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At least 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Characterization of Roughness, Porosity and Thermal Resistances of Continuous Casting Mold Slag Layers Devitrified and Crystallized in Laboratory

This paper presents an experimental investigation about the variation, with temperature, of surface roughness, porosity, degree of crystallization and microstructure, occurring in solid layers of a commercial mold powder slag used for casting medium carbon steel thin slabs. Characterization is done with samples devitrified and crystallized at 698 K, 823 K, 898 K and 973 K (425 °C, 550 °C, 625 °C and 700 °C) for 10,800 seconds, in the furnace of a high-temperature confocal laser scanning microscope. As well as, with slag disks devitrified non-isothermally in a heat flow apparatus based on the application of Fourier's law in steady state conditions, where the high temperature surface is maintained at selected values, between 927 K and 1241 K (654 °C and 968 °C). Surface roughness and porosity determinations are performed by image analysis of confocal laser scanning and scanning electron micrographs, respectively. For the time considered and temperatures ≥ 823 K (550 °C) the slag crystallizes completely, and variations of roughness and porosity with temperature are associated with changes in size and packing of the primary crystalline-phase grains. Crystallization induced porosity is significant and causes slag layer expansion. Hence crystallization does not lead to gap formation with a neighboring surface (e.g., mold wall) by shrinkage. Instead, surface separation arises from development of roughness, and measurements with the heat flow apparatus confirm that interfacial thermal resistance between a slag layer and a metallic wall can be estimated from the sum of the means of maximum peak to valley height of their surfaces. Furthermore, the results establish that slag layers roughness and porosity increase with temperature and reveal effective thermal conductivities in the range of ~ 0.3 to ~ 0.5 W/m K. Low effective thermal conductivities must be a consequence of porous bands, whose porosity depends on temperature and reaches values as high as ~ 0.20 and ~ 0.50.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Cationic Effect of Ferrous Ions on Sulfide Capacity of CaO-Fe{sub t}O-Al{sub 2}O{sub 3}-SiO{sub 2} Slag System

The cationic effect of ferrous ions on the sulfide capacity of CaO-Fe{sub t}O-Al{sub 2}O{sub 3}-SiO{sub 2} slags was studied from the viewpoint of the ionic structure in the slag using micro-Raman spectroscopy. In the cation-excess region (M{sup 2+}/2(Fe{sup 3+} + Al{sup 3+}) > 1.0), the sulfide capacity was directly proportional to the basicity of the slags, owing to the S{sup 2−} stabilizing effect of excess cations. However, in the cation-deficient region (M{sup 2+}/2(Fe{sup 3+} + Al{sup 3+}) < 1.0), the sulfide capacity was independent of the basicity of the slags owing to the deficiency of cations required for charge compensation with Al{sup 3+} and Fe{sup 3+}. The cation-substitution effect on the sulfide capacity of the CaO-rich slags (Fe{sub t}O/(Fe{sub t}O + CaO < 0.5) exhibited a linear relationship with the Fe{sup 2+} content because Fe{sup 2+} had a stronger affinity with S{sup 2−} compared to that with Ca{sup 2+}. However, in the Fe{sub t}O-rich slags (Fe{sub t}O/(Fe{sub t}O + CaO > 0.5), the sulfide capacity decreased with the increase of the Fe{sup 2+} content owing to the Q{sup n} unit affinity of the Fe{sup 2+} ion. The sulfide capacity was determined by the competition between the Q{sup n} unit affinity and stability of the S{sup 2−} ion, depending on the type of cation. Therefore, the partial covalent bonding between the M{sup 2+} cations (M: Ca, Fe) and aluminosilicate affected the ionic interactions with the S{sup 2−} ions.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Electromagnetic Wave-Absorbing Properties of Steel Slag

This research explores the electromagnetic radiation protection function of steel slag for use as a building material. Scanning electron microscopy, x-ray diffraction, x-ray photoelectron spectroscopy and Mössbauer spectroscopy were used to analyze the chemical composition and mineralogical phase of steel slag powder. Electromagnetic parameters of the samples were analyzed and discussed in detail for the frequency range of 1-18 GHz. We found that steel slag had the electromagnetic wave-absorbing property due to electric components (such as FeO and carbon powder) and magnetic components [such as magnetite (Fe{sub 3}O{sub 4}) and hematite (α-Fe{sub 2}O{sub 3})]; electric loss was far greater than magnetic loss. With the increasing milling time, the electric and magnetic properties were increased. The calculated reflectivity curve of steel slag powder epoxide resin–matrix composite at a thickness of 10 mm had several interference peaks, and the absorbing properties increased gradually with increasing frequency. Moreover, the minimum reflectivity was − 21 dB (Decibel) at 13 GHz (Gigahertz). The steel slag powder cement-based composite showed electromagnetic wave-absorbing properties at 10-18 GHz, and the greatest absorption of the 25 mm sample reached 11.5 dB; therefore, the steel slag shows promise as a building material for electromagnetic protection.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Hydration of potassium citrate-activated BOF slag

Basic Oxygen Furnace (BOF) slag is currently utilized with low-grade applications or landfilled. Here, we investigate a novel route to upgrade BOF slag to a high-performance binder by chemical activation with tri-potassium citrate. The impact of tri-potassium citrate on hydration and phase assemblage of BOF slag is analyzed with a multi-technique approach. Results reveal that the addition of tri-potassium citrate considerably enhances the reactivity of brownmillerite and accelerates the hydration of belite at early ages. The majority of brownmillerite hydrates within 24 h, and the reaction kinetics is controlled by the activator dosage. The main products of BOF slag hydration are siliceous hydrogarnet and C-S-H gel. Acting as a strong water reducer, tri-potassium citrate enables the manufacture of slag pastes with high compressive strength (up to 75 MPa at 28 days) and low porosity. Leaching of heavy metals from the slag pastes fulfills the Dutch Soil Quality Decree limits.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Rapid Separation of Copper Phase and Iron-Rich Phase From Copper Slag at Low Temperature in a Super-Gravity Field

A novel approach for quickly separating a metal copper phase and iron-rich phase from copper slag at low temperature is proposed based on a super-gravity method. The morphology and mineral evolution of the copper slag with increasing temperature were studied using in situ high-temperature confocal laser scanning microscopy and ex situ scanning electron microscopy and X-ray diffraction methods. Fe{sub 3}O{sub 4} particles dispersed among the copper slag were transformed into FeO by adding an appropriate amount of carbon as a reducing agent, forming the slag melt with SiO{sub 2} at low temperature and assisting separation of the copper phase from the slag. Consequently, in a super-gravity field, the metallic copper and copper matte were concentrated as the copper phase along the super-gravity direction, whereas the iron-rich slag migrated in the opposite direction and was quickly separated from the copper phase. Increasing the gravity coefficient (G) significantly enhanced the separation efficiency. After super-gravity separation at G = 1000 and 1473 K (1200 °C) for 3 minutes, the mass fraction of Cu in the separated copper phase reached 86.11 wt pct, while that in the separated iron-rich phase was reduced to 0.105 wt pct. The recovery ratio of Cu in the copper phase was as high as up to 97.47 pct.

36 MATERIALS SCIENCE↗
DOE OSTI2022

ETF Grout Expansion: Effects of Different Slags and Struvite Precipitation Protocols (Stirring Time)

The ETF ammonia tolerant grout waste form was developed by the Vitreous State Laboratory (VSL) to stabilize ammonium and thereby prevent emission of ammonia vapor during solidification of an ammonium-rich, concentrated sodium sulfate aqueous waste stream generated at the Hanford Effluent Treatment Facility (ETF). VSL personnel did not observe expansion in samples prepared during the waste form development work. However, Savannah River National Laboratory (SRNL) personnel detected expansion, in a few ETF grout samples, up to ~ 20 percent vertical expansion, while preforming work scope to evaluate the effect of ETF brine compositional ranges on the precipitation and solidification processes. The initial work requests can be found in Washington River Protection Services (WRPS) Statement of Work (SOW, Requisitions #: 339922 Revisions 0 and 1, March 11, 2021, and November 2021, respectively. As a result of the waste form expansion observed by SRNL, additional evaluation was requested by WRPS SOW Requisitions #: 356730 Revision 0 and Revision 1, February 1, 2022, and July 11, 2022, respectively. The goal of these requests was to determine whether differences in the slags and / or in sample preparation protocols used by VSL and SRNL were the cause of the expansion observed in the SRNL samples. G. Chen, WRPS, arranged a materials exchange between VSL and SRNL and coordinated the VSL protocol(s) for grouting and curing 1L batches of Base Case ETF base case simulant. Materials were exchanged between VSL and SRNL. Both laboratories performed the VSL struvite precipitation-solidification protocol and cured samples for at least 28 days. Differences in VSL and SRNL slag compositions, mineralogy and particle size results in themselves or combined were determined to not be the cause of the expansion because all samples expanded regardless of whether the VSL or SRNL slags were used. The fundamental cause of the observed expansion could not be attributed to minor variations in the following: 1) chemistry of the slag and other reagents, 2) container wall thickness, 3) ambient bench top curing conditions at VSL and SRNL, 4) pH adjustments to 7 ± a few tenths of unit, nor 5) stirring time between the precipitation and solidification process steps. Additional observations include: grout samples prepared with VSL slag expanded less than those prepared with the SRNL slag and, based on a very limited sample set, some samples stirred for longer times expanded less than those stirred for 20 minutes.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS1977

Velocity and temperature distributions of coal-slag layers on magnetohydrodynamic generators walls

Approximate analytical expressions are derived for the velocity and temperature distributions in steady state coal slag deposits flowing over MHD generator walls. Effects of slag condensation and Joule heating are included in the analysis. The transport conditions and the slag temperature at the slag-gas interface are taken to be known parameters in the formulation. They are assumed to have been predetermined either experimentally or from the slag properties and the gas dynamic calculations of the free stream flow. The analysis assumes a power law velocity profile for the slag and accounts for the coupling between the energy and momentum conservation equations. Comparisons are made with the more exact numerical solutions to verify the accuracy of the results.

Pian, C. C. P.↗
NASA NTRS1995

Effects of Slag Ejection on Solid Rocket Motor Performance

In past firings of the Reusable Solid Rocket Motor (RSRM) both static test and flight motors have shown small pressure perturbations occurring primarily between 65 and 80 seconds. A joint NASA/Thiokol team investigation concluded that the cause of the pressure perturbations was the periodic ingestion and ejection of molten aluminum oxide slag from the cavity around the submerged nozzle nose which tends to trap and collect individual aluminum oxide droplets from the approach flow. The conclusions of the team were supported by numerous data and observations from special tests including high speed photographic films, real time radiography, plume calorimeters, accelerometers, strain gauges, nozzle TVC system force gauges, and motor pressure and thrust data. A simplistic slag ballistics model was formulated to relate a given pressure perturbation to a required slag quantity. Also, a cold flow model using air and water was developed to provide data on the relationship between the slag flow rate and the chamber pressure increase. Both the motor and the cold flow model exhibited low frequency oscillations in conjunction with periods of slag ejection. Motor and model frequencies were related to scaling parameters. The data indicate that there is a periodicity to the slag entrainment and ejection phenomena which is possibly related to organized oscillations from instabilities in the dividing streamline shear layer which impinges on the underneath surface of the nozzle.

Whitesides, R. Harold↗
DOE OSTI2017

Model Implementation of Boron Removal Using CaCl{sub 2}-CaO-SiO{sub 2} Slag System for Solar-Grade Silicon

A new CaCl{sub 2}-CaO-SiO{sub 2} slag system was recently proposed to remove boron from metallurgy-grade silicon by oxidized chlorination and evaporation. To further investigate the boron transformation process at a high temperature, a model implementation to present the transfer of boron from molten silicon to the gas phase via slag is introduced. Heat transfer, fluid flow, the chemical reactions at the interface and surface, the mass transfer and diffusion of boron in the molten silicon and slag, and the evaporation of BOCl and CaCl{sub 2} were coupled in this model. After the confirmation of the thermal field, other critical parameters, including the boron partition ratios (L{sub B}) for this slag from 1723 K to 1823 K (1450 °C to 1550 °C), the thicknesses of the velocity boundary layer at the surface and interface, the mass transfer coefficients of the boundary layer at the surface and interface, and partial pressure of BOCl in the gas phase were analyzed to determine the rate-limiting step. To verify this model implementation, boron removal experiments were carried out at various temperatures and with various initial mass ratios of slag to silicon (μ). The evaporation rate of CaCl{sub 2} was also measured by thermogravimetry analysis (TGA).

36 MATERIALS SCIENCE↗
DOE OSTI2018

Mathematical Investigation of Fluid Flow, Mass Transfer, and Slag-steel Interfacial Behavior in Gas-stirred Ladles

In this study, the Euler-Euler and Euler-Lagrange modeling approaches were applied to simulate the multiphase flow in the water model and gas-stirred ladle systems. Detailed comparisons of the computational and experimental results were performed to establish which approach is more accurate for predicting the gas-liquid multiphase flow phenomena. It was demonstrated that the Euler-Lagrange approach is more accurate than the Euler-Euler approach. The Euler-Lagrange approach was applied to study the effects of the free surface setup, injected bubble size, gas flow rate, and slag layer thickness on the slag-steel interaction and mass transfer behavior. Detailed discussions on the flat/non-flat free surface assumption were provided. Significant inaccuracies in the prediction of the surface fluid flow characteristics were found when the flat free surface was assumed. The variations in the main controlling parameters (bubble size, gas flow rate, and slag layer thickness) and their potential impact on the multiphase fluid flow and mass transfer characteristics (turbulent intensity, mass transfer rate, slag-steel interfacial area, flow patterns, etc.,) in gas-stirred ladles were quantitatively determined to ensure the proper increase in the ladle refining efficiency. It was revealed that by injecting finer bubbles as well as by properly increasing the gas flow rate and the slag layer thickness, the ladle refining efficiency can be enhanced significantly.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Wetting Behavior of Calcium Ferrite Slags on Cristobalite Substrates

Calcium ferrite (CF) is a significant intermediate adhesive phase in high-basicity sinters. The wettability between calcium ferrite (CF) and gangue plays an important role in the assimilation process. The wettability of CF-based slags, in which a constant amount (2 mass pct.) of Al{sub 2}O{sub 3}, MgO, SiO{sub 2}, and TiO{sub 2} was added, on solid SiO{sub 2} (cristobalite) substrates at 1523 K (1250 °C) was investigated. The interfacial microstructure and spreading mechanisms were discussed for each sample. All the tested slag samples exhibited good wettability on the SiO{sub 2} substrate. The initial apparent contact angles were in the range of 20 to 50 deg, while the final apparent contact angles were ~ 5 deg. The wetting process could be divided into three stages on the basis of the change in diameter, namely the “linear spreading” stage, “spreading rate reduction” stage, and “wetting equilibrium” stage. It was found that the CF-SiO{sub 2} wetting system exhibits dissolutive wetting and the dissolution of SiO{sub 2} into slag influences its spreading process. The spreading rate increases with a decrease in the ratio of viscosity to interfacial tension, which is a result of the addition of Al{sub 2}O{sub 3}, MgO, SiO{sub 2}, and TiO{sub 2}. After cooling, a deep corrosion pit was formed in the substrate and a diffusion layer was generated in front of the residual slag zone; further, some SiO{sub 2} and Fe{sub 2}O{sub 3} solid solutions precipitated in the slag.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Mechanism of Selenium Loss in Copper Slag

During smelting of copper sulfide concentrate, selenium is distributed between silica-saturated iron-silicate slag and copper-iron sulfide matte. The recovery coefficients of selenium between slag and matte were determined as a function of the initial concentration of selenium at 1523 K (1250 °C) under an inert atmosphere in a vertical tubular furnace. The initial concentration of selenium was varied by the addition of metallic selenium as well as selenium dioxide to the mixture of slag and matte. Analysis of the results indicated high affinity of selenium for matte. The apparent loss of selenium with the slag was attributed to the presence of selenium-enriched matte particles entrapped in the slag, rather than dissolved SeO{sub 2}. The mechanisms proposed by previous investigators were discussed and also compared with the results of the present investigation.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Interactions of Alumina-Based and Magnesia-Based Refractories with Iron Melts and Slags: A Review

A novel flash ironmaking technology (FIT) based on the direct reduction of iron ore concentrate with a reductant gas (such as hydrogen, natural gas, coal gas, or a combination thereof) in a flash furnace is being developed at the University of Utah. This technology which is undergoing large-scale laboratory testing aims at overcoming the limitations of blast furnace ironmaking by bypassing the problematic pelletization/sintering and cokemaking steps.[1–5] Refractory selection is expected to play an important step in the development of FIT and its proposed scale-up. For nominating an appropriate refractory for the FIT, understanding the interactions of candidate refractories with iron/iron oxide and slags under H{sub 2}/CO/CO{sub 2}/H{sub 2}O environments is necessary. This work is undertaken to review the existing literature on the interactions of important refractories with iron melts and relevant slags with an emphasis on two of the most commonly used refractories in ironmaking and steelmaking applications: the alumina-based refractories (used widely in blast furnace operations) and the magnesia-based refractories (used extensively in primary as well as secondary steelmaking). First, a comprehensive review on the interactions of alumina-based refractories with iron melts and slags has been done. Next the existing literature on the interactions of magnesia-based refractories with iron melts and relevant slags has been reviewed. Summaries have been included after each section and sub-section along with comments and critical insights from the authors. Finally, in the concluding remarks the differences in operating conditions between existing iron and steelmaking practices and the novel FIT have been highlighted. On the basis of these differences, it has been argued that the results and conclusions available from previous studies on refractory–metal–slag interactions are of little significance to flash ironmaking. Thus, there exists a need to carry out laboratory experiments for evaluating refractory performance in flash ironmaking under conditions relevant to the current process (FIT).

36 MATERIALS SCIENCE↗
DOE OSTI2018

Rheological Transitions of the Solid-Bearing Slag During Cooling Process

The viscosity of basic oxygen furnace slag modified by the addition of Al{sub 2}O{sub 3}, SiO{sub 2}, and Na{sub 2}O was measured via a rotational-type rheometer. The experiment was performed under both continuous cooling condition (5 °C/min) at a constant rotational speed (30 rpm) and isothermal condition at various rotational speeds (between 2 and 120 rpm). The present work suggests that during cooling from liquid to solid, the slag successively undergoes Newtonian regime, shear thinning (time depedent) and thixotropy with a time-dependent apparent yield stress. The corresponding slag microstructure is (1) a fully liquid or partially liquid slag with negligible crystal–crystal interaction in the Newtonian regime, (2) a liquid slag with crystal aggregates/clusters in the shear thinning regime and (3) a skeletal solid network in the regime of thixotropy with a certain level of apparent yield stress.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Effect of Direct Reduced Iron (DRI) on Dephosphorization of Molten Steel by Electric Arc Furnace Slag

We investigated the effect of direct reduced iron (DRI) addition on dephosphorization of molten steel by electric arc furnace (EAF) slag at 1823 K (1550 °C). Various phenomena such as CO gas evolution and slagmaking by gangue oxides in DRI were experimentally observed at each reaction step. Thermodynamic behaviors of phosphorus, oxygen, and carbon were strongly dependent on DRI content. Basicity, which is the thermodynamic driving force of dephosphorization, decreased with the increasing DRI content because SiO{sub 2} concentration in the slag was proportional to DRI addition. The excess free energy of P{sub 2}O{sub 5} increased with the increasing SiO{sub 2} content in slag. A higher DRI content made dephosphorization difficult by decreasing the basicity and stability of P{sub 2}O{sub 5} in the slag. Therefore, when using DRI in EAF process, it is very important to control the basicity of slag.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Kinetic Modeling of the Silicothermic Reduction of Manganese Oxide from Slag

A model was developed to describe the mixed rate control kinetics in systems with MnO-SiO{sub 2}-CaO-Al{sub 2}O{sub 3} slags and Fe-Si metal droplets. During the reaction of Fe-Si droplets and slag, Mn{sup 2+} transport was found to be part of controlling the system but could not sufficiently describe all initial conditions (chiefly, changes to initial silicon content). The current model describes the kinetics of the stated system and offers answers to the question of rate control; the model has been fitted to nine datasets of varying initial conditions including initial [Si], initial (MnO), initial droplet size, and reaction temperature. The fitted mass transfer coefficients for metal and slag were 2.3 × 10{sup −4} and 6.7 × 10{sup −4} m/s, respectively; these values are constant across the nine datasets. Previous claims about the efficiency of silicon usage in reducing manganese have been modified; it appears that the formation of silica is favored throughout the reaction, but that the formation of a silicon monoxide gas layer on the metal surface dramatically impacts the rate of reaction. As a measure of overall fit of the model, the average of the root-mean-square errors for all datasets is 14 pct. Mass transport in slag is twice as influential on rate control as the metal phase. The simultaneous transport of both Mn{sup 2+} and silicate dimers controls mass transport in the slag. Both [Si] and [Mn] can control from the metal side but are dependent on the initial conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Physicochemical Properties of the Molten Iron-Rich Slags Related to the Copper Recovery

The properties of a molten slag play an important role in the separation of the slag from the matte during copper smelting. In this study, the viscosity, electrical conductivity, density, and surface tension of molten FeO{sub t}-SiO{sub 2}-CaO-based slags were measured, and the effects of the common constituents, such as CaO, Fe{sub 3}O{sub 4}, and Cu{sub 2}O, on various properties were investigated. The primary phases in the molten slags which are suitable for the copper recovery process were obtained, and they mainly correspond to fayalite and tridymite. The comparison of the static settling properties of molten industrial copper slag before and after modification is also discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Improving the Modeling of Slag and Steel Bath Chemistry in an Electric Arc Furnace Process Model

An improvement to the thermochemical module of the electric arc furnace (EAF) process model developed by Meier based on the work of Logar, Dovžan, and Škrjanc is presented. Different models for the calculation of activities in melt and slag are implemented, and separate reaction zones are defined for the interaction of slag and melt, the injection of oxygen, and the injection of carbon. For each zone, equilibrium compositions and reaction rates are calculated. Furthermore, diffusion of species is considered as a rate-limiting factor in reactions between slag and melt, and diffusion rates are calculated from the bulk melt to the reaction zone where reactions with the slag take place. Oxygen and sulfur dissolved in the melt and CaS in the slag are added as new species not previously considered in the EAF model. The treatment of carbon is revised to reduce model complexity and improve accuracy. The improved model is validated using extensive data from an industrial EAF, and results are compared to measured data as well as results obtained with the unmodified model. The different models for the determination of thermodynamic activities and their impacts on the duration of the simulation as well as its results are evaluated.

36 MATERIALS SCIENCE↗