- CMP TC 076 "Plasma Arc Technology"
Plasma arc heaters are electrical resistance heaters where the resistive
element is the electrically-conductive partially ionized gas between two
electrodes. Whereas plasma arcs occur in nature as sudden lightning
discharges, plasma arc heaters provide a continuously-controlled electrical arc
discharge. The unique advantage for the application of plasma arc technology
include: gas environment control, gas-flow rate control, fine particle feed
capability, high temperature, high energy fluxes, rapid quenching, and no
products of combustion.
- CMP 92-9 "Ion Beam Assisted Deposition of Coatings on Carbon Steel"
This report presents the results of research to evaluate Ion Beam Assisted
Deposition (IBAD) for applying zinc and zinc-iron coatings to carbon steel.
IBAD is a dry process essentially free from environmental problems. Another
unique feature of the process is that it can deposit any metal or alloy onto
metal surfaces. The report recommends that additional static tests should be
conducted and consideration be given to conducting pilot line trials to
determine the potential of applying this coating method to high-speed
industrial coil coating lines.
- CMP 92-7 "Electrotechnologies for Sand Reclamation"
Until recently, used foundry sand, amounting to over 7 million tons annually,
was disposed of primarily by dumping in landfills. However, the number of
available landfills is decreasing while disposal costs have been increasing
each year. Consequently foundries are now examining sand reclamation methods
in order to avoid the environmental problems and economics associated with
disposal. This report represents the results of a performance evaluation of
the Castec "Thermpak" electric indirect radiant-heated sand reclaimer. An
energy and economic evaluation are also provided.
- TR-101600 "Nitrogen Control in Electric Arc Furnace Steelmaking"
This report presents the results of a study to evaluate practices for
controlling or reducing nitrogen in EAF-produced steels. Overall, the study
concluded that nitrogen content can be reduced through an increase in carbon
monoxide evolution sustained by oxygen injection and carbon additions.
- CMF 92-5 "Infrared Treating of Aluminum Wheels"
This project investigated the feasibility of using high-intensity electric
infrared (IR) heating in the solution heat treatment of cast-aluminum wheels.
It was expected that this technology would overcome drawbacks found in
conventional gas-fired or electric-resistance furnaces and its implementation
would reduce cost and improve quality.
- IN-100070 "CONSTEEL Process Boosts Steelmaker's Productivity"
Intersteel Technologies developed the CONSTEEL process in the mid-1980s. Based
on the results obtained from a prototype installation at another steelmaking
facility, Florida Steel, a Duke Power customer, installed the first CONSTEEL
electric furnace. The CONSTEEL process continuously charges scrap to the
furnace via an enclosed conveyor system. The hot furnace waste gases move
counter-current to the scrap direction transferring a portion of their energy
to the scrap. The carbon monoxide emanating from the electric arc furnace
undergoes combustion as the gases flow through the preheater
- CMF TC V8 N1 "Infrared Heating, Drying and Curing"
Electric infrared technologies provide fast and efficient heating. Drying, and
curing capabilities in a wide variety of applications. Compared with
convection oven processing, electric infrared methods greatly improve energy
efficiency, speed, and control. Infrared processes supply heat primarily by
radiation, so they are ideally suited for manufacturers involved in drying and
curing coatings, paints, inks, and adhesive; and drying paper, textiles, filter
media, etc.
- CMF TC V7 N3 "Powder Coating and Curing"
Powder coating is a relatively new method that is making a major impact in the
finishing industry. It offers manufacturers increased economic benefits and
superior quality while meeting all environmental regulations. Powder coating
is a modern technology that allows end-use manufacturers to precisely engineer
their finishing operations while eliminating many of the traditional problems
caused by solvents, such as runs, sags, solvent popping etc. One of the most
significant advantages of powder coating is that there is a minimum requirement
for makeup air to the coating booth.
- PIO TA V4 N7 "IR Moisture Profiling of Linerboard"
The Packaging Corporation of America (PCA) needed to find a way to fully
utilize its existing paper machine to produce sheets of uniformly dry
linerboard. Infrared dryers, placed on the top and front of the paper machine,
reduce the moisture content in the linerboard's edges without over-drying the
center. The final moisture profile across the sheet varies by less than one
percent.
- PIO TA V4 N6 "Ultrafiltration in Food Processing"
Atlantic Gelatin's examination of the feasibility of using a membrane
ultrafiltration (UF) system to concentrate the gelatin led to improved product
quality, reduced energy use, and a cleaner environment. The spiral-wound UF
membrane systems at Atlantic Gelatin remove water from the gelatin solution
using less energy than the tripe-effect evaporators they replaced. A new
combination of a UF and reverse osmosis unit is being installed to lower the
biological oxygen demand and chemical oxygen demand levels in Atlantic
Gelatin's waste water and to increase the amount of reclaimed water.
- TR-101379 "Application of Ultrasound in Textile Wet Processing: Phase
1"
Ultrasound, or ultrasonic energy, promises significant benefits to the textile
industry through improvements in two vital areas -- cost of manufacturing and
solutions to environmental impact problems. Cost of manufacturing would be
reduced through the improved quality and speed of processing. Significant
environmental benefits would be realized because of the reductions in
requirements for energy, water, and processing chemicals.
- CMP 92-10 "Electric Arc Furnace Efficiency"
This report concentrates on the relation between equipment, operating
practices, etc., and energy consumption.
DOE Materials:
- Dosaj, V.D., et al., "Silicon Smelting in a Closed Furnace", American
Institute of Metallurgical Engineers/Iron and Steel Institute, 1991 Electric
Arc Furnace Conference, Toronto, Canada, November 11-13, 1991.
- Dosaj, V.D., et al., "The Smelting of Taconite to Produce Ferrosilicon,"
Iron and Steel Society, 50th Electric Furnace Conference, Atlanta, GA, November
10-13, 1992.
- Harkness, J., Gorski, A., Daniels, J., "Microwave Plasma Dissociation of
Hydrogen Sulfide", presented at the American Institute of Chemical Engineers
Spring National Meeting New Orleans, Louisiana, March 1988.
Order copies from the Office of Scientific and Technical Information, P.O. Box
62, Oak Ridge, TN, 37831, (615) 576-8401, or the National Technical Information
Service, U.S. Department of Commerce, 5285 Port Royal Rd., Springfield, VA
22161.
- Harkness, J., Gorski, A., Daniels, J., "Hydrogen Sulfide Waste Treatment
by Microwave Plasma Dissociation", Vol 6, p 197, Proceedings of the 25th
Intersociety Energy Conversion Engineering Conference, American Institute of
Chemical Engineers, New York, 1990. Order copies from Dr. Hohn Harkness,
Argonne National Laboratory, 9700 South Cass Avenue, Argonne, Il, 60439-4815,
(708) 972-7636.
- Harkness, John B.L., Richard D. Doctor, and Edward J. Daniels,
"Plasma-Chemical Waste Treatment of Acid Gases." Presented at the Air &
Waste Management Association Annual Meeting, Denver, Colorado, June 13-18,
1993.
- Purdy, G., C. Zawodzinski, W.H. Smith, B.F. Smith, "The Application of
Electrodialysis to Extend the Lifetime of Commercial Electroplating Baths,"
Eighth Symposium on Separation Science and Technology for Energy Applications,
Gatlinburg, TN, October 24-28, 1993.