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The slag foaming practice enables high energy efficiency in the electric arc furnace, and its optimization is based on empirical knowledge and process modeling. Thus, it is essential to predict the physical properties of slags, as this phenomenon depends on their density, surface tension, and viscosity. Although thermodynamic calculations provide insights into the chemical composition of slags in equilibrium with liquid steel and refractories, and commercial software packages (such as FactSage) include modules to estimate slag viscosity, there are limitations regarding the chemical species considered and the properties that can be forecasted. In this study, predictive models of surface tension, density, and viscosity are evaluated for their ability to estimate experimental properties of metallurgical slags. These models, developed for glass compositions using machine‐learning algorithms, were subsequently validated on slags in this work. On the basis of their performance and limitations, a framework coupling FactSage and GlassNet was proposed and applied to investigate potential slag conditioners for controlling foamy slag. The tested candidates were silica sand, sodalite, and steel scale, and their effects on the characteristic times of foam collapse (or aging) were predicted in the results. This work combined computational thermodynamics and ML models to predict slag properties and, consequently, the foam aging times. Using this framework, three alternative slag conditioners were investigated to control slag foaming in the EAF.

The use of industrial byproducts as replacement of natural aggregates has been extensively investigated to design eco-friendly roads. One of the most examined byproducts for this purpose is steel slag. However, existing studies do not explore the blending of different slags to enhance the engineering performance of base layers. The applicability of Linz–Donawitz (LD), Blast Furnace (BF) and Kambara Reactor (KR) steel byproducts is evaluated as a single base layer for rural (unsurfaced) roads in Brazil. A series of laboratory experiments were performed to assess the characteristics of eight soil-byproduct mixtures with 50% and 75% byproduct contents, including new blends of LD/KR and BF/KR slags. Additionally, the most suitable mixture was proposed considering different performance indicators. Results demonstrate the coarse-grained, nonplastic and non-expansive nature of the byproducts, with CBR values higher than 100%. The more byproduct added to soil, the larger is the strength and the lower the expansion. The mixture with 75% of the proposed LD/KR blend and 25% of a clayey soil was considered as optimum, based on a trade-off between engineering properties, environmental impacts, and material costs. Findings and discussions are relevant to reduce waste stockpiles of steel companies, helping engineers and policy makers reuse blended slag byproducts.

Copper in discarded slag decreases the profits and copper recovery during the pyrometallurgical extraction processes. The copper losses to slag can be reduced by using a settling furnace, in which mechanically entrained copper droplets separate from the slag under the action of gravity. The settling rate of entrained droplets can be increased by modifying the slag composition and, thus, the slag properties, which are known to influence the settling rate. The knowledge of industrial CaO slag modification in a reduced iron silicate slag with a Fe/SiO2 ratio close to unity is limited. An industrial trial was thus conducted in an electric settling furnace, where the slag had been pretreated in a fuming furnace, to investigate the effect of CaO slag modification on the final slag copper content. Slag samples were collected from the ingoing and outgoing slag and from within the furnace of batches modified with CaO up to about 16 wt %. The trial was evaluated by comparing the final slag copper content and the copper recovery in the settling furnace. The results indicate that the settling becomes more efficient with the CaO modification as the final slag copper content decreased with increasing CaO content.

AbstractThe world of stainless steel production was 52 Mt in 2019, and the annual amount of slags including electric furnace, AOD converter, ladle, and casting tundish, was estimated at 15–17 Mt. Nowadays, only a minor fraction of slags from stainless steel production is utilized and a major part goes to landfilling. These slags contain high-value elements (Cr, Ni, Mo, Ti, V…) as oxides or in metallic form, some of them being environmentally problematic if dumped. Thus, any approach toward circular economy solutions for stainless steel slags would have great economic and environmental impacts. This contribution examines the slags from different process stages, and the available and new potential means to increase internal recycling and to modify slags composition and structure by optimizing their properties for reclaiming in high-value applications. Eventual methods are, e.g., fast controlled cooling and modifying additives. Means to recover valuable metals are discussed as well as potential product applications to utilize various slags with different chemical, physical, and mechanical properties. By integrating the treatments and steering of slags′ properties to the total process optimization system, the principles of circular economy could be achieved.Graphical Abstract

Na2O is an alkaline oxide, which can significantly improve the dephosphorization ability of converter slag. The effect of Na2O on the dephosphorization of converter slag was analyzed with a high-temperature dephosphorization experiment in a MoSi2 resistance furnace. We found that the dephosphorization rate increased with the increase of (Na2O) in the dephosphorization slag. The elements of Ca, Si, O, and P in the dephosphorization slag are distributed in the same area, mainly in the form of phosphate minerals, such as Ca2SiO4·0.05Ca3(PO4)2 and 6Ca2SiO4·Ca3(PO4)2. After adding Na2O, part of the Na will replace the Ca in the phosphorus-containing phase to form Ca2SiO4·Ca2Na2(PO4)2. The industrial test showed that the average dephosphorization rate in the early stage of the test heats with the CaO-MgO-FeO-SiO2-0.5%Na2O slag system could reach 62.39%, which was 19.62% higher than that of the conventional heats. The average basicity of the final slag was 0.19% lower than that of the conventional heats, while w(P2O5) increased by 0.36%, and T.Fe decreased by 0.69%. The average consumption of the slagging materials was 35.93 kg/t, which was 7.24 kg/t less than that of the conventional heats. Through thermodynamic calculation, we found that with the increase of (Na2O), the phosphorus distribution ratio between slag and steel increased significantly, the area of the liquid phase zone of the slag system increased continuously, and the viscosity decreased continuously.

The traditional blast furnace ironmaking process is the most widely used ironmaking process globally, yet it is associated with significant drawbacks, including high energy consumption and carbon emissions. To achieve low-carbon ironmaking, researchers have developed hydrogen ironmaking, which is capable of achieving lower CO2 emissions. Nevertheless, the distribution behavior of impurities has been less studied in the existing research on hydrogen ironmaking. Therefore, in this study, the factors affecting the slag properties and distribution of impurity elements during hydrogen ironmaking were investigated using FactSage, and smelting experiments were carried out. The results show that temperature has the greatest influence on the distribution behavior of the impurities, and excessively elevated temperatures result in the ingress of a significant quantity of impurities into the reduced iron. Reduced iron with a purity of 98.52% was obtained under the conditions of 10%, 10%, 2%, and 2% ratios of CaO, SiO2, MgO, and Al2O3, respectively, a hydrogen flow rate of 12 mL/min, and a temperature of 1400 °C; Lg L Mg, Lg L Al, Lg L Si, and Lg L Ca were 2.72, 2.41, 3.36, and 2.45, respectively (“L” stands for slag-to-metal ratio). The slag was mainly dominated by the silicate, and the iron was mainly lost in the form of mechanical inclusions in the slag. This study will enrich the basic theory of hydrogen ironmaking and is of great significance for the realization of carbon neutralization.

Granulated iron silicate slag, a by-product of pyrometallurgical copper extraction, has excellent properties for construction applications. Slag modification with CaO enhances the application properties regarding pozzolanic reactivity, potentially extending slag use in the future. The slags’ short-term leaching behavior has already been investigated with promising results, while the long-term leaching effects are less studied. Therefore, this study aims to determine the long-term leaching effects on CaO-modified iron silicate slags. The CaO-modifications were conducted during full-scale slag treatment operation. The slags were characterized and leached, and the remaining slags were investigated regarding the formation of secondary phases. The long-term leaching of main and trace elements was determined over 30 days using a dynamic leaching method corresponding to an extended time period. The leaching tests showed increased leaching of the main slag elements (Si, Ca). Zn and Cu showed peak leaching after four days of leaching, and the leaching of As and Sb decreased with the increasing CaO content in the samples. After dynamic leaching, secondary phases formed on the Cu-containing inclusions on the sample surfaces. Independent of the CaO content, the leaching of Cu was increased when subjected to external acidic and oxidating conditions using static pH titration at pH 5 in dilute nitric acid.

The zinc in the fayalite slag of copper smelters, in which Zn-containing raw materials are used, is mainly found to be in oxidic phases, such as glassy iron silicate. During the slag water granulation process, the molten slag is heated, whereby the granulated slag achieves varying granulation temperatures. Therefore, in this study, we aimed to characterize and assess the leaching behavior of a synthesized Fe-saturated (FeX,Zn(1−X))2SiO4 system to understand the dependance of the zinc leaching behavior on the parameters of the ZnO content (1–10 wt.%) and granulation temperature (1300 or 1400 °C). It was found that the Zn leaching increased with the increasing Zn content and granulation temperature, using both batch and static pH leaching methods. Zn leaching was further increased at pH 5 using diluted nitric acid under oxidation conditions. Among the oxides in the samples—fayalite, spinel, and glass—glass was found to contribute to Zn leaching, owing to its weathering during pH-titration.

The effect of coal ratio on the high-lead slag reduction was reported in this article. First, the phase diagrams of the PbOFeO- SiO2-2%CaO-10%ZnO slag system at various temperatures and coal ratios were thermodynamically constructed. Next, the density, the melting temperature, the viscosity, the chemical composition and the phase transformation of the reduced slag were investigated. The thermodynamic results indicated that the variation of coal ratio could affect the chemical composition of the reduced slag, which led the physical properties of the reduced slag to change further. The experimental results illustrated that the content of lead and copper in the reduced slag decreased, while the contents of iron, silicon, calcium and zinc in the reduced slag increased as the coal ratio increased, which led the density and viscosity of the reduced slag to decrease further. The melting temperature of the reduced slag increased sharply when the coal ratio varied in the range of 1.5% to 3%. The mineralogy of the reduced slag indicated that lead mainly existed in the reduced slag in the form of metallic lead, while the iron and zinc were mainly enriched in the reduced slag in the form of a silicate phase. The industrial verification test results demonstrated that the average recovery rate of the lead exceeded 96.0%, the average lead content in the reduced slag was below 2.0% and the average fume rate was approximately 12.0%. nema

In pyrometallurgy process involving drying, calcination and reductive smelting steps, Saprolite ore is subjected in an electric arc furnace to produce Fe–Ni alloy and Ni matte. To optimize the nickel smelting step, the slag consisted of MgO–SiO 2 –FeO and having a lower viscosity and high fluidity is required. In this study, a number of new slag samples with varied degree of compositions are manufactured and used to examine the effect of their viscosity on nickel dissolution. Further correlation between the slag basicity and FeO addition on the smelting was also tested and simulated using Fe–Ni alloy from saprolite ore. As per the observations, the nickel dissolution increases with the increased content of FeO at a certain degree of activity which in turn can cause oxidation of nickel during the process. The slags with the ratio of MgO/SiO 2  = 0.4–0.6, 30% fraction of FeO, and a viscosity of 1.8–1.06 poise in the olivine zone are found effective for the lowest dissolution rate of nickel with 0.021, 0.022, and 0.018 wt.%. The lowest dissolution rate is recorded for the slag with MgO/SiO 2 ratio about 0.6. These slags with controlled amount of constituents could be used to recover precious metal from nickel smelter at a lower dissolution rate and thereby allowing to reduce the waste of the metal during smelting process.