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QUADRENNIAL REPORT 2008 – 2011

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DEPARTMENT OF PROCESS AND ENVIRONMENTAL ENGINEERING

LABORATORY OF PROCESS METALLURGY

QUADRENNIAL 2008 – 2011

EDITORS: KAISA HEIKKINEN, MIKKO ILJANA, RIKU MATTILA and TIMO FABRITIUS

UNIVERSITY OF OULU

Laboratory of Process Metallurgy

P.O. Box 4300

FI-90014 UNIVERSITY OF OULU

FINLAND

OULU 2012

QUADRENNIAL REPORT 2008 – 2011

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PREFACE

This report concentrates on events that have taken place in the Laboratory of Process Metallurgy during

the years 2008- 2011.

During the four year period the educational actions of process metallurgy have been integrated more

intensely to studies in Process and Environmental Engineering. The number of annually graduating

diploma engineers has remained constant with an average figure of 9 per year. During the previous four

years teaching has been developed further by three new courses based on problem-based learning and

experiences of close co-operation with metallurgical industry. In the field of research, TEKES (the Finnish

Funding Agency for Technology and Innovation), Academy of Finland and metallurgical industry have

been our main sources of financial funding. Furthermore, we have participated intensively on the

research programs organized and funded by Fimecc Ltd (Finnish Metals and Engineering Competence

Cluster) from the May 2009. The share of external competitive market funding comprises 80% of the

total funding.

Core competencies of the laboratory have been strengthened by new analyzing methods and laboratory

equipment: Transport phenomena (mass, heat and momentum), reactions (thermodynamics and

kinetics) and structure (mineralogy and petrology). Our research activities related to iron, steel and

ferroalloy production have been integrated more closely to CASR (Centre for Advanced Steels Research).

The CIRU (Centre for Industrial Residual Utilisation) covers our environmental engineering related

research including slag utilisation, secondary raw material treatments and recycling.

Professor Jouko Härkki, head of laboratory since the establishment of laboratory in 1991, retired at the

end of February 2010. Timo Fabritius was appointed as his successor and started as the new professor of

process metallurgy in March 2010.

All in all, the last four years have been a period of major changes on many levels. Despite many changes

and challenges, close collaboration with Finnish metallurgical industry and research institutes has

continued and strengthened. Once again I would like to extend my thanks to our collaboration partners

and capable staff.

Head of laboratory

Professor Timo Fabritius

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TABLE OF CONTENTS

PREFACE .................................................................................................................................................. 2

TABLE OF CONTENTS ............................................................................................................................... 3

LABORATORY STAFF 31.12.2011 ............................................................................................................. 5

ACADEMIC STAFF................................................................................................................................. 5

RESEARCHERS ...................................................................................................................................... 5

MASTER’S THESIS WORKERS ................................................................................................................ 6

TECHNICAL STAFF ................................................................................................................................ 6

VISITING TEACHERS ............................................................................................................................. 6

EDUCATIONAL ACTIVITIES ....................................................................................................................... 7

COURSE DESCRIPTIONS...................................................................................................................... 10

RESEARCH ACTIVITIES ............................................................................................................................ 15

I REDUCTION METALLURGY ............................................................................................................... 16

II REFINING METALLURGY .................................................................................................................. 25

III REDUCING AGENTS ........................................................................................................................ 32

IV SLAGS, DUSTS AND WASTES .......................................................................................................... 38

V REFRACTORY MATERIALS ................................................................................................................ 44

VI OTHER ........................................................................................................................................... 46

LABORATORY DEVICES ........................................................................................................................... 48

THERMAL ANALYSIS ........................................................................................................................... 48

OTHER HIGH TEMPERATURE DEVICES ................................................................................................ 49

OTHER ............................................................................................................................................... 49

PUBLICATIONS ....................................................................................................................................... 51

SCIENTIFIC JOURNAL PAPERS ............................................................................................................. 51

CONFERENCE PAPERS, SEMINARS AND SYMPOSIUMS........................................................................ 53

OTHER REPORTS & PUBLICATIONS ..................................................................................................... 58

THESES .................................................................................................................................................. 63

BACHELOR’S DEGREE ......................................................................................................................... 63

2008 ................................................................................................................................................... 63

QUADRENNIAL REPORT 2008 – 2011

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2009 ................................................................................................................................................... 63

2010 ................................................................................................................................................... 63

2011 ................................................................................................................................................... 64

MASTER’S DEGREE ............................................................................................................................. 64

2008 ................................................................................................................................................... 64

2009 ................................................................................................................................................... 65

2010 ................................................................................................................................................... 65

2011 ................................................................................................................................................... 66

CONTACT INFORMATION ....................................................................................................................... 67

QUADRENNIAL REPORT 2008 – 2011

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LABORATORY STAFF

31.12.2011

ACADEMIC STAFF

Härkki Jouko D.Sc. (Tech), Professor, Head of the Laboratory ( →28.02.2010)

Fabritius Timo D.Sc. (Tech), Professor, Head of the Laboratory (01.03.2010→)

Heikkinen Eetu-Pekka Lic.Sc. (Tech), University Teacher Tanskanen Pekka M.Sc. (Geol), University Teacher

RESEARCHERS

Alatarvas Tuomas M.Sc. (Tech), Research Assistant Angerman Mikko Research Manager Aula Matti M.Sc. (Tech), Doctoral Student Gornostayev Stanislav PhD (Geol.Min.), Research Fellow,

Academy of Finland Haapakangas Juho M.Sc. (Tech), Doctoral Student Heikkilä Anne Lic.Sc. (Math), Doctoral Student Heikkinen Eetu-Pekka Lic.Sc. (Tech), University Teacher Heikkinen Kaisa Research Assistant, Webmaster, Part-Time Heino Jyrki D.Sc. (Tech), Doc. Researcher Huttunen Satu M.Sc. (Chem), Doctoral Student Härkki Jouko D.Sc. (Tech), Emeritus Iljana Mikko M.Sc. (Tech), Doctoral Student Kanerva Pyry Research Assistant Kemppainen Antti M.Sc. (Tech), Doctoral Student Kokkonen Tommi M.Sc. (Chem), Project Researcher Kärnä Aki M.Sc. (Phys), Doctoral Student Leppänen Ahti Research Assistant Makkonen Hannu M.Sc. (Geol.Min.), Doctoral Student Mattila Riku M.Sc. (Tech), Laboratory Manager Mäkelä Anssi M.Sc. (Chem), Doctoral Student Riipi Jaana M.Sc. (Math), Doctoral Student Roininen Juha M.Sc. (Tech), Doctoral Student Salo Antti B.Sc. (Tech), Research Assistant Sulasalmi Petri M.Sc. (Math), Doctoral Student Suopajärvi Hannu M.Sc. (Tech), Doctoral Student Tanskanen Pekka M.Sc. (Geol), University Teacher Visuri Ville-Valtteri M.Sc. (Tech), Doctoral Student Välikangas Juho M.Sc. (Tech), Doctoral Student

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MASTER’S THESIS WORKERS

Salo Antti B.Sc. (Tech)

TECHNICAL STAFF

Kokkonen Tommi M.Sc. (Chem), Project Researcher Mattila Riku M.Sc. (Tech), Laboratory Manager

VISITING TEACHERS

Ahola Juha University of Oulu Hekkala Lauri Outotec Hooli Paavo D.Sc. (Tech), Outokumpu Stainless Oy, Tornio Ikäheimonen Topi M.Sc. (Tech), Outokumpu Stainless Oy, Tornio Isokääntä Jani M.Sc. (Tech), Metso Minerals, Pohto Isokääntä Simo M.Sc. (Tech), Ruukki Metals Oy, Raahe Kujala Kauko University of Oulu Laitinen Tiina University of Oulu Louhenkilpi Seppo D.Sc. (Tech), Docent, Aalto University, Ollila Seppo M.Sc. (Tech), Ruukki Metals Oy, Raahe Paananen Timo M.Sc. (Tech), Ruukki Metals Oy, Raahe Petäjäjärvi Marko M.Sc. (Tech), Outokumpu Chrome Oy, Tornio Pisilä Erkki M.Sc. (Tech), Ruukki Metals Oy, Raahe Päätalo Mika M.Sc. (Tech), Outokumpu Chrome Oy, Tornio Roininen Juha M.Sc. (Tech), Outokumpu Stainless Oy, Tornio Sarpola Arja D.Sc (Tech), University of Oulu Savolainen Jari M.Sc. (Tech), Outokumpu Stainless Oy, Tornio

QUADRENNIAL REPORT 2008 – 2011

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EDUCATIONAL ACTIVITIES Eetu-Pekka Heikkinen

The primary goal of the education organized by the laboratory of process metallurgy is to educate

people with master’s and doctoral degrees (M.Sc.Eng. and D.Sc.Tech.) into the service of metallurgical

industry. As a part of the department of process and environmental engineering, the laboratory also

aims to organize its educational activities in a way that serves the educational objectives of the whole

department (i.e. to understand and to control the phenomena occuring in the industrial processes).

Because of this it is not laboratory’s only goal to teach people to understand the metallurgical processes

of iron, steel and ferroalloys production as thoroughly as possible. It is equally important to give

students different viewpoints and perspectives to the phenomena and problems concerning

metallurgical processes as well as other challenges which a freshly graduated M.Sc.Eng. may encounter

in his or her future career. This means that the students have the abilities to understand, model and

control the phenomena inside the processes no matter what the process in question is.

The bachelor level studies (180 ECTS credits) in the department of process and environmental

engineering are organized according to a so-called DAS-formalism, that consists of the descriptive

(saying what something is like, describing something), analytical (using a logical method of thinking

about something in order to understand it, especially by looking at all the parts separately) and synthetic

(combination of two or more parts by design) phases, through which education in all orientations is

carried out. In contrast to the conventional ‘analytical’ approach, where engineering education starts

with studies of chemistry, physics and mathematics, the DAS formalism approach concentrates on

engineering from the first day, starting with ‘description’.

During the bachelor level studies, the students of process engineering are not yet divided into the

students of metallurgy, automation engineering, pulp and paper engineering, and so on. All the students

have a similar curriculum that aims at general engineering competencies of which the most important

ones are:

- Phenomena-based modelling and design and the competence areas leading to those: The

student learns the basic principles of phenomena-based design and will be able to produce

static and dynamic process models both in industrial and natural processes, as well as analyse

physical, chemical, biological and geo-scientific phenomena occurring in those processes.

- Mastery of the entities for manufacturing activities: The student can evaluate the production

and manufacturing activities as entities with the technological, environmental protection,

economic, occupational safety and juridical factors.

- Command of automation technology: The student can recognise the need for automation

technology for controlling the functions of different systems, and can design the physical and

programmatic parts of those systems.

- Non-technical capabilities: In technical design, research and development tasks certain non-

technical professional working-life skills are needed. These include, among other things, social,

multicultural and internationality skills. The student is able to write, analyse and evaluate texts

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within his/her own professional and scientific field and work in a target-oriented fashion in

different working life situations including personal performance and group communication.

The laboratory of process metallurgy organizes three courses (5 ECTS credits each) for the bachelor level

curriculum:

- Introduction to process and environmental engineering I (formerly Introduction to process

engineering)

- Thermodynamic equilibria

- Solid inorganic materials (formerly Solid state structures)

After the bachelor level, the students of process engineering choose whether their further studies are

focused on automation, chemical engineering, metallurgy, mineral processing, pulp and paper

engineering or industrial engineering and management. The master level studies (120 ECTS credits)

consist of four modules (30 ECTS credits each). One or two of these modules are determined based on

the major topic chosen by the student, whereas one or two are more freely chosen. The final module

consists of the master’s thesis.

Laboratory of process metallurgy organizes one module with an objective according to which the

students are able to utilize experimental, analytical and modelling tools that are required in the research

and development of pyrometallurgical processes in which iron, steel and ferroalloys are produced.

Additionally, they can identify how these research methods are connected to the metallurgical

applications (i.e. processes, materials and environmental effects) and to the phenomena (i.e. reactions,

transport phenomena, structural changes), that take place in these applications. The students that focus

on process metallurgy, may choose two modules freely. The most common choices are materials science

and engineering, automation engineering, industrial management and engineering as well as mineral

processing.

Until 2010, the module of process metallurgy consisted of the following courses:

- Thermodynamics of pyrometallurgical solutions (5 ECTS credits)

- Thermodynamics of hydrometallurgical solutions (3 ECTS credits)

- Surfaces and phase boundaries in pyrometallurgy (4 ECTS credits)

- Melting and solidification (4 ECTS credits)

- Oxidation and reduction in pyrometallurgy (5 ECTS credits)

- Slags and slag formation in pyrometallurgy (5 ECTS credits)

- Laboratory exercises of metallurgy (4 ECTS credits)

Since 2011, the module of process metallurgy have included the following courses:

- Phenomena-based modelling in extractive metallurgy (10 ECTS credits)

- Experimental research in extractive metallurgy (10 ECTS credits)

- Process simulation in extractive metallurgy (10 ECTS credits)

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In addition to the courses mentioned above, the course of Environmental load of metallurgical industry

(4 ECTS) has been organized as a research seminar in co-operation with the Luleå University of

technology in 2005, 2008 and 2010. The personnel of the laboratory of process metallurgy has also

taken an active role in the educational activities of other academic institutions. For example D.Sc. (Tech.)

Jyrki Heino has acted as an invited lecturer on various courses concerning the industrial ecology and

environmental load at the Helsinki, Jyväskylä and Aalto Universities.

The educational activities are constantly being developed by the individual teachers as well as within the

educational development groups that operate in both laboratory and department levels. The

educational development has not been unnoticed since the department of process and environmental

engineering has been credited as a national centre of excellence in university education by The Finnish

Higher Education Evaluation Council three times in 2004-2006, 2007-2009 and 2010-2012. Additionally,

university teacher Eetu-Pekka Heikkinen received a national ‘Good teacher’ -award from the Finnish

Foundation for Technology Promotion in 2009.

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COURSE DESCRIPTIONS

477011P Introduction to process and environmental engineering I

ECTS credits: 5 cr.

Objective: To give an overview on process and environmental engineering and to get familiar with the

concepts of these disciplines.

Learning outcomes: Students can examine industrial processes using the methods and perspectives of

process and environmental engineering (e.g. unit operations, mass and energy balances, identification

of mechanical, chemical and transport phenomena in the processes, automation, process design) and

they recognize the role of different areas of the process and environmental engineering, when these

areas are considered in the forthcoming courses.

Contents: 1. Introduction to process engineering. 2. Mechanical unit operations. 3. Transport

phenomena. 4. Reaction engineering. 5. Structures. 6. Automation. 7. Bioprocess engineering and its

possibilities. 8. Process design.

Target group: Students of process and environmental engineering

Recommended optional programme components: This course is an introduction to the other courses of

process and environmental engineering.

Person responsible: Professor Timo Fabritius

477401A Thermodynamic equilibria

ECTS credits: 5 cr.

Objective: The goal is to understand the fundamentals of thermodynamics in order to be able to

consider thermodynamic equilibria in industrial processes.

Learning outcomes: Student is capable of defining chemical equilibria of the systems that are related to

industrial processes and understands the relevance of equilibria (and their computational

determination) as a part of process analysis, planning and control. Additionally, (s)he can define a

meaningful system to be considered in computation thermodynamics; i.e. (s)he can create a

computationally solvable problem based on technical problem that in itself is not solvable

computationally.

Contents: Concepts of entalphy (H), entropy (S) and Gibbs free energy (G). The effect of temperature

and pressure on H, S and G. Chemical and phase equilibria. Activity and activity coefficient. Calculation

of thermodynamic equilibria using equilibrium constant as well as Gibbs free energy minimisation.

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Target group: Students of process and environmental engineering

Recommended optional programme components: This is one of the courses in which physical chemistry

is used in the applications of process and environmental engineering. It is part of a stream that aims at

skills needed in the phenomenon-based modelling and planning of industrial processes.

Person responsible: University Teacher Eetu-Pekka Heikkinen

477402A Solid inorganic materials

ECTS credits: 5 cr.

Objective: This cource aims to increase the ability of students to understand structure and properties of

solid inorganic materials and interdependency between the structure and properties. Additionally,

characterization methods of solid materials and the importance solid mineral materials for modern

society and their sources, usage, refining chains and environmental impacts are introduced.

Learning outcomes: Students passing the cource can name the most important solid inorganic materials

(metals and compounds) and their applications. Students can describe the significance of the materials

for the society and tell about the refining chains and environmental impacts of the materials. Students

can describe the structure and properties of solid materials and their interdependency and

characterization methods. Students can compare and classify materials and tell the factors the

classification is based on. Additionally, students can tell about the importance of the structural approach

on the materials when estimating their performance in use or in reprocessing.

Contents: Sources, usage, importance, refining and environmental impacts of inorganic solid materials

(metals and compounds) used in modern society. Structure, properties and interdependency between

the structure and properties and material characterization methods. Application examples: solid

materials as raw materials and products in process industry (e.g. steel and concrete).

Target group: Students of process engineering

Recommended optional programme components: This course is an introduction to the advanced

courses of metallurgy. Additionally, it gives a material-based perspective for the consideration of

industrial processes. It is part of the streams that aim at skills needed in the phenomenon-based

modelling and planning of industrial processes as well as holistic understanding of industrial processes.

Person responsible: University Teacher Pekka Tanskanen

477412S Phenomena-based modelling in extractive metallurgy

ECTS credits: 10 cr.

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Objective: To familiarize with the essential phenomena of the metallurgical processes as well as to learn

to use the models and methods developed for the investigation of these phenomena in the metallurgical

research and development.

Learning outcomes: Students passing the course are familiar with the most important computational

methods used to investigate the most essential phenomena in the research and development of

metallurgical processes. Students can e.g. calculate thermodynamic equilibria, read and construct phase

stability diagrams as well as other diagrams used in the investigation of pyrometallurgical and

electrochemical reactions, describe the role of inclusions in metal production, describe the structure of

metallurgical slags, etc. It should however be noted that these are only examples since the contents of

the course are under continuous development and therefore more detailed learning outcomes are given

each year at the beginning of each course.

Contents: Models and methods that are used to investigate the most essential chemical and physical

phenomena in the research and development of metallurgical processes.

Target group: Students of process metallurgy

Recommended optional programme components: The module of process metallurgy consists of

courses 477412S, 477413S and 477414S.

Person responsible: University Teacher Eetu-Pekka Heikkinen

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477413S Experimental research in extractive metallurgy

ECTS credits: 10 cr.

Objective: The cource aims to increase skills of students to make laboratory scale research and

development projects concerning high temperature research in extractive metallurgy. Team work,

project managing and reporting skills are also aimed to be developed.

Learning outcomes: Students passing the course are familiar with the most important experimental and

analytical methods used in the laboratory scale research of materials and metallurgical processes.

Students can determine and separate research problems to reasonable pieces, collect the background

information, select the reasonable methods and make the research and reporting on planned schedule.

Additionally, students can observe the metallurgical phenomena and their interconnections and

consequences. It should also be noted that the contents of the course are under continuous

development and therefore more detailed learning outcomes are given each year at the beginning of

each course.

Contents: Typical experimental and analytical methods used to research the high temperature

modification and behaviour (oxidation, reduction, melting, surface phenomena, kinetics) of materials.

Determining and separating research problems to reasonable pieces, making the background research,

selecting suitable methods, reporting and presenting the results.

Target group: Students of process metallurgy

Recommended optional programme components: The module of process metallurgy consists of

courses 477412S, 477413S and 477414S.

Person responsible: University Teacher Pekka Tanskanen

477414S Process simulation in extractive metallurgy

ECTS credits: 10 cr.

Objective: To introduce the most important metal production processes and metallurgical unit

operations used in Finland as well as to learn the modelling and simulation methods concerning these

processes. Additionally, the roles of slags, reduction agents and refractory materials in the metallurgical

processes are considered.

Learning outcomes: Students passing the course are familiar with the metal production processes and

metallurgical unit operations used in Finland and they can create process simulations describing these

processes. Additionally, students can identify the boundary conditions of the process simulations

created by e.g. availability of the data and possibilities to model the phenomena involved in these

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processes. It should also be noted that the contents of the course are under continuous development

and therefore more detailed learning outcomes are given each year at the beginning of each course.

Contents: The most important metal production processes and metallurgical unit operations used in

Finland as well as modelling and simulation of these processes.

Target group: Students of process metallurgy

Recommended optional programme components: The module of process metallurgy consists of

courses 477412S, 477413S and 477414S.

Person responsible: Professor Timo Fabritius

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RESEARCH ACTIVITIES Timo Fabritius

Main research activities of the Laboratory of Process Metallurgy have focused on the ironmaking and

steelmaking processes and phenomena that occur at high temperature processes. Topics of studies

cover whole chain of process metallurgy from raw material treatments into the metallurgical quality of

casted steel slabs. The research actions have been divided into five main divisions: I reduction

metallurgy, refining metallurgy, reducing agents, refractory materials and slags, dusts and wastes at high

temperature processes. As part of CASR, the Laboratory of Process Metallurgy conducts high-level

scientific and applied research on modern steels, their processing methods and properties, in

conjunction with several universities, research institutes and steel companies. Research of

environmental engineering at high temperature processes is collected under the guidance of The Centre

for Industrial Residue Utilisation, CIRU.

During 2008-2011 the most important scientific contribution of the laboratory has been in the blast

furnace metallurgy including coke and charge material research as well as fluid flow modelling of

refining and secondary steelmaking processes.

Total laboratory funding has been balanced at the level of 1.5 M euros per year. The laboratory employs

about 22-25 personnel on average including diploma thesis workers. In practice, almost all research

activities are based on the collaboration with industrial partners. The role of Tekes (the Finnish Funding

Agency for Technology and Innovation) as a financer is remarkable, although the laboratory has also

acquired more funding from the Academy of Finland as a form of research projects and Graduate School

vacancies.

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I REDUCTION METALLURGY

Efficient electric arc metallurgy (EffArc)

Contact person: Olli Mattila (05/2009 – 01/2011) and Anne Heikkilä (02/2011 −)

Researchers: Olli Mattila (05/2009 – 01/2011), Arto Rousu (05/2009 – 09/2010), Juha Roininen (up to

07/2011 at Outokumpu Stainless Oy, then from 07/2011 at University of Oulu), Anne Heikkilä (01/2011

−) and Matti Aula (11/2011 −)

Duration: 01.05.2009 – 30.04.2013

Objective and results: Efficient electric arc metallurgy (EffArc) is a part of project named Energy &

Lifecycle Efficient Metal Processes (ELEMET). Originally the objectives of the project are to attain

information on the radiation characteristics emitted from electric arc and its effects on the stabilities of

oxides in the furnace and to improve the understanding of the influence of electric heating on the slag –

metal reactions. Renewed research plan steers the focus a bit from electric arc furnace (EAF) to

submerged arc furnace (SAF), more precisely to the electrical behavior of the SAF charge. The original

idea is further studied in TULI-funded spinoff project lead by laboratory of process metallurgy. Co-

operation is intense between participating laboratories and companies involved with project. In the near

future, the project will involve more studies relating to direct contactless measurement from EAF

process and slag foaming to get more material and energy efficient processing developed.

Partners: Outokumpu Stainless Oy, Outotec Oyj, VTT and University of Oulu

Financiers: The Finnish Funding Agency for Technology and Innovation (TEKES), Outokumpu Stainless Oy

and Outotec Oyj

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Figure 1. Measurements for EffArc project in electron spectroscopy laboratory.

Material Efficient Blast Furnace (MEBF) – High Temperature Properties of Coke

Contact person: Juho Haapakangas

Researchers: Juho Haapakangas (07/2009 –), Olli Mattila, (07/2009 − 01/2011), Tommi Kokkonen (part-

time, 07/2009 −)

Duration: 07/2009 – 04/2012

Objective and results: The main goal of the project has been to radically improve material and energy

efficiency in the ferrous industry. Each member of the project has had their own area of focus: Oulu-

MHT: modeling of oil injection in the tuyere and raceway area of a blast furnace, Oulu-MTG:

metallurgical limitations of injection, development of coke hot strength, effect of burden water content

on blast furnace gas atmosphere, Ruukki Metals Oy: utilization of secondary raw materials in

briquetting, high productivity with low CO2-emissions, industrial trials with 100 % pellet operation,

modeling pellet reduction kinetics, ÅA-HE: simulation of blast furnace charging, CIRU-Centre & Aalto

University: novel briquetting recipes, Outotec Finland Oy: simulation and optimization of an igglu-type

sintering furnace, new methods for Mn pelletizing and sintering.

The original focus of Laboratory of Process Metallurgy was to study how the increase of residual fuel oil

injection changes the internal conditions inside a blast furnace and to find possible limitations of

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injection. For this purpose an Excel-HSC-model was developed to calculate the gas composition in

different parts of a blast furnace with various rates of oil injection. The calculated gas atmospheres were

then utilized by reacting coke with the Blast Furnace gas phase Simulator (BFS). Reactions rates of cokes

were analyzed as well as the effect of the gas atmosphere on fine coke formation in a blast furnace

shaft. The results were published at METEC InSteelCon 2011, Düsseldorf, Germany. The gasification and

burning properties of both residual fuel oil and coal tar were also evaluated using a differential scanning

calorimetry. Due to the changes in Ruukki company’s future plans for injected fuels, the focus of the

project shifted toward study of strength properties of coke. For this purpose a new method for

evaluating coke hot strength up to 1750 °C was developed.

Partners: University of Oulu (Laboratory of Process Metallurgy, Laboratory of Mass and Heat Transfer);

Åbo Akademi (Laboratory of Thermal and Flow Engineering), Ruukki Metals Oy; Outotec Finland Oy;

CIRU-Centre and Aalto University

Financiers: The Finnish Funding Agency for Technology and Innovation (TEKES), Ruukki Metals Oy and

Outotec Finland Oy

Material Efficient Blast Furnace (MEBF) – New Briquetting Materials

Contact persons: Jyrki Heino and Satu Huttunen

Researchers: Mikko Angerman (part-time), Jyrki Heino (19.10.2009 –), Satu Huttunen (23.8.2011 –),

Tommi Kokkonen (part-time) and Hannu Makkonen (20.8.2009 –)

Duration: 01.08.2009 – 30.04.2013

Objective and results: Blast furnace operation in Raahe has been changed to 100 % pellet charging in

the beginning of 2012. Together with this transition the sinter plant has been shut down and a new

briquetting plant has been built to utilize by-products from the steel works. Briquetting itself offers all

new possibilities to introduce different type of previously unutilized materials into the blast furnace

process. Secondary materials from pulp and paper industry or from steel industry can be used to act as

cheaper binder materials or to shift oxides reduction or slag formation energetically into favourable

path. These new types of briquetting recipes have been and will be established and tested in this

subproject. The subproject provides phenomenological knowledge of the briquette cold bonding

mechanisms and mineralogical associations and metamorphosis in an increasing temperature.

Partners: Ruukki Metals Oy, Raahe; Clean Technologies Research Group, Department of Forest Products

Technology, Aalto University School of Chemical Technology; Mass and Heat Transfer Process

Laboratory, Department of Process and Environmental Engineering, University of Oulu

Financiers: The Finnish Funding Agency for Technology and Innovation (TEKES) and Ruukki Metals Oy

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Figure 2. Coke briquettes for laboratory scale experiments made of coke, cement and different amounts

of water.

Material Efficient Blast Furnace (MEBF), Industrial part

The MEBF project is part of the Energy Efficiency & Lifecycle Efficient Metal Processes (ELEMET) research

program coordinated by the Finnish Metals and Engineering Competence Cluster (FIMECC). Ruukki

Metals Oy acts as industrial partner and is also funded by them.

Reduction of olivine pellets in CO-CO2-H2-H2O-N2 gas

Contact person: Timo Fabritius

Researchers: Olli Mattila, Antti Kemppainen, Jari Savolainen, Tommi Kokkonen and Eetu-Pekka

Heikkinen (part-time)

Duration: 01.10.2009 − 30.04.2010

Objective and results: The aim of the research was to investigate the kinetics of reduction phenomena

in olivine pellets in various gas atmospheres and gas flow rates. In the first part of the project it was

noticed that sample pellets had variation in the iron oxide distribution (hematite and magnetite) and the

pellets were sorted by the amount of magnetite in the structure to enhance comparison between

samples. Particle size distribution (PSD analysis) was also made to sample pellets. The investigation was

mainly realized by numerous high temperature laboratory experiments conducted with

thermogravimetric analysis furnace (TGA). The reduction gas compositions and temperatures for the

experiments were selected by estimating the conditions in the different levels of blast furnace shaft.

This way the pellet reduction to magnetite, wüstite and iron in the blast furnace shaft was simulated

with TGA.

The following observations were made from the results of the TGA experiments:

- The amount of magnetite in the pellet has no significant effect on the reduction rate

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- Comparison between reduction rates of a pellet half and powdered pellet hald showed that the

reduction rate increases markedly with the increasing surface area in the reduced sample

material

- Comparison of reduction rates of the hematite pellets in 1 l/min and 2 l/min flow rates in

identical gas atmospheres showed that gas flow rate has no significant effect on the reduction

rate

- Nitrogen has a retarding effect on the reduction rate when added to CO-CO2 or to CO-CO2-H2-

H2O atmosphere

- 8 % H2-H2O addition to CO-CO2 gas has no significant effect on the reduction rate of pellet when

the reduction potentials of H2 and CO are set to equal by fixing CO/CO2 and H2/H2O ratios

- Two phase reductions of pellets showed that the amount of wüstite non-stoichiometry has no

significant effect on the reduction rate when the pellet is reduced to iron in the second phase

- Reduction rate increases with increasing CO partial pressure in CO-CO2 mixtures as well as in CO-

CO2-H2-H2O mixtures

Analysis of EBF briquette samples

Contact person: Timo Fabritius

Researchers: Olli Mattila, Antti Kemppainen and Sauli Pisilä

Duration: 01.05.2010 − 30.04.2011

Objective and results: Properties of briquette samples treated in MEFOS pilot scale blast furnace were

analyzed in the project. The research focused on the structural changes in briquettes descending in the

blast furnace. Briquettes were supplied in the blast furnace in material cages which were collect after

heating the furnace. Material cages were positioned in different layers of the blast furnace and cages

included also pellets and slag as reference samples. Structural changes of briquettes were examined

with a light microscope and an electron microscope and chemical composition was analyzed.

The results showed that the more reductive the atmosphere and the more higher the temperature at

the lower parts of blast furnace the more coherent were the briquette samples. At higher parts of the

blast furnace the briquette samples were degraded probably by the effect of temperature because the

atmosphere was not reductive enough to enable the formation of ferric matrix in the briquette which

binds the structure together. The ferric matrix is formatted from the cement ingredients in the briquette

in reductive atmosphere and as the ingredients evaporate from structure in non-reductive atmosphere

the structure collapses.

Effect of water content of the burden material on the blast furnace gas

Contact person: Timo Fabritius

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Researcher: Antti Kemppainen

Duration: 01.05.2011 − 30.04.2012

Objective and results: The aim of the research is to estimate if the water content of the burden material

is able to affect the blast furnace gas composition through water-gas shift reaction as burden material

falls in the blast furnace shaft and encounters with rising hot gases. This is an important issue as it may

have effect on the utilization of the blast furnace gas later in the process.

The research consists of three parts: 1) The examination of the drying processes of the water containing

blast furnace burden materials (pellet, briquette) will be made and an estimation of the water content in

the burden material as it falls in the blast furnace shaft and encounters with rising hot gases. 2)

Determination of the critical temperature for occurrence of water-gas shift reaction in blast furnace

shaft will be made and the possible reaction catalytic factors in the blast furnace shaft environment will

be investigated. 3) Based on the investigations made in parts 1 and 2 will be made an estimation if the

water content of the blast furnace burden material is able to affect the composition of blast furnace gas

through water-gas shift reaction. All these investigations will be made with applicable laboratory

equipment.

Optimal Pellet Blast Furnace Charging (PEMAS)

Contact persons: Olli Mattila (01.03.2009 – 31.01.2011) and Mikko Iljana (01.02.2011 –)

Researchers: Jari Kurikkala (03/2009 – 04/2010), Olli Mattila (part-time, 03/2009 – 01/2011), Mikko

Iljana (11.01.2011 –) and Tuomas Alatarvas (17.01.2011 –)

Project technicians: Tommi Kokkonen (part-time) and Riku Mattila (part-time)

Duration: 01.03.2009 − 30.04.2012

Objective and results: The PEMAS project is focused on the transition from sinter-pellet mixture to 100

% pellet burden in both blast furnaces at the Raahe steelworks at the end of 2011 as the sintering plant

was closed. The aim of this project is to attain knowledge of the blast furnace shaft phenomena when

pellets are used as a burden material. This requires laboratory simulation experiments under controlled

conditions. As these phenomena are understood, the blast furnace operation can be optimized for the

100 % pellet operation. At the University of Oulu the PEMAS project is mainly focused on two research

areas both including a lot of microscopy and FESEM-EDS analyses:

1) Determination of the change in the blast furnace gas composition in sinter, pellet and coke layers

with a Layer Furnace (LF) equipment constructed in this project. Based on the experimental results the

suitable pellet and coke layer thicknesses for the BF operation can be defined.

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2) Study of the reduction swelling and cracking behaviour of olivine pellets and fluxed pellets in

comparison with acid pellets under sulphur and potassium containing atmospheres with Blast Furnace

gas phase Simulator (BFS) and the evaluation of the effect of these phenomena on shaft permeability.

For the layer charging part of the project, it was detected that the utilization rates of gases rise higher in

pellet operation than when using sinter as iron-bearing material. Furthermore, hydrogen and water

vapour were observed to start participating in the reduction reactions in pellet and sinter bed and

solution-loss reactions in coke bed at somewhat higher temperatures than carbonaceous gases (CO and

CO2).

In the second part comprising the pellet swelling, it was noticed that the olivine pellets are not of

uniform quality as the size of the magnetite nucleus varies having effect on the reduction swelling

behaviour. Swelling tendency of SiO2-rich pellets was observed to be more restrained in comparison to

olivine pellets. In addition, it was verified that standard swelling tests carried out under isothermal

conditions such as ISO 4698 leads to markedly high reduction swelling indices and do not simulate the

swelling behaviour in the blast furnace very well. Thus, the reduction swelling behaviour of iron ore

pellets should preferably be studied dynamically under simulated blast furnace conditions. Sulphur in

excess quantities was associated with partial melt formation of FeO-FeS and pellet shrinking while

potassium in reducing atmosphere with normal swelling. Sulphur in excess quantities was associated

with partial melt formation of FeO-FeS and pellet shrinking (see Figs. 3 and 4) while potassium in

reducing atmosphere with normal swelling

Partner: Ruukki Metals Oy

Financier: Ruukki Metals Oy

Figure 3. Pellet images after dynamic reduction up to 1100 oC under high sulphur partial pressure (max

1.0 vol-% S2) conditions.

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Figure 4. LOM images from pellet periphery reduced under high sulphur partial pressure (max 1.0 vol-%

S2) conditions.

Ferrochromium production in submerged arc furnace

Contact person: Timo Fabritius

Researchers: Jouko Härkki, Topi Ikäheimonen (01/2007 – 08/2007) and Arto Rousu (09/2007 – 12/2009)

Duration: 1.1.2007 – 31.12.2009

Objective and results: The aim of this project was to clarify the temperature, phase and material

distribution in a submerged arc furnace with drillings and temperature measurements when producing

ferrochromium. Drillings were carried out with the tuyere drilling machine of Rautaruukki. Furthermore,

drill samples from the submerged arc furnace gave new knowledge of the prevailing conditions in the

furnace.

Additionally, investigations with two different furnace models were carried out at the University of Oulu.

With these models the flow of electric current in the charge material bed in a submerged arc furnace

and structural changes in particles during ferrochromium production process were investigated.

Partners: Outokumpu Stainless Oy and Outotec Finland Oy

Financier: Outokumpu Säätiö Oyj

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Improvement of Hearth Drainage Efficiency and Refractory Life for High BF

Productivity and a Well Adjusted Reductant Injection Rate at Varying Coke Quality

(Hearth Efficiency)

Contact person: Timo Fabritius

Researcher: Olli Mattila

Technician: Tommi Kokkonen

Duration: 01.07.2007 − 31.12.2010

Objective and results: The objective of the Laboratory of Process Metallurgy was to use new and

innovative methods to study the blast furnace coke and to combine the information obtained with

existing knowledge of blast furnace process to find the reasons of deadman blocking in close co-

operation with Ruukki and Åbo Akademi. Feed coke samples were studied by the means of optical

reactive texture, pore shape distribution and coke ash grain size distribution and the gasification

behavior of metallurgical coke under simulated shaft conditions (K, S, etc.) with Blast Furnace gas phase

Simulator (BFS). Drilled core samples were studied by the means of bulk chemical analysis (co-operation

with Ruukki), SEM study of polished sections (co-operation with Ruukki), SEM study of extracted

submicron particles and coke ash grain size distribution. Research method development was applied on

image analysis and submicron particle analysis methods.

New information of tuyere level operation was obtained leading to highlight the importance of charging

pattern in the top of the BF as it reflects to the shape, composition and location of cohesive zone and

behavior of circulation processes in the BF. This affects on the flow fields of gases escaping the raceway

area and together with deadman behavior − sitting or (partly) swimming − it can lead to deadman

blocking.

Partners: VDEh-Betriebsforschungsinstitut, Germany; AG der Dillinger Hüttenwerke, Germany; Arcelor

Eisenhüttenstadt, Germany; Ruukki, Finland; Åbo Akademi University, Finland; University of Oulu,

Finland; Arcelor Research SA, France; Arcelor España, Spain; C.S.I.C/CENIM, Spain; MEFOS, Sweden;

Lucchini, Italy and CSM, Italy

Financier: European Commission (the Research Fund for Coal and Steel, RFCS) and University of Oulu

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II REFINING METALLURGY

Advanced Melt Metallurgy (AMMe)

Contact persons: Timo Fabritius (2009 – 2011) and Ville-Valtteri Visuri (2012 −)

Researchers: Petri Sulasalmi (2009 −), Aki Kärnä (2009 −) and Eetu-Pekka Heikkinen (part-time)

Duration: 01.05.2009 – 31.12.2014

Objective and results: The aim of this project is to develop holistic process oriented models describing

dominating phenomena similar to all secondary metallurgy process units and to simulate process

procedures in case specific studies of vacuum, AOD, CAS-OB and BOF processes.

Supersonic lance and jet interaction with melt have been studied in CAS-OB, AOD and BOF processes.

Supersonic lance model has been applied to full scale CAS-OB flow model. Slag emulsification has been

simulated with 3-phase modeling and tracking the interface between the phase. Main focus was on

average droplet size, droplet distribution and number of droplets. Splashing of steel during lance

blowing has been modeled as a 2-phase flow. Final goal of CFD modeling is to provide detailed models of

all processes considered in the project.

Partners: University of Oulu, Laboratory of Process Metallurgy; University of Oulu, Mass and Heat

Transfer Process Laboratory; Aalto University, Department of Energy Technology; Aalto University,

Department of Materials Science and Engineering; VTT Technical Research Centre of Finland;

Outokumpu Stainless Oy and Ruukki Metals Oy

Financiers: The Finnish Funding Agency for Technology and Innovation (TEKES), Ruukki Metals Oy and

Outokumpu Stainless Oy

Advanced Melt Metallurgy (AMMe), Industrial part

Researchers: Sauli Pisilä (2010 – 2011), Ville-Valtteri Visuri (2011 −) and Eetu-Pekka Heikkinen (part-

time)

Duration: 1.5.2009 – 31.12.2014

Objective and results: The aim of this project is to develop holistic process oriented models describing

dominating phenomena similar in the AOD process. A slag formers, converter geometry and different

blowing practises have all been considered. At this point, the model is validated for the last side-blown

decarburization phases. Next development steps for the AOD model are lance modules for considering

lance-blowing and reactions between the steel bulk and the top slag.

Partner: Outokumpu Stainless Oy

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Financier: Outokumpu Stainless Oy computationally efficient AOD process model has been

developed. Main reactions in the plume zone, additions of scrap and

Determination of inclusion size distribution of steel by electrolytic extraction

method

Contact person: Timo Fabritius

Researchers: Anssi Mäkelä (01.12.2010 − 14.02.2012), Heikki Pärkkä (01.01.2010 – 31.10.2010), Ville

Hakkarainen (01.01.2010 – 31.10.2010) and Eetu-Pekka Heikkinen (part-time)

Duration: 01.01.2010 − 31.12.2013

Objective and results: The main aim is to research an electrolytic extraction method for determination

of inclusion size distribution in the different stages of steel manufacturing process and in the final

products. At first research method consisted of electrolytic dissolution with acid solutions combined

with laser diffraction particle size analyzer. Afterwards the method was modified to utilize non-aqueous

electrolytes, potentiostatic controlling and a scanning electron microscope equipped with EDS detector

and a semi-automatic particle detection software.

With the growing demand for stronger and harder steels, the inclusion control in different steel types

has become very important. The inclusion size distribution is an essential parameter, because different

sized inclusions have diverse effects on the mechanical properties of steel. Large inclusions are

considered to be more detrimental to the quality of the steel than small inclusions. On the other hand,

certain inclusions having a specific size, shape and composition are desired constituents in steel when

they are utilized to control the microstructure of steel and thus improving the properties of steel.

Due to small size and surrounding iron matrix, there are some problems when determining non-metallic

inclusions directly from steel samples with conventional metallographic methods. Therefore, in this

research the inclusions are separated from the steel matrix by selectively dissolving the steel sample by

the electrolytic extraction method. After the extraction the inclusions are collected onto a membrane

filter prior to analysis. The quantity, morphology and elemental composition of the inclusions are semi-

automatically determined by a scanning electron microscope equipped with an EDS system and

INCAFeature software. The detected inclusions can be classified into groups by their elemental

composition. As a result inclusion size distribution graphs for different types of inclusions can be

achieved. The method can be applied for determining changes in inclusion number, size, shape and

composition during the steel making process.

Partner: Ruukki Metals Oy

Financiers: Ruukki Metals Oy and Teknologiateollisuuden 100-vuotissäätiön Metallinjalostajien rahasto.

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Figure 5. Inclusion density (Al2O3) at different process states.

Production of metal-ceramic composites (Hybrimat)

Contact person: Timo Fabritius

Researchers: Olli Mattila, Antti Kemppainen, Jari Savolainen, Olli Mattila, Petri Sulasalmi, Tommi

Kokkonen and Eetu-Pekka Heikkinen (part-time)

Duration: 01.04.2008 − 30.03.2011

Objective and results: The aim of the research was to investigate the production of composite materials

by examining infiltration process of molten steel into the layer of reinforcement materials. Various steel

grades and reinforcement materials were investigated. Practically the research focused on phenomena

called dynamic temperature and wetting in the infiltration process.

Research methods applied for the investigation of dynamic temperature were high temperature

laboratory experiments and computational modeling (Computational fluid dynamics) for the

examination of heat transfer processes. The computational modeling was made in the project

simultaneously with laboratory experiments and assisted the conditions selection for different materials

in the actual infiltration experiments. Applicable laboratory scale equipment was developed for the high

temperature infiltration experiments. Various types of reinforcement material layers were developed

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and tested as well as various steel casting techniques. Temperature dependence of the infiltration

process progression was one the investigated variables in the infiltration experiments assisted by the

results of computational modeling.

Wetting properties of different steel grades with different reinforcement materials were determined

with thermodynamic modeling and were tested with high temperature dilatometric experiments.

Results of all high temperature dilatometric experiments and infiltration experiments were analyzed

with scanning electron microscope (SEM).

Partner: Metso

Financier: Metso

Effective and cost-efficiency AOD-process for production of ferritic and Mn-alloyed

stainless steels (FEMA)

Contact person: Timo Fabritius

Researchers: Jouko Härkki, Aki Kärnä, Petri Sulasalmi, Jaana Riipi and Timo Fabritius

Duration: 01.01.2007 – 23.06.2009

Objective and results: The aim of the project was to develop blowing practices for AOD converter to

produce ferritic and Mn-alloyed stainless steels with low oxygen, nitrogen and sulphur contents. To

achieve this purpose three kinds of models: 1) CFD model of AOD converter, 2) slag sub-model and 3)

sub-model for gas-slag-metal system were formed. The final goal was a model that describes all the

significant phenomena taking place in the converter, in three spatial and one time dimension.

The AOD model was carried out as a three dimensional, time-dependent 2-phase model. Based on the

time-dependent model an averaged flow field was obtained which was coupled with a reaction sub-

model that calculated a local chemical equilibrium based thermodynamic properties of the phases. In

addition to reaction sub-model, also a model for momentum transfer between steel and gas and a

model for gas bubble size were written and coupled with the CDF model.

The main purpose of slag sub-model was to study slag emulsification caused by steel flow at the slag-

steel interface. For this a 3-phase model, based on a physical model that had been used to study

emulsification on water-oil systems, was developed. CFD simulations were started by choosing four

water-oil cases which were simulated by the CFD model and validated by using the data from physical

experiments. After that three cases were simulated by using the physical properties of slag and steel

corresponding to AOD process. The main interest in this study was on average droplet sizes and

distributions. It resulted that droplet distributions were quite similar in all cases. Also an equation for

the average droplet size was obtained.

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Behavior of gas-slag-steel –system is determined by the surface energy of the system. The surface

energy can be calculated as a function interfacial tension between slag and steel. The physical state of

the gas-slag-steel –system was studied with a sub-model that assumes that inertial forces don’t

dominate the behavior. It was obtained that intensive reactions between slag and steel decrease the

interfacial tension considerably and may affect to the behavior of the system.

Partners: Outokumpu Stainless Oy; Laboratory of Energy Engineering and Environmental Protection

from Helsinki University of Technology

Financiers: Outokumpu Stainless Oy and the Finnish Funding Agency for Technology and Innovation.

Modelling interfacial partitioning in multi-phase systems (INTER)

Contact person: Timo Fabritius

Researchers: Jouko Härkki, Ville Hakkarainen, Jaana Riipi, Timo Fabritius, Olli Mattila, Riku Mattila and

Eetu-Pekka Heikkinen (part-time)

Duration: 01.01.2008 – 31.12.2009

Objective and results: The aim of the work carried out in the laboratory of process metallurgy in the

University of Oulu was to study the phenomenon of electrowetting to modify the surface tension of

oxide materials in high temperature conditions and to generate a mathematical model to calculate the

surface tension and the interfacial tension of oxide materials. The study was started with experiments in

water system in which electrowetting was examined in room temperature for a electrolyte liquid and

after that continued with tests under high temperature conditions with silicate, aluminate and oxide

slags having plenty of free ions.

A model based on the Butler equation was generated to calculate the surface tension in the oxide

system. The model uses the ionic radiuses of oxide materials and the surface tension and the molecular

volume of pure oxides. The calculation is carried out as a function of temperature and composition. The

model can calculate systems having 2−9 components with different compositions as a function of

temperature. Accuracy of the model was estimated to be within 7% of the surface tension of tested

materials with validation tests.

Partners: Åbo Akademi University, Helsinki University of Technology and Technical Research Centre of

Finland

Financiers: Outokumpu Stainless Oy and Outotec Research

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Thermochemical Model for Gas-Liquid Metal System

Doctoral student: Jaana Riipi

Duration: 02/2008 −

Objective and results: In traditional practise the great amount of unit operations in the production of

steel is based on the reactions between gas bubbles and liquid metal. Temperature of liquid bulk phase

varies temperature range of 1500 oC to 1800 oC and in addition to the large variations in the chemical

composition. Furthermore, the composition of surface phase is totally different than bulk phase because

of the differences in surface activities of solution elements. There is very little published information

concerning the measurements of the reactions on the gas-steel melt interphase. However, surface

phenomena such as surface tension of melt and adsorption of different components have remarkable

effect on the behaviour of high temperature metallurgical processes. For example, adsorption and

desorption of nitrogen during decarburization and secondary metallurgical treatments is related to the

composition of gas-metal interphase. Surface tension also affects the diameter of gas bubbles in liquid

metal and slag. Hence the reaction area as well as fluid flow dynamics of the gas-liquid metal system is

affected by the surface tension. While the surface tension affects fluid flows it is generally assumed to

be constant in CFD simulations.

The aim of this study is to generate a model for surface tension of liquid steel system (including surface

active elements) and chemical composition of the surface. Model for the nitrogen behaviour between

gas bubble (Ar, N2, O2, CO, CO2) and steel melt will be also derived. Additionally model for the surface

tension of steelmaking slag and interfacial tension between slag and steel melt will be derived. Finally,

effects of reactions and external energy on different interfacial tensions in steelmaking process will be

studied.

Financier: Graduate School in Chemical Engineering (GSCE)

VISTA: CFD-thermochemical Model for Gas-to-liquid Blow Reactor

Contact person: Timo Fabritius

Researchers: Jaana Riipi and Aki Kärnä

Duration: 2004 – 06/2008

Objective and results: Aim of the project is to minimize the consumption of argon in AOD converter

blowing with the production of different steel grades. This will be made by optimizing the switch point

from nitrogen to argon during the decarburization period. The CFD-model pursues an economical way to

optimize processing practices and to allow improved control of nitrogen content in liquid steel before

tapping. Several tasks were done: dynamic model for nitrogen behavior during AOD process was

completed, surface tension model for Fe-N-S-O system and CFD model for AOD converter were

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developed. As result of new models the accuracy of the predicted nitrogen content after AOD process

was improved.

Partners: Outokumpu Stainless Oy, Rautaruukki and Ovako

Financiers: Outokumpu Stainless Oy, Rautaruukki and Ovako

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III REDUCING AGENTS

Inorganic Compounds of Coke

Contact person / responsible scientist: Stanislav Gornostayev

Project scientists: Satu Huttunen, Tommi Kokkonen and Hannu Makkonen

Duration: 08/2006 – 07/2011

Objective and results: This project is focused on detailed laboratory studies and theoretical

investigations of natural and synthetic inorganic compounds in the feed and blast furnace (BF) coke. The

project is aimed to investigate the fundamentals of processes related to chemical reactions and physical

transformations of inorganic compounds (mineral phases and minor elements in the carbon matrix) of

feed and BF coke, which take place in coke oven batteries and in the BF, and their influence on

properties of coke. The detailed laboratory research include XRD, EDS and WDS analyses, optical and

electron microscopy, X-Ray mapping as well as laboratory experiments, which include simulation of

different operating conditions of the BF and coke battery to point out the differences in material

behavior put to these processes. The applied part of the research is focused on qualitative and

quantitative estimations of the influence of inorganic compounds on quality of coke and reactions that

affect the BF operations. The overall practical aim of the research is to reach more economically and

environmentally efficient use of coke in the BF process.

Partner: Ruukki Metals Oy

Financier: Academy of Finland

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Figure 6. Octahedral crystal of spinel on a surface of blast furnace coke.

Figure 7. Droplet of slag on a surface of blast furnace coke.

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Efficient Fuel for a Blast Furnace (EFBF)

Contact person: Stanislav Gornostayev

Responsible scientists: Stanislav Gornostayev and Jyrki Heino

Project scientist: Satu Huttunen

Project technician: Tommi Kokkonen

Duration: 01.09.2011 – 31.08.2015

Objective and results: Metallurgical coke, which is a compound of carbon and inorganic phases, is a key

material for a blast furnace (BF) iron making, acting as a major fuel (energy source), a reductant, a

carburisation agent and a structural support. Natural reserves of coking coal are limited and the

standards for BF iron making are becoming increasingly strict, encouraging steel producers to implement

environmentally friendly processes, while trying to maintain cost efficiency. In this regard, the

production of high quality coke requires a better control of its properties as well as sustainable and

economic management of coke oven gases and solid residues.

This multidisciplinary (coke, metallurgy, mineralogy, chemistry, thermodynamics, industrial ecology)

project is focused on detailed laboratory studies and theoretical investigations of inorganic compounds

and carbon-based matrix of feed and BF coke and experimental cokes made with addition of various

plastics. The objectives of the project include the investigations of: Contact phenomena between

mineral phases and coke matrix in the feed and BF coke; Solid-solid, solid-C and solid-gas reactions

between minerals and coke matrix in the feed and BF coke; Mode of occurrence, size and composition

of Fe-Si droplets on the surface of BF coke and their relationships with the coke matrix; Properties of

“contact coke” from coke oven, including of carbon spheres on its surface; Intercalation features of K,

Na, Ba, Sr and Ca with graphite; Heterogeneity of pore-surrounding matter in the feed and experimental

cokes; How coking process proceeds when coking coal without and with varying amounts of plastics,

including measurements of gas phases; Physical properties of coke fines agglomerates made with

various primary (cement) and secondary (waste lime, ashes from pulp and paper industry, blast furnace

and other type of slags from steel industry) binders; Utilization potentials of coke oven gases and coke

fines agglomerates applying ideas of industrial ecology.

The project will utilize modern research tools and methods, including (but not limited to): sophisticated

equipment for samples preparation; Optical and Scanning electron microscopes; Confocal Raman

Microscope System; Electron-probe micro analyser, Chamber furnace, Blast Furnace Gas Simulator, X-

Ray Diffraction spectrometer; X-Ray Fluorescence spectrometer and Inductively coupled plasma mass

spectrometer.

The main results of the project are expected to be a considerably deepened knowledge on the coking

and BF processes as well as related issues of industrial ecology.

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Partner: Ruukki Metals Oy

Financier: Academy of Finland

Figure 8. Nine laboratory scale coke ovens and coke oven battery. Photographer: Tommi Kokkonen

Possibilities of bio-based materials in reduction applications (Bioreducer)

Contact person: Mikko Angerman

Researchers: Hannu Suopajärvi and Mikko Iljana (part-time)

Duration: 1.9.2010 – 31.8.2012 (possibly longer)

Objective and results: Steel industry is causing roughly 9 % of Finland’s greenhouse gas (GHG)

emissions, though the processes are already generally driven at a close thermodynamic limits. To be

able to further lower the GHG emissions, the reduction energy’s fossil carbon intensity must decrease.

In principle this can be achieved in three ways: by increasing carbon neutral electricity and scrap use, or

by increasing bio-based carbon and hydrogen share on the reduction energy mix or by adapting carbon

capture and storage (CCS) practices.

Bioreducer project is concentrating on possibilities and impacts of bio-based materials in reduction

applications. Project tasks include various biomaterial resource and quality estimations, study on various

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required pre-processing steps to actual utilization phase at present metallurgical processes and overall

assessment of the biomaterial use on plant wide view.

Research so far shows that even partial coverage of current fossil reduction agents with bio-based

materials means rather huge, yet sustainably coverable quantities. Also, bio-based material could even

help other reactions and phenomena inside the metallurgical processes.

Partners: Aalto University, Åbo Akademi, Rautaruukki Oyj Plc, Pohjolan Voima Oy Ltd, Taivalkoski

community, Council of Oulu region, GasEK Oy, Ltd, Sievin Biohake Oy Ltd, Naturpolis Oy Ltd, Lassila &

Tikanoja Oyj Plc and Suomen Biosähkö Oy.

Financiers: The Finnish Funding Agency for Technology and Innovation (TEKES), Rautaruukki Oyj Plc,

Pohjolan Voima Oy Ltd, Lassila & Tikanoja Oy Plc, Taivalkoski community and Council of Oulu region.

margin to their

Biomass use in metallurgical industry − Sustainability Assessment with layered

approach

Doctoral student: Hannu Suopajärvi

Duration: 12/2009 −

Objective and results: There are several possibilities in integrated steel plant to modify existing

processing routes, which may contribute to more sustainable operations. Basically the proposed

solutions concern the use of new technology or finding new raw materials whether recycled or entirely

new. New technologies include e.g. Carbon Capture and Storage (CCS) technology, Top gas recycling

blast furnace (TGR-BF), TGR-BF combined with CCS, use of process gases (coke plant, BF, BOF) for direct

reduction process purposes, or methanol production, better utilization of by-products (dusts, scales).

The easy ways to decrease the environmental burden of iron and steelmaking have already been

adopted. There is a need for new approaches towards a more sustainable and CO2-lean operations. One

such alternative is to use non-conventional raw materials such as biomass for iron ore reduction. It is

expected that wood and other biomass reserves in Finland could provide sustainable alternatives for

fossil fuels in iron and steelmaking processes. However, there have been no studies made earlier neither

is a methodology to evaluate the sustainability of substituting fossil-based fuels to renewable.

The objective of this research is to develop a sustainability assessment framework that can be used to

evaluate the impacts of biomass utilization in iron and steelmaking. The layered approach means that

dimensions of sustainability; economic, environmental, social and also technological are systematically

evaluated with specified system boundaries. Hypothesis that guides the research can be formulated as

following: “Domestic biomass is sustainable raw material for Finnish iron and steelmaking in a form of

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reducing agent”. The research as such is not based on hypothesis testing, but gives possibility to

formulate suitable research questions and tasks.

Methods used in the research for supporting the hypothesis range from process modeling based on

mass and energy balances to economic calculations and life cycle evaluations. Plant-wide process

modeling scheme is taken to evaluate the effects of biomass introduction to CO2 emissions and energy

balances of integrated steelworks. Life cycle evaluation, which takes the environmental burdens into

account from cradle-to-grave, is essential for assessing the sustainability of the biomass use. Economic

calculations and availability assessment are needed for evaluating the implementation potential of

proposed alternatives.

The research thus far has concentrated on developing and utilizing unit process models for integrated

BF-BOF route accompanied with biomass pyrolysis unit where biomass can be converted into charcoal

used in the blast furnace. Modeling is based on thermodynamics, distribution coefficients and other

engineering methods and tools. Layered sustainability assessment framework has been developed and it

will be used for the evaluation of the sustainability of biomass use in iron and steelmaking industry in

Finland. In addition, extensive literature review on thermochemical processes has been conducted.

Availability of energy wood in Finland has been evaluated by utilizing calculation procedures provided in

literature.

Financier: Graduate School in Chemical Engineering (GSCE)

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IV SLAGS, DUSTS AND WASTES

New metallurgical solutions for ferrous dust treatment (METDUST)

Contact person: Hannu Makkonen

Researcher: Hannu Makkonen

Duration: 11.05.2009 − 30.04.2013

Objective and results: The aim of this project is to develop new processes and technologies for steel mill

dust and sludge treatment. The purpose is to recover the valuable metals. This will save costs and

reduce environmental load. To reach this objective both pyrometallurgical and hydrometallurgical

processes will be considered. In University of Oulu the main task has been the characterization of the

steel plant dusts as a result of which the chemical and mineralogical compositions as well as

microtexture of the dusts are known.

Partners: Aalto University; Lappeenranta University of Technology; Technical University of Kosice,

Slovakia; University of Oulu; Boliden Oy; Outokumpu Stainless Oy; Outotec Finland Oyj

Financiers: The Finnish Funding Agency for Technology and Innovation (TEKES), Boliden Oy, Outokumpu

Stainless Oy and Outotec Finland Oyj

Process alternatives for low-grade ores (LOWGRADE)

Contact person: Hannu Makkonen

Researcher: Hannu Makkonen

Duration: 01.05.2011 − 30.04.2012

Objective and results: The aim of this project is to develop processes and technologies for utilization of

low-grade ores. Both hydrometallurgical and biometallurgical processes are considered. In University of

Oulu the main task has been the characterization of the concentrate from Suurikuusikko gold mine as a

result of which the chemical and mineralogical (XRD-analysis) compositions as well as grain-size

distribution of the material are known.

Partners: Aalto University, Tampere University of Technology, University of Oulu and Outotec Finland

Oyj

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Life-cycle approaches in supporting business decision making process (FinLCA)

Contact person: Mikko Angerman

Researcher: Hannu Suopajärvi & Jyrki Heino

Duration: 01.08.2009 – 31.12.2011

Objective and results: Environmental issues and viewpoints have recently risen in importance in

corporate decision making process, even within the framework of the global capitalism. The project was

established to enhance and better utilize life cycle approaches in Finnish companies. The main mean to

achieve this was to strengthen cooperation between research institutes and businesses.

Specific task for the laboratory of process metallurgy in the project was to study and present examples

on how to incorporate and utilize traditional engineering methods like thermodynamic calculations or

mathematical modelling and simulation results into more orthodox life cycle studies. Hypothesis was

that these methods could help estimating LCA with yet unknown processes and products that lack the

LCI-data.

An example simulation case with derived LCI-like results was constructed and results have been

reported in separate project paper and project reports.

More information (in Finnish) http://www.ymparisto.fi/syke/finlca

Partners: SYKE (leader), VTT, Aalto University and Åbo Akademi

Financiers: The Finnish Funding Agency for Technology and Innovation (TEKES) and a large number of

industrial associations

Hidden potential for gross reduction in energy demand and emissions in

steelmaking (GreenSteel)

Contact person: Mikko Angerman

Researchers: Hannu Suopajärvi, Ahti Leppänen, Jukka Sippola and Markus Harju

Duration: 01.01.2008 – 31.12.2012

Objective and results: The objectives of the research are to develop methods by which virgin

environmentally benign ways of primary steelmaking can be found, and to evaluate their feasibility in

the future by studying their performance under a variety of scenarios for the price and availability of

energy and raw materials, and costs of emissions and by-products.

A key element in the work will be Factory simulation tool ⎯ versatile software for evaluation and

comparison of alternative process routes. The program was designed at the laboratory of process

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metallurgy and has been extended by process databases and new process units in various research

projects at the laboratory of process metallurgy and Aalto University.

Factory is an ideal platform for analyzing interconnected balance based steady-state models of novel

cross-industrial systems. Here it will be extended from basic flow-sheet calculations to considering

economical performance indices and CO2 emissions, as well as other Life Cycle Inventory type analysis.

The tool itself will also be substantially developed and expanded with new process descriptions,

databases and algorithms to fulfill the requirements of the project. Factory will be used for rapid

prototyping in studying and evaluating the performance of new process models, and for providing the

model representation of the processes to be used in the systems optimization.

Partners: Aalto University, Åbo Akademi and Rautaruukki Oyj Plc

Financier: The Academy of Finland

Efficient electric arc metallurgy (EffArc) and New metallurgical solutions for ferrous

dust treatment (METDUST), Industrial part – Reduced dust formation and enhanced

recycling in EAF and AOD

Contact person: Juha Roininen

Researchers: Jari Savolainen (2009 – 2010), Juho Kunelius (2010 – 2011) and Juha Roininen (up to

07/2011 at Outokumpu Stainless Oy, then from 07/2011 at University of Oulu)

Duration: 2009 – (every year new contract for one researcher)

Objective and results: Efficient electric arc metallurgy (EffArc) and New metallurgical solutions for

ferrous dust treatment (METDUST) are a part of project named Energy & Lifecycle Efficient Metal

Processes (ELEMET). Objectives of the project are to attain information to make process even more

material and energy efficient. Especial interest is to look ideas which are lowering emissions of material

to dust collection unit or to utilize dust in processing to achieve material efficiency without sending dust

to expensive and environmentally inefficient process in southern Sweden. Also some benefits for

process can be achieved with correct timing and feeding of the material. To find out correct timing for

feeding better equipment to control process are needed and for that reason several studies and ideas to

make new measurements and models to control process are also presented in this project.

Partner: Outokumpu Stainless Oy

Financier: Outokumpu Stainless Oy

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Boliden Harjavalta Oy Copper and Nickel Slag Research and Product Development

Project (KUNI)

Contact persons: Jyrki Heino and Hannu Makkonen

Researchers: Mikko Angerman (1.5.2008 – 31.12.2008), Eetu-Pekka Heikkinen (part-time), Jyrki Heino

(1.1.2006 – 31.12.2008), Tuomas Hallikainen (1.4.2007 – 31.8.2007), Tommi Kokkonen (part-time), Virpi

Leinonen (1.1.2006 – 31.12.2007), Hannu Makkonen (1.6.2006 – 31.12.2008), Anna-Leena Pitsinki

(29.5.2006 – 20.11.2006), Erika Rova (1.1.2008 – 31.12.2008), Pekka Tanskanen (1.1.2008 – 31.12.2008)

and Esa Virtanen (1.1.2006 – 30.4.2008)

Duration: 01.01.2006 – 31.12.2008

Objective and results: The aim of the project was to research and develop the environmental properties

of nickel slag. As a result mineralogy and microstructure and their origins in slag are known. Also the

mineralogical grounds of leachability of harmful components were recognized. Based on this knowledge

four methods for modifying the properties of slag were suggested and part of them tested.

Partners: Boliden Harjavalta Oy; Outotec Research Oy; Clean Technologies Research Group, Department

of Forest Products Technology, Aalto University School of Chemical Technology; Water Resources and

Environmental Engineering Laboratory, Department of Process and Environmental Engineering,

University of Oulu

Financiers: The Finnish Funding Agency for Technology and Innovation (TEKES) and industrial partners

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Effect of Mineralogy to Leachability of Synthetic Earthwork Materials (MINERALI)

Contact person: Hannu Makkonen

Researchers: Hannu Makkonen (part-time, 06/2006 – 12/2008), Tuomas Herlevi (08/2007 – 05/2008)

Duration: 1.6.2006 – 31.12.2008

Objective and results: The main idea of Minerali project was to give a new tool for evaluating leaching

of some harmful elements from known minerals in solid residue materials. Nowadays there is a lot of

knowledge about leaching behaviour from different kind of slag materials but it is not yet compared to

mineralogy of those solids. Leach ability testing is also expensive and a very slow method to be used in

production. A new way suggested as a result of the project is to estimate leaching and other

environmental properties of slag and other industrial wastes based on mineralogy and microtexture of

materials.

Partners: SYKE and University of Oulu

Financier: Finnish Ministry of Environment

Pro-Environmental Product Planning in a Dynamic Operational Environment Now

and in Future - Methods and Tools (PRODOE)

Contact person: Jyrki Heino

Researchers: Jyrki Heino (01.01.2007 – 31.12.2010), Jouko Härkki (01.01.2007-28.02.2010) and Esa

Virtanen (01.01.2007 – 30.04.2008)

Duration: 01.01.2007 – 31.12.2010

Objective and results: The main purpose of the project was to produce a position paper of the research

group of the existing situation concerning the metal and fibre cycles and the interconnected energy

cycle. The legislative and regulatory development needs were identified in order to promote sustainable

use of resources and the closure of material cycles in Bothnian Arc industrial area. It was also proposed

effective policies and legal instruments related to material cycles (legal, technical and economic means

to control the material flow). The utilisation rate of side-streams or rejects in the hypothetic Bothnian

Arc industrial ecosystem was intensified, while taking into account the aspects rising from legislation,

management, economy, ecology, material properties and processing. The possibilities for cross-linking

waste and by-product stream from different industrial sectors were also explored.

Partners: Laboratories of Mechanical Process Technology and Recycling, Clean Technologies Research

Group, Energy Engineering and Environmental Protection, Environmental Protection, and Institute of

Law, and Lahti Centre in Aalto University School of Chemical Technology; Laboratories of Environmental

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Law and Politics in University of Helsinki; Laboratory of Process Metallurgy in Luleå University of

Technology; Ruukki Metals Oy Raahe

Financier: Academy of Finland

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V REFRACTORY MATERIALS

Here is a list of public projects concerning refractory materials studies. Some of the refractory material

studies made during the years are short term and reported to customers only, so they are not listed in

below.

Master's thesis project: Ferrochromium furnace lining monitoring system

Contact person: Riku Mattila

Researchers: Olli Pekkala and Jouko Härkki

Duration: 01.12.2007 − 01.12.2008

Objective and results: The purpose was to study different lining option and lining monitor systems used

in submerged arc furnace. A mathematical model was created to monitor submerged arc furnace lining

by using pairs of thermocouples. Model was later utilized for base of lining wear monitoring system.

Partners: Outotec, Outokumpu Tornio mill, Comsol

Financier: Outotec

Refractory materials comparative plant trial in soda recovery boiler. Part of project:

SKYREC-Increasing recovery boiler electricity generation to a new level

Contact person: Timo Fabritius

Researchers: Jouko Härkki, Riku Mattila and Tommi Kokkonen

Duration: 21.12.2009 − 02.05.2011

Objective and results: The project focused on comparing refractory materials in a soda recovery boiler

condition. The comparative plant trial was carried out in the soda recovery boiler at Stora Enso Oulu

Mills while it was running. The aim was to study the corrosion resistance of some alternative refractory

materials in comparison to the current lining material. Main findings were:

- The best material Hassle D39A castable is already in use

- ZrO2 castable could have the potential, but they lacking manufacturers.

- Full spinel castable, the same applies to these. - MgO*Cr2O3 brick could be potential but it was not tested.

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- Some more preliminary laboratory test need to be made before next plant trial to ensure quality

and potential against Hassle castable.

Partners: Finnish recovery boiler committee, Stora Enso Oulu Mill

Financier: Finnish recovery boiler committee

Master's thesis project: Suitability of high emissivity and high reflectivity coatings to

improve energy efficiency of reheating furnace

Contact person: Timo Fabritius

Researchers: Antti Vasankari and Riku Mattila

Duration: 22.09.2010 − 25.04.2011

Objective and results: The purpose was to study refractory material coating to improve reheating

furnace energy efficiency by means of laboratory tests for commercials and developed coatings. All

measurements indicates that coatings worked. The exact amount of energy improvement is depending

also furnace type and other factors.

Partners: Ruukki Raahe mill

Financier: Ruukki corporation

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VI OTHER

Improving the properties of lithium ion battery chemicals (IMPOLI)

Contact person: Pekka A Tanskanen

Researchers: Pekka A Tanskanen and Juho Välikangas

Duration: 01.09.2010 − 31.08.2012

Objective and results: The IMPOLI project aims at studying novel lithium battery chemicals which are

suitable for large applications and which are economically feasible to produce. The main focus will be in

the improvement of properties of lithium ion battery chemicals by improving the capacities of the active

cathode and anode materials. Special attention will be paid to the electrode materials with higher

capacities. Professor Ulla Lassi (University of Oulu, Department of Chemistry) acts as the coordinator of

the research consortium.

Partners: The University of Oulu (Department of Chemistry and Laboratory of Process Metallurgy) and

the Aalto University School of Science and Technology (Department of Chemistry)

Financiers: The Finnish Funding Agency for Technology and Innovation (TEKES) and industrial partners

Nanostructured materials for lithium ion battery chemicals (NANOLI)

Contact person: Pekka A Tanskanen

Researchers: Pekka A Tanskanen and Juho Välikangas

Duration: 01.05.2010 − 30.04.2013

Objective and results: In the NANOLI project both stoichiometric and non-stoichiometric compound will

be synthesized with the aim of to (1) increase the lithium amount and mobility in the structure by

chemical modifications and (2) to develop the conductivity by carbon coating or by adding carbon in-situ

during the synthesis. New structured layers of nanopowders and nanotubes will be used. Professor Ulla

Lassi (University of Oulu, Department of Chemistry) acts as the coordinator of the project.

Partners: Department of Chemistry, Microelectronics and Materials Physics Laboratories and Laboratory

of Process Metallurgy in the University of Oulu

Financier: Technology Industries of Finland Centennial Foundation

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Production of lithium ion battery chemicals from lithium carbonate (LITIUM)

Contact person: Pekka A Tanskanen

Research Assistants: Juho Välikangas, Antti Kemppainen and Outi Kurikkala

Duration: 01.09.2008 − 30.08.2010

Objective and results: The aim of the LITIUM project was to develop expertise in secondary batteries

and promote the lithium mining and chemical industries in Finland. During the project different

syntheses methods of Li-ion battery chemicals was studied and samples prepared. Three master’s theses

were done of three different Li-ion battery electrode materials. Professor Ulla Lassi (University of Oulu,

Department of Chemistry) acted as the coordinator of the project.

Partners: Laboratory of Process Metallurgy and Department of Chemistry in the University of Oulu

Financiers: The Finnish Funding Agency for Technology and Innovation (TEKES) and industrial partners

Figure 9. FESEM images of different Li-ion battery electrode materials (LiMn2O4, Li4Ti5O12 and LiFePO4).

Quality of Central Ostrobothnia Spodumene occurences (SPODULA)

Contact person: Pekka A Tanskanen

Researchers Assistants: Jukka Karjalainen, Sari Seppelin, Mika Leppälä, Jussi Ruokanen and Eetu-Pekka

Heikkinen (part-time)

Duration: 1.3.2008 − 31.12.2008 (SPODULA) and 1.3.2009 − 31.12.2009 (SPODULA II)

Objective and results: Quality and behaviour of spodumene from different lithium ore occurrences

during heating were researched. Results containing phase transformation temperatures and related

data were reported in four master’s theses. Professor Ulla Lassi (University of Oulu, Department of

Chemistry) acted as the coordinator of the projects.

Partners: Department of Chemistry and Laboratory of Process Metallurgy and in the University of Oulu

Financier: K H Renlund foundation.

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LABORATORY DEVICES

THERMAL ANALYSIS

TMDSC-TGA-MS (STA) Simultaneous mass and heat difference measurement with mass spectrometer gas analysis, modulated heating 2000 °C DSC-TGA-MS (STA) Simultaneous mass and temperature difference measurement with mass spectrometer gas analysis 1550°C DTA–TGA (STA) Simultaneous mass and temperature difference measurement 1500°C TGA Mass measurement in reducing atmosphere 1500°C Optical dilatometer Dimensional measurement 1500°C High temperature viscometer Rotational viscosity measurement 1700°C Blast furnace gas phase alkali simulator Mass measurement in reducing CO, CO2, N2, H2, H2O, K, S, atmosphere 1600°C Blast furnace gas phase layer simulator Furnace 1000 mm (H), 80mm (D) is heated in three zones and it uses the same gases as alkali simulator. Evolved Gas Analysis, CO, CO2, H2, H2O, measurement in reducing atmosphere 1300°C Confocal Raman microscope hot stage Raman spectrum and dimensional measurement with High temperature microscope stage 1500°C

Figure 10. Viscosimeter.

Figure 11. DCS-TGA-MS (Netzsch STA 409PC)

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OTHER HIGH TEMPERATURE DEVICES

- Pressure furnace 10 bar, 1500 °C

- Induction furnace 125 ml

- Chamber furnace 1800 °C

OTHER

- Gas chromatograph, Lancom Series II, CO,CO2,O2 gas analyzer, Wuhan CO,CO2,H2 gas analyzer

- Rapidox O2 gas analyzer,Vaisala H2O gas analyzer

- BioLogic SP150 potentiostat with Electrochemical Impedance Spectroscopy measurement

- Optical microscopes

- Materialographic surface preparation

- Water-models ( CC, LD, AOD)

- Computational Fluid Dynamics software (Fluent, Comsol, OPENFoam)

- Thermodynamic calculation programs (HSC, Fact Sage)

Figure 12. Layer Furnace (LF). Figure 13. TGA furnace.

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Furnace 1 Reduction tube 2 Sample basket 3 Thermocouple 4 Electrically heated furnace 5 Gas inlet 6 Transparent lid with cooling gas inlet and reducing gas outlet Gas supply system 7 Gas containers 8 Mass flow controllers 9 Potassium generator 10 Sulphur generator 11 Water vapour generator Camera redording system 12 Light source 13 Mirror 14 Camera Auxiliary instruments 15 Scale for TGA 16 Computer system

Figure 14. Blast Furnace gas phase Simulator (BFS)

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PUBLICATIONS

SCIENTIFIC JOURNAL PAPERS

Fabritius T., Riipi J., Järvinen M., Mattila O., Heikkinen E.-P., Kärnä A., Kurikkala J., Sulasalmi P. &

Härkki J.

Interfacial phenomena in metal-slag-gas system during AOD process. ISIJ International 50 (6), 797-803.

2010. http://www.jstage.jst.go.jp/article/isijinternational/50/6/797/_pdf

Gornostayev S. & Härkki J.

Carbon Tubular Morphologies in Blast Furnace Coke. Research Letters in Materials Science, Article ID

751630, 4 pages, doi:10.1155/2008/751630 2008, 1-4

Gornostayev S., Härkki J. & Kerkkonen O.

Transformations of pyrite during formation of metallurgical coke. Fuel 88 (10), 2032-2036. 2009.

http://dx.doi.org/10.1016/j.fuel.2009.02.044

Gornostayev S., Kerkkonen O. & Härkki J.

Behavior of coal associated minerals during coking and blast furnace processes- a review. steel research

international 80 (6), 390-395. 2009. http://onlinelibrary.wiley.com/doi/10.2374/SRI09SP007/abstract

Gornostayev S., Härkki J., Kerkkonen O. & Fabritius T.

Carbon spheres in metallurgical coke. Carbon 48, 4200-4203. 2010.

Heikkinen E.-P., Riipi J., Fabritius T, Pajarre R. & Koukkari P.

Computational modelling of oxide surface tensions in secondary metallurgy and continuous casting.

Steel research international 81 (11), 959-964. 2010

Heikkinen E.-P., Fabritius T. & Riipi J.

Holistic analysis on the concept of process metallurgy and its application on the modelling of the AOD

process. Metallurgical and materials transactions B 41 (4), 758-766. 2010

http://www.springerlink.com/content/m071m753x1811566/fulltext.pdf

Heikkinen E.-P., Kokkonen T., Mattila R. & Fabritius T.

Influence of sequential contact with two melts on the wetting angle of the ladle slag and different steel

grades on magnesia-carbon refractories. Steel research international 81 (12), 1070-1077. 2010

Hiltunen J., Heikkinen E.-P., Jaako J. & Ahola J.

Pedagogical basis of DAS formalism in engineering education. European journal of engineering

education. 36 lehden numero 1. S.75-85. 2011

Järvinen M., Kärnä A. & Fabritius T.

A detailed single bubble reaction sub-model for AOD process. steel research international 80 (6), 431-

438. 2009

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Järvinen M., Pisilä S., Kärnä A. & Fabritius T.

Fundamental Mathematical Model for AOD Process. Part I: Derivation of the model. Steel research

international 82 (6), 638-649. 2011

Leinonen V., Heino J. & Makkonen H.

Towards eco-efficiency: granulated nickel slag's transformation into a product. Progress in Industrial

Ecology - An International Journal 6 (1), 29-43. 2009

Mäkelä M., Paananen T., Kokkonen T., Makkonen H., Heino J. & Dahl O.

Preliminary evaluation of fly ash and lime for use as supplementary cementing materials in cold-

agglomerated blast furnace briquetting. ISIJ International 51 (2011) (5), 776-781. 2011

Niemelä M., Huttunen S., Gornostayev S. & Perämäki P.

Determination of Pt from coke samples by ICP-MS after microwave assisted digestion and microwave

assisted cloud point extraction. Microchimica Acta. 166. 2009. Sivut 255-260.

Paananen T., Heikkinen E.-P., Kokkonen T. & Kinnunen K.

Preparation of mono-, di- and hemicalcium ferrite phases via melt for reduction kinetics investigations.

steel research international 80 (6), 404-409. 2009

Pisilä S, Järvinen M, Kärnä A. & Fabritius T.

Mathematical Model for AOD Process. Part II: Model validation. Steel research international 82 (6), 650-

657. 2011

Riipi J., Fabritius T., Heikkinen E.-P., Kupari P. & Kärnä A.

Behavior of nitrogen during AOD process. ISIJ International 49 (10), 1468-1473. 2009

Rousu A. & Mattila O.

Electrical conductivity of the screening residuals of coke production in context of ferrochromium

production in a submerged arc furnace. Steel research international 80 (11), 796-799. 2009

Savolainen J., Fabritius T. & Mattila O.

Effect of fluid physical properties on the emulsification. ISIJ International 49 (1), 29-36. 2009

Savolainen J., Rousu A., Fabritius T., Mattila O. & Sulasalmi P.

Modelling of Pressure Distribution inside the SEN in a Stopper-rod controlled System. Steel research

international 81 (11), 980–986. 2010

Sulasalmi P., Kärnä A., Fabritius T. & Savolainen J.

CFD model for emulsification of slag into the steel. ISIJ International 49 (11), 1661-1667. 2009.

http://www.jstage.jst.go.jp/article/isijinternational/49/11/1661/_pdf

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CONFERENCE PAPERS, SEMINARS AND SYMPOSIUMS

Dahl O., Mäkelä M., Watkins G., Husgafvel R. & Heino J.

Teollisuuden sivuainevirrat ja niiden hyödyntäminen. Kemian päivät, Helsinki, Suomi. Esitelmä ja

PowerPoint –kalvot. 2011.

Dahl O., Mäkelä M., Watkins G., Husgafvel R. & Heino J.

Industrial symbiosis for sustainable production. Helsingin yliopiston ympäristötutkimuksen – ja

opetuksen yksikön HENVI –esitelmäsarja, Helsinki, Suomi. Oral presentation and PowerPoint –slides.

2011.

Fabritius T. & Luomala M.

Potential of physical models for developing of metallurgical process units. Scanmet III, 3rd International

Conference on Process Development in Iron and Steelmaking, 8-11 June 2008, Luleå, Sweden. SCANMET

3. Luleå, Sweden, MEFOS. 31-40

Gornostayev S. & Härkki J.

EPMA and SEM in characterization of inorganic compounds in blast furnace coke. COM2008: 47th

Conference of Metallurgists conference, August 24-27, 2008, Winnipeg, Canada. -. Conference of

Metallurgists 47. Winnipeg, Manitoba, Canada, METSOC. 11-18

Gornostayev S. & Härkki J.

Formation of Carbon Microtubes in Blast Furnace Coke. 3rd International Symposium on Environment,

22-25. toukokuuta 2008, Ateena, Kreikka. Theophanides M., Theophanides T. (eds.). Ateena, ATINER.

ISBN: 978-960-6672-58-3; 407-412.

Gornostayev S., Kerkkonen O. & Härkki J.

Use of mineralogical data for coking and blast-furnace processes. SCANMET III - 3rd International

Conference on Process Development in Iron and Steelmaking, 8-11 June 2008, Luleå, Sweden. -.

SCANMET 3. Luleå, Sweden, MEFOS. 255-264

Gornostayev S., Fabritius T. & Härkki J.

SEM and EPMA in characterization of inorganic compounds in metallurgical coke. Abstracts of 62nd

Meeting of the Scandinavian Microscopy Society, Oulu, Finland. Ronkainen V-P., Karppinen S-M.,

Järvenpää, S.. Oulu, University of Oulu Press. 89. 2011

Gornostayev S., Fabritius T. & Härkki J.

SEM/FESEM in characterization of carbon matter on a surface of metallurgical coke. Abstracts of 62nd

Meeting of the Scandinavian Microscopy Society, Oulu, Finland. Ronkainen V-P., Karppinen S-M.,

Järvenpää, S. Oulu, University of Oulu Press. 88. 2011

Gornostayev S., Fabritius T, Kerkkonen O. & Härkki J.

Observations on graphite in Fe-Si droplets of blast furnace coke. Abstracts of the Microscopy

Conference 2011 in Kiel, Germany. ISBN 978-3-00-033910-3. 2011.

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Haapakangas J., Mattila O. & Fabritius T.

Effect of injection rate on coke dust formation and coke gasification in a blast furnace shaft. METEC

InSteelCon 2011, Düsseldorf, Germany. Kim J, Lüngen H B. Session 13

Heikkinen E-P., Riipi J., Fabritius T., Pajarre R. & Koukkari P.

Computational modelling of oxides' surface tensions in secondary metallurgy and continuous casting.

MOLTEN 2009, 18-21. tammikuuta 2009, Santiago, Chile. Sanchez M. et al. (eds.). Santiago. 507-515

Heikkinen E-P. & Jaako J.

Context-free education - mission: impossible. Proceedings of Reflektori 2010 - Symposium of

Engineering education December 9-10, 2010. Myller Eeva. Dipoli-raportit / Dipoli-reports B 2010:1. 79-

88. http://opetuki2.tkk.fi/p/reflektori2010/documents/reflektori2010.pdf

Heikkinen E-P., Ikäheimonen T., Mattila O. & Fabritius T.

A thermodynamic study on the oxidation of silicon, carbon and chromium in the ferro-chrome

converter. Proceedings of the twelwth international ferro alloy congress. Sustainable Future. Volume I.

June 6-9. 2010 Helsinki, Finland. Vartiainen Asmo, Outotec. 229-237

Heikkinen E-P., Ikäheimonen T., Mattila O., Fabritius T. & Visuri V-V.

Behaviour of silicon, carbon and chromium in the ferrochrome converter - a comparison between CTD

and process samples. Proceedings of the 6th European Oxygen Steelmaking Conference. Stockholm,

Sweden, 9..-10.9.2011. Sivut 316-329 Artikkelinumero 3-04. 2011

Heino J. & Dahl O.

Teollisen ekologian soveltaminen Perämerenkaaren metallurgiseen teollisuuteen – Haasteet ja

mahdollisuudet. Esitelmä Suomen Teollisen ekologian seuran järjestämässä ”Materiaalivirrat ja

ilmastonmuutos” seminaarissa 28.4.2008.

Heino J., Watkins G., Makkonen H., Koskenkari T., Leinonen, V., Dahl O., Fabritius T. & Virtanen E.

Industrial ecology applied to metallurgical, chemical and pulp and paper industries around the Bothnian

Arc. Scanmet III. 3rd International Conference on Process Development in Iron and Steelmaking. 8.-

11.6.2008, Luleå, Sweden. MEFOS. Scanmet 3. Luleå, Sweden, MEFOS. 243-252

Heino J., Mälkki H., Leinonen V. & Koskenkari T.

Harjavalta industrial park as an example of an industrial ecosystem when developing local and regional

sustainability. 14th Annual International Sustainable Development Research Conference September 21-

23, 2008, India Habitat Center New Delhi, India . Annual International Sustainable Development

Research Conference 14. http://www.14aisdrc2008.com/

Heino J.

Common solution around Baltic sea. Presentation in Nordic Recycling Day IV in Luleå 7th – 8th of October,

2008.

Heino J.

Harjavalta industrial ecopark – A success story of the industrial ecology in the area of metallurgical

QUADRENNIAL REPORT 2008 – 2011

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55

industry to increase regional and global sustainability. Presentation in Metal producers UUMA seminar

in Tornio 28.4.2009.

Heino J. & Dahl O.

Industrial ecology applied to metallurgical, chemical and pulp and paper industries around Bothnian arc.

Presentation in Metal producers UUMA seminar in Tornio 28.4.2009.

Heiskanen K., Dahl O., Fogelhom C-J., Salmi O., Mälkki H., Eloneva S., Wierink M., Pajunen N., Watkins

G., Mäkelä M., Kainiemi L., Hukkinen J., Ekroos A., Levänen J., Pusa E-V., Paavola I-L., Fabritius T. &

Heino J.

Pro-environmental Product Planning in a Dynamic Operational Environment Now and in the Future -

Methods and Tools (ProDOE). Poster presentation in Ketju seminar. 2010.

Husgafvel R., Nordlund H., Heino J., Mäkelä M., Watkins G. & Dahl O.

LCA as a part of the utilization of cross-industrial residue flows. Application of life cycle methodologies

to support corporate environmental decision-making, Finnish Environment Institute, (SYKE), 10.3.2011.

Husgafvel R., Nordlund H., Heino J., Mäkelä M., Watkins G. & Dahl O.

Sustainability assessment of secondary products from integrated pulp and paper mill and carbon steel

plant around Bothian Arc, The Symposium on Industrial Ecology for Young Professionals (SIEYP II), June

11, 2011 Berkeley, California.

Husgafvel R., Nordlund H., Heino J., Mäkelä M., Watkins G. & Dahl O.

Sustainability assessment of secondary products from integrated pulp and paper mill and carbon steel

plant around Bothnian arc. 3rd NorLCA Symposium, 15th-16th of September 2011, Helsinki Environment

Institute, Helsinki, Finland. Poster presentation.

Jaako J., Hiltunen J., Ahola J. & Heikkinen E-P.

Department of process and environmental engineering. Centres of excellence in university education –

seminar. 24-25.2.2009. Helsinki. Korkeakoulujen arviointineuvosto.

Juuti T., Karjalainen P., Rovatti L., Heikkinen E-P. & Pohjanne P.

Contribution of Mo and Si to Laves-phase precipitation in type 444 steel and its effect on steel

properties. 7th European Stainless Steel Conference, 21-23 September, 2011, Como, Italy. Proceedings.

CD-ROM. 1-9 artikkelinumero 77.

Järvinen M., Kärnä A. & Fabritius T.

Detailed numerical modelling of gas-liquid and liquid-solid reactions in steel making processes. Scanmet

III, 3rd International Conference on Process Development in Iron and Steelmaking, 8-11 June 2008,

Luleå, Sweden. SCANMET 3. Luleå, Sweden, MEFOS. 347-355

Järvinen M., Pisilä S., Kärnä A., Visuri V-V., Fabritius T., Ikäheimonen T. & Kupari P.

Fundamental Mathematical Modelling of AOD Process. 4th International Conference on Modelling and

Simulation of Metallurgical Processes in Steelmaking 27.6.-1.7.2011. Stahlinstitut VDEh. Düsseldorf,

Germany, Stahlinstitut VDEh

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56

Kemppainen A., Mattila O. & Paananen T.

Reduction of olivine pellets in CO-CO2-H2-H2O-N2 gas. METEC InSteelCon 2011 Düsseldorf, Germany.

Kim J, Lüngen H. METEC InSteelCon 2011 Proceedings. Düsseldorf, Germany, Steel Institute VDEh.

Session 8. 2011

Kokkonen T., Gornostayev S. & Fabritius T.

Preparation of samples of metallurgical coke for solid-state analysis. Abstracts of 62nd Meeting of the

Scandinavian Microscopy Society, Oulu, Finland, June 8-10, 2011. Ronkainen V-P., Karppinen S-M.,

Järvenpää, S.. University of Oulu Press, Scandinavian Microscopy Society. 91

Kukurugya F., Orac D., Takacova Z., Vindt T., Miskufova A., Havlik T., Kekki A., Aromaa J., Forsen O. &

Makkonen H.

Chemical and structural characterization of steelmaking dust from stainless steel production.

Proceedings of EMC 2011. Volume 4. EMC 2011 (European Metallurgical Conference 2011). June 26-29,

2011, Düsseldorf, Germany. Harre, J., Waschki, U. (eds.), GDMB. 1171-1184

Kärnä A., Hekkala L., Fabritius T., Riipi J. & Järvinen M.

CFD model for nitrogen transfer in AOD converter. Scanmet III, 3rd International Conference on Process

Development in Iron and Steelmaking, 8-11 June 2008, Luleå, Sweden. SCANMET 3. Luleå, Sweden,

MEFOS. 155-161

Leinonen M., Heikkinen E-P., Ollila S. & Lilja J.

Improvement of the ladle slag reduction practice based on industrial trials and thermodynamic

calculations. Scanmet III. 3rd International Conference on Process Development in Iron and Steelmaking.

8-11.6.2008 Luleå, Sweden. MEFOS 305-314.

Leiviskä T., Sarpola A., Heikkinen E-P. & Tanskanen J.

2011. Surface charge properties and thermal behaviour of aluminium silicate clays. Ninth Keele meeting

on Aluminium – Aluminium and life: Living in the aluminium age. 19-23.2.2011. Niagara-on-the-lake,

Ontario, Canada. Birchall centre for inorganic chemistry and material science, Keele University,

McMaster University and Ryerson University. s.19.

Makkonen H.

Chemical and mineralogical characterization of dusts forming in stainless steel production in Tornio

plants. Proceedings of hydrometallurgical solutions for ferrous dust treatment seminar, 24-25 November

2010, Espoo Finland, Aalto University Publications in Materials Science and Engineering. Kekki A (toim.).

44-87. 2010

Miettunen H., Kaukonen R., Kokkonen T., Ojala S. & Keiski R.

Mineral Synthesis and Carbon Dioxide adsorption on Some Platinum-Group Minerals. Geological Society

of India Golden Jubilee. 2010. http://www.geosocindia.org/Goldenjubilee/Fulltext_pdf/Miettunen.pdf

Mälkki H., Heino J. & Pajunen N.

Sustainable development in the Harjavalta industrial park. Lahti Science Day, November 25, 2008. Poster

presentation.

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57

Ollila J., Niemelä P., Rousu A. & Mattila O.

Preliminary Characterization of the Samples Taken From A Submerged Arc Furnace Ferrochrome

Furnace During Operation. Proceedings of the Twelfth International Ferroalloys Congress. Sustainable

Future. Volume I. June 6-9. 2010 Helsinki, Finland. Vartiainen Asmo, Outotec Oyj. 317-326

Paananen T., Heikkinen E-P., Kokkonen T. & Kinnunen K.

Preparation of mono-, di- and hemicalcium ferrite phases via melt for the reduction kinetics

investigations. Scanmet III - 3rd International Conference on Process Development in Iron and

Steelmaking. 8.-11.6.2008. Luleå, Sweden. MEFOS. Scanmet 3. Luulaja, MEFOS. 601-610

Riipi J., Fabritius T., Pajarre R. & Koukkari P.

Calculation of surface tension of casting powder systems used in steelmaking. Calphad XXXVII,

International Conference on Computer Coupling of Phase Diagrams and Thermochemistry, Saariselkä,

Finland, June 15.-20. 2008. Calphad 37. http://www.calphad.org/meetings/2008/index.html

Rousu A., Mattila O. & Tanskanen P.

A Laboratory Investigation of the Influence of Electric Current on the Burden Reactions in A Submerged

Arc Furnace. Proceedings of the Twelfth International Ferroalloys Congress. Sustainable Future. Volume

I. June 6-9. 2010 Helsinki, Finland. Vartiainen Asmo (ed.), Outotec Oyj. 303-310

Salmi O., Heino J., Hukkinen J., Pajunen M. & Wierink M.

Interplay between industrial ecosystems and environmental governance at different spatial scales.

Paper presented at the 5th International Conference on Industrial Ecology “Transitions towards

Sustainability”. Lisbon, June 21-24 2009, Portugal.

Savolainen J., Fabritius T. & Mattila O.

Research of slag emulsification with physical miniature model. Third Nordic Symposium for Young

Scientists in Metallurgy, May 14-15, 2008, TKK, Espoo, Finland. Nordic Symposium for Young Scientists in

Metallurgy 3. Helsinki, Helsinki University of Technology. 27-33

Suopajärvi H. & Angerman M.

Layered Sustainability Assessment Framework. MetecInSteelCon 2011 Proceedings, EECRsteel 1st

International Conference on Energy Efficiency and CO2 Reduction in the Steel Industry. Hans Bodo

Lüngen, Grant Mahmutovic, MetecInSteelCon 2011 Proceedings, Düsseldorf, Germany. 10

Tanskanen P., Kinnunen K. & Paananen T.

Significant mineralogical differences between basic test and production iron ore sinters with equal

chemical composition. MOLTEN 2009, 18-21. tammikuuta 2009, Santiago, Chile. Sanchez M. et al. (eds.).

Chile. 947-956

Tanskanen P., Heikkinen E-P., Karjalainen J., Seppelin S. & Lassi U.

An experimental study on the alpha-to-beta-spodumene phase transformation. Proceedings of the Eco-

mates 2011. International symposium on materials science and innovation for sustainable society - Eco-

materials and Eco-innovation for global sustainability. Takahashi Yasuo. 219-220

QUADRENNIAL REPORT 2008 – 2011

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OTHER REPORTS & PUBLICATIONS

Angerman M., Dahl O., Heino J., Härkki J., Makkonen H., Rova E. & Tanskanen P.

Boliden Harjavalta Oy:n nikkelikuonan tutkimus- ja kehitysprojekti 1.1.2006 – 31.12.2008. Loppuraportti

Prosessimetallurgian laboratorion osuudesta. CIRU/Prosessimetallurgian laboratorio. Oulu 2008, Oulun

yliopisto. 4 s. (Only for internal use of Outotec Research Oy)

Gornostayev S. & Härkki J.

Mineralogical properties of metallurgical coke. Energy research at the University of Oulu. Pongracz Eva

(ed. .; ISBN 978-951-42-9154-8). Oulu, Kalevaprint. 123-127. 2009

Hakkarainen V., Riipi J., Fabritius T., Mattila O. & Mattila R.

Control of surface phenomena and separation technologies by external electric potentials. Oulu,

University of Oulu, Department of Process and Environmental Engineering. Report 338. 55. 2009

Heikkinen E-P. & Fabritius T.

Artikkelinkirjoitusviikosta vauhtia julkaisun tekoon. Peda forum. Jyväskylä, Kirjapaino Oma. 43-45. 2008

Heikkinen E-P.

Brief introduction to portfolio learning. Sustainable production and energy: Catalysis by nanomaterials,

catalytic microreactors. COST Action 543 Training School. Keiski, Riitta; Huhtanen, Mika & Kangasharju,

Liisa. - University of Oulu, Department of Process and Environmental Engineering. Report 333. Oulu,

Prosessi- ja ympäristötekniikan osasto. 19-26. 2008

Heikkinen E-P.

Brief introduction to portfolio learning. Environmental application of TiO2 photocatalysis, COST actions

540, 543 and P19 training school. Keiski Riitta, Huuhtanen Mika, Kangasharju Liisa (eds.). - Prosessi- ja

ympäristötekniikan osasto. Moniste Report 336. Oulu, University of Oulu, Department of Process and

Environmental Engineering. Report. 17-24. 2009

Heikkinen E-P.

Mikä ihmeen TkK? Materia 67 (3), 6-8. 2009

Heikkinen E-P.

Yhteistyöllä ja verkostoitumalla tulosta tutkimuksesta. Materia 67 (4), 36-37. 2009

Heikkinen E-P. & Jaako J.

Continuous Assessment in Process Engineering Education – Two Case Studies. Control Engineering

Laboratory. Report A. Oulu, Oulun yliopisto. 20 s. 2011. http://jultika.oulu.fi/Record/isbn978-951-42-

9721-2

Heino J. & Tuominen O.

Harjavalta ja Outokummun kuparitehdas1940-luvulla. Harjavaltalaismuistoja vuosikymmenten varrelta

Emil Cedercreuzin museon muistelolehti, 22-24. 2008

QUADRENNIAL REPORT 2008 – 2011

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59

Heino J., Makkonen H. & Leinonen V.

Boliden Harjavalta Oy:n vuoden 2006 nikkeliraekuonanäytteenottokampanjan tulokset. Pori 2008,

Outotec Research Oy. 27 s. (Only for internal use of Outotec Research Oy)

Heino J., Makkonen H., Tanskanen P. & Rova E.

KUNI –projektin kokoomaraportti Prosessimetallurgian laboratorion osuudesta. Pori 2008, Outotec

Research Oy. 15 s. (Only for internal use of Outotec Research Oy)

Heino J.

Harjavalta industrial park as an industrial ecosystem to increase regional and global sustainability.

Environmental management in networks course. University of Jyväskylä 18.3.2008. 26 p.

Heino J., Mäkelä M. & Makkonen H.

”MEBF briketti” – osion työpaketin 2 loppuraportti: Olemassa oleva tieto, aiheeseen liittyvä kirjallisuus

ja esitiedot materiaaleista. Oulun yliopisto, 109 s. 2010. (Only for internal use of Outotec Research Oy)

Heino J., Paananen T., Mäkelä M., Makkonen H., Kallio R., Kinnunen K. & Nevalainen T.

”MEBF Briketti” – osuuden työpaketin 3 loppuraportti: Koemateriaalien valinta ja näytteenotto. Oulun

yliopisto, 25 s. 2010. (Only for internal use of FIMECC)

Heino J., Paananen T., Makkonen H. & Mäkelä M.

”MEBF Briketti” – osuuden työpaketin 4 loppuraportti osa 1: Ruukin sekundäärien raaka-aineiden

analyysitulokset. Oulun yliopisto, 35 s. 2010. (Only for internal use of FIMECC)

Heino J., Samuelsson C. & Heikkinen E-P.

A full decade of Nordic recycling days. Materia 68 (5), 45-47. 2010

Heino J. & Nordlund H.

Materiaalien ympäristöominaisuuksia ennakoivat termodynaamiset menetelmät. Elinkaarimetodiikkojen

nykytila, hyvät käytännöt ja kehitystarpeet. Riina Antikainen (toim.). - Suomen ympäristökeskuksen

raportteja 7/2010. Helsinki, Suomen Ympäristökeskus. 50-61. 2010

http://www.ymparisto.fi/download.asp?contentid=116835&lan=fi

Heino J.

Vireä yli viisikymppinen Nobel -yliopisto. Department of Process and Environmental Engineering. Report

341. Oulu, Oulun yliopisto, Teknillinen tiedekunta, Prosessi- ja ympäristötekniikan osasto. 2010

http://herkules.oulu.fi/isbn9789514293757/isbn9789514293757.pdf

Heino J., Mäkelä M., Paananen T. & Makkonen H.

The final report of MEBF briquette work packages 5 part II: Agglomerating practices of fine coke

materials – Literature survey. 18 p. 2011. (Only for internal use of FIMECC)

Heino J.

Harjavalta industrial ecopark – A success story of the industrial ecology in the area of metallurgical

industry to increase regional and global sustainability. Environmental management in networks course.

Held originally at 2009 in the University of Jyväskylä to be updated at 2010 and 2011. 25 p.

QUADRENNIAL REPORT 2008 – 2011

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60

Heino J., Koskenkari T., Leinonen V. & Mälkki H.

Harjavalta eco-industrial system. Industrial Ecology –course. Held originally at 2008 in the University of

Oulu to be updated at 2009 - 2011. 25 p.

Heino J.

Nikkelin valmistus. Hapetus- ja pelkistys -kurssi. Oulun yliopisto 2009 – 2011. 19 s.

Heino J.

Teollinen ekologia ja teollinen ekosysteemi - Johdatus teolliseen ekologiaan. Teollinen ekologia –kurssi.

Aalto-yliopisto 2011. 22 s.

Heino J.

Industrial ecology applied to carbon steel manufacture to develop environmental friendliness of carbon

steel. Industrial Ecology –course. Aalto University School of Engineering 2011. 21 p.

Heino J.

Hypothetic Bothnian Arc metallurgical industrial ecology enterprise - A challenging potential to minimise

local and regional waste accumulation and reduce local, EU, and global carbon footprint. Industrial

Ecology –course. Aalto University School of Engineering 2011. 26 p.

Huttunen S., Niemelä M. & Gornostayev S.

Preliminary study of the determination of platinum group elements in coke samples. Prosessi- ja

ympäristötekniikan osasto. Moniste Report 334. Oulu, University of Oulu, Department of Process and

Environmental Engineering. Report. 59. 2009

Huttunen S., Niemelä M., Perämäki P. & Gornostayev S.

Preliminary study of the determination of major and trace elements in coke samples by LA-ICP-MS.

Department of Process and Environmental Engineering. Report 340. Oulu, University of Oulu,

Department of Process and Environmental Engineering. 63. 2010

Huttunen S., Gornostayev S., Kokkonen T. & Mattila R.

Study of mineral phases in coke samples by confocal Raman microscopy. Department of Process and

Environmental Engineering. Report 342. Oulu, University of Oulu, Department of Process and

Environmental Engineering. 56. 2011.

Jaako J. & Heikkinen E-P.

Yliopistokoulutuksen laatuarviointi – Ketkä menestyvät

Materia. 66 lehden numero 1/2009. Sivut 32-34. 2009

Jaako J., Ahola J., Heikkinen E-P & Hiltunen J.

Teekkareiden opintojen ohjaaminen

Oulun yliopisto, säätötekniikan laboratorio. 20 s. Raportti B, 70. 2010

Jaako J. & Heikkinen E-P.

Tekniikan pedagogiikka - Opetuksen linjakkuuden toteutus jatkuvan arvioinnin avulla

Oulun yliopisto, säätötekniikan laboratorio. Raportti B, 73. 2010

QUADRENNIAL REPORT 2008 – 2011

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61

Karjalainen P. & Fabritius T.

Terästutkimuksen Steel Forum II. Materia. 68 lehden numero 5. 34-35. 2010

Kokkonen T. & Gornostayev S.

Preparation of samples of metallurgical coke for optical and electron microscopy and electron probe

microanalysis. Department of Process and Environmental Engineering. Report 339. Oulu, Oulun

yliopisto. 22. 2010

Kärnä A., Sulasalmi P. & Fabritius T.

Physiochemical modelling of AOD process. Prosessi- ja ympäristötekniikan osasto. Report 337. Oulu,

University of Oulu, Department of Process and Environmental Engineering. Report. 67. 2009

Makkonen H. & Heino J.

Nikkeliraekuonan liukoisuusominaisuudet ja siihen vaikuttavia tekijöitä. Pori 2008, Outotec Research Oy.

16 s. (Only for internal use of Outotec Research Oy)

Makkonen H., Leinonen V. & Heino J.

Nikkeliraekuonan mineralogia. Pori 2008, Outotec Research Oy. 40 s. (Only for internal use of Outotec

Research Oy)

Makkonen H., Mattila O. & Gornostayev S.

Preliminary Study of the Image Analysis of Coke Textures. Report 335, ISBN 978-951-42-9189-0,

Department of Process and Environmental Engineering, University of Oulu, 41p. 2009.

Makkonen H., Angerman M., Rova E., Tanskanen P, Koskela S, Dahlbo H, Myllymaa T. & Holma A.

Mineralogiset tutkimukset teollisuuden jäännöstuotteiden ja jätteiden ympäristökelpoisuuden

arvioinnissa, kehittämisessä ja laadunvalvonnassa. Uusiomateriaalien käyttö maarakentamisessa

Tuloksia UUMA-ohjelmasta 2006-2010. Inkeröinen J, Alasaarela E. - Ympäristöministeriön raportteja 13.

Helsinki, Ympäristöministeriö. 41-51. 2010 http://www.ymparisto.fi/

Makkonen H., Paananen T., Heino J. & Mäkelä M.

”MEBF briketti” – osion työpaketin 4 loppuraportti osa 3: Ruukin sekundääristen briketointiraaka-

aineiden SEM-EPMA analysointi: Masuunin valuhallin pöly. 43 s. 2011. (Only for internal use of FIMECC)

Miettunen H., Kaukonen R., Kokkonen T., Ojala S. & Keiski R.

PGM synthesis and CO2 adsorption. Clean air research at the University of Oulu, Proceedings of the

SkyPro Conference, June 3rd 2010, University of Oulu, Finland. 2010. Sivut 89-92

Miettunen H., Kaukonen R., Kokkonen T., Ojala S. & Keiski R.

The method for PGM synthesis. Miscellanous Data Release by the Ontario Geological Survey, 21-24 June

2010. Sivut 100-101.

Mäkelä M., Paananen T., Kokkonen T., Heino J. & Makkonen H.

”MEBF briketti” – osion työpaketin 4 loppuraportti osa 2: Sekundäärien sideaineiden analyysi- ja

testitulokset. 21 s. 2010. (Only for internal use of FIMECC)

QUADRENNIAL REPORT 2008 – 2011

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62

Mäkelä, M., Paananen T., Makkonen H. & Heino J.

The final report of MEBF briquette work package 5 part I: Plan of briquetting recipes, preparation of

recipes and briquetting test series. 21 p. 2010. (Only for internal use of FIMECC)

Mäkelä M., Makkonen H., Paananen T., Maaninka A., Kokkonen T. & Heino J.

The final report of MEBF briquette work packages 6 and 7 part I: Manufacture of the briquettes and

results of the briquetting test series I. 38 p. 2011. (Only for internal use of FIMECC)

Savolainen J., Isokääntä S., Mattila O. & Fabritius T.

Modelling of inclusion removal and slag emulsification. University of Oulu, Department of Process and

Environmental Engineering. Report 332. Oulu, University of Oulu. 33. 2008.

Tanskanen,P.

Nikkelisähköuunikuonan boorioksidiseostukset. Pori 2008. Outotec Research Oy. 14 s. (Only for internal

use of Outotec Research Oy)

Wienink M. & Heino J.

ProDOE and Bothnian arc industrial ecology enterprise. Materia-lehti (4), 40-41. 2008

QUADRENNIAL REPORT 2008 – 2011

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63

THESES

BACHELOR’S DEGREE

2008

Paukkeri Anni Elinkaariarviointi – esimerkkejä terästeollisuudesta Torvikoski Tarja Hilseen määrään vaikuttavat tekijät Raahen terästehtaan

askelpalkkiuuneissa / Scale formation in the walking beam furnace in the Raahe steel plant

Visuri Ville-Valtteri Laatukustannukset - mallit ja mittaaminen

2009

Alatarvas Tuomas Rautarikastepellettien pelkistysnopeuden määrittäminen termovaa’alla

Angelva Oskari Rautarikastepellettien pelkistysnopeuden määrittäminen termovaa’alla, osa 2

Aula Matti CaO-FeO-SiO2-systeemin pintajännityksen estimoiminen geometrisilla menetelmillä

Kantomaa Juhani Vakuumin käyttö teräksen valmistuksessa Kunelius Juho Ruostumattomien terästen kuumavalssauksen keskeisimmät

ongelmat Kuusisto Lauri Spodumeenin faasitransformaatiolämpötilan tutkiminen ja

spodumeenipegmatiitit Rantala Jaakko Palautevirtauksia sisältävän säiliösysteemin mallinnus ja simulointi Vasankari Antti Kuumavalssaamon jäähdytysjärjestelmän lietteet

2010

Hanhisuanto Elina Tornion terästehtaan kuumavalssaamon alitteen sisäisen kierrätyksen mahdollistaminen

Harvala Tero Raahen terässulaton konvertterikaasun pesulietteen ominaisuudet Huotari Pirita Riskienhallinnan lainsäädännölliset vaatimukset ja riskienhallinnan

dokumentoinnin toteuttaminen yrityksessä Iljana Mikko Rautapellettien pelkistymiskokeita termovaa’alla – Vedyn ja

vesihöyryn vaikutus rautapellettien pelkistymiseen Kauppinen Mikko Differentiaalitermaalinen analyysi ja spodumeenin

faasitransformaatio-lämpötilan mittaaminen Kemppainen Lauri Ksyloosin käyttö biopolttoainekomponenttien valmistuksessa Keränen Janne Hartsituotteiden granulointi Meriläinen Tuomas Deoksidaatiotasapainot ruostumattomissa teräksissä Naakka Ville Välialtaan lämpöhäviöt magnesia- ja oliviini-

pinnoitteilla teräksen jatkuvavalussa Vaitiniemi Ilkka Konvertterin geometristen parametrien vaikutus prosessin toimintaan Vehkamäki Ville lmiöt prosessitekniikassa

QUADRENNIAL REPORT 2008 – 2011

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64

2011

Hyttinen Niko Terästeollisuuden valukoneiden välialtaissa käytetyt pinnoitevuoraukset (MgO ja SiO2)

Kalaoja Mikko Erilaisten arkinvalmistusmenetelmien vertailu jäännösmustemittauksessa

Kallio Timo Masuuni nro 2:n peruskorjaus 25.6.-19.8.2011 kulumisprofiilin määritys

Kangas Ville Anaerobisen fermentoinnin syötteet ja niiden käsittely Palovaara Petri Terässulaton hajapölypäästöt ja keinot niiden vähentämiseksi Salo Antti Nikkelin valmistuksessa syntyvän fayaliittisen (2FeO-SiO2) kuonan

pelkistyskokeet Tikka Johanna Kromiittipellettien pelkistysnopeuden määrittäminen termovaa’alla Upola Heikki Butanolin valmistus fermentoinnilla Veijola Riikka Laskennallinen tarkastelu suolojen saostumisesta suola- ja

rikkihappojen vesiliuoksesta

MASTER’S DEGREE

2008

Hakkarainen Ville Jäähdytysosan teknistaloudellinen tarkastelu lannoiteprosessissa / Effect of external potential on wetting of an electrolyte droplet

Helkomaa Jussi Teräksen sulkeumarakenteen määrittäminen kenttäemissioelektroni-mikroskoopilla / Defining inclusion composition with fieldemission scanning electron microscope

Herlevi Tuomas Metallurgisten kuonien mineralogia, liukoisuus ja hyötykäyttö / Mineralogy, solubility and utilisation of metallurgical slags

Karassaari Olli-Pekka Valokaariuunin energiatase ja kaatolämpötilan mallinnus /Energy balance of stainless steel EAF and calculation of end-point temperature

Karjalainen Jukka Läntän spodumeenin faasitransformaatio ja lämpökäsittelyn energian tarve / Phase transformation and energy consumption in heat treatment of Länttä spodumene

Pekkala Olli Ferrokromiuunin muurauksen valvontajärjestelmä / Ferrocromium furnace lining monitoring system

Peuranen Eliisa Ti- ja Nb-stabiloidun ferriiittisen ruostumattoman teräksen sulkeumakuva / Inclusions in Ti and Nb stabilized ferritic stainless steel

Rousu Arto Virrankulku uppokaariuunin panoksessa / The current transfer in the burden of a submerged-arc furnace

Rova Erika Nikkelisähköuunikuonan hapetus ja sen tuottamat rakenteet / The effect of oxidation on nickel slag and its microstructure

Savolainen Jari Kuonan emulgoitumisen tutkiminen fysikaalisella pienoismallilla / The research of slag emulsification with physical miniature model

Suikkanen Päivi Rikkihapon elohopeapitoisuuden hallinta /Sulphuric acid mercury control

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2009

Haapakangas Juho Kuumavalssatujen ultralujien nauhaterästen hilseen kiinnipysyvyys ja vaikutus pinnan-laatuun / Adhesion of scale of ultra high-strenght steels and effect on surface quality

Halonen Lauri Valokaariuunin kuonan modifiointi magnesiumoksidilla ja alumiinilla / Modification of EAF slag with magnesium oxide and aluminium

Jääskeläinen Kari Separation processes of the PGE’s from upgraded concentrates by hydrometallurgy / Platinaryhmän metallien hydrometallurginen erottaminen konsentroidusta rikasteista

Karppinen Anni Katsaus fluorin, boorin ja molybdeenin ympäristö- ja terveysvaikutuksiin / Survey on the impacts of fluorine, boron and molybdenum on environmental and health

Kemppainen Antti Pyrometallurgical synthesis methods for LiMn2O4 cathode material / LiMn2O4 katodimateriaalin pyrometallurginen valmistaminen

Kettunen Pekka RAP5-linjan virtaustase sekä prosessiliuosten ja -sakkojen metallipitoisuudet / RAP5 flow balance and metal concentrations of process solutions and sludges

Kurikkala Jari Reaktiivisen kaasun vaikutus rauta-hiili-sulan kostutukseen keraamimateriaalien pinnalla / The effect of reactive gas on the wetting of molten iron-carbon alloy on ceramic substrates

Kurikkala Outi Litium titaanispinellin pyrometallurginen valmistaminen / Pyrometallurgical preparation of lithium titanium spinel

Leppälä Mika Syväjärven spodumeenin faasitransformaatio ja lämmönsiirto epäsuorasti lämmi-tettävässä rumpu-uunissa / Phase transformation of Syväjärvi spodumence and heat transfer in indirect fired rotary kiln

Pisilä Sauli Sekundäärisistä raaka-aineista valmistetun masuunibriketin ominaisuudet / Propertiies of blast furnace briquettes made from secondary raw materials

Pärkkä Heikki Konenäön hyödyntäminen koksiuunien analysoinnissa / The use of machine vision for analyzing coke ovens

Ruokanen Jussi Spodumeenin ja eräiden muiden teollisten silikaattimineraalien faasitransformaatio / The phase transformations of spodumene and some other industrial silicate minerals

Seppelin Sari Keski-Pohjanmaan spodumeenin faasitrasformaatiolämpötila ja koostumus / Phase transformation temperature and composition of Central Osthrobotnia spodumene

Torvikoski Tarja Valuhiekan ja teräksen väliset kemialliset vuorovaikutukset valukappaleiden pintavikojen aiheuttajana / Chemical interactions between steel and casting sand as a cause for casting defects

Välikangas Juho Pyrometallurgical synthesis of LiFePO4 cathode material / LiFePO4 katodimateriaalin pyrometallurginen valmistus

2010

Hanhisuanto Elina Metallioksidipitoisten sivuvirtojen pelkistys valokaariuunissa /

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Reduction of metal rich residues in electric arc furnace 2 Harvala Tero Johannes Seleenin pasutus hopeapitoisesta anodiliejusta / Selenium roasting

from silver rich anode slimes Härkönen Mikko Metallurgisen koksin vaikutukset nikkelisähköuunin kuonan

pelkistykseen / Properties of metallurgical coke in reduction of nickel flash smelting furnace slag in electric furnace

Iljana Mikko Pohjalinssin muodostuminen reunakäyntisessä masuunissa / Formation of salamander in a wall-working furnace

Kangas Jyrki Ferrokromikonvertterin puhalluslopetusajankohdan määritys savukaasuanalyysin avulla / CRC-process endpoint determination with off gas analysis

Kunelius Juho Valokaariuuni 2:n kaatolämpötilan mallinnus / Modelling tapping temperature of EAF 2

Oinas Miika Savukaasujen jatkuvatoiminen mittaus VKU2:n ohjauksen kehittämisessä /Continuous off-gas analysis in EAF 2 dynamic control development

Pussinen Juho Sähköisten ominaisuuksien mittaaminen ferrokromin valmistuksessa käytettävän uppokaariuunin yksittäisistä materiaalirakeista / Measuring the electrical properties of single burden particles from a submerged arc furnace used to produce ferrochromium

Saatio Tommi Läpityöntöuunin virtausmallinnus / Numerical simulation of pushertype furnace

Tuomikoski Sakari Teräksen kemiallinen lämmitys CAS-OB-prosessilla / Chemical heating of steel with CAS-OB process

2011

Alatarvas Tuomas Panoskerrosten pelkis-tyminen ja hapettuminen masuuniolosuhteissa The reduction and oxidation of burden layers under simulated blast furnace conditions

Aula Matti Jatkuvavalukoneen toisiojäähdytyksen optimointi / Optimization of secondary cooling of continuous casting machine

Keskimölö Aapo Developing and optimizing the temperature control of continuous annealing furnace

Paukkeri Anni Jaloterässulaton aihiokuumahiomon suodatinlaitoksen toiminnan kehittäminen / Development activities in the slab hot grinding shop’s filtering plant in the steel melting shop

Pirttiaho Henna Accelerating additives in sulfating roasting of nickel-containing ores and concentrates

Vasankari Antti Vuorausmateriaalien pinnoittamisen soveltuvuus kuumennusuunien lämpötalouden parantamiseen / Suitability of high emissivity and high reflectivity coatings to improve energy efficiency of reheating furnace

Visuri Ville-Valtteri Kuonanmuodostuksen termodynamiikka AOD-prosessimallissa / Thermodynamics of slag formation in an AOD process model

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CONTACT INFORMATION

UNIVERSITY OF OULU

Department of Process and Environmental Engineering

Laboratory of Process Metallurgy

P.O. Box 4300

FI-90014 UNIVERSITY OF OULU

FINLAND

Invoice address (Finland):

Oulun yliopisto

PL 7633

01051 LASKUT

Internet: http://www.oulu.fi/pomet/

Figure 15. Personnel of the Laboratory of Process Metallurgy on December 2011.