Final Technical Report Microwave Assisted Electrolyte Cell for Primary Aluminum Production

This research addresses the high priority research need for developing inert anode and wetted cathode technology, as defined in the Aluminum Industry Technology Roadmap and Inert Anode Roadmap, with the performance targets: a) significantly reducing the energy intensity of aluminum production, b) ultimately eliminating anode-related CO2 emissions, and c) reducing aluminum production costs. This research intended to develop a new electrometallurgical extraction technology by introducing microwave irradiation into the current electrolytic cells for primary aluminum production. This technology aimed at accelerating the alumina electrolysis reduction rate and lowering the aluminum production temperature, coupled with the uses of nickel based superalloy inert anode, nickel based superalloy wetted cathode, and modified salt electrolyte. Michigan Technological University, collaborating with Cober Electronic and Century Aluminum, conducted bench-scale research for evaluation of this technology. This research included three sub-topics: a) fluoride microwave absorption; b) microwave assisted electrolytic cell design and fabrication; and c) aluminum electrowinning tests using the microwave assisted electrolytic cell. This research concludes that the typically used fluoride compound for aluminum electrowinning is not a good microwave absorbing material at room temperature. However, it becomes an excellent microwave absorbing material above 550°C. The electrowinning tests did not show benefit to introduce microwave irradiation into the electrolytic cell. The experiments revealed that the nickel-based superalloy is not suitable for use as a cathode material; although it wets with molten aluminum, it causes severe reaction with molten aluminum. In the anode experiments, the chosen superalloy did not meet corrosion resistance requirements. A nicked based alloy without iron content could be further investigated

REVAMPING OF THE NO. 2-3 SLAB CASTER AT POSCO GWANGYANG: DESIGN, START-UP AND INITIAL OPERATION RESULTS

One of the purposes of revamping the No. 2-3 caster was to have annual production capacity of 3.5 milliontonnes per year for automotive application. Under a given caster length of 47m, the basic requirement underthis value is to achieve 2.7 m/min casting speed for 250mm x 1600mm in slab section. In order to ensurestable operation for this high casting speed, many technologies were newly developed and implementedduring the revamping process. The roller geometry was designed to minimize mould level huntingdue to unsteady bulging. The concept of Intensive secondary cooling was applied to shorten crater endposition as well as to decrease corner transverse cracking by applying the concepts of surface structurecontrol [1]. A movable multi-mode electromagnetic system was designed to control mould flow tomeet diverse operation conditions. An Automatic Ar control system was applied at the caster nozzleto minimize nozzle clogging. This caster was started in Nov. 2007 and went up to 2.7m/min incasting speed very quickly. This paper discusses the behaviour of mould level, mould surface flow andsecondary cooling temperature to the directions of slab width and thickness experienced during casting speedincrease and in particular at 2.7m/min maximum casting speed. Initial productivity and slab-quality resultsare also presented

Thorn-like TiO2 nanoarrays with broad spectrum antimicrobial activity through physical puncture and photocatalytic action

To overcome the conventional limitation of TiO2 disinfection being ineffective under light-free conditions, TiO2 nanowire films (TNWs) were prepared and applied to bacterial disinfection under dark and UV illumination. TNW exhibited much higher antibacterial efficiencies against Escherichia coli (E. coli) under dark and UV illumination conditions compared to TiO2 nanoparticle film (TNP) which was almost inactive in the dark, highlighting the additional contribution of the physical interaction between bacterial membrane and NWs. Such a physical contact-based antibacterial activity was related to the NW geometry such as diameter, length, and density. The combined role of physical puncture and photocatalytic action in the mechanism underlying higher bactericidal effect of TNW was systematically examined by TEM, SEM, FTIR, XPS, and potassium ion release analyses. Moreover, TNW revealed antimicrobial activities in a broad spectrum of microorganisms including Staphylococcus aureus and MS2 bacteriophage, antibiofilm properties, and good material stability. Overall, we expect that the free-standing and antimicrobial TNW is a promising agent for water disinfection and biomedical applications in the dark and/or UV illumination.11Ysciescopu

Time and Amplitude of Afterpulse Measured with a Large Size Photomultiplier Tube

We have studied the afterpulse of a hemispherical photomultiplier tube for an upcoming reactor neutrino experiment. The timing, the amplitude, and the rate of the afterpulse for a 10 inch photomultiplier tube were measured with a 400 MHz FADC up to 16 \ms time window after the initial signal generated by an LED light pulse. The time and amplitude correlation of the afterpulse shows several distinctive groups. We describe the dependencies of the afterpulse on the applied high voltage and the amplitude of the main light pulse. The present data could shed light upon the general mechanism of the afterpulse.Comment: 11 figure

Crystal structure and two-stage hydrolysis of dimethoxo(meso-tetra(4-methoxyphenylporphyrinato))tin(IV), Sn(tmpp)(OMe)(2)

In this work, we determine the crystal structure of dimethoxo(meso-tetra(4-methoxyphenylporphyrinato))tin(IV), Sn(tmpp)(OMe)(2) (1). Experimental results indicate that the tin atom has an octahedral geometry. The geometry around the tin center has Sn(1)-O(5) = 2.020(6), Sn(1)-O(6) = 2.003(7) Angstrom and an average Sn(1)-N = 2.10(1) Angstrom. The two methoxo groups are unidentately coordinated to the tin(IV) atom. Two-stage hydrolysis of Sn(tmpp)(OMe)(2) in CDCl3 was observed by H-1 and C-13 NMR spectroscopy. Compound (1) crystallizes in the space group P2(1)/n with a = 14.7492(1), b = 19.2022(3), c = 16.0806(2) Angstrom, beta = 94.104(1)degrees and Z = 4

Chinese Script vs Plate-Like Precipitation of Beta-Al9Fe2Si2 Phase in an Al-6.5Si-1Fe Alloy

The microstructure of a high-purity Al-6.5Si-1Fe(wt pct) alloy after solidification at various cooling rates was investigated. In most of the cases, the monoclinic beta-Al9Fe2Si2 phase was observed as long and thin lamellae. However, at a very slow cooling rate, Febearing precipitates with Chinese script morphology appeared together with lamellae. Further analysis showed all these Chinese script precipitates correspond also to the monoclinic beta phase. This finding stresses that differentiating second phases according to their shape may be misleading

Gamma Prime Precipitate Evolution During Aging of a Model Nickel-Based Superalloy

The microstructural stability of nickel-based superalloys is critical for maintaining alloy performance during service in gas turbine engines. In this study, the precipitate evolution in a model polycrystalline Ni-based superalloy during aging to 1000 hours has been studied via transmission electron microscopy, atom probe tomography and neutron diffraction. Variations in phase composition and precipitate morphology, size and volume fraction were observed during aging, whilst the constrained lattice misfit remained constant at approximately zero. The experimental composition of the γ matrix phase was consistent with thermodynamic equilibrium predictions, whilst significant differences were identified between the experimental and predicted results from the γʹ phase. These results have implications for the evolution of mechanical properties in service and their prediction using modeling methods.The authors wish to acknowledge Mrs. S. Rhodes, Dr. H.T. Pang, Dr. D.M. Collins, and Dr. O.M.D.M. Messé for their assistance with the experiments performed. Funding was provided by the EPSRC/Rolls-Royce Strategic Partnership under EP/M005607/1 and EP/H022309/1. The Oxford Atom Probe facility was funded by the EPSRC under EP/M022803/1. Neutron diffraction beam time was supported through the Canadian Neutron Beam Centre under Experiment number 1258