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Submit a ProposalHigh Electrical Resistant Materials
 | Ferrochrome Slag Resource Ceramics By Muktikanta Panigrahi, Ratan Indu Ganguly and Radha Raman Dash Copyright: 2024 | Status: Published ISBN: 9781394231256 | Hardcover | 290 pages Price: $195 USD  |
One Line Description
The book describes how the utilization of high-carbon slag/pond ash/fly ash for making value-added ceramics is useful for the electrical sectors.
Audience
The book will be used by electrical and civil engineers in the electrical, construction, and ceramic industries as well as the industrial waste sector. Researchers in materials science, structural, civil and electrical engineering, environmental science, and ceramic engineering, will also have high interest.
The book will be used by electrical and civil engineers in the electrical, construction, and ceramic industries as well as the industrial waste sector. Researchers in materials science, structural, civil and electrical engineering, environmental science, and ceramic engineering, will also have high interest.
Description
Since waste materials are currently endangering our environment, ways of utilizing them have become a global challenge. Currently, R&D work is being carried out to utilize these materials for producing value-added products.
This book details the investigations to utilize fly ash (FA) and pond ash (PA) - both waste materials from thermal power plants - with high-carbon ferrochrome (HCFC) slag (by-product of the ferrochrome industry), for producing a novel material for ceramics. Kaolin/K-feldspar is mixed with PA/HCFC slag to produce ceramics with the formation of mullite. The FA/PA/HCFC slag-based ceramics can replace porcelain-based ceramics, and some permanent ceramic structures can be constructed with such wastes.
Properties and structures made with ceramics are found to be comparable with those made with porcelain-based ceramics. Performances of these materials above ambient temperature have been evaluated and results indicate the possible replacement of porcelain with these newly invented ceramics.
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Since waste materials are currently endangering our environment, ways of utilizing them have become a global challenge. Currently, R&D work is being carried out to utilize these materials for producing value-added products.
This book details the investigations to utilize fly ash (FA) and pond ash (PA) - both waste materials from thermal power plants - with high-carbon ferrochrome (HCFC) slag (by-product of the ferrochrome industry), for producing a novel material for ceramics. Kaolin/K-feldspar is mixed with PA/HCFC slag to produce ceramics with the formation of mullite. The FA/PA/HCFC slag-based ceramics can replace porcelain-based ceramics, and some permanent ceramic structures can be constructed with such wastes.
Properties and structures made with ceramics are found to be comparable with those made with porcelain-based ceramics. Performances of these materials above ambient temperature have been evaluated and results indicate the possible replacement of porcelain with these newly invented ceramics.
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Author / Editor Details
Muktikanta Panigrahi, PhD, completed his doctorate in materials science, Indian Institute of Technology, Kharagpur. He is an assistant professor in the Department of Materials Science, Maharaja Sriram Chandra Bhanja Deo University, Odisha, India. He has completed a project on Geopolymer sponsored by the Ministry of Mines, Govt. of India. He has innovations/discoveries in the area of Geopolymer/MMCs/Ceramics/Polymers and is skilled in the field of basification of industrial wastes, organic semiconductors, biodegradable polymers and gas sensors.
Muktikanta Panigrahi, PhD, completed his doctorate in materials science, Indian Institute of Technology, Kharagpur. He is an assistant professor in the Department of Materials Science, Maharaja Sriram Chandra Bhanja Deo University, Odisha, India. He has completed a project on Geopolymer sponsored by the Ministry of Mines, Govt. of India. He has innovations/discoveries in the area of Geopolymer/MMCs/Ceramics/Polymers and is skilled in the field of basification of industrial wastes, organic semiconductors, biodegradable polymers and gas sensors.
Ratan Indu Ganguly, PhD, completed his doctorate in materials science, Indian Institute of Technology, Kharagpur. He has 50 years of experience for academic teaching. He has completed an industry sponsored project for the development of floor and wall tiles from industrial waste such as fly ash. He is now supporting a research project which relates to development of geopolymer from pond ash.
Radha Raman Dash, PhD, completed his doctorate in materials science, Indian Institute of Technology, Kharagpur. He spent decades at the CSIR-National Metallurgical Laboratory (NML), Jamshedpur as Senior Scientist. He now is Dean of research & development), Gandhi Institute of Engg. & Technology, University, Gunupur, Orissa. He has 10 inventions/discoveries and his research interests are in foundry, composite materials, corrosion, ceramic matrix composites, fractal images and advanced materials.
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Table of Contents
Preface
1. Fundamentals of Ferrochrome (FeCr) Alloy and Its Slag
Muktikanta Panigrahi, Ratan Indu Ganguly and Radha Raman Dash
1.1 Introduction
1.2 Chromite Smelting Technologies
1.2.1 Conventional Smelting Process
1.2.2 Outokumpu Process
1.2.3 DC-Arc Process
1.2.4 Premus Process
1.3 Ferrochrome Production
1.4 Chemical and Physical Properties of Ferrochrome
1.4.1 Characteristics of Ferrochrome
1.5 Ferrochrome Uses
1.5.1 Low-Carbon Ferrochrome Alloy
1.5.1.1 Low-Carbon Ferrochrome – Chemical Analysis
1.5.2 Problems of Carbon in FeCr
1.5.2.1 Refining of Ferrochrome by Chromium Ore
1.5.2.2 Refining of Ferrochrome by Blowing Oxygen
1.5.2.3 Refining of Ferrochrome in Presence of Silicon
1.5.2.4 Silicothermic Process (Production of Low-Carbon Ferrochrome)
1.5.2.5 Production of Carbon-Free Ferrochrome (Aluminothermic Process)
1.5.3 Non-Conventional Techniques
1.5.3.1 Decarburization of Solid Ferrochrome
1.5.3.2 Decarburization Using Oxidizing Gas Mixture
1.5.3.3 Production of Low-Carbon Ferrochrome from Chromite Ore
1.5.3.4 Khalafalla Method
1.5.3.5 Other Methods
1.5.4 High-Carbon Ferrochrome Alloy
1.6 Waste Generation During Ferrochrome Production
1.6.1 Ferrochrome Slag
1.6.2 Ferrochrome Slag Products
1.6.2.1 Petrographic Analysis of Low-Carbon Ferrochrome Slag
1.6.2.2 Description of Crystalline Phases in Ferrochrome Slag
1.6.2.3 Slag Properties
1.6.3 Reactivity of Slag with Container (Metal and Atmosphere)
1.6.3.1 Slag/Container Reactions
1.6.3.2 Slag/Metal Reactions
1.6.3.3 Slag/Atmosphere Reactions
1.6.4 Corrosion and Erosion of Refractories
1.6.4.1 Mechanism of Slag Line Erosion
1.6.4.2 Mechanism of Erosion in Carbon/Oxide Refractories
1.6.5 Thermophysical Properties
1.6.5.1 Estimation of Thermophysical Properties
1.7 Structure of Slags and Glasses
1.7.1 Parameters Used to Represent Structure
1.7.1.1 NBO/T and Q
1.7.1.2 Optical Basicity (Ʌ)
1.7.2 Structural Changes in Glasses and Slags with Temperature
1.7.3 Effect of Structure on Properties
1.7.3.1 Effect of Structure (Q or (NBO/T)) on Properties
1.7.4 Factors Affecting Property
1.7.4.1 Size of Cations
1.7.5 Factors Affecting Measurements
1.7.6 Measurement Methods
1.7.6.1 Methods of Estimating Electrical Conductivity
1.7.7 Factors Affecting Surface Tension (γ)
1.7.8 Interfacial Tension (γMS)
1.7.9 Factors Affecting Thermal Conductivity
1.7.9.1 Thermal Conductivity of Crystalline Slags
1.8 Physical and Mechanical Properties of the Ferrochrome Slag Aggregate
1.9 Characterizations of Ferrochrome (FeCr) Slag
1.9.1 Physical Characterization
1.10 Environmental Aspects of Ferrochrome Production
1.10.1 Raw Material Preparation
1.10.1.1 Smelting
1.10.2 Environmental Management Program
1.10.2.1 Geohydrological Survey
1.10.3 Remediation
1.10.3.1 Environmental Impact Assessment
1.10.3.2 Chemical Reduction of Cr(VI)
1.10.3.3 Bacterial Reduction of Cr(VI)
1.10.3.4 Solidification/Stabilization
1.10.3.5 Other Methods of Remediation
1.11 Conclusions
Acknowledgments
References
2. Production and Test Methods of Waste-Based Ceramics
Muktikanta Panigrahi, Ratan Indu Ganguly and Radha Raman Dash
2.1 Introduction
2.2 Ceramic Process Parameters
2.2.1 Parameters During Mixing
2.2.2 Parameters During Compaction
2.2.3 Parameters During Sintering
2.3 Characterization Techniques
2.3.1 X-Ray Diffraction (XRD) Technique
2.3.2 Fourier Transform Infrared (FTIR) Spectroscopy
2.3.3 Scanning Electron Microscopy (SEM)
2.3.4 Two-Probe Electrical Resistance Measurement (at Room Temperature)
2.4 Conclusion
Acknowledgments
References
3. High Resistance HCFC Slag Ceramic Materials
Muktikanta Panigrahi, Ratan Indu Ganguly and Radha Raman Dash
3.1 Introduction
3.2 Experiment Details
3.2.1 Materials and Chemicals
3.2.2 Sintered HCFC Slag Preparation
3.2.3 Test Methods
3.2.4 Results and Discussion
3.2.5 Conclusions
Acknowledgments
References
4. High Resistant HCFC Slag/Kaolin Ceramics
Muktikanta Panigrahi, Ratan Indu Ganguly and Radha Raman Dash
4.1 Introduction
4.2 Experiment Details
4.2.1 Materials and Chemicals
4.2.2 HCFC Slag/Kaolin Composite Preparation
4.2.3 Test Methods
4.2.4 Results and Discussion
4.3 Conclusions
Acknowledgments
References
5. High Resistant HCFC Slag/K-Feldspar Ceramics
Muktikanta Panigrahi, Ratan Indu Ganguly and Radha Raman Dash
5.1 Introduction
5.2 Experiment Details
5.2.1 Materials and Chemicals
5.2.2 Materials Preparation
5.2.2.1 HCFC Slag-Sintered Materials
5.2.2.2 Preparation of HCFC Slag/K-Feldspar-Based Sintered Composite
5.2.3 Test Methods
5.2.4 Results and Discussion
5.3 Conclusions
Acknowledgments
References
6. High Resistant HCFC Slag-Based Geopolymer Materials
Muktikanta Panigrahi, Ratan Indu Ganguly and Radha Raman Dash
6.1 Introduction
6.2 Experiment Details
6.2.1 Chemicals and Materials
6.2.2 Synthesis of Geopolymer from HCFC Slag
6.2.3 Characterization Techniques
6.2.4 Results and Discussion
6.3 Conclusions
Acknowledgments
References
7. High Resistant PA/HCFC Slag Geopolymer Materials
Muktikanta Panigrahi, Ratan Indu Ganguly and Radha Raman Dash
7.1 Introduction
7.2 Experiment Details
7.2.1 Source of Materials
7.2.2 PA/HCFC Slag Geopolymer (GP) Preparation
7.2.3 Test Methods
7.2.4 Results and Discussion
7.3 Conclusions
Acknowledgments
References
8. High Resistant Exposed HCFC Slag Geopolymer
Muktikanta Panigrahi, Ratan Indu Ganguly and Radha Raman Dash
8.1 Introduction
8.2 Experiment Details
8.2.1 Chemicals and Materials
8.2.2 Geopolymer Synthesis
8.2.3 Test Methods
8.2.4 Results and Discussion
8.3 Conclusions
Acknowledgments
References
9. High Resistant HCFC Slag/Fly Ash Hybrid Ceramics
M. K. Panigrahi, R. I. Ganguly and R. R. Dash
9.1 Introduction
9.2 Experiment Details
9.2.1 Materials and Chemicals
9.2.2 FA/HCFC Slag/CC/PY/k-FD/BC Sintered Hybrid Materials Reparation
9.2.3 Test Methods
9.2.4 Results and Discussion
9.3 Conclusions
Acknowledgements
References
10. High Resistant HCFC Slag/Pond Ash Hybrid Ceramics
M. K. Panigrahi, R.I. Ganguly and R.R. Dash
10.1 Introduction
10.2 Experiment Details
10.2.1 Materials and Chemicals
10.2.2 PA/HCFC Slag Hybrid Materials Preparation
10.2.3 Test Methods
10.2.4 Results and Discussion
10.3 Conclusions
Acknowledgments
References
11. Applications, Challenges and Opportunities of Industrial Waste Resources Ceramics
Muktikanta Panigrahi, Ratan Indu Ganguly and Radha Raman Dash
11.1 Introduction
11.2 Different Ways of Utilizing FeCr Slag Waste
11.2.1 Ferrochromium Slag for Ceramic and Refractory Application
11.2.2 Ferrochrome Slag in Road/Building Construction Applications
11.2.2.1 Ferrochrome Slag Concrete
11.2.3 Hazardous Hexavalent Cr Treatment
11.2.4 Manufacture of Cost-Effective High-Strength MMCs
11.2.5 Valuable Metals Recovery from FeCr Slag
11.2.5.1 Recovery of Iron
11.2.5.2 Recovery of Chromium
11.2.5.3 Recovery of Mg
11.2.5.4 Recovery of Aluminum, Sodium and Potassium
11.2.6 Rip Rap Application
11.2.7 Stone Column Application
11.3 Challenges
11.4 Opportunity
11.5 Conclusions
Acknowledgments
References
Index
Back to Top
Preface
1. Fundamentals of Ferrochrome (FeCr) Alloy and Its Slag
Muktikanta Panigrahi, Ratan Indu Ganguly and Radha Raman Dash
1.1 Introduction
1.2 Chromite Smelting Technologies
1.2.1 Conventional Smelting Process
1.2.2 Outokumpu Process
1.2.3 DC-Arc Process
1.2.4 Premus Process
1.3 Ferrochrome Production
1.4 Chemical and Physical Properties of Ferrochrome
1.4.1 Characteristics of Ferrochrome
1.5 Ferrochrome Uses
1.5.1 Low-Carbon Ferrochrome Alloy
1.5.1.1 Low-Carbon Ferrochrome – Chemical Analysis
1.5.2 Problems of Carbon in FeCr
1.5.2.1 Refining of Ferrochrome by Chromium Ore
1.5.2.2 Refining of Ferrochrome by Blowing Oxygen
1.5.2.3 Refining of Ferrochrome in Presence of Silicon
1.5.2.4 Silicothermic Process (Production of Low-Carbon Ferrochrome)
1.5.2.5 Production of Carbon-Free Ferrochrome (Aluminothermic Process)
1.5.3 Non-Conventional Techniques
1.5.3.1 Decarburization of Solid Ferrochrome
1.5.3.2 Decarburization Using Oxidizing Gas Mixture
1.5.3.3 Production of Low-Carbon Ferrochrome from Chromite Ore
1.5.3.4 Khalafalla Method
1.5.3.5 Other Methods
1.5.4 High-Carbon Ferrochrome Alloy
1.6 Waste Generation During Ferrochrome Production
1.6.1 Ferrochrome Slag
1.6.2 Ferrochrome Slag Products
1.6.2.1 Petrographic Analysis of Low-Carbon Ferrochrome Slag
1.6.2.2 Description of Crystalline Phases in Ferrochrome Slag
1.6.2.3 Slag Properties
1.6.3 Reactivity of Slag with Container (Metal and Atmosphere)
1.6.3.1 Slag/Container Reactions
1.6.3.2 Slag/Metal Reactions
1.6.3.3 Slag/Atmosphere Reactions
1.6.4 Corrosion and Erosion of Refractories
1.6.4.1 Mechanism of Slag Line Erosion
1.6.4.2 Mechanism of Erosion in Carbon/Oxide Refractories
1.6.5 Thermophysical Properties
1.6.5.1 Estimation of Thermophysical Properties
1.7 Structure of Slags and Glasses
1.7.1 Parameters Used to Represent Structure
1.7.1.1 NBO/T and Q
1.7.1.2 Optical Basicity (Ʌ)
1.7.2 Structural Changes in Glasses and Slags with Temperature
1.7.3 Effect of Structure on Properties
1.7.3.1 Effect of Structure (Q or (NBO/T)) on Properties
1.7.4 Factors Affecting Property
1.7.4.1 Size of Cations
1.7.5 Factors Affecting Measurements
1.7.6 Measurement Methods
1.7.6.1 Methods of Estimating Electrical Conductivity
1.7.7 Factors Affecting Surface Tension (γ)
1.7.8 Interfacial Tension (γMS)
1.7.9 Factors Affecting Thermal Conductivity
1.7.9.1 Thermal Conductivity of Crystalline Slags
1.8 Physical and Mechanical Properties of the Ferrochrome Slag Aggregate
1.9 Characterizations of Ferrochrome (FeCr) Slag
1.9.1 Physical Characterization
1.10 Environmental Aspects of Ferrochrome Production
1.10.1 Raw Material Preparation
1.10.1.1 Smelting
1.10.2 Environmental Management Program
1.10.2.1 Geohydrological Survey
1.10.3 Remediation
1.10.3.1 Environmental Impact Assessment
1.10.3.2 Chemical Reduction of Cr(VI)
1.10.3.3 Bacterial Reduction of Cr(VI)
1.10.3.4 Solidification/Stabilization
1.10.3.5 Other Methods of Remediation
1.11 Conclusions
Acknowledgments
References
2. Production and Test Methods of Waste-Based Ceramics
Muktikanta Panigrahi, Ratan Indu Ganguly and Radha Raman Dash
2.1 Introduction
2.2 Ceramic Process Parameters
2.2.1 Parameters During Mixing
2.2.2 Parameters During Compaction
2.2.3 Parameters During Sintering
2.3 Characterization Techniques
2.3.1 X-Ray Diffraction (XRD) Technique
2.3.2 Fourier Transform Infrared (FTIR) Spectroscopy
2.3.3 Scanning Electron Microscopy (SEM)
2.3.4 Two-Probe Electrical Resistance Measurement (at Room Temperature)
2.4 Conclusion
Acknowledgments
References
3. High Resistance HCFC Slag Ceramic Materials
Muktikanta Panigrahi, Ratan Indu Ganguly and Radha Raman Dash
3.1 Introduction
3.2 Experiment Details
3.2.1 Materials and Chemicals
3.2.2 Sintered HCFC Slag Preparation
3.2.3 Test Methods
3.2.4 Results and Discussion
3.2.5 Conclusions
Acknowledgments
References
4. High Resistant HCFC Slag/Kaolin Ceramics
Muktikanta Panigrahi, Ratan Indu Ganguly and Radha Raman Dash
4.1 Introduction
4.2 Experiment Details
4.2.1 Materials and Chemicals
4.2.2 HCFC Slag/Kaolin Composite Preparation
4.2.3 Test Methods
4.2.4 Results and Discussion
4.3 Conclusions
Acknowledgments
References
5. High Resistant HCFC Slag/K-Feldspar Ceramics
Muktikanta Panigrahi, Ratan Indu Ganguly and Radha Raman Dash
5.1 Introduction
5.2 Experiment Details
5.2.1 Materials and Chemicals
5.2.2 Materials Preparation
5.2.2.1 HCFC Slag-Sintered Materials
5.2.2.2 Preparation of HCFC Slag/K-Feldspar-Based Sintered Composite
5.2.3 Test Methods
5.2.4 Results and Discussion
5.3 Conclusions
Acknowledgments
References
6. High Resistant HCFC Slag-Based Geopolymer Materials
Muktikanta Panigrahi, Ratan Indu Ganguly and Radha Raman Dash
6.1 Introduction
6.2 Experiment Details
6.2.1 Chemicals and Materials
6.2.2 Synthesis of Geopolymer from HCFC Slag
6.2.3 Characterization Techniques
6.2.4 Results and Discussion
6.3 Conclusions
Acknowledgments
References
7. High Resistant PA/HCFC Slag Geopolymer Materials
Muktikanta Panigrahi, Ratan Indu Ganguly and Radha Raman Dash
7.1 Introduction
7.2 Experiment Details
7.2.1 Source of Materials
7.2.2 PA/HCFC Slag Geopolymer (GP) Preparation
7.2.3 Test Methods
7.2.4 Results and Discussion
7.3 Conclusions
Acknowledgments
References
8. High Resistant Exposed HCFC Slag Geopolymer
Muktikanta Panigrahi, Ratan Indu Ganguly and Radha Raman Dash
8.1 Introduction
8.2 Experiment Details
8.2.1 Chemicals and Materials
8.2.2 Geopolymer Synthesis
8.2.3 Test Methods
8.2.4 Results and Discussion
8.3 Conclusions
Acknowledgments
References
9. High Resistant HCFC Slag/Fly Ash Hybrid Ceramics
M. K. Panigrahi, R. I. Ganguly and R. R. Dash
9.1 Introduction
9.2 Experiment Details
9.2.1 Materials and Chemicals
9.2.2 FA/HCFC Slag/CC/PY/k-FD/BC Sintered Hybrid Materials Reparation
9.2.3 Test Methods
9.2.4 Results and Discussion
9.3 Conclusions
Acknowledgements
References
10. High Resistant HCFC Slag/Pond Ash Hybrid Ceramics
M. K. Panigrahi, R.I. Ganguly and R.R. Dash
10.1 Introduction
10.2 Experiment Details
10.2.1 Materials and Chemicals
10.2.2 PA/HCFC Slag Hybrid Materials Preparation
10.2.3 Test Methods
10.2.4 Results and Discussion
10.3 Conclusions
Acknowledgments
References
11. Applications, Challenges and Opportunities of Industrial Waste Resources Ceramics
Muktikanta Panigrahi, Ratan Indu Ganguly and Radha Raman Dash
11.1 Introduction
11.2 Different Ways of Utilizing FeCr Slag Waste
11.2.1 Ferrochromium Slag for Ceramic and Refractory Application
11.2.2 Ferrochrome Slag in Road/Building Construction Applications
11.2.2.1 Ferrochrome Slag Concrete
11.2.3 Hazardous Hexavalent Cr Treatment
11.2.4 Manufacture of Cost-Effective High-Strength MMCs
11.2.5 Valuable Metals Recovery from FeCr Slag
11.2.5.1 Recovery of Iron
11.2.5.2 Recovery of Chromium
11.2.5.3 Recovery of Mg
11.2.5.4 Recovery of Aluminum, Sodium and Potassium
11.2.6 Rip Rap Application
11.2.7 Stone Column Application
11.3 Challenges
11.4 Opportunity
11.5 Conclusions
Acknowledgments
References
Index
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