Phase Diagram Approach to the Fluxing Effect of Additions of CaCO3 on Australian Coal Ashes

Abstract

This paper presents a phase diagram approach to predict the melting temperatures of coal ash/flux mixtures and the viscosity versus temperature characteristics of the molten slags. This is illustrated by calcium oxide fluxing studies of three Australian bituminous coal ashes covering a range of silica to alumina ratios. Reasonable agreement was obtained between the observed melting temperatures of the calcium oxide/coal ash mixtures and predictions based on equilibrium phase diagrams for the ternary system silica, alumina, and calcium oxide or for the quaternary system silica, alumina, calcium oxide, and ferrous oxide. The approach is supported by energy dispersive scanning electron microscopy (SEM), SEM microprobe, and X-ray diffraction (XRD) studies of the slags. Slag viscosity measurements were made with a rotational viscometer over the range 1200−1600 °C. The measured viscosities were compared with predicted values using a model based on experimental results for the ternary system silica, alumina, and calcium oxide. The agreement between experimental results and predictions from this approach suggests that sensible estimates can be made of the amount of fluxing agent necessary for satisfactory slag tapping from the ash content and ash composition of the coal.