Silesian University of Technology | Department of Metallurgy and Recycling

Physical Modeling Laboratory for Metallurgical Processes

Despite over 30 years of experience, the laboratory is characterized by continuous progress in utilizing new modeling techniques. Currently, it relies primarily on hybrid modeling, which involves the simultaneous use of both physical and numerical models in a coherent research program. This method allows for ongoing verification of obtained research results and, consequently, is characterized by high reliability. Research conducted in the laboratory primarily focuses on identifying hydrodynamic phenomena occurring during metallurgical processes. This applies to the flow and mixing of fluids in both liquid-liquid systems (i.e., single-phase flows) and liquid-gas systems (i.e., multiphase flows). The working elements of the research stations used for this purpose are water-based physical models of metallurgical reactors. These models are built based on the theory of similarity, enabling the application of the obtained results to industrial conditions. These models are equipped with advanced control and measurement equipment, enabling precise control and efficient recording of obtained results. Numerical calculations are primarily conducted using FluentAnsys software. It should be emphasized that the laboratory has recently undergone a comprehensive renovation in terms of its functionality and the safety of the research conducted there, while maintaining the possibility of its further expansion.

Laboratory equipment for physical modeling of metallurgical processes

A universal physical model of a station for blowing steel with inert gases into a steel ladle – with the ability to test various types of industrial gas-permeable shapes.
A physical model of a station for blowing steel with gases into a steel ladle – with the ability to simultaneously blow the melt through one, two, or three gas-permeable shapes installed in the bottom of the model.
A physical model of a station for blowing steel with inert gases, with the ability to use high gas flow rates.
A universal hydrodynamic, modular physical model of a combined-blow oxygen converter.
A physical model of a combined-blow oxygen converter.
A model of a RH device.
A model of a shaft furnace.
A 3D physical model of two-phase gas-dust flow through a moving lump bed in a metallurgical shaft furnace.
A physical model of the liquid phase flow through a lump bed in a metallurgical shaft furnace.
A physical model of a URO-200 refining reactor.
A physical model of a refining reactor. URC-7000

Research offer and scope of services
We conduct comprehensive research for clients on diagnostics and the potential for implementing innovative solutions during liquid metal processing, with particular emphasis on the steel industry. This primarily concerns steel flow and mixing processes in reactors such as the basic oxygen converter, steel ladle, and continuous casting machine. We also offer research services for aluminum producers, particularly in the optimization of refining processes. The nature of the laboratory and the knowledge and experience of our research staff enable us to conduct research on fluid hydrodynamics across a wide range of industries, including those outside the metallurgical industry.

Persons responsible for the laboratory – contact details
Faculty of Materials Science and Engineering
Department of Metallurgy and Recycling
40-019 Katowice, Krasińskiego St. 8

dr hab. inż. Tomasz Merder, prof. PŚ
e-mail:
tomasz.merder@polsl.pl
tel.: 32 603 4168

dr hab. inż. Jacek Pieprzyca, prof. PŚ
e-mail:
jacek.pieprzyca@polsl.pl
tel.: 32 603 4142

dr hab. inż. Mariola Saternus, prof. PŚ
e-mail:
mariola.saternus@polsl.pl
tel.: 32 603 4275

Thermal Analysis Laboratory

The Netzsch STA 449 F3 Jupiter thermal analyzer allows for simultaneous thermogravimetric (TG) measurement and differential thermal analysis (DTA) or differential scanning calorimetry (DSC). The device is equipped with a high-temperature water-cooled graphite furnace and enables standard measurements up to 1600°C. Heating and cooling rates up to 50°C/min. Protective, reducing, and oxidizing atmospheres can be used.

Thermal analysis laboratory equipment

Netzsch STA 449 F3 Jupiter Thermal Analyzer
S-type carrier for TG, TG/DTA, and TG/DSC measurements
Al2O3 crucibles
Proteus software for result analysis
RADWAG analytical balance (accuracy 0.1 mg)
Gases to ensure an inert, reducing, and oxidizing atmosphere

Research offer and scope of services

Conducting tests that analyze the transformations occurring in a material under the influence of a given temperature program and the atmosphere used. The range of applications is very wide. Limiting ourselves solely to metallurgical issues, these include determining the melting point, solidification point, order-disorder transformations, allotropic transformations, studying oxidation kinetics, determining the heat of transformation, analyzing mass changes during the reduction of metallurgical materials, etc.
Scope of services:

TG analysis
DTA analysis
DSC analysis

All additional accessories can be used to extend the device’s testing capabilities, as presented in Netzsch catalogs.

Persons responsible for the laboratory – contact details
Faculty of Materials Science and Engineering
Department of Metallurgy and Recycling
40-019 Katowice, Krasińskiego St. 8

dr inż. Tomasz Maciąg
e-mail:
tomasz.maciag@polsl.pl
tel. 32 603 4386, kom. 888 860 794

Hydrometallurgy and biometallurgy laboratory

The laboratory conducts research in the areas of hydrometallurgy and biometallurgy of non-ferrous metals and their compounds. The scope of work includes the use of leaching and bioleaching processes for the extraction of metals from waste materials, metal recovery studies, purification, phase separation, and material characterization. The laboratory is equipped with research, control, and measurement equipment enabling the implementation of hydrometallurgical work in collaboration with other research institutions and for contractors and external companies.

Hydrometallurgy and biometallurgy laboratory equipment

A thermally jacketed chemical reactor for leaching from Lenz Laborglas GmbH & CO. KG with a Heidolph SN mechanical stirrer and a Grant LT ecocool 150 SN thermostat.
A Bandelin SONOPULS HD 4200 ultrasonic homogenizer for grinding, emulsifying, suspending, and accelerating reactions.
Bacterial strains of the genus Acidithiobacillus oxidize elemental sulfur and iron.
Electromagnetic sieve for material analysis
from Multiserw-Morek LPzE-2e with a set of 0.2-2.0 mm sieves
Air and water ozonator – Korona L 20 Spalab ozone generator
Zeiss Axio Imager A2 research microscope
Halo DB20 UV-Vis spectrophotometer
Basic laboratory equipment: pH, Eh, and O2 meters, laboratory scales, mechanical and magnetic stirrers, a drying oven, an incubator, shakers, Nutsch filters, vacuum and peristaltic pumps, an ultrasonic cleaner, knife mills, and ion columns

Research offer and scope of services
The laboratory offers its partners services in areas related to the recovery of base and precious metals from semi-finished products, industrial waste, and post-consumer waste using hydrometallurgical and biometallurgical methods, conceptual development of waste material processing technologies that fit into the circular economy system, and research on physicochemical separation and solution purification processes.

Persons responsible for the laboratory – contact details
Faculty of Materials Science and Engineering
Department of Metallurgy and Recycling
40-019 Katowice, Krasińskiego St. 8

dr inż. Joanna Willner
e-mail: joanna.willner@polsl.pl
tel. 32 603 4273

Material joining and heat treatment laboratory

The laboratory conducts weldability tests on metallic and plastic materials. The range of joining technologies used includes:

arc welding, including MAG/MIG, TIG, submerged arc, and coated electrode welding
resistance butt and spot welding, and capacitor discharge welding
soldering
adhesive bonding

The laboratory also conducts technological tests for resistance to hot cracking (transvarestraint) and cold cracking (Fisco and Houldcroft tests), heat distribution analysis during joining processes, and full heat treatment of completed joints. The research capabilities are complemented by macro- and micrographic examinations performed by certified non-destructive testing personnel and a full range of material removal facilities.

Materials Joining and Heat Treatment Laboratory Equipment

Submerged arc welding station
ESAB Canddy 150 welder
ESAB Origo welder
Lincoln Electric Invertec V270TP welder
Lincoln Electric PowerWave S500 welder
Plasma cutter
Spot welder
Butt welder
Capacitor discharge welder
Six-channel temperature recorder
Heat treatment furnaces up to 1700°C
Lathe, milling machine

Research offer and scope of services

The Materials Joining and Heat Treatment Laboratory offers material weldability testing, technological tests for welding, brazing, soldering, and gluing, as well as tests to assess the weldability of materials. As part of the testing, it is also possible to perform heat treatment of joints. The offer is complemented by visual and structural testing and assessment of joints. The laboratory also specializes in developing joining technologies and determining the causes of damage to welded structures.

Scope of services:

Joining technological tests
Weldability testing of materials
Assessment of joint resistance to hot and cold cracking
Development and qualification of welding technologies
Heat treatment of materials (up to 1700°C)

Persons responsible for the laboratory – contact details
Faculty of Materials Science and Engineering
Department of Metallurgy and Recycling
40-019 Katowice, Krasińskiego St. 8

prof. dr hab. inż. Janusz Adamiec
e-mail:
janusz.adamiec@polsl.pl
tel.: 32 603 4463

Non-destructive testing laboratory

The NDT Laboratory at the Faculty of Materials Science and Engineering, Silesian University of Technology, conducts scientific and industrial research using a variety of testing and measurement methods, including visual testing, penetrant testing, magnetic particle testing, ultrasonic testing, radiograph evaluation, hardness testing, and the replica method. Testing is conducted in accordance with the procedures outlined in the PN-EN ISO and ASME standards.

Non-destructive testing laboratory equipment

Olympus EP650 Ultrasonic Flaw Detector
EquoTip Portable Hardness Tester
Luxmeter
Gauss Meter
Bosch Endoscope
Electromagnetic Yoke
UV Lamp

Research offer and scope of services

The scope of testing allows for the inspection of semi-finished and finished components using non-destructive testing methods. Tests and analyses are performed in the industrial sector, i.e., PW – manufacturing, PE – pre- and in-service testing including manufacturing, PED – including inseparable connections of pressure equipment in accordance with European Directive 2014/68/EU. Tests are performed in the product-related sector: (c) – castings, (f) – forgings, (w) – bonded joints, (wp) – plastically processed products except for forgings, (t) – pipes of various diameters and wall thicknesses.

Scope of services:

Visual Testing – VT
Penetrant Testing – PT
Magnetic Particle Testing – MT
Radiogram Interpretation – RT2 ORS
Ultrasonic Testing – UT
Replica Production
Hardness Testing

Tests provided to clients are performed in accordance with applicable PN-EN ISO and ASME standards and client requirements.

Persons responsible for the laboratory – contact details
Faculty of Materials Science and Engineering
Department of Metallurgy and Recycling
40-019 Katowice, Krasińskiego St. 8

dr inż. Katarzyna Łyczkowska
katarzyna.lyczkowska@polsl.pl
tel.: 32 603 4030

Extractive Metallurgy Laboratory

The laboratory conducts comprehensive processes for obtaining non-ferrous metals from primary materials, as well as from recycled secondary materials. Specialized equipment enables metallurgical processes up to 1500°C. Material processing can be carried out in a controlled atmosphere (reducing, oxidizing, or neutral).

Extractive metallurgy laboratory equipment

Resistance pit furnace (maximum operating temperature 1300°C)
Resistance chamber furnace (maximum operating temperature 1100°C)
Resistance chamber-silicate furnace (maximum operating temperature 1500°C)
Controlled atmosphere tube furnace (maximum operating temperature 1200°C)

Research offer and scope of services
We perform comprehensive research on the melting, refining, casting, and production of metals and alloys from both primary and secondary raw materials. Our specialized equipment enables metallurgical processes up to 1500°C. Our research equipment allows us to investigate the potential use of alternative carbon-bearing materials in the production of non-ferrous metals, as well as to conduct recycling of metal-containing waste materials. Our services include:

Melting of metals and alloys
Metal refining
Casting of metals and alloys
Controlled atmosphere melting
Metal extraction from primary and secondary materials
Recycling of metals and alloys

Persons responsible for the laboratory – contact details
Faculty of Materials Science and Engineering
Department of Metallurgy and Recycling
40-019 Katowice, Krasińskiego St. 8

dr inż. Tomasz Matuła
e-mail:
tomasz.matula@polsl.pl
tel. 32 603 4177

Corrosion and Protective Coating Technology Laboratory

The laboratory conducts scientific, research, development, and implementation work in the following areas:

technology for applying anti-corrosion coatings, tribological wear-resistant coatings, thermal barriers, and protective layers using immersion metallization, thermal diffusion, thermal spray, and surfacing methods
constitution of protective layers and coatings on structural elements, shaping their microstructure and properties
testing electrochemical corrosion resistance, oxidation resistance, and high-temperature corrosion, and assessing the performance properties of protective coatings and layers
development of new coating materials and optimization of their production technologies
analysis and optimization of industrial coating processes using immersion metallization, thermal diffusion, thermal spray, and surfacing methods

Equipment for the corrosion and protective coatings technology laboratory

Erichsen CORROTHERM Model 610 Salt Spray Chamber
Erichsen
HYGROTHERM Model 519 Koesternich Chamber
Laboratory Station for Immersion Metallization
High-Temperature
Corrosion Testing Station

Research offer and scope of services
Testing the corrosion resistance of metals and alloys, coatings, and anti-corrosion protection in accordance with PN EN ISO 9227 (neutral salt spray testing) and PN EN ISO 6988 (humid sulfur atmosphere testing), as well as protective coatings under high-temperature corrosion conditions. Diagnostics of electrochemical and chemical corrosion, research and assessment of the causes of corrosion damage, scientific and technical expertise on the quality and wear of coatings obtained by immersion metallization, thermal diffusion, thermal spray, and hardfacing, as well as optimization of industrial processes for their production.

Persons responsible for the laboratory – contact details
Faculty of Materials Science and Engineering
Department of Metallurgy and Recycling
40-019 Katowice, Krasińskiego St. 8

dr hab. inż. Henryk Kania
e-mail: henryk.kania@polsl.pl
tel.: 32 603 4478