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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

Influence of limestone on the hydration of ternary slag cements

The hydration kinetics, microstructure and pore solution composition of ternary slag-limestone cement have been investigated. Commercial CEM I 52.5 R was blended with slag and limestone; maintaining a clinker to SCM ratio of 50:50 with up to 20% slag replaced by limestone. The sulphate content was maintained at 3% in all composite systems. Hydration was followed by a combination of isothermal calorimetry, chemical shrinkage, scanning electron microscopy, and thermogravimetric analysis. The hydration of slag was also followed by SEM image analysis and the QXRD/PONKCS method. The accuracy of the calibrated PONKCS phase was assessed on slag and corundum mixes of varying ratios, at different water/solid ratios. Thus, the method was used to analyse hydrated cement without dehydrating the specimens. The results show that the presence of limestone enhanced both clinker and slag hydration. The pore volume and pore solution chemistry were further examined to clarify the synergistic effects. The nucleation effects account for enhanced clinker hydration while the space available for hydrate growth plus the lowering of the aluminium concentration in the pore solution led to the improved slag hydration.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Inhibition mechanisms of steel slag on the early-age hydration of cement

Steel slag inhibits the early-age hydration of cement. However, its mechanism is still unclear. In this paper, the early-age hydration kinetics and the evolution of the solid phases, aqueous species and microstructures in a cement-steel slag composite binder are investigated to explore how steel slag inhibits the early-age hydration of cement. Two novel phenomena are found: (1) steel slag slows the depletion of gypsum and reduces the formation of ettringite, and (2) steel slag significantly inhibits the precipitation of CH and CSH. The results show that the addition of steel slag increases the Ca concentration in the pore solution, reduces the supersaturation of the pore solution with respect to CH and inhibits the nucleation and growth of CSH. Based on the above results, the retardation mechanisms of steel slag on the initial setting of cement paste are explained.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Experimental study of dissolution of minerals and CO{sub 2} sequestration in steel slag

Highlights: • CO{sub 2} sequestration potential of steel slag under aqueous medium without the usage of any additive chemicals. • Formation of residue and product layers on the surface of slag particles. • Stabilization of steel slags by carbonation process. •Determining the impact of carbonation of slag on environment. - Abstract: This study strives to achieve a substantial amount of steel slag carbonation without using any harmful chemicals. For this purpose, experiments were performed in an aqueous medium, in a semi-batch reactor, to investigate the effect of varying reaction conditions during the steel slag CO{sub 2} sequestration process. Further, studying the effect of dissolution on carbonation reactions and the mineralogical changes that subsequently occur within the slag helps provide insight into the parameters that ultimately have an impact on the carbonation rate as well the magnitude of the impact.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2019

Assessment of Physicochemical Properties of Electrical Arc Furnace Slag and Their Effects on Foamability

The composition of slags of an electric arc furnace (EAF) in a commercial melt shop was systematically analyzed with a focus on slag foaming. Basic behavior of FeO in an EAF slag was confirmed using fundamental thermodynamics. Monoxide ([Mg,Fe,Mn]O = M’O) and spinel ([Mg,Fe]Al{sub 2}O{sub 4}) phases in EAF slag were confirmed by X-ray diffraction analysis, and these results were interpreted in the context of equilibrium cooling calculation using FactSage™ software. Furthermore, the distribution of MgO with respect to the M’O-saturation limit at different basicity ratios (=CaO/SiO{sub 2}=C/S) and temperatures was evaluated. In particular, the relationship between MgO and FeO for C/S ratios ranging from 1.3 to 1.6 was considered with reference to phase equilibria. Foam height was affected by slag viscosity (η) and gas generation according to changes in C/S ratio and FeO content. Foaming index (Σ) decreased with the increasing C/S ratio and FeO content. The measured foam heights were relatively higher than the calculated values, and the result indicates that the effect of M’O on slag foaming in commercial process is remarkable. Therefore, slag chemistry should be optimized based on thermodynamic considerations and thermophysical properties to achieve good foaming characteristics.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Effect of blast furnace slag on self-healing of microcracks in cementitious materials

The physico-chemical process of self-healing in blast furnace slag cement paste was investigated in this paper. With a high slag content i.e., 66% in cement paste and saturated Ca(OH)₂ solution as activator, it was found that the reaction products formed in cracks are composed of C-S-H, ettringite, hydrogarnet and OH–hydrotalcite. The fraction of C-S-H in the reaction products is much larger than the other minerals. Large amount of ettringite formed in cracks indicates the leaching of SO₄⁻² ions from the bulk paste and consequently the recrystallization. Self-healing proceeds fast within 50 h and then slows down. According to thermodynamic modeling, when the newly formed reaction products are carbonated, the filling fraction of crack increases first and then decreases. Low soluble minerals such as silica gel, gibbsite and calcite are formed. Compared to Portland cement paste, the potential of self-healing in slag cement paste is higher when the percentage of slag is high. Highlights: • Self-healing reaction products in slag cement paste were characterized. • Self-healing reaction products formed in time were quantified with image analysis. • Self-healing in slag cement paste was simulated with a reactive transport model. • Effect of carbonation on self-healing was investigated by thermodynamic modeling. • Effect of slag on self-healing was discussed based on experiments and simulation.

36 MATERIALS SCIENCE↗
DOE OSTI2016

A Slag Management Toolset for Determining Optimal Coal Gasification Temperatures

Abstract Gasifier operation is an intricate process because of the complex relationship between slag chemistry and temperature, limitations of feedstock materials, and operational preference. High gasification temperatures increase refractory degradation, while low gasification temperatures can lead to slag buildup on the gasifier sidewall or exit, either of which are problematic during operation. Maximizing refractory service life and gasifier performance require finding an optimized operating temperature range which is a function of the coal slag chemistry and viscosity. Gasifier operators typically use a slag’s viscosity-temperature relationship and/or ash-fusion fluid temperature to determine the gasification temperature range. NETL has built a slag management toolset to determine the optimal temperature range for gasification of a carbon feedstock. This toolset is based on a viscosity database containing experimental data, and a number of models used to predict slag viscosity as a function of composition and temperature. Gasifier users typically have no scientific basis for selecting an operational temperature range for gasification, instead using experience to select operational conditions. The use of the toolset presented in this paper provides a basis for estimating or modifying carbon feedstock slags generated from ash impurities in carbon feedstock.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1996

Application of Two-Phase CFD to the Design and Analysis of a Subscale Motor Experiment to Evaluate Propellant Slag Production

The redesigned solid rocket motor (RSRM) Pressure Perturbation Investigation Team concluded that the cause of recent pressure spikes during both static and flight motor burns was the expulsion of molten aluminum oxide slag from a pool which collects in the aft end of the motor around the submerged nozzle nose during the last half of motor operation. It is suspected that some motors produce more slag than others due to differences in aluminum oxide agglomerate particle sizes which may relate to subtle differences in propellant ingredient characteristics such as particle size distribution, contaminants, or processing variations. In order to determine the effect of suspect propellant ingredient characteristics on the propensity for slag production in a real motor environment, a subscale motor experiment was designed. An existing 5 inch ballistic test motor was selected as the basic test vehicle due to low cost and quick turn around times. The standard converging/diverging nozzle was replaced with a submerged nozzle nose design to provide a positive trap for the slag which would increase both the quantity and repeatability of measured slag weights. Computational fluid dynamics (CFD) was used to assess a variety of submerged nose configurations to identify the design which possessed the best capability to reliably collect slag. CFD also was used to assure that the final selected nozzle design would result in flow field characteristics such as dividing streamline location, nose attach point, and separated flow structure which would have similtude with the RSRM submerged nozzle nose flow field. It also was decided to spin the 5 inch motor about its longitudinal axis to further enhance slag collection quantities. Again, CFD was used to select an appropriate spin rate along with other considerations, including the avoidance of burn rate enhancement from radial acceleration effects.

Whitesides, R. Harold↗
NASA NTRS1999

Predicting Slag Generation in Sub-Scale Test Motors Using a Neural Network

Generation of slag (aluminum oxide) is an important issue for the Reusable Solid Rocket Motor (RSRM). Thiokol performed testing to quantify the relationship between raw material variations and slag generation in solid propellants by testing sub-scale motors cast with propellant containing various combinations of aluminum fuel and ammonium perchlorate (AP) oxidizer particle sizes. The test data were analyzed using statistical methods and an artificial neural network. This paper primarily addresses the neural network results with some comparisons to the statistical results. The neural network showed that the particle sizes of both the aluminum and unground AP have a measurable effect on slag generation. The neural network analysis showed that aluminum particle size is the dominant driver in slag generation, about 40% more influential than AP. The network predictions of the amount of slag produced during firing of sub-scale motors were 16% better than the predictions of a statistically derived empirical equation. Another neural network successfully characterized the slag generated during full-scale motor tests. The success is attributable to the ability of neural networks to characterize multiple complex factors including interactions that affect slag generation.

Wiesenberg, Brent↗
DOE OSTI2017

The Influence of Phosphorous Additions on Phase Evolution in Molten Coal Slag

Carbon feedstocks used in power, chemical and metallurgical industries typically contain numerous minerals or impurities that liquefy during high temperature processing to form slag as a byproduct. Slags have many industrial applications, for example, as construction materials and for element recovery. In addition to other variables, the extent of slag utilization is dependent on its composition and post treatments. In this work, the influence of temperature and phosphorus additions on phase evolution in coal slag was investigated. Synthetic slag mixtures with varying AlPO<sub>4</sub> contents (0–14 wt%) were heated from 1380–1470 °C in air, then water-quenched to preserve the phases formed. SEM/EDS, XRF and XRD analyses were performed before/after testing to gain insight about slag chemistry and phases present. It was found that coal slag exhibited a large solubility of phosphorous, affecting morphology of mullite formed under the conditions studied. Results obtained and their significance are discussed.

Hawa, Hani↗
DOE OSTI2018

The Integration of Plant Sample Analysis, Laboratory Studies, and Thermodynamic Modeling to Predict Slag-Matte Equilibria in Nickel Sulfide Converting

The Kalgoorlie Nickel Smelter (KNS) produces low Fe, low Cu nickel matte in its Peirce–Smith converter operations. To inform process development in the plant, new fundamental data are required on the effect of CaO in slag on the distribution of arsenic between slag and matte. A combination of plant sample analysis, high-temperature laboratory experiments, and thermodynamic modeling was carried out to identify process conditions in the converter and to investigate the effect of slag composition on the chemical behavior of the system. The high-temperature experiments involved re-equilibration of industrial matte-slag-lime samples at 1498 K (1225 °C) and P(SO{sub 2}) = 0.12 atm on a magnetite/quartz substrate, rapid quenching in water, and direct measurement of phase compositions using electron probe X-ray microanalysis (EPMA) and laser ablation–inductively coupled plasma–mass spectrometry (LA-ICP-MS). A private thermodynamic database for the Ca-Cu-Fe-Mg-Ni-O-S-Si-(As) system was used together with the FactSage software package to assist in the analysis. Thermodynamic predictions combined with plant sample characterization and the present experimental data provide a quantitative basis for the analysis of the effect of CaO fluxing on the slag-matte thermochemistry during nickel sulfide converting, in particular on the spinel liquidus and the distribution of elements between slag and matte as a function of CaO addition.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Kinetic Investigations of SiMn Slags From Different Mn Sources

The kinetics of MnO and SiO 2 reduction were investigated for Silicomanganese (SiMn) slags using a Thermogravimetric analysis (TGA) between 1773 K and 1923 K (1500 °C and 1650 °C) under CO atmospheric pressure. The charge materials were based on Assmang ore and HC FeMn Slag. Rate models for MnO and SiO 2 reduction were applied to describe the metal-producing rates, as shown by the following equations: r MnO =k MnO ×A×(a MnO -((a Mn )/(K{sub T})))r SiO 2 =k SiO 2 ×A×(a SiO 2 -((a Si )/(K T ))).The results show that the choice of raw materials in the charge considerably affected the reduction rate of MnO and SiO 2 . The highest reduction rate was found to be from charges using HC FeMn slag. The difference in the driving forces was insignificant among the SiMn slags, and the similar slag viscosities could not explain the different reduction rates. Instead, the difference is attributed to small amounts of sulfur and the amount of iron in the charge. In addition, the rate models were applicable to describe the reduction of MnO and SiO 2 in SiMn slags.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Effect of Iron Redox Equilibrium on the Foaming Behavior of MgO-Saturated Slags

In this study, the foaming index of CaO-SiO{sub 2}-Fe{sub t}O and CaO-SiO{sub 2}-Fe{sub t}O-Al{sub 2}O{sub 3} slags saturated with MgO was measured to understand the relationship between their foaming behavior and physical properties. The foaming index of MgO-saturated slags increases with the Fe{sub t}O content due to the redox equilibrium of Fe{sub t}O. Experimental results indicated that MgO-saturated slag has relatively high ferric ion concentration, and the foaming index increases due to the effect of ferric ion. Therefore, the foaming behavior of MgO-saturated slag is more reasonably explained by considering the effect of ferric ion on the estimation of slag properties such as viscosity, surface tension, and density. Specifically, the estimation of slag viscosity was additionally verified by NBO/T, and this is experimentally obtained through Raman spectroscopy.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Viscosity of TiO{sub 2}-FeO-Ti{sub 2}O{sub 3}-SiO{sub 2}-MgO-CaO-Al{sub 2}O{sub 3} for High-Titania Slag Smelting Process

The present study demonstrates the dependence of viscosity on chemical composition and temperature of high-titania slag, a very important raw material for producing titanium dioxide. The results indicated that completely molten high-titania slag exhibits a viscosity of less than 1 dPa s with negligible dependence on temperature. However, it increases dramatically with decreasing temperature slightly below the critical temperature, i.e., the solidus temperature of the slag. Above the critical temperature, the slag samples displayed the same order of viscosity at 0.6 dPa s, regardless of their compositional variation. However, the FeO, CaO, and MgO were confirmed to decrease viscosity, while SiO{sub 2} and Ti{sub 2}O{sub 3} increase it. The apparent activation energy for viscosity-temperature relation and liquidus temperature based on experiments and thermodynamic calculations are also presented. Conclusively, the critical temperatures of the slags are on average 15 K below their corresponding calculated liquidus temperatures. The increase in FeO content was found to considerably lower the critical temperature, while the increase in both Ti{sub 2}O{sub 3} and TiO{sub 2} contents increases it. The main phases of the slag in solid state, as indicated by X-ray diffraction, are (Fe, Mg){sub x}Ti{sub y}O{sub 5} (x + y = 3, pseudobrookite) and rutile.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Wetting Behavior of TiO{sub 2} by Calcium Ferrite Slag at 1523 K

The wetting behaviors of a TiO{sub 2} substrate by calcium ferrite (CF) series slags were investigated using an improved sessile drop method at 1523 K (1250 °C). The initial contact angles were in the range 35 to 50 deg, the final equilibrium apparent contact angles were < 20 deg, and the spreading durations were in the range 75 to 180 seconds. The CF-TiO{sub 2} system showed reactive wetting, which was categorized into four dynamic stages. Stage I: physical spreading, stage II: slow linear spreading, stage III: fast linear spreading, and stage IV: equilibrium. Interfacial reactions yielded CaTiO{sub 3} during reactive spreading, thereby transitioning TiO{sub 2} wetting into CaTiO{sub 3} wetting and then forming Fe{sub 2}TiO{sub 5} and FeTiO{sub 3} owing to the excess Fe{sub 2}O{sub 3} and FeO that had accumulated in the interfacial zone. Although stage III spreading was faster than stage II spreading, adding MgO to the slag slowed stage III spreading. The interfacial microstructure of the residual slag was roughly divided into three layers owing to the different densities of the slag and solid products. The top layer was composed of CaTiO{sub 3} and Fe{sub 2}O{sub 3}, the middle one was composed of CaTiO{sub 3} and Fe{sub 2}TiO{sub 5}, and the bottom one was composed of Fe{sub 2}TiO{sub 5} and FeTiO{sub 3}. Adding TiO{sub 2} to the slag produced a dense CaTiO{sub 3}-containing interfacial layer, resulting in CF being detected in the residual slag.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Characterization and Recovery of Copper from Converter Copper Slag Via Smelting Separation

Converter copper slag can be viewed as an important secondary resource for valuable metals, considering its high commercial value. The current research investigates the recycling of copper by a combination of theoretical and experimental methods. Based on a modified Stokes equation, it was determined that copper droplets in the molten slag exhibited a low terminal settling velocity of 2.140 × 10{sup −6} m/s. The copper particles will collide with each other during settling, resulting in particle growth. The results from high temperature experimentation, scanning electron microscopy, and energy-dispersive spectroscopy confirm that in the absence of reducing agents, copper droplets are encased in magnetite to form composite ‘Cu droplet–magnetite’ particles. Other copper droplets adhere to magnetite particles which are suspended in the slag in a short-range-ordered array. The study also confirms that in the presence of increasing amounts of anthracite as a reducing agent, the magnetite content of the slag is progressively decreased and the recovery of copper from the slag is significantly improved. Based on the findings from this work, a new processing route is proposed to treat copper slag for the recovery of copper.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Molecular Dynamics Simulation on the Effect of MgO/Al{sub 2}O{sub 3} Ratio on Structure and Properties of Blast Furnace Slag Under Different Basicity Conditions

The SiO{sub 2}-Al{sub 2}O{sub 3}-CaO-MgO is the basic structural system of blast furnace slag and the composition directly affects the performance of the slag. Molecular dynamics simulations were carried out to analyze the local structure, structural unit, bond angle, transport properties, and enthalpy of the slag with the increase of MgO/Al{sub 2}O{sub 3} mass ratio under different basicity conditions. It was found that the change of MgO/Al{sub 2}O{sub 3} ratio does not affect the short-range order structure, but it will reduce the overall stability of the network structure. Through the analysis of the structural unit of the slag, it was found that the polymerization degree of the system decreases with the increase of MgO/Al{sub 2}O{sub 3} ratio, indicating that the complex network structure of the system is partially depolymerized. Besides, the self-diffusion coefficients of each ion were concluded and the magnitudes were observed to be in the following order: Mg{sup 2+}>Ca{sup 2+}>Al{sup 3+}>O{sup 2-}>Si{sup 4+}. The diffusivity of the slag increases with the increase of MgO/Al{sub 2}O{sub 3} ratio and the corresponding viscosity decreases. And the enthalpy of the slag is increased with the increase of MgO/Al{sub 2}O{sub 3} ratio or basicity, therefore the fuel consumption should also be properly adjusted during the operation of blast furnace to ensure the target temperature.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Oxygen Potential of High-Titania Slag from the Smelting Process of Ilmenite

Oxygen potential of TiO{sub 2}-FeO-Ti{sub 2}O{sub 3} ternary slags was determined by the electromotive force (EMF) method based on the solid electrolyte oxygen sensor at 2003 K (1730 °C). The effect of FeO content and Ti{sup 3+}/Ti{sup 4+} mass ratio on the oxygen potential of the high-titania slag was also studied. At a fixed Ti{sup 3+}/Ti{sup 4+} mass ratio of 3.11, the oxygen potential increased with increasing FeO content. Increase of Ti{sup 3+}/Ti{sup 4+} mass ratio from 2.29 to 3.60 caused a significant decrease in the oxygen potential of the slag. Comparing measured oxygen potential with the calculated values indicated that the oxygen potential of the slag might be determined by FeO/Fe equilibrium reaction rather than TiO{sub 2}/Ti{sub 2}O{sub 3} reaction. In addition, the experimentally measured oxygen potential values were modeled by multiple linear regression analysis, and a semi-empirical mathematical correlation was established between the oxygen potential and slag compositions. The iso-oxygen potential distribution diagram based on the mathematical model was obtained for the high-titania slag.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Phosphorus Removal from Si-Fe Alloy Using SiO{sub 2}-Al{sub 2}O{sub 3}-CaO Slag

Phosphorus removal from silicon using a combination of solvent and slag refining, with lower carbon footprint and lower energy requirement than the current industrial process, is investigated by evaluating the distribution of phosphorus between Si-Fe alloy and SiO{sub 2}-Al{sub 2}O{sub 3}-CaO slag. An alloy with the composition of silicon-20 wt pct iron was treated with a slag of CaO-Al{sub 2}O{sub 3}-SiO{sub 2} at 1600 °C. The effects of slag basicity and oxygen potential on the distribution of phosphorus were studied via changing the slag composition. The critical oxygen potential, at which the maximum removal of phosphorus is obtained, was calculated as 6.3 × 10{sup −18} atm. Normalized distribution and phosphate capacity values were calculated for each slag composition with the purpose of isolating the effect of basicity. In a separate experiment, calcium was also added to the alloy with the purpose of improving the removal efficiency of phosphorus. Results show that the addition of calcium can almost double the partition ratio of phosphorus. The removal rate of phosphorus was quantified via kinetics calculations, and the total mass-transfer rate of phosphorus was estimated to be 8.58 × 10{sup −7} cm/s.

36 MATERIALS SCIENCE↗