Visualization of Slag Data for Efficient Monitoring and Improvement of Steelmaking Slag Operation in Electric Arc Furnaces, with a Focus on MgO Saturation

Kirschen, Marcus

doi:10.3390/met11010017

Cited by 5 publications

(3 citation statements)

References 24 publications

(39 reference statements)

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“…Over the years, a number of research work have been done to describe the relation between slag composition and MgO content at saturation like Suito et al (1981) and Selin (1987Selin ( , 1991. Examples of recent work are Kirschen (2021) and finally Song et al (2020) studying refractory wear. Economic assessments of DRI quality and DRI use have been made by Gyllenram et al (2015a) and Gyllenram et al (2015b).…”

Section: Raw Materials Qualitymentioning

confidence: 99%

Driving investments in ore beneficiation and scrap upgrading to meet an increased demand from the direct reduction-EAF route

Gyllenram

Arzpeyma²,

Wei

et al. 2021

Miner Econ

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The pressure on the steel industry to reduce its carbon footprint has led to discussions to replace coke as the main reductant for iron ore and turn to natural gas, bio-syngas or hydrogen. Such a major transition from the blast furnace-basic oxygen furnace route, to the direct reduction-electric arc furnace route, for steel production would drastically increase the demand for both suitable iron ore pellets and high-quality scrap. The value for an EAF plant to reduce the SiO2 content in DRI by 2 percentage points and the dirt content of scrap by 0.3 percentage points Si was estimated by using the optimization and calculation tool RAWMATMIX®. Three plant types were studied: (i) an integrated plant using internal scrap, (ii) a plant using equal amounts of scrap and DRI and (iii) a plant using a smaller fraction of DRI in relation to the scrap amount. Also, the slag volume for each plant type was studied. Finally, the cost for upgrading was estimated based on using mainly heuristic values. A conservative estimation of the benefit of decreasing the silica content in DRI from 4 to 2% is 20 USD/t DRI or 15 USD/t DR pellets and a conservative figure for the benefit of decreasing the dirt in scrap by 0.3 percentage points Si is 9 USD/t scrap. An estimate on the costs for the necessary ore beneficiation is 2.5 USD/t pellet concentrate and for a scrap upgrade, it is 1-2 USD/t scrap.

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Section: Raw Materials Qualitymentioning

confidence: 99%

Driving investments in ore beneficiation and scrap upgrading to meet an increased demand from the direct reduction-EAF route

Gyllenram

Arzpeyma²,

Wei

et al. 2021

Miner Econ

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“…Several review articles have discussed using ternary phase diagrams to explain slag-refractory interactions in fields other than gasification. − Plešingerová et al used liquidus projection in their study in which adding MgCO 3 to biomass fuel caused a reduction in corrosion of corundum refractory by the biomass ash. Due to the increase in MgO in the biomass ash, the composition of the biomass ash shifted from the region of dicalcium silicate to the region of periclase in the liquidus projection.…”

Section: Introductionmentioning

confidence: 99%

Application of Liquidus Projections in SiO₂–Al₂O₃–CaO Systems with Fe₂O₃ and V₂O₅ to Study the Dissolution of Alumina Crucibles in Gasification Slags Containing Vanadium

Banik,

Sridhar,

Pisupati

2024

ACS Omega

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Entrained flow gasification occurring above 1400 °C is a technique to convert petroleum coke, a byproduct of petroleum refining, into synthesis gas. The molten ash/slag formed in the process has a high amount of V and Ni compounds, which are corrosive to the reactor walls. Slag viscosity is an important parameter that must be controlled to tap the slag from the gasifier. The viscosity of the slags is measured in high-temperature viscometers. Alumina crucibles, used in viscosity measurements, were severely corroded by high V/Ni slags in several in-house experiments. To study the chemistry of these dissolutions, saturation solubilities of alumina crucibles in the slags (at 1500 °C) and precipitated primary phases were determined from liquidus projections prepared in Factsage. The 10 slags considered in this study were composed of SiO 2 (<50.2 wt %), Al 2 O 3 (<29.2 wt %), Fe 2 O 3 (<41.4 wt %), CaO (<16.6 wt %), NiO (<20.4 wt %), and V 2 O 5 (<20.5 wt %). The precipitated primary phases were corundum (solid solution), spinel (solid solution), V_spinel (solid solution), mullite (solid solution), and anorthite. Experiments were performed with ash placed on alumina discs in a reducing atmosphere. The ash compositions were based on previous in-house viscosity and ash melting experiments. Saturation solubilities were above 30 wt % in multiple tests with perforated and intact crucibles. In two such cases, hercynite, which can inhibit slag penetration into a crucible, was predicted as a primary phase. In another test with an intact crucible, anorthite, which leads to indirect dissolution, was predicted as a primary phase and was also identified in the X-ray diffraction (XRD) results of the slag-crucible interface. Here, saturation solubility was 8.9 wt %. It was concluded that determination of saturation solubilities and primary phases would lead to successfully measuring the viscosity of slags containing V and Ni in alumina crucibles.

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“…The excess MgO in slag, just above the MgO saturation limit with suitable basicity helps in precipitation of solid particles which minimizes the refractory erosion. Solid particles formed due to slag saturation of MgO and CaO, serve as nucleation sites for gas bubbles and helps in slag foaming also [6,7]. EAF slags with basicity value of 2, should have a typical MgO concentration of approximately 9% [8].…”

Section: Introductionmentioning

confidence: 99%

Thermodynamic modelling of steelmaking slag to reduce refractory consumption during CONARC ^® process

Rozario

Mukhopadhyay

Haidar

et al. 2023

Ironmaking & Steelmaking

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CONARC ® steelmaking process which combines the basic oxygen and electric arc furnace steelmaking, requires precise operation and control of slag chemistry within an optimum range to reduce the refractory wear. The target slag should be MgO saturated, containing solid particles of magnesium wustite which ensures good foamy slag and causes less erosion of MgO-C refractory. In this present study, FactSage™ software was utilized to study and visualize the MgO saturation of slag through MgO-SiO 2 -FeO-CaO-Al 2 O 3 -MnO and CaO-SiO 2 -FeO-MgO-Al 2 O 3 -MnO systems. The ternary phase diagrams revealed, the slag was MgO-under saturated based on the current pattern of calcined lime and dolomite addition during the process. Based on the findings of this study, the addition pattern were altered to bring the slag regime within the MgO saturation level with good slag basicity. This change showed significant improvement in reducing the erosion rate of MgO-C lining in furnace and thereby reducing the specific gunning mass requirement.

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Visualization of Slag Data for Efficient Monitoring and Improvement of Steelmaking Slag Operation in Electric Arc Furnaces, with a Focus on MgO Saturation

Cited by 5 publications

References 24 publications

Driving investments in ore beneficiation and scrap upgrading to meet an increased demand from the direct reduction-EAF route

Driving investments in ore beneficiation and scrap upgrading to meet an increased demand from the direct reduction-EAF route

Application of Liquidus Projections in SiO₂–Al₂O₃–CaO Systems with Fe₂O₃ and V₂O₅ to Study the Dissolution of Alumina Crucibles in Gasification Slags Containing Vanadium

Thermodynamic modelling of steelmaking slag to reduce refractory consumption during CONARC ^® process

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Visualization of Slag Data for Efficient Monitoring and Improvement of Steelmaking Slag Operation in Electric Arc Furnaces, with a Focus on MgO Saturation

Cited by 5 publications

References 24 publications

Driving investments in ore beneficiation and scrap upgrading to meet an increased demand from the direct reduction-EAF route

Driving investments in ore beneficiation and scrap upgrading to meet an increased demand from the direct reduction-EAF route

Application of Liquidus Projections in SiO2–Al2O3–CaO Systems with Fe2O3 and V2O5 to Study the Dissolution of Alumina Crucibles in Gasification Slags Containing Vanadium

Thermodynamic modelling of steelmaking slag to reduce refractory consumption during CONARC ® process

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Application of Liquidus Projections in SiO₂–Al₂O₃–CaO Systems with Fe₂O₃ and V₂O₅ to Study the Dissolution of Alumina Crucibles in Gasification Slags Containing Vanadium

Thermodynamic modelling of steelmaking slag to reduce refractory consumption during CONARC ^® process