Research of Microstructure,Phase,and Mechanical Properties of Aluminum-Dross-Based Porous Ceramics

In this study,the effect of sintering temperature and the addition of kaolin,a sintering agent,on the microscopic,phase,and mechanical properties of ceramics were investigated using secondary aluminum dross(SAD)as the main component in the manufacturing of ceramics.The basic phases of the ceramics were Al_(2)O_(3),MgAl_(2)O_(4),NaAl_(11)O_(17),and SiO_(2)without the addition of kaolin.The diffraction peaks of MgAl_(2)O_(4),NaAl_(11)O_(17),and SiO_(2)kept decreasing while those of Al_(2)O_(3)kept increasing with an increase in temperature.In addition,the increase in temperature promoted the growth of the grains.The grains were uniform in size and regular in distribution,with a shrinkage of 2.2%,porosity of 72.5%,bulk density of 1.076 g/cm^(3),and compressive strength of 1.12 MPa.When the sintering temperature was 1450°C,the basic phases of the ceramic after the addition of kaolin were Al_(2)O_(3),MgAl_(2)O_(4),NaAl_(11)O_(17),and SiO_(2).With the increase of kaolin,the diffraction peaks of NaAl_(11)O_(17)and SiO_(2)decreased until they disappeared,while the diffraction peaks of Al_(2)O_(3)increased significantly.When kaolin was added at 30 wt.%,the ceramics obtained had shrinkage of 18%,a porosity of 47.26%,a bulk density of 1.965 g/cm^(3),and compressive strength of 31.9 MPa.Cracks existed inside the ceramics without the addition of kaolin,while the addition of kaolin significantly changed this defect.It is shown that SAD can obtain porous ceramics with good properties at a sintering temperature of 1450°C and a kaolin addition of 30 wt.%.

Extraction and characterization of alumina nanopowders from aluminum dross by acid dissolution process

A significant amount of aluminum dross is available as a waste in foundry industries in Bangladesh. In this study, alumina was ex- tracted from aluminum dross collected from two foundry industries situated in Dhamrai and Manikgang, near the capital city, Dhaka. Alu- minum dross samples were found to approximately contain 75wt% A1203 and 12wt% SIO2. An acid dissolution process was used to recover the alumina value from the dross. The effects of various parameters, e.g., temperature, acid concentration, and leaching time, on the extrac- tion of alumina were studied to optimize the dissolution process. First, AI（OH）3 was produced in the form of a gel. Calcination of the AI（OH）3 gel at 1000℃, 1200℃, and 1400℃ for 2 h produced O-AlcOa, （t~＋O）-A1203, and u-alumina powder, respectively. Thermal charac- terization of the AI（OH）3 gel was performed by thermogravimetric/differential thermal analysis （TG/DTA） and differential scanning calo- rimetry （DSC）. The phases and crystallite size of the alumina were determined by X-ray diffraction analysis. The dimensions of the alumina were found to be on the nano level. The chemical compositions of the aluminum dross and alumina were determined by X-ray fluorescence （XRF） spectroscopy. The microstructure and morphology of the alumina were studied with scanning electron microscopy. The purity of the alumina extracted in this study was found to be 99.0%. Thus, it is expected that the obtained alumina powders can be potentially utilized as biomaterials.

Feasibility of aluminum recovery and MgAl_2O_4 spinel synthesis from secondary aluminum dross

The feasibility of aluminum recovery from secondary aluminum dross by extraction with NaOH solution and the subsequent synthesis of MgAl_2O_4 spinel by sintering the extracted slag were studied. The extraction percentage of soluble aluminum from the dross reached 80% at a temperature of 353 K, liquid-to-solid ratio of 12 mL·g^(-1), stirring speed of 300 r·min^(-1), and an extraction time of 15 min; the hydrolysis percentage of AlN reached 40% with an extraction time of 30 min. The activation energies of the soluble aluminum and AlN extracted from the dross were 7.15 and 8.98 kJ·mol^(-1), respectively, indicating that their kinetics were controlled by outer diffusion without a product layer. The extracted slag was sintered in the temperature range 1373–1773 K; MgAl_2O_4 spinel with a compressive strength as high as 69.4 MPa was produced in the sample sintered at 1673 K for 3 h. This value exceeds the threshold(40 MPa) prescribed by the National Standard for the Magnesia and Magnesia-alumina Refractory Bricks of China(GB/T 2275-2007). These results establish the effectiveness of aluminum recovery from secondary aluminum dross and subsequent MgAl_2O_4 spinel synthesis.

Multi-stage Electrostatic Separation for Recovering of Aluminum from Fine Granules of Black Dross

Separation of aluminum from fine granules of black dross, which is a waste by-product in secondary aluminum production, was investigated. The separation was performed by a multi-stage electrostatic separation method. There are three stages to complete the separation, including preliminary separation, pulse charging enhancement and secondary concentration. Chemical and mineralogical compositions of collection products were analyzed and determined by X-ray diffraction(XRD) and X-ray Fluorescence(XRF). After multistage electrostatic separation, the Al2O3 content of the collection products increases from 50.74% to 69.77%.The mineralogical phase analysis indicates that the final recovery of metallic aluminum phase increases from 8%to 37%, and the aluminum oxide phase increases from 20% to 26%. The research results show the multi-stage electrostatic separation method is effective for recovering of aluminum from fine granules of black dross, and upgrades the black dross to a recoverable material.

Recycling of Secondary Aluminum Dross to Fabricate Porous <i>γ</i>-Al₂O₃Assisted by Corn Straw as Biotemplate

In the aluminum industry, secondary aluminum dross (SAD) is an inevitable solid residue, which usually contains 30 - 70 wt% Al2O3. In this work, Al(OH)3 was extracted from SAD through acid-leaching and alkali purification process. The as-obtained Al(OH)3 precipitation then was calcinated to synthesize porous γ-Al2O3 assisting by an agricultural waste biomass-corn straw as biotemplate. Effects of H2SO4 concentration, reaction temperature and time on the recovery of SAD were investigated. Furthermore, the dependence of calcination temperature on specific surface area, pore volume and content of porous γ-Al2O3 was analyzed. X-ray diffraction (XRD) and X-ray fluorescence (XRF) were used to inspect the phase compositions and their contents, respectively. Scanning electron microscopy (SEM) was employed to analyze the morphologies of the sintered porous γ-Al2O3. It was found that the highest recycle rate of aluminum from SAD was obtained under optimum conditions of 80&#176;C, acid concentration of 1.6 mol/l, and reaction time of 5 h by acid process. The porous γ-Al2O3 with specific surface area, 261.22 m2/g and average pore diameter, 52.64 nm, was obtained under calcination at 850&#176;C through mixing the as-obtained Al(OH)3 precipitation and corn straw.

Zinc dross distribution and effects on the surface quality of steel sheet

Through sampling from different depth and different zones in the zinc bath, the size distribution of dross particles built during galvannealed （GA） production is analyzed and compared with that during galvanized （GI） production. The relationship between the dross formation during transitions from GA to GI and the effective Al of the melt is discussed. Finally, the characteristics of dross particles in GA coating and its effects on GA punching and painting performances are studied.

Phase Composition Analysis of TiN-AI_2O_3Synthesized from Aluminum-containing Dross and Rutile by Aluminothermic Reductionnitridation Method

TiN- Al2O3 composite powder was prepared by aluminothermic reduction- nitridation method with starting materials of aluminum-containing dross and rutile,and metallic aluminum in the aluminum-containing dross as reducer. The influences of synthesis temperature（600-1 400 ℃） and aluminum-containing dross addition（20% lower than theoretical value,theoretical value,20% higher than theoretical value,and 50% higher than theoretical value） on phase compositions and microstructure of the composites were investigated,and the reaction mechanism was analyzed. The results show that（1） TiN- Al2O3 composite powder can be synthesized under the experimental conditions; the main phases are TiN,α-Al2O3,a little bytownite,and MgAl2O4;（2）enhancing synthesis temperature or increasing aluminumcontaining dross addition favors the reaction of aluminothermic reduction- nitridation;（3） in the synthesized products,α-Al2O3 is platy or columnar; TiN is sub-micron granular,which reinforces and toughens the composite.

Bottom dross defect and its transformation behavior during the galvannealing process

Bottom dross obtained from zinc bath and the typical bottom dross defects on galvanized and galvannealed coating were metallographically investigated.Galvannealing simulations with different holding time were conducted,and the bottom dross transformation behavior during the galvannealing process was revealed.The fast diffusion between bottom dross particles and the surrounding zinc occurs during the galvannealing process,resulting in the formation of an Al-containing Zn-Fe intermetallic outburst structure at the defect position.The thicker and harder coating will cause a shiny spot on the coating surface and a deep dent on the substrate after being temper rolled.

Process of aluminum dross recycling and life cycle assessment for Al-Si alloys and brown fused alumina

In 2008,around 596 000 t of aluminum dross was generated from secondary aluminum industry in China;however,it was not sufficiently recycled yet.Approximately 95% of the Al dross was land filled without innocent treatment.The purpose of this work is to investigate Al dross recycling by environmentally efficient and friendly methods.Two methods of Al dross recycling which could utilize Al dross efficiently were presented.High-quality aluminum-silicon alloys and brown fused alumina(BFA) were produced successfully by recycling Al dross.Then,life cycle assessment(LCA) was performed to evaluate environmental impact of two methods of Al dross recycling process.The results show that the two methods are reasonable and the average recovery rate of Al dross is up to 98%.As the LCA results indicate,they have some advantages such as less natural resource consumption and pollutant emissions,which efficiently relieves the burden on the environment in electrolytic aluminum and secondary aluminum industry.

Dechlorination of zinc dross by microwave roasting

Traditional treatments of zinc dross have many disadvantages,such as complicated recovering process and serious environmental pollution.In this work,a new process of chlorine removal from zinc dross by microwave was proposed for solving problem of recycling the zinc dross.With better ability of absorbing the microwave than zinc oxide,the main material in zinc dross,chlorides,can be heated and evaporated rapidly during microwave roasting.Various parameters including roasting temperature,duration time and stirring speed were optimized.The microstructure of roasted materials was characterized by X-ray diffraction(XRD) and scanning electron microscope(SEM).The content of the chloride was analyzed by the method of chlorine ion selective electrode.The experiments indicate that the best duration time is 60 min with a stirring speed of 15 r/min during the microwave roasting process.The dechlorination rate reaches peak value of 88% at 700 ℃.The chlorine is removed as HCl gas when water vapor is used as activating agent,which means that it can be recovered into hydrochloride acid.

Dissolution characteristics of black aluminum dross in Na_(3)AIF_(6)-AIF_(3)-Al_(2)O_(3)molten salt system

The dissolution performance of black aluminum dross(BAD)in cryolite electrolyte is key to its recovery by molten salt electrolysis.The stable operation of the electrolyzer depends mainly on the rapid dissolution of BAD in Na_(3)AlF_(6)-AlF_(3)-Al_(2)O_(3)electrolyte system.In this paper,the dissolution performance and behavior of BAD and its main components in the cryolite system were studied,and the saturation solubility of aluminum nitride in this system was determined.The dissolution performance of BAD in cryolite electrolyte before and after denitration was compared,and the effects of temperature,cryolite ratio,and the doping ratio of BAD and alumina on the dissolution rate were investigated.The obtained results showed that aluminum nitride was the main factor affecting the dissolution performance of BAD in the electrolyte.Aluminum nitride was partly converted toα-Al_(2)O_(3)after addition to the electrolyte,and the convertedα-Al_(2)O_(3)was partially dissolved in the cryolite electrolyte,while the remaining precipitated and accumulated at the bottom with aluminum nitride.Aluminum nitride was almost insoluble in the cryolite electrolyte,with 0.0022%solubility.A higher proportion ofα-Al_(2)O_(3)in BAD was negatively influenced its solubility in the cryolite electrolyte.The dissolution rate of BAD in cryolite electrolytes was effectively improved by mixing BAD withγ-Al_(2)O_(3).

Fundamental research on recovering metals from hot-dip Zn-Al-Mg dross by supergravity separation

The dross generated in the hot-dip Zn–Al–Mg coating process is a valuable co-product,since it contains high quantities of recyclable alloy.A new method to recover Zn–Al–Mg alloy from the industrial Zn–Al–Mg dross was proposed using supergravity separation.The separation efficiency was analyzed as a function of gravity coefficient(G),separation time,and separation temperature.The separation of Zn–Al–Mg alloy from the dross can be achieved at G>100.The alloy content in the dross decreased gradually with an increase in the gravity coefficient,the separation time,and the separation temperature.The alloy ratio in the enriched dross decreased almost linearly as the gravity coefficient increased,and the recovery of Zn–Al–Mg alloy from the dross exceeded 78%;these results were consistent with the results of the FactSage software calculation.The purified alloy can be in-situ used in the hot-dip Zn–Al–Mg bath for production.The feasibility of supergravity separation as a promising process for efficiently recovering Zn–Al–Mg alloy from Zn–Al–Mg dross was thus demonstrated.

铝灰水解制氢过程动力学研究

研究设计了一套铝灰水解制氢装置,考察了反应温度、液固体积质量比、搅拌速度及铝灰粒径对铝灰水解制氢过程的影响,并探讨了铝灰水解制氢过程的动力学。结果表明:铝灰水解制氢的最佳工艺条件为反应温度85℃,液固体积质量比10 mL/1 g,搅拌速度130 r/min,铝灰粒径>80目;最佳条件下所得水解渣的主要物相为MgAl_(2)O_(4)、Al(OH)_(3)及Al_(2)O_(3);铝灰水解制氢过程受化学反应控制,化学表观活化能为67.01 kJ/mol,浸出过程符合Avrami-Erofeyev模型。该法可为铝灰水解制氢工艺过程的设计提供一定技术参考。

二次铝灰无害化处理和资源化利用研究进展

二次铝灰是铝熔渣经提取金属铝后得到的固体废弃物,含有氮化铝以及盐类精炼剂,二次铝灰具有污染和资源的双重属性,长期堆存会对环境构成威胁,而夹杂其中的铝化合物可用于二次回收利用,缓解环境危机。目前,二次铝灰的回收利用方法主要包括湿法冶金和火法冶金,湿法冶金主要是将二次铝灰进行溶解,提取里面的铝元素制备氧化铝、聚合氯化铝等;火法冶金主要是在高温条件下煅烧,制备微晶玻璃、耐火材料等。本文总结了二次铝灰的危害,概述了二次铝灰的无害化处理和资源化利用的现状,以期提高二次铝灰的资源化利用效率,降低二次铝灰对环境的污染。

中镍无限冷硬球墨铸铁轧辊辊颈缺陷原因分析及应用

分析了中镍无限冷硬球墨铸铁轧辊离心铸造时产生气孔、夹渣的工艺原因,采取了预脱氧处理、控制稀土镁球化剂使用率、提高浇注速度、提高型砂透气性、控制混合保护渣使用量、配箱时间控制在3 min以内等措施,辊颈气孔和夹渣产生的废品率从40%降低到6%以内,有效降低了废品率。

混掺垃圾飞灰和二次铝灰活性粉末混凝土性能研究

将二次铝灰(SAD)与焚烧垃圾飞灰(WFA)混掺制备成活性粉末混凝土(RPC),研究二次铝灰在两种混合料中的掺量对RPC流变性能参数(扩展度和塑性黏度)、抗折强度、抗压强度以及干燥收缩率的影响,并测定RPC在水中的重金属元素(Cr和Zn)渗出量;观察RPC的微观形貌,揭示RPC性能的机理。结果表明:当二次铝灰的掺量为60%时,RPC的扩展度、抗折强度与抗压强度以及干燥收缩率达到最高,此时RPC的塑性黏度值最小;RPC中Cr与Zn的渗出量与其渗出时间成正相关,与RPC中二次铝灰的掺量成反相关;当二次铝灰掺入60%时,RPC的微观结构最密实。

二次铝灰产品化方案及评价

综述了近年来以二次铝灰为原料制备氧化铝、净水剂、耐火材料、冰晶石、分子筛和陶瓷材料的现状,同时分析其产品及技术特点,对二次铝灰产品化利用给出评价和建议。

铝灰综合利用技术及应用研究

文章简要介绍了铝灰的来源和分类,概述了一次铝灰提铝的不同方法和应用,综述了二次铝灰湿法处理、火法处理、湿法火法联合处理及其他技术的研究和应用现状。针对铝灰综合利用目前存在的问题,提出了分质梯级利用技术,详细介绍了其工艺流程及优势,展望了铝灰综合利用的未来发展趋势。

反射炉粗铅中锡分离的工业研究

铅冶炼采用反射炉熔炼处理铜浮渣时,锡主要进入反射炉粗铅及铜锍,继而分别进入铅电解、铜电解系统,不仅对电解产品质量及电解阳极泥中稀贵金属分离率存在影响,同时造成有价金属锡的流失。针对该情况,本文根据金属对氧元素亲和力的大小,在铜浮渣氧化造渣的基础上,对反射炉粗铅中锡的分离回收进行工艺研究,通过理论性研究及工业实践,可有效的在铜浮渣氧化造渣过程中将金属锡富集于渣相中,实现金属锡的富集分离,富锡渣既可以直接外售,也可以通过进一步的熔炼、真空蒸馏、电解等生产精锡,实现有价元素综合利用,提高企业效益。

Study on the cluster of floating dross before nucleating during hot-dipping process

During hot-dipping in molten Zn-55Al, the forming of “floating” dross is closely re- lated with the interaction between the Al and the Fe atoms. Utilizing the thita-thita X-ray diffraction and the Percus-Yevick hard sphere model, this paper investigates the structure of molten Al3Fe that is an approximant of partial melt in practical Zn-55Al alloy melt. It is found that in the melt there exist clusters that resemble the structure of intermetallic compound Al3Fe. The strong in- teraction between Al and Fe atoms is also indicated by the deficiency of the coordination number from 12 and the shrinkage of averaged atomic diameter. Based on such information, it is specu- lated that in the molten Zn-55Al, with the accumulation of Fe, Al3Fe-like clusters form with priority, then grow into dross. On the other hand, after deflating of the effective hard sphere diameter of pure Al atom and enlarging that of the pure Fe atom, the modified model can achieve reasonable fit to the experimental structure factor. Hard sphere modeling also gave a good estimation of the mass density 3.65 g/cm3 of liquid Al3Fe alloy at 1550℃. Compared with the density of 3.7 g/cm3 of Zn-55Al, the reason for dross floating is satisfactorily understood.