An innovative method for determining the structural zones in the large static steel ingots has been described. It is based on the
mathematical interpretation of some functions obtained due to simulation of temperature field and thermal gradient field for solidifying
massive ingot. The method is associated with the extrema of an analyzed function and with its points of inflection. Particularly, the CET
transformation is predicted as a time-consuming transition from the columnar- into equiaxed structure. The equations dealing with heat
transfer balance for the continuous casting are presented and used for the simulation of temperature field in the solidifying virtual static
brass ingot. The developed method for the prediction of structural zones formation is applied to determine these zones in the solidifying
brass static ingot. Some differences / similarities between structure formation during solidification of the steel static ingot and virtual brass
static ingot are studied. The developed method allows to predict the following structural zones: fine columnar grains zone, (FC), columnar
grains zone, (C), equiaxed grains zone, (E). The FCCT-transformation and CET-transformation are forecast as sharp transitions of the
analyzed structures. Similarities between steel static ingot morphology and that predicted for the virtual brass static ingot are described.
The Structural Peclet Number has been estimated experimentally by analyzing the morphology of the continuously cast brass ingots. It
allowed to adapt a proper development of the Ivantsov’s series in order to formulate the Growth Law for the columnar structure formation
in the brass ingots solidified in stationary condition. Simultaneously, the Thermal Peclet Number together with the Biot, Stefan, and
Fourier Numbers is used in the model describing the heat transfer connected with the so-called contact layer (air gap between an ingot and
crystallizer). It lead to define the shape and position of the s/l interface in the brass ingot subjected to the vertical continuous displacement
within the crystallizer (in gravity). Particularly, a comparison of the shape of the simulated s/l interface at the axis of the continuously cast
brass ingot with the real shape revealed at the ingot axis is delivered. Structural zones in the continuously cast brass ingot are revealed: FC
– fine columnar grains, C – columnar grains, E – equiaxed grains, SC – single crystal situated axially.
A vertical cut at the mid-depth of the 15-ton forging steel ingot has been performed by curtesy of the CELSA – Huta Ostrowiec plant.
Some metallographic studies were able to reveal not only the chilled undersized grains under the ingot surface but columnar grains and
large equiaxed grains as well. Additionally, the structural zone within which the competition between columnar and equiaxed structure
formation was confirmed by metallography study, was also revealed. Therefore, it seemed justified to reproduce some of the observed
structural zones by means of numerical calculation of the temperature field. The formation of the chilled grains zone is the result of
unconstrained rapid solidification and was not subject of simulation. Contrary to the equiaxed structure formation, the columnar structure
or columnar branched structure formation occurs under steep thermal gradient. Thus, the performed simulation is able to separate both
discussed structural zones and indicate their localization along the ingot radius as well as their appearance in term of solidification time.
There are presents the internal recycling in anode furnace, in addition to mainly blister copper and converter copper. During the process
there arise the two types of semi-finished products intended for further pyro metallurgical processing: anode copper and anode slag. The
stream of liquid blister copper enters into the anode furnace treatment, in which the losses are recovered, e.g. copper, resulting from
oxidation and reduction of sulfides, oxides and the oxidation of metallic compounds of lead, zinc and iron. In the liquid phase there are
still gaseous states, which gives the inverse relationship relating to the solid phase, wherein the gases found an outlet in waste gas or
steam. The results of chemical analysis apparently differ from each other, because crystallite placement, the matrix structure and the
presence of other phases and earth elements are not compared, which can be regained in the process of electrorefining. One should not
interpret negatively smaller proportion of copper in the alloy, since during the later part of the production more elements can be obtained,
for example from sludge, such as platinum group metals and lanthanides. According to the research the quality of blister copper, to a large
extent, present in the alloy phase to many other elements, which can be recovered.
The scope of work included the launch of the process of refining slag suspension in a gas oven using a variety of technological additives.
After the refining process (in the context of copper recovery), an assessment of the effect of selected reagents at the level of the slag
refining suspension (in terms of copper recovery). Method sieve separated from the slag waste fraction of metallic, iron - silicate and
powdery waste. Comparison of these photographs macroscopic allowed us to evaluate the most advantageous method of separating
metallic fraction from the slag. After applying the sample A (with KF2 + NaCl) we note that in some parts of the slag are still large
amounts of metallic fraction. The fraction of slag in a large majority of the elements has the same size of 1 mm, and a larger portion of the
slag, the size of which is from 2 to 6 mm. Definitely the best way is to remove the copper by means of the component B (with NaCl ) and
D (with KF2
). However, as a result of removing the copper by means of component C (with CaO) were also obtained a relatively large
number of tiny droplets of copper, which was problematic during segregation. In both cases we were able to separate the two fractions in a
fast and simple manner.