Working with molten metal has always been and will always be a dangerous workplace. No matter how carefully equipment is designed, workers are trained and procedures are followed, the possibility of an accident can occur in melting workplace. Some primary causes of melt splash and furnace eruptions include wet or damp charge material, dropping heavy charge into a molten bath, wet or damp tools or additives and sealed scrap or centrifugally cast scrap rolls. Induction melting brings together three things (water, molted metal and electricity) that have the potential for concern if the furnace is not properly working. Induction furnace must have a water cooling system built into the coil itself. Water picks up the heat caused by the current as well as heat conducted from the metal through the refractory. The water carries the heat to a heat exchange for removal. Spill pits serve to contain any molten metal spilled as a result of accident, run out or dumping of the furnace in an emergency. If a leak is suspected at any time, cease operation and clear the melt deck area of all personnel and empty the furnace. Molten metal fins can penetrate worn or damaged refractory and come into contact with the coil. A furnace or a close capture hood which suddenly swings down from a tilted position will cause injury or death. Whenever workers are working on a furnace or close capture hood when it is in the tilted position, be sure that it is supported with a structural brace that is strong enough to keep it from dropping if hydraulic pressure is lost. In theory refractory wear should be uniform, however, in practice this never occurs. The most causes of lining failure are improper installation of refractory material, inadequate sintering of refractory material, failure to monitor and record normal lining wear, allowing the lining to become too thin, installation of the wrong refractory, improper preheating of a used cold lining, failure to properly maintain the furnace the sudden or cumulative effects of physical shocks or mechanical stress, and excessive slag or dross buildup. Pouring cradles provide bottom support for crucibles. A crack in the crucible occur below the bottom ring support, the bottom of the crucible can drop and molten metal will spill and splash, possibly causing serious injury or death. To reduce this danger, a pouring cradle that provides bottom support for the crucible must be used. Power supply units must have safety locks and interlocks on all doors and access panels. Workers who work with low voltage devices must be made aware of the risk posed by high levels of voltage and current. The most causes of accidents are introduction of wet or damp material, improper attention to charging, failure to stand behind safety lines, coming into contact with electrically charged components and lack of operator skills and training. Only trained and qualified personnel are to have access to high risk areas. Safety lockout systems are another effective measure to prevent electrical shock

Various radioactive metal wastes are generated during operation and decommissioning of nuclear facilities. Radioactive metal wastes with complex geometries or volumetric contamination can be difficult to decontaminate and disposal costs may increase. To solve these problems, the radioactive metal wastes can be treated by melting method. In this study, we designed a melting furnace system of air induction melting type, which is widely utilized due to its advantages of good thermal efficiency, uniform heating and guaranteed safety for radioactive material. By utilizing the melting furnace system, volatile radionuclides existed in the base material can be captured in the form of gas or dust by the filter. The radionuclides whose chemical properties can easily form metal oxides present as slag. For this reason, the specific radioactivity of the base material can be reduced. Radionuclides that are difficult to transport to slag and dust are uniformly distributed in the base material. A dedicated power supply and a transformer were necessary to be included in the melting furnace system since the induction furnace uses high-frequency currents. In addition, a hood is placed on top of the furnace to capture fumes generated during melting, and additional hoods were installed around the furnace to remove airborne dust. In particular, a dust collection unit consisting of a cyclone and a HEPA filter were constructed to effectively collect dust containing radionuclides. During the melting process, the slag is removed and accumulated separately, and the ingot production system was designed to produce the ingot using molten metal. The furnace was constructed for tilting the molten metal by moving the furnace using hydraulic system. The water cooling system and cooling tower were prepared to cool off the equipment with high temperature during melting is cooled off. The above process was specified in the operating procedure developed for this melting furnace system, and the operator shall operate and inspect according to the prescribed procedures. The radioactivity concentration in the sample taken in the step of tilting shall be analyzed whether they meet clearance level for self-disposal determined and publicly announced by the Commission. We can conduct self-disposal for the product of melting furnace system confirmed by the Commission as having the radioactivity concentration by nuclide not exceeding the value determined by the Commission.

  Glass melting process is influenced by both control and observation factors, where control factors include quantity and mixing ratio of raw material, the amount of fuel and air in-take. Further observation factors include temperature and pressure at eac

한국원자력연구소 내의 연구용 원자로(TRIGA II, III) 해체 시 발생한 방사성 알루미늄 해체 폐기물의 감용 및 제염 특성을 평가하기 위해 아크로에서 알루미늄의 용융 특성 및 방사성 핵종의 분배 특성에 대한 연구를 수행하였다. 알루미늄 폐기물은 흑연전극(graphite electrode)을 이용한 전기아크로에서 4가지 종류의 플럭스를 함께 첨가하여 용융시켰다. 또한 알루미늄의 용융 시 방사성 핵종의 분배 특성을 고찰하기 위해 알루미늄 시편에 방사성 모의 핵종인 코발트, 세슘, 스트론튬의 화합물을 오염시킨 후 혹연도가니에 넣어 알루미늄 용융실험을 수행하였다. 전기아크로에서 알루미늄의 용융실험을 수행한 결과 플럭스의 종류에 따라 다소 차이는 있으나 플럭스의 첨가에 의해 알루미늄 용융체의 유동성이 증가됨을 확인할 수 있었다. 아크 용융에 의해 생성된 슬래그의 발생량은 플럭스 A와 B를 첨가한 알루미늄 용융실험에 비해 플럭스 C와 D를 첨가한 실험에서 상대적으로 많은 양이 생성됨을 알 수 있었으며, 첨가된 플럭스의 양이 증가할수록 이에 비례하여 슬래그의 발생량이 증가함을 알 수 있었다. 슬래그(slag)의 XRD 분석을 통해 방사성 핵종이 주괴에서 슬래그 상으로 이동한 후 슬래그를 구성하고 있는 산화알루미늄과 결합하여 안정한 화합물로 슬래그 상에 포집됨을 알 수 있었다. 알루미늄 폐기물의 용융시 Co의 분배율은 플럭스를 첨가한 경우에 보다 높은 제염계수를 나타냈으며, 모든 플럭스에서 40% 이상의 제염 효과를 나타내었다. 반면에 휘발성 핵종인 Cs과 Sr은 주괴로부터 98% 이상이 제거되어 대부분이 슬래그상과 분진으로 이동되는 특성을 확인할 수 있었다.

Geopolymer foam block was prepared and its characteristics discussed to evaluate the possibility of replacing blastfurnace slag (below BFS) with melting slag in this study. 10~20wt% of BFS was replaced with melting slag. And also10wt% of mine tailing was replaced with fly ash discharged from municipal solid waste incinerator (below MSWI). Thecompressive strength of foam block prepared was similar to that of foam block prepared without replacing BFS. Andalso it was increased by replacing 10wt% of mine tailing with MSWI fly ash. Considering these results, melting slagmay be used instead of BFS without damaging the quality of foam block.

Recently, the recycling of end-of-life vehicles is becoming increasingly interesting for less waste discharge and recovering useful materials such as valuable metals. Hence, in Korea, the target of the recycling rate is made to 85% until 2014 (energy recovery within 5%) and the recycling rate to 95% after 2015 (energy recovery within 10%) according to the law of "regulation about resource recycling of electrical and electronic products and automobiles". However, the recycling rate is around 84% in 2010, and registered numbers of shredder residue recyclers among dismantling recyclers, crushing recyclers, shredder residue recyclers, and waste gases recyclers are very few. In order to meet the goal of 85% until 2014, Korean recycling industry of ASR should grow bigger and innovative recycling technologies have to be developed as well. In the meantime, a recycling technology of automobile shredder residue is developed in the present study, in which ASR is introduced to a copper smelting process. This process is very promising because of co-beneficial effects such as recovering copper and process heat simultaneously from ASR. In this study, lab-scale melting furnace was developed and melting tests for various ASR were carried out. From the results, the physicochemical characteristics of Korean ASR were analyzed and its melting behavior was investigated for the application to the copper smelting process. In particular, melted slag products were fabricated at different melting temperatures. Then, the basicity and pouring index in the lab-scale melting furnace were examined to find out appropriate operating conditions for the melting process. As a result, Because the amount of lump coal that included in existing process samples is a little, melting state and value of pouring index are very similar to existing process samples. In result of this experiment, in case of changing lump coal to ASR, The existing copper smelting facilities, if basicity and melting temperature are well controlled, flow of melting material is considered that is almost not affected.