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Papers by Florian Kongoli
2016-Sustainable Industrial Processing Summit, May 17, 2016
The industrial area around RTB Bor encompasses about 9,190,940 tons of techno genic deposits of c... more The industrial area around RTB Bor encompasses about 9,190,940 tons of techno genic deposits of copper smelting slag with an average of 0.715% copper content. As part of a project to recuperate copper from these deposits, this work investigates the effect of the rapid cooling of these slags on their physicochemical milling and flotation properties. Two sets of samples from these deposits were analyzed and compared. The first set of samples were analyzed as is, without any pre-treatment. The second set of samples were melted in a furnace and then quenched and granulated in the water. Both sets of samples were analyzed and compared in terms of their physicochemical, milling and flotation properties. This included the results of chemical and SEM - EDS tests, Bond Work Index in rods and balls mills, milling kinetics and flotation parameters. The analysis and comparison served to draw proper conclusions on the copper recovery of each set of conditions.
2017-Sustainable Industrial Processing Summit, Mar 12, 2017
The impact of two different types of refractory materials and layout in the life cycle of an elec... more The impact of two different types of refractory materials and layout in the life cycle of an electro-reduction Fe-Ni arc furnace, during regular production periods, with two different refractory lining materials, are described. It is shown the refractory lining consisting of a combination of magnesite bricks in vertical walls and graphite blocks in the slag levels has a life cycle about 3 times higher compared to the case when all walls were lined with magnesite bricks only. It was also found that although graphite blocks are very resistant to the molten slag, they are vulnerable to molten Fe-Ni alloy, which dilute carbon in it from graphite blocks. In order to avoid this, a modification has been proposed for the layout of the combined refractory lining that prevents the contact of graphite blocks with molten Fe-Ni when raising bath levels of molten metal inside the furnace occur, thus prohibiting carbon from dissolving into the molten alloy. This modification further increases the life cycle of the furnace refractory. This work is part of a long-term project undertaken in cooperation with FLOGEN Technologies Inc. In a subsequent future article, an overall physical simulation of all the above-mentioned phenomena will be presented.
2014-Sustainable Industrial Processing Summit & Exhibition, Dec 15, 2014
ABSTRACT A new technology to treat metallurgical waste containing zinc, lead and tin has been dev... more ABSTRACT A new technology to treat metallurgical waste containing zinc, lead and tin has been developed. It can treat electric furnace steelmaking dust, copper plant dust and dross and recover valuable components. This technology is able produce various marketable products such as zinc as metal, lead and tin as concentrates, iron as iron-containing clinker. The new technology uses among others a two stage Waelz process for distinct separation of elements from complex oxide systems in reductive conditions. New technical solutions were developed for a variety of processes and a new flowsheet has been developed. The new solutions are implemented in all stages of the flow sheet from raw material preparation for metallurgical processing; volatilization of zinc, lead and tin in the tube furnace (I stage of Waelz process); pyro-selection of lead (II-stage of Waelz process); fumes preparation for hydrometallurgical recovery of zinc in the solution, electrolysis with the producing of branded metal, lead and tin in concentrates. Implementation of this new technology has allowed JSC " Chelyabinsk Zinc Plant " (JSC " CZP ") to produce more than 10 thousand tons of zinc as metal and 4 thousand tons of lead and tin in concentrates annually from these metallurgical wastes only.
2015-Sustainable Industrial Processing Summit & Exhibition, Dec 15, 2015
Mineral Processing and Extractive Metallurgy, Sep 29, 2016
In order to meet the ever-growing human needs, the development of new materials implies generatio... more In order to meet the ever-growing human needs, the development of new materials implies generation of byproducts or residues that might pollute the environment. This has been a fact not only in massive commercial production but also at pilot-plant and laboratory scale. In today’s world the issue of residues not only cannot be neglected anymore but should also constitute a key requirement for any new research or technology proposal. Consequently, sustainability, reutilisation and recycling aspects should be considered from the outset as equal factors. This can be achieved systematically and methodologically through ‘the modified central paradigm of materials science and engineering’, described previously by the authors as ‘processing → structure → property → performance → reutilisation/recyclability’ and presented here through a new graphical model. This modified central paradigm is equally valid during the extraction and production of a given material for the first time as well as during its reutilisation/recycling.
2018-Sustainable Industrial Processing Summit, Mar 25, 2018
The liquid slag with chemical composition 55- 70 % SiO2; 0 - 7 % Al2O3; 0 - 5 % Fe2O3; 5 - 13 % C... more The liquid slag with chemical composition 55- 70 % SiO2; 0 - 7 % Al2O3; 0 - 5 % Fe2O3; 5 - 13 % CaO and 0 -5 % MgO, is sufficient raw material for glass wool production [1]. Part of the electric arc furnace slag, which is currently being discharged as a sterile material, can be used directly from a 42 MW electric arc furnace for Fe-Ni production, in a liquid state to produce glass wool. The liquid slag from the electric arc furnace flows continuously through a special channel via a feeder to the fiberizing machine for the fiberizing process (creation of the fibers), and the blanket then passes through a curing oven, normalizing its structure and achieving its final thickness as a final glass wool product. Glass wool production as a new product will have positive impacts of increasing the profits of the company and significantly decreasing the production cost of Ni. In a subsequent future article, an overall glass wool production line, with all details and technical explanations will be presented.
Steel in Translation, Aug 1, 2022
Известия высших учебных заведений. Черная металлургия, Sep 1, 2022
Rybenko I.A., Kongoli F. Determination of optimal technological modes for obtaining manganese all... more Rybenko I.A., Kongoli F. Determination of optimal technological modes for obtaining manganese alloys from poor carbonate and oxide ores ...
Materials Transactions, 2005
2016-Sustainable Industrial Processing Summit, May 17, 2016
The industrial area around RTB Bor encompasses about 9,190,940 tons of techno genic deposits of c... more The industrial area around RTB Bor encompasses about 9,190,940 tons of techno genic deposits of copper smelting slag with an average of 0.715% copper content. As part of a project to recuperate copper from these deposits, this work investigates the effect of the rapid cooling of these slags on their physicochemical milling and flotation properties. Two sets of samples from these deposits were analyzed and compared. The first set of samples were analyzed as is, without any pre-treatment. The second set of samples were melted in a furnace and then quenched and granulated in the water. Both sets of samples were analyzed and compared in terms of their physicochemical, milling and flotation properties. This included the results of chemical and SEM - EDS tests, Bond Work Index in rods and balls mills, milling kinetics and flotation parameters. The analysis and comparison served to draw proper conclusions on the copper recovery of each set of conditions.
2017-Sustainable Industrial Processing Summit, Mar 12, 2017
The impact of two different types of refractory materials and layout in the life cycle of an elec... more The impact of two different types of refractory materials and layout in the life cycle of an electro-reduction Fe-Ni arc furnace, during regular production periods, with two different refractory lining materials, are described. It is shown the refractory lining consisting of a combination of magnesite bricks in vertical walls and graphite blocks in the slag levels has a life cycle about 3 times higher compared to the case when all walls were lined with magnesite bricks only. It was also found that although graphite blocks are very resistant to the molten slag, they are vulnerable to molten Fe-Ni alloy, which dilute carbon in it from graphite blocks. In order to avoid this, a modification has been proposed for the layout of the combined refractory lining that prevents the contact of graphite blocks with molten Fe-Ni when raising bath levels of molten metal inside the furnace occur, thus prohibiting carbon from dissolving into the molten alloy. This modification further increases the life cycle of the furnace refractory. This work is part of a long-term project undertaken in cooperation with FLOGEN Technologies Inc. In a subsequent future article, an overall physical simulation of all the above-mentioned phenomena will be presented.
2014-Sustainable Industrial Processing Summit & Exhibition, Dec 15, 2014
ABSTRACT A new technology to treat metallurgical waste containing zinc, lead and tin has been dev... more ABSTRACT A new technology to treat metallurgical waste containing zinc, lead and tin has been developed. It can treat electric furnace steelmaking dust, copper plant dust and dross and recover valuable components. This technology is able produce various marketable products such as zinc as metal, lead and tin as concentrates, iron as iron-containing clinker. The new technology uses among others a two stage Waelz process for distinct separation of elements from complex oxide systems in reductive conditions. New technical solutions were developed for a variety of processes and a new flowsheet has been developed. The new solutions are implemented in all stages of the flow sheet from raw material preparation for metallurgical processing; volatilization of zinc, lead and tin in the tube furnace (I stage of Waelz process); pyro-selection of lead (II-stage of Waelz process); fumes preparation for hydrometallurgical recovery of zinc in the solution, electrolysis with the producing of branded metal, lead and tin in concentrates. Implementation of this new technology has allowed JSC " Chelyabinsk Zinc Plant " (JSC " CZP ") to produce more than 10 thousand tons of zinc as metal and 4 thousand tons of lead and tin in concentrates annually from these metallurgical wastes only.
2015-Sustainable Industrial Processing Summit & Exhibition, Dec 15, 2015
Mineral Processing and Extractive Metallurgy, Sep 29, 2016
In order to meet the ever-growing human needs, the development of new materials implies generatio... more In order to meet the ever-growing human needs, the development of new materials implies generation of byproducts or residues that might pollute the environment. This has been a fact not only in massive commercial production but also at pilot-plant and laboratory scale. In today’s world the issue of residues not only cannot be neglected anymore but should also constitute a key requirement for any new research or technology proposal. Consequently, sustainability, reutilisation and recycling aspects should be considered from the outset as equal factors. This can be achieved systematically and methodologically through ‘the modified central paradigm of materials science and engineering’, described previously by the authors as ‘processing → structure → property → performance → reutilisation/recyclability’ and presented here through a new graphical model. This modified central paradigm is equally valid during the extraction and production of a given material for the first time as well as during its reutilisation/recycling.
2018-Sustainable Industrial Processing Summit, Mar 25, 2018
The liquid slag with chemical composition 55- 70 % SiO2; 0 - 7 % Al2O3; 0 - 5 % Fe2O3; 5 - 13 % C... more The liquid slag with chemical composition 55- 70 % SiO2; 0 - 7 % Al2O3; 0 - 5 % Fe2O3; 5 - 13 % CaO and 0 -5 % MgO, is sufficient raw material for glass wool production [1]. Part of the electric arc furnace slag, which is currently being discharged as a sterile material, can be used directly from a 42 MW electric arc furnace for Fe-Ni production, in a liquid state to produce glass wool. The liquid slag from the electric arc furnace flows continuously through a special channel via a feeder to the fiberizing machine for the fiberizing process (creation of the fibers), and the blanket then passes through a curing oven, normalizing its structure and achieving its final thickness as a final glass wool product. Glass wool production as a new product will have positive impacts of increasing the profits of the company and significantly decreasing the production cost of Ni. In a subsequent future article, an overall glass wool production line, with all details and technical explanations will be presented.
Steel in Translation, Aug 1, 2022
Известия высших учебных заведений. Черная металлургия, Sep 1, 2022
Rybenko I.A., Kongoli F. Determination of optimal technological modes for obtaining manganese all... more Rybenko I.A., Kongoli F. Determination of optimal technological modes for obtaining manganese alloys from poor carbonate and oxide ores ...
Materials Transactions, 2005