GB1580607A - Treatment of metallurgical slag - Google Patents

Treatment of metallurgical slag Download PDF

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Publication number
GB1580607A
GB1580607A GB2186578A GB2186578A GB1580607A GB 1580607 A GB1580607 A GB 1580607A GB 2186578 A GB2186578 A GB 2186578A GB 2186578 A GB2186578 A GB 2186578A GB 1580607 A GB1580607 A GB 1580607A
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slag
slags
phosphate
products
treatment
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    • CCHEMISTRY; METALLURGY
    • C05FERTILISERS; MANUFACTURE THEREOF
    • C05BPHOSPHATIC FERTILISERS
    • C05B5/00Thomas phosphate; Other slag phosphates
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B5/00Treatment of  metallurgical  slag ; Artificial stone from molten  metallurgical  slag 
    • C04B5/06Ingredients, other than water, added to the molten slag or to the granulating medium or before remelting; Treatment with gases or gas generating compounds, e.g. to obtain porous slag

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  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)

Description

(54) TREATMENT OF METALLURGICAL SLAG (71) I, FRANCIS GAGNERAUD, a French citizen, of Villa Montmorency, 6 Avenue des Tilleuls, 75016 Paris, France, do hereby declare the invention, for which I pray that a patent may be granted to me, and the method by which it is to be performed, to be particularly described in and by the following statement:- The present invention relates to the field of slags (which term as used herein includes drosses), obtained in the production and in the various kinds of treatment of iron, cast iron and steels as well as of non-ferrous metals. Most particularly, it concerns the use of novel compositions in modifying the physical and/or chemical properties of these slags by injection into the molten mass of the latter without external supply of heat.
It is known that the crystallised slags, arising in ferrous metallurgy and in the metallurgy of non-ferrous metals, have to undergo, after slow cooling, a comminution, achieved by crushing, when it is desired to obtain a material in pieces, or a more or less far-reaching grinding operation, when it is wished to reduce the material to powder of great fineness. These crushing and/or grinding operations require large consumption of energy per tonne of treated material and very heavy outlay in equipment and maintenance on account of the rapid wear of the active equipment parts.
In order to improve the susceptibility of the slags to fragmentation and/or fine grinding, after cooling, it has been advocated to inject into the slags in the molten state, while they are being poured from the casting-ladle, products of fine particle size distribution, capable of generating gases, which, remaining occluded in the particles of slag, give rise to the production of cellular of porous materials. It has been proposed for this purpose to use carbon black coke dust or, even better, compounds such as alkaline earth metal carbonates, as, for example, limestone, which, on thermal decomposition, cause an endothermic reaction with the molten slag and which, after decomposition, supply enriching elements for the slag, (cf. British Patent Specification No. 1,463,956).
It has now been found that it is possible to obtain, at the same time, expansion of the slags and a desirable modification of the physical and/or chemical properties of the latter, with maximum utilization of the perceptible heat of the molten mass at the instant, at which it comes out of the converters of the steel-works or of the blast furnaces, by means of the injection of poregenerating mixtures, specially designed and based on at least two components.
According to the invention, in a method of treating metallurgical slags, there is injected into the slag while the slag is in the molten state, a pulverulent pore-generating composition comprising a mixture of a carbonate component and a free carbon component.
The products of the mixture can be natural materials or industrially manufactured. It has, however, been found particularly advantageous to employ in the mixtures in question by-products, which are regarded, at present, as scrap and residues and are discarded as waste products.
Thus it is possible to replace the metal carbonates, synthetic or in the form of their calcareous ores or sands, by-products such as sterile material found in mines or quarries, rich in calcium carbonate, and holding combined water.
Similarly, regarding the free carbon component, it is advantageous to substitute for the coke dust, which represents a certain market value, blast furnace gas dusts, which are usually recovered in the dust-removal cyclones.
These dusts may contain from 10 to 30% of free carbon.
In determining the respective adequate proportions of each of the components in the compositions according to the invention, it is necessary to take into account the parts that can be played, particularly in the heat balance, by the ingredients added to the ferrous and other metallurgical slags. For example, it is known that the decomposition of carbonates, for example of alkaline earth metals, is endothermic; the cooling power, therefore, is raised on their injection into the molten slag. On the other hand, the oxidation of carbon is exothermic. For its part, the direct reduction of the iron oxides by carbon is endothermic, although the indidrect reduction of these same oxides by carbon monoxide takes place virtually without thermal exchange.It is thus possible to vary the type of foaming treatment with lowering of temperature, according to the nature and the ultimate uses of the slags, submitted to injection with the composition according to the invention.
This kind of juxtaposition of carbonate material and carbon material proves favourable, as it makes it possible to combine rapid liberation of CO2, arising from the thermal decomposition of carbonates and the delayed liberation of the CO+CO2 mixture, arising from the reduction of the iron oxides, contained in the steelworks slag, by the carbon of the carbon material. The cooling power of this mixture, required for obtaining stabilisation of the slag foam by increase of its viscosity before solidification, lies between those of the carbonate products and of the carbon products, used separately.
In practice, it has been possible to show in the course of industrial processes for expanding LD (Linz and Donnawitz, a pure oxygen refining process, first used at the works of this Austrian firm) steelworks slags and of phosphate slags that it was necessary to have liberation of available gas of at least 4 m3 per tonne of slag-the volume being measured in conditions of normal temperature and pressure-in order to obtain porous granulates, easy to crush and grind. This volume is attained on employing sufficient quantities of suitably composed mixtures and generally lying between 10 and 40 kg, most frequently between 20 and 30 kg, per tonne of slag to be treated. The composition is adjusted in relation to the thermal state of the slag, the different cooling powers of the components being taken into account.The abovementioned quantities are easy to inject and do not require employment of complex equipment.
For example, when a sterile mine material-particle diameter: 0 to 6 mm--arising in the magnetic enrichment of a calcareous iron ore and having the following composition (% by weight) is used: CaO 38 SiO2 15 CO2 25 Foe203 12 Awl203 3 combined H2O 4 23 kg of this carbonate sterile material have to be injected, approximately, per tonne of slag, in order to obtain the 4 m3 of gas required for expansion.
In the case of blast furnace gas dusts, the quantities required for obtaining the 4 m3 of expansion gas vary between 7 and 22 kg, approximately, per tonne of slag, according to the free carbon content of the said dusts.
As regards the respective quantities of carbonate products and of carbon products, they can vary between wide limits, such as: 10 to 90 kg of the former to from 90 to 10 kg of the latter, (for 100 kg of total mixture).
It is possible to add to the mixtures of the above-mentioned components other residues, which do not contain ingredients capable of liberating or forming gases.
Their role is to act as support material; i.e.
diluent or extender; particularly in view of the fineness of the gas dust particles.
Besides, certain residues can serve to introduce into the slag ingredients which contribute to the modification of certain physico-chemical properties.
In a first embodiment, corresponding the.
the case of non-phosphate steelworks slags of the LD type, intended, at least partly, for recycling in the ferro-metallurgical cycle, such supports can be advantageously made up of the steelworks slags themselves, having a fine particle size distribution. By "fine" particle size is meant from 1 to 6 mm, approximately.
Alternatively, when dealing with the treatment of phosphate slags intended for agriculture, it is possible to add to at least one of the components of the abovementioned mixtures sodium slags, arising in the desulphurisation of cast iron by means of sodium-based compounds, (sodium carbonate or hydroxide). It is known that these sodium slags, usually put on the slag dump, present difficult environmental and pollution problems, owing to the fact that they can be easily leached out, liberating aqueous solutions of sodium compounds.
An ingenious solution has already been advocated to use these residues as sources of alkaline agents for the heat treatment of natural phosphates at a temperature of at least 1000 C for the purpose of obtaining fertiliser products, (French published Patent Application No. 2,368,451). The invention points the way to another useful outlet for this scrap. In fact, the sodium supply of these sodium slags makes it possible to increase the citric solubility of the calcium phosphate, contained in the phosphate slag, yielding sodium/calcium phosphates. This property can be particularly appreciated if, apart from the slags, natural phosphates or similar enriching products are also injected as support material.In practice, it is possible to inject, apart from the mixtures of carbonate products and of carbon products, at least 10 kg of sodium drosses per tonne of phosphate slag, thus supplying from 2 to 3 kg of Na2O.
Thus, thanks to the improvements resulting from the invention, it becomes possible to remove, and increase the value of, part of the mining and metallurgical scrap and, at the same time, to produce an expansion and/or an enrichment of the slags in conditions at least as favourable as those observed during the injection of materials, the market value of which is higher, such as the alkaline earth metal carbonates and coke dust or lean coal.
The cellular products, obtained from the invention, after optional comminution to suitable particle size distribution, can find a multiplicity of uses in construction and building, water treatment (filter-beds), the manufacture of abrasive materials, use as road granulates or, certainly, as fertilisers and basic soil conditioners.
The following examples show the manner in which the process can be carried out: Example 1 Treatment has been given to a nonphosphate steelworks slag of the LD type, having the following chemical composition (% by weight): SiO2 11to16 Al2O3 I CaO 42 to 49 MgO 2 to 7 total Fe 14 to 30 Mn 3 to 8 P205 I to 2 S 0.1toO.3 For the treatment, a pulverulent mixture, (average particle diameter of from 2 to 4 mm, approximately), of 9.5 kg of blast furnace gas dust, containing 12% of carbon and 11.5 kg of sterile mining material of composition (% by weight):: CaO 33 SiO2 15 Fe2O3 12 Al203 3 CO2 25 combined H2O 4 was injected into the slag (1000 kg), being poured in the molten state at about 1450"C from the ladle into the cooling-pit.
In this way, a cellular material of apparent density less than 1000 kg/m3, i.e. a third to a fourth of the specific gravity of the starting slag, was obtained in the cooling-pit. The porous material was very easy to grind, leading to substantial saving in energy. Similarly good results were obtained with fine calcareous quarry sand, containing about 40 /n of CO2, instead of the above sterile mining material.
It should be observed that the use of these materials, hitherto regarded as undesirable waste-products, is very beneficial to the environment and more economical than the use of known poregenerating materials, such as simple or mixed carbonates, natural or synthetic.
Example 2 A phosphate steel slag, (Bessemer or similar basic type), having the composition (% by weight): SiO2 5 Al203 0.5 CaO 49 MgO 2 Total Fe 15 Mn 2 P2Os 16 was treated in the same way as in Example 1, (injection by pouring from a ladle into the molten slag), with a pulverulent mixture, (average particle diameter: from 1.5 to 2.5 mm), of 20 kg calcareous quarry sand, containing 35% of CO2, gas dust, containing 12% of C (50/50) and 10 kg of sodium slag from the desulphurisation of cast iron. This type of mixture was injected into a stream of slag, at the rate of 30 kg per 1000 kg of slag and generated about 4mof expansion gas.
This treatment, which can be applied to a wide range of phosphate slags, (from 6 to 22% of P2O) yields a porous and friable slag and makes it possible to increase the citric solubility of the phosphate ions, contained in the phosphate slag, rendering the formation of compounds such as: 2P205 . 2CaO . Na2O at the treatment temperature of about 1500"C easier.
WHAT WE CLAIM IS: 1. A method of treating metallurgical slags wherein there is injected into the slag while the slag is in the molten state, a pulverulent pore-generating composition comprising a mixture of a carbonate component and a free carbon component.
2. A method according to Claim 1, wherein the injection occurs while the slag
**WARNING** end of DESC field may overlap start of CLMS **.

Claims (13)

**WARNING** start of CLMS field may overlap end of DESC **. supply of these sodium slags makes it possible to increase the citric solubility of the calcium phosphate, contained in the phosphate slag, yielding sodium/calcium phosphates. This property can be particularly appreciated if, apart from the slags, natural phosphates or similar enriching products are also injected as support material. In practice, it is possible to inject, apart from the mixtures of carbonate products and of carbon products, at least 10 kg of sodium drosses per tonne of phosphate slag, thus supplying from 2 to 3 kg of Na2O. Thus, thanks to the improvements resulting from the invention, it becomes possible to remove, and increase the value of, part of the mining and metallurgical scrap and, at the same time, to produce an expansion and/or an enrichment of the slags in conditions at least as favourable as those observed during the injection of materials, the market value of which is higher, such as the alkaline earth metal carbonates and coke dust or lean coal. The cellular products, obtained from the invention, after optional comminution to suitable particle size distribution, can find a multiplicity of uses in construction and building, water treatment (filter-beds), the manufacture of abrasive materials, use as road granulates or, certainly, as fertilisers and basic soil conditioners. The following examples show the manner in which the process can be carried out: Example 1 Treatment has been given to a nonphosphate steelworks slag of the LD type, having the following chemical composition (% by weight): SiO2 11to16 Al2O3 I CaO 42 to 49 MgO 2 to 7 total Fe 14 to 30 Mn 3 to 8 P205 I to 2 S 0.1toO.3 For the treatment, a pulverulent mixture, (average particle diameter of from 2 to 4 mm, approximately), of 9.5 kg of blast furnace gas dust, containing 12% of carbon and 11.5 kg of sterile mining material of composition (% by weight):: CaO 33 SiO2 15 Fe2O3 12 Al203 3 CO2 25 combined H2O 4 was injected into the slag (1000 kg), being poured in the molten state at about 1450"C from the ladle into the cooling-pit. In this way, a cellular material of apparent density less than 1000 kg/m3, i.e. a third to a fourth of the specific gravity of the starting slag, was obtained in the cooling-pit. The porous material was very easy to grind, leading to substantial saving in energy. Similarly good results were obtained with fine calcareous quarry sand, containing about 40 /n of CO2, instead of the above sterile mining material. It should be observed that the use of these materials, hitherto regarded as undesirable waste-products, is very beneficial to the environment and more economical than the use of known poregenerating materials, such as simple or mixed carbonates, natural or synthetic. Example 2 A phosphate steel slag, (Bessemer or similar basic type), having the composition (% by weight): SiO2 5 Al203 0.5 CaO 49 MgO 2 Total Fe 15 Mn 2 P2Os 16 was treated in the same way as in Example 1, (injection by pouring from a ladle into the molten slag), with a pulverulent mixture, (average particle diameter: from 1.5 to 2.5 mm), of 20 kg calcareous quarry sand, containing 35% of CO2, gas dust, containing 12% of C (50/50) and 10 kg of sodium slag from the desulphurisation of cast iron. This type of mixture was injected into a stream of slag, at the rate of 30 kg per 1000 kg of slag and generated about 4mof expansion gas. This treatment, which can be applied to a wide range of phosphate slags, (from 6 to 22% of P2O) yields a porous and friable slag and makes it possible to increase the citric solubility of the phosphate ions, contained in the phosphate slag, rendering the formation of compounds such as: 2P205 . 2CaO . Na2O at the treatment temperature of about 1500"C easier. WHAT WE CLAIM IS:
1. A method of treating metallurgical slags wherein there is injected into the slag while the slag is in the molten state, a pulverulent pore-generating composition comprising a mixture of a carbonate component and a free carbon component.
2. A method according to Claim 1, wherein the injection occurs while the slag
is being poured between a casting-ladle and a cooling-pit.
3. A method according to Claim I or Claim 2, wherein the composition is used in a proportion with respect to the slag such that liberation of gas within the slag of at least 4 m3 per tonne of slag is obtained.
4. A method according to any one of the preceding claims, wherein the total quantity of the composition used lies between 10 and 40 kg per tonne of slag.
5. A method according to any one of the preceding claims, characterized in that the carbonate component is a sterile material found in mines or quarries, rich in calcium carbonate, and containing combined water.
6. A method according to any one of the preceding claims, characterized in that the free carbon component is a blast furnace gas dust.
7. A method according to any one of the preceding claims, characterized in that the pulverulent mixture has a particle diameter of between 0 and 6 mm.
8. A method according to any one of the preceding claims, characterized in that the mixture is combined with a powder support material.
9. A method according to Claim 8, characterized in that the support material is an inert material consisting of a steelworks slag of fine (as hereinbefore defined) particle size distribution, whereby the slags treated with the composition are capable of being recycled for the agglomeration of the ores before treatment in the blast furnace.
10. A method according to Claim 8, characterized in that the support material consists of sodium slags, arising from the desulphurisation of cast and of natural phosphates, whereby the treated phosphate slags intended for use as fertilizer products have increased solubility.
Il. A method according to Claim 1, substantially as described with reference to any one of the examples.
12. A slag which has been treated by a method according to any one of the preceding claims.
13. A product formed by comminuting a slag according to Claim 12.
GB2186578A 1978-05-24 1978-05-24 Treatment of metallurgical slag Expired GB1580607A (en)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0579309A2 (en) * 1992-07-14 1994-01-19 PELT & HOOYKAAS B.V. Method for preparing a cement base material, and cement composition containing this base material

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0579309A2 (en) * 1992-07-14 1994-01-19 PELT & HOOYKAAS B.V. Method for preparing a cement base material, and cement composition containing this base material
EP0579309A3 (en) * 1992-07-14 1994-11-23 Pelt & Hooykaas Method for preparing a cement base material, and cement composition containing this base material.
US5395443A (en) * 1992-07-14 1995-03-07 Pelt & Hooykass B.V. Method for preparing a cement base material, together with a cement composition containing this base material

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