Development of Refractory Material from Water Quenched Granulated Ferrochromium Slag

Sahu, Nilamadhaba; Biswas, Arijit; Kapure, Gajanan

doi:10.1080/08827508.2016.1181630

Cited by 20 publications

(8 citation statements)

References 10 publications

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“…The chemical composition of the ferrochromium slag is close to the refractory composition. It contains high refractor phases such as spinel and forsterite Türkmen et al (2016) and Sahu et al (2016b). These are the two main reasons for the improved thermal resistance of AASFC mixtures when compared to NCA based OPC mixtures.…”

Section: Resultsmentioning

confidence: 99%

Numerical and experimental studies on sustainable alkali activated concretes at elevated temperatures

Yaragal

Kumar

Abhinav

2019

JSFE

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Purpose To reduce environmental impact caused by excessive use of ordinary Portland cement (OPC) and to mitigate scarcity of base materials such as natural coarse aggregate (NCA), industrial by-products can be carefully used as alternatives to OPC and NCA, in production of concrete. This paper aims to describe the performance of using ground granulated blast furnace slag (GGBS), fly ash (FA) as a complete replacement to OPC and ferrochrome slag (FCS) as replacement to NCA in production of novel FCS based alkali activated slag/fly ash concretes (AASFC) and evaluate their performance at elevated temperatures. Design/methodology/approach Two control factors with three levels each i.e. FA (0, 25 and 50 per cent by weight) and FCS (0, 50 and 100 per cent by volume) as a GGBS and NCA replacement, respectively, were adopted in AASFC mixtures. Further, AASFC mixture specimens were subjected to different levels of elevated temperature, i.e. 200°C, 400°C, 600°C and 800°C. Compressive strength and residual compressive strength were considered as responses. Three different optimization techniques i.e. gray relational analysis, technique for order preference by similarity to ideal solution and Desirability function approach were used to optimize AASFC mixtures subjected to elevated temperatures. Findings As FA replacement increases in FCS based AASFC mixtures, workability increases and compressive strength decreases. The introduction of FCS as replacement to NCA in AASFC mixture did not show any significant change in compressive strength under ambient condition. AASFC produced with 75 per cent GGBS, 25 per cent FA and 100 per cent FCS was found to have excellent elevated temperature enduring properties among all other AASFC mixtures studied. Originality/value Although several studies are available on using GGBS, FA and FCS in production of OPC-based concretes, present study reports the performance of novel FCS based AASFC mixtures subjected to elevated temperatures. Further, GGBS, FA and FCS used in the present investigation significantly reduces CO2 emission and environmental degradation associated with OPC production and NCA extraction, respectively.

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Section: Resultsmentioning

confidence: 99%

Numerical and experimental studies on sustainable alkali activated concretes at elevated temperatures

Yaragal

Kumar

Abhinav

2019

JSFE

View full text Add to dashboard Cite

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“…However, those methods have a few drawbacks, causing inefficient utilization of the slag. In specific, because of the high content of MgO in the ferronickel slag (often >20 wt%) which has swelling problems, its usage in construction and building materials as well as geopolymers is greatly limited . Due to low contents of valuable metals in the slag, it is often considered uneconomic by direct extraction of the elements.…”

Section: Introductionmentioning

confidence: 99%

Promoting spinel formation and growth for preparation of refractory materials from ferronickel slag

Peng

Zhang

et al. 2020

Int J Applied Ceramic Tech

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The study provides a method for improving the quality of the refractory material prepared from ferronickel slag by promoting the spinel formation and growth in the slag which was sintered with sintered magnesia and chromium oxide in a broad sintering temperature range from 1200°C to 1500°C. According to the thermodynamic analysis, except for forsterite due to the addition of sintered magnesia, a number of high‐melting point spinel phases can also be formed in the presence of chromium oxide and this trend becomes more apparent with increasing sintering temperature, along with declined presence of low‐melting point clinopyroxene, mainly enstatite. This expectation was verified by conversion of a part of the original phase of ferronickel slag, olivine, to two main spinel phases, including magnesium aluminate spinel and donathite which was produced by the replacement of nontoxic Cr3+ ions with Fe3+ ions in the octahedral vacancies of magnesium chromate spinel. The formation and growth of these spinel phases were promoted by elevating temperature from 1200°C to 1500°C, which accelerated the transition of initially generated enstatite to a glassy phase, in favor of densification. The formation and growth of spinel during sintering contributed to high refractoriness and compressive strength of the resulting refractory materials

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“…The main components of the ferronickel slag are magnesia and silica, which exhibit a similar composition to forsterite refractory materials. It was reported that value-added forsterite refractory materials ($1100–1300/t) could be produced using high-magnesia and silica waste as raw materials, including ferrochromium slag, iron ore tailing and amorphous rice husk, after properly altering their chemical compositions at 1500–1650 °C for 3–6 h. Hence it may be feasible to prepare forsterite refractory materials by a similar approach from ferronickel slag despite the lack of relevant report in literature. Furthermore, the relatively high chromium content in the ferronickel slag may serve as an advantageous factor for preparation of refractory material as the Cr(III) contained in ferronickel slag can be stabilized in the high melting point spinel phase without leachability during the refractory material sintering process. − This strategy will not only solve the potential chromium contamination of ferronickel slag in the preparation but also improve the refractoriness of the material.…”

Section: Introductionmentioning

confidence: 99%

Facile Route for Preparing Refractory Materials from Ferronickel Slag with Addition of Magnesia

Peng

Zhang

et al. 2018

ACS Sustainable Chem. Eng.

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The feasibility of a facile technological route to preparation of refractory materials from a ferronickel slag with the addition of sintered magnesia was verified in this study based on the thermodynamics analysis and the experimental exploration of the effect of the sintered magnesia addition on the phase transformation of ferronickel slag during the sintering process. For the first time, the results of thermodynamics calculation, X-ray diffraction (XRD), and scanning electron microscopy-energy dispersive X-ray spectroscopy (SEM-EDS) analyses revealed that the original phase of the slag can be transformed to high melting point phases by addition of MgO during the sintering process at high temperatures (e.g., 1350 °C). Specifically, the olivine in ferronickel slag decomposed initially, generating a low-iron olivine phase and an enstatite phase. With increasing addition of sintered magnesia, the enstatite phase changed to forsterite, and the iron, aluminum, and chromium components in the ferronickel slag converted to high melting point spinel phases, including magnesium aluminate spinel and magnesium chromate spinel via a low-magnesium transient phase. The experimental results showed that a good refractory material with refractoriness of 1660 °C, bulk density of 2.92 g/cm3, apparent porosity of 1.82%, and compressive strength of 100.61 MPa could be obtained when the slag was sintered with addition of 20 wt % sintered magnesia at 1350 °C for 3 h. Due to the low production cost and property superiority of the prepared refractory material over commercial counterparts, the method proposed in this study is expected to have widespread applications in recycling of ferronickel slag.

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Development of Refractory Material from Water Quenched Granulated Ferrochromium Slag

Cited by 20 publications

References 10 publications

Numerical and experimental studies on sustainable alkali activated concretes at elevated temperatures

Numerical and experimental studies on sustainable alkali activated concretes at elevated temperatures

Promoting spinel formation and growth for preparation of refractory materials from ferronickel slag

Facile Route for Preparing Refractory Materials from Ferronickel Slag with Addition of Magnesia

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