Evaluation of Functional, Microstructural, Environmental Impact, and Economic Performance of Concrete Utilizing Ferrochrome Ash and Slag

Acharya, Prasanna Kumar; Patro, Sanjaya Kumar

doi:10.1007/s40831-022-00587-9

Cited by 5 publications

(2 citation statements)

References 29 publications

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“…The concentrate of the 0-3 mm fraction and the 0-1 mm ore sieve of the 0-10 mm fraction had similar compositions and ratios of the main components. However, the aspiration dust from the bag filters of the ore-smelting furnace had a noticeably different composition, with a lower content of oxides of chromium, iron, and aluminum but a higher content of oxides of silicon and magnesium [27][28][29][30][31].…”

Section: Methodsmentioning

confidence: 99%

Pilot Tests of Pre-Reduction in Chromium Raw Materials from Donskoy Ore Mining and Processing Plant and Melting of High-Carbon Ferrochromium

Shabanov,

Makhambetov,

Saulebek

et al. 2024

Metals

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Experiments were conducted to pilot the initial reduction in chromium raw materials using the innovative Hoganas technology in a tunnel furnace. To simulate the process, a gas-fired bogie hearth furnace was employed. Technological containers made of silicon carbide crucibles were utilized. Sixteen different combinations of ore and coal mixtures were employed for the initial reduction process. Their total mass was more than 20 tons. Their heat treatment was performed at different temperatures and durations. During the pilot tests, the possibility of achieving chromium metallization was confirmed. Thus, it explains the application of a pre-reduction instead of the sintering or charge heating before the ferrochromium melting, i.e., the power consumption is minimized during the final remelting of the product in DC furnaces. The pilot melting of three batches of the pre-reduced chromium raw materials with various chromium metallization degrees has been tested in the ore-smelting furnace at Zh. Abishev Chemical–Metallurgical Institute (Karaganda). The capacity was 0.2 MVA. To evaluate the technical and economic efficiency of remelting pre-reduced chromium raw materials in commercial DC furnaces, a specific batch of primary ingredients for producing high-carbon ferrochromium, including chromite ore, coke, and quartz flux, was successfully melted in a segregated phase. As a result of the study, it was found that the specific energy consumption for melting high-carbon ferrochromium in the pilot furnace depends on the chromium metallization degree. The researchers tested a range of chromium metallization degrees from 0 to 65% and determined the corresponding specific energy consumption for each degree. Using the data obtained from the study, the researchers were able to assess the melting indexes of high-carbon ferrochromium in a larger 72 MW furnace. They found that by using a pre-reduced product with a chromium metallization degree of 65%, it was possible to reduce the specific energy consumption by half, to around 3.4 MW·h per ton of chromium. Overall, this study highlights the importance of considering the chromium metallization degree when determining the specific energy consumption for melting high-carbon ferrochromium. By optimizing the metallization degree, significant energy savings can be achieved, leading to more efficient and sustainable production processes.

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Section: Methodsmentioning

confidence: 99%

Pilot Tests of Pre-Reduction in Chromium Raw Materials from Donskoy Ore Mining and Processing Plant and Melting of High-Carbon Ferrochromium

Shabanov,

Makhambetov,

Saulebek

et al. 2024

Metals

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show abstract

“…Khabibulin [ 12 ] prepared the concrete by using Chrome slag, fly ash and cement as raw materials. Acharya [ 13 ] reviewed the preparation of concrete from chromite slag, and reported its work characteristics, economic advantages, and environmental benefits. Isil [ 14 ] evaluates the feasibility of ferrochrome slag as cementing material, and studied the effect of it as concrete admixture on mechanical properties.…”

Section: Introductionmentioning

confidence: 99%

Preparation and Hydration Mechanisms of Low Carbon Ferrochrome Slag-Granulated Blast Furnace Slag Composite Cementitious Materials

Ren

Wang

et al. 2023

Materials

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Low carbon ferrochrome slag (LCFS) is the metallurgical waste slag from the carbon ferrochrome alloy smelting process. Compared with high carbon ferrochrome slag, LCFS has great potential as cementitious material; the chemical compositions of the two types of slag are quite different. In this research, composite cementitious materials are prepared which use low carbon ferrochrome slag and granulated blast furnace slag (GBFS) as the main raw material. Steel slag mud (SSM) and flue gas desulfurization gypsum (FGDG) are used as the activator. In order to find the variety rule of compressive strength on the composite cementitious materials, a three-factor three-level Box-Behnken design is used to discuss the following independent variables: LCFS content, GBFS content, and water-binder ratio. Moreover, the hydration characteristics of the LCFS-GBFS composite cementitious materials is studied in this paper in terms of hydration product, micromorphology, and hydration degree, based on multi-technical microstructural characterizations. The results show that the compressive strength of the LCFS-GBFS composite cementitious materials is significantly affected by single factors and the interaction of two factors. The mechanical property of the mortar samples at 3, 7, and 28 days are 26.6, 35.3, and 42.7 MPa, respectively, when the LCFS-GBFS-SSM-FGDG ratio is 3:5:1:1 and the water-binder ratio is 0.3. The hydration products of LCFS-GBFS composite cementitious materials are mainly amorphous gels (C-S-H gel), ettringite, and Ca(OH)2. With the increase of LCFS content, more hydration products are generated, and the microstructure of the cementitious system becomes more compact, which contributes to the compressive strength. The results of this research can provide a preliminary theoretical foundation for the development of LCFS-GBFS composite cementitious materials and promote the feasibility of its application in the construction industry. Deep hydration mechanism analysis and engineering applications should be studied in the future.

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Synergistic Effects of Rice Husk Ash and Ferrochrome Ash on Mechanical Properties, Acid Resistance, Chloride Resistance and Economic Performance of Green Concrete

Saha,

Mohanty,

Acharya

et al. 2024

Iran J Sci Technol Trans Civ Eng

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Evaluation of Functional, Microstructural, Environmental Impact, and Economic Performance of Concrete Utilizing Ferrochrome Ash and Slag

Cited by 5 publications

References 29 publications

Pilot Tests of Pre-Reduction in Chromium Raw Materials from Donskoy Ore Mining and Processing Plant and Melting of High-Carbon Ferrochromium

Pilot Tests of Pre-Reduction in Chromium Raw Materials from Donskoy Ore Mining and Processing Plant and Melting of High-Carbon Ferrochromium

Preparation and Hydration Mechanisms of Low Carbon Ferrochrome Slag-Granulated Blast Furnace Slag Composite Cementitious Materials

Synergistic Effects of Rice Husk Ash and Ferrochrome Ash on Mechanical Properties, Acid Resistance, Chloride Resistance and Economic Performance of Green Concrete

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