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At least 379 records · Page 21

FEAA90: Physics-based Creep Simulation of Thick Section Welds in High Temperature and Pressure Applications

Welded microstructures of ?’-strengthened, nickel-based alloy, 740H, contain significant microstructural heterogeneities that can have a strong influence on the dislocation dynamics, resulting in very different creep behavior compared to the base metal. Crystal plasticity-based finite element method (CPFEM) has been widely used to incorporate the effect of microstructural heterogeneities on deformation at the polycrystalline scale and is being utilized in this work to model the creep behavior of 740H GTA welds. Current model development is focused on secondary creep considering dislocation climb, glide, and, anti-phase boundary shearing or Orowan looping. A dislocation-density based CPFEM model addressing these mechanisms is currently being implemented in the Multi-Physics Object Oriented Simulation Environment (MOOSE: mooseframework.org) software that provides the ability to solve problems involving multiple physics concurrently and implicitly. Short term creep tests at 700-800°C of cross weld and all-weld metal samples from GTA welds in Alloy 740 will be used to determine input parameters for the model. Long term creep tests at 750°C on Alloy 740H GTA welds will be used to validate the results of modeling and simulation. The model will also be applied to welds with microstructures that develop during hybrid laser arc welding (HLAW) of Alloy 740H to evaluate the effect of weld microstructure on of the validity of the model.

20 FOSSIL-FUELED POWER PLANTS↗

Modeling Induction Stirring and Particle Tracking in Molten Uranium

Two independent numerical models have been developed to simulate the behavior of carbon impurities in molten uranium metal. Informed by experimental parameters, one model was created using the commercial software Star-CCM+ and compared with another developed using open-source codes, including OpenFOAM, Finite Element Method Magnetics (FEMM) and a First Passage Kinetic Monte Carlo (FPKMC) approach. The target experimental system features a 404g uranium metal charge containing an average carbon concentration of 139 ppm which was melted in a vacuum induction furnace at 1400° C then resolidified. The microstructures of the uranium and its impurities before and after melting have been characterized and reported separately. Prior to simulating the uranium-carbon system described, the numerical models were validated using a previously published nonradioactive experimental system to ensure agreement with expected output values. Focus has been placed on modeling velocity fields under induction stirring and impurity particle trajectories.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Molecular dynamics study of mechanical properties of carbon nanotube reinforced aluminum composites

Atomistic simulations were conducted to estimate the effect of the carbon nanotube (CNT) reinforcement on the mechanical behavior of CNT-reinforced aluminum (Al) nanocomposite. The periodic system of CNT-Al nanocomposite was built and simulated using molecular dynamics (MD) software LAMMPS (Large-scale Atomic/Molecular Massively Parallel Simulator). The mechanical properties of the nanocomposite were investigated by the application of uniaxial load on one end of the representative volume element (RVE) and fixing the other end. The interactions between the atoms of Al were modeled using embedded atom method (EAM) potentials, whereas Adaptive Intermolecular Reactive Empirical Bond Order (AIREBO) potential was used for the interactions among carbon atoms and these pair potentials are coupled with the Lennard-Jones (LJ) potential. The results show that the incorporation of CNT into the Al matrix can increase the Young’s modulus of the nanocomposite substantially. In the present case, i.e. for approximately 9 with % reinforcement of CNT can increase the axial Young’s modulus of the Al matrix up to 77 % as compared to pure Al.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

Development and Experimental Optimization of High-Temperature Modeling Tools and Methods for Concentrated Solar Power Particle - Systems

A novel, open-source radiative modeling toolset was developed to extend the functionality of particle-based modeling software (e.g. discrete element method (DEM)) to environmental conditions relevant to concentrated solar power applications. This toolset was optimized for deployment on desktop workstations instead of high-performance computing systems, to render such tools more accessible to the research community. Both particle-based modeling and radiative exchange modeling are computationally expensive and often require specialized programming expertise, making these methods cumbersome to use. Recent developments in DEM software by DCS Computing have greatly reduced these challenges, providing a graphical-user-interface based platform and modeling optimization for desktop workstations, HPCs, and cloud computing. The University of Dayton leveraged the experience of DCS Computing in developing a user-friendly, open-source radiative heat transfer expansion for DEM modeling. The University of Dayton DEM+ radiative modeling toolset was developed using a combination of fundamental experimental measurements, modeling, and simplified flow experiments over a range of temperatures and flow conditions. The toolset provides researchers with access to multiple radiative models including an accelerated Monte-Carlo Ray Tracing (application agnostic, highly computationally expensive), an expanded database of distance-based approximations (application limited, computationally light), and a weighted blending of the two methods capable of achieving over 90% reduction in computation time with equivalent accuracy compared to Monte-Carlo Ray Tracing. Through a graphical user interface, users can customize the radiative models to match their desired accuracy and available computational resources, improving access to particle based modeling for the research community. Ceramic sintered bauxite proppants were used in modeling and experimentally as a baseline. Both the radiative heat transfer and flow properties for particulate systems were investigated at elevated temperatures up to 800 °C. The major accomplishments for this work include a verified, open-source radiative modeling toolset to be distributed amongst the research community and the fabrication of three small-scale test facilities to investigate particle behavior and tune DEM flow properties for operation up to 800 °C. The findings have been shared with the research community via conference modeling workshops, deployment of the tools in DCS Computing Aspherix®, and open-source access to the developed radiative modeling tool. The development of next-generation CSP facilities and thermal energy storage systems based on ceramic particles requires providing access to computationally efficient and accurate modeling tools. Particles will experience a wide range of environments (20-800 °C) and handling conditions (dilute curtains or dense packing), requiring specially designed and optimized equipment. Optimizing solid particle physics models and establishing best-practices for particle modeling in CSP environments will assist researchers with designing optimized equipment, accelerating the deployment of more economically-competitive CSP facilities.

14 SOLAR ENERGY↗

Using Eye-Tracking to Quantify Reverse Engineering Expertise

Software reverse engineering (RE) requires analysts to closely read and make decisions about code. Little is known about what makes an analyst successful, making it difficult to train new analysts or design tools to augment existing ones. The goal of this project was to quantify the eye movement behaviors supporting RE and code comprehension more generally. We applied eye-tracking methods from the language comprehension literature to understand where analysts direct their attention over time when completing tasks (e.g., function identification, bug detection). Across three studies, we manipulated aspects of code hypothesized to impact comprehension (e.g., variable name meaningfulness, code complexity) and presentation methods (e.g., line-by-line, free viewing, gaze-contingent moving window) to understand effects on accuracy and gaze patterns. Results showed clear benefits of meaningful variable names, and effects of expertise on global and line-specific viewing patterns. Findings could inspire empirically-supported tool or analytic adaptations that help to reduce analyst workload.

97 MATHEMATICS AND COMPUTING↗

A Novel Method of Modeling the Deformation Resistance for Clad Sheet

Because of the excellent thermal conductivity, the clad sheet (3003/4004/3003) of aluminum alloy is extensively used in various heat exchangers, such as radiator, motorcar air conditioning, evaporator, and so on. The deformation resistance model plays an important role in designing the process parameters of hot continuous rolling. However, the complex behaviors of the plastic deformation of the clad sheet make the modeling very difficult. In this work, a novel method for modeling the deformation resistance of clad sheet was proposed by combining the finite element analysis with experiments. The deformation resistance model of aluminum 3003 and 4004 was proposed through hot compression test on the Gleeble-1500 thermo-simulation machine. And the deformation resistance model of clad sheet was proposed through finite element analysis using DEFORM-2D software. The relationship between cladding ratio and the deformation resistance was discussed in detail. The results of hot compression simulation demonstrate that the cladding ratio has great effects on the resistance of the clad sheet. Taking the cladding ratio into consideration, the mathematical model of the deformation resistance for clad sheet has been proved to have perfect forecasting precision of different cladding ratio. Therefore, the presented model can be used to predict the rolling force of clad sheet during the hot continuous rolling process.

36 MATERIALS SCIENCE↗

Mesoscale Numerical Characterization of Kevlar and Carbon–Kevlar Hybrid Plain-Woven Fabric Compression Behavior

A mesoscale finite element model (FEM) of the plain-woven fabric representative elementary volume (REV/unit cell) is developed. The developed FEM is used to predict the nonlinear compaction behavior of monolithic and intraply hybrid fabric made of high-strength carbon and Kevlar fibers. For geometrical modeling of the fabric REV, TexGen, an open-source geometrical modeling software (developed at Nottingham University), is utilized, and for mechanical characterization, FE simulation tool Abaqus{sup ®} is used. Geometrical nonlinearity of the fabric, including periodic boundary conditions and yarn interactions, is incorporated in the REV FE model. Material nonlinearity caused by transversely isotropic behavior of fibrous yarns is implemented through the user material subroutine form in FE simulation along with local orientation assigned to each yarn in the REV. Material properties of fibers are extracted from the literature and supplier data. The compression behavior of monolithic Kevlar and hybrid carbon–Kevlar (carbon warp and Kevlar weft yarns, C–K) fabric is predicted using the proposed FE model. FEM-predicted results were found to have good agreement with the experimentally obtained ones. Results depict that C–K hybrid fabrics have improved compression strength. Hybridization effect is governed by yarns mutual interaction, yarn area at crossovers, and transverse in-plane properties of the interyarn hybridized fabric. The proposed FE model can be used to predict the mechanical behavior of woven fabrics with different weaving patterns, unit cell geometry, material properties, and loading conditions.

36 MATERIALS SCIENCE↗

Inter-Disciplinary Collaboration in Support of the Post-Standby TREAT Mission

Although analysis methods have advanced significantly in the last two decades, high fidelity multi- physics methods for reactors systems have been under development for only a few years and are not presently mature nor deployed. Furthermore, very few methods provide the ability to simulate rapid transients in three dimensions. Data for validation of advanced time-dependent multi- physics is sparse; at TREAT, historical data were not collected for the purpose of validating three-dimensional methods, let alone multi-physics simulations. Existing data continues to be collected to attempt to simulate the behavior of experiments and calibration transients, but it will be insufficient for the complete validation of analysis methods used for TREAT transient simulations. Hence, a 2018 restart will most likely occur without the direct application of advanced modeling and simulation methods. At present, the current INL modeling and simulation team plans to work with TREAT operations staff in performing reactor simulations with MAMMOTH, in parallel with the software packages currently being used in preparation for core restart (e.g., MCNP5, RELAP5, ABAQUS). The TREAT team has also requested specific measurements to be performed during startup testing, currently scheduled to run from February to August of 2018. These startup measurements will be crucial in validating the new analysis methods in preparation for ultimate application for TREAT operations and experiment design. This document describes the collaboration between modeling and simulation staff and restart, operations, instrumentation and experiment development teams to be able to effectively interact and achieve successful validation work during restart testing.

97 MATHEMATICS AND COMPUTING↗

SU-E-J-106: The Use of Deformable Image Registration with Cone-Beam CT for a Better Evaluation of Cumulative Dose to Organs

Purpose: The knowledge of dose accumulation in the patient tissues in radiotherapy helps in determining the treatment outcomes. This project aims at providing a workflow to map cumulative doses that takes into account interfraction organ motion without the need for manual re-contouring. Methods: Five prostate cancer patients were studied. Each patient had a planning CT (pCT) and 5 to 13 CBCT scans. On each series, a physician contoured the prostate, rectum, bladder, seminal vesicles and the intestine. First, a deformable image registration (DIR) of the pCTs onto the daily CBCTs yielded registered CTs (rCT) . This rCT combined the accurate CT numbers of the pCT with the daily anatomy of the CBCT. Second, the original plans (220 cGy per fraction for 25 fractions) were copied on the rCT for dose re-calculation. Third, the DIR software Elastix was used to find the inverse transform from the rCT to the pCT. This transformation was then applied to the rCT dose grid to map the dose voxels back to their pCT location. Finally, the sum of these deformed dose grids for each patient was applied on the pCT to calculate the actual dose delivered to organs. Results: The discrepancy between the planned D98 and D2 and these indices re-calculated on the rCT, are, on average, of −1 ± 1 cGy and 1 ± 2 cGy per fraction, respectively. For fractions with large anatomical motion, the D98 discrepancy on the re-calculated dose grid mapped onto the pCT can raise to −17 ± 4 cGy. The obtained cumulative dose distributions illustrate the same behavior. Conclusion: This approach allowed the evaluation of cumulative doses to organs with the help of uncontoured daily CBCT scans. With this workflow, the easy evaluation of doses delivered for EBRT treatments could ultimately lead to a better follow-up of prostate cancer patients.

60 APPLIED LIFE SCIENCES↗

Signal Decomposition for Intrusion Detection in Reliability Assessment in Cyber Resilience (Summary Report)

The complexity of assuring cyber resilience for physical process interactions in connected systems such as energy grids increases dramatically as the coupling between processes becomes more direct and responsive. An example of this growing complexity is provided by Integrated Energy Systems (IES), in which various processes such as nuclear heat generation and commodity production are being directly coupled for increased responsiveness to highly variable signals such as market pricing or electricity demand. As such, the potential attack surface of the coupled processes is larger than the two processes independently. Securing these complex systems requires two-fold monitoring: cybersecure monitoring for potential malicious incursion, and physics monitoring for system tampering. Physics monitoring includes analyzing the behavior of the signals within the system for anomalous behavior. This analysis has been shown to be insufficient if approached by only data-driven machine learning and artificial intelligence (MLAI) techniques or only low-level model comparison. Previous efforts at Purdue University suggested combining high-fidelity models with MLAI algorithms as a basis for a software tool for detecting anomalies in physical processes. This work built on that suggestion, developing an advanced library for signal decomposition and analysis using both MLAI and high-fidelity physics algorithms for greatly improved anomaly detection, especially false data injection. This software can be used as part of a secure imbedded intelligence (SEI) system designed under Consequence-driven Cyber-informed Engineering (CCE) for complex coupled systems. This library established a foundation for online and posteriori analysis of digital signals for the purpose of detecting potential malicious tampering in digital signals representing physical processes. Demonstrations carried out throughout the development highlight the effective use of characterization algorithms to detect signal perturbations, particularly triangle attack-style perturbations, in three wide-ranging applications: seismic monitoring, nuclear thermal hydraulics system simulation, and custom manufacturing.

97 MATHEMATICS AND COMPUTING↗

GDSA - Modeling and Integration – ORNL: PFLOTRAN modeling

This report summarizes work done at Oak Ridge National Laboratory (ORNL) related to post-closure criticality consequence analysis of dual-purpose canister (DPC) direct disposal in unsaturated alluvium. PFLOTRAN software was used to model the behavior of a breached DPC with low water infiltration rates and unsaturated conditions in alluvial deposits such that a low-power criticality event occurs with a focus on thermal hydrological constraints on criticality timing and power output. This summary describes initial exploration of those thermal hydrological processes and of the long-term average power output from a criticality event that could be sustained without driving water out of the DPC package and thereby terminating the criticality event. The objectives are (1) to identify, for different groundwater infiltration rates, the time at which the DPC fills with water sufficiently to potentially initiate criticality; (2) to bound the power output that could be produced by a criticality event that would thermally drive water out of the package at various percolation rates; and (3) provide an estimate of how the size of a package breach affects the water infiltration and therefore the possibility timing of criticality.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

WISP: Watching grid Infrastructure Stealthily through Proxies (Final Technical Report)

The complex interdependencies of cyber systems (sensors and communications), physical grids and associated electricity market operations make protecting electric power grids a significant challenge. The energy sector is constantly under new, targeted, advanced and dangerous cyber-attacks that have the potential to result in the loss of human life. These threats are further exacerbated by our need to modernize the grid. One focus of cyber security research in smart grids is the securing of the SCADA system through advanced intrusion detection systems (IDS) and bad data detection algorithms in state estimation. These methods either require full knowledge of the system topology and parameters or fail to understand the physical behaviors under attack. WISP (Watching grid Infrastructure Stealthily through Proxies) is designed to provide additional protection to the power grid using only publicly available data. In particular, WISP exploits the spatio-temporal nature of the real time locational marginal prices (LMPs), in conjunction with other information such as bids, weather, outages and load data to analyze anomalous power pricing behaviors and then correlate those observations to localize regions of interest and identify potential cyber events. WISP is non-intrusive as the tool is deployed as a service in the Cloud or on premise and provides reliable information to system operators for enhanced situational awareness, without impeding energy delivery functions. The WISP technology comprises three modules: the data-driven anomaly detection core, the vulnerability and risk analysis and the root cause analysis. The data-driven anomaly detection core performs the tasks of feature selection, anomaly detection and attack region localization. The vulnerability and risk analysis module provides system level information of the vulnerable variables and times, assisting the operators in selecting monitoring and protection nodes. The root cause analysis module takes the detection results and identifies potential operational conditions that contribute to the detected anomalies. In Phase I, we have demonstrated the feasibility and effectiveness of WISP. We developed a realistic electricity market simulator capable of generating normal and attack market data under various operational conditions. We developed a series of cyber-attack detection and analysis algorithms and evaluated them under multiple data sources. Finally, we integrated all modules into an end-to-end software, providing functions for data management, data analytics and visualization. Specifically, we have achieved: (i) real-time data acceptance from external utility interfaces with >99% acceptance rate; (ii) high performance anomaly detection algorithms with >98% detection accuracy and <0.1% false alarm rate; and (iii) ultra-low computing delay <50 milliseconds. Additionally, our team developed algorithms to identify the vulnerable variables in electricity market operations and root cause analysis functions to identify major contributors to the price spikes. These ancillary modules are necessary when deploying WISP in real world industry environment. In Phase II, we have demonstrated the effectiveness of WISP software on realistic largescale power systems. We performed red team testing for the Phase I WISP software and identified software vulnerabilities and implemented corresponding mitigation solutions. We adapted the electricity market simulator for the Texas synthetic 2000-bus system and generated datasets for the false data injection attacks. We created database and visualization interfaces for the Texas system and the ISO New England system. We performed software optimization in terms of operation efficiency, computing speed and detection accuracy. Finally, we tested the software on the Texas system and the ISO New England system and evaluated the detection performance. Overall, we achieved above 89% detection rate, below 3% false alarm rate and below 37 seconds of end-to-end detection delay.

24 POWER TRANSMISSION AND DISTRIBUTION↗

SU-F-T-213: Commissioning Results of the Prototype Active Scanning Irradiation System of Korea Heavy Ion Medical Accelerator

Purpose: A prototype actives scanning beam delivery system was designed, manufactured and installed as a part of the Korea Heavy Ion Medical Accelerator Project. The prototype system includes the most components for steering, modulating, detecting incident beam to patient. The system was installed in MC-50 cyclotron beam line and tested to extract the normal operation conditions. Methods: The commissioning process was completed by using 45 MeV of proton beam. To measure the beam position accuracy along the scanning magnet power supply current, 25 different spots were scanning and measured. The scanning results on GaF film were compared with the irradiation plan. Also, the beam size variation and the intensity reduction using range shifter were measured and analyzed. The results will be used for creating a conversion factors for asymmetric behavior of scanning magnets and a dose compensation factor for longitudinal direction. Results: The results show asymmetry operations on both scanning × and y magnet. In case of scanning magnet × operation, the current to position conversion factors were measured 1.69 mm/A for positive direction and 1.74 mm/A for negative direction. The scanning magnet y operation shows 1.38mm/A and 1.48 mm/A for both directions. The size of incoming beam which was 18 mm as sigma becomes larger up to 55 mm as sigma while using 10 mm of the range shifter plate. As the beam size becomes large, the maximum intensity of the was decreased. In case of using 10 mm of range shifter, the maximum intensity was only 52% compared with no range shifter insertion. Conclusion: For the appropriate operation of the prototype active scanning system, the commissioning process were performed to measure the beam characteristics variation. The obtained results would be applied on the irradiation planning software for more precise dose delivery using the active scanning system.

43 PARTICLE ACCELERATORS↗

Benchmark Modeling and Simulation of the FFTF LOFWOS Test #13 Using SAM

The Fast Flux Test Facility (FFTF) was a 400 MW thermal powered, oxide-fueled, liquid sodium cooled test reactor, built to assist development and testing of advanced fuels and materials for fast breeder reactors. In July 1986, a series of unprotected Loss of Flow Without Scram (LOFWOS) transients were performed in FFTF as part of the Passive Safety Testing (PST) program. The LOFWOS Test #13, which was initiated at 50% power and 100% flow with the pump pony motors left off, has been chosen as a benchmark case by IAEA to support collaborative efforts within international partnerships on the validation of simulation tools and models in the area of sodium fast reactor passive safety in an IAEA Coordinated Research Project (CRP), launched in October 2018. The System Analysis Module (SAM) is an advanced and modern system analysis tool under development at Argonne National Laboratory for advanced non-LWR safety analysis. It utilizes the object-oriented application framework MOOSE to leverage the modern software environment and advanced numerical methods. The capabilities of SAM are being extended to enable the transient modeling, analysis, and design of various advanced nuclear reactor systems. To participate the IAEA CRP and enhance the SAM validation base for advanced reactor transient safety analysis, benchmark simulations of the FFTF LOFWOS Test #13 are performed using the SAM code. In this first phase of the validation effort, the thermal-hydraulic behavior of the reactor system is the focus and the reactor kinetics is not considered in the SAM FFTF model. Instead, the results of Argonne’s neutronics calculations are directly used, including the power shape of the active core region and the power history during the transient. The simulation results of FFTF at steady state agreed well with the measured data from the test. During the transient, reasonably good agreement were also obtained. Future work to improve the model will focus on introducing the reactivity predictions into the model, as well as better understanding or resolving the current discrepancies with the measured data.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Methodology for assessing the safety of Hydrogen Systems: HyRAM 1.1 technical reference manual

The HyRAM software toolkit provides a basis for conducting quantitative risk assessment and consequence modeling for hydrogen infrastructure and transportation systems. HyRAM is designed to facilitate the use of state-of-the-art science and engineering models to conduct robust, repeatable assessments of hydrogen safety, hazards, and risk. HyRAM is envisioned as a unifying platform combining validated, analytical models of hydrogen behavior, a stan- dardized, transparent QRA approach, and engineering models and generic data for hydrogen installations. HyRAM is being developed at Sandia National Laboratories for the U. S. De- partment of Energy to increase access to technical data about hydrogen safety and to enable the use of that data to support development and revision of national and international codes and standards. This document provides a description of the methodology and models contained in the HyRAM version 1.1. HyRAM 1.1 includes generic probabilities for hydrogen equipment fail- ures, probabilistic models for the impact of heat flux on humans and structures, and computa- tionally and experimentally validated analytical and first order models of hydrogen release and flame physics. HyRAM 1.1 integrates deterministic and probabilistic models for quantifying accident scenarios, predicting physical effects, and characterizing hydrogen hazards (thermal effects from jet fires, overpressure effects from deflagrations), and assessing impact on people and structures. HyRAM is a prototype software in active development and thus the models and data may change. This report will be updated at appropriate developmental intervals.

97 MATHEMATICS AND COMPUTING↗

CRNT4SBML: a Python package for the detection of bistability in biochemical reaction networks

Motivation: Signaling pathways capable of switching between two states are ubiquitous within living organisms. They provide the cells with the means to produce reversible or irreversible decisions. Switchlike behavior of biological systems is realized through biochemical reaction networks capable of having two or more distinct steady states which are dependent on initial conditions. Investigation of whether a certain signaling pathway can confer bistability involves a substantial amount of hypothesis testing. The cost of direct experimental testing can be prohibitive. Therefore, constraining the hypothesis space is highly bene?cial. One such methodology is based on Chemical Reaction Network Theory which uses computational techniques to rule out pathways that are not capable of bistability regardless of kinetic constant values and molecule concentrations. Although useful, these methods are complicated from both pureandcomputationalmathematicsperspectives.Thus,theiradoptionisverylimitedamongstbiologists. Results: We brought Chemical Reaction Network Theory approaches closer to experimental biologists by automating all the necessary steps in CRNT4SMBL. The input is based on SBML format which is the community standard for biological pathway communication. The tool parses SBML and derives C-graph representations of the biological pathway with mass action kinetics. Next steps involve an ef?cient search for potential saddle-node bifurcation points using an optimization technique. This type of bifurcation is important as it has the potential of acting as a switching point between two steady states. Finally, if any bifurcation points are present, numerical continuation analysis extends the equilibria branches for generating the diagram. Presence of an S-shaped bifurcation diagram indicates that the pathway acts as a bistable switch for the given optimization parameters. Availability: CRNT4SBML is available via the Python Package Index. The documentation can be found at https://crnt4sbml.readthedocs.io. CRNT4SBML is licensed under the Apache Software License 2.0. Contact: vladislav.petyuk@pnnl.gov

Reyes, Brandon C.↗

Assessment of Physicochemical Properties of Electrical Arc Furnace Slag and Their Effects on Foamability

The composition of slags of an electric arc furnace (EAF) in a commercial melt shop was systematically analyzed with a focus on slag foaming. Basic behavior of FeO in an EAF slag was confirmed using fundamental thermodynamics. Monoxide ([Mg,Fe,Mn]O = M’O) and spinel ([Mg,Fe]Al{sub 2}O{sub 4}) phases in EAF slag were confirmed by X-ray diffraction analysis, and these results were interpreted in the context of equilibrium cooling calculation using FactSage™ software. Furthermore, the distribution of MgO with respect to the M’O-saturation limit at different basicity ratios (=CaO/SiO{sub 2}=C/S) and temperatures was evaluated. In particular, the relationship between MgO and FeO for C/S ratios ranging from 1.3 to 1.6 was considered with reference to phase equilibria. Foam height was affected by slag viscosity (η) and gas generation according to changes in C/S ratio and FeO content. Foaming index (Σ) decreased with the increasing C/S ratio and FeO content. The measured foam heights were relatively higher than the calculated values, and the result indicates that the effect of M’O on slag foaming in commercial process is remarkable. Therefore, slag chemistry should be optimized based on thermodynamic considerations and thermophysical properties to achieve good foaming characteristics.

36 MATERIALS SCIENCE↗