Microemulsion leaching of vanadium from sodium-roasted vanadium slag by fusion of leaching and extraction processes

The fusion of the leaching and purification processes was realized by directly using microemulsion as the leaching agent.The bis-(2-ethyhexyl)phosphoric acid(DEHPA)/n-heptane/NaOH microemulsion system was established to directly leach vanadates from sodium-roasted vanadium slag.The effect of the leaching agent on the leaching efficiency was investigated,in addition to the molar ratio of H_(2)O/NaDEHP(W),DEHPA concentration,solid/liquid ratio,stirring time,and leaching temperature.In optimal situations,the vanadium leaching efficiency reaches 79.57%.The X-ray diffraction characterization of the leaching residue and the Raman spectrum of the microemulsion before and after leaching demonstrate the successful entry of vanadates from the sodium-roasted vanadium slag into the microemulsion.The proposed method successfully realizes the leaching and purification of vanadates in one step,thereby greatly reducing production costs and environmental pollution.It also offers a new way to achieve the green recovery of valuable metals from solid resources.

Prediction of Free Lime Content in Cement Clinker Based on RBF Neural Network

Considering the fact that free calcium oxide content is an important parameter to evaluate the quality of cement clinker, it is very significant to predict the change of free calcium oxide content through adjusting the parameters of processing technique. In fact, the making process of cement clinker is very complex. Therefore, it is very difficult to describe this relationship using the conventional mathematical methods. Using several models, i e, linear regression model, nonlinear regression model, Back Propagation neural network model, and Radial Basis Function （RBF） neural network model, we investigated the possibility to predict the free calcium oxide content according to selected parameters of the production process. The results indicate that RBF neural network model can predict the free lime content with the highest precision （1.3%） among all the models.

Plant Test of Industrial Waste Disposal in a Cement Kiln

Destruction of industrial waste in cement rotary kilns (CRKs) is an alternative technology for the treatment of certain types of industrial waste (IW). In this paper, three typical types of industrial wastes were co-incinerated in the CRK at Beijing Cement Plant to determine the effects of waste disposal (especially solid waste disposal) on the quality of clinker and the concentration of pollutants in air emission. Experimental results show that (1) waste disposal does not affect the quality of clinker and fly ash, and fly ash after the IW disposal can still be used in the cement production, (2) heavy metals from IW are immobilized and stabilized in the clinker and cement, and (3) concentration of pollutants in air emission is far below than the permitted values in the China National Standard-Air Pollutants Emission Standard (GB 16297-1996).

Simulation of clinker grinding circuits of cement plant based on process models calibrated using GA search method

Particle size distributions of obtained samples from several sampling campaigns were determined and raw data were mass balanced before being used in simulation studies.After determination of breakage function,selection function,Bond work index,residence time distribution parameters,and Whiten's model parameters for air separators and diaphragms between the two compartments of tube ball mills,performance of the circuits was simulated for given throughputs and feed particle size distribution.Whiten's model parameters were determined by GA(genetic algorithm) toolbox of MATLAB software.Based on implemented models for modeling and simulation,optimization of circuits was carried out.It increased nearly 10.5% and 15.8% in fresh feed capacity input to each tube ball mill.In addition,circulating load ratios of circuits are modified to 118% and 127% from low level of 57% and 22%,respectively,and also cut points of air separators are adjusted at 30 and 40 μm from high range of 53 and 97 μm,respectively.All applications helped in well-operation and energy consumption reduction of equipments.

Composition Design for High C_3S Cement Clinker and Its Mineral Formation

A new composition of Portland cement clinker was studied, in which KH, SM and IM was 0.98,2.4 and 2.4 respectively as well as its meal added 1%CuO （in mass）. Fired at 1 200℃,1 350℃,1 400℃ and 1 450℃ for 30 min, the resultant mineral phases component and mineral morphology were analyzed. The performances of the cement which was made of clinker burned at 1 450℃ and fly ash were determined. By means of QXRD, XRD and optical microscopy, it is shown that the clinker burnt at 1 450℃ has the larger size crystals and distinct crystal interface, in which the C3S content is 73.37% and the mineral phases is dominantly C3S, following by minor C2S, C3A and tetracalcium aluminoferrite. The results reveal that a new type of high C3S content clinker can completely be made by traditional temperature-time schedule. The performances of the cement produced from this clinker with addtion of 50% fly ash and 5% gupsum were in agreement with the 32.5 strength grade of Portland fly-ash cement. The results also show that the clinker has a significant effect of saving energy and utilizing waste slag.

Characterization of multiphase gas–solid flow and accuracy of turbulence models for lower stage cyclones used in suspension preheaters

This study involved the analysis and characterization of the multiphase flow phenomenon inside the lower stage cyclone separator used in the clinker burning process.The analysis was performed using both CFD and experimental research methods.Very few studies are devoted to such types of cyclone separators,which in addition to their basic functions are also responsible for the technological process.Due to the atypical working conditions of these cyclone separators,they are characterized with a complex geometry,which significantly differs from that of the traditional separators.Furthermore,the evaluation of the accuracy and level of reliability of the two models of turbulence closure—k-e RNG and RSM(RANS),and the LES.The results obtained led to the conclusion that for the lower stage cyclone separators,the LES model proved to be the most accurate(both in the case of forecasting the separation efficiency and pressure drop).The performance parameter(in particular the separation efficiency)values obtained for the RSM model were also characterized by high accuracy.The k-e RNG model was characterized by significantly larger deviations.

Use of recycled gypsum in the cement-based stabilization of very soft clays and its micro-mechanism

This paper presents an experimental study and micro-mechanism discussion on gypsum role in the mechanical improvements of cement-based stabilized clay(CBSC).A soft marine clay at two initial water contents(i.e.50%and 70%)was treated by reconstituted cementitious binders with varying gypsum to clinker(G/C)ratios and added metakaolin to facilitate the formation of ettringite,followed by the measurements of final water contents,dry densities and strengths in accordance with ASTM standards as well as microstructure by mercury intrusion porosimetry(MIP)and scanning electron microscopy(SEM).Results reveal that the gypsum fraction has a significant influence on the index and mechanical properties of the CBSC,and there exists a threshold of the G/C ratio,which is 10%and 15%for clays with 50%and 70%initial water contents,respectively.Beyond which adding excessive gypsum cannot improve the strength further,eliminating the beneficial role.At these thresholds of the G/C ratio,the unconfined compressive strength(UCS)values for clays with 50%and 70%initial water contents are 1.74 MPa and 1.53 MPa at 60 d of curing,respectively.Microstructure characterization shows that,besides the common cementation-induced strengthening,newly formed ettringite also acts as significant pore infills,and the associated remarkable volumetric expansion is responsible,and may be the primary factor,for the beneficial strength gain due to the added gypsum.Moreover,pore-filling ettringite also leads to the conversion of relatively large inter-aggregate to smaller intra-aggregate pores,thereby causing a more homogeneous matrix or solid skeleton with higher strength.Overall,added gypsum plays a vital beneficial role in the strength development of the CBSC,especially for very soft clays.

Utilization of Bayer Red Mud Derived from Bauxite for Belite-Ferroaluminate Cement Production

Bayer red mud(BRM)is a kind of industrial solid waste characterized by huge volume and high alkalinity.Its disposal generates serious environmental pollution and occupies a large number of farmland.The utilization and recycling of BRM is currently a crucial issue and needs to be addressed as soon as possible.The chemical composition of BRM is similar to cement clinker.In this study,the feasibility of preparing Belite-ferroaluminate clinker(BFAC)with different BRM was explored.The physical properties,mechanics performance,radioactivity levels and trace harmful metals leaching were measured.XRD,BEI and EDS were used to characterize the mineral formation,and SEM is used to reveal the solidified mechanism of trace harmful metal.The results show that the preparation of BFAC using a certain amount of BRM was feasible.The formed phases in clinkers mainly included C_(4)A_(3)Š,C_(2)S and C_(4)AF.The flexural strength and compressive strength of BFAC at 3 days increased whereas 28 and 90 days decreased with the increase of BRM due to the formation of higher C_(4)AF and lower C_(2)S.The formation of large amounts of Al_(2)O_(3)·3H_(2)O gel and Fe_(2)O_(3)·3H_(2)O gel in hydration products enhanced the adsorption capability to heavy metals and other ions.The trace harmful metal concentration in the leaching solution was much less than the upper limits.The radioactivity level of leaching solution was close to natural radioactive background.BRM is safe as raw material of BFAC.

Effect of CuO on the Burnability and Mineral Formation of High C_3S Cement Clinker

The effect of CuO on the clinkering process and mineral structure, components and morphology of high C3S cement clinker was studied. One reference mixture was prepared according to the potential mineral phase components C3S=75%, C3A=7%, C4AF=18% and then was mixed, respectively, with 0.5%, 1%, 1.5%, 2%, 2.5% and 4% CuO. All samples were heated at a rate of 10°C/min to the design temperatures and then maintained for 40 min. Analyses by the glycerol-ethanol method, XRD and SEM-EDS show that the minimum of free lime （f-CaO） content was related to temperature and CuO amount. The higher the temperature, the lower the amount of CuO corresponding to the f-CaO minimum content. CuO promotes the formation and growth of C3S and C4AF and a new compound is found. In addition, these phenomena are discussed theoretically. In conclusion, CuO alters the burnability and the formation and structure of C3S in a high C3S cement system.

Catalytic performance of cement clinker supported nickel catalyst in glycerol dry reforming

The paper reports the development of cement clinker-supported nickel （with metal loadings of 5 wt%, 10 wt%, 15 wt% and 20 wt%） catalysts for glycerol dry （CO2） reforming reaction. XRF results showed that CaO constituted 62.0% of cement clinker. The physicochemical characterization of the catalysts revealed 32-folds increment of BET surface area （SBET） with the addition of nickel metal into the cement clinker, which was also corroborated by FESEM images. Significantly, XRD results suggested different types of Ni oxides formation with Ni loading, whilst Ca3SiO5 and Ca2Al0.67Mn0.33FeO5 were the main crystallite species for pure cement clinker. Temperature-programmed reduction analysis yielded three domains of H2 reduction peaks, viz. centered at approximately 750 K referred to as type-Ⅰ peaks, another peaks at 820 K denoted as type-Ⅱ peaks and the highest reduction peaks, type-Ⅲ recorded at above 1000 K. 20 wt% Ni was found to be the best loading with the highest XG and H2 yield, whilst the lowest methanation activity. Syngas with lower H2/CO ratios （0.6 to 1.5） were readily produced from glycerol dry reforming at CO2-to-Glycerol feed ratio （CGR） of unity. Nonetheless, carbon deposit comprised of whisker type （Cv） and graphitic-like type （Cc） species were found to be in majority on 20 wt%Ni/CC catalysts.

NMR Research on Cement Clinker and Its Structures in Early Age Hydration

Clinker has long been regarded as a critical factor for cement hydration and solidification.α-C2S and β-C2S in 2CaO·SiO2（C2S） phase and C3S Monoclinic 1（C3S M1） and C3S Monoclinic 3 （C3S M3） in 3CaO·SiO2 （C3S） phase were clearly recorded in the 29Si MAS NMR spectra.The content of C3S phase in the clinker deduced from the fine peak analysis coincides with the phase quantification analysis calculated by the Taylor-Bogue method based on XRF,which also accords to the statistical data in industrial production.NMR provides a proof that C3S M1 and β-C2S phases have a prior reaction in the early age hydration of clinker,and demonstrates that aluminum coordination changes from tetracoordinated 4CaO·Al2O3·Fe2O3（C4AF） to hexacoordinated [Ca2Al（OH）6]（SO4）0.3·3H2O（Aft） in one day hydration and changes to the 3CaO·Al2O3·CaSO4·nH2O （Afm） in a seven-day hydration.

Optimization of Blended Mortars Using Steel Slag Sand

A new kind of mortar made of ground granulated blast-furnace slag （GGBFS）, gypsum, clinker and steel slag sand （〈4.75 mm） was developed. The ratio of steel slag sand to GGBFS was 1 ： 1 and the amount of gypsum was 4% by weight while the dosage of clinker ranged from 0% to 24%. The optimization formulation of such mortar was studied. The content of steel slag sand should be less than 50% according to the volume stability of blended mortar, and the dosage of clinker is about 10% based on the strength development. Besides strength, the hydration heat, pore structure and micro pattern of blended mortar were also determined. The experimental results show the application of steel slag sand may reduce the dosage of cement clinker and increase the content of industrial waste product such as GGBFS, and the clinker is also a better admixture for blended mortar using steel slag sand.

Quantitative XRD Analysis of Cement Clinker by the Multiphase Rietveld Method

Quantitative phase analysis of Portland cement clinker samples was performed using an adaptation of the Rietveld method.The Rietveld quantitative analysis program,originally in Fortran 77 code,was significantly modified in visual basic code with windows 9X graph user interface,which is free from the constraint of direct utilizable memory 640 k,and can be conveniently operated under the windows environment.The Rietveld quantitative method provides numerous advantages over conventional XRD quantitative method,especially in the intensity anomalies and superposition problems.Examples of its use are given with the results from other methods.It is concluded that,at present,the Rietveld method is the most suitable one for quantitative phase analysis of Portland cement clinker.

Effect of Microwave Processing on Aluminate Cement Clinkering

When raw materials were preheated to 1000-1300 ℃ by electricity and microwave was inputted for 1 min 5 s-4 mins, then alunminate clinkers were obtained. The f-CaO contents,XRD patterns and lithofacies analysis show that the microwave processing accelerates the clinkering reaction,and Fe_2O_3 is contributed to the aluminate cement clinkering. The appearance of liquid phase in process of microwave heating increases the microwave absorbability of materials greatly.

Research on the stability and compatibility of the cementitious materials of Baosteel steel slag fine powder

The application technology using Baosteel steel slag powder as an admixture of concrete is the developmental direction of steel slag recycling treatment and utilization, which fully reflects the basic features and good compatibility of the over-calcined clinker of steel slag resources. It is beneficial to fully exploit the water hardening characteristic and potential activity of steel slag, to reduce and control the unstable factors, such as free calcium oxide and magnesium oxide, and to realize high value-added applications and explore new application fields.

Study on Sintered Synthetic Hercynite Clinker

Special grade bauxite and roll scale were used as raw materials to investigate the influences of reducing atmosphere and firing temperature on sintering clinker. The results showed that: 1) The mixture of the materials could be sintered enough to synthesise hercynite under reducing atmosphere by adding reducing reagent; 2) The hercynite clinker could be sintered to high density and the content of FeAl 2O 4 may attain 80～90% under the firing temperature of 1550℃.

Investigating the Local Granulated Blast Furnace Slag

The promotion of blast furnaces slag in construction industry aims at protecting the environment, fighting against the nuisance such as waste dumps and promoting local products. The use of granulated slag as a part replacement of Portland cement or in the production of clinker free binder constitutes a valuable outlet for this product. The aim of this study is the characterization of local granular slag using various techniques such as chemical analysis, X ray diffraction, differential thermal analysis, infrared spectrometry, and conductimetry. These methods provide a clearer understanding of the vitreous structure of this type of slag and also provide clues as to the nature of its hydraulic reactivity. Mechanical tests have been carried out using 4 × 4 × 16 cm3 prismatic mortars using a composition activated by the clinker, varying the fineness of slag, its content and the nature of clinkers. Results obtained show that this type of slag is reactive, the evolution of its mechanical resistance depends on its fineness, and that long-term mechanical performance is of great interest.

Behavior of SiO_2 in the leaching process of alumina clinker with high concentration

It is essential for alumina production by alkaline process to know the behavior of minerals containing Al and Si in basic solution,and the behavior of SiO2 in the process of clinker leaching is an important portion. To study the behavior of SiO2 in the process of high concentration clinker leaching,experiments were carried out in home-made reactors. The results indicate that factors,such as temperature,time,Al2O3 concentration,as well as SiO2 concentration,have profound impact on the SiO2 and Al2O3 concen-tration of pregnant liquor during the high concentration leaching. However,sodium carbonate and free caustic soda concentrations have no remarkable effect on it,thus they are the secondary factors compared with Al2O3 concentration. The concentration of SiO2 in the pregnant liquor could be reduced to a lower level when the major effect parameters of this process are controlled properly.

Effect of Fused MgO-ZrO_2 Clinker Addition on Thermal Shock Resistance of MgO-ZrO_2 Unfired Bricks

MgO -ZrO2 unfired bricks with ZrO2 content up to 8% at the interval of 2% were prepared, using fused magnesia （ MgO ： 97% ） and fused MgO - ZrO2 clinker （ ZrO2 ： 14. 33% ） as starting materials and phenolic resin as binder. The effects of ZrO2 content on thermal shock resistance （TSR） and other properties such as cold and hot modulus of rupture have been investigated. Re- sidual cold modulus of rupture ratio after heating at 1 000 ℃ and quenching by air blowing was adopted to characterize TSR. Addition of the MgO -ZrO2 clinker improves TSR, attributing to the microcrack toughening effect by thermal expansion mismatch between different phases. When ZrO2 content goes above 4%. the impro- ving effect tends to be moderate. The introduction of MgO- ZrO2 clinker can also improve the HMOR at 1 500 ℃, while the increased ZrO2 content reduces CMOR of the bricks prefired at 1 600 ℃, due to the thermal expansion mismatch effect. Compromising the overall properties, the optimal ZrO2 content for such magnesia based unfired brick is suggested to be 4%.

Effect of Bauxite Aggregate on Properties of Al_2O_3-SiC-C Iron Trough Castables

A1203-SiC-C iron trough castables were prepared using high alumina bauxite clinker GL-90 （ 〉 1 mm ） or homogenized bauxite GL-88 to replace the traditional brown corundum aggregates （ 〉 1 mm ） to reduce the cost of iron trough castables. Effects of the two bauxite aggregates on properties of iron trough eastables were investigated. The results show that the two kinds of bauxite affect flowability, bulk density, strength and slag corrosion resistance of trough castables differently. Compared with homogenized bauxite, high alumina bauxite clinker is more suitable to substitute brown corundum. The castables prepared from the bauxite clinker have similar performances with those prepared from brown corundum, especially used in medium or small blast furnaces with weak thermal impact and lower temperature hot metal. However, in large blast furnaces with severe thermal impact and high temperature hot metal, the performances of the two castables are significantly different. So it is suggested to use the brown corundum based castables in the front gyral zone of the slag skimmer.