Heavy Metal Emissions through Particulate Matter from Aluminium Electrolysis

Heavy metal emissions from the aluminium industry are mainly carried from the plant through fugitive particulate matter (PM) originating from the aluminium electrolysis pot room. To evaluate the behaviour of metal-carrying PM, both airborne and settled PM from two different primary aluminium smelters have been characterized and analyzed for composition and particle size distribution, with special emphasis on heavy metals and carbon. In addition, optical particle sensors have been placed at different elevations in one of the plants to determine the concentrations of different particle sizes in fugitive PM. Metals such as Fe and Ni were primarily found as particles together with S and P on partly combusted carbon PM. Settled PM from both plants were generally coarser (mean = 32–39 μm) and had a higher Al:Na ratio compared with airborne PM, with a mean PM of 21–22 μm. The optical sensors measured PM100 concentrations at roof level in the plant 5–6 times higher than the PM10 concentration during fuming events such as anode shift operations.acceptedVersio

Magnesiothermic Reduction of Silica: A Machine Learning Study

undamental studies have been carried out experimentally and theoretically on the magnesiothermic reduction of silica with different Mg/SiO2 molar ratios (1–4) in the temperature range of 1073 to 1373 K with different reaction times (10–240 min). Due to the kinetic barriers occurring in metallothermic reductions, the equilibrium relations calculated by the well-known thermochemical software FactSage (version 8.2) and its databanks are not adequate to describe the experimental observations. The unreacted silica core encapsulated by the reduction products can be found in some parts of laboratory samples. However, other parts of samples show that the metallothermic reduction disappears almost completely. Some quartz particles are broken into fine pieces and form many tiny cracks. Magnesium reactants are able to infiltrate the core of silica particles via tiny fracture pathways, thereby enabling the reaction to occur almost completely. The traditional unreacted core model is thus inadequate to represent such complicated reaction schemes. In the present work, an attempt is made to apply a machine learning approach using hybrid datasets in order to describe complex magnesiothermic reductions. In addition to the experimental laboratory data, equilibrium relations calculated by the thermochemical database are also introduced as boundary conditions for the magnesiothermic reductions, assuming a sufficiently long reaction time. The physics-informed Gaussian process machine (GPM) is then developed and used to describe hybrid data, given its advantages when describing small datasets. A composite kernel for the GPM is specifically developed to mitigate the overfitting problems commonly encountered when using generic kernels. Training the physics-informed Gaussian process machine (GPM) with the hybrid dataset results in a regression score of 0.9665. The trained GPM is thus used to predict the effects of Mg-SiO2 mixtures, temperatures, and reaction times on the products of a magnesiothermic reduction, that have not been covered by experiments. Additional experimental validation indicates that the GPM works well for the interpolates of the observations.publishedVersio

Influence of Atmosphere and Temperature on Polycyclic Aromatic Hydrocarbon Emissions from Green Anode Paste Baking

Coal tar pitch, a well-known source of polycyclic aromatic hydrocarbons (PAHs), is used as a binder of petroleum coke in prebaked anodes used for electrolysis of aluminum. Anodes are baked up to 1100 °C over a 20-day period, where flue gas containing PAHs and volatile organic compounds (VOCs) are treated using techniques such as regenerative thermal oxidation, quenching, and washing. Conditions during baking facilitate incomplete combustion of PAHs, and due to the various structures and properties of PAHs, the effect of temperature up to 750 °C and various atmospheres during pyrolysis and combustion were tested. PAH emissions from green anode paste (GAP) dominate in the temperature interval of 251–500 °C, where PAH species of 4–6 rings make up the majority of the emission profile. During pyrolysis in argon atmosphere, a total of 1645 μg EPA-16 PAHs are emitted per gram of GAP. Adding 5 and 10% CO2 to the inert atmosphere does not seem to affect the PAH emission level significantly, at 1547 and 1666 μg/g, respectively. When adding oxygen, concentrations decreased to 569 μg/g and 417 μg/g for 5% and 10% O2, respectively, corresponding to a 65% and 75% decrease in emission.publishedVersio

Use of a Distributed Micro-sensor System for Monitoring the Indoor Particulate Matter Concentration in the Atmosphere of Ferroalloy Production Plants

Airborne particulate matter (PM) is a concern for both occupational health and the environment, and, in the ferroalloy industry, the level of such particles in the air can be considerable. Small, low-cost sensors for measuring PM have generated interest in recent years, providing widespread monitoring of PM levels in the environment. However, such sensors have not yet been sufficiently tested under conditions relevant for the indoor environment of the metallurgical industry. This study aims to bridge this gap by benchmarking the commercial, low-cost Nova PM SDS011 particle sensor in two different ferroalloy plants. Benchmarking was performed against the Fidas 200S, which has been suitability-tested and certified according to the latest EU requirements (EN 15267, EN 16450). Twelve Nova sensors were tested over 3 months at a silicomanganese alloy (SiMn) plant, and 35 sensors were tested during 1 month at a silicon (Si) plant. The results showed that the low-cost Nova sensors exhibited all the same trends and peaks in terms of PM concentration, but measured lower dust concentrations than the Fidas 200S. The difference was larger at the silicon plant, which is in line with expectations, due to the size and mass fractions of particles in Si dust compared to SiMn dust, and to the larger measurement range of the Fidas, measuring down to 180 nm compared to the Nova which measures down to 300 nm. Despite the difference in absolute values, the Nova sensors were found to provide data for comparing dust levels over time for different processes, at different locations, and under different operational conditions.publishedVersio

Silane Gas Production Through Hydrolysis of Magnesium Silicide by Hydrochloric Acid

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Effect of (5%) CO2 on the Oxidation Rate During Cooling of Industrial Aluminum White Dross

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Analysis of Polycyclic Aromatic Hydrocarbon Emissions from a Pilot Scale Silicon Process with Flue Gas Recirculation

Flue gas recirculation (FGR) is a method used in several industries to control emissions and process conditions, such as NOx reduction and temperature levels, and increase the CO2 concentration in the off-gas, to be better suited for methods of carbon capture. In this study, the influence of FGR, varying levels of flue gas flow and oxygen concentration on the emissions of polycyclic aromatic hydrocarbons (PAHs) was investigated during Si alloy production. In addition, computational fluid dynamics (CFD) modeling was performed using OpenFOAM for combustion of C2H2 and H2 with varying O2 levels to simulate FGR and to gain better insight into the impact of furnace operations on the PAH evolution. Experimental results show that increasing FGR (0–82.5%) and decreasing levels of oxygen (20.7–13.3 vol %) increase the PAH-42 concentration from 14.1 to 559.7 μg/Nm3. This is supported by the simulations, where increased formation of all PAHs species was observed at high levels of FGR, especially for the lighter aromatic species (like benzene and naphthalene), due to the lower availability of oxygen and the reduction in temperature. Residence time was identified as another key parameter to promote complete combustion of PAHs. Benzene oxidation can be prevented with temperatures lower than 1000 K and residence times smaller than 1 s, while complete oxidation is found at temperatures of around 1500 K.publishedVersio

Kinetics of Magnesiothermic Reduction of Natural Quartz

In this work, the kinetics of natural quartz reduction by Mg to produce either Si or Mg2Si was studied through quantitative phase analysis. Reduction reaction experiments were performed at various temperatures, reaction times and Mg to SiO2 mole ratios of 2 and 4. Rietveld refinement of X-ray diffraction patterns was used to obtain phase distributions in the reacted samples. SEM and EPMA examinations were performed to evaluate the microstructural change during reduction. The results indicated that the reduction reaction rate was slower at a mole ratio of 2 than 4 at the same temperature, as illustrated by the total amount of Si formed (the percent of Si that is reduced to either Si or Mg2Si to total amount of Si) being 59% and 75%, respectively, after 240 min reaction time for mole ratios of 2 and 4. At the mole ratio of 4, the reaction rate was strongly dependent on the reaction temperature, where SiO2 was completely reduced after 20 min at 1273 K. At the lower temperatures of 1173 and 1073 K, total Si formed was 75% and 39%, respectively, after 240 min reaction time. The results of the current work show that Mg2Si can be produced through the magnesiothermic reduction of natural quartz with high yield. The obtained Mg2Si can be processed further to produce silane gas as a precursor to high purity Si. The combination of these two processes offers the potential for a more direct and low carbon method to produce Si with high purity

Kinetics of Magnesiothermic Reduction of Natural Quartz

In this work, the kinetics of natural quartz reduction by Mg to produce either Si or Mg2Si was studied through quantitative phase analysis. Reduction reaction experiments were performed at various temperatures, reaction times and Mg to SiO2 mole ratios of 2 and 4. Rietveld refinement of X-ray diffraction patterns was used to obtain phase distributions in the reacted samples. SEM and EPMA examinations were performed to evaluate the microstructural change during reduction. The results indicated that the reduction reaction rate was slower at a mole ratio of 2 than 4 at the same temperature, as illustrated by the total amount of Si formed (the percent of Si that is reduced to either Si or Mg2Si to total amount of Si) being 59% and 75%, respectively, after 240 min reaction time for mole ratios of 2 and 4. At the mole ratio of 4, the reaction rate was strongly dependent on the reaction temperature, where SiO2 was completely reduced after 20 min at 1273 K. At the lower temperatures of 1173 and 1073 K, total Si formed was 75% and 39%, respectively, after 240 min reaction time. The results of the current work show that Mg2Si can be produced through the magnesiothermic reduction of natural quartz with high yield. The obtained Mg2Si can be processed further to produce silane gas as a precursor to high purity Si. The combination of these two processes offers the potential for a more direct and low carbon method to produce Si with high purity

Valorization of SiMn Sludge for Production of Low-Phosphorus Ferroalloys

The sludge generated by wet scrubbing the off-gas from a silicomanganese plant in Norway represents a significant loss in silicon and manganese values. This work seeks to extract these values in the production of ferroalloys and slags that can be utilized by alternative industries. Carbothermic smelting the sludge together with iron or iron scraps at 1600 °C produced FeSiMn alloys consisting of 57–64 wt.% Mn, 16–22 wt.% Si and 18–25 wt.% Fe. The low level of phosphorus in the sludge allowed for beneficial phosphorus concentrations as low as 500 ppmw in the metal alloys. The addition of lime to the material mix resulted in increased evaporation of alkalis, capture of sulfur in the slags as calcium sulfides and slag compositions similar to conventional steel-making slags that can be recycled accordingly