology in Stockholm. Professor Seetharaman has more than 320 publications in peer-reviewed journals, 130 conference presentations and 10 patents. He is the editor for the books, "Fundamentals of Metallurgy" and "Treatise on Process Metallurgy". He received the President’s award for teaching merits in 1994. He was nominated as the best teacher in Materials Science eight times and was chosen as the best teacher of the Royal Inst. of Technol. In 2004. He has been visiting professor at Kyushu Inst. Technol., Kyoto university, Japan and TU-Bergakademie, Freiberg, Germany. He was awarded the Brimacomb prize for the year 2010 Hon. Doctor at Aalto University, Finland in 2011 and Hon. Professor at the Ukrainian Metallurgical Academy, 2011. Prof. Seetharaman is an Hon. Member of the Iron and Steel Institute of Japan, 2011, He has been honoured as the Distinguished Alumni of the Indian Institute of Science, Bangalore, India in the year 2013. He is currently a visiting professor at TATA Steel, Jamshedpur, India

Affiliations and expertise

Professor Emeritus, Royal Institute of Technology, Stockholm, Sweden

Roderick Guthrie

Roderick Guthrie works in the Department of Mining and Materials Engineering at McGill Metals Processing Centre, Quebec, Canada.

Affiliations and expertise

Department of Mining and Materials Engineering, McGill Metals Processing Centre, Quebec, Canada

Alexander McLean

Alexander McLean works in the Department of Materials Science and Engineering at University of Toronto, Toronto, Ontario, Canada.

Affiliations and expertise

Department of Materials Science and Engineering, University of Toronto, Toronto, Ontario, Canada

Sridhar Seetharaman

Sridhar Seetharaman is the Fulton Professor of Industrial Decarbonization at Arizona State University. He received his undergraduate degree from the Royal Institute of Technology and his PHD from MIT. He is a Distinguished Member and Fellow of the Association for Iron and Steel Technology.

Affiliations and expertise

Fulton Professor of Industrial Decarbonization at Arizona State University, USA

H. Y. Sohn

Hong Yong Sohn holds the rank of Distinguished Professor at the University of Utah, having joined the Department of Metallurgical Engineering in 1974. He received his B.S. degree in Chemical Engineering from Seoul National University in Korea and his Ph.D. degree in Chemical Engineering in 1970 from the University of California at Berkeley. He worked as a Research Engineer at Du Pont’s Engineering Technology Laboratory. Dr. Sohn has authored or co-authored 7 monographs, 19 edited books, 28 book chapters, 11 patents, some 600 papers, and 39 technical reports. He has served as a Director of TMS-AIME (The Minerals, Metals and Materials Society), was a U.S. DOE Fossil Energy Lecturer, 1978–81, and is an Advisor to LS-MnM (formerly LS-Nikko Copper Inc.) of Korea and also Korea Institute of Geoscience and Mineral Resources (KIGAM). He is an Honorary Professor of Metallurgy at the Kunming University of Science and Technology at the Anhui University of Technology, China. Professor Sohn’s work has been recognized through various awards, which include the 2014 Educator Award from TMS; the Distinguished Scholarly and Creative Research Award, 2012 from the University of Utah; Billiton Gold Medal, 2012 from The Institute of Materials, Minerals and Mining in the U.K.; the TMS 2009 Fellow Award “in recognition of outstanding contribution to the practice of metallurgical/materials science and technology” from The Minerals, Metals and Materials Society (TMS); the 2001 James Douglas Gold Medal Award (“for leadership and outstanding contributions in research and education of nonferrous extractive metallurgy and for work related to the modeling of gas-solid reactors and the development of novel solvent extraction systems”) from the American Institute of Mining, Metallurgical, and Petroleum Engineers (AIME); Fellow Award from the Korean Academy of Science and Technology, 1998; the TMS Champion H. Mathewson Gold Medal Award (1993 “for the most notable contribution to Metallurgical Science in the 3–year period”); the TMS Extractive Metallurgy Lecturer Award (1990 “in recognition as an outstanding scientific leader in the field of nonferrous extraction and processing metallurgy”); the TMS Extraction and Processing Science Award (1990, 1994, 1999 and 2007, respectively, for analysis of flash furnace shaft; modeling of in situ solution mining operations; synthesis of ultrafine particles of intermetallic compounds; and analysis of the influence of chemical equilibrium on fluid-solid reaction rates and the falsification of activation energy); the Fulbright Distinguished Lecturer (1983); and the Camille and Henry Dreyfus Foundation Teacher-Scholar Award (1977). In 2006, TMS honored Dr. Sohn by holding the “Sohn International Symposium on Advanced Processing of Metals and Materials”. Professor Sohn’s research interests have covered a wide range of subjects, such as Development of a Novel Flash Ironmaking; Plasma-Assisted Chemical Synthesis of Inorganic and Ceramic Nanomaterials; Metallurgical Process Engineering including Computational Fluid Dynamics (CFD) Modeling; Nonferrous metal production (especially coppermaking at high temperatures); Fluid–Solid Reaction Engineering; Synthesis and Processing of Ceramic and Intermetallic Compounds; Hydrogen Storage Materials; Solvent Extraction. A major common theme through these research efforts has been the development and application of reaction kinetics theories, especially the engineering analysis of the reactions between solids and fluids. He coauthored a seminal monograph in the field, “Gas-Solid Reactions”, which had been a standard reference on the subject for more than 40 years: Professor Sohn recently updated and expanded the book as “Fluid-Solid Reactions” incorporating the massive amount of work he has continued on the topic since the publication of “Gas-Solid Reactions” and expanding the coverage to include reactions between a solid and a liquid. A major accomplishment by Professor Sohn in this field is the formulation of a rate law called “Sohn’s Law of Additive Reaction Times” that governs the reactions between solids and fluids that are affected by mass transfer processes. A new monograph entitled “Flash Ironmaking” he wrote at the request of Taylor & Francis Publishers has been released in March 2023. Among the numerous plenary and keynote lectures Professor Sohn has given, he delivered a talk on “Novel Ironmaking Technology with Low Energy Requirement and CO2 Emission” to the U.S. Congress on April 21, 2008. He has also served as a technical consultant to many industrial companies, government units, and research institutes, in addition to serving on a number of editorial/advisory boards of international journals.

Affiliations and expertise

Distinguished Professor, Metallurgical Engineering; Adjunct Professor, Chemical Engineering, University of Utah, USA

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Treatise on Process Metallurgy

Volume 3: Industrial Processes

Purchase options

Institutional subscription on ScienceDirect

Seshadri Seetharaman

Roderick Guthrie

Alexander McLean

Sridhar Seetharaman

H. Y. Sohn