The viscosity of blast-furnace slag and its relation to iron metallurgy, including a description of a new method of measuring slag viscosity at high temperatures

Feild, A.L.

doi:10.1039/tf9171300003

Cited by 3 publications

(3 citation statements)

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“…The first high-temperature rotary viscometer was built and operated by the U.S. Bureau of Mines to investigate the viscosity of blast furnace slags [100] based on principles outlined by Margules in 1881 [101]. Nicholls, Reid and Cohen later extended the study to include coal ash slags [37,102].…”

Section: High-temperature Rotary Viscometrymentioning

confidence: 99%

Correlation between the critical viscosity and ash fusion temperatures of coal gasifier ashes

Hsieh

Kwong

Bennett

2016

Fuel Processing Technology

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Coal gasification yields synthesis gas, an important intermediate in chemical manufacturing. It is also vital to the production of liquid fuels through the Fischer-Tropsch process and electricity in Integrated Gasification Combined Cycle power generation. Minerals naturally present in coal become molten in entrained-flow slagging gasifiers. Molten coal ash slag penetrates and dissolves refractory bricks, leading to costly plant shutdowns. The extent of coal ash slag penetration and refractory brick dissolution depends on the slag viscosity, the gasification temperature, and the composition of slag and bricks. We measured the viscosity of several synthetic coal ash slags with a high-temperature rotary viscometer and their ash fusion temperatures through optical image analysis. All measurements were made in a carbon monoxide-carbon dioxide reducing atmosphere that approximates coal gasification conditions. Empirical correlation models based on ash fusion temperatures were used to calculate critical viscosity temperatures based on the coal ash compositions. These values were then compared with those obtained from thermodynamic phase-transition models. An understanding of slag viscosity as a function of ash composition is important to reducing refractory wear in slagging coal gasifiers, which would help to reduce the cost and environmental impact of coal for chemical and electricity production.Published by Elsevier B.V.

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Section: High-temperature Rotary Viscometrymentioning

confidence: 99%

Correlation between the critical viscosity and ash fusion temperatures of coal gasifier ashes

Hsieh

Kwong

Bennett

2016

Fuel Processing Technology

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“…As the reduction of FeO occurs during the iron nugget making process occurs, the activity (concentration) of FeO within the slag phase will reduce and liquidus temperature of the slag system will increase as the reduction reactions progress. There is a trade-off in processing iron nuggets to allow for some FeO to remain within the slag post-reduction, increased slag fluidity may reduce the demand for auxiliary fluxing agent additions, lower theoretical plant operating temperatures and promote the kinetics of slag-metal desulfurization reactions which are diffusion controlled (Feild, 1917). These benefits are of course offset by the loss of iron, the primary product of iron nugget making to the slag phase.…”

Section: Low Liquidus Temperature Slagmentioning

confidence: 99%

The production of high value pig iron nuggets from steelmaking by-products – A thermodynamic evaluation

Stewart

Thomson

Barron

2021

Resources, Conservation and Recycling

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“…As the reduction of FeO occurs during the iron nugget making process occurs, the activity (concentration) of FeO within the slag phase will reduce and liquidus temperature of the slag system will increase as the reduction reactions progress. There is a trade-off in processing iron nuggets to allow for some FeO to remain within the slag post-reduction, increased slag fluidity may reduce the demand for auxiliary fluxing agent additions, lower theoretical plant operating temperatures and promote the kinetics of slag-metal desulfurization reactions which are diffusion controlled 200 . These benefits are of course offset by the loss of iron, the primary product of iron nugget making to the slag phase.…”

Section: Methodsmentioning

confidence: 99%

Value Generation by Recovering By-Products from Steelmaking Processes: Dezincification of Basic Oxygen Steelmaking Slurry

Stewart¹

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The production of steel through the blast furnace/basic oxygen steelmaking route generates approximately 10kg of ferrous dusts and sludges per tonne of hot metal produced. This ferrous material is readily recyclable via a sinter plant to recover iron units but is difficult to recycle when the material is contaminated with zinc. Historically, excess material has been stockpiled or landfilled which presents an environmental issue but also a commercial opportunity to recover huge volumes of ferrous material from operating and former steelmaking sites. A review of best available technology for recovery of zinc from steelmaking by-product dusts identified that the Rotary Hearth Furnace (RHF) is the most attractive commercialized option for processing of material at an integrated plant such as Tata Steel Port Talbot, but due to the relatively low value of the ferrous direct reduced iron (DRI) product is still not commercially viable. A characterization study of basic oxygen steelmaking dust from Port Talbot, Redcar and Scunthorpe steel plants in the United Kingdom was undertaken using a variety of techniques and indicated pyrometallurgical recovery would be the preferred recovery route due to the high metallization and variability of the morphology of the dusts. Benchmarking of material from Port Talbot material processed in laboratory furnace trials under conditions mimicking the RHF showed that while volatile metal removal and iron reduction performance is adequate for recycling at realistic RHF temperatures and hold times, the high sulfur and gangue content mean the produced DRI would not be valuable enough to offset production costs. A computational thermochemical study was undertaken using FactSage and identified the possibility of applying next generation RHF technology to produce high value pig iron nuggets from steelmaking by-products. This possibility was confirmed experimentally, producing pig iron nuggets from BOS dust with complete removal of zinc from the material, at feasible process conditions, by addition of SiO2 and MgO fluxes. Alternative reductants for the RHF were also explored, specifically adapting the RHF process to utilize the enormous volume of plastic waste generated from facemasks in the wake of the COVID-19 pandemic. The addition of facemask plastic to a low-volatile coal was found to increase its CO2 gasification reactivity, which has associated process benefits for direct reduction.

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The viscosity of blast-furnace slag and its relation to iron metallurgy, including a description of a new method of measuring slag viscosity at high temperatures

Cited by 3 publications

References 0 publications

Correlation between the critical viscosity and ash fusion temperatures of coal gasifier ashes

Correlation between the critical viscosity and ash fusion temperatures of coal gasifier ashes

The production of high value pig iron nuggets from steelmaking by-products – A thermodynamic evaluation

Value Generation by Recovering By-Products from Steelmaking Processes: Dezincification of Basic Oxygen Steelmaking Slurry

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