Papers by Author: John H. Courtenay

Abstract: The costs of salt flux treatment have received a strong industry focus as solid flux addition has replaced the usage of Chlorine for alkali and inclusion reduction. The magnesium chloride component has historically had the higher cost incidence but since 2008 the potassium chloride component because of its role as feedstock of fertilizer production has been subject to large commodity price driven fluctuations and rose 350% in 200 – 2009. As demand for world food production and bio fuels increases as the global economy recovers further price rises can be anticipated. A programme of work and field results are presented on the development of an alternative flux system based on a ternary composition.

Abstract: Filtration technology based on a three stage process where a ceramic foam filter is operated in cake mode in the first stage; grain refiner added in a second chamber and a further filtration means is used in the third stage to remove oxide inclusions or agglomerates originating from the grain refiner addition has been developed along two directions. In one case, the XC Filter uses a small deep bed filter (DBF) in the third chamber, whereas in the second case a cyclone is employed. The most recent results with both are reported.

Abstract: The development of a new prototype multi stage filter was described at TMS 2008 in which a ceramic foam filter was applied in a first chamber operating in cake mode; grain refiner added in a second chamber and a cyclone deployed in a final chamber to ensure removal of any oxides or agglomerates arising from the grain refiner addition or release events from the foam filter. The first industrial prototype was installed at Trimet Aluminium at Essen in Germany and demonstrated that liquid metal could pass through the cyclone successfully without excessive turbulence or splash. The further development of the prototype based on new water modeling work is described.