Slag Metal Research Articles

Applicability of Waste from Al Industry toward Dephosphorization of Hot Metal in Primary Steel Making

Managing industrial waste is a global challenge. Red mud is a byproduct of the aluminum industry posing serious concerns. The presence of FeO and CaO in red mud makes it a potential DeP flux. Red mud has been utilized as a DeP flux in previous studies, but these studies deal with low Si content and no P2O5 content in the red mud. However, certain steel makers have high initial Si content (0.6–0.7 wt%) in the hot metal, and with increasing demand for low P steel, new dephosphorization fluxes need to be explored. Addressing this gap, this study investigates red mud's potential as a flux for dephosphorization in hot metal with elevated Si levels. Conducting slag–metal equilibrium experiments at 1350 °C, using red mud‐based fluxes, the research achieves a 40% dephosphorization degree under optimized conditions of double deslagging and fluxing. Analysis via wet chemical methods and inductively coupled plasma mass spectrometry confirms the effectiveness of the approach. Furthermore, thermodynamic calculations highlight the influence of O2 partial pressure and Si content on dephosphorization efficacy. Through laboratory experiments and theoretical insights, this study provides a valuable roadmap for leveraging red mud as a sustainable flux in hot metal dephosphorization processes, contributing to both waste management and steel production efficiency.

Extraction of Vanadium from High Phosphorus Vanadium Containing Waste Residue via Carbonation: Optimization Using Response Surface Methodology

Vanadium (V) was successfully extracted from a high phosphorus vanadium residue (HPVR) through a carbonation process. Vanadium within HPVR substitutes for Fe in the mineral structure of Ca9(Fe,V)(PO4)7 at elevated temperatures, Na2CO3 reacts with V to form sodium metavanadate (NaVO3), concurrently generating calcium carbonate (CaCO3) through its interaction with Ca9(Fe,V)(PO4)7. Subsequently, V is liberated and leached by water, dissolving in the aqueous phase as metavanadate ions (VO3−). Crucial factors influencing V leaching efficiency include roasting time, roasting temperature, and the amount of Na2CO3 utilized. Response Surface Methodology (RSM) was employed. The optimized parameters determined were as follows: a roasting temperature of 850 °C, a roasting duration of 120 min, a Na2CO3 dosage of 8.01%, a liquid-to-solid ratio (L/S) of 3, and a leaching time of 60 min. Under these conditions, a remarkable V leaching efficiency of 83.82% was achieved. This study underscores the viability of a simplified approach for treating solid waste containing metal slag, which not only mitigates environmental pollution but also yields valuable metals.

Co-pyrolysis of refinery oil sludge with biomass and spent fluid catalytic cracking catalyst for resource recovery.

Catalytic co-pyrolysis of two different refinery oily sludge (ROS) samples was conducted to facilitate resource recovery. Non-catalytic pyrolysis in temperatures ranging from 500 to 600°C was performed to determine high oil yields. Higher temperatures enhanced the oil yields up to ~ 24 wt%, while char formation remained unchanged (~ 45%) for S1. Conversely, S2 exhibited a notably lower oil yield (~ 4 wt%) than S1. Pyrolysis oil of S1 consisted of phenolics (~ 50% at 600°C) whereas hydrocarbons were predominant in S2 oil (~ 80% at 600°C). Catalytic pyrolysis of S1 did not exhibit a substantial impact on oil yields but the oil composition varied significantly. High hydrocarbons, phenolics, and aromatics were obtained with molecular sieve (MS), metal slag, and ZSM-5, respectively. Catalytic co-pyrolysis of S2 with sawdust (SD) in the presence of MS enhanced the oil yield, and the resulting oil consisted of high hydrocarbons (~ 54%) and aromatics (~ 44%).

Variation in Flow Characteristics of Molten Baths at Different Blowing Stages in the Converter

The metallurgical tasks at different stages of converter blowing are different. The process operation and physical properties of molten baths are also different. It is very important to determine the flow characteristics of molten baths at different blowing stages for optimizing process operation. In this paper, a three-dimensional, full-scale model of a 120 t top–bottom combined blowing converter is established. Based on the parameters of oxygen lance position, bath temperature, bottom blowing intensity, and bath physical properties at different blowing stages, the changes in bath flow field, turbulent kinetic energy, impact depth, impact area, and wall shear force with blowing process are studied. The results show that at the initial stage of blowing, the lance position is high, the impact depth of the molten bath is 0.23 m, the impact area is 5.06 m2, the dead zone area of the longitudinal section is 0.40 m2, and the high-speed zone area is 2.73 m2. As the blowing time increases, the lance position decreases, the impact depth of the molten bath increases, the impact area decreases, and the internal velocity of the molten bath increases. In the later stage of tuyere blowing, the lance level decreases to its lowest, the impact depth increases to 0.42 m, the impact area decreases to 2.83 m2, the dead zone area of longitudinal section decreases to 0.18 m2, and the high-speed area increases to 3.34 m2. The area with the highest wall shear stress is situated within the gas–slag–metal three-phase region, where the lining experiences the most significant erosion. The fluctuation in the slag–metal interface is small, and the wall shear force is 2.80 Pa at the initial stage of blowing. From the early to late stages of blowing, the lance position decreases, the fluctuation range of the slag–metal interface increases, and the erosion of the furnace lining increases. In the later stage of blowing, the maximum wall shear force is 3.81 Pa.

Effect of ladle slag composition on the cleanliness of Al-Ti deoxidized interstitial-free steel

The effect of slag composition on the cleanliness of Al-Ti deoxidized interstitial-free steel produced via basic oxygen furnace (BOF)-ladle furnace (LF)-Ruhrstahl-Heraeus (RH)-continuous casting (CC) process was investigated by the systematic samplings and analyses for four heats in a steel plant in China. Oxygen/nitrogen analyzer, automatic scanning electron microscope, field-emission scanning electron microscope, and energy spectroscopy analysis were used to analyze the variations of number, size, type, and morphology of inclusions in molten steel from RH to tundish, and X-ray fluorescence was used to analyze the slag composition. The relationship between slag composition and inclusion characteristics in molten steel was investigated. The effect of slag composition on the oxygen mass transfer from the slag–metal interface to liquid steel was also studied through a theoretical calculation. The results showed that the cleanliness of molten steel was greatly affected by the slag composition. The deterioration of steel cleanliness was mainly arisen from a serious reoxidation of molten steel by oxidizing components like (T.Fe + MnO) in top slag during RH refining process. A weak ability to absorb inclusions of top slag with high CaO/Al2O3 and CaO/SiO2 mass ratios was confirmed from the inclusions analyses. The size and number of Al2O3 inclusion clusters were larger, and Ti content in Al2O3-TiO x inclusions was higher from RH to tundish in the case of serious reoxidation. The reduction of FeO content and keeping the CaO/Al2O3 and CaO/SiO2 ratios at about 1.6 and 4–7, respectively, in top slag during RH refining process was beneficial to minimize the reoxidation of Al and Ti and increase the inclusion absorption ability of top slag.

Spatial distribution and source apportionment of soil heavy metals in the areas affected by non-ferrous metal slag field in southwest China

Spatial distribution and source apportionment of soil heavy metals in the areas affected by non-ferrous metal slag field in southwest China

Features of the pottery assemblage of the XIII–XIV centuries from excavations of the Syukeyevsky Vzvoz II Campsite medieval sediments

The article deals with the ceramic material from the excavations of 2021 on the territory of the multilayer archaeological site Syukeyevsky Vzvoz II. Judging by the totality of the finds (metal slag and pig iron, blanks and semi-finished iron products, blacksmithing tools), a blacksmithing workshop could have been located here in the Golden Horde period. Russian pottery make up the majority of the assemblage, which suggests that there is a settlement of immigrants from Russian lands here. By the nature of the finds, this location can be interpreted as the artisan periphery of a small urban-type settlement associated with iron processing.

Nano-Strand Formation via Gas Phase Reactions from Al-Co-Fe Reacted with CaF2-SiO2-Al2O3-MgO Flux at 1350 °C: SEM Study and Thermochemistry Calculations

The submerged arc welding (SAW) process is operated at high temperatures, up to 2500 °C, in the arc cavity formed by molten oxy-fluoride flux (slag). These high arc cavity temperatures and the complex interaction of gas–slag–metal reactions in a small space below the arc render the study of specific chemical interactions difficult. The importance of gas phase reactions in the arc cavity of the SAW process is well established. A low-temperature (1350 °C) experimental method was applied to simulate and study the vaporisation and re-condensation behaviour of the gas species emanating from oxy-fluoride flux. Energy dispersive X-ray spectroscopy (EDX) analyses and reaction thermochemistry calculations were combined to explain the role of Al as a de-oxidiser element in gas phase chemistry and, consequently, in nano-strand formation reactions. EDX element maps showed that the nano-strands contain elemental Ti only, and the nano-strand end-caps contain Co-Mn-Fe fluoride. This indicates a sequence of condensation reactions, as Ti in the gas phase is re-condensed first to form the nano-strands and the end-caps formed from subsequent re-condensation of Co-Mn-Fe fluorides. The nano-strand diameters are approximately 120 nm to 360 nm. The end-cap diameter typically matches the nano-strand diameter. Thermochemical calculations in terms of simple reactions confirm the likely formation of the nanofeatures from the gas phase species due to the Al displacement of metals from their metal fluoride gas species according to the reaction: yAl + xMFy ↔ xM + yAlFx. The gas–slag–metal equilibrium model shows that TiO2 in the flux is transformed into TiF3 gas. Formation of Ti nano-strands is possible via displacement of Ti from TiF3 by Al to form Al-fluoride gas.

Application of an Artificial Neural Network for Efficient Computation of Chemical Activities within an EAF Process Model

The electric arc furnace (EAF) is considered the second most important process for the production of crude steel and is usually used for the melting of scrap. With the current emphasis on defossilization, its share in global steelmaking is likely to further increase. Due to the large production quantities, minor improvements to the EAF process can still accumulate into a significant reduction in overall energy and resource consumption. A major aspect in the efficient operation of the EAF is achieving beneficial slag properties, as the slag influences the composition of the steel and can reduce energy losses as well as the maintenance cost. In order to investigate the EAF operation, a dynamic process model is applied. Within the model, the chemical reactions of the metal–slag system are calculated based on the activities of the involved species. In this regard, multiple models for the calculation of the chemical activities have been implemented. However, depending on the chosen model, the computation of the slag activities can be computationally demanding. For this reason, the application of a neural network for the calculation of the chemical activities within the slag is investigated. The performance of the neural network is then compared to the results of the previously applied models by using the commercial software FactSage as a reference. The validation shows that the surrogate model achieves great accuracy while keeping the computation demand low.

Calculation and experimental study of reactivity between CaO–BaO–Al2O3–CaF2–Li2O mould slag and low density and high strength steel

In the continuous casting of low-density and high-strength steel, minimising or eliminating steel–slag reactions is imperative to ensure stable slag properties and a smooth casting process. This study conducted steel–slag contact experiments at 1400 °C, based on thermodynamic calculations predicting the reaction trends of the proposed CaO–BaO–Al2O3–CaF2–Li2O mould slag with low-density and high-strength steel containing 8 wt-% Al. The changes in compositions, rheological, and solidification characteristics of slags pre- and post-reaction are analysed. The findings reveal that only Li2O reacts with Al in the steel, forming LiAlO2 rather than Al2O3. Reactivity is affected by component activity and the partial pressure of Li vapour at the reaction interface, established to vary between 0.154 and 0.253 atm. Within the current range of slag composition, increasing Al2O3 and reducing Li2O content in the slag inhibits the slag–metal reaction. Specifically, Li2O remains unreactive with Al when 2.5 wt-% < Li2O < 5 wt-% and Al2O3 > 27 wt-%. Conversely, the reaction occurs when Li2O > 4.5 wt-% and Al2O3 < 18 wt-%. In conclusion, low- and non-reactive mould slags suitable for casting low-density and high-strength steel are proposed, considering both reactivity and stable slag properties.

Physical and chemical properties of CaF2−CaO−Al2O3−MgO slag for electroslag remelting of Mg-containing GH3128 superalloy

During electroslag remelting, Mg in the electrode reacts with some components in the slag, resulting in its serve oxidation loss. The CaF2−CaO−Al2O3−MgO slags with high MgO content are generally used for remelting Mg-containing Fe- and Ni-based alloys. However, there is a scarcity of foundational data available on the physical and chemical properties of the slags, posing a challenge in developing a suitable slag for remelting Mg-containing GH3128 superalloy. Hence, this paper conducted a comprehensive study on the melting temperature, viscosity, and reactivity of four known slags. The results show that D2 slag (50%CaF2–20%CaO–20%Al2O3–10%MgO) has the lowest melting temperature of 1588 K due to containing fewer high-melting-point phases and possesses lower viscosity because of simpler aluminate structures. Additionally, the D2 slag has the highest activity ratio, enabling the superalloy to achieve the highest equilibrium Mg content of 0.0174%. The D2 slag exhibits a heightened MgO activity and facilitates the release of more Mg2+ ions, thereby exerting a pronounced inhibitory effect on the diffusion of Mg2+ ions from the slag–metal interface to the slag. The superalloy attains a highest Mg yield of about 30%. Therefore, the D2 slag emerges as the most suitable choice for remelting the Mg-containing GH3128 superalloy.

Corrosion, permeation and mass transfer mechanisms of alkali metals in corundum refractories

During the operation of the waste liquid incinerator, the alkali metal slag might adhere to the surface of the refractory material to form an inhomogeneous solid slag layer, causing the furnace lining to be simultaneously corroded by three phases of alkali metals: vapor, molten salt, and slag. This phenomenon intensifies the damage to the refractory material. Therefore, this paper investigates the mass transfer and permeation process, phase change process and corrosion rate of Na2CO3 inside corundum refractory materials in three phases: Na vapor, molten Na2CO3 and Na-slag. The results showed that alkali vapor penetrated the interior through the pores, and the NaAlO2 and β-Al2O3 generated by the reaction led to the volume expansion and microcracks. Na vapor continued to penetrate the interior along the cracks and eroded the sample, and the higher the temperature the greater Na vapor penetration. In vapor phase corrosion, the effect of corrosion time on the erosion resistance of corundum refractories is less than that of temperature, and the increase in corrosion time does not lead to the formation of additional new phases. In the molten salt corrosion experiments, it was found that the molten salt corrosion was accompanied by vapor phase corrosion at 1100 °C, and the amount of Na2CO3 has a greater effect on the corroded mass than the temperature. Comparing the corrosion of refractory materials by the three phases of Na2CO3, the molten salt corrosion rate was the highest, followed by the vapor phase corrosion, and finally the slag corrosion. It is concluded that the slag layer can effectively prevent the corrosion of the refractory material by alkali metal molten salts and vapors, thus prolonging the service life of refractories.

A mild and efficient closed-loop recycling strategy for spent lithium-ion battery

As lithium metal resource supply and demand stabilize and prices decrease, the efficient recovery of valuable metals other than lithium from spent lithium-ion batteries is receiving increasing attention. Currently, challenges remain in the selective lithium recovery efficiency and the high cost of regenerating valuable metal slag after lithium extraction, particularly for spent ternary cathode materials. To address these challenges, this study introduces a closed-loop recovery process for spent ternary cathode materials, employing sulfur-assisted roasting to achieve efficient lithium extraction and high-value direct regeneration of ternary leaching residues. At moderate temperatures (500 ℃), LiNixCoyMn1−x-yO2 (NCM) materials undergo a directional transformation of lithium to Li2SO4 in synergy with sulfur and oxygen, achieving a lithium leaching extraction rate of 98.91 %. Additionally, the relatively mild reaction conditions preserve the secondary spherical morphology and uniform distribution of NiCoMn-based oxide residue without introducing adverse impurities, ensuring the successful regeneration of high-value NCM cathode materials (R-NCM). The R-NCM material exhibits good discharge capacity (144.3 mA·h/g at 1 C) and relatively stable cycling performance, with a capacity retention rate of 80 % after 150 cycles. This work provides a viable pathway for the efficient and environmental-friendly pyrometallurgical closed-loop recovery of spent lithium-ion batteries.

Ecological risk assessment of heavy metals in coal gasification slags and their leaching toxicity

ABSTRACT The coal gasification process produces a large amount of coal gasification slag (CGS), which accumulates heavy metals from the raw coal. The CGS not only occupies land resources during long-term storage but also poses potential ecological pollution risks. In this study, eight different CGS samples from various regions of China were analyzed to determine their chemical composition and evaluate their environmental risks. Two leaching methods recommended by the Ministry of Ecology and Environment of China were employed to conduct leaching experiments, aiming to assess the hazardous waste level of CGS. The results indicated that the risk index of YL-FS and XJ-CS reached 101.87 and 87.15, respectively, classifying them as medium-risk materials. The remaining samples were categorized as low-risk materials. CGS itself is not classified as hazardous solid waste. The leaching results revealed that the concentration of Be in the leaching solution of NMG-CS and XJ-CS exceeded 0.005 mg/L, placing them in Class II of general industrial solid waste. The remaining samples exhibited minimal leaching toxicity and were classified as Class I general industrial solid waste.

Slag Electrical Conductivity and Its Effect on Mass Transport and Interfacial Reaction Kinetics

Pyrometallurgical refining typically involves slag–metal reactions which are commonly controlled by transport of reactants in the slag or metal phase. For the simplicity of analysis, mass transport in slag is generally treated on a phenomenological basis as transport of molecules. Although this approach works well for many of the reaction systems over narrow ranges of conditions, it can fail when extrapolated over a wide range of conditions. In many refining processes, transport of oxygen in slag determines the kinetics of major reactions. Transport of oxygen in slag is strongly influenced by the electrical conductivity of slag. Whilst this has been well understood since the 1950s, there have been relatively few attempts to quantify the effects of slag electrical properties on the refining kinetics. Herein, an overview is presented focusing on the electrical properties of slags and their effects on the transport kinetics in steelmaking reactions. An analysis is conducted based on a modified version of the approach taken by Wagner to describe oxygen transport in solid oxides. Data from the literature including work from the authors’ laboratory is discussed in an evaluation of literature oxygen transport in CaO–SiO2–FetO, CaO–SiO2–Al2O3–FetO, and PbO–Fe2O3 slags.

EMD-based noise reduction study of steel cored conveyor belt containing slag signal

This paper proposes a noise reduction technique that combines empirical mode decomposition (EMD) and wavelet thresholding to eliminate the noise interference caused by metal slag in the steel cord conveyor belt damage signal. Initially, the original signal undergoes decomposition by EMD into high- and low-frequency intrinsic mode function (IMF) components based on metal slag signal feature analysis. The wavelet threshold de-noising method is then applied to filter out the high-frequency noise while preserving the low-frequency IMF components. The IMF components containing slag noise are discarded, and the filtered signal and the low-frequency IMF components are used for signal reconstruction to obtain an optimal noise reduction effect. The study demonstrates that this method is more effective in suppressing metal slag noise, environmental noise, and other noise interferences than traditional EMD decomposition noise reduction and wavelet threshold noise reduction methods. This research provides a valuable reference for noise reduction in steel cord conveyor belt detection data.

Distribution, occurrence, and leachability of typical heavy metals in coal gasification slag

Coal gasification slag (CGS) contains variable amounts of heavy metals, which can negatively impact the environment. The mineral composition, element distribution, occurrence, and leaching characteristics of heavy metals in coal gasification coarse slag (CGCS) and coal gasification fine slag (CGFS) are studied to explain the leaching behavior of heavy metals in CGS. The movable components of heavy metals in CGFS (0.06 %–63.03 %) are significantly higher than those in CGCS (0 %–18.72 %). Leaching Environmental Assessment Framework 1313 data shows that heavy metals Zn, Cr, Cd, As, Pb, Ni, and Cu exhibit high leaching rates at low pH conditions, with Zn leaching concentrations as high as 2.11 mg/L at pH 2. Zn, Cr, and As exhibit obvious amphoteric leaching characteristics, and the leaching concentration of As at high pH (1.34 mg/L) even exceeds that at low pH (1.31 mg/L). Except for Cu, all heavy metals in CGS exceed the class III groundwater standard in some cases. Therefore, evaluation is needed before resource utilization of CGS due to potential leaching of some heavy metals.

Effects of Carbonation–Hydration Curing on CO2 Uptake, Mechanical Properties, and Leaching Behavior of Heavy Metals in Stainless Steel Slag

Effects of Carbonation–Hydration Curing on CO2 Uptake, Mechanical Properties, and Leaching Behavior of Heavy Metals in Stainless Steel Slag

New approach to evaluating the thermodynamic consistency of melts in the ‘metal-slag’ system based on interatomic interaction parameters

The article presents a new approach to evaluating the thermodynamic state of the ‘metal–slag’ system during metal smelting in oxidizing-reducing conditions. The interaction between the metal and slag is analyzed using the model of the structure of metallurgical melts, which considers cooperative ion exchange processes and interatomic interaction parameters. As a result of analyzing experimental data on the compositions of reacting melts during pig iron and steel smelting, criteria were developed for assessing the degree of achieving the equilibrium in the system regarding sulfur. The charge state parameters of the metallic system ZY and the slag system Δe, the slag stoichiometry index ρ, and the charge state parameter of the melt components Zi were used. The regularity of a consistent formation of metallic and slag melts has been established, which is evidenced by a significant correlation between the chemical equivalent of the metal composition ZY and the slag Δe. Analytical dependences were obtained in the form of ZY = f(Δe,ρ). The identified patterns and criteria can be integrated into automated process control systems for regulating the slag regime and producing high-quality pig iron and steel.

Computational Fluid Dynamics Numerical Simulation on Flow Behavior of Molten Slag–Metal Mixture over a Spinning Cup

Centrifugal granulation technology using a spinning cup opens a potential way to recycle steel slag that is currently difficult to reuse. The objective of this research was to study the flow characteristics of a molten slag–metal mixture that was produced during smelting reduction in molten steel slag, passing over a spinning cup, so as to explore the feasibility of using centrifugal granulation technology to treat the steel slag. This was achieved by developing and implementing a computational fluid dynamics (CFD) model that incorporated free-surface multiphase flow to predict the thickness of the liquid slag film at the edge of the spinning cup (slag film thickness for short), which was an important parameter for estimating the size of the slag particles resulting from centrifugal granulation of the molten slag–metal mixture. The influences of various relevant parameters, including spinning cup diameter, slag feeding rate, cup spinning speed, etc., on the slag film thickness were analyzed. Additionally, hot experiments on centrifugal granulation of a molten slag–metal mixture were conducted to verify the results of the numerical simulations. The experimental results indicated a progressive reduction in the Sauter mean diameter of the slag particles as the metallic iron content in the slag increased. Specifically, when the iron content rose from 5% to 15% at a cup spinning speed of 2500 RPM, the Sauter mean diameter decreased by 13.77%. The numerical simulation results showed that the slag film thickness had a positive relationship to the slag feeding rate but a negative relationship to the spinning cup diameter and the cup spinning speed. Furthermore, the ratio between the mean slag particle diameter and the slag film thickness decreased nearly linearly with the increase in the metallic iron content in slag, with the average ratio being approximately 4.25, and this relationship was useful for estimating the slag particle size from the slag film thickness. Therefore, the present research results can provide theoretical guidance for the industrial application of spinning cup centrifugal granulation technology to effectively treat and recycle steel slags.